Thank you panic mode, that was indeed the problem and the fix!
I enquired with KUKA earlier this year about a system update because we were considering purchasing RSI and they told us they were only selling it for 8.5 and later. Unfortunately the logistics of shipping the controller to KUKA deterred us from doing it.
Do you know if we can update to something like 8.3.42 ourselves without shipping the entire controller to KUKA?