Mike,
I don't know if this will help you or not, but I don't see where it can hurt anything. I was having all kinds of problems and I, like a lot of other folks, am running the rock . When I upgraded to 2.004 was when all my problems started. I was about ready to pull my hair out. After going thru a lot of frustration, I formatted one of my cards and then installed 2.002 firmware. Solved almost all of my problems. I still have a couple things I have to work around, but they are minor. You might try this and see if it helps. If you try this, when you load a project to the card, it will tell you that you have the older control logic and do you want to update to the newer logic. Just say no and go on to upload your project.
Mikemi
All Gave Some,
Some Gave All.
My computer configuration and software used:
Gigabyte GA-990XA-UD3 Motherboard, AMD FX 6-core Processor Black Edition, 32 Gig DDR 3 Ram, Gigabyte HD 6450 Video Card with 1 Gig DDR 3 ram, Windows 10
Designer 2.007, Designer 3.102, Pattern Editor, Centerline, Conforming Vectors, 2d Tools, 3d Tools, DXF Importer, STL Importer and Rotary Jig.