So I dug into my notes about the last time I encountered this and found that my new formatter card was delivered with a 2-year old firmware level. Aack! Fortunately, I'd saved the current firmware file and have just completed the (not flawless) upgrade. (I got a 08:11 error that freaked me out because it hinted at PCA hardware failure.) About to make a print and see how it goes....3PM update: The inconsistency issue is now worse than it was before the firmware upgrade.
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