This isn’t really a forum discussion. You may wish to open an official support request.
You could have several problems:
1)Incorrect panels attached (not a valid console in vista eyes)
2)Addressing on the panels
3)Dirty ribbon cable connections
4)Bad riser card
How did you build the console you have working now? Is it made out of panels from a mix of T2 and T4 hardware?
I would check the panels you have connected. In particular check the addressing.
On the top edge of the playback and programmer circuit boards is the card address selection consisting of 2 rows of pins with a jumper vertically connecting two pins. If the jumper is missing the panel will not respond at all, just as if it was unplugged from the flat cable.
The addresses do not represent the physical location of each panel, however the following convention should be followed when setting the jumpers:
• The left most Playback Panel is set to address 1, the next to address 2, etc…
• The right most Programmer Panel is set to address 4, the previous to address 3, etc…
The Tablet Panel is hardwired to address 8 (no jumper).
For the console to operate correctly the software must detect a valid configuration of front panels (at the correct addresses). The console must be rebooted for the address changes to take effect.
The jumper can be monitored with an oscilloscope, it will be normally high (+5v) and momentarily drop low (0v) each time the card is accessed