I am not up on protected mode AOI's but can it be uploaded from one project and merged into the fault PLC without the keycode?
In case the problem is something in the AOI itself creating the -29 that the other PLC he has is not doing.
Stallone,
it might need both projects saved, I don't have a RSL5K laptop with me to be sure. In RSL500 you can upload the connected PLC or open a saved file, then compare to another saved file. I think RSL5K is similar.