I have read details of your post and wonder if this info may be relevant to your issue
Your setup of RSLinx, I believe is in one of those cache files.
Something I have posted before.
Just a different slant that may be worth trying.
Sometimes when edits are done in RSView 32, the project just does not want to release the cache files, and tries to keep running on previous settings.
A repair I do if any issue crops up, is to shut down the project, then in windows explorer, go into the project folder, open the projects cache folder, and blow away all files in that cache folder, they will be rebuilt on the next start up.
The next thing I do is go to the projects Tag folder, and look for one file with "the project name".cac
I THEN BLOW THAT ONE ONLY AWAY, leaving all the other files in that folder, this .cac file also will be rebuilt on project start up.
Then shut down computer and reboot and run your project.
I cant promise this will fix your problem, but it wont harm it either.