[sparks-1784]

So - to close this issue out (for the benefit of others)...
We were able to get the cRIO to program every time without the need for periodically running the imaging tool.
The problem appeared to be that the incorrect robot framework was being used - last years framework was used which apparently causes issues with the 2012 cRIO configuration.
A 2012 framework was opened and elements that were desired for re-use were copied from the older files and pasted into the new framework. I thought this was done initially, but apparently the old framework was used instead.
I personally encourage team members to redraw designs that are being re-used in a new framework. One can gain experience using labview through the re-drawing process.