Stan Fiorentino:

Is it possible to use the AES ins and outs AND get the 2 analogue outputs to mirror the digi outputs?

This would be tough, as there are 8 digi outs and only 2 analog. You could certainly have the 2 analog outs monitoring any 2 chosen digital outs, or 2+2 summed digital outs. Suggestion – try the Routing8000 download, to demonstrate the routing options.

Stan Fiorentino:

Would upgrading to FW eliminate this?

Not sure what this refers to.

Stan Fiorentino:

seems to give up with distorted sounding output

Sounds like a hardware problem – if it can't be avoided you will need to send the unit home for some TLC.