whenever i encounter the auto calibration error this is what I do to have it complete it's calibration.

1. turn tone defeat ON
2. set all speakers to small, even though I have large mains
3. set crossover to 180 or 200 for fronts and rears

that's it.. it works 99% of the time for auto calibration now. otherwise if I don't do these three steps.. i get the error message every time.

good luck