This is going to sound crazy, but can you try rebuilding the character in a new por file? I suspect you added and then deleted something with a configurable, and for some reason that thing is still causing the problem. What I would also do is to add 1-2 things to the character, and then re-save the por as a new file. That way you end up with por files for each set of changes you made. Then re open the file, make 1-2 more changes and save again. If the error pops up again we can see what new items where added to the por that might be at fault.
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