That cassette stores a custom program (i.e Macro Executer) created by the OEM or a 3rd party. That is why the purchased cassette and original's contents do not match. They are not interchangeable.
You would need to burn the original contents onto the new cassette assuming it is not corrupt.
If you unplug that cassette will the control boot past the system alarm?
Specifically what series 0 control are you working on?
Can you advise on the led status on the mother board?