I have an assembly with multiple configs. When I go to balloon the items, if there is only one config everything is fine, but when I select additional configs to populate the BOM just one balloon turns from "5" to "*". I created a new drawing and BOM thinking there was some corruption, but it makes no difference. I've had an identical problem on other drawings, always involving the same part (hinge). I ended up doing some "not best practice" stuff to get it to work last time.
This is driving me crazy. It seems it might be something with the configs. Any ideas greatly appreciated.
Finallly figured it out! Seems like a bug to me.
I went to the problem parts in the assembly, selected them all and did "configure component". From the list I could see that the config of the parts were the same, BUT a few of them were "Camel Case" while others were ALL CAPS. There were only 2 configs for the part, but it was acting as if there were 3. When I hit the drop down menu, it showed the ALL CAPS variation(and not the Camel Case), after making them all the same, it worked.
So in conclusion, I had a phantom CamelCase config that was screwing things up. Hopefully I explained this well enough to help someone else out.