@James *****
okay, for the online system to work you need to have entered the country by land at least after 2014 and by air after about 2013 or so otherwise your TM.6 departure card is not in the online data base (no matter how many times you've filed a 90 day report in person).
To use the online program you also need to apply from 15 days before down until 7 days BEFORE your current due date. Outside that widow of opportunity the online program won't work.
If you're getting this error message it means one of the above criteria is not met and you need to do it in person or by mail.