I have sometimes seen this error. I do not exactly remember the reason but I have commented it in the Known problems section as:
Error Zero or insignificant PSF Signal Weight estimate
In some cases like when using starless images you may get an error “Zero or insignificant PSF Signal Weight estimate” in the AutoIntegrate log files. You may get rid of this problem by using an option “ImageIntegration use ssweight”.
I cannot immediately figure it out what goes wrong here. It would be very helpful if you could send me the AutoIntegrate.log file. Also a very small subset of your data to reproduce the issue would be helpful, but the AutoIntegrate.log file should be enough. The email address is info@astroimagetools.net.