[KenWittlief]

If you have a competition port adapter connected you should power up in 'disabled' mode

I would have someone look at your code. It sounds like maybe you are using some motion smoothing algorythm, and one of the variables gets cleared to zero on powerup (instead of the last commanded or last output value)

in otherwords, you may have variables in your code that are not correctly initialized, so the first time through the loop you get an unexpected output.

PID control can be especially tricky to initialize, there may be several variables that would have to be initalized to the right value to get a 127 output on the first pass through the loop.