[nheft]

When we hit the reset button and the code error goes away, the p1_y still gets read as p1_x. Do you see the same?

It makes a difference how you power up the controller. We placed a toggle switch between the fuse panel and the RC. Sure enough, the power-up fault occurs much less often (but still happens occasionally) when we use the switch to turn the controller on. I think the difference is in the contact bounce of the switch vs the circuit breaker.

Your description of the joystick's p1_y being read as p1_x is exactly what we're getting; my previous statement that x and y were reversed was inaccurate.

I sent our controller back to IFI and they claim they cannot duplicate the problem at IFI.

I spoke to Mark Lambert IFI's RC digital/software guru. He can't identify a mechanism that would explain what we're seeing. Since it does not happen with the IFI default code, they will not spend much time investigating. The only software they "support" is the IFI default code.

Mark did give me some information that might help. The "reserved" word in the rxdata structure always contains the number 12, which is the firmware revision number for the master uP. When the rxdata gets misaligned (p1_y read as p1_x, etc), the reserved word will probably be wrong too. I can use this to detect the error, go into an infinite loop, and force the RC to crash. This way we can tell by looking at the RC LED's that something is wrong and try recycling power. Yes, it's just a band-aid but we don't have time to dig in and find the root cause.