Actually, what is happening when the controller 'changes com ports' is that something in the software setup in the cab has triggered the bootloader.
The controller uses a static VID, PID and Serial Number in the plunger firmware and because of these, after the initial discovery of the device on 1st connection to the system, Windows will always assign it to the same com port assignment going forward.
It's why the plunger controller doesn't assign a new com port after a firmware update unless the serial number, VID or PID is changed in the new firmware prompting a reassignment.
Tripping into the bootloader requires hitting the existing, open com port with an attempt to open the already open port with a toggling of the DTR line and a communication rate greater than 1200baud. Translated into simpler terms, if the port is already open by one piece of software and some other piece of software tries to open it, the board assumes that the bootloader is being requested (usually for a firmware upgrade) and switches accordingly.
When the bootloader starts, the com port number changes to the com port number assigned by Windows to the bootloader and ESP32 is displayed (usually with an exclamation mark.) This is where the assumption has been made that the com port has changed, which is a correct assumption in that it has since something requested it. Where the mistake is being made is assuming that because the exclamation mark has appeared, there is a need for a driver install where in fact there isn't. The exclamation mark is indicating that no driver exists for the DFU (Direct Firmware Update) portion of the bootloader which is never going to be used anyway and therefore has no need to be installed.
What does happen is that people go looking for a driver and install it, and then find that the communication issues start occurring more frequently as they have installed a driver meant for Windows 7 which has a deprecated USB stack that is far away from the current one in Windows 10/11. This creates new issues with the communication and further increases the frustration with the controller as once modified by the new driver, the USB stack becomes unstable and is a bear to uninstall. There is no driver required for installation of the plunger in any version of Windows from Windows 8 on.
Ultimately, the issue that created this cycle has been created by something in the cabinet software configuration, usually a software initialized com port (since the hardware ports are assigned by Windows to avoid such conflicts) that has been assigned to the same port assignment as the plunger com port. Tripping of the bootloader occurs when that software port attempts to open in an effort to accomplish whatever it needs to do without any way of knowing that the hardware com port exists and is already in use.
This is why resetting the board makes the issue magically disappear. By the time the board resets, the software com port has given up on the communication attempt and the hardware port of the board has reconnected without issue and the conflict has gone away until the next time the cycle repeats.
Searching the ini files of the cabinet software usually reveals the location of the software com port responsible and it usually comes down to something like a DMD extension that has a software initialized com port on a system default assignment (COM3 for example) which is in conflict with the hardware assigned com port (if it too is assigned to COM3 by default.)
I've had one of these boards on the bench, connected to the development setup for over a year now. It has been heavily abused both electronically and physically (amazing how many times you run into something while walking past it even though you know it is there), has been left connected for the entire time through power outages, computer sleep modes, system crashes, you name it. It only ever exhibits the symptoms described by others under the circumstance explained above.
Edit**
As for the assertion earlier that someone was 'ghosted by support', I seem to recall replying to that email with a question and never receiving back a reply, but I guess that's just my faulty memory as I'm renowned for my poor customer service efforts.
Edited by zebulon, 12 March 2025 - 01:49 PM.