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Hardware issues I ruled out because it happens on his virtualbox, normal desktop (tried two different models) and his laptop. We used three different OS versions with different sp's (about 12 different cd's/dvd's thinking that the install was bad. It happens in XP, Vista, and Win 7 with no prompting and most times he isn't at his desk when it occurs (here was in the field yesterday afternoon and this morning his machine was all hosed again).
So we have 3 different PCs and 3 different OSes................that cannot be hardware.