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Here are relevant snippets of code

union LONG_UNION
{
signed int32 sl;
unsigned int32 ul;
signed int16 si[2];
unsigned int16 ui[2];
signed int8 sc[4];
u ...

Thanks, I plan on looking into restructuring the code when I have time. I'm already at 85% of ROM usage on the 18F452 so at some point I'll need to address it.

Thanks for you input.

I agree with K&R and this is the only exception I ever use one in (In my day job, I'm a C++ engineer for the Aerospace industry and we have very strict coding standards). ...

Here are relevant snippets of code. On C_CLAMP_FWD_IN, the bit test gets optimized out so it immediately advances to the next step before the CLMP_FWD_IN prox switch is made. This happens with every r ...

I use these chips in embedded boards I have designed to run industrial equipment. When running in automatic mode, I use a state machine to sequence the operations. Each output requires a specific inpu ...

The original program is working again. So, what I have I learned? Lots, but most important,

MPLAB 8.63 and CCS 5.061 BAD!
MPLAB 8.92 and CCS 5.061 GOOD!

But going forward, you guys have helped ...

WOO HOO!!!! Upgraded to 8.92 and my hex file matches yours and works.

Now to get my original program running again.

Yep, yours works. Upgrading to 8.92 now since that appears to be the only difference.

Can you post a copy of your hex file that works? Also let me know what baud it uses.

I have version 4.119 and MPLAB 8.63 on my notebook and compiled the code. Burned a chip and tested it. It didn't generate an interrupt. Ran a diff on the files and there is a bit of difference. Couldn ...

I have a dumb question, how do I post a hex file? Embarassed

Out of desperation (I have an angry customer and this is way overdue), I decided to re-wire stuff so I can test the simple routine.

I wired B6 & B7 with 10K pull-ups and a switch to ground so I ...

In MPLAB, Project->Build Options->Project
Under CCS Compiler Tab, Category->Optimization, slider to low.

+DF +LN I+="$(INCDIR)" +T +A +M -Z +Y=0 +EA
The Y value is optimization

Thanks, knowing it still works means my code is the issue and gives me a direction forward. Something may have changed between 4.016 and 5.061 that allowed it before and needs to be fixed now.

I don't get any warnings that would matter, just variables not used. i could write a simple program but wouldn't have an easy way of testing it. This chip goes into a board that controls industrial eq ...