Ok everyone, here's my latest update.... I've done some pretty extensive testing at this point and think I've narrowed it down pretty well.
As Dr G stated, it does appear that my board suffers the screen glitch issue, despite being one that had apparently been "corrected" (grey epoxy/silicon of some sort under the ribbon cable).
At first I thought it wasn't JUST the screen glitch because of the other issues I've been experiencing, but I've come to realize what I believe to be is causing all of the issues.
When the screen glitch happens, and the display locked up I've noticed that sometimes it "drops out of temperature protection mode". What I've come to the conclusion of now, is that most times it's not dropping out, but... When it glitches it appears to immediately do a "reset" on the atty. It doesn't prompt or ask, it just does it... And depending on WHERE during the firing it happens, it's anyone's guess as to what temp the coil is at that point...
I'm going to throw some wild numbers out here... These aren't based on any accuracy, I'm just using them purely for demonstration purposes...
Let's say I have a .15 build. And let's say the resistance increases .1 ohm for every 100 degrees in temp....
If the coil has JUST began to fire, and has only raised 50 degrees in temp when the screen glitches, it resets the atty to .20 ohm.... So now it will fire 50 degrees higher than my set temp... So my 460 degree setting becomes 510 degrees....
But what seems to happen MOST often is that it glitches much later into the fire... So let's say my build has reached 400 degrees.... Now the screen glitches and resets... Now it thinks the base resistances is .55... Meaning that the next time I fire it it's going to let it hit 850 degrees....
Again those aren't real numbers... just demonstrating what's happening...
I spoke to another person who was having this issue, and they believed this "reset" of the base resistance was only happening after the unit sat idle and was powered back up. In my case it appears to happen immediately when the glitch happens... I'm guessing that when the screen glitches out, it's shorting the power supply and sagging to a level where it essentially resets itself without actually doing a true reboot. If that makes
sense... MCUs can do all sorts of things when there is noise on the power rail or when voltage dips below it's minimum levels, so who knows what else it might do when this happens... Which explains some of the weird things I've seen.
My solution in the mean time has been to keep the unit in stealth mode. By doing so it never glitches... hence it never resets the base resistance, and therefore continues to function perfectly normal.
Evolv has sent me an RMA, so at this point here's where I'm at. I've ordered a second board. When it arrives I'm going to swap out this one with that one. Then I'm going to exam the old one. I have some surface mount soldering equipment, so I may just pull the ribbon off, insulate the vias, and replace it myself to see if that fixes the issue. Otherwise I may just send it back and have it replaced. Does anyone know how long it typically takes them to replace a board?