Matthew -
I recently replaced the USB interface on my Fun, it was the older 48/16 USB, not the newer TE7022 based interface. The old one would not work, plug and play saw it, but reported it as an unknown device. Obviously it was fried, as replacing it got it to work again. I have had the same experience as you with finicky USB, I have an old compaq laptop, and getting the USB interface to PnP on that is a chore, yet on my somewhat newer desktop PC, it works like clockwork. Here is something you can try - each time you install a USB device (or pretty much any device for that matter) in windows, a device is created in the device manager. These devices never leave the system, they just become hidden when not in use. In case one of the instances of the USB is causing you the problem, you can clear out the hidden instances of the USB DAC from the machine.
You need to run a CMD.exe command prompt
as administrator, then once in the command prompt, follow
http://support.microsoft.com/kb/315539, which consists of setting this environment variable:
set devmgr_show_nonpresent_devices=1
and then from that command prompt window with the environment variable set, run devmgmt.msc. Once in devmgmt, make sure to click on "show hidden devices" on the view tab to see the hidden devices.
Here is a sample from my desktop PC:
You see the TE7022 shows up 3 times, why?... because I've used different USB ports, causing the PnP detection to trigger a new device each time. Also notice they are "dim", as they are not active devices on the system, and are hidden. You can highlight each entry, right click and choose Uninstall to remove the device. You can also see a good example below, the "Fuji FinePix Camera" device got installed when my camera PnP'ed on the system.
Essentially all this will do is make the next occurance of a PnP detection re-detect and reset all the device settings. It might help, and won't take over 5 minutes try.
Good luck!
RonO