Running the Aquaero 6 XT with Aqua computer D5 pump, MPS flow 200, two GPU blocks, CPU block, 3 fans on each channel (12 total). Two radiators.
Pump -> GPU Rad -> Flow Mtr -> CPU -> CPU Rad -> GPU blocks in parallel -> Res -> pump

Been working fine for a year or so then I had a glitch where the fans went to 100% during boot up and took about a minute before dropping back to normal.
This would happen every few weeks or so then it stopped for a few months.
July of 2014 it did it again only this time it failed to return to normal.
I installed Aquasuite and reconfigured everything and it seemed to work for a while until November when it did the little trick of staying at 100% for some time.
Since then I've re-installed windows but did not install aquasuite.
Last week, January 21, I walked into the computer room and saw the Aquaero 6 XT faceplate laying on the floor in front of my computer. I replaced it and powered up the PC.
Powering up the PC I had the fans at 100% again and they never dropped back.
I installed Aquasuite and got the updated firmware. Went through and reconfigured everything, saved and exported the config.
All seemed fine for two days. Now I'm stuck again.

Fans are at 100%, pump is at 0%.
I reset to factory and redid the config. Now when I add one bank of fans to the control, they drop to 0%.
When I setup a virtual temp sensor it shows the average of the two real sensors but the data does not transfer to the widget in the control, it's stuck at 50.0c
Flow meter data is erratic. When it is displaying data it seems correct but the display drops to zero frequently even though the pump is showing RPM (typically 2 to 3K rpm)

Any ideas??

Thanks

James

Update:
Uninstalled Aquasuite using Revo uninstaller. Re-installed with the start fresh option.
Reconfigured all curve controllers and it seemed to be working OK.
This morning when I booted up. Same thing. Fans to 100%, pump to 0% and when I pulled up Aquasuite, all the curves were garbled, fans aren't responding to controls and showing max RPM and 0v.
What is the warranty on the 6 XT USB? Bought in June 2014.

The face plate is held on with adhesive. It seems to be failing.
The computer is in my computer room and the temp is very stable there. Always 22 to 25 c.

Just now I was reading some web page and the two sets of fans change to 100% and the other two sets drop to 0%.

I will see what support has to say.

Thanks