Everything else is working fine. I have four PCS switches and an IR543/Pronto. They all work flawlessly.

I have a Maxi controller which also functions at many different locations in the house. I'm not sure what you mean by using the maxicontroller with alligator clips.

The only other thing I can think of is to move the PCS switch and the KPL to a completely different 3-way location. Do you think that would be a worthwhile troubleshooting move? It sure would be a bit of work to do it especially if it won't make a difference.
Alden