What kind of IR hardware do you use? I've had the kind of experiences you describe with both Xantech and Niles Audio, and have found that using Xantech exclusively has eliminated 90% of the controllable problems. Niles, much as I like them, just does not have the depth of experience, breadth of product, nor tech support talent of Xantech in the IR arena. Mixing the two brands of hardware in a system was a nightmare for us.

Glue all the flashers on with fish tank repair silicone as Xantech suggests. Many of our remaining service calls are for flashers that fell off from age or a hot enviroment inside a cabinet.