a) Thanks for the assist - have got USB up and running again after doing a bunch of stuff as suggested/found out - see "tech" stuff at end in case anyone else ever has similar problem and wants some ideas. Ending up installing a USB/PCI card after everything else failed (unknown device everytime) - everything installed right first time, then thought wtf lets try old ports and they worked! Didn't work before card put in - all previous steps may have helped. Still reckon the USB controller is suspect (USB dropping from 2 to 1, USB item dropping altogether, kboard not found on boot up, unknown item etc and both on XP and Vista) - but I have 18months warranty left so we'll see. Will probably run external HD and mouse off the card just in case. Will check out Dr B's stuff too.
ps Apologies to Bose - he got lumbered with my first game back on a reasonable DPI mouse. After the previous 3 days I was used to using whole mouse mat to rotate, end result when I used a 800 dpi mouse I found it initially (er laughably embarrasing) difficult to navigate corridors let alone shoot anything. If you don't believe me change sensitivity on mouse from low to max and have fun getting dizzy.
b) TF2 actually runs fine either way, stutter (or tearing as it seems to be termed on the net) occurred on a couple of previous games (although no way near as bad as many seemed to have). I think you are right that Vysnc would have solved the problem on them, although I'm sure I tried it at the time. Maybe the problem was that Planetside ran at 300-600 fps
Have set card to global Vysnc forced on (was App to choose previously) - think it over rides game, although in Vista pre Sp1 it doesn't apparently.
Manufacturer recommended I clean the card - its covered in dustbunnies. Guess that's the next job - sticking a bloody hoover in the case. Actually not a bad upgrade for engineer - Hoover - it cleans up stickies etc.
Thanks again - I really wasn't enjoying TF2 without my normal hardware.
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Tech sorta stuff to sort out USB - in the order I did it:
Swear, Tinker, Switch machine on and off a few times, try lotsa ports, connect serial keyboard & switch off annoying Bios No keyboard warning
Run virus & malware check with AVG 8 etc
Fall asleep
Remove vendor drivers for mouse and keyboard
Run device detective (free bit)
Update motherboard bios and misc hardware drivers
Run device manager the following way
Run -> cmd
set DEVMGR_SHOW_DETAILS=1
set DEVMGR_SHOW_NONPRESENT_DEVICES=1
start devmgmt.msc
Select Hidden devices
Delete all greyed out and <!> USB connections & HID under mouse and keyboard (and there were a lot)
[should run through safe mode if device still connected according to 1 source]
Deleted a bunch of others that were now redundant and no longer on machine
Swear at windows a bit, finally find a serial mouse that works and plug it in. Hooray can now navigate Windows easier.
Contact manufacturer - who insists that the following will work
"Click on the Run and type Regedit.
In regedit use the following path
Hkey_Local_Machine \ Software \ Microsoft \ Windows \ Current Version
Once you click on current version in the right hand windows you should find and entry for DevicePath right click it and select modify and enter C:\Windows\Inf and click ok . [Actually its c:\winxp\inf on mine - was %SystemRoot%\inf ]
Reboot the PC and try the USB device again."
It didn't.
Check Bios settings -
Set OS to detect Plug and Play rather than Bios (toggled this a bit beforehand in sheer desperation)
Check that Legacy USB is on (for serial mouse & keyboard - it was)
Check USB controller 2.0 is on (it was)
Still not working - %%$^£%*
Plug in USB/PCI card. Windows detects - sets up USB controller etc. Connect mouse - YAY - play TF2.
Die a lot
Correct settings
Still die a lot - but hey that's me
Try other ports - woot they are recognised and work first time
Keep fingers crossed