I would check your COS line voltage.  My first repeater that I built had a similar problem.  I was using a Hamtronics controller and a Midland receiver.  The COS line voltage was running somewhere in the 1 volt range when the receiver was active. (Hard to remember specific voltages).  Anyway, I was in a range of voltage that the controller was geting confused if it was suppose to key up the transmiter or not.  Any change in temperature or voltage or noise on the line made it get stuck in the keyed mode.  I fixed this by adding a coupe of transistors to pull the line closed to ground when the receiver was active and added a "pull up" resistor to pull the line closer to 12VDC when the reciever was idle.  Instant reliability of the receiver!
 
Different controllers may need different voltages to tell it if the input is acitve or idle.  For example, my S-Comm controllers use 2.1VDC as the crossover point.  You need to pull the COS line above or below this voltage to indicate active/idle COS.
 
73, Joe, K1ike
 
Repeater-Builder@yahoogroups.com wrote:
rtoplus wrote:

>Well I visited the site and powered down everything...let it all
>rest for about 5 minutes.  After powering back up, everything seems
>fine.  The heat sink was hot as a firecracker, naturally (got up to
>90 degrees here today as well and the repeaters are in a tupperware
>tool/garden house). 









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