I have now determined that in some cases, the IRToy will become unresponsive with an IR singal alone, i.e. irtoy.exe does NOT need to be running for the issue to occur. My Sony remote will only cause an issue if used when irtoy.exe is running, but I've found another which will break the IRToy at any time.
I've attached a capture from irtoy.exe of the IR command which causes this. It's the Power command from a MINIX remote. This is an RF remote which I use with Kodi, but the power button is IR. As I don't have a MINIX PC, the power button doesn't do anything on my hardware, so I am unable to test the accuracy of the capture. If someone else with two IRToys can give it a go, that might help track down the cause of the problem.
EDIT: While the Sony remote doesn't normally cause the IRToy to become unresponsive, it does result in a garbage error reading the firmware version the next time I try to send.
I recently purchased two IRToys, one for personal use, and the other for a project I have been working on. These have both been upgraded to firmware v22.
I noticed that irtoy.exe would occasionally freeze after "Transmit was successful and glitch free!" message, and subsequent attempts to use the device would result in irtoy.exe freezing on "Opening IR Toy on com7 at 115200bps...", requiring the IRToy to be reconnected in order to get it to come to life again.
I tried unsuccessfully to reproduce the issue by repetition, but found the IRToy to be 100% reliable, even after hundreds of cycles.
It turns out, that the problem occurs when an IR signal is being sent from the remote while irtoy.exe is running. It looks like just sending a signal when "Transmit was successful and glitch free!" is displayed is enough to cause the issue.
It might be a simple change in irtoy.exe, or require a firmware change if the IRToy is handling interrupts/polling for received signals when in send mode.
Has anyone experienced this issue or developed a workaround?