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only a few things could cause this really. you have eliminated most of them. i would check for heating on the inside of the controller causing condensation (although very highly unlikely). next possible guess and probably the cause is water in the cable coming out due to capillary effect as sp5it mentioned. disconnect the cable from controller and put it on the desk, watch if it weeps water. a key piece of the puzzle which you didn't mention is the weather outside when this phenomena occurs. only when it rains, after it rains, sunny all day every day, snow, ice, etc. one last thing, if you have the cable length to spare, cut a few inches off and check the wires for corrosion. that will also help solve the mystery.