No hardware issues, the latest Raspian build found the Edimax USB card with no issues. My problem was the wlan0 interface would not work without eth0 also being active.
Further investigation led me to find the MAC address both the wlan0 & eth0 IP responded from was in fact the eth0 address.
Now this goes against everything I understand but in my case with the RPI ethernet cable plugged in:
Take note of the HWaddr on each card.
$ ifconfig
eth0 Link encap:Ethernet HWaddr b8:27:eb:b0:0c:39
inet addr:192.168.99.75 Bcast:192.168.99.255 Mask:255.255.255.0
UP BROADCAST RUNNING MULTICAST MTU:1500 Metric:1
wlan0 Link encap:Ethernet HWaddr 80:1f:02:82:33:24
inet addr:192.168.99.78 Bcast:192.168.99.255 Mask:255.255.255.0
UP BROADCAST RUNNING MULTICAST MTU:1500 Metric:1
Then from another workstation, in this case I'm using NMAP:
$ sudo nmap -sn 192.168.99.75 **<< - ETH0**
Starting Nmap 6.25 ( http://nmap.org ) at 2013-02-03 10:19 GMT
Nmap scan report for 192.168.99.75
Host is up (0.020s latency).
MAC Address: B8:27:EB:B0:0C:39 (Raspberry Pi Foundation)
Nmap done: 1 IP address (1 host up) scanned in 0.09 seconds
Paul@lo-mbp-preg / $ sudo nmap -sn 192.168.99.78
$ sudo nmap -sn 192.168.99.78 **<< - WLAN0**
Starting Nmap 6.25 ( http://nmap.org ) at 2013-02-03 10:19 GMT
Nmap scan report for 192.168.99.78
Host is up (0.0044s latency).
MAC Address: B8:27:EB:B0:0C:39 (Raspberry Pi Foundation)
Nmap done: 1 IP address (1 host up) scanned in 0.07 seconds
You can see that the MAC Address/HWAddr for both ETH0 and WLAN0 is the same, and matches the ETH0 HWAddr from ifconfig. So in my case the Wireless was not working and all traffic was passing via ETH0
I never actually found 'the reason' for this. In the process of debugging it started working reliably. Which I hate. But this config is now working :
**/etc/network/interfaces**
auto lo
iface lo inet loopback
iface eth0 inet dhcp
allow-hotplug wlan0
iface wlan0 inet manual
wpa-roam /etc/wpa_supplicant/wpa_supplicant.conf
iface default inet dhcp
**/etc/wpa_supplicant/wpa_supplicant.conf**
ctrl_interface=DIR=/var/run/wpa_supplicant GROUP=netdev
ctrl_interface_group=root
update_config=1
ap_scan=1
network={
ssid="<ssid>"
psk=<key>
}
network={
ssid="<ssid>"
scan_ssid=1
key_mgmt=WPA-EAP
pairwise=CCMP TKIP
group=CCMP TKIP
eap=PEAP
identity="<uid>"
password="<password>"
#ca_cert="/etc/cert/ca.pem"
phase1="peapver=1"
#phase1="fast_provisioning=1"
phase2="MSCHAPV2"
pac_file="/etc/wpa_supplicant/pac"
}
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