We're recently deployed a major WPF app that has replaced an ancient of days VB6 app (thank God that's gone!) It's been working fine. However this morning one of my users got the "The communication object, System.ServiceModel.Channels.ServiceChannel, cannot be used for communication because it is in the Faulted state." error message. We encountered this months ago and I looked up the answer here on Stackoverflow, and found this. I was careful, from that point forward, to not use the using statement to wrap my WCF services. Nevertheless, this user got this error message. What's worse, when I tried running the app on my development box, using the same data, it worked fine.
So what could be causing this error to occur, sometimes? Both machines are Windows 7 Pro machines; both are 64-bit. Naturally, mind is more powerful, but beyond that I don't think there's much difference.