Electronic – Arduino resetting/hanging due to sparks in ac line

I dont understand your confusion. You want to communicate between the two controllers with UART, then ofcourse both of them need UART capabilities and code for this. Your computer has drivers and software for dealing with this, so your microcontroller also needs a driver for it.

Your ATmega32 need UART TX functionality, while AT90USB1287 need UART RX functionality. Having already written both TX and RX for your ATmega32, writing the UART RX routine for AT90 should be a breese. You could add a bitvalue of some kind, identifying that the UART RX on AT90 is coming from your ATmega32, and directly pass it through to USB.

EDIT: Code from AVRFreaks that is written for at90usb1287

#include <avr/io.h> 
#include <util/delay.h> 

#define RXC      (RXC1) 
#define TXC      (RXC1) 
#define UCSRC    (UCSR1C) 
#define UCSRB    (UCSR1B) 
#define UCSRA    (UCSR1A) 
#define UDR      (UDR1) 
#define UBRRL    (UBRR1L) 
#define UBRRH    (UBRR1H) 
#define UBRR     (UBRR1) 
#define UDRE     (UDRE1) 
#define RXCIE    (RXCIE1) 
#define TXEN     (TXEN1) 
#define RXEN     (RXEN1) 
#define UCSZ0    (UCSZ10) 
#define UCSZ1    (UCSZ11) 
#define UMSEL0   (UMSEL10) 
#define UMSEL1   (UMSEL11) 

#define FRAMING_ERROR (1<<FE1) 
#define PARITY_ERROR (1<<UPE1) 
#define DATA_OVERRUN (1<<DOR1) 
#define DATA_REGISTER_EMPTY (1<<UDRE1) 
#define RX_COMPLETE (1<<RXC1) 

#define FOSC 16000000 

typedef unsigned char       Uchar; 
typedef unsigned long int   Uint32; 

#define Wait_USART_Ready() while (!(UCSR1A & (1<<UDRE1))) 

#define lowByte(w) ((uint8_t) ((w) & 0xff)) 
#define highByte(w) ((uint8_t) ((w) >> 8)) 

int main(void) 
{ 
/* Disable clock division */ 
clock_prescale_set(clock_div_1); 
   UBRRH = (Uchar)((((Uint32)FOSC)/((Uint32)USART_BAUDRATE*16)-1)>>8); 
   UBRRL = (Uchar)(((Uint32)FOSC)/((Uint32)USART_BAUDRATE*16)-1) & 0x0ff; 

   UCSRB |= (1 << RXEN) | (1 << TXEN); 
   UCSRC |= (1 << UCSZ1) | (1 << UCSZ0); 

   char ReceivedByte; 
   for (;;) // Loop forever 
   { 
      while ((UCSRA & (1 << RXC)) == 0) {}; // Do nothing until data have been received and is ready to be read from UDR 
      ReceivedByte = UDR; // Fetch the received byte value into the variable "ByteReceived" 

      while ((UCSRA & (1 << UDRE)) == 0) {}; // Do nothing until UDR is ready for more data to be written to it 
      UDR = ReceivedByte; // Echo back the received byte back to the computer 
   } 
}

It is possible that the power supply for your ATmega is unable to supply enough power during those sparkling times when you turn your AC load on. If the power to the processor drops to below a certain voltage, it will reset. You want to add a big electrolytic capacitor between the Vcc and Gnd pins: you probably have two Vcc and two Gnd pins; add a capacitor for both.

I don't know how you are controlling your AC device: is it possible that some of the line voltage is reaching your ATmega? That would be bad.

Also as Rick_2047 notes, make sure you are not pulling more than 40mA from each one of your ATmega pins, and even 40mA is a bit much. If you need to drive loads more than 20mA consider using transistors or FETs. If you are using a relay to switch your AC load it likely needs a decent amount of power, so use a transistor.

Finally, if you are using a relay, you need to snub the transient voltages generated when you turn it off. There needs to be a diode in parallel with the relay contacts to safely handle the transient voltages.