Is the old Particle WEB IDE good for Photon 2?

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This section in the datasheet covers the VUSB pin:

The pin is internally connected to the VBUS of the USB port. The nominal output should be around 4.5 to 5 VDC when the device is plugged into the USB port and 0 when not connected to a USB source. You can use this pin to power peripherals that operate at such voltages. Do not exceed the current rating of the USB port, which is nominally rated to 500mA. This pin is also protected with an internal fuse rated at 1000mA.

It is also possible to use the VUSB to power the Photon 2 at 5V if not using the USB port. There is no blocking diode between the USB port and VUSB, so you should not use both at the same time.

An external supply powering the Photon 2 via VUSB must be 500 mA at 5V minimum, however using a 5V 1A (5W) power supply is recommended.

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What sorts of bad things would happen when they're powered at the same time? I can see this happening during manufacturing unless we were very very explicit in our instructions.

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It depends on the robustness of your power supply and the USB host.

Your computer is not expecting the USB power lines to be powered; the host (computer or hub) is normally responsible for that. Ideally it will not be damaged, but there's no guarantee.

On the other side, many regulators will not be damaged if there is power supplied to their power output, but could be.

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