I've suffered a similar problem overnight. In the interest of assisting an accurate diagnosis, here is a detailed account of the events.
Unpacked a FlightDEK-D180 upon delivery yesterday. The supplied harness was checked and the connector for the compass module was completed in accordance with the warning contained within the harness instructions. The compass module was then connected. The unit was then powered by its internal battery and functioned normally, as was expected. The EFIS and EMS menus indicated that the firmware installed was Version 1.08, matching the supplied documentation. An internal battery voltage was displayed within the EMS pages.
The latest Product Support program, Version 3.0.1, was downloaded and successfully installed onto my desktop PC using the Windows Vista operating system. The supplied USB to Serial Converter cable was successfully installed with its associated software driver.
The D180 was then connected to the PC via the harness serial connector and the serial converter. A “Detect Firmware” operation was completed normally, reading back the D180 and compass module firmware versions with unit serial numbers.
A “Firmware Backup” was then attempted, but toward the end of the procedure, the program lost the connection. I then investigated the integrity of the 3 connections being used between the PC and the D180. Cable connections were confirmed and each checked firm. A second attempt was successfully completed.
An “Upgrade Firmware” was then attempted. A few minutes into the operation, the process began to have trouble, attempting a retry for the block write operations every few blocks, and subsequently progressing very slowly as a result. I estimated that the write rate would result in a couple of hours to complete, immediately realising that I had better quickly complete an external power connection before proceeding too long on internal battery. (Pilot User Guide, Product Overview – Power, pages 2-2 and 2-3 were quite sobering at this point!)
After about 90 minutes and a seriously depleted internal battery, the Product Support program indicated that it had lost connection with the D180 and aborted. “Upload Aborted – Error!!! Connection with FlightDEK-D180 has been lost”, followed by “Upload Failed – Try uploading again but do not disconnect ...”. The D180 then shutdown itself, (presumably because of a low internal battery voltage, but I’m not certain of that).
Expecting the worst, external power was connected and I was really surprised when the unit completed what appeared to be a normal “boot” sequence. The EFIS and EMS menus indicated that the firmware installed was Version 3.0.0. The unit appeared to be functional and would cycle correctly using the power switch and external power. The internal battery voltage was displayed as 0.0 within the EMS pages and apparently confirmed when the unit would not boot from internal battery.
While the D180 was connected to external power and switched on, the Product Support program was re-launched, establishing a connection with the D180, but the software indicated that the firmware upgrade was incomplete. Re-establishing a software connection resulted in “Continue last upload? – Error! Last upload did not complete successfully. Continue last upload?”
I decided to attempt an “Upload Firmware Backup”, successfully returning the D180 to Version 1.08 without any communications issues during the block write and in an appropriate time for the task.
At this point, I setup my Toshiba laptop on its expansion dock. The operating system is Windows XP Pro. The Product Support program was installed, launched and a direct serial connection was established with the D180, without the use of the serial converter.
Another attempt at the firmware upgrade to Version 3.0.0 resulted in a steady, continuous upload for about 12 minutes, without any of the previously observed stalling for rewrites. At Block #15,280, the same communications problem occurred, followed by 3 retries and then an abort with the same messages.
The D180 remained with a yellow screen. Relaunching a “Detect Firmware” call resulted in the expected “connection” with yellow screen, followed by a “disconnect” with D180 reboot and the appropriate firmware information returned to the PC.
Any reattempt to upload the Version 3.0.0 firmware results in the same communications failure at the same block.
The unit remains connected to the lab power supply and the EMS voltmeter shows the expected 13.8V. The EFIS information area voltmeters show M-13.8V, E-00.0V (expected) and I-15.3V.
I’ve kept the unit switched ON for now, pending further technical advice. Request DynonSupport comments and instructions please.
Regards,
MB