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Related Manuals for Fluke COMARK RF500A
Summary of Contents for Fluke COMARK RF500A
- Page 1 RF500A Gateway Service Manual Issue 1.0 17 November 2011...
- Page 2 Comark RF500A/AP Service Manual Copyright Copyright © 2011 by Comark Instruments. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise without the prior written permission of Comark Instruments.
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Page 3: Table Of Contents
Comark RF500A/AP Service Manual Contents Introduction..................................6 Related Documentation..............................6 Safety Information................................7 Warnings..................................7 WEEE....................................7 Specification..................................8 System Block Diagram.................................9 Visual Tour..................................10 Front View..................................10 Bottom View.................................11 Side View (USB Connector)............................11 Side View (Serial Number Label)..........................12 Top View..................................12 Software Utilities................................13 RF500A Config Utility..............................13 Driver Update Software..............................14 Tftpd32 Software..............................14... - Page 4 Comark RF500A/AP Service Manual Procedure.................................33 Replace μSDHC Cards..............................35 Replace μSDHC Card 1............................35 Replace μSDHC Card 2............................36 Replacement of both μSDHC Cards..........................36 Tier 3: RF500A Component Level Repair..........................37 Operator Technical Competency...........................37 Functional Test Equipment Required..........................37 Initial Observation.................................37 Status Indicators..............................37 Circuit Diagrams..............................37 Circuit Description................................38...
- Page 5 Comark RF500A/AP Service Manual check SD card slots possible error with SD1........................54 File Error..................................54 Appendix D – Restore Data to an RF500A/AP........................55 Restore From Manual Backup............................55 Restore From Shared Drive Backup..........................56 Appendix E – RF500A/AP Hidden Commands.........................58 Clear Data Commands..............................58 clr-data..................................58...
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Page 6: Introduction
Comark RF500A/AP Service Manual Introduction Introduction This manual is intended for all aspects of fault diagnosis and repair for the RF500A/AP. It is structured into 3 tiers of testing each requiring more technical competence than the last. Each tier indicates the technical requirements at the beginning of the section under the “Operator Technical Competency”... -
Page 7: Safety Information
Comark RF500A/AP Service Manual Safety Information Safety Information Under no circumstances may a user make any changes to the RF500A Gateway that would alter its performance. Any modification would void the CE compliance of the Gateway and may invalidate the warranty. -
Page 8: Specification
Comark RF500A/AP Service Manual Specification Specification No of Channels Up to 256 No of Transmitters Up to 64 Storage Capacity Up to 10 years storage RF Frequency 2.4GHz using IEEE 802.15.4 Operating Conditions 0°C to 40°C, 10-90% RH non-condensing AC power adaptor, rechargeable Ni-Mh battery... -
Page 9: System Block Diagram
Comark RF500A/AP Service Manual System Block Diagram System Block Diagram 17 November 2011 Page 9 of 65... -
Page 10: Visual Tour
Comark RF500A/AP Service Manual Visual Tour Visual Tour Front View Item Description Steady Blue: Gateway is running ¼s on ¼s off Blue : Gateway is starting up 2s off 2s on Blue: Gateway is shutting down POWER/BATTERY Steady Green: External Power is available... -
Page 11: Bottom View
Comark RF500A/AP Service Manual Visual Tour Bottom View Item Description Cable Clamp To secure cables during installation 12V DC Input Input for Friwo DT12 external power adapter Jack Socket for Relay Output 1 Jack Socket for Relay Output 2 RJ45 Socket... -
Page 12: Side View (Serial Number Label)
Comark RF500A/AP Service Manual Visual Tour Side View (Serial Number Label) Item Description Model Indicates which build variant the unit is (RF500AP is the PoE version) ON/OFF Switch Gateway Startup/Powerdown switch Status LED's Diagnostic LEDs (See Fault Code table) AUX Button... -
Page 13: Software Utilities
Comark RF500A/AP Service Manual Software Utilities Software Utilities RF500A Config Utility This accompanying software is released to the customer to allow basic configuration of the unit via the USB interface. Additionally it can provide a status report to aide fault finding. -
Page 14: Driver Update Software
Comark RF500A/AP Service Manual Software Utilities Driver Update Software The stock PC module requires custom drivers to be installed before it can be used in an RF500A/AP. A simple software utility is available to apply the update. The system uses the USB port for control and the Ethernet port for the actual data transfer. -
Page 15: Hyper-Terminal
Comark RF500A/AP Service Manual Software Utilities Hyper-terminal Further access to the RF500A/AP can be gained using a terminal program such as Hyper-terminal. Root access can be achieved via the USB port for further fault diagnosis. Hyper-terminal Settings Item Description Comms Port This is the Virtual Com Port created by the USB drives (if the number is not known it can be found in Device Manager →... -
Page 16: Disassembly
Comark RF500A/AP Service Manual Disassembly Disassembly Tools To disassemble an RF500A/AP you will need the following tools: Wrist grounding strap and conductive mat for preventing electrostatic discharge • Phillips screwdriver • 8mm box driver • 5mm box driver • Thin nose pliers •... -
Page 17: Exploded View
Comark RF500A/AP Service Manual Disassembly Exploded View 17 November 2011 Page 17 of 65... -
Page 18: Remove Μsdhc Cards
Comark RF500A/AP Service Manual Disassembly Remove μSDHC Cards The memory cards are located behind the metal plate located on the USB connector side of the unit: Remove the 2 retaining screws: The memory cards are now exposed and can be removed. -
Page 19: Remove Case Front
Comark RF500A/AP Service Manual Disassembly Remove Case Front Remove the 8 case retaining screws securing the case front to the case rear: USB Side View Serial Number Side View Top View Bottom View The case front can now be carefully removed. -
Page 20: Remove Rf Shield
Comark RF500A/AP Service Manual Disassembly Remove RF Shield Remove the 3 retaining screws: Once the retaining screws have been removed the shield will simply lift off. Remove the PC Module Remove the 2 hexagonal pillars with the 5mm box driver: Once the pillars have been removed the module will self locate for removal. -
Page 21: Remove The Main Pcb From Base Plate
Comark RF500A/AP Service Manual Disassembly Remove the main PCB from base plate Undo the brass nut securing the antenna connector to the base plate using the 8mm box driver: Remove Nut and Washer Now remove the 4 remaining PCB securing screws: Once removed the PCB will slide away from the antenna hole as indicated. -
Page 22: Remove Rf Pcb From Main Pcb
Comark RF500A/AP Service Manual Disassembly Remove RF PCB from main PCB The RF PCB is secured to the main PCB by 3 nylon pillars: Using a pair of thin nosed pliers, Now gently lift the edge of the PCB: compress the head of the pillar: Repeat the process on each of the 3 pillars and then gently remove the RF PCB. -
Page 23: Fully Disassembled Replaceable Parts
Comark RF500A/AP Service Manual Disassembly Fully Disassembled Replaceable Parts Part No. Item Comments 20077/2 Case Front Including all labels 20078 Case Rear Including all labels 20079 Memory Card Plate A20052 Main Board Including Battery Pack and board level interconnect lead... -
Page 24: Reassembly
Comark RF500A/AP Service Manual Reassembly Reassembly Reassembly is the reverse of the disassembly process: 1. Replace the RF module 2. Secure the main PCB to the chassis base plate: ◦ Tighten RF nut (support the RF module when tightening the nut). -
Page 25: Tier 1: Rf500A Functional Testing
Comark RF500A/AP Service Manual Tier 1: RF500A Functional Testing Tier 1: RF500A Functional Testing Operator Technical Competency The Tier 1 section can be followed by a non-technician level operator. Functional Test Equipment Required RF500A AC Adaptor • PoE Injector Mode-A •... -
Page 26: Startup Sequence
Comark RF500A/AP Service Manual Tier 1: RF500A Functional Testing Startup Sequence PLUG IN MAINS CHECK Flashing READ STATUS KNOWN FAULT SEE FAULT LEDS APPENDIX B IS PWR CHECK EXTERNAL TURN ON CHECK FAULT CHECK IS ON LED Strobeing STATUS BATTERY CHARGING... -
Page 27: Battery Test
Comark RF500A/AP Service Manual Tier 1: RF500A Functional Testing Battery Test Initial Conditions: Mains Power Attached • RF500A/AP successfully booted and website running • UNPLUG MAINS IS PWR LED ARE ANY BATTERY FAULT FLASHING LEDS ON SUCCESSFUL TEST PCB LEVEL FAULT... -
Page 28: Network Test
Comark RF500A/AP Service Manual Tier 1: RF500A Functional Testing Network Test Initial Conditions: Mains Power Attached • RF500A/AP successfully booted and website running • PLUG IN NETWORK CABLE ARE LAN CONNECTOR FAULT LEDs SUCCESSFUL TEST Alarm Output Test Initial Conditions: Mains Power Attached •... -
Page 29: Alarm Led Test
Comark RF500A/AP Service Manual Tier 1: RF500A Functional Testing Alarm LED Test Initial Conditions: Mains Power Attached • RF500A/AP successfully booted and website running • Add and task a transmitter to the system, ensure the task has alarm limits and force the transmitter into alarm. Configure the transmitter location to enable alarms. -
Page 30: Tier 2: Rf500A Module Replacements
Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements Tier 2: RF500A Module Replacements Operator Technical Competency The Tier 2 section requires a technician level operator. Test Equipment Required RF500A AC Adaptor. • PoE Injector. • Computer running Microsoft Windows with Comark RF500ACONFIG Utility, Driver Update Utility and •... -
Page 31: Replace The Battery Pack
Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements Replace the Battery Pack Completely disassemble the RF500A/AP as per the Disassembly section. NOTE: Self adhesive pads should be cut with sharp knife when lifting the battery pack. The battery pack is held in place by 2 cable ties that pass through 4 holes in the PCB. Additionally there are 4 double sided adhesive foam pads under the pack. -
Page 32: Replace Rf Module
Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements Replace RF Module Remove the RF module as described in the Disassembly section above. Replace with new unit (pre-configured with RF500A firmware A4/AI/11277) and reassemble into case. Reboot the RF500A/AP and add a transmitter to the system, ensure the transmitter is found and tasks. -
Page 33: Replace Pc Module
Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements Replace PC Module Remove the PC module as described in the Disassembly section above(Remove the PC Module). Replace with new unit and secure into place. Upload latest drivers Before starting this procedure the following conditions must be met: Remove both SD cards •... - Page 34 Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements 4. Run Tftpd32 in the background as this will show transfers and the test PC ip address needed later. 5. From the start menu go to the Comark program group and run “RF500A Driver Update Util”...
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Page 35: Replace Μsdhc Cards
Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements Replace μSDHC Cards The following procedure will describe how to change one or both of the memory cards. The RF500A/AP will inform the user of memory card problems via error messages displayed on the web interface see Appendix C – Website Error Messages. -
Page 36: Replace Μsdhc Card 2
Comark RF500A/AP Service Manual Tier 2: RF500A Module Replacements Replace μSDHC Card 2 1. Switch off the RF500A/AP and remove mains/PoE power. 2. Remove the memory card door as described in Remove μSDHC Cards. 3. Replace SD2 with a blank. -
Page 37: Tier 3: Rf500A Component Level Repair
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Tier 3: RF500A Component Level Repair Operator Technical Competency The Tier 3 section requires an engineer level operator. Functional Test Equipment Required RF500A AC Adaptor • PoE Injector Mode-A •... -
Page 38: Circuit Description
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Circuit Description Power Supply The PSU for RF500A can be broken down into three main power sources each having ancillary electronics associated with them. The remainder of the PSU is common between these three sources. -
Page 39: Usb
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair U541 is a Silicon Labs CP2102 UART to USB bridge, it is configured in self powered mode so will only operate when the 5V rail is active. TVS541,2 & 3 provide protection from transient spikes, it should be noted that TVS542 and TVS543 are special low capacitance type for hi speed transmission lines. -
Page 40: In Circuit Testing
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair In Circuit Testing The testing detailed here should be performed on a PCB with the PC module removed but the battery in placed and charged, any test requiring a deviation from this criteria will specify in the instructions. -
Page 41: Common Power Rail (Pwr)
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Common Power Rail (Pwr) This is the common power rail, it will always be the input voltage (Either external supply, PoE or battery) less the diode drop of either D306, D311 or D323 (see respective data sheets for diode drop) depending on the input. -
Page 42: Usb Chip Verification
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair USB Chip Verification This test requires the “N5001USB-Tools.exe” software and paired original Silicon Labs USB drivers. Ensure a charged battery pack is plugged in and turn on the main board (press and hold the On/Off switch for 4 seconds). Making sure no other RF500A/AP devices are attached to the USB port of the test PC plug in the DUT to the USB port of the PC. -
Page 43: Replace Poe Module
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Replace PoE Module The PoE module (U321) is a conventional component and is soldered directly to the main PCBA: PoE Module De-solder the 10 pins remove the module and replace, no further configuration is required. -
Page 44: Control Mpu Firmware Upgrade
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Control MPU firmware upgrade NOTE: Remove battery pack and all power before continuing! The control MPU is an Atmega329, both an E-Lab ISP USB programmer and E-LAB AVR ISP-ICP software are required for this process. -
Page 45: Check The Fuses
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Check the Fuses If only trying to upgrade the firmware this step is optional. 1. Plug the programming lead into the 6-way connector site marked J423. Make sure Pin-1 goes to the square pad. -
Page 46: Fault Finding
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Fault Finding Before any component level fault finding the following should be checked for: • Missing Components • Lifted Pins • Dry Joints • Solder Shorts • Ensure inter-connecting tracks reach their destination Common faults resulting in the MPU not functioning are: •... -
Page 47: 3Vc Rail
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair 3VC Rail If the 3VC rail is inoperative of out of specification, common items to check would be: • Check supply to U361 • Check D361 and D362 • Ensure inter-connecting tracks reach their destination •... -
Page 48: Additional Fault Diagnostic Information
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Additional Fault Diagnostic Information The RF500A/AP web interface can provide additional information for intermittent type faults which can be more troublesome to identify. Hardware Status Page Only the “System” section of the hardware page will be discussed here, for further information regarding the rest of the page consult the web view manual. -
Page 49: Audit Trail Information
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Brownout Reset Event This is the number of times the MPU has been reset due to a Brownout reset, the voltage threshold is set at 2.7V. This should remain at 0, anything else could imply PSU problems. -
Page 50: Email Output Screen
Comark RF500A/AP Service Manual Tier 3: RF500A Component Level Repair Email Output Screen To aid with any email issues there is a button on the email setup page called output, this displays the email script and email server response of the last attempted email. The image below is an example of a successful attempt: If there are any issues with emails this output screen can provide detailed information to help the diagnosis of the problem. -
Page 51: Appendix-A - Front Panel Indicators
Comark RF500A/AP Service Manual Appendix-A – Front Panel Indicators Appendix-A – Front Panel Indicators The Front Panel Indicators show information about the Gateway under normal operation conditions. P O W E R / F A U L T A L A R M... -
Page 52: Appendix B - Status Indicators
Comark RF500A/AP Service Manual Appendix B – Status Indicators Appendix B – Status Indicators The Status Indicators are found on the LHS of the Gateway and indicate self-diagnosed faults when accompanied by the Font Panel Fault indicator. C o m a r k I n s t r u m e n t s , 5 2 H u r r i c a n e w a y ,... -
Page 53: Appendix C - Website Error Messages
Comark RF500A/AP Service Manual Appendix C – Website Error Messages Appendix C – Website Error Messages No Hardware Pass message Actual Message: No Hardware Pass message The RF500A/AP has detected that the control PCBA has not been tested correctly at the manufacturing stage, the board must be returned to the PCBA manufacturer and run through the Comark PCBA test equipment. -
Page 54: Check Sd Card Slots Possible Error With Sd2
Comark RF500A/AP Service Manual Appendix C – Website Error Messages check SD card slots possible error with SD2... Actual Message: check SD card slots possible error with SD2 or card in wrong slot The RF500A/AP has detected the master SD card but cannot access it. Replace the master SD card as described in the Replace μSDHC Card 2 section. -
Page 55: Appendix D - Restore Data To An Rf500A/Ap
Comark RF500A/AP Service Manual Appendix D – Restore Data to an RF500A/AP Appendix D – Restore Data to an RF500A/AP NOTE: Network settings are not restored as part of this process and have to be entered manually. Restore From Manual Backup Using the latest manual back up file the procedure is as follows: 1. -
Page 56: Restore From Shared Drive Backup
Comark RF500A/AP Service Manual Appendix D – Restore Data to an RF500A/AP Restore From Shared Drive Backup Navigate to the shared drive containing the backup. The folder structure will be: COMARK_RF500 RF500_CSV_EXPORT RF500_SNO_xxxxxxxx-IDxxxx RF500_SNO_xxxxxxxx-IDxxxx RF500_DATA_BACKUP RF500_BKUP4_SNO_xxxxxxxx-IDxxxx RF500_BKUP4_SNO_xxxxxxxx-IDxxxx 1. Within the RF500_DATA_BACKUP folder find the latest folder with the correct serial number and the most recent date. - Page 57 Comark RF500A/AP Service Manual Appendix D – Restore Data to an RF500A/AP 6. The following message should be displayed: 7. The RF500A/AP will now restart. 8. Once the reboot has completed login as one of the users (that have now been restored) and reset the network settings, if required.
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Page 58: Appendix E - Rf500A/Ap Hidden Commands
Comark RF500A/AP Service Manual Appendix E – RF500A/AP Hidden Commands Appendix E – RF500A/AP Hidden Commands The RF500A/AP contains hidden service and diagnostic level commands which can be useful. THESE COMMANDS CAN POTENTIALLY WIPE STORED DATA ON THE RF500A/AP ONLY USE IF ABSOLUTLY NECASSARY... -
Page 59: Clr-Datax
Comark RF500A/AP Service Manual Appendix E – RF500A/AP Hidden Commands clr-datax This command will clear all data and settings on the RF500A/AP with the exception of the IP address and shut down the gateway, since the memory cards will not be initialised they could be removed and used elsewhere. The command is called from: Administration →... -
Page 60: Utility Commands
Comark RF500A/AP Service Manual Appendix E – RF500A/AP Hidden Commands Utility Commands The following commands all required the same input method, using a web browser type the following: http://your-ip-address/cgi-bin/msg?msg=command-name • Where: your-ip-address is the current IP address of the RF500A/AP •... -
Page 61: Sshd
Comark RF500A/AP Service Manual Appendix E – RF500A/AP Hidden Commands sshd If remote access to the RF500A/AP command line/operating system is required it is possible to enable a Secure Shell (SSH) connection. Once the command has been run the RF500A/AP will respond as follows:... - Page 62 Comark RF500A/AP Service Manual Appendix E – RF500A/AP Hidden Commands The first time PuTTY connects to a new RF500A/AP if will ask the user if it is ok to store a key fingerprint: Select “Yes” and you will be presented with the login screen. Login to the RF500A/AP using the following details: User Name: root •...
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Page 63: Mbklog
Comark RF500A/AP Service Manual Appendix E – RF500A/AP Hidden Commands mbklog This command displays the log generated when creating a manual backup, the excerpt below illustrates a successful backup request. If a manual backup fails this log will detail the error. -
Page 64: Appendix F - Repair Procedure For Rf500 Radio Module
Comark RF500A/AP Service Manual Appendix F – Repair Procedure for RF500 RADIO MODULE Appendix F – Repair Procedure for RF500 RADIO MODULE Recovery from Transmitter Error 104 Condition Operation of the module at Vcc below 2.7V does cause problems requiring re-flashing of the firmware. This can occur in a RF51X transmitter running firmware prior to 2.0.0 when ever the battery becomes very low. - Page 65 Comark RF500A/AP Service Manual Appendix F – Repair Procedure for RF500 RADIO MODULE Press 1 for “Program Upload” Await the XMODEM prompt character 'C'. Send the file: Cipher-Meter-EM2420_RF1.1R.bin using XMODEM (In HyperTerminal use Transfer - Send File) Upon successful upload choose option-3 “run program image”.