Fluke COMARK RF500A User manual

RF500A Gateway
Service Manual
Issue 1.0
17 November 2011

Comark RF500A/AP Service Manual
Copyright
Copyrig t © 2011 by Comark Instruments. All rig ts reserved. No part of t is 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, mec anical, magnetic, optical, c emical, manual or ot erwise wit out t e prior written
permission of Comark Instruments.
Disclaimer
T e information in t is guide is subject to c ange wit out notice.
Comark Instruments makes no representations or warranties, eit er expressed or implied, wit respect to t e contents
ereof and specifically disclaims any warranties of merc antability or fitness for any particular purpose. Any Comark
Instruments software described in t is manual is licensed “as is”. S ould t e programs prove defective following t eir
acquisition t e user (and not Comark Instruments) assumes t e entire cost of all necessary servicing, repair and any
incidental or consequential damages resulting from any defect in t e software.
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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
Hyper-terminal..............................................................................................................................................................15
Hyper-terminal Settings..........................................................................................................................................15
Disassembly........................................................................................................................................................................16
Tools..............................................................................................................................................................................16
Prerequisites..................................................................................................................................................................16
Exploded View..............................................................................................................................................................17
Remove μSDHC Cards.................................................................................................................................................18
Remove Case Front.......................................................................................................................................................19
Remove RF S ield........................................................................................................................................................20
Remove t e PC Module................................................................................................................................................20
Remove t e main PCB from base plate........................................................................................................................21
Remove RF PCB from main PCB.................................................................................................................................22
Fully Disassembled Replaceable Parts.........................................................................................................................23
Reassembly.........................................................................................................................................................................24
Replace Case Front.......................................................................................................................................................24
Tier 1: RF500A Functional Testing....................................................................................................................................25
Operator Tec nical Competency...................................................................................................................................25
Functional Test Equipment Required............................................................................................................................25
Initial Observation.........................................................................................................................................................25
Status Indicators......................................................................................................................................................25
Startup Sequence...........................................................................................................................................................26
Battery Test...................................................................................................................................................................27
Power Over Et ernet (PoE) Testing..............................................................................................................................27
Network Test.................................................................................................................................................................28
Alarm Output Test.........................................................................................................................................................28
Alarm LED Test............................................................................................................................................................29
Radio Module Test........................................................................................................................................................29
Audit Trail & System Software Test ............................................................................................................................29
S utdown Test...............................................................................................................................................................29
Software...................................................................................................................................................................29
Hardware.................................................................................................................................................................29
Tier 2: RF500A Module Replacements..............................................................................................................................30
Operator Tec nical Competency...................................................................................................................................30
Test Equipment Required..............................................................................................................................................30
Initial Observation.........................................................................................................................................................30
Status Indicators......................................................................................................................................................30
Replace t e Battery Pack..............................................................................................................................................31
Replace RF Module......................................................................................................................................................32
Replace PC Module......................................................................................................................................................33
Upload latest drivers................................................................................................................................................33
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Comark RF500A/AP Service Manual
Procedure.................................................................................................................................................................33
Replace μSDHC Cards..................................................................................................................................................35
Replace μSDHC Card 1..........................................................................................................................................35
Replace μSDHC Card 2..........................................................................................................................................36
Replacement of bot μSDHC Cards.............................................................................................................................36
Tier 3: RF500A Component Level Repair..........................................................................................................................37
Operator Tec nical Competency...................................................................................................................................37
Functional Test Equipment Required............................................................................................................................37
Initial Observation.........................................................................................................................................................37
Status Indicators......................................................................................................................................................37
Circuit Diagrams.....................................................................................................................................................37
Circuit Description........................................................................................................................................................38
Power Supply..........................................................................................................................................................38
External Mains Power.............................................................................................................................................38
Power Over Et ernet (PoE).....................................................................................................................................38
Battery.....................................................................................................................................................................38
Main 5V Rail...........................................................................................................................................................38
Permanent 3.3V Rail...............................................................................................................................................38
Control MPU Circuit...............................................................................................................................................38
PC Module...............................................................................................................................................................38
USB.........................................................................................................................................................................39
RF Module...............................................................................................................................................................39
Real Time Clock (RTC)...........................................................................................................................................39
In Circuit Testing...........................................................................................................................................................40
Common Power Rail (Pwr).....................................................................................................................................41
5V Rail....................................................................................................................................................................41
3VM Rail.................................................................................................................................................................41
3VC Rail..................................................................................................................................................................41
Battery C arging.....................................................................................................................................................41
USB C ip Verification.............................................................................................................................................42
Replace PoE Module...............................................................................................................................................43
Control MPU firmware upgrade...................................................................................................................................44
C eck t e Fuses.......................................................................................................................................................45
Program t e Firmware.............................................................................................................................................45
Fault Finding.................................................................................................................................................................46
MPU........................................................................................................................................................................46
Serial Communications...........................................................................................................................................46
USB Communications.............................................................................................................................................46
5V Rail....................................................................................................................................................................46
3VM Rail.................................................................................................................................................................46
3VC Rail..................................................................................................................................................................47
Battery C arging.....................................................................................................................................................47
PoE (If Fitted)..........................................................................................................................................................47
RTC.........................................................................................................................................................................47
Memory Cards.........................................................................................................................................................47
Additional Fault Diagnostic Information......................................................................................................................48
Hardware Status Page..............................................................................................................................................48
Audit Trail Information...........................................................................................................................................49
Email Output Screen...............................................................................................................................................50
Appendix-A – Front Panel Indicators.................................................................................................................................51
Appendix B – Status Indicators..........................................................................................................................................52
Battery Pack Pre-C arge Indication..............................................................................................................................52
Appendix C – Website Error Messages..............................................................................................................................53
No Hardware Pass message..........................................................................................................................................53
SD cards appear to be in t e wrong slots......................................................................................................................53
SD cards appear to ave different data ID tags ............................................................................................................53
Looks like you ave no data on t e master SD.............................................................................................................53
booted up from backup SD card...................................................................................................................................53
c eck SD card slots possible error wit SD2................................................................................................................54
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Comark RF500A/AP Service Manual
c eck SD card slots possible error wit SD1................................................................................................................54
File Error.......................................................................................................................................................................54
Appendix D – Restore Data to an RF500A/AP..................................................................................................................55
Restore From Manual Backup......................................................................................................................................55
Restore From S ared Drive Backup.............................................................................................................................56
Appendix E – RF500A/AP Hidden Commands.................................................................................................................58
Clear Data Commands..................................................................................................................................................58
clr-data.....................................................................................................................................................................58
clr-datax...................................................................................................................................................................59
Utility Commands.........................................................................................................................................................60
emberlog2................................................................................................................................................................60
ss d..........................................................................................................................................................................61
Connecting wit PuTTY.........................................................................................................................................61
mbklog..........................................................................................................................................................................63
Command List...............................................................................................................................................................63
Appendix F – Repair Procedure for RF500 RADIO MODULE........................................................................................64
Recovery from Transmitter Error 104 Condition..........................................................................................................64
17 November 2011 Page 5 of 65

Comark RF500A/AP Service Manual Introduction
Introduction
T is manual is intended for all aspects of fault diagnosis and repair for t e RF500A/AP. It is structured into 3 tiers of
testing eac requiring more tec nical competence t an t e last. Eac tier indicates t e tec nical requirements at t e
beginning of t e section under t e “Operator Technical Competency” eading.
Familiarity wit use of t e RF500A Gateway is assumed and procedures suc as t ose w ic appear in t e user manual
or RF500A System Manual will not be detailed ere.
Related Documentation
Installation and Basic Operation RF500A System Manual
Web Interface Operation RF500A-WebView Help
RF500A System Manual is supplied in printed form wit eac Gateway
T e above can be downloaded from ttp://www.comarkltd.com/comark-operator-manuals.tpl
17 November 2011 Page 6 of 65

Comark RF500A/AP Service Manual Safety Information
Sa ety In ormation
Under no circumstances may a user make any c anges to t e RF500A Gateway t at would alter its performance. Any
modification would void t e CE compliance of t e Gateway and may invalidate t e warranty.
If t e equipment is used in a manner not specified by Comark Instruments, t en t e protection provided by t e
equipment may be impaired.
Warnings
•Before connecting or disconnecting t e antenna, ensure anti-static precautions are observed.
•Use only t e FRIWO 12V AC adaptor; Type FW74010/12 as supplied; wit t e RF500A Gateway.
•Do not modify t e RF500A Gateway AC adaptor in any way.
•Use only t e PHIHONG, PSM11R-050 5V AC adaptor or FRIWO type FW7662/05 wit RF500 Transmitters.
It is supplied by Comark Instruments as t ree variants:
RF520 Transmitter AC adaptor wit UK plug
RF520/EU Transmitter AC adaptor wit European style plug
RF520/US Transmitter AC adaptor wit Nort American style plug
•Do not modify t e AC adaptor in any way.
•RF500 Transmitters contain a C-size lit ium cell. T is cell must not be incinerated or subjected to temperatures
in excess of 100°C. Do not deform, mutilate, crus , pierce, disassemble, rec arge or s ort circuit. Suc abuse
can result in loss of seal, and/or cell explosion. Also exposure to umid conditions for long periods s ould be
avoided.
•Do not insert metal objects into connectors.
•Ensure t e antenna is securely connected before powering t e equipment. Internal damage may result
ot erwise.
•T e Gateway and Transmitters ave been designed to operate wit t e antenna supplied by Comark, and aving
a maximum gain of 7dBi. Antennas not supplied by Comark Instruments or aving a gain of greater t an 7dBi
are strictly pro ibited for use wit t is device. T e required antenna impedance is 50 O ms. If in doubt please
contact Comark Instruments or your Distributor for advice.
WEEE
RF512, RF513, RF515 and RF516 Transmitters contain a non-rec argeable lit ium battery. T is battery
must be disposed of in accordance wit local regulations.
17 November 2011 Page 7 of 65

Comark RF500A/AP Service Manual Specification
Speci ication
No of C annels 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
Power Sources
AC power adaptor, rec argeable Ni-M battery
RF500AP only:
Power over Et ernet (PoE) capability. Compliant to
IEEE 802.3af
Power Adaptor 100-240VAC 1.5A 50/60Hz
FRIWO DT12 12V 1A O/P
Battery Backup 4.3A Ni-M Rec argeable Battery.
Running time approximately 1 our
Clock Accuracy 4ppm (2 minutes per year)
Relay Outputs (SW1 & SW2) Two individual 2.5mm jack sockets.
Contacts: 24Vdc 500mA maximum
Power Consumption 12W Max
Dimensions L 225mm x W 150mm x D 40mm
Weig t 1.3kg
17 November 2011 Page 8 of 65

Comark RF500A/AP Service Manual System Block Diagram
System Block Diagram
17 November 2011 Page 9 of 65

Comark RF500A/AP Service Manual Visual Tour
Visual Tour
Front View
No. Item Description
1ON Steady Blue: Gateway is running
¼s on ¼s off Blue : Gateway is starting up
2s off 2s on Blue: Gateway is s utting down
2POWER/BATTERY Steady Green: External Power is available
Flas ing Green: Gateway is on and running off t e battery pack
Off: Gateway is off and external power is not available
3FAULT Flas ing: T ere is a fault wit t e system, could indicate ardware or
software fault
4ALARM Flas ing Red: An enabled alarm event as occurred
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