GRASS VALLEY K2 DYNO - User manual

K2 Dyno
Replay Controller
Service Manual
071-8702-02
February 2012

Affiliate with the N.V. KEMA in The Netherlands
CERTIFICATE
Certificate Number: 510040.001
The Quality System of:
Thomson Inc, and its worLdwide Grass Valley division affiliates DBA
GRASS VALLEY
Headquarters
400 Providence Mine Rd
Nevada City, CA 95959
United States
15655 SW Greystone Ct.
Beaverton, OR 97006
United States
10 Presidential Way
Suite 300
Woburn, MA 01801
United States
Kapittelweg 10
4827 HG Breda
The Nederlands
7140 Baymeadows Way
Ste 101
Jacksonville, FL 32256
United States
2300 So. Decker Lake Blvd.
Salt Lake City, UT 84119
United States
Rue du Clos Courtel
CS 31719
35517 Cesson-Sevigné Cedex
France
1 rue de l’Hautil
Z.I. des Boutries BP 150
78702 Conflans-Sainte
Honorine Cedex
France
Technopole Brest-Iroise
Site de la Pointe du Diable
CS 73808
29238 Brest Cedex 3
France
40 Rue de Bray
2 Rue des Landelles
35510 Cesson Sevigné
France
Spinnereistrasse 5
CH-5300 Turgi
Switzerland
Brunnenweg 9
D-64331 Weiterstadt
Germany
Carl-Benz-Strasse 6-8
67105 Schifferstadt
Germany
Including its implementation, meets the requirements of the standard:
ISO 9001:2008
Scope:
The design, manufacture and support of video and audio hardware and software products and
related systems.
This Certificate is valid until: June 14, 2012
This Certificate is valid as of: June 14, 2009
Certified for the first time: June 14, 2000
H. Pierre Sallé
President
KEMA-Registered Quality
The method of operation for quality certification is defined in the KEMA General Terms
And Conditions For Quality And Environmental Management Systems Certifications.
Integral publication of this certificate is allowed.
KEMA-Registered Quality, Inc.
4377 County Line Road
Chalfont, PA 18914
Ph: [phone]
Fax: [phone]
CRT 001 073004
Accredited By:
ANAB
CERTIFICATE
Certificate Number: 510040.001
The Quality System of:
Grass Valley USA, LLC and its Grass Valley Affiliates
Headquarters:
400 Providence Mine Road
Nevada City, CA 95945
United States
15655 SW Greystone Ct.
Beaverton, OR 97006
United States
Brunnenweg 9
D-64331 Weiterstadt
Germany
Kapittelweg 10
4827 HG Breda
The Nederlands
2300 So. Decker Lake Blvd.
Salt Lake City, UT 84119
United States
Including its implementation, meets the requirements of the standard:
ISO 9001:2008
Scope:
The design, manufacture and support of video and audio hardware and software products and related
systems.
This Certificate is valid until: June 14, 2012
This Certificate is valid as of: December 23, 2010
Certified for the first time: June 14, 2000
H. Pierre Sallé
President
KEMA-Registered Quality
The method of operation for quality certification is defined in the KEMA General Terms And Conditions For
Quality And Environmental Management Systems Certifications. Integral publication of this certificate is allowed.
KEMA-Registered Quality, Inc.
4377 County Line Road
Chalfont, PA 18914
Ph: [phone]
Fax: [phone]
CRT 001 042108
A
ccredited By:
ANAB

K2 Dyno
Replay Controller
Service Manual
071-8702-02
February 2012

4K2 Dyno Service Manual
Contacting Grass Valley
Copyright © Grass Valley USA, LLC. All rights reserved.
This product may be covered by one or more U.S. and foreign patents.
Grass Valley Web Site
The www.grassvalley.com web site offers the following:
Online User Documentation — Current versions of product catalogs, brochures,
data sheets, ordering guides, planning guides, manuals, and release notes
in .pdf format can be downloaded.
FAQ Database — Solutions to problems and troubleshooting efforts can be
found by searching our Frequently Asked Questions (FAQ) database.
Software Downloads — Download software updates, drivers, and patches.
International
Support Centers
France
24 x 7 [phone] or [phone] United States/Canada 24 x 7 [phone] or [phone]
Local Support
Centers
(available
during normal
business hours)
Asia
Hong Kong, Taiwan, Korea, Macau: [phone] Indian Subcontinent: [phone]
Southeast Asia/Malaysia: [phone] Southeast Asia/Singapore: [phone]
China: [phone] Japan: [phone]
Australia and New Zealand: [phone] Central/South America: [phone]
Middle East: [phone] Near East and Africa: [phone] or [phone]
Europe
Belarus, Russia, Tadzikistan, Ukraine, Uzbekistan: [phone] Switzerland: [phone]
S. Europe/Italy-Roma: [phone] -Milan: [phone] S. Europe/Spain: [phone]
Benelux/Belgium: [phone] Benelux/Netherlands: [phone] N. Europe: [phone]
Germany, Austria, Eastern Europe: [phone] UK, Ireland, Israel: [phone]

02 February 2012 K2 Dyno Replay Controller Service Manual 5
Contents
Safety Summaries..............................................................................................7
Finding Information...........................................................................................25
Chapter 1 Product Description
Overview description...............................................................................................28
Dyno controller orientation ......................................................................................29
FRU functional descriptions ....................................................................................30
Base chassis ......................................................................................................30
Compact Flash boot media.................................................................................30
Jog knob.............................................................................................................30
Plastic cover.......................................................................................................30
T-bar lever assembly..........................................................................................31
Type I Control panel UI board ............................................................................31
Type II Control panel UI board ...........................................................................31
Type II Encoder ..................................................................................................32
LCD screen.........................................................................................................32
LCD screen inverter board .................................................................................32
Front I/O board ...................................................................................................32
Fan .....................................................................................................................32
USB board..........................................................................................................32
Motherboard.......................................................................................................32
Power supply......................................................................................................33
Status indicators......................................................................................................34
Rear panel indicators..........................................................................................34
System beep codes............................................................................................35
General specifications.............................................................................................35
Counter top installation............................................................................................36
Chapter 2 Service Procedures
Exporting log files (software version 2.x).................................................................37
Exporting log files (software version 1.x).................................................................37
Calibrating the control panel....................................................................................37
Upgrading software.................................................................................................38
Updating firmware (software version 2.x)................................................................38
Updating firmware (software version 1.x)................................................................38
Using recovery disk images ....................................................................................39
About the recovery disk image process..............................................................39
Creating a recovery disk image..........................................................................40
Restoring from a system-specific recovery disk image.......................................41
Restoring from a generic recovery disk image...................................................43
Replacing a Dyno controller....................................................................................44
Chapter 3 Troubleshooting problems
Step 1: Check configurations ..................................................................................48
Step 2: Check connections and external equipment...............................................48
Step 3: Identify problems using the startup sequence ............................................48
Step 4: Run hardware diagnostics ..........................................................................48
Run hardware diagnostics (software version 2.x)...............................................48
Run hardware diagnostics (software version 1.x)...............................................50
BIOS startup information.........................................................................................51
Shutdown/restart problems .....................................................................................51
Checking external equipment..................................................................................52
VGA display problems........................................................................................52
Keyboard and mouse problems..........................................................................52
BIOS startup............................................................................................................52
BIOS POST error messages...................................................................................52

6K2 Dyno Replay Controller Service Manual 02 February 2012
Contents
Windows startup...................................................................................................... 56
LCD screen problems ............................................................................................. 57
Thermal problems ................................................................................................... 57
Power supply problems........................................................................................... 57
Isolating functional problems................................................................................... 58
Chapter 4 Removing and replacing FRUs
Job knob removal.................................................................................................... 60
Control panel UI board identification....................................................................... 61
Job knob bearing assembly removal....................................................................... 62
Job knob replacement............................................................................................. 64
T-bar lever handle removal..................................................................................... 64
Compact Flash boot media removal ....................................................................... 65
Top removal ............................................................................................................ 66
Top unit cable removal Type I control panel UI board ............................................ 67
Top unit cable removal Type II control panel UI board ........................................... 68
Top replacement ..................................................................................................... 69
T-bar lever assembly removal................................................................................. 69
Plastic cover removal.............................................................................................. 70
LCD screen inverter board removal........................................................................ 71
Type I control panel UI board removal.................................................................... 72
Type II control panel UI board removal................................................................... 74
Type II encoder removal ......................................................................................... 76
LCD screen removal ............................................................................................... 77
Front I/O board removal.......................................................................................... 78
Fan removal ............................................................................................................ 79
Motherboard removal.............................................................................................. 80
Cabling diagram with Type I control panel UI board............................................... 81
Cabling diagram with Type II control panel UI board .............................................. 82
USB board removal................................................................................................. 83
Power supply removal............................................................................................. 84
Appendix A Trademarks and Agreements
Trademarks............................................................................................................. 86
Index...................................................................................................................... 87

02 February 2012 K2 Dyno Replay Controller Service Manual 7
Safety Summaries
Read the following sections for important safety information.
• Safety Summary
• Sicherheit – Überblick
• Consignes desécurité
• Certifications and compliances
• ESD Protection

8K2 Dyno Replay Controller Service Manual 02 February 2012
Safety Summaries
Safety Summary
Read and follow the important safety information below, noting especially those
instructions related to risk of fire, electric shock or injury to persons. Additional
specific warnings not listed here may be found throughout the manual.
Safety terms and symbols
Terms in this manual
Safety-related statements may appear in this manual in the following form:
Terms on the product
These terms may appear on the product:
DANGER — A personal injury hazard is immediately accessible as you read the
marking.
WARNING — A personal injury hazard existsbut is not immediately accessible as you
read the marking.
CAUTION — A hazard to property, product, and other equipment is present.
Symbols on the product
The following symbols may appear on the product:
WARNING:Anyinstructionsinthismanualthatrequireopening
the equipment cover or enclosure are for use by qualified service
personnel only. To reduce the risk of electric shock, do not
perform any servicing other than that contained in the operating
instructions unless you are qualified to do so.
WARNING: Warning statements identify conditions or practices
that may result in personal injury or loss of life.
CAUTION: Caution statements identify conditions or practices
that may result in damage to equipment or other property, or
which may cause equipment crucial to your business
environment to become temporarily non-operational.
Indicates that dangerous high voltage is present within the
equipment enclosure that may be of sufficient magnitude to
constitute a risk of electric shock.
Indicates that user, operator or service technician should refer to
product manual(s) for important operating, maintenance, or service
instructions.
Thisisa prompttonotefuseratingwhenreplacingfuse(s).Thefuse
referenced in the text must be replaced with one having the ratings
indicated.

02 February 2012 K2 Dyno Replay Controller Service Manual 9
Warnings
The following warning statements identify conditions or practices that can result in
personal injury or loss of life.
Dangerous voltage or current may be present — Disconnect power and remove battery
(if applicable) before removing protective panels, soldering, or replacing
components.
Do not service alone — Do not internally service this product unless another person
capable of rendering first aid and resuscitation is present.
Remove jewelry — Prior to servicing, remove jewelry such as rings, watches, and
other metallic objects.
Avoid exposed circuitry — Do not touch exposed connections, components or
circuitry when power is present.
Use proper power cord — Use only the power cord supplied or specified for this
product.
Ground product — Connect the grounding conductor of the power cord to earth
ground.
Operate only with covers and enclosure panels in place — Do not operate this product
when covers or enclosure panels are removed.
Use correct fuse — Use only the fuse type and rating specified for this product.
Use only in dry environment — Do not operate in wet or damp conditions.
Use only in non-explosive environment — Do not operate this product in an explosive
atmosphere.
High leakage current may be present — Earth connection of productis essential before
connecting power.
Dual power suppliesmay be present — Be certain to plug each power supply cord into
a separate branch circuitemployinga separate service ground. Disconnect both power
supply cords prior to servicing.
Double pole neutral fusing — Disconnect mains power prior to servicing.
Use proper lift points — Do not use door latches to lift or move equipment.
Avoid mechanical hazards — Allow all rotating devices to come to a stop before
servicing.
Identifiesaprotectivegroundingterminalwhichmust beconnected
to earth ground prior to making any other equipment connections.
Identifies an external protective grounding terminal which may be
connected to earth ground as a supplement to an internal grounding
terminal.
Indicates that static sensitive componentsare present which may be
damaged by electrostatic discharge. Use anti-static procedures,
equipment and surfaces during servicing.

10 K2 Dyno Replay Controller Service Manual 02 February 2012
Safety Summaries
Cautions
The following caution statements identify conditions or practices that can result in
damage to equipment or other property
Use correct power source — Do not operate this product from a power source that
applies more than the voltage specified for the product.
Use correct voltage setting — If this product lacks auto-ranging power supplies,
before applying power ensure that the each power supply is set to match the power
source.
Provide proper ventilation — To prevent product overheating, provide equipment
ventilation in accordance with installation instructions.
Use anti-static procedures — Static sensitive components are present which may be
damaged by electrostatic discharge. Use anti-static procedures, equipment and
surfaces during servicing.
Do not operate with suspected equipment failure — If you suspect product damage or
equipment failure, have the equipment inspected by qualified service personnel.
Ensure mains disconnect — If mains switch is not provided, the power cord(s) of this
equipment provide the means of disconnection. The socket outlet must be installed
near the equipment and must be easily accessible. Verify that all mains power is
disconnected before installing or removing power supplies and/or options.
Route cable properly — Route power cords and other cables so that they ar not likely
to be damaged. Properly support heavy cable bundles to avoid connector damage.
Use correct power supply cords — Power cords for this equipment, if provided, meet
all North American electrical codes. Operation of this equipment at voltages
exceeding 130 VAC requires power supply cords which comply with NEMA
configurations. International power cords, if provided, have the approval of the
country of use.
Use correct replacement battery — This product may contain batteries. To reduce the
risk of explosion, check polarity and replace only with the same or equivalent type
recommended by manufacturer. Dispose of used batteries according to the
manufacturer’s instructions.
Troubleshoot only to board level — Circuit boards in this product are densely
populatedwithsurfacemounttechnology(SMT)componentsandapplicationspecific
integrated circuits (ASICS). As a result, circuit board repair at the component level is
very difficult in the field, if not impossible. For warranty compliance, do not
troubleshoot systems beyond the board level.