Flight Core 2 Firmware update through QGC

[hula]

@Vinny I hate to say this, but I believe you have a batch of defective USB cables. I was running into the same issue as @VictorG and @Michael-Mortensen , so I broke out the multimeter and confirmed that 5V and GND are swapped (note the negative 5V instead of +5V). I grabbed another generic USB cable that I had on-hand and the FCv2 powered up and connected to QGC fine.

ModalAI Support was kind enough to send me 3x replacement USBs...but unfortunately they are all mis-wired as well.

[Vinny]

Hi @hula
Interesting. I will investigate. The cable appears as it should according to our tech docs and every batch is sample tested but I will inspect further and respond tomorrow.
https://docs.modalai.com/cable-datasheets/#mcbl-00010
Thanks
Vinny

[Vinny]

Hi @hula
YOU ARE CORRECT!
I found a whole bag of mis-wired MCBL-00010's in our inventory.
I'll work with our @Moderator to figure out a plan.
We will likely need to setup an email where any customer can let us know if they have offending cables and we will send replacements promptly.

[hula]

@Vinny Glad I could help, and thank you for confirming so quickly on your side.

[VictorG]

Hi @Vinny,

If this is likely to be the explanation for the problem I reported, how can I get a good replacement cable? I'd rather try that first before going the alternative route of using the power module.

Thanks,
Victor

[Martin Lukac]

I just tested my cable and it is the same issue that caused mine to melt. I sent my board for RMA so I'll respond to that email thread.

FYI it is possible to pull the pins out and swap them, but it weakens the little plastic retaining piece so it is not as solid anymore ... and it makes it confusing since the red is now ground.

[Martin Lukac]

When you all are testing, can you also confirm that the two USB wires are not swapped. Thanks!

[Vinny]

@Martin-Lukac , @VictorG
Yes, we are working a replacement solution.
Exactly what @Martin-Lukac said is a temporary solution by swapping the conductors until we can source replacement cables. We might need a few weeks honestly.
Any HW that was compromised by this issue is an no-brainer replacement by my standards, and I will help ensure our production and operations team replaces any HW at jeopardy of this issue promptly. We have the HW in stock to replace, just not the USB cables as of yet.

We apologize for this issue. We actually had that batch of cables in stock for over 2 years and our sample lot from a different sealed bag in the same shipment that was tested did not experience this issue, so we were caught flat footed and we will put in better inspection processes to ensure this does not happen again.

Thanks!
Vinny

[VictorG]

Hi @Vinny, given my Flight Core 2 got extremely hot, do you think there is a good chance it is now fried? Or should I wait for the new cable to see if it will work? My preference is to not waste time and just get a replacement for both items if that is OK with you.

Thanks,
Victor

[Vinny]

Hi @VictorG
You should RMA the FlightCore and we should replace it. Just mention this thread or place a link to it in the form:
https://www.modalai.com/pages/rma?_pos=1&_sid=190e46152&_ss=r

We do not yet have a replacement set of cables, under normal circumstances, it takes us 6-8 weeks to get more, so we are trying to see if we have any small batch in our inventory to hold us over and replace every bad cable that we shipped.

If you want to try to re-pin your cable for the interim (you will not need to send it back, we can just replace it when we get more), try this link:
https://docs.modalai.com/cable-userguides/ and at the bottom are tips for re-pinning

or you can just search youtube for s JST GH re-pin tutorial and I'm sure you'll find plenty of good techniques. All that is needed is tweezers.

[VictorG]

Hi @Vinny,

I submitted the RMA, sent back the FC2 and got a replacement, along with two MCBL-10 cables. Before attempting to flash it with QGC I checked the voltage as lo and behold both cables showed -5.22 volts. Picture attached. Glad I did the test first or I would have fried the replacement FC2

[Vinny]

Hi @VictorG ,
That is unacceptable of us. I worked directly with operations to screen 100% of these units so I need to dig in and find out what happened.
So sorry and we'll get this sorted out.
FYI @Moderator

[VictorG]

Hi @Vinny,

What is your recommendation at this point? I can try to fix the cable myself, but please advise whether swapping the black and the red wires is the only change needed. If a replacement cable will be sent in the next few days, I'd rather wait for it.

Thanks,
Victor

[Vinny]

Hi @VictorG
Our team went back and quarantined all units again and we have some working.
I'll request they get shipped today, otherwise very soon!!
Again apologies for all the delays, distractions, and stress on this!!
Thanks for your patience.

[VictorG]

@Vinny any ETA on this?

[Vinny]

Hi @VictorG
I thought they sent it out last week. I'll ping the team again...
Thanks!

[Vinny]

HI @VictorG
The team told me they mixed up the original replacement with this request and thought they were done already. Sorry about that, they sent a new order today.

[VictorG]

Hi @Vinny, FYI I have not yet received it.

[Vinny]

Hi @VictorG
Our team sent another batch out...
FedEx tracking 884700036314
They claim Monday you should get it ... sorry for all these delays. We tried!!!

I do not have visibility into our product shipment status, but this issue and experience has escalated the need for me to have that visibility, so I will explore that.

We'll try better next time
Keep me posted.
Thanks!