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Oct 6, 2008

Issues caused by power supply harness used on early ESPs

Summary
We have seen cases where the power supply harness used on ESP-88s built prior to November 2008 can develop a poor connection reducing the voltage delivered to the cards and leading to a number of different issues.

Possible symptoms include:
  • ESP fails to boot correctly, Status LED remains unlit and communication cannot be established
  • One or more ESP expansion cards not detected correctly during a scan
  • ESP powers up with red Status LED and no audio passes.
  • Audio playing but ESP has become unresponsive to user controls such as the CC-64
  • Issues with serial communication via RS232 port.
Similar symptoms can also be caused by an incorrectly adjusted power supply

Cause
The pins on the power supply end of the harness can separate from the power supply pins causing a drop in voltage for the unit. Typically this drop was gradual and the unit would continue to play audio but may become unresponsive to controls such as the CC-64. In other situations, the ESP would not power on correctly and the Status LED would be unlit or red. This problem was most often observed in humid or high temperature environments.

Product
ESP-88 (manufactured before Nov 1 2008)

Workaround
Not Applicable

Resolution
Any ESPs manufactured after November 1, 2008, are fitted with a new harness which has an upgraded connector. The date of manufacture for an ESP can be determined by the 4 numbers following the ‘Z’ in the serial number. If the number is greater than 8305 (Nov 1, 2008) the unit includes the new harness:

ESP-88 041758Z70290047AE RoHS = Original Harness
ESP-88 041758Z84100047AE RoHS = Updated Harness

It is also possible to identify the harness visually. The original harness connector had a translucent plastic body.



Replacement harnesses are available for ESPs manufactured before November 1,2008. For critical installations or those operating in humid/high temperature environments you may want to consider upgrading the harness preemptively.

Two types of power supply have been used for the ESP-88/ESP-00 and the replacement harness and instructions are specific to each model. With the cover removed it is easy to identify the two versions by comparing with the pictures below:

Integrated Power Designs (IPD) Power Supply (used on earlier models)



Instructions for replacing harness on ESPs with IPD Power Supplies
Replacement harness for IPD PSU Part# 318938-001S

Astec Power Supply (used on later models)



Instructions for replacing harness on ESPs with Astec Power Supplies
Replacement harness for Astec PSU Part# 318935-001S

Links
Issues caused by an incorrectly adjusted ESP power supply
ESP fails to boot correctly - Status LED remains unlit
ESP fails to boot correctly - Red Status LED
One or more ESP expansion cards not detected correctly during scan
ESP is passing audio but has become unresponsive to changes made via CC-64
.