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DLPC900REF-SW: Uploading of firmware to certain DLP6500 projectors Stuck at 58% then GUI hang

Part Number: DLPC900REF-SW
Other Parts Discussed in Thread: DLPC900

Tool/software:

We have a DLP6500 firmware that we used for years without any issues in our production floor when uploading the firmware to DLP6500. Starting this year, somehow there are bunches of DLP6500 having issue when we try to upload the same firmware to the projector. It will stuck at 58% during programming then causing GUI to hang. It happens to be the same even after we reset the projector using JTAG module.

Screenshot

This cause serious interruption to our production operation as we need to filter out projectors that cant be flashed.

We try to rebuild and debug the GUI using Sources folder that comes with the application installation. 

It seems that stuck in GetOverlappedResult() function in hid_write function in hid.c file

debugger

Have anyone face this issue before, we are trying to find out the root cause but unsure whether this is hardware issue or it can be solved in software application.


We are using DLPC900REF-SW-4.0.1 by the way

We also did try flash it using DLPC900REF-SW-5.0.0, it is still the same