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Description
First off my apologies for the delay in getting this issue resolved, as we're launching some new products on a tight schedule so I've been super busy working with that.
As a first step I wanted to setup this new issue with a more detailed diagnosis of what's caused this issue, what the plan to fix it will be and answer some questions.
So what's caused the issue?
The most recent batch of pHATs have been programmed with a newer firmware, of which the manufacturer of the Radio module we use decided to change significantly the commands the module uses so the commands the Pi issues aren't no longer what the Module expects.
This has caused the latest batch to break, it isn't common for a component like this to change the way it communicates without for example changing the part number or maintaining some level of backwards compatibility.
What's the fix?
There's two possible fixes to work around this.
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Firmware Downgrade - It is possible to downgrade the firmware on the modules, while not a complicated process it is a process that we'd need to document and perform a few times ourselves to ensure it works. At the same time we currently don't have the capacity to re-program the rest that are sitting in stock as some distributors may already have received stock of these so we can't ensure they would all be done.
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Update the Library - This is the route we're going to try and do, essentially it shouldn't be complicated just more a time consuming task. This would however pose the issue of which version of firmware is the unit running and matching this to the version of software.
 
It's likely that for now we'd then have the two versions of software with the default then being the newer one but keeping it possible to still install the old one.
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Later on it would then be nice to integrate the ability for the same version to either support both and automatically detect, or have a flag in the software. However I think to begin with the main focus will be a new version just supporting the new one.
Why has this happened?
The first few batches came with the original firmware as default and later batches we got the supplier of the modules to keep with the older version to prevent this from happening.
However for the latest batch a miscommunication issue happened and instead the latest set was shipped with the newest firmware sent.
Why wasn't this picked up in testing?
While quite a lot of our products are tested to a further extent, these undergo only an electrical test during production to ensure all the electrical traces are correct and a full test isn't performed.
As the firmware isn't programmed by us, it's not something we would have checked for compared to other products where we program firmware onto the modules.
Until this batch, I believe we've had a <2% failure rate which is why we've not had to add extra testing during production.
TL;DR
The latest batch unfortunately has a new version of software that causes them to not work, I'm working on getting a fix out ASAP.
If you've got any other questions feel free to post them above and I'll try to help out where possible.