As the first SPARK Flex and NEO Vortex units are starting to be delivered to their pre-order customers, we'd like to take this opportunity to talk about the some day-zero software updates as well as some manufacturing variances you may encounter.

REVLib and REV Hardware Client Updates for SPARK Flex

Updated software resources that include compatibility for SPARK Flex can be found here:

• REVLib
• REV Hardware Client (You may also check for updates within an existing installation)

Stay tuned for additional season updates at or shortly after Kickoff

Initial SPARK Flex Firmware Update

The first 1500 SPARK Flexes are running factory firmware version 23.0.0. This firmware version only supports updating over USB by first manually putting the SPARK Flex into Recovery Mode. It does not support updating over CAN or through the standard USB method. Full CAN and USB updating is enabled in version 23.0.2. You should only have to perform the Recovery Mode steps once, and only with these first-batch units, to bring them up to date.

The REV Hardware Client will detect this earlier factory firmware on the SPARK Flex and prompt you with the appropriate steps to update. If you do not see the prompt, you have version 23.0.2 or newer on the device and can update as normal.

Mode Button Position Variances

We have noticed greater than expected variance in the position of the Mode Button relative to the SPARK Flex case hole. The most significant misalignment we saw in our sampling equates to a 75% obstruction of the button. However, the majority of samples were less than 25% obstructed and in the worst case misalignment, the button was still pressable. An example of the button misalignment:

We are tuning our tolerances to reduce this misalignment in future batches. Please reach out to support@revrobotics.com if you have any questions regarding the SPARK Flex Mode Button.

NEO Vortex Spindle Hex Bore Fit

The 1/2 in hex bore on the NEO Vortex Spindle is designed to be tight to minimize backlash when using the motor with hex stock and not a Vortex-specific shaft. Aluminum hex shafts are made through an extrusion process which means there is a wide tolerance band for these shafts. REV has a reference set of shafts from multiple vendors across multiple seasons to validate fitment of shafts in our hex bore products. While the NEO Vortex motors we ship are in spec, it is possible that some 1/2in hex shafts in the market may not slide easily through the motor. In the worst cases, we have found a small bit of sanding on the flats of the hex shaft will resolve the problem.

As we continue forward with the NEO Vortex, we will take feedback from the community to evaluate whether teams prefer the tighter fit with some extra work sanding larger shafts, or if accommodating a wider band of hex shafts by opening up the tolerance makes more sense.