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ROM upgrade in PDAs from Acer is not as sophisticated as e.g. in iPAQs from HP but if you strictly follow the directions, there should not be any problem. Theoretically, if the bootloader is functional, it is always possible to do something about the device's condition, so do not despair. Besides adherence to instructions, I strongly recommend great patience during installation of the upgrade. Some stages of the process may take longer than you would expect, so leave the device alone for 15 more minutes when in doubt. If nothing happens in those fifteen minutes, it is time to try "plan B".
Before upgrading, you have to make several provisions. First of all, charge the battery to 100 %. If your device has frozen, it is hard to check battery status, so let the device recharge for a few hours. Then you need an SD or MMC card of at least 64 MB that you will load the upgrade from. Format this card to FAT16 to avoid any troubles. The card's capacity should therefore be smaller than 4 GB;) Finally, you need a ZIP file with the new firmware version, which is downloadable from the Acer FTP.
The procedure is as follows:
Step 1 - Preparation
Go through the previous paragraph once more. Key is the sentence about the fully charged battery - do not underestimate its importance! One thing is that you need more current when writing to the FlashROM (as far as I know) which you might fail to squeeze from a low battery, but more importantly, if the battery runs flat during the process of writing a new bootloader, you can throw the device away and order a new one. Serious.
Then format your SD card to FAT16, unpack the ZIP archive and create a folder with exactly the same name on the card and copy the files there (the package actually contains the folder, so just copy it to the card). For your information, chain.lst is a text file stating the order of files to write, EBOOT.nb0 is the new bootloader, flash.dio is the ROM image, and the last file remains a mystery to me.
We have successfully prepared the device for flashing.
Step 2 - Flashing
IMPORTANT NOTICE :: Firmware update is a process that can, under certain circumstances, result in serious damage or irrecoverable failure of your device. The likelihood of an accident is very small provided you follow the instructions. Nevertheless, I strongly recommend users, especially those inexperienced, to consider contacting Acer's customer service to obtain the upgrade. Those who decide to go it themselves are urged to strictly follow the installation procedure as described herein. I have tried the procedure and guarantee that it is formally correct. However, I shall not be held liable for any problems that may occur during the upgrade. You are undertaking the upgrade by your sovereign decision and with full responsibility for its potential undesired consequences.
Remove the device from the cradle and insert the SD card with the upgrade files. Now, let's do a little exercise with your fingers. The installation process takes two steps to initialise. It requires you to perform a hardware reset by simultaneously pressing Home (the button with the small house) and Inbox (the envelope button) and activating the software reset (see Img. 1). Hold all the three buttons for about a second and release. IMMEDIATELY after that press and hold the main switch for five seconds.
If you were quick enough, the screen will turn black (see Img. 3) and will start counting down from five to nil. If you keep the main switch pressed all the time, the device will get ready for reading from the card (see Img. 4). If you release it prematurely, the device will start booting normally (white screen) and you will need to repeat the procedure. The same applies to a situation when you press the main switch too late.
After a short while, the upgrade process will start automatically. You will be notified of the current status on the screen - the new version of the bootloader will install and then the operating system. At this point, you MUST NOT intervene in any way. It is not until you see the green "Update finish" message on the screen that you can relax and start playing with your device again. Actually, you should perform a hard reset by pressing the Home, Inbox and reset buttons and wait for completion of the upgrade. The device will restart automatically and that's it.
... what the heck is this supposed to mean? Frozen during boot again?? No change??? Help!!! Calm down and do not despair. For some mysterious reason, you need to perform the upgrade twice because the first time, it is only the bootloader that gets updated. After you perform the whole Step 2 once again (HW reset, entering the card read mode and then letting the device work for several minutes), the device will boot normally after the final restart. I observed this behaviour in two Acer n311s, so it looks like a feature. Now, the update is really completed. To make sure, you can check the version number of the bootloader and the system in he Settings.
Conclusion
Provided you followed the instructions, your device is now running a fully functional new version of the operating system. If you run into trouble in the process, stay calm. First of all, allow the device enough time to "recover" and then try to perform Step 2 over again. If that does not help, seek advice in discussion forums but I strongly suspect you will have to turn to professionals.