FMnoise

Yes, I had the same issue (search past threads). The only way I could restore function to the BAR 48 was to load the previous revision of firmware's batch file (one that works) onto the USB drive and reload. It reloaded w/o any issues and got me back to where I was before the "latest" firmware locked it up. Important: Please double check you uploaded the correct firmware version for your specific serial number. *This is a known issue.

Have you installed the most recent BAR 48 firmware file (Released on Dec 13th, 2019) from Klipsch's "BAR 48 Support" page ? It is supposed to fix many of the bugs. You can find the correct firmware file by inputting your serial number (Please go to the Klipsch Support Page for more info). If it does not work, then I would suggest you contact Klipsch Supoort for assistance as their are a lot of systems with problems. Update: They revised some of the firmware file online. One of the defective Dec 13th versions was replaced with a Nov 29th version. If you are still having issues, re-check S/N in case they changed your file.

Klipsch has different versions of firmware available for the different ranges of BAR 48 production units (by serial number). You have a newer module with the 2.4GHz wireless signal feature vs the older ones which do not have that. They have changed the modules a few times during production so different software for the hardware is needed to update them ("firmware"). Sometimes the soundbars are defective so no version of firmware will fix them. Other times, it will. In any case, it is important that you load the correct revision for your unit (i.e. V23 or V83).

I do know that "Installer" mode disables the AUTO on feature and enables the always on mode (so it does not power off after no audio signal is detected). Not sure about external player mode...

I have been able to update the previous firmware files on the BAR 48 with no problem as the process is simple. The LED's light up just as described in the instructions. However, the new V83 firmware version they supplied for my soundbar proved defective and would not load onto the unit. The USB drive flashed indicating an error, not 'loading" so the problem was related to the Soundbar being defective. *That is why it was sent back. BTW: If you attempted to load a firmware revision on yours using the zip file on your USB drive (as you indicated), then most likely, you did not load the firmware at all. The actual firmware files are executable batch files, not zip files. If it correctly loaded, then you would have seen all of the source LEDs light up sequentially, as stated in the instructions indicating success. The fact that you did not, probably means you still have the original firmware file you started with on the soundbar. When it works, it should go quickly, as described in the update instructions. It would have been nice if they could have provided a way to know which firmware is currently loaded. At least the newer versions of firmware have an "installer" mode which allows you to keep the sound bar turned on, and not cycle off after so many minutes of no audio output.

Klipsch posted a firmware update on Dec 13th, which is supposed to address that problem. You can download the firmware on their support page (BAR 48 Firmware).

BTW: They introduced another firmware update for the BAR 40/48 products on Dec 13th, (V83 and V23) which I also downloaded and tried. The latest V83 software for my version did not even load. I downloaded the file to the root directory of my USB drive (as before) and when I tried to install it on the soundbar, the software was unable to load. The soundbar never showed any LED lights, never reset and was left "dead" after the failed install. I deleted the new firmware file from my USB drive and re-loaded the V2 firmware back on the drive. I ran the same firmware update procedure with that version and it loaded perfectly, getting me right back to where I was before, with a working sound bar, but the same sub woofer unplug/plug issue. I advised Tech Support of this and they issued a return ticket to me. I have shipped back the BAR 48 soundbar and am awaiting the replacement. I sure hope the replacement fixes the issue (and will update after I receive it).

After receiving my BAR 48, I had the exact same problem (and so do many, many others...). Works great, as long as you unplug, wait for the blue LED to go out, re-plug the sub back in.... until the soundbar powers down again (or stops receiving an audio signal). *At turn-on, you can even see the Soundbar communicate with the sub properly. The sub turns on, just like it should, the sub's blue LED goes from flashing to steady, indicating proper pairing, but no sound will be heard from the sub unless manually unplug/re-plug it in (every single time). VERY ANNOYING. I did upload the Version 2 firmware, as requested by Tech support, and the firmware update went smoothly, but it made absolutely no difference in fixing the unplug/plug-in subwoofer issue (loss of pairing).