HTM Card MSU Final Assembly ------------------------------ Original Rev. 4-June-2018 Current Rev. 24-Aug-2018 This file describes the Electrical and Mechanical MSU Final Assembly of the HTM Cards. HTM Card Mechanical Final Assembly: ------------------------------------- 1. Shorts Check the card - 5 buses to check. 2. Write the Serial Number on the HTM card. 3. Clean aka de-flux the card. 4. File off the rail break away shards and round the back corners of the PCB. Chamfer the holes for the LED light-pipes. 5. Pull out the power input fuses that will not be used. 6. Press in the K1 Alignment Pin Receptacle. 7. Press in the P10 Zone #1 ATCA power connector. 8. Check verify the full depth press-in installation of the P10 and J23 backplane connectors and the J13 and J14 front panel connectors. 9. Install the Vertical and Horizontal Air Baffles. 10. Install the Top and Bottom Front Panel Brackets. 11. Install the LED Light Pipes. 12. If this HTM Card will not use MiniPODs then install the block out to cover the front panel openings for the two MTP connectors - else install the MTP Feed Through connectors into the Front Panel. 13. Install the ON/OFF power switch into the Front Panel including the wires that run from the power switch to the terminal vias in the PCB. 14. Center punch thr Front Panel on its inner surface in 4 places around the mounting screw hole for the Top Handle. This is to improve the chance of making a good Shelf Ground connection to the Top Handle. 15. Install the Front Panel. 16. Install the Insertion/Extraction Handles at the top and bottom of the Front Panel. Recall that the switch activation taps on the stock handles must be cut off and rounded and filed smooth. 17. Ohm meter check to verify that the Shelf Ground is connected to: both front panel handles, the K1 alignment block, both of the RJ45 shields, through a resistor to the rear ESD strip, directly to the front ESD strip. HTM Card Electrical Final Assembly: ------------------------------------- 1. Connect the front panel On/Off power switch: Switch center terminal - via red wire - to WTERM_12 Switch lower terminal - via yellow wire - to WTERM_11 2. Solder in a scope Gnd loop to terminals: WTERM_1 WTERM_2 3. Install the power supply voltage set point resistors: BULK_3V3 1780 Ohm R102 BULK_2V5 1070 Ohm R112 4. Install the Receiver CMM Bias voltage divider resistors R254 and R256 2.74k Ohm 1% 0603 5. Install the 40.0787 MHz PLL at location U253. Use teflon tape under the PLL component. Recall that PLL pins 3, 4, 5 are not soldered to the PCB. Use the Ohm meter to verify that the metal shield on the PLL has not caused a short circuit to any pins on the PLL. 6. Install only one fuse pair: F1 & F3 or F2 & F4 3 Amp fuses 7. Shorts Check the power buses: ISO_12V, BULK_3V3, BULK_2V5, MEZZ_3V3, MEZZ_1V8. Initial Power Up of the HTM Card: --------------------------------- 1. Verify that the Logic and Shelf Ground connections on the HTM Card are setup correctly. Verify that the ground connection to the front panel and its handles are correct. Verify that the connections to the ESD strips are correct. 2. Connect the HTM Card to the ATCA bench power supply. 3. Turn on the HTM Card and use the J11 Power Supply monitor test points to check the: ISO_12V, BULK_3V3, and BULK_2V5 power supply voltages. 4. Set the trim pots to adjust the two linear supplies: BULK_3V3 R103 trim pot BULK_2V5 R113 trim pot 5. Verify that you have an approximate 40 MHz clock signal coming out of the front panel J15 Hub-1 LEMO Clock monitor connector. 6. Use the scope to verify that all 6x Clock Fanout signals are running. 7. Check and record that the Reference Clock Receiver CMM Bias voltage is correct, i.e. about 1.25 Volts. 8. Attach the transformer isolated HP Ref Clk Generator and check and record: the reference frequency range over which the PLL will re-lock to the reference clock, at 40.0787 MHz how much HP generator output is required to get the PLL to re-lock, the free run frequency of the PLL. Install the ZYNQ FPGA Mezzanine on the HTM Card: ------------------------------------------------ 1. Install the FPGA Mezzanine. 2. If used - install the M2.5 hold down screws for the FPGA Mezzanine in just the diagonal corners that have adjacent screw holes. The order of the hardware is: screw head, flat washer, HTM pcb, flat washer, lock nut, space, FPGA Mezz pcb, flat washer, lock nut. The idea is that the lock nut on top of the FPGA Mezz pcb is not tight - rather it's run down just to the point of zero gap. 3. Shorts check the following buses to verify that the HTM pcb and the FPGA Mezz pcb are matched up OK and both free of power supply shorts: ISO_12V, BULK_3V3, BULK_2V5, MEZZ_3V3, and MEZZ_1V8. Contact MEZZ_3V3 at: C77, C78, C79, or C80 Contact MEZZ_1V8 at: C73, C74, C75, or C76 Second Power Up of the HTM Card: -------------------------------- 1. For its second power up the HTM Card is operated in a ATCA Shelf. 2. Connect a JTAG cable, power up the HTM Card from the ATCA and verify that Vivado Hardware Manager can see the ZYNQ FPGA. 3. Run the SysMon on the FPGA Mezz and check the Si Temp and the Core and Aux voltages. If used - Install the two MiniPODs on the HTM Card: --------------------------------------------------- 1. Verify that the Transmit and Receive MiniPODs have the correct heat-sinks installed on them. 2. Verify that the external top optical area of the MiniPODs has been properly cleaned. 3. Install the two MiniPODs paying attention to the alignment pins to get the correct type of MiniPOD in the correct socket. 4. Use M1.6 x 6mm screws to hold the MiniPODs onto the HTM circuit board. This is a shorter screw than we have used in the past but will match the thiner HTM circuit board. 5. Install the Front Panel MTP feedthrough connectors. Because the ATCA front panels are thiner than the minimum panel thickness for the MTP feedthrough connectors - these connectors must be glued in place. 6. Route the Fiber Optic Cables under the Horizontal Air Baffle and connect to the Front Panel MTP connectors and to the MiniPOD Prizm connectors. Our standard Horizontal Air Baffles will need a small notch milled in their bottom surface to pass the Fiber Optic Ribbon Cables through. It would be good to pad the ribbons with tape where they pass under the Horizontal Air Baffle. Hardware Screw Lengths: ----------------------- - Top Bracket to PCB: 2x 1/2" 4-40 to Front Panel: 1x 1/2" 4-40, 1x 1/4" 4-40 - Bot Bracket to PCB: 2x 1/2" 4-40 to Front Panel: 2x 3/8" 4-40 - Air Baffles Horz and Vert to PCB: 6x 5/16" 4-40 Horz to Front Panel: 2x 5/16" 4-40 Horz to Vert: 2x 7/16" 4-40 - K1 Alignment Block: 1x 10mm M2.5 with flat washer