Notes on Hub Module SN 01: Latest Rev. 15-Sept-2017 -------------------------- Start MSU Final Assembly on SN 01 on 24-May_2017 Hub SN-01 is the card without an FPGA and without either of the two ATCA Power Supply Modules. This is not necessarily the order in which the stups were done. Many items have been re-ordered to put them into what is now with hind sight clearly the rational order to do them in. 1. List on Ground Touch Points on the Hub Card: - Shields on the top of the RJ-45 connectors. - ESD Strip on Bottom Edge by the Fuses. - Top Edge ROD Board Mount Screw Hole by the Backplane. - Alignment Pin Receptacle Blocks (once they are installed) - Mounting screws for the FPGA Heat Sink (once they are installed) Note that most of these Ground Touch Points are tied to the Hub Ground Planes through a 1 Meg Ohm resistor. So you must touch one of these Ground Touch Points for 2 or 3 seconds to come to the same potential. 2. Write the Serial Number on the card. 3. Check the resistance to Ground from the various power supply bus lines. - DCDC-1 FPGA_Core about 220 Ohm - DCDC-2 MGT_AVCC => 1k Ohm - DCDC-3 MGT_AVTT => 1k Ohm - DCDC-4 MGT_AVAUX => 1k Ohm - DCDC-5 Switch_1V2 about 450 Ohm - DCDC-6 BULK_1V8 => 1k Ohm - DCDC-7 FAN_1V8 => 1k Ohm - DCDC-8 BULK_3V3 => 1k Ohm - DCDC-9 BULK_2V5 => 1k Ohm - CNST_5V0 => 1k Ohm Check Both Ends - IPMC_3V3 => 1k Ohm Check Both Ends - CLK_BULK_2V5 => 1k Ohm - ISO_12V => 1k Ohm - Hold_UP_+ => 1k Ohm - Hold_Up_- Check Both Ends 4. Check the ESD connections to the Hub's Ground Planes - Shields over 3x RJ-45 connectors to Gnd about 1 Meg - Bottom Edge ESD Strips to Ground about 1 Meg - Top Edge ROD mounting Screw Hole to Gnd zero Ohm - Alignment Pin Receptacle Block Holes to Gnd about 1 Meg - Shield Hatch for ROD and ATCA Modules to Gnd about 180 Ohm 5. Install the 4x MPO Backplane Optical Connectors We want these installed now because they provide board support when the card is on the bench up-side-down. Wipe the area under these connectors before installing them to verify that nothing will be trapped under them. The screw supplied with these connectors are not long enough for the Hub pcb thickness. The supplied screws are 1/4" long. Use the 5/16" 2-56 round head Philips screws with a #2 flat washer under the head. 6. Install the two Guide Pin Receptacle Blocks Use 8 or 9 mm M2.5 Cheesehead screws with a M2.5 flat washer under the head. Press the Receptacle Blocks in using the small arbor press with a platten on the bottom side to support the pcb and protect the bottom side SMD components. After the Receptacle Blocks are installed check with an Ohm meter to verify their connection to the Hub Ground Planes. 7. Verify the the Zone 1, Zone 2, and RJ-45 Connectors are fully pressed in. Use the small arbor press and the 3 plattens to support the pcb and protect the bottom side SMD components. It is easy to held the plattens (one at a time) to the bottom side of the pcb. Signt these connectors for a gap between them and the pcb. Sight along the set of Zone 2 connectors to verify that they are all lined up. 8. Install the Front Panel for now using just the Top and Bottom Mounting Brackets. This is a temporaty install that is uned to protect the card when it is either side up on the bench. 9. Install the 2x 74AVHC8T245 and 1x 74LVC07A ICs These are TSSOP-24 and TSSOP-14 components. 74AVCH8T245s at U551, U553, U554 74LVC07A at U552 Time: currently 3 to 4 hours 10. Clean the assembly house flux off of the ATCA Power Module pins and the J2 Access Connector pins. Check that these pins look to be soldered correctly and that the front panel pins on J2 are clean of flux 11. File the Rail Connection Stubs from the Top and Bottom Card Edges Use the large flat file and clean it well before starting. It appears best to first file one stub at a time filling across the card and then file along the edge to make things as smooth as possible. Be very of: where you hold the card, how tightly you hold the card, and not bumping any of the components on either card surface. Clearly the front panel needs to be removed to file the stubs nearest the front of the card. File at an angle that does not cause vibration. Filling only in the cut direction seems to reduce vibration. Can round the back edges of the milled surfaces that go into the card guides first. After filling must air hose off the card very well to get rid of the G10 fillings. First hose away from the connector entry holes to remove the bulk of the fillings. Enentually we need to open the dust caps on the 89 pin MiniPOD connectors and on the 400 pin ROD connectors to remove and G10 fillings from these connectors. Time: 40 minutes 12. Install L1953 on the bottom side by the Phys chips which is a Wurth No 742792116 ferrite "bead" in a 1206 package. Place a small piece of Kapton tape under L1953 to cover the via that is under this part. 13. Install the Power Good Comparator Scale Resistors R2972 3.48k Ohm 0603 R2974 2.26k Ohm 0603 These are on the bottom side up near the top edge. 14. Install the BULK_3V3 bypass capacitor by the I2C Sensor Bus EEPROM. This is on the bottom side along the top edge near the backplane by U1541. C1541 470 nFd 25 V 0805 xy. Remove and replace the transistor Q2951 and replace it with one in the new fancy required orientation. 15. Remove the following components: R1001 DCDC_1 Assembly House value was 180 Ohm R1201 DCDC_5 Assembly House value was 180 Ohm R1251 DCDC_6 Assembly House value was 180 Ohm Remove the following resistor "straps" "jumpers" from the Phys Chips circuits U21 and U22 to set them up in the standard way for Hub Module operation. R1901 Remove the 10k Ohm resistor U21 Adrs_0 = Low Bot R1903 Remove the 10k Ohm resistor U21 Adrs_1 = Low Bot R1905 Remove the 10k Ohm resistor U21 Adrs_2 = Low Bot R1910 Remove the 1k Ohm resistor U21 Mode_1 = Hi Bot R1912 Remove the 1k Ohm resistor U21 Mode_0 = Hi Bot R1951 Remove the 10k Ohm resistor U22 Adrs_0 = Low Bot R1953 Remove the 10k Ohm resistor U22 Adrs_1 = Low Bot R1955 Remove the 10k Ohm resistor U22 Adrs_2 = Low Bot R1960 Remove the 1k Ohm resistor U22 Mode_1 = Hi Bot R1962 Remove the 1k Ohm resistor U22 Mode_0 = Hi Bot Electrical Final Assembly: -------------------------- 1. Power Supply RC Components: Install or remove and replace the following RC components in the power supply circuits. DCDC_1 FPGA_CORE Converter 0.950 Volt C1001 Cap_10_nFd_0805 Loop Compensation CTune Bot R1001 Res_220_Ohm_0805 Loop Compensation RTume Bot R1002 Res_34k_Ohm_0805 Output Voltage Set RTrim Bot R1006 Res_34k_Ohm_0805 Ramp Scale Resistor Bot DCDC_2 MGT_AVCC Converter 1.000 Volt R1051 Res_2k_Ohm_0805 Loop Compensation RTune Bot C1051 Cap_100_nFd_0805 Loop Compensation CTune Bot R1052 Res_30k_Ohm_0805 Output Voltage Set RTrim Bot R1056 Res_30k_Ohm_0805 Ramp Scale Resistor Bot R1053 Res_15.4k_Ohm_0603 Adrs_0 Set resistor Bot C1053 Not Installed Loop Direct FB capacitor Bot JMP1051 Not_Installed V_Sense_+ pre inductor Top JMP1052 Res_Zero_Ohm_0603 V_Sense_+ post insuctor Top JMP1053 Res_Zero_Ohm_0603 HF Feedback pre incudtor Bot JMP1054 Not_Installed HF Feedback post inductor Bot DCDC_3 MGT_AVTT Converter 1.200 Volt R1101 Res_2k_Ohm_0805 Loop Compensation RTune Bot C1101 Cap_100_nFd_0805 Loop Compensation CTune Bot R1103 Res_23.7k_Ohm_0603 Adrs_0 Set resistor Bot C1103 Not Installed Loop Direct FB capacitor Bot JMP1101 Not_Installed V_Sense_+ pre inductor Top JMP1102 Res_Zero_Ohm_0603 V_Sense_+ post insuctor Top JMP1103 Res_Zero_Ohm_0603 HF Feedback pre incudtor Bot JMP1104 Not_Installed HF Feedback post inductor Bot DCDC_4 MGT_AVAUX 1.800 Volt Linear R1152 Res_464_Ohm_0603 Voltage Set Resistor Top R1153 Set Full CCW DCDC_5 SWCH_1V2 Converter 1.200 Volt C1201 Cap_10_nFd_0805 Loop Compensation CTune Bot R1201 Res_220_Ohm_0805 Loop Compensation RTume Bot R1203 Res_36.5k_Ohm_0603 Adrs_0 Set resistor Bot DCDC_6 Bulk_1V8 Converter 1.800 Volt C1251 Cap_10_nFd_0805 Loop Compensation CTune Bot R1251 Res_220_Ohm_0805 Loop Compensation RTume Bot R1253 Res_54.9k_Ohm_0603 Adrs_0 Set resistor Bot DCDC_7 FAN_1V8 Converter 1.800 Volt R1301 Res_2k_Ohm_0805 Loop Compensation RTune Bot C1301 Cap_100_nFd_0805 Loop Compensation CTune Bot C1303 Not Installed Loop Direct FB capacitor Bot JMP1301 Not_Installed V_Sense_+ pre inductor Top JMP1302 Res_Zero_Ohm_0603 V_Sense_+ post insuctor Top JMP1303 Res_Zero_Ohm_0603 HF Feedback pre incudtor Bot JMP1304 Not_Installed HF Feedback post inductor Bot DCDC_8 Bulk_3V3 Converter 3.300 Volt C1351 Cap_10_nFd_0805 Loop Compensation CTune Bot R1351 Res_220_Ohm_0805 Loop Compensation RTume Bot R1352 Res_4.42k_Ohm_0805 Output Voltage Set RTrim Bot R1356 Res_4.42k_Ohm_0805 Ramp Scale Resistor Bot R1353 Res_130k_Ohm_0603 Adrs_0 Set resistor Bot DCDC_9 Bulk_2V5 2.500 Volt Linear R1172 Res_1070_Ohm_0603 Voltage Set Resistor Top R1173 Set Full CCW 5. Install the Quartz Crystal PLL modules: There are vias in the middle of the U502 and U506 layout patterns. Verify that none of these Hub pcb vias could touch vias in the Quartz Crystal PPL modules. Use kapton tape to cover any vias on the Hub pcb that need to be protected from signals on the PLL modules. U502 Install a IC_PLL_40M0787 Hub Clock System Top U506 Install a IC_PLL_320M6296 Quartz Crystal PLLs Top 6. Install the Front Panel Handle Switch and wire it to the IPMC connection vias that are just above the lower mounting bracket. 7. Install the Discrete Power Wiring These 8 discrete power wire runs are all made with AWG #20 wire having the special PPE Polyphenylene Ether insulation. In total about 8.5 feet of power wiring is installed and held in place with Cyanoacrylate glue. Insulated Function Connection Points Connection Point Locations Length ----------- ------------------ -------------------------- ------ Hold-Up Pos WTERM41 to WTERM42 (91.0 8.3) (276.7 246.4) 424 mm Hold-Up Neg WTERM31 to WTERM32 (97.4 8.3) (266.3 246.4) 407 mm 12V_ISO WTERM21 to WTERM25 (16.0 8.3) ( 30.5 217.5) 224 mm 12V_ISO WTERM22 to WTERM26 (20.5 8.3) (112.0 213.0) 296 mm 12V_ISO WTERM23 to WTERM27 (25.0 8.3) (252.0 227.0) 446 mm IPMC_3V3 WTERM1 to WTERM2 (96.5 40.5) ( 30.0 271.4) 297 mm CNST_5V0 WTERM11 to WTERM12 (101.0 40.5) ( 30.5 306.0) 336 mm BULK_2V5 WTERM51 to WTERM52 (28.9 137.7) (174.5 86.0) 197 mm 8. Install the two MiniPOD Modules and their Fiber Optic Ribbon Cables 9. Setup the DCDC Converters on the Hub Module Rev. 13-June-2017 There are 7 DCDC Converters on the Hub Module that can be monitored and controlled via the I2C PMBus. Control of these converters includes setting values in their non-volatile memory that they will use the next time that they power up. Values that we may want/need to install in their non-volatile memory include: a trimmed value of their output voltage, voltage limits for asserting Output_Good, turn On and turn Off input voltages and we must set their Vout_Scale_Loop parameter. Recall the general start up of the DPI_GUI and the setup of the 7 DCDC Converters on the Hub that use the TI controller chip. DPI_GUI startup on the tough-book: > cd C:\DPI Suite\DPI Suite\DPI_GUI > dpi_gui 6 This is how you get the 6 "POL" windows. Running the DPI GUI with 6 POL windows what you can monitor and control is: Setup of the 7 DCDC Converter (see only the first 6 with DPI_GUI) Not Seen Address: 40 41 42 43 44 45 46 0x28 0x29 0x2a 0x2b 0x2c 0x2d 0x2e DCDC: 1 2 3 5 6 7 8 Vset Res kOhm: 34 30 20 20 10 10 4.42 Power Bus: FPGA MGT MGT Swch Bulk Fan Bulk Core AVCC AVTT 1V2 1V8 1V8 3V3 Vout-Scale_Loop: 0.632 0.600 0.500 0.500 0.333 0.333 0.182 From the DPI_GUI (which can only see and work with up to 6 POL converters) one could set in their non-volatile memory new values in Turn On and Turn Off Input Voltage by doing: - When the DPI_GUI starts up use the "find modules" button in the very bottom right-hand corner. You sould now see DCDC Converters number 40 through 45 by their decimal I2C address. Setup the Vset Resistor value in k Ohms for each converter and you should then see the correct default Vout voltage. - Edit the lower section of the main DPI_GUI window for new values of Vin Turn_On and Vin Turn_Off. This is the Settings section of the main window. - For now I'm using a Vin_ON of 6.5 Volts and a Vin_Off of 5.5 Volts. - Make certain the the Polling is turned off and that none of the POL modules are seleced for Status Polling. If the polling is running the its I/O seems to make errors in the write settings and Store Defaults I/O. - Select the column, i.e. the POL converter that you want to update by setting it select radio button at the very bottom of its column. - If necessary do a Clear Faults. - Do a Get Status to verify that there are no problems. - Do a Write Settings to put the new/edited settings from this GUI display into the Working Memory of this converter. - Do a Store Defaults to write the new/edited settings from this GUI display into the non-volatile memory of this converter. - Do a Get Status to verify that there have been no I/O errors with this converter will the new/edited settings were being written to it. - The Store Defaults should just be storing into the controller's eeprom of each converter new values for: Vout_Scale_Loop, Vout_ON, and Vout_Off even thouch it's rewriting all of the values in the eeprom. Loop over all of the converters that you want to update. Note that in the above scheme that you are writing new values into both the working memory and into the non-volatile memory. For the 7th DCDC Converter, Bulk_3V3, you need to use the DPI_CLI program to reach it. When DPI_CLI starts you need to enter "46" to select the Bulk_3V3 converter. You can read things e.g. > read vout > read iout > read vin > read vin_on > read vin_off > read vout_scale_loop You can write values to the convertrs working memory e.g. > write vin_on 6.5 > write vin_off 5.5 > write vout_loop_scale To save all working registers to the non-volital eeprom you can use: write 11. Comman 13 for saving just a specified register to the eeprom does not seem to work as it just causes the program to crash. - Recall how to operate SN-01 30-July-2017 SN-01 does not have either of the ATCA power supply modules. SN-01 requires an external low current +5 Volt supply and an external medium current (a few Amps) +12 Volt supply. Turn on the +5V supply first and then turn on the +12V supply. Shut down in the reverse order. The Ethernet Switch on SN-01 should work like the Enet Switch on any other Hub card - thus SN-01 may be used for an initial detailed study of the Hub Ethernet Switch. - Install Enet Switch EEPROMs 15-Sept-2017 Installed all 3 Switch EEPROMs that were cooked using the hub_at93c66b_prom_for_bcm53128_switch_rev4.bin content file, i.e. just setup all of the Switch LEDs for Green = 1000 speed and Yellow = Link & Activity.