Notes on Hub Module SN 05: Latest Rev. 13-Aug-2019 -------------------------- - Start work on SN-05 at 17:30 25-July-2017 - Verify that the ESD Grounds, e.g. strips along the bottom of the card, RJ-45 shields, and guide pin receptacles are all connected. - Check the resistance from the various power buses to Ground looking for shorts - all OK with similar values as SN-02. - Write SN on SN-05. - File smooth the top and bottom edges. - EOD Tuesday - Clean off flux residue around J2 and around ATCA Power Modules. - Install the Guide Pin Receptacles with M2.5 10mm and flat washer. - Re-press in the Zone 1 & 2 connetors and the RJ45s. - Temporarily install the two front panel delrin mounting brackets to help support the front edge of the Hub pcb when it is up side down. Use 4-40 x 1/2" button head screws. Note that flat washers can not be used under these because with flat washers the head of the screw does not fit under the lip of the front panel. - Install the 4 backplane MPO connectors with 2-15 5/16" screws and lock washers. - Cut down the thickness of the pcb for the front panel Handles. Cut from the back side. Cut in a circle about 0.40" diameter and running tangent to the edges of the card. Cut down through 2 Ground Planes - just barely cutting through the second Ground Plane. Using the micrometer verify that the whole cut down area is flat. The remaining pcb thickness sould be about 107 to 109 mils. File the edges smooth. Explore with an exacto knife to verify that there are no loose strands of copper trapped in the edges of the cut out area. Clean up in copper burs in the bore of the lower front panel mounting hole (the upper hole has a G10 bore). Air hose all cut G10 and Copper off from the card. Super glue the rough edge of the cout out area to seel the rough edge and improve the look of this part of the card. There are now almost two full layers of G10 between the metal of the ATCA handle and the next Ground Plane in the card. There are no traces in danger in this part of the card. There are two Ground Planes between the metal part of the ATCA Handle and the first possible "hot" parts of the card. - Install the 4 TSSOP parts on the back side; 3x 24 pin 1x 14 pins. U551, U553, U554 are 74AVCH8T245s U552 is 74LVC07A Do a full clean up of the area around these 4 IC installations including on the top side. - Remove the following components from the Power Supply sections: 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 new standard way for Hub Module operation, i.e. Physical Address = 000 Phys Chip Mode = 1100. 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 R1909 Remove the 10k Ohm resistor U21 Mode_1 = Low Bot R1911 Remove the 10k Ohm resistor U21 Mode_0 = Low 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 R1959 Remove the 10k Ohm resistor U22 Mode_1 = Low Bot R1961 Remove the 10k Ohm resistor U22 Mode_0 = Low Bot Remove the following SMD components: R2995 part of ROD Power Good circuit Bot R2998 part of ROD Power Good circuit Bot Q2951 part of power supply Ramp circuit Bot R1607 PLL series input resistor Top R1608 PLL series input resistor Top - Install all of the Resistor, Capacitor, and BJT SMD components: R2995 20k Ohm 0603 part of ROD Power Good circuit Bot R2998 2k Ohm 0603 part of ROD Power Good circuit Bot Q2951 mmbt-3904 part of power supply Ramp circuit Bot R1607 150 Ohm 0603 PLL series input resistor Top R1608 150 Ohm 0603 PLL series input resistor Top R2972 3.48k Ohm 0603 Power Good Comparator Scale Res. Bot R2974 2.26k Ohm 0603 Power Good Comparator Scale Res. Bot C1541 470 nFd 25 V 0805 BULK_3V3 bypass capacitor Bot L1953 Wurth No 742792116 with kapton tape by Phys U22 Bot 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 JMP1052 Res_Zero_Ohm_0603 V_Sense_+ post insuctor Top JMP1053 Res_Zero_Ohm_0603 HF Feedback pre incudtor 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 JMP1102 Res_Zero_Ohm_0603 V_Sense_+ post insuctor Top JMP1103 Res_Zero_Ohm_0603 HF Feedback pre incudtor 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 JMP1302 Res_Zero_Ohm_0603 V_Sense_+ post insuctor Top JMP1303 Res_Zero_Ohm_0603 HF Feedback pre incudtor 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 - EOD Wednesday - Install the post L RC network on the filtered MGT supplies. MGT_AVCC 2x 820 uFd 2.5V 7 mOhm Al-Poly plus 25 mOhm MGT_AVTT 1500 uFd 6.3V 7 mOhm Al-Poly plus 25 mOhm FAN_1V8 1500 uFd 6.3V 7 mOhm Al-Poly plus 25 mOhm Use heat shrink tubing and teflon tubing to insulate the leads on these RC networks. Use keystone solder lugs to ground the MGT_AVCC and MGT_AVTT networks to heat sink mounting screw holes (which are grounded). Use teflon tape to insulate the cases of the MGT_AVCC capacitors from the FPGA heat sink and from the Hub pcb itself. Be especially careful of the small vias in the pcb that are under the lead end of these MGT_AVCC capacitors. - Install the discrete power wires. So far it appears that I do not need to connect the big hold-up capacitors in the NE corner for the ATCA Power Entry module to work. So currently there are 6 discrete power wires that need to be installed: 3x Iso_12V, IPMC_3V3, CNST_5V0, Clk_2V5. So far I have not glued down the discrete power wires. - Thursday 14:00 27-July-2017 More Mechanical Final Assembly steps: ---------------------------------------- - Install the LED Light Guides 6 Single LED Light Pipes 6 Quad LED Light Pipes - Cut the height of the active edge of the mid bracket down by 0.185" as it no longer loops in back of the card but rather uses 7x of the high density tape. - Machine as required the diameter of the front panel handle mounting boss. Add as required any additional holes or cut-outs to the front panel. Add 7 layers of the UHD tape to the backside of the pcb directly under where the front panle center mounting bracket is located. - Install the Front Panel If you install the heatsink last then it is easy to work with the card (i.e. no problem of setting the card on its FPGA heatsink) but it is hard / impossible to see in to verify that the MGT_AVCC capacitors are OK. Remember that the FPGA heatsink needs kapton tape on the edge of the fill block and on the bottom surface of the heatsink in the area of the MGT_AVCC capacitors. More Electrical Final Assembly: ------------------------------- - Install the On-Off Switch if it is being used on this Hub card. - Install the Insulated Lemo Connector if it is being used on this Hub card. Initial Power Up Checks: work done on 3-Aug-2017 ------------------------ - Check of the Hub SN-05 currents during initial running. Try Configuring with the Safe/Foundation firmware. Power Bus: FPGA MGT MGT Swch Bulk Fan Bulk Core AVCC AVTT 1V2 1V8 1V8 3V3 ---- ---- ---- ---- ---- ---- ---- Address: 40 41 42 43 44 45 46 Volts: 0.94 1.00 1.19 1.20 1.79 1.82 3.313 Amps: 1.25 0.19 0.12 2.00 0.62 12.12 1.688 Safe Config - Check of the Hub SN-05 PLL clocks: 40.08 MHz PLL 40.072858 MHz free run 40.08 MHz PLL 40.0731 to 40.0845 MHz track 320.64 MHz PLL 40.0755 to 40.0824 MHz track Spare Oscillator 40.078553 MHz running Both sides of all clock fanouts were checked and are running: to Hub logic, to ROD, to Backplane, to MGT Quad Reference clock. Once the range of the PLLs has been checked then install the "Spare Oscillator" and the two 324 Ohm pull-down resistors. Record the frequency of the Spare Oscillator (shown above). MiniPOD Loop Test: 4-Aug-2017 through 10-Aug-2017 ------------------ - On Hub SN-05 install a MiniPOD Rec and Tx. These are from the just arrived 14 Gbps MiniPODs that belong to Hub with Fiber Ribons from CMX. - This IBERT FW is running 3 Quads; 224, 225, 226. Look at the power draw vs Line Rate. These numbers are from the DCDC converters. Power Bus: FPGA MGT MGT Swch Bulk Fan Core AVCC AVTT 1V2 1V8 1V8 ---- ---- ---- ---- ---- ---- 4.8 Gbps 3 of 3 links run with zero errors Volts: 0.94 1.02 1.19 1.20 1.79 1.82 Amps: 2.06 1.75 1.06 2.00 0.62 12.12 6.4 Gbps 3 of 3 links run with zero errors Volts: 0.94 1.00 1.20 1.20 1.80 1.82 Amps: 2.31 1.94 1.06 2.00 0.62 12.12 9.6 Gbps 3 of 3 links run with zero errors 1 hour Volts: 0.94 1.02 1.20 1.20 1.80 1.82 Amps: 2.44 2.19 1.06 2.00 0.62 12.12 11.2 Gbps 3 of 3 links run with zero errors BER = 3.68 E-16 start the run late Tues Aug 8th end the run noon Fri Aug 11th SysMon Says: 36 deg C VAux = 1.811 V VCore = 0.955 V Volts: 0.94 1.00 1.19 1.20 1.79 1.80 Amps: 2.62 2.25 1.06 2.00 0.62 12.12 Hub SN-05 Heat Sink: Work done on 14-Aug-2017 -------------------- - I still have an un-anodized heat sink and filler block on Hub SN-05. - Machine the heat sink and filler block to provide the holes and threads to install an air barb when it is required to remove the heat sink from the FPGA. Re-assemble the filler block to the heat with thermal paste. Fully tighten the 6 PEM studs. Clean off the excess thermal paste and then install the short piece of kapton tape to insulate the MTG_AVCC capacitors. Use 9 small dobs of thermal paste on top of the FPGA and then install the heat sink filler block assembly on the Hub card. Tighten the compression springs until the 4-40 threads are just flush with the upper surface of the hex nuts. All surfaces: heat sink, filler block, and FPGA lid were fully cleaned and air hosed off before the assembly with thermal paste was done. - The intent is to use Hub SN-05 for full FPGA power tests. This heat sink assembly should be full final form except that it is not anodized. Install a ROD on this Hub: 25-Aug-2017 -------------------------- Friday install ROD SN-01 onto Hub SN-05. I do not know which version of the ROD card this is. It does have one wire on its upper side. I made two supports to put under the Hub's 400 pin MegArrays so that all force to push the ROD and Hub together went straight down into the bench with no flexing of the Hub. As Ed and I had discussed, I removed the heat sink from the ROD to do this installation so that all force was applied directly over the ROD's 400 pin MegArrays so that there would be no flexing of the ROD. This technique basically works OK and it is much much better that what Ed and I did in his lab. I carefully cleaned and air hosed the top of the ROD's FPGA and the bottom of its heat sink before reinstalling the ROD's heat sink. The ROD's TIM was not stuck to either its FPGA or its heat sink. I used the 14 mm M3 screws, with a metal flat washer under the screw head (against the Hub) and a metal flat washer under the hex nut (against the ROD). I used 6 mm outside diameter 4 mm tall nylon spacers at all 3 locations. This set of hardware looks all OK and final now except of something to lock the threads. There was not problem in this setup with metal parts of this hardware getting too close to the power vias on the ROD. - Bring Hub SN-05 up to Final Form: 13-Aug-2019 ----------------------------------- Starting on about 12-Aug-2019 the work was done to bring Hub SN-05 up to Final Form. This work included: - Install an anodized and lettered Front Panel and Center Bracket. - Replace the Air Block with a drilled Air Block. - On the two Fiber Optic Ribbons install Clips for the backplane MPO connectors. Note that the two MiniPODs on Hub SN-05 do not have Heat Sinks installed on them. - Split the Enet Switch A,B not connected to C by pulling off the 8 coupling capacitors. - Install the Isolated LEMO Connector for the ROD. - Romove the power control "bypass" so that the IPMC now controls the pay load power On-Off state. Note that Hub SN-05 has IPMC SN-203 which I programmed with Fatih's constant 25 deg C software. 30 OCT 2019 - HUB SN-05 is now located 6SS #1 02 JUL 2021 - This is a note to confirm that the board has been through the fiber ribbon replacement. See hub/hardware/details/Hub_Inventory_Status_Final_Assembly/Fiber%20Ribbon%20Problem/00_Hub_Fiber_Ribbon_Issue.txt for details.