Notes on Hub Module SN 07: Latest Rev. 4-Oct-2019 -------------------------- - Start work on SN-07 on 20-Sept-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-07. - 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. - Cut and File smooth the top and bottom edges. - 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. - Clean off flux residue around J2 and around ATCA Power Modules. While cleaning J2 I saw that two of its pins along the front edge of the card were not well soldered, i.e. no sign of solder on the top side of the card - fluxed from the top side and re-soldered them. - Install the Guide Pin Receptacles with M2.5 10mm and flat washer. - Re-press in the Zone 1 & 2 connetors and the RJ45s. - Install 2 of the 4 backplane MPO connectors with 2-15 5/16" screws and lock washers. For now I'm installing the top and bottom MPO connectors. - 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 * ---> Not yet removed 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 - Install the 40.08 and 320.64 MHz PLLs. Note that these have Kapton tape under them to make certain that the PLL PCB does not contact any of the vias in the Hub PCB and visa-versa. - 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 just tied and not glued down the discrete power wires. Install the discrete power wires in the order: Bulk_2V5 at the regulator end Bulk_2V5 at the clock generator end IPMC_3V3 at the power supply end CNST_5V0 at the power supply end Shortest ISO_12V at the power supply - east most via Middle ISO_12V at the power supply - middle via Longest ISO_12V at the power supply - west most via Shortest ISO_12V at the load Middle ISO_12V at the load Longest ISO_12V at the load IPMC_3V3 at the load CNST_5V0 at the load More Mechanical Final Assembly steps: ---------------------------------------- - Install the LED Light Guides 6 Single LED Light Pipes (1x 1, 1x 2, 1x 3) 6 Quad LED Light Pipes - Cut the height of the active edge of the mid bracket down by 0.190" as it no longer loops in back of the card but rather uses 7x of the high density tape. Cut a notch that is 0.160" wide by 0.060" deep (i.e. almost up to the screw holes) in the active edge of the mid bracket. This notch is for the IPMC_3V3 and CNST_5V0 power wires. In a new version of the front panel and this bracket I need to move the location of the two 4-40 screw holes to the right by 100 or 200 mils. - 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, e.g. along the back side lip. - 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. without the FPGA heat sink there is no problem of setting the card on its FPGA heatsink). Once both the front panel and FPGA heat sink are on the card 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. In any case temporarily install an On-Off Switch so that the card can be powered up on the bench. If the Lemo is not installed the the Lemo front panel hole may be used for a temporary On/Off switch. - Install the Insulated Lemo Connector if it is being used on this Hub card. Initial Power Up Checks: ------------------------ - Check of the Hub SN-07 currents during initial running. Setup the 7x DCDC converter power supplies as described in the MSU Final Assembly document and check all power supplies. Power Bus: FPGA MGT MGT Swch Bulk Fan Bulk Core AVCC AVTT 1V2 1V8 1V8 3V3 ---- ---- ---- ---- ---- ---- ---- Fluke Volts: 0.953 1.001 1.198 1.198 1.798 1.797 3.310 MGT_AVAUX 1.804 SysMon_Ref 1.252 Bulk_2V5 2.503 SysMon: 32 deg C VAUX 1.808 VINT 0.958 - Check of the Hub SN-07 PLL clocks: 40.08 MHz PLL 40.072985 MHz free run 40.08 MHz PLL 40.0734 to 40.0842 MHz track 320.64 MHz PLL 40.0756 to 40.0823 MHz track Spare Oscillator 40.078555 MHz running Check both sides of all clock fanouts: 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 255 Ohm pull-down resistors. Record the frequency of the Spare Oscillator (shown above). - Program the Flash Config Memory with the Safe/Foundation firmware. - Verify that this Hub Auto-Configures at power up. - Verify that the 4 front panel Ethernet jacks work. Hub SN-07 Install Its FPGA Heat Sink: -------------------------------------- - I used un-anodized heat sink and filler block on Hub SN-07. - Milled the filler block NW edge to give space for the MGT_AVCC capacitors: 80 mils deep with the center of the 3/8" cutter moving 0.700" past the long edge of the filler block. - Mill flat the two surfaces of the filler block. Sand the two surfaces flat with 120 and 180 grit paper. - Clean and Assembly the filler block and heat sink. - Use Kapton tape in the area of the MGT_AVCC capacitors. - Use the good end of the compression springs against the 4x tightening nuts. Tighten just far enough so that all threads in the nut are in use. Final Bench Checks of SN-07: ----------------------------- 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 1.20 1.21 1.80 1.82 3.312 Amps: 1.25 0.06 0.25 2.00 0.56 12.00 1.938 Safe Config Fluke Volts: 0.953 1.001 1.198 1.198 1.798 1.796 3.310 MGT_AVAUX 1.804 SysMon_Ref 1.252 Bulk_2V5 2.502 ISO_12V 12.053 SysMon: 29 deg C VAUX 1.808 VINT 0.955 - Remove the temporary On/Off switch and install IPMC SN-13? after filling its edges by the break off holes. Currently Missing from Hub SN-07: date 6-Oct-2017 --------------------------------- IPMC PROM and its contents 3x Enet Switch PROMS Phys Chip Mode Jumpers Lemo Connector on front panel FP Handle Switch FPGA Heat Sink thermal bond MiniPODs and their Heat Sink and Fiber Optic Ribbon Cable Correct Fuses Glue down of the discrete power wiring Testing and Shipment to CERN SN-07: date 15-Nov-2018 ------------------------------------ - Hub SN-07 has spent a lot of time in the 14 Slot Shelf undergoing MGT Link tests and Ethernet Switch tests. Philippe, Spencer, and Gabriel have collected lots of test data on SN-07. - Hub SN-07 has an IPMC installed but the IPMC does not control the Power On/Off state of the card. The ATCA Handle Switch controls the enable/disable state of the Iso 12 Volt supply and the Handle Switch sends the card extract signal to the IPMC. Recall that the Hub's Power Entry Module must have input power and backplane Enable signals for perhaps 3 seconds before the enable is given to the Iso 12V supply, i.e. lever the card in slowly and give it time before the Handle Switch Latch closes. More details in Hub Final Assembly Notes. - Ship Hub SN-07 to Yuri on 13-Nov-2018 on air waybill: 8112 7236 3224. In this shipment there are also 24 IPMC modules that are being sent to Yuri for forwarding to Annecy or where ever they are going next. Return SN-07 to MSU: date 4-Oct-2019 -------------------- Hub SN-07 which had been in Yuri's office was returned to MSU on October 3rd on DHL Air Way Bill 6540110113. 07 OCT 2019 Inspected unit for signs of damage or heat stress. Found none. Installed final production front panel on unit. Unit is sitting in our storage cabinet waiting for a turn on SS14. 11 OCT 2019 SN-07 was placed in SS14 in slot #2 for validation tests over the weekend. 15-OCT-2019 SN-07 passed preliminary testing per Pawel. It was removed from SS14 and placed in our storage cabinet. 30-OCT-2019 Installed ROD V3 #1 onto this HUB. It is currently in the storage cabinet waiting for its turn in the 14SS. 05-Nov-2019 ----------- Hub-SN07 + ROD-V3-SN01 shipped to CERN Airway Bill 8112 7236 3084