H-Clk Check-In Steps ----------------------- Original Rev. 24-Apr-2012 Current Rev. 27-July-2012 This procedure describes the steps in the process to make an H-Clk card, as received from the assembly vendor, ready for detailed testing and use by the HAWC experiment. Both the H-Clk card and the MEZ-456 card contain electrostatic discharge sensitive components. These cards should only be handled while using a grounded anti-static wrist strap and working at an anti-static workbench. When initially touching either card you should touch some part of its ground or power distribution structure - not a signal trace or pin. In that way, the current that must flow to bring the card and you to the same potential will flow through the ground or power nets and not through a signal net. - A safe place to initially touch the H-Clk card is the 2 extended length pins at the top end of the P1 VME connector or the 2 extended pins at the bottom end of P2 VME connector. - A safe place to initially touch the MEZ-456 card is the 3 heavy leads on either of the 3 terminal power regulators. H-Clk Final Assembly Steps: --------------------------- 1. Serial Number Write the serial number (1 through 20) and the H-Clk card type (either Clock or Control) with an indelible pen in the white silkscreen block on the front side of the card between the P1 and P2 connectors. - On Clock type H-Clk cards: U17:U48 are 9638 type ICs - On Control type H-Clk cards: U17:U48 are 65LVDT34 type ICs - On Clock type H-Clk cards: U1:U16 are 65LVDT34 type ICs U17:U80 are 9638 type ICs - On Control type H-Clk cards: U1:U48 are 65LVDT34 type ICs U49:U80 are 9638 type ICs Make an initial entry in the H-Clk card inventory list for the card that you have started work on. Include in this entry the date, card serial number, and the name of the person who is doing the check-in and final assembly of this card. 2. Tantalum Capacitors Flip all 9 of the "D" case Tantalum capacitors on the front side of the card. The bevelled edge of the capacitor with the black band goes in the direction of the "+" sign in silkscreen on the pcb. All 9 of these capacitors are mounted with the long axis horizontal and with their bevelled edge with the black band toward the front-panel edge of the pcb. All 9 capacitors are the same except for C411 which is near the K11 GPS Receiver connector. C411 is a higher voltage capacitor and must be returned to the same location. The other 8 capacitors may be installed in any of the other 8 locations. Be particularly careful that C238, just above the large black power inductor in the middle of the 4 FSI connectors is correctly installed and soldered. Obviously check the polarity and examine all 18 solder connections after you have finished flipping the Tantalums. 3. Push-Button Switches Before mounting the 2 push-button switches test them with the Ohm meter. On some of these high quality switches, the N.O. contact appears to never close when the switch is pressed. Install the 2 push-button switches S1 and S2. Make certain that these switches are fully pressed in and down against the circuit board before soldering them. At this time solder only the mechanical mounting tab near the front of the switch. The mechanical mounting pin may be folded over to help hold the switch in place while soldering. Make certain that the back of the switch is not too low. The center contact pin and the mechanical mounting tab are thermally tied to the ground planes and require fluxing and the heavier soldering iron to properly solder them. Only after the front-panel is installed should you please verify that the switch button is properly centered in the hole in the front-panel (move it around if necessary) and then solder the 3 electrical contact terminals. The LED leads between the 2 switches are longer than I would like to leave on the card. Please trim these 18 leads as part of the switch installation process. 4. Component Checks: - On the back side are all of the ceramic capacitors mounted OK and none of them broken off. - Check and tighten if necessary the mounting screws on the P1 and P2 connectors. - Check that the FSI connector pins all look straight and uniform. I would not touch them unless it is necessary to straighten one of them - and then touch only the side of the contact and not the surface that must make the actual connection to the MEZ-456 card. - Very carefully inspect all of the components in the area that will be covered by the MEZ-456 card. Are the correct components installed ? Proper orientation on all components ? All soldering looks OK ? Any solder bridges on the high density parts ? - Inspect the soldering of the 5 high density pin components that are adjacent to the P1 and P2 connectors. All pins are soldered ? Any bridges ? 5. Install the Front-Panel with its Cable Clamps - Recall that a small 0.5mm deep notch needs to be filed in the corner of the mounting boss of the lower insert/ eject handle in the location that is right next to the GPIO connector K1. - Assembly the mounting bracket for the K11 connector to the front-panel. - Assembly the permanent side of the cable clamp to a front-panel with the appropriate "Clock" or "Control" labelling for the type of H-Clk card that you are working on. - Loosely mount the top and bottom (not interchangeable) insert/eject levers to the front panel. - Mount the front-panel to the H-Clk card using M2.5 screws and using flat washers under the screw heads that press against the pcb. Tighten the insert/ eject lever's pcb screws and front-panel screws in an even way that keeps everything aligned properly and pulls all 3 of these components together. - Install the screws that run up through the K11 connector and into the front-panel mounting bracket. - Write the Serial Number of the card that you are working in the silkscreen box near the top of the front panel. 6. Install the MEZ-456 Card: - Please dry air hose both the H-Clk card and the MEZ-456 card before mounting them together. Concentrate this cleaning on the areas that will make electrical connection and the areas that will be "permanently" covered up once the MEZ-456 is installed. - I would not touch either the FSI connector contacts on the H-Clk card or the back side contact area on the MEZ-456 card. - Please make a final inspection of the FSI connector contact surfaces and the pads on the bottom of the MEZ-456 card. Are they all clean and free of any dust or particles that could interfere with them making a good electrical connection ? - Inspect the top of the MEZ-456 card before you install it. Try to sight under the BGA part to verify that no dirt or metal particles are trapped under it. Check for solder bridges on the high pin density parts. Check for no missing parts, e.g. ceramic caps or SMD resistors. - Mount the MEZ-456 to the H-Clk using the 2-56 allen screws, flat washers, and nylon washers. - Install all 12 screws to a point just short of where any of them put clamping pressure on the the MEZ-456 card. - Wiggle the MEZ-456 card to make certain that it is held in the center based on these 12 screws. You should be able to see the alignment pins on each of the FSI connectors through the holes in the MEZ-456 card. - Tighten the 12 screws in an even manner so that the MEZ-456 remains flat during the clamping process. This is harder than it sounds like it would be. Please frequently look at the MEZ-456 card edge on to see if it is bending. - Tighten all 12 screws to a torque that is appropriate for a 2-56 screw. - Finally verify that all of the visible FSI contact look like they are appropriately pressing against the pads on the MEZ-456 card. 7. If it is required for the planned application for this H-Clk card then install the appropriate cable between the Access connector on the H-Clk card and the Access connector on the MEZ-456 card. For example of the S2 push-button on the H-Clk card is going to be used to cause the FPGA on the MEZ-456 to Configure then an appropriate Access connector to Access connector cable will be required. H-Clk Card Final Checks Before Power ------------------------------------- 1. If there is any dirt or contamination on the card please use the dry air hose to blow it off. 2. Use the Ohm-meter to make the following checks from the ground structure on the H-Clk card to: - Fuse F400 - check both contacts. Expect to see electrolytic capacitors filling up. - Fuse F410 - check both contacts. Expect to see an open circuit. - Fuse F411 - check both contacts. Expect to see an open circuit. - Fuse F420 - check both contacts. Expect to see electrolytic capacitors filling up. - The positive terminal of capacitor C410 near connector K11. Expect to see electrolytic capacitors filling up. A convenient ground contact to use for these final "shorts checks" is one of the extended ground pins on either the P1 or P2 VME connectors. Extended P1 pins D2 and D31 are grounds Extended P2 pin D31 is a ground H-Clk Initial Power Up and Firmware Load ----------------------------------------- 1. Install the H-Clk card in the VME-64X crate. 2. Connect the JTAG cable to the card and have the appropriate initial test firmware (Clock or Control type) ready to program into the Configuration PROM on the MEZ-456 card with the Xilinx Impact tool. 3. Power up the card and once you have checked that things look OK then please move directly to programming the Configuration PROM and then causing the FPGA to Configure from the PROM contents. 4. Verify that the VME +3.3V +5.0V and +12V current draws looks as expected and that nothing looks hot on the H-Clk or MEZ-456 card. 5. Make whatever tests are appropriate and supported by the initial power up and check out firmware.