Z3 Technology DM8168-MOD-35 Bedienungsanleitung

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

Z3-DM8168-MOD-35 Module

Z3-DM8168-APP-41 PCIe Carrier

Manufacturing Test Procedure

VERSION 2.1.1

November 25, 2012

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

Z3 Technology, LLC, Lincoln, NE 68508

No part of this document may be copied or reproduced in any form or by any means without prior written consent of Z3

Technology, LLC.

Z3 Technology, LLC assumes no responsibility for any errors that may appear in this document.

This document contains confidential proprietary information that is not to be disclosed to any unauthorized person without

prior written consent of Z3 Technology, LLC.

“Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These

limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can

radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio

communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful

interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:—Reorient or relocate the receiving antenna.—Increase the separation between the equipment

and receiver.—Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.—Consult the dealer or an

experienced radio/TV technician for help.”

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

Document Revision History

Version Date Change Note Author

1.0 11/19/12 Based upon 1.0.3 of MOD-35 & APP-22 Test Procedure. Modified for

used with APP-41 and two HDMI inputs

2.0 11/20/12 Added photo MC

2.1 11/21/12 Minor revision to Figure 1 and section 5, 6, and 7. PS

2.1.1 11/25/2012 Minor page and TOC update. Updated address on page 22. AC

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

TABLE OF CONTENTS

1 Purpose........................................................................................................................................................ 5

2 General Description ................................................................................................................................... 5

3 Testing modules and application boards ................................................................................................ 6

4 Overview of the Process ........................................................................................................................... 7

5 Test and Programming Setup................................................................................................................... 8

5.1 Materials needed ................................................................................................................................. 8

5.1.1 The HDMI cables............................................................................................................................ 8

5.2 BOOTP Server Setup ......................................................................................................................... 9

5.3 Wiring setup.......................................................................................................................................... 9

5.4 Target configuration........................................................................................................................... 10

6 Flash Programming Step ........................................................................................................................ 10

6.1 Procedure ........................................................................................................................................... 10

6.2 Procedure Test Coverage................................................................................................................. 10

6.3 Pass/Fail Criteria ............................................................................................................................... 11

7 Functional Tests........................................................................................................................................ 11

7.1 Functional test coverage .................................................................................................................. 13

7.2 Procedure.............................................................................................................................................. 13

8 Pass/Fail Criteria......................................................................................................................................... 14

9 Reloading the Flash................................................................................................................................. 14

10 Log of Successful Flash Programming................................................................................................. 15

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

1 Purpose

This document specifies the manufacturing test procedure for the Z3-DM8168-MOD-35 modules and

Z3-DM8168-APP-41 application boards. These procedures are necessary in order to load the initial software

into the Flash and perform a functional test with as much coverage as possible of the circuitry of the module for

correctness of assembly.

2 General Description

The Z3-DM8168-MOD-35 is a compact OEM module, supporting H.264 codec at up to two channels of 1080p

at 60 fps (frames per second) encode and stream, decode from stream or store in applications. The

Z3-DM8168-MOD-35 features a unique expansion interface comprised of five high density connectors

providing access to the greatest majority of interface signals available from the DM8168 processor. Figure 1

below shows the Z3-DM8168-MOD-35 system on module mounted on a Z3-DM8168-APP-41 carrier board.

Figure 1: DM8168-APP-41 with DM8168-MOD-35

HDMI In 1

HDMI Out

+12V

Power In

Serial

port

Ethernet

HDMI In 2

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

3 Testing modules and application boards

Since the DM8168-MOD-35 module has no I/O ports, it is necessary to use a carrier board of some sort to be

able to connect power and signal to the various inputs and outputs. The Z3-DM8168-APP-41 application

board was selected to be the carrier. The DM8168-MOD-35 requires a DM8168-APP-41 in order to be tested.

The DM8168-APP-41 board has all the I/O connections necessary to interface to the Z3-DM8168-MOD-35.

All the interfaces on the DM8168-APP-41 board match those of the DM8168-MOD-35 module, and therefore

the DM8168-MOD-35 module is required in order to test the DM8168-APP-41.

The DM8168-MOD-35 and the DM8168-APP-41 have to be paired in order for both to be tested.

The preferred method to test newly assembled DM8168-APP-41 boards and newly assembled

DM8168-MOD-35 is to test new boards as a pair:

1) Plug a DM8168-MOD-35 to a DM8168-APP-41.

2) Connect the cables and run the flash programming step followed by the functional test as described in

sections 5, 6 and 7 below.

3) If the flash programming and functional test succeeds, then screw the boards together using 4 pcs of

M2.5 x 4mm screw and ship.

If any of the steps fail it becomes necessary to test each one individually to determine which board

requires rework.

Testing individual Z3-DM8168-MOD-35 modules consists of connecting a module to be tested onto a known

good DM8168-APP-41 application board and running the same programming and functional test processes.

In a similar manner, testing individual DM8168-APP-41 boards can be accomplishing by using a known good

DM8168-MOD-35 module. In this case, the module will already have had its flash programmed by the flash

programming step described in section 6, and therefore that procedure does not need to be executed again.

When testing DM8168-APP-41 boards with a known good module already containing the right firmware in

the flash it is only required to perform the functional tests step.

Please refer to section 9 for the procedure of how to erase and reload the flash.

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

4 Overview of the Process

All Z3-DM8168-MOD modules contain a NAND flash chip for storage of firmware and data, including sections

necessary for the board to boot. The Flash also stores the Linux kernel and filesystem. In order to allow the

module to boot, the Flash needs to contain at least the u-boot code and its environment variables.

The Flash chip is initially blank. The various software components that are to be loaded into the flash are

stored in a server on the network. The module can be configured to boot from the network using BOOTP

protocol so that the initial load is provided from the server. This initial load will cause the subsequent blocks of

data to be loaded into the Flash. When the load process is complete a status message will be printed to the

console. If the software load was performed without errors, the message will be “NAND update SUCCESS”.

After the flash content is successfully programmed, the manufacturing tests must be performed. When the

functional test completes without issues, the module will display a success message on the serial console port.

Note that the same process can be used to recover a module that had the content of its Flash compromised

and no longer boots.

Once the flash is programmed, the module can be subject to further functional tests. Such tests can be run

from a USB memory stick plugged into one of the module’s USB ports or by connecting the manufacturing

jumper option.

In summary, the following steps are used to program the Flash and verify the assembly process:

1. Plug the module under test with a blank flash into a known good Z3-DM8168-APP-41 board.

2. Connect the cables according to the setup instructions. Make sure that the power switch is in the “OFF”

position before connecting the power plug.

3. Power up the system.

This will automatically start the Flash programming step procedure described in section 6.

Since the Flash is initially empty, the module retrieves its IPL code from the BOOTP server.

The IPL code runs and retrieves various other portions of software from the TFTP server.

a. Get the file “

u-boot-uartboot.bin.scr

” from the server and write to Flash.

b. Get the file “

u-boot-env.scr'

” from the server and write to Flash.

c. Get the file “

u-boot.bin.img

” from the server and write to Flash.

d. Get the file “

uImage

” from the server and write to Flash.

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

e. Get the file “

ubifs-image

” from the server and write to Flash.

4. Once all sections of the Flash are written successfully, a success message is displayed.

If the test succeeds, then proceed to the next step, otherwise troubleshoot.

5. Turn power off.

6. Next run the functional tests as described in section 7 below.

Insert the manufacturing jumper or use a pair of tweezers to place the board into manufacturing test

mode and turn power on again to start the functional tests.

When the jumper or tweezers is detected correctly, the message “

Factory jumper detected.

" is

displayed. At this point you can remove the tweezers.

7. The manufacturing functional verification tests will execute in an endless loop.

8. If the test is successful, then remove the manufacturing jumper (if one was used) and the module is

good for shipping.

Otherwise, troubleshoot the module or the process.

5 Test and Programming Setup

5.1 Materials needed

The following materials are required to perform the programming and functional verification steps.

•A Linux PC properly configured with BOOTP and TFTP servers and the programming files

•A serial console terminal, such as a PC running a terminal emulator.

•Two media players to be used as source of video content.

•A TV monitor with HDMI input, capable of displaying 1080p60 video.

•One USB flash drive with standard format.

•One 12V power AC-DC converter rated for 2A.

•One Ethernet RJ-45 cable.

•Three good quality HDMI cables.

•One 2.5mm stereo plug to DB-9 for the serial console port.

5.1.1 The HDMI cables

Please obtain HDMI cables of good quality. For this test setup the cables need to be capable of

operating at 1080p60, so the extra-thin cables will NOT work. Ensure that the cable is capable of

1080p60 by testing it from the media player to the TV monitor, with the media player configured for

1080p60 output.

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

5.2 BOOTP Server Setup

1. Set up a BOOTP server as per instructions of the server software provider.

2. Create a directory to contain the files that will be passed on to the module and place the manufacturing

image files there.

3. Configure the BOOTP server so that it serves the u-boot-uartboot.bin file to the BOOTP client modules.

4. The IP address of the BOOTP/TFTP server must be set to 192.168.0.6, and the netmask needs to be

set to 255.255.0.0.

If the IP address of the server is different than 192.168.0.6, then a secondary IP address can be

created to accommodate the requirement, using the command

ifconfig eth0:1 192.168.0.6 netmask 255.255.0.0

5.3 Wiring setup

1. Connect a media player set-top-box “A” to the TV monitor using a HDMI cable. Configure the player to

output 1080p60 (if using Brite-View player set output to HDMI Auto) and set it to playback a video file in

a continuous loop. Do not use a Blu-Ray player as a source for the HDMI input of the APP-41.

2. Once the player is running remove the cable from the TV monitor and connect it to HDMI input 1 of the

Z3-DM8168-APP-41 board.

3. Connect a second HDMI source to the HDMI input of the TV monitor using a HDMI cable. Configure

the player to output 1080p60 (if using Brite-View player set output to HDMI Auto) and set it to playback

a video file in a continuous loop. Do not use a Blu-Ray player as a source for the HDMI input of the

APP-41.

4. Once the player is running remove the cable from the TV monitor and connect it to HDMI input 2 of the

Z3-DM8168-APP-41 board.

5. Connect the network cable to the RJ-45 jack on the Z3-DM8168-APP-41 board. It is possible to

connect the Z3 board directly to the BOOTP server if so desired. If there are switches or hubs between

the module and the server, make sure that they allow BOOTP packets through.

6. Connect a serial terminal to the serial port jack on the Z3-DM8168-APP-41.

7. Configure the terminal with 115200 bps, 8 data bits, 1 stop bit, no parity and no flow control. Since the

functional test takes advantage of ANSI escape codes, using the Teraterm terminal program is highly

recommended.

8. Apply power to the DM8168-APP-41.

Z3 Technology, LLC ♦

100 N 8

ST, STE 250 ♦Lincoln, NE 68508-1369 U.S.A.

♦+1.402.323.0702

5.4 Target configuration

1. Configure the boot jumpers on the module so that it will boot either from the BOOTP server or from the

Flash.

2. Place jumpers on pins 1-2, 3-4, and 5-6 of the boot jumper block J20 for BOOTP. The default; 5-6, 9-10,

and 15-16 is shown below.

6 Flash Programming Step

6.1 Procedure

To run the procedure and install the firmware in the flash, once the test environment is setup and the system is connected

according to the instructions in section 5 above, simply apply power to the Z3-DM8168-APP-41 board. In about 4 seconds,

the initial BOOTP will complete and the programming will start. The entire procedure is complete in about 40 seconds.

6.2 Procedure Test Coverage

If the test is successful, the result is a module with a programmed Flash chip.

The following functions are also tested and verified working by this procedure:

•All power supplies

•Power switch

•CPU core

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