TinyGv8 Production Test Instructions for Revision 2 Tester

Background and Shorthand

The following shorthand is used in these instructions:

Term	Description
UUT	Unit Under Test. They TinyGv8 board that is being programmed and tested
HOST	Tester's host computer used to program the board and start the tests via USB
AVRISP	The blue Atmel programmer. It has a USB connector and a programming header
TESTER	The large blue board with four mounting standoffs, 18 pogo pins, and the wired motor and power connectors
POWER SUPPLY	The bench power supply providing current-limited 24 volts for testing

Verification steps are marked as [VERIFIED xxxxxx] for the step

Initial Setup

Host Setup

The host computer can be a Mac OSX machine, Linux or a Windows machine. Instructions are provided for OSX, but Linux and Windows should be similar. The host needs to be set up with Avrdude and a terminal application (Coolterm). Setup steps are:

• Download and install Coolterm for your platform.
• Set up a directory for programming. Copy in everything that's in this directory. The Avrdude in the directory is for OSX. Other platforms can be found here:
• https://github.com/arduino/Arduino/blob/master/build/macosx/dist/tools-universal.zip
• https://github.com/arduino/Arduino/tree/master/build/linux/dist/tools
• https://github.com/arduino/Arduino/tree/master/build/windows
• The tinyg.hex file in the directory is the current release. If you need a different hex file replace this one.

Test Rig Setup

The test rig should look something like this:

Test kit includes:

• Tester board with 14 pogo pins
• 4 NEMA23 motors
• Atmel AVRISP MkII programmer (blue thing)
• 2 USB cables - one for the AVRISP and 1 for the UUT
• MPJA 9631PS bench power supply
• Extra pogo pins and hold-down standoffs

The large bench supply, oscilloscope and the Ultimaker in the picture are not part of the tester kit.

• Turn on the bench supply and adjust to 24.0 volts, it not already set. Turn off.
• Connect the bench supply and the motors to the tester.
• Verify that the pogo pins are all at the same starting level and have about 1/4" of good travel

[VERIFIED TEST JIG KIT]

Prep for a Test Run

These steps need to be done at the start of each test run

• Turn off the bench supply.
• Inspect the test rig and verify against the picture above

1. Verify that you have at least two 1 inch 4/40 hex standoffs available to secure the UUT to the tester

• With power off, align motor flags so they all point vertically - i.e. the 12:00 position.
• Boot the host computer
• Connect the AVRISP (blue thing) and the USB cable for the TinyG board to the host USB ports
  • Verify the green LED inside the AVRISP is lit (not flashing). This verifies USB connection between the BBB
• Start Coolterm
• Select the OPTIONS dialog and set up the Serial Port and Terminal windows as shown. You don't have a board plugged in yet so you won't see the usbserial-xxxxx option. Just set the baud rate and flow control.

• Open up a command line terminal window (e.g. Terminal on OSX, Command on Win) and navigate to your Avrdude directory.

[VERIFIED PREP]

Per-Board Instructions

Per-board tests should take about 1 to 2 minutes minute to complete.

Per Board Summary

Mount and Prep Board

1. With power off, mount board on tester
2. Plug in programmer and USB cable
3. Check pots for 50%
4. Place fan jumper on 12v position
5. Turn on bench supply and verify blue LED [VERIFIED 3.3v POWER]

Program Board

1. Cut and paste into terminal window: avrdude -q -c avrisp2 -p atxmega192a3 -P usb -u -U flash:w:tinyg.hex -U boot:w:xboot-boot.hex -U fuse0:w:0xFF:m -U fuse1:w:0x00:m -U fuse2:w:0xBE:m -U fuse4:w:0xFE:m -U fuse5:w:0xEB:m
   
   Alterate: ./avrdude -C ./avrdude.conf -q -c avrisp2 -p atxmega192a3 -P usb -u -U flash:w:tinyg.hex -U boot:w:xboot-boot.hex -U fuse0:w:0xFF:m -U fuse1:w:0x00:m -U fuse2:w:0xBE:m -U fuse4:w:0xFE:m -U fuse5:w:0xEB:m
2. Look for red PWM LED to be dimly lit [VERIFIED PROGRAMMING]

Connect to Board

1. Coolterm sequence: Disconnect, Options, Re-Scan Serial Ports, OK, Connect
2. Enter ? to verify connection [VERIFIED USB CONNECTION]
3. Press reset to verify flasshing bot loader and startup strings [VERIFIED BOOT LOADER]

Run Board Functional Tests

1. Enter $test=1
2. Confirm LED pattern [VERIFIED OUTPUTS]
3. Confirm motor movement and current levels [VERIFIED MOTOR DRIVERS]
4. Turn off bench power and wait for blue LED to turn off before removing board

Mount and Prep Board

• With the bench supply off, affix the UUT board onto the tester. Make sure all pogos connect, and secure with two hold-down standoffs as pictured.

• Plug in the programmer (blue thing) and the USB port to the board

• Verify that the potentiometers are in the 50% position:

• Place a jumper on the +12v position on J12

• Turn ON bench power supply.

• Verify that the blue power LED is lit

[VERIFIED 3.3v POWER]

Program the Board

• Go to the terminal window. Copy and paste the programming string from the ProgrammingString.txt file into the terminal window and hit return: avrdude -q -c avrisp2 -p atxmega192a3 -P usb -u -U flash:w:tinyg.hex -U boot:w:xboot-boot.hex -U fuse0:w:0xFF:m -U fuse1:w:0x00:m -U fuse2:w:0xBE:m -U fuse4:w:0xFE:m -U fuse5:w:0xEB:m

• If you don't have AVRdude already installed you can get if from these links: http://www.ladyada.net/learn/avr/setup-mac.html http://www.obdev.at/products/crosspack/download.html

  Or just go to the programming directory and enter this command string: ./avrdude -C ./avrdude.conf -q -c avrisp2 -p atxmega192a3 -P usb -u -U flash:w:tinyg.hex -U boot:w:xboot-boot.hex -U fuse0:w:0xFF:m -U fuse1:w:0x00:m -U fuse2:w:0xBE:m -U fuse4:w:0xFE:m -U fuse5:w:0xEB:m

<See Synthetos/PRoduction Support/TinyGv8_tester_version_2> You should see something like this:

avrdude: AVR device initialized and ready to accept instructions
avrdude: Device signature = 0x1e9744
avrdude: NOTE: FLASH memory has been specified, an erase cycle will be performed
         To disable this feature, specify the -D option.
avrdude: erasing chip
avrdude: reading input file "tinyg.hex"
avrdude: input file tinyg.hex auto detected as Intel Hex
avrdude: writing flash (117856 bytes):
avrdude: 117856 bytes of flash written
avrdude: verifying flash memory against tinyg.hex:
avrdude: load data flash data from input file tinyg.hex:
avrdude: input file tinyg.hex auto detected as Intel Hex
avrdude: input file tinyg.hex contains 117856 bytes
avrdude: reading on-chip flash data:
avrdude: verifying ...
avrdude: 117856 bytes of flash verified
avrdude: reading input file "xboot-boot.hex"
avrdude: input file xboot-boot.hex auto detected as Intel Hex
avrdude: writing boot (4496 bytes):
avrdude: 4496 bytes of boot written
avrdude: verifying boot memory against xboot-boot.hex:
avrdude: load data boot data from input file xboot-boot.hex:
avrdude: input file xboot-boot.hex auto detected as Intel Hex
avrdude: input file xboot-boot.hex contains 4496 bytes
avrdude: reading on-chip boot data:
avrdude: verifying ...
avrdude: 4496 bytes of boot verified
avrdude: reading input file "0xFF"
avrdude: writing fuse0 (1 bytes):
avrdude: 1 bytes of fuse0 written
avrdude: verifying fuse0 memory against 0xFF:
avrdude: load data fuse0 data from input file 0xFF:
avrdude: input file 0xFF contains 1 bytes
avrdude: reading on-chip fuse0 data:
avrdude: verifying ...
avrdude: 1 bytes of fuse0 verified
avrdude: reading input file "0x00"
avrdude: writing fuse1 (1 bytes):
avrdude: 1 bytes of fuse1 written
avrdude: verifying fuse1 memory against 0x00:
avrdude: load data fuse1 data from input file 0x00:
avrdude: input file 0x00 contains 1 bytes
avrdude: reading on-chip fuse1 data:
avrdude: verifying ...
avrdude: 1 bytes of fuse1 verified
avrdude: reading input file "0xBE"
avrdude: writing fuse2 (1 bytes):
avrdude: 1 bytes of fuse2 written
avrdude: verifying fuse2 memory against 0xBE:
avrdude: load data fuse2 data from input file 0xBE:
avrdude: input file 0xBE contains 1 bytes
avrdude: reading on-chip fuse2 data:
avrdude: verifying ...
avrdude: 1 bytes of fuse2 verified
avrdude: reading input file "0xFE"
avrdude: writing fuse4 (1 bytes):
avrdude: 1 bytes of fuse4 written
avrdude: verifying fuse4 memory against 0xFE:
avrdude: load data fuse4 data from input file 0xFE:
avrdude: input file 0xFE contains 1 bytes
avrdude: reading on-chip fuse4 data:
avrdude: verifying ...
avrdude: 1 bytes of fuse4 verified
avrdude: reading input file "0xEB"
avrdude: writing fuse5 (1 bytes):
avrdude: 1 bytes of fuse5 written
avrdude: verifying fuse5 memory against 0xEB:
avrdude: load data fuse5 data from input file 0xEB:
avrdude: input file 0xEB contains 1 bytes
avrdude: reading on-chip fuse5 data:
avrdude: verifying ...
avrdude: 1 bytes of fuse5 verified
avrdude done.  Thank you.

• At this point the red PWM LED should light, perhaps somewhat dimly, as it's PWMing.

[VERIFIED PROGRAMMING]

Connect to Board

To connect Coolterm to the board:

• Hit Disconnect if connection to previous board has not already been disconnected.
• In the Options, Serial Port dialog box hit Re-Scan Serial Ports. Select the one that looks like usbserial-DA00xxxx on OSX, or a new COM-xx port on Windows. (Note: There is a bug on Windows that prevents the com port from incrementing past 255. We have a fix for that. Ask us if you need it).
• Connect to the board using the Connect button.
• You should be able to enter in one or more ?'s and see something like below. The TinyG firmware takes about 4 seconds to start up, so it will be unresponsive until then.

X position:          0.000 mm
Y position:          0.000 mm
Z position:          0.000 mm
A position:          0.000 deg
Feed rate:           0.000 mm/min
Velocity:            0.000 mm/min
Units:               G21 - millimeter mode
Coordinate system:   G54 - coordinate system 1
Distance mode:       G90 - absolute distance mode
Feed rate mode:      G94 - units-per-minute mode (i.e. feedrate mode)
Motion mode:         G80 - cancel motion mode (none active)
Machine state:       Ready
tinyg [mm] ok>

[VERIFIED USB CONNECTION]

• Press the RESET button and verify that the SpDIR LED flashes about 12 times then returns the PWM LED

  You should see the startup strings below.

  {"r":{"fv":0.970,"fb":435.24,"hp":1,"hv":8,"id":"3X3566-HUR","msg":"Initializing configs to default settings"},"f":[1,15,0,3266]}
  {"r":{"fv":0.970,"fb":435.24,"hp":1,"hv":8,"id":"3X3566-HUR","msg":"SYSTEM READY"},"f":[1,0,0,7259]}
  

[VERIFIED BOOT LOADER]

Run Board Functional Tests

In Coolterm:

• Enter $test=1 followed by carriage return to start the on-board tests. Please note that (at least on the mac) Coolterm may not always accept the first character ($) and you may need to type it twice.

• The first phase of the test lights the output bits for about 1 second each. Sequence is:

• Spindle ON LED lit (I need to fill this in when I'm in front of the board. I might fix this to make is easier to watch, too)

• Spindle DIR LED lit

• Spindle ON and DIR LED off *.... [VERIFIED OUTPUTS]

• Next the motors should become active for about 60 seconds, during which the following should be verified.

1. Motor 1 turns clockwise at high speed for about 2 seconds, CCW for about 2 seconds and stops with the flag in the starting position (12:00). One or more four green LEDs D9, D10, D11, D12 should be lit and/or flashing during this and other motor movement operations. Also, the terminal should be displaying position information during motor movements. The values in [brackets] indicate the current draw that should not be exceeded during each move. [500 ma] Note: I will adjust these numbers when I can sit down in front of the tester
2. Motor 2 does the same [500 ma]
3. Motor 3 does the same [500 ma]
4. Motor 4 does the same [500 ma]
5. All four motors do the same simultaneously [800 ma]
6. All four motors turn clockwise at low speed for about 2 seconds, reverse for about 2 seconds and stop with the flags in the 12:00 starting positions [800 ma]
7. A final short move on motor 1 indicates that the test sequence is complete (not all green LEDs will light)

[VERIFIED MOTOR DRIVERS]

• Turn off bench power and wait until the blue power LED (D2) is completely off before removing the board. A Windows "Serial Port Disconnected Error" is normal. Click OK to ignore. Ignore any other Windows errors that may occur at this point.
• Verify the blue power LED (D2) is completely off before removing UUT as so:

1. Disconnect USB cable
2. Unscrew the 2 hex standoffs
3. Remove the UUT

You can now go back to the per board instructions for the next board.