NetFusion CAT5 Hardware

Transcription

1 NetFusion CAT5 Hardware Reference Guide 1

2 Table of Contents NetFusion-CAT5 Hardware Reference Guide 1 INTRODUCTION NINE WAYS RESEARCH & DEVELOPMENT LTD MICROSEMI INC EMCRAFT INC M2S050-SOM-F NETFUSION CAT5 PRODUCT HARDWARE ARCHITECTURE FORM FACTOR OF THE PCB TOP LEVEL ARCHITECTURE Overview M2S050-SOM-F484 Architecture Hardware Platform Overview Net Fusion Baseboard Block Diagram COMPONENT DESCRIPTION DETAILS SOM connectors USB UART Interface Ethernet Interface USB OTG Interface FlashPro JTAG Interface ARM JTAG Interface Power Supply Reset Button Generic Option-Jumpers and Configuration Dials User Buttons & LCD Display Power, User & USB LEDs Audio Compatibility Voltage Monitor & Temperature Sensor Real-Time Clock (RTC) RS232 Peripheral RS485 Peripheral Voltage Free Relay Peripheral Analogue Contact Inputs Peripheral GPIO Peripheral Earth Protection PCB OVERVIEW COMPONENT LAYOUT SOM & Relays PCB Layout LC, GPIO & BNC Ethernet, PHY & ACI Inputs Main Connectivity CONNECTOR PIN-OUT DEFINITIONS

3 4.1 CONNECTOR SUMMARY MINI USB TYPE B CONNECTORS JTAG CONNECTORS POWER SUPPLY MARVELL PHY MDIO MODE SWITCH OPTION SWITCHES LCD CONNECTOR ANALOGUE CONTACT INPUT CONNECTOR RELAY OUTPUT CONNECTOR SERIAL CONNECTORS GPIO CONNECTOR STEREO AUDIO PHONO-JACKS EARTHING OUT OF THE BOX, POWERING UP & PROGRAMMING APPLYING POWER Bench Supply Screw Terminal Installation Output 5V Auxiliary JTAG Programming USB UART Terminal NETFUSION FUNCTIONAL DESCRIPTION USB UART INTERFACE ETHERNET INTERFACE USB OTG INTERFACE FLASHPRO JTAG INTERFACE ARM JTAG INTERFACE BNC COAX SOCKETS POWER SUPPLY RESET BUTTON GENERIC OPTION SWITCHES AND CONFIGURATION DIALS USER BUTTONS & LCD STEREO AUDIO PHONO-JACKS TEMPERATURE SENSOR VOLTAGE MONITOR REAL-TIME CLOCK RS232 SERIAL INTERFACE RS485 SERIAL INTERFACE VOLTAGE FREE RELAYS ANALOGUE CONTACT INPUTS (ACI) GPIO SPARE CONNECTOR EARTH AND LIGHTNING PROTECTION LED INDICATORS CAT5E ETHERNET CABLE & CONNECTORS RJ45 PLUG AND CAT5 6E CABLE CONNECTIONS FUTURE PCB CONSIDERATIONS WITH NEWER VERSIONS

4 9 FAQ ENVIRONMENTAL SPECIFICATIONS REFERENCES CONTACT DOCUMENT HISTORY

5 List of Figures NetFusion-CAT5 Hardware Reference Guide Figure 1 - PCB Form Factor Nano-ITX Figure 2 - Graphical Comparison of Nano-ITX Figure 3 SmartFusion2 M2S-SOM-F484 Functional Block Diagram Figure 4 - Block Diagram Architecture of the NetFusion-M2S-SOM-F484-CAT5 Main Board Figure 5 - Top View of a NetFusion CAT5 PCB (RJ45) Figure 6 - Overall NetFusion Primary Components Figure 7 - System-On-Module (SOM) & Relays Figure 8 LCD, BNC, LEDs & GPIO Figure 9 - ACI, HALO Ethernet RJ45 & Configuration Figure 10 - Audio, USB, Power & Legacy Communications Figure 11 - Power Connector Options Figure 12 - Desk Mains Power Connected to Receptacle (Q2) Figure 13 - Screw Terminal Power Figure 14 - Microsemi FlashPro4 USB JTAG Programming Figure 15 - USB Cable Connected to the USB-UART Interface from a PC Figure 16 - USB UART PC Typical Settings Configuration Figure 17 - An Example of a Terminal Screen connected through USB-UART to Emcraft uclinux Figure 18 - ARM JTAG Emulator & Debugger Figure 19 - Other Examples of M3 JTAG Emulation Hardware Figure 20 - A Standard typical 18V DC Desk Mains Supply Figure mm Phono Plug (3-pin)

6 List of Tables Table 1 : Summary of PCB Connectors Table 2: USB Receptacles Table 3: FlashPro JTAG Connector (J28) Table 4: ARM JTAG Connector (J26) Table 5: Removable Power Connectors (J30, J32) Table 6: Molded Power Receptacle (Q2) Table 7: External Power Connector (J33) Table 8 : Marvell PHY MDIO Sharing Mode (J52) Table 9: JTAG Mode Selection (LK3) Table 10: Generic Configuration Switches (J9) Table 11: GPIO Sharing RS232 (JP3, JP4, JP5, JP6, JP7) Table 12: GPIO Sharing Relays (JP8, JP9) Table 13: Relay 1 Polarity (LK1) Table 14: Relay 2 Polarity (LK2) Table 15: LCD Mating Connector (J17) Table 16: Contact Input Connector (J1 J8) Table 17: Voltage Free Relay 1 Connector (J10) Table 18: Voltage Free Relay 2 Connector (J11) Table 19: COM1 Serial RS232 9-Way D-Type Connector (J15) Table 20: COM1 Serial RS232 VERT Connector (J16) Table 21: COM2 Serial RS485 4-Way Connector (J19) Table 22: Generic General Purpose I/O Connector (J27, J31) Table 23: Stereo Audio Line OUT Connector Jack (J14) Table 24: Stereo Audio Line IN Connector Jack (J18) Table 25: Local Clean Earth Connection (J29) Table 26 : Voltage and Current Consumption on Power Supply Table 27: RS485 Distance capabilities with respect to BAUD rate Table 28 : Typical CAT5 6 cable wiring Table 29: Document History Entry Log

7 About This Document This specification fully documents and describes the NetFusion-CAT5 PCB baseboard. Use this manual to fully understand all aspects of the hardware product and to gain a full understanding of the operation and capability. Intended Audience This document is fully written for Nine Ways customers using the hardware NetFusion-CAT5 baseboard for evaluation, full product deployment, test and/or further customer product development. 7

8 1 Introduction NetFusion-CAT5 Hardware Reference Guide The NetFusion-CAT5 PCB baseboard forms several different product usages. Simplistically, it is an interface product for Emcraft's M2S050-SOM-F484 series SmartFusion 2 FPGA sub-system to allow realworld connectivity in a deployed light/heavy industrial environment. It incorporates not only many different legacy connectors and interfaces but also compact high speed connectivity such as 10/100/1000 Ethernet, USB and GPIO. Its versatility enables it to be an ideal platform as a conduit for the highly reputable and endurable M2S-SOM-484 family of SmartFusion2 FPGA system-on-module to interact in many given environments and deployable scenarios. On their own, the SOM FPGA units have no housing or any means to operate alone and must be hosted on a customized baseboard to allow the devices to perform the tasks that developers desire. NetFusion short cuts the development process in achieving a customized baseboard as much as possible with exceptions only when extremely bespoke design requirements are needed. The product can be used either in the format of an IP core Ethernet SWITCH development kit (as most of the hardware orientates network communications - hence the name NetFusion), or as an M2S-SOM SmartFusion2 trial and evaluation baseboard (more extensive interfaces than the more basic competitors), or finally as a fully ready-to-deploy industrial product solution to a user's needs having developed customized software and IP core designs to tailor to intended product functionality. 1.1 Nine Ways Research & Development Ltd Nine Ways R&D are the design house and support center for the NetFusion product. The boards Intellectual Property is owned and maintained by us. We are part of a family of companies including MorethanIP GmbH who themselves create ideal and suitable extensive IP cores particularly in the area of high-end Ethernet communications. 1.2 Microsemi Inc Microsemi is the designer and manufacturer of the FPGA device on the System-On-Module (M2S050- SOM-F484) that is the brain-board that plugs onto the NetFusion baseboard. Without the SOM, the baseboard NetFusion has no purposeful capability as the SOM contains the IP cores and the ARM Cortex-M3 processor. The FPGA used on the SOM is the SmartFusion2-050 BGA

9 1.3 Emcraft Inc NetFusion-CAT5 Hardware Reference Guide Emcraft is a US based company that opened up the possibility of the NetFusion baseboard being designed. NetFusion was designed purposefully with a SOM plug-in card in mind rather than populating the baseboard with the FPGA and the processor sub-system directly on the PCB. Emcraft supplies the M2S050-SOM-F484 System-On-Module and is the primary component on NetFusion. The heart of the SOM is the SmartFusion2 M2S050 FPGA from Microsemi. 1.4 M2S050-SOM-F484 The System-On-Module (SOM as described above) M2S050-SOM-F484 is the Smartfusion2 FPGA and ARM Cortex-M3 sub-system. The Flash, RAM, clocks, default Ethernet PHY, FPGA and all essential voltage level generation are contained on the SOM plug-in to the NetFusion. All the connections from the SOM to the NetFusion baseboard go through durable connectors and allow for inter-changeability if needed or required by the user. The usage of a SOM on the baseboard reduces the risk of writing-off the value of the sub-system when interfacing to the real-world, damage occurs or installation faults. 9

10 1.5 NetFusion CAT5 Product The product is a baseboard for the M2S050-SOM-F484 System-On-Module that is populated with useful hardware interfaces, designed for industrial electrically harsh environments (including lightning protection using local earth diffusion), and can be ready for customer deployment as-is, whilst allowing for customer evaluation and development on the exact same technology. As a baseboard, it is ideal for a user to take advantage of the Smartfusion2 FPGA technology whilst at the same time, binding it with the industrial hardware interfaces and environmental protection on the connectors and over engineered power supply system. NetFusions are sold as variants of a core family and the CAT5 copper variant concentrates on the hardware supporting 10/100/1000 Ethernet through a Marvell PHY. No fiber optic support exists with this variant, as all Ethernet pathways are copper orientated as the central emphasis on the hardware. Obviously, the PCB hosts a range of supporting hardware for customer interfacing and communication to allow the product to have a usage and functional reason to be deployed by the user. 10

11 2 Hardware Architecture 2.1 Form Factor of the PCB NetFusion-CAT5 Hardware Reference Guide Figure 1 - PCB Form Factor Nano-ITX The NetFusion PCB will use the Nano-ITX form factor. This is a very common standard for the micromotherboards available in the world-wide commercial market for miniature PCs. It is targeted at smart digital entertainment devices such as PVRs, set-top boxes, media centers and Car PCs, and thin devices. The dimensions are 170mm x 170mm to form a square. The holes will be 4 x 5mm hole, 2mm ring of copper surround with hole centre at 10mm diagonal from corner of PCB on all holes. 11

12 Figure 2 - Graphical Comparison of Nano-ITX 2.2 Top Level Architecture Overview The main NetFusion NETFUSION-M2S-SOM-F484-CAT5 motherboard PCB has a DC input power supply, Ethernet connections for 10/100/1000 on copper, a variety of peripheral connections for real-world applications, SOM, USB connectivity, audio compatibility, an option for a comprehensive LCD display together with buttons. 12

13 2.2.2 M2S050-SOM-F484 Architecture Figure 3 SmartFusion2 M2S-SOM-F484 Functional Block Diagram 13

14 2.2.3 Hardware Platform Overview The following are the key hardware features of the SmartFusion2 SOM: Compact (34 mm x 59 mm) mezzanine module; External interface using two 80-pin 0.4 mm-pitch connectors; Compliant with the Restriction of Hazardous Substances (RoHS) directive; SmartFusion2 SoC FPGA in FG484 package capable of running the system clock at 166 MHz; JTAG interface to SmartFusion2; Powered from single +3.3 V power supply; Low-power mode with fast wake-up times; On-module clocks; 64 MBytes LPDDR; 16 MBytes SPI Flash; Serial console interface at UART CMOS levels; Ethernet interface; Watchdog Timer (WDT); Key uncommitted interfaces of the SmartFusion2 device available on the Interface connectors Microcontroller & SmartFusion2 FPGA The architecture of the SmartFusion2 SOM is built around the Microsemi SmartFusion2 SoC FPGA that combines a 32-bit ARM Cortex-M3 processor core with a wide range of the integrated peripheral controllers as well as the FPGA fabric. The SmartFusion2 device is implemented using the FG484 package SmartFusion2 Capabilities, Memories and Speed Please refer to the SmartFusion2 Product Brief - Microsemi Serial Interface Bandwidths and Operation Please refer to the SmartFusion2 High Speed Serial Interfaces User Guide. Important Note: the SOM does not support SERDES routing traces to the NetFusion. Please ignore the SERDES capabilities of the SmartFusion2 FPGA macro blocks. On NetFusion-SFP PCB variant, the Marvell PHY provides SERDES to SFP transceivers without the SmartFusion2 being part of that function. 14

15 SmartFusion2 On-Chip Configuration and FPGA Design Users of the SmartFusion2 SOM are provided with a SmartFusion2 on-chip configuration and FPGA design suitable for the intended operation of the SmartFusion2 SOM. The SmartFusion2 SOM on-chip configuration and FPGA design can be viewed as an extension of the SmartFusion2 SOM hardware design. It contains a logical definition of the internal SmartFusion2 architecture, which consists of the Microcontroller Subsystem (MSS) configuration, as well as FPGA logic developed by Microsemi Inc and Emcraft Systems. It also describes an electrical interface between the SmartFusion2 device and external components, such as the SmartFusion2 device pin configuration and assignment. On a baseboard, the SmartFusion2 SOM is installed into two 80-pin Hirose DF40 series 0.4 mm-pitch board-to-board connectors. The exact part number of the connectors is Hirose DF40C-80DP-0.4V(51). The recommended mating connectors for a baseboard are the Hirose DF40HC(4.0)-80DS-0.4V connector, which provides 4 mm stacking height for the SmartFusion2 SOM. The maximum height of the SOM above a baseboard for 4 mm stacking height is 7.6 mm. For extensive details please refer to the SmartFusion2 SOM Hardware Architecture Specification - Microsemi document. 15

16 2.2.4 Net Fusion Baseboard Block Diagram Figure 4 - Block Diagram Architecture of the NetFusion-M2S-SOM-F484-CAT5 Main Board 16

17 2.3 Component Description Details SOM connectors The NetFusion PCB provides two Hirose DF40 series connectors (J12, J13) for the connection to the SOM. The connectors are 80-pin, 0.4mm pitch receptacles, providing 4mm stacking height USB UART Interface The NetFusion PCB provides a USB UART interface on the type B mini USB connector (JP2). The interface is provided using an FTDI FT232RL USB-UART bridge (U33). The FT232RL UART TX and RX pins are connected to the SOM serial console UART port Ethernet Interface The NetFusion NETFUSION-M2S-SOM-F484-CAT5 PCB provides 4 x 10/100/1000 Ethernet interface using the (U5) connector. This is a quad RJ-45 Ethernet port from HALO 1052RL (HFJ14-1G16ER-L12). The first three ports are wired through the three SDI-X channels of the Marvell QuadPHY (U3). Note: The Marvell device supports G/MII for 10/100/1000 speeds of operation. The 4 th RJ45 port as part of the integrated HALO connector block is wired directly through the SOM connectors to the SOM on-board PHY and dedicated MAC to the MSS for the ARM processor. This can be re-routed inside the fabric of the FPGA by the system designer to IP hardware Ethernet switch (either by MorethanIP or 3 rd party) but will only operate at 10/100 because of the SOM PHY being limited to only Fast Ethernet 10/ USB OTG Interface The NetFusion PCB provides a USB OTG interface on the type B mini USB connector (JP1). The interface is implemented using the USB ULPI interface of the SmartFusion2 FPGA. The interface is buffered using an SMSC USB3300-EZK ULPI USB PHY device (U26). To improve the quality of the USB signals for customers and project designers/integrators it is recommended to add voltage suppressors such as the Littelfuse PGB M device to the USB data lines (USB_OTG_N, USB_OTG_P, USB_N and USB_P). Note: The SmartFusion2 SOM has to be the M2S-SOM Rev 1A-F484 for correct operational functionality. There is no board modification that allows for the M2S-SOM Rev 1A/2A/3A-F896 version that preceded the newer version. CAUTION: Electrical connectivity conflicting with the M2S-SOM F896 Rev 1/2/3A could cause component damage. 17

18 2.3.5 FlashPro JTAG Interface NetFusion-CAT5 Hardware Reference Guide The NetFusion PCB provides a JTAG interface on the (J28) connector for use with the MicroSemi FlashPro device for programming of the SOM SoC FPGA. The connector is a standard 10-pin header 2x5 that is compatible with FlashPro3/4 devices ARM JTAG Interface The NetFusion PCB provides an ARM JTAG interface on the (J26) connector for debugging of the FPGA MSS. The connector is a standard 20-pin header 2 x10 supported by standard Cortex-M series programmers/emulators. When using the Cortex-M series programmer for debugging of the MCU/MSS the settings of the (LK3) header should be closed. For further details on this jumper setting, please refer to the Jumpers subsection later in this document Power Supply The NetFusion PCB receives a wide-range voltage capability from 9-36V DC. This is provided from either a VERT 2-way header (Q2) (for industrial deployment) or in parallel with a standard power-pin input (J30, J32). The wide range input is converted via a DC-DC module (PW1) to a steady 5V and 3.3V rail. The 5V is then available via a connector (J33) for customer s attached hardware that may wish to use a small amount of 5V DC power from the NetFusion PCB. The 5V rail is distributed across the NetFusion PCB to all components that require 5V voltage levels. The 3.3V rails are then derived from the 5V using TPS73733DCQ LDO regulators (U30, U31, U32, U35, U36). There is in-fact two of such regulators to ease the load across the PCB and into the SOM. The NetFusion PCB provides a RED power input LED (LED2) (from 5V) and also a RED power good indicator (LED3) from the 3.3V/2.5V outputs of the LDO regulators Reset Button The NetFusion PCB provides the (S1) edge PCB reset button used to trigger a reset of the SOM. This in turn should propagate reset signals to the PHYs and other circuitry dependant on a reset_n Generic Option-Jumpers and Configuration Dials The NetFusion PCB provides a 6-Way Option jumper header (J9) for general customer application configuration and basic settings. Additional to this, there is a BCD 0-9 selector switch that offers a form of basic configuration for the high-level operation of the PCB. These are wired to the GPIO of the SOM headers (J12, J13) for FPGA routing to the ARM sub-system for software operation and control. 18

19 User Buttons & LCD Display The NetFusion PCB provides a standard header for a comprehensive LCD display (U17, J17). The signals lines are routed into the SOM headers (J12, J13) for control from the ARM Cortex-M3 CPU via GPIO. The LCD header also has 3.3V power rail and GND supplied. The intention of the LCD display is to be controlled simplistically by three buttons on the PCB for configuration and control of customer/client functionality. This is performed using (S4, S5 and S6) by a user in a default manner. If the LCD display (purchased and supplied separately to this NetFusion PCB), is mounted and in operation, then the user will be able to implement source code in the ARM processor as an application that can control the LCD display. This all assists the user ability of the NetFusion product to facilitate for end-user operation in the field where ever deployed industrially. The brightness of the backlight in the LCD module is controlled by a POT (VR2) with POT (VR1) adjusting the contrast Power, User & USB LEDs The PCB has 5 LEDs used for different purposes. A green user application LED (LED1), red power +5V (LED2), red power +2.5V (LED3), red USB-UART RX LED (RX) and finally a red USB-UART TX LED (TX). The power LEDs are driven from the voltage rails, the USB LEDs directly from the FL232 USB IC (U33) and the user LED is driven from the I/O expansion I2C device Audio Compatibility The NetFusion PCB provides an Audio Line In connection (J18) and Audio Line Out phone jack connection (J14). These are associated with IC devices (U28) for Line In which is an ADC AD7911ARMZ dual channel input. The stereo input utilizes the dual channel input on the AD7911ARMZ with Left and Right audio into channels 1 and 2. The audio output is controlled by the AD5621 DAC (U8, U11). Both the ADC and DAC IC devices are SPI bus accessible. This is connected back to the SOM connectors with the GPIO. Volume and amplitude control can be managed from the software digitally as the operational amplifier and signal conditioning circuitry for the audio output are fixed and tuned to provide a full-swing voltage not to exceed the clipping threshold when the digital values are at maximum. Therefore, as no variable gainamplification exists, the software should use digital signal processing algorithms for louder or quieter audio in either direction. For audio output in stereo, two AD5621 SPI DAC ICs will allow SPI addressing from the FPGA/ASIC fabric to an audio line out amplifier and signal conditioning circuitry. Again, the volume is set for maximum non-clipping line-out power levels of 600Ohm/1kOhm. The software can digitally multiply the signal to allow for changing audible levels. 19

20 Voltage Monitor & Temperature Sensor The NetFusion PCB has an on-board PCB temperature sensor MAX6577 SOT23-6 SM device (U6). It uses the 3.3V power rail and provides a square wave duty cycle 3.3V output frequency. The device has been hard-wired to produce an output frequency of 1Hz per Kelvin degree. So water melting/freezing is 273 Hz (273 degrees absolute) and boiling point is 373Hz (373 degrees absolute). The PCB also has an AD7998 ADC SM IC (U15). Like the analogue contact inputs ADC, this is the same device except that it is used to read the analogue proportional levels of the PCBs own voltage power rails. Vin, 5, 2.5, 3.3, 1.2 and 0V are all connected. The reference voltage is 3.3V across Zener diode (D12). Vin is divided down to 25% so that up to 20.4V in the terminals power inputs can be calculated in the micro-processor. The processor interface is an I2C bus that is wired back to the GPIO of the SOM headers (J12, J13) Real-Time Clock (RTC) The NetFusion PCB has a resident real-time IC device (RTC) component (U34). This is backed-up voltage-wise by battery (BATT1) which is 3V. The battery does not have to be populated unless a customer wishes to use the RTC capability which keeps time even during a power-down. The RTC device is a DS1307 SM IC that has an I2C bus interface. These are wired back to the SOM headers (J12, J13) so that GPIO can be used to allow the software to communicate with the RTC device IC RS232 Peripheral The RS232 peripheral on the NetFusion PCB is connected to the SOM header UART signals. The MSS in the SmartFusion2 device has dedicated UART modules but they are used for the USB feature. However, the user can choose to internally wire in the FPGA fabric, the UART signals from the NetFusion PCB to IP hardware UARTS instead which arises in more flexibility. The RS232 uses connectors (J15, J16) and is wired through the RS232 level shifters (U9, U12) which are MAX232ESE-3.3V SM ICs. The two connectors are a 9-way DB9 D-type for general office debugging and connections on a desk, and the VERT 8-way header is more for the Industrial deployment and is wired in by screw-driver by the installation engineer. This eliminates RX/TX cross-over conflict issues as the RX and TX are clearly labeled on the PCB legend. Extra RS232 signals such as RTS, CTS, DTR, DSR can be driven from GPIO using options jumpers (JP3, JP4, JP5, JP6, JP7). 20

21 RS485 Peripheral NetFusion-CAT5 Hardware Reference Guide The RS285 peripheral on the NetFusion PCB is connected to the SOM header UART signals. The MSS in the SmartFusion2 device has dedicated UART modules but they are used for the USB feature. However, the user can choose to internally wire in the FPGA fabric, the UART signals from the NetFusion PCB to IP hardware UARTS instead which arises in more flexibility. The RS485 uses connector (J19) and is wired through the RS485 level shifter (U23, U27, U19, U24) which is a DS75176 RS485 level-shifter DIP IC. The connector is a 4-way header for the Industrial deployment and is wired in by screw-driver by the installation engineer. It allows for a 4-wire RS485 system operating at full-duplex rather than the inferior two-wire system at half-duplex Voltage Free Relay Peripheral The NetFusion PCB has two voltage free relays for general purpose output signaling. This is often used by project designers to communicate basic but important states of equipment in a retro-styled manner. The GPIO from the SOM headers are wired to firstly, a solid-state IC stage (U2, U7) which is an AQW610s device. However, these wirings from the SOM headers are shared with the GPIO lines. Use option jumpers (JP8, JP9) to select the usage of these relays. These devices are good for being able to have the polarity changed by option header jumpers. The output from this device then feeds to a relay coil 1D device (RL1, RL2) that connects to the Relay connectors (J10, J11). This provides protection for the ARM and the SmartFusion2 device with the SM IC solid-state device then staging to a relay coil double-pole output. These can therefore, by being staged in this manner, switch high voltage, high current equipment directly. The earth connection on the NetFusion PCB provides protection in addition to the solid-state device. Jumpers (LK1, LK2) provide the polarity settings (detailed later in the sub-sections) Analogue Contact Inputs Peripheral The NetFusion PCB provides 8 contact input channels from connectors (J1-J8). These channels are treated as an analogue signal for two reasons; (a) so that they can be used to sample analogue levels at a relatively slow sampling rate if required and (b) some digital readings use monitored contacts with resister biasing to detect sabotage and analogue to digital conversion can detect the change. The sampling is performed by (U1) which is an AD7998 SM IC that allows for 8-channel on a single device. The communication is controlled by an I2C bus which is wired back to the SOM headers for GPIO access from the ARM/MSS. These inputs from the connectors on the NetFusion PCB also have passive-ferrite and transzorb protection. 21

22 GPIO Peripheral NetFusion-CAT5 Hardware Reference Guide The NetFusion PCB provides for 14 of the GPIO lines from the SOM. This implies that SPI, I2C, TTL can all be applied to these signal lines as they are all fed and driven/sensed by the GPIO in the SOM. The connectors on the PCB (J27, J31) also provide the 3.3V rail and GND as these levels are referenced to the signals. Note: GPIO1, GPIO2, GPIO3, GPIO4, GPIO5, GPIO6 and GPIO7 are available through option jumpers (JP3, JP4, JP5, JP6, JP7, JP8, and JP9). They share with the relays and the RS232 extra signals. CAUTION: These lines are NOT protected. They are direct to the SOM FPGA and must only be used with-in an electrically safe environment and controlled enclosure especially when industrially deployed Earth Protection An EARTH spade (J29) is provided on the NetFusion PCB. This is kept away from the main circuitry and planes. It is used to allow excessive voltages on the relays, input contacts and RS232/485 lines to route safely back to a local ground situated by the deployment of the PCB and its housing. Note: The outer shielding of the RJ45 Ethernet HALO connector however is not connected to the Earth as the design of the differential pairs is transformer isolated. 22

23 3 PCB Overview NetFusion-CAT5 Hardware Reference Guide Figure 5 - Top View of a NetFusion CAT5 PCB (RJ45) Note: the image has been combined as a schematic wireframe with the significant components still shown to make it easier to view and locate the different areas of the board. 23

24 3.1 Component Layout NetFusion-CAT5 Hardware Reference Guide 2 x Voltage Free 2000V isolated AC mains capable relay outputs LCD Screen Adjustment Optional 16x2 alpha numeric LCD display System-On-Module M2S050-SOM-F484 LCD Menu Buttons Digit Configuration Selectors ACI Input Connections RS485 Connection Header RS232 Screw Header ttys1 GPIO Spare Expansion Slot Power, Application & USB [RX, TX] LEDs Deployed Installed Power Connectors USB-UART ttys0 4 x RJ45 Ethernet HALO Stereo Line IN OUT Audio JTAG FPGA Programming USB ULPI OTG Interface RS232 9Way D-TYPE ttys1 9-36V DC Input Jack Figure 6 - Overall NetFusion Primary Components 24

25 3.1.1 SOM & Relays PCB Layout NetFusion-CAT5 Hardware Reference Guide Relay 2 Connector Voltage FREE No Polarity Relay 1 Connector Voltage FREE No Polarity Local EARTH Protection. Connect to Spike or Lattice Voltage PADS for Debug & Analysis Relay Operational Polarity. If the Relays are used, then these select NO/NC Relay 1 Operation Selector. It can be disabled so the I/O is switched to the GPIO header. Relay 2 Operation Selector. It can be disabled so the I/O is switched to the GPIO header. Figure 7 - System-On-Module (SOM) & Relays 25

26 3.1.2 LC, GPIO & BNC NetFusion-CAT5 Hardware Reference Guide Optional 16x2 Alpha Numeric, Backlit, Contrast adjustable LCD RS232 Signals Selectors. Any individual additional RS232 signal (other than RX and TX) can be sent instead to the GPIO connectors (below) 3 x Menu LCD Buttons. These can still be used by application code even without the presence of the LCD screen NetFusion PCB on-board battery back-up for 3 year power-off time operation General Purpose I/O Connector GPIO 1-7. This allows for unused un-assigned I/O from the SOM to be exposed In-rush charge pump. This capacitor is predominant on the PCB but helps alleviate supply dips. General Purpose I/O Connector GPIO This allows for unused un-assigned I/O from the SOM to be exposed FPGA Reset Button. This resets the Cortex-M3, logic and the SOM hardware 2 x RED LEDs for USB-UART RX & TX activity Green application user LED driven by Cortex-M3 software 2 x RED LEDs for Power Supply. +2.5V and +5V BNC Test points for Oscilloscope connection or highly screened connection of the Audio In Out Stereo Figure 8 LCD, BNC, LEDs & GPIO 26

27 3.1.3 Ethernet, PHY & ACI Inputs NetFusion-CAT5 Hardware Reference Guide SmartFusion2 FPGA Programming Mode. This jumper selects between normal JTAG and Cortex-M3 debug analysis If the LCD screen is present then this potentiometer controls contrast If the LCD screen is present then this potentiometer controls backlight brightness Analogue Contact Input (ACI) Inner Connectors (1-4). These can be horizontal or vertical. They are visible from the application code. 0-9 Selector Switches. These feed into the application code of the processor for user customization Analogue Contact Input (ACI) Inner Connectors (5-8). These stand vertical to allow for overhead wiring Marvell QuadPHY for the 3 x 10/100/1000 RJ45 Ethernet. G/MII, MII and RMII capable with independent MDIO Cortex-M3 register software control 3 x 10/100/1000 RJ45 Copper Ethernet. The HALO connector has in-built LEDs and magnetic stages 10/100 dedicated SOM PHY RJ45 Connector. This route to the SmartFuasion2 fabric then on to the Cortex- M3 MAC Figure 9 - ACI, HALO Ethernet RJ45 & Configuration Marvell PHY MDIO Mode Selector. The MDIO from the first MAC from the SmartFusion2 fabric can drive ALL PHY MDIOs or it can be individual instead 27

28 3.1.4 Main Connectivity GND test pins (scattered around the PCB) for electrical testing NetFusion-CAT5 Hardware Reference Guide 6 x User application configuration selectors. These are visible directly to the Cortex-M3 processor RS232 pin header. This is electrically in-parallel with the DB9 connector below on this diagram Industrial Power screw terminal for 9-36V DC input Industrial Power screw terminal for 9-36V DC input RS485 screw terminal header. This 4-wite TX, RX differential pair bus for legacy communications is heavily electrically protected JTAG Programmer for the SmartFusion2 FPGA (if selected) +5V on-board generated power supply for external usage with peripherals connected to this board Audio Stereo Line-Out Jack. This allows for 3.5mm phono leads with extended 4-pin connectors to provide analogue audio to be produced from the processor application code via a DAC Audio Stereo Line- In Jack. This allows for 3.5mm phono leads with extended 4-pin connectors to provide analogue audio to be digitized in the processor application code USB On-The-Go OTG ULPI Connector. This is routed into the SmartFusion2 FPGA fabric to be converted for the Cortex-M3 USB support RS232 DB9 Male Connector. This is electrically in-parallel with the pin-header above on this diagram USB UART for accessing ttys0 on uclinux for main debug and command prompt control Power inlet in parallel with (above) power connectors. This is for desk and molded power cables. Figure 10 - Audio, USB, Power & Legacy Communications 28

29 4 Connector Pin-out Definitions 4.1 Connector Summary Connector JP2 J26 J28 JP1 Description Mini USB type B connector (USB UART interface) ARM JTAG connector Microsemi FlashPro JTAG connector Mini USB type B connector (USB OTG interface) Q2, J30, J32, J33 Input D.C Power Supply & External +5V Output J9 J17 J1 J8 Generic User option jumper header LCD connector mating interface Analogue input contacts connectors J10, J11 Voltage free output relays connector J27, J31 General purpose I/O (GPIO) user interface J14, J18 Standard phono-jack for Audio Line IN/OUT J29 JP3, JP4, JP5, JP6, JP7, JP8, JP9, J52 Earth spade attachment for transient protection GPIO sharing option jumpers with relays and RS232 extra signals Table 1 : Summary of PCB Connectors 29

30 4.2 Mini USB Type B Connectors The (JP1) and the (JP2) USB connectors have a standard mini-b receptacle pin-out. Pin Signal Type Description 1 USB_VCC POWER VCC from USB cable to the USB IC PHY 2 USB_DATA+ I/O USB Data differential positive 3 USB_DATA- I/O USB Data differential negative 4 USB_ID I/O USB presence detection 5 USB_GND POWER GND from USB cable to the USB IC PHY Table 2: USB Receptacles 30

31 4.3 JTAG Connectors NetFusion-CAT5 Hardware Reference Guide PIN 1 (JTAG_TCK) notated with the yellow DOT. This matches up with the RED cable of the 10-way ribbon from the JTAG FlashPRO4 Pin Signal Type Description 1 JTAG_TCK INPUT JTAG clock signal to the SOM 2 GND POWER Target ground 3 JTAG_TDO OUTPUT JTAG data output from the SOM 4 N/C JTAG mode set target MCU 5 JTAG_TMS INPUT JTAG mode select 6 VJTAG_VPP POWER For IC on PCB. Not for SOM 7 VJTAG_VPP POWER For IC on PCB. Not for SOM 8 JTAG_nTRST INPUT JTAG controller reset 9 JTAG_TDI INPUT JTAG data input to the SOM 10 GND POWER Target ground Table 3: FlashPro JTAG Connector (J28) 31

32 The polarity is protected by the notch. Pin1 is located at the bottom-right as you look at the diagram. Pin Signal Type Description 1 VJTAG_VPP POWER Target MCU reference voltage 2 N/C 3 JTAG_nTRST INPUT JTAG controller reset 4, 6, 8, 10, 12, 14, 16, 18, 20 GND POWER Target ground 5 JTAG_TDI INPUT JTAG data input to the SOM 7 JTAG_TMS INPUT JTAG mode select 9 JTAG_TCK INPUT JTAG clock signal to the SOM 11 GND TIE LOW Not connected to the SOM 13 JTAG_TDO OUTPUT JTAG data output from the SOM 15 SOM_nRESET I/O Target MCU reset signal 17 GND TIE LOW Not connected to the SOM 19 GND TIE LOW Not connected to the SOM Table 4: ARM JTAG Connector (J26) 32

33 4.4 Power Supply NetFusion-CAT5 Hardware Reference Guide GROUND (0V) 9-36V DC Voltage Wire point GROUND (0V) 9-36V DC Voltage Wire point Pin Signal Type Description 1 +VIN POWER Input main DC-wide range 2 GND POWER Power supply ground 3 +VIN POWER Input main DC-wide range (Duplicated for chain wiring) 4 GND POWER Power supply ground Table 5: Removable Power Connectors (J30, J32) Center pin is exposed to the rear and is +VIN with GND underside of the PCB. 33

34 Pin Signal Type Description A GND POWER Power supply ground B +VIN POWER Input main DC-wide range Table 6: Molded Power Receptacle (Q2) GROUND (0V) +5V (0.5 Watt) Voltage OUTPUT Pin Signal Type Description 1 +5VEXT POWER Output Voltage for Slave Hardware 2 GND POWER Power supply ground Table 7: External Power Connector (J33) 34

35 4.5 Marvell PHY MDIO Mode Switch Marvell QuadPHY MDIO Sharing Mode Name Settings Description Marvell PHY MDIO Sharing MERGED INDIVIDUAL MDIO1 from GMII bus 1 accessed ALL ports with addressing differentiation Port 1 uses MDIO1, Port 2 uses MDIO2 and Port 3 uses MDIO3. Note: correct MDIO address still required Table 8 : Marvell PHY MDIO Sharing Mode (J52) 4.6 Option Switches Single 2-pin jumper for JTAG Programming MODE 35

36 Name Settings Description JTAG Mode Selection 1-2 Closed 1-2 Open The SOM JTAG controller is in the Cortex- M3 debug mode. The JTAGSEL pin of the SOM is LOW The SOM JTAG controller is in the FPGA programming mode. The JTAGSEL pin of the SOM is HIGH Table 9: JTAG Mode Selection (LK3) The UP position labeled ON produces a 1 on the software read data. Oppositely, the DOWN position labeled OFF produces a 0 on the software read data. Name Description User Customer Option Strap 1 User Customer Option Strap 2 Generic Configuration Header User Customer Option Strap 3 User Customer Option Strap 4 User Customer Option Strap 5 User Customer Option Strap 6 Table 10: Generic Configuration Switches (J9) For each of the additional extra RS232 signals such as DTR, DSR etc, they can be switched instead to the GPIO connector if the RS232 functionality is not required. UP position = RS232 signal. DOWN position = GPIO USR signal 36

37 Name Settings Description RS232 / GPIO Sharing RS232 USER RS232 signal used and GPIO line not used RS232 signal not used and GPIO line active Table 11: GPIO Sharing RS232 (JP3, JP4, JP5, JP6, JP7) For each of the Relays RL1 and RL2, they can be switched instead to the GPIO connector if the relay output functionality is not required. LEFT position = GPIO USR signal RIGHT position = RELAY operation Name Settings Description Relays / GPIO Sharing RELAY GPIO Relay signal used and GPIO line not used Relay signal not used and GPIO line active Table 12: GPIO Sharing Relays (JP8, JP9) Important Note: the first 7 GPIO lines do route to the GPIO header directly (J27, J31). The lines are fed through 3-way option jumpers to select differing functionality. The tables above illustrate the split functionality. 37

38 In the UP position, these Relay Polarity selector switches electrically cause the outputs to be Normally OPEN. DOWN infers normally CLOSED NetFusion-CAT5 Hardware Reference Guide Name Settings Description Voltage Free Relay 1 Polarity NC NO J10 Normally Closed when Relay RL1 deasserted J10 Normally Open when Relay RL1 deasserted Table 13: Relay 1 Polarity (LK1) Name Settings Description Voltage Free Relay 2 Polarity NC NO J11 Normally Closed when Relay RL2 deasserted J11 Normally Open when Relay RL2 deasserted Table 14: Relay 2 Polarity (LK2) 38

39 4.7 LCD Connector NetFusion-CAT5 Hardware Reference Guide PIN 1 (GND) here on the LEFT with PIN 16 (Backlight Current Source) at the far end Pin Signal Type Description 1 GND POWER Power Supply Ground 2 +5V POWER 5V Power Rail 3 CONTRAST INPUT Contrast Setting from POT (VR1) 4 LCD_RS INPUT LCD Control Line 5 LCD_RW INPUT LCD Control Line 6 LCD_EN INPUT LCD Control Line 7 LCD_D0 INPUT LCD Data Bus 8 LCD_D1 INPUT LCD Data Bus 9 LCD_D2 INPUT LCD Data Bus 10 LCD_D3 INPUT LCD Data Bus 11 LCD_D4 INPUT LCD Data Bus 12 LCD_D5 INPUT LCD Data Bus 13 LCD_D6 INPUT LCD Data Bus 14 LCD_D7 INPUT LCD Data Bus 15 BACKLIGHT POWER Backlight Current Sink 16 BACKLIGHT POWER Backlight Current Source Table 15: LCD Mating Connector (J17) 39

40 4.8 Analogue Contact Input Connector ACI 1 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 2 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 5 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 6 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 3 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 4 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 7 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) ACI 8 signal pin 1 pointed to by arrow. GND is the other screw pin (pin 2) Pin Signal Type Description 1 ACI_1 INPUT Analogue Input 1 reference to GND 2 GND POWER Target ground 3 ACI_2 INPUT Analogue Input 2 reference to GND 4 GND POWER Target ground 5 ACI_3 INPUT Analogue Input 3 reference to GND 6 GND POWER Target ground 7 ACI_4 INPUT Analogue Input 4 reference to GND 8 GND POWER Target ground 9 ACI_5 INPUT Analogue Input 5 reference to GND 10 GND POWER Target ground 11 ACI_6 INPUT Analogue Input 6 reference to GND 12 GND POWER Target ground 13 ACI_7 INPUT Analogue Input 7 reference to GND 14 GND POWER Target ground 15 ACI_8 INPUT Analogue Input 8 reference to GND 16 GND POWER Target ground Table 16: Contact Input Connector (J1 J8) 40

41 4.9 Relay Output Connector Relay RL2 nonpolarized voltage free isolation protected screw terminals Relay RL1 nonpolarized voltage free isolation protected screw terminals Pin Signal Type Description 1 RLY_1_A OUTPUT Floating isolated relay signal 2 RLY_1_B OUTPUT Floating isolated relay signal Table 17: Voltage Free Relay 1 Connector (J10) Pin Signal Type Description 1 RLY_2_A OUTPUT Floating isolated relay signal 2 RLY_2_B OUTPUT Floating isolated relay signal Table 18: Voltage Free Relay 2 Connector (J11) 41

42 4.10 Serial Connectors NetFusion-CAT5 Hardware Reference Guide 8-way screw terminal header RS232 with pin 1 on the right (indicated by the arrow). This is electrically in parallel and the same as the DB9 connector below. This is electrically in parallel and the same as the above connector. It exposes a Male 9-way connector for normal serial cable attachment. Pin (on PCB) Signal Type Description 1 DCD INPUT Data Carrier Detect 2 RxD INPUT Receive Data 3 TxD OUTPUT Transmit Data 4 DTR OUTPUT Data Terminal Ready 5 SG POWER Signal/Chassis Ground 6 DSR INPUT Data Set Ready 7 RTS OUTPUT Request To Send 8 CTS INPUT Clear To Send 9 RI INPUT Ring Indicator Table 19: COM1 Serial RS232 9-Way D-Type Connector (J15) 42

43 Pin Signal Type Description 1 COM1_232TX OUTPUT COM1 RS232 TX 2 COM1_232RX INPUT COM1 RS232 RX 3 COM1_232RTS OUTPUT COM1 RS232 RTS 4 COM1_232CTS INPUT COM1 RS232 CTS 5 COM1_232DTR OUTPUT COM1 RS232 DTR 6 COM1_232DSR INPUT COM1 RS232 DSR 7 GND POWER Signal ground 8 GND POWER Signal ground Table 20: COM1 Serial RS232 VERT Connector (J16) The RS485 screw terminals provide a full-duplex industrial bus system. Pin 1 is indicated by the arrow with pin 6 at the other end. Pin Signal Type Description 1 COM2_485TX+ I/O COM2 TX+ 2 COM2_485TX- I/O COM2 TX- 3 GND POWER Chassis Ground 4 COM2_485RX+ I/O COM2 RX+ 5 COM2_485RX- I/O COM2 RX- 6 GND POWER Chassis Ground Table 21: COM2 Serial RS485 4-Way Connector (J19) 43

44 4.11 GPIO Connector NetFusion-CAT5 Hardware Reference Guide Pin 1 (VCC3). These pins provide a user expansion connector for some of the dedicated signals on this PCB and also for the rest of the spare GPIO from the SOM headers. Pin 8 Pin 9 Pin 16 Pin Signal Type Description 1 VCC3 POWER GPIO power supply level 2 GPIO_USR1 I/O GPIO User I/O 1 3 GPIO_USR2 I/O GPIO User I/O 2 4 GPIO_USR3 I/O GPIO User I/O 3 5 GPIO_USR4 I/O GPIO User I/O 4 6 GPIO_USR5 I/O GPIO User I/O 5 7 GPIO_USR6 I/O GPIO User I/O 6 8 GPIO_USR7 I/O GPIO User I/O 7 9 GPIO_USR8 I/O GPIO User I/O 8 10 GPIO_USR9 I/O GPIO User I/O 9 11 GPIO_USR10 I/O GPIO User I/O GPIO_USR11 I/O GPIO User I/O GPIO_USR12 I/O GPIO User I/O GPIO_USR13 I/O GPIO User I/O GPIO_USR14 I/O GPIO User I/O GND POWER Target ground Table 22: Generic General Purpose I/O Connector (J27, J31) 44

45 4.12 Stereo Audio Phono-Jacks Line Out 4-pin 3.5mm Stereo Jack. The contacts on the PCB are labeled in the below tables Line In 4-pin 3.5mm Stereo Jack. The contacts on the PCB are labeled in the below tables Pin Signal Type Description 1 Left AUDIO Left Audio Analogue Channel 2 GNDAA POWER Analogue Ground 3 Right AUDIO Right Audio Analogue Channel 4 GNDAA POWER Analogue Ground 5 GNDAA POWER Analogue Ground 6 GNDAA POWER Analogue Ground Table 23: Stereo Audio Line OUT Connector Jack (J14) 45

46 Pin Signal Type Description 1 Left AUDIO Left Audio Analogue Channel 2 GNDAA POWER Analogue Ground 3 Right AUDIO Right Audio Analogue Channel 4 GNDAA POWER Analogue Ground 5 GNDAA POWER Analogue Ground 6 GNDAA POWER Analogue Ground Table 24: Stereo Audio Line IN Connector Jack (J18) 4.13 Earthing Earth STUD for local lightning and environmental electrical protection Pin Signal Type Description 1 PEARTH EARTH Local EARTH reference Table 25: Local Clean Earth Connection (J29) 46

47 5 Out of the Box, Powering Up & Programming The product should be presented boxed, bubble wrapped and protected with anti-static packaging. Be careful not to static discharge yourself through the PCB as this can cause severe if not irreparable damage. Note: always try to use earth straps when handling the NetFusion PCB. 5.1 Applying Power There are two different methods of supplying the DC power to the NetFusion product. They are electrically wired in parallel and should not be used simultaneously, even though there is on-board protection for such a circumstance. Auxiliary 5V derived output connector Figure 11 - Power Connector Options Both power methods allow for 9-36V DC voltage variant. Important Note: you should always consider equipping and providing a power supply delivery unit that provides at least twice the maximum current consumption in the table below. 47

48 Input Voltage Current Maximum FPGA Fabric Usage and Switching mA mA mA mA mA Table 26 : Voltage and Current Consumption on Power Supply Bench Supply You can use a standard 18V L.T.E. or similar mains desk supply. The molded connector on the mains supply will plug directly into the power receptacle (Q2) on the NetFusion PCB. Figure 12 - Desk Mains Power Connected to Receptacle (Q2) This method of connection is ideal for desk, evaluation, development and test. It avoids the cumbersome bench supply and allows for product usage when there is no industrial supply. If you use NetFusion as a Development Kit for instance, this supply will be provided with the delivery. 48

49 5.1.2 Screw Terminal Installation NetFusion-CAT5 Hardware Reference Guide Figure 13 - Screw Terminal Power Whilst only one of the two pairs of power is necessary, having a dual approach allows for daisy chaining equipment, or having two parallel bench or industrial power available (if current is limited to less than 500mA per output unit) Output 5V Auxiliary Next to the two screw-terminal power supply connectors is a +5V DC derived output supply. This is generated on-board NetFusion and can be used to supply external TTL/CMOS peripheral devices connected to the baseboard. This may not be necessary when powering up the board for the first time or getting started, but it is mentioned so that you do not get this confused with the input DC power supply connectors. Please Note: maximum current delivery capability of the auxiliary supply is 5V JTAG Programming With the on-board PCB JTAG programming mode LINK removed and not present, the SmartFusion2 FPGA on the SOM will accept normal JTAG programming, validation and verification. This is all controlled using the FlashPro IDE from Microsemi or the FlashPro embedded in Libero SoC/IDE. Figure 14 - Microsemi FlashPro4 USB JTAG Programming Firstly, check that the two Red LED power indicators are illuminated on the NetFusion PCB. With the JTAG programming mode LINK removed, plug in the USB programmer (as shown above). Using the Microsemi IDE application, program your IP fabric and envm u-boot image. Note: for Libero IDE, FlashPro4 & uclinux compilation, please see the other NetFusion PDF guides. 49

50 Once the Microsemi IDE has signaled that the programming operation was successful and completed, you can optionally remove the JTAG ribbon cable from the header on the PCB. You must remove and then re-apply the DC power. Once the power is restored and the NetFusion System-On-Module s SmartFusion2 FPGA is operating and the Cortex-M3 is launching the envm RAM u-boot, progress to the following sub-section (below) USB UART Terminal As the SOM s Cortex-M3 processor (embedded inside the SmartFusion2 FPGA) begins to boot-up, the debug and process can be observed using the USB-UART interface. This is a USB device that your connected PC will recognize as a USB Serial Device and allocate a COM port to it (Windows XP/7/8) Note: /dev/ttys0 1 2 for Linux PCs. Figure 15 - USB Cable Connected to the USB-UART Interface from a PC The IDE on the PC should open a window that can see the debug and allow for commands and text to be entered. This will interact with the u-boot. Once you have programmed the SPI Flash with the uclinux (see NetFusion uclinux Guide PDF) then the interaction and debug will be with the booted uclinux. This includes how to connect a CAT5 to the 10/100 RJ45 for TFTP network transfer of the Linux kernel file. 50

51 6 NetFusion Functional Description As described in the earlier section, there are a wide range of components relating to individual functionality. However, as before the earlier section concentrated upon the electronic component details and wiring, this section describes the general customer functional scenarios for each interface. 6.1 USB UART Interface The main USB interface is a more default, statutory interface for the reason of commanding the NetFusion on loading code into the memory and viewing debug. It is the main viewing portal for the Linux OS inside the SOM, although a user/customer can during run-time change the usage of this port to suit their own needs. The FL232 SM IC on the NetFusion PCB is a USB device that presents itself on a connected Windows/Linux/Mac PC as a USB Serial Device. This has a programmed baud rate and other attributes as you would logically expect but the default is N1. Figure 16 - USB UART PC Typical Settings Configuration 51

52 Figure 17 - An Example of a Terminal Screen connected through USB-UART to Emcraft uclinux 52

53 6.2 Ethernet Interface NetFusion-CAT5 Hardware Reference Guide The HALO 4-port 10/100/1000 Ethernet connectors provide RJ45 industrially shielded sockets. The three on the left (labeled on the PCB) connect to the Marvel PHY IC and can fully throughput 1Gbit/s data bursts or downwards negotiate or be fixed at 10/100 Fast Ethernet. The right socket labeled as [SOM] is a direct connection to the PHY on the System-On-Module. The maximum capability of this port is 100Mbit/s. This is due to the PHY on the SOM and the usage of only an MII 25MHz interface into the SmartFusion2 FPGA embedded MSS MAC. This RJ45 port does route through the FPGA fabric in the way to the MSS MAC which means that it can be intercepted and wired through a SWITCH for instance. Note: The first 3 10/100/1000 ports are routed through the Marvell QuadPHY on the baseboard, then into the SmartFusion2 FPGA fabric with G/MII traces. However, by default it is used as a means to allow re-compiled uclinux kernels and application code to be programmed into the SPI FLASH memory using TFTP. The commands are initiated using the USB- UART interface (above). It also is then useful as the default /dev/eth0 in the Linux system and provides an immediate Ethernet interface without any added IP cores in the FPGA fabric. Nine Ways Research & Development Ltd can provide dedicated SWITCH projects that do re-route this SOM RJ45 and also we do provide full SWITCH solutions for the other 10/100/1000 ports but this is as an additional sale. In short, all 4 x RJ45 ports of the HALO connector can be used in the fabric with a SWITCH or MACs including the 4 th 10/100 port. However, by default, the 4 th 10/100 port is a convenient pathway to a startup Linux system and u-boot software programming mechanism by connecting direct to the MSS MAC. HALO LED Definitions: Note: For DUPLEX LEDs: ON = FULL OFF = HALF. For SPEED LEDs: ON = 100Mbit/s OFF = 10Mbit/s PHY Port 1 Duplex (Full = LED ON) PHY Port 2 Duplex (Full = LED ON) PHY Port 3 Duplex (Full = LED ON) SOM MSS Port Speed PHY Port 1 Link(solid) PHY Port 2 Link(solid) PHY Port 3 Link(solid) SOM MSS Link/ACT 53

54 6.3 USB OTG Interface NetFusion-CAT5 Hardware Reference Guide The second USB port on the NetFusion PCB baseboard has no default purpose. The traces from the USB host hardware on the PCB trace route through to the SOM SmartFusion2 FPGA fabric and present to a ULPI/UTMI converter IP core. This can be used either in the fabric or to the MSS ARM Cortex-M3 processor embedded MSS USB support. A customer/user can choose how to use this port and has complete control of the usage and purpose. The OTG on-the-go mechanism is very flexible and is widely recommended in the USB industry. Important Note: the SmartFusion2-SOM-M2S-050 does not implement ULPI in the MSS USB peripheral so the fabric has the ULPI/UTMI converter for the user s convenience when they plan how to use the USB. For useful documents on understanding USB OTG then please refer to: OTG Specification - USB.org 6.4 FlashPro JTAG Interface The JTAG header allows for the 10-way ribbon cable from a FlashPro USB programmer to access the SmartFusion2 FPGA. In particular the actions relate to programming the envm Flash with the u-boot code to boot the device from reset. Moreover, it access and re-programs all of the FPGA fabric Flash that houses the IP cores and project integration. The programmer is controller on a host PC by Libero IDE or FlashPro4 stand-alone application. Just connect the ribbon from the programmer onto the header (make sure that the RED ribbon line is on the same side as the PCB silkscreen dot). The IDE handles all of the integration of the u-boot code and the fabric. This goes beyond the scope of the document from here. Once the SmartFusion2 FPGA on the SOM is released from a full reset, the fabric flash is loaded into the SDRAM of the core and provides the RAM based fabric operation. Additionally, the envm flash is loaded into the envm RAM for u-boot execution. It is at this stage that the u-boot loads the uclinux from the SPI external flash on the SOM into the external LPDDR SDRAM memory. The Linux environment then boots and execution of the user applications can begin. 6.5 ARM JTAG Interface The NetFusion PCB provides an ARM JTAG interface for debugging of the SmartFusion2 SoC FPGA on the SmartFusion2 SOM. The connector is a standard 20-pin JTAG port supported by standard Cortex-M3 programmers/emulators. When using this function, make sure that the option jumper LINK setting is correct for the JTAG mode. 54

55 Figure 18 - ARM JTAG Emulator & Debugger For specific information on the usage and the datasheet of the Cortex-M3 ARM Debugger please refer to the following document: Download JTAGJET-CORTEXM3 datasheet. There are other manufacturers of similar applicable products that interface with the M3 Debugging JTAG interface (below) Figure 19 - Other Examples of M3 JTAG Emulation Hardware 55

56 6.6 BNC Coax Sockets NetFusion-CAT5 Hardware Reference Guide The 4 x BNC bayonet sockets situated in the middle central area of the NetFusion baseboard allow for a screened coax cable transmission of the audio line IN and audio line OUT function. Whilst these are already provided as 2 x 3.5mm phono jacks elsewhere on the board, the BNC feature allows for either oscilloscope analysis for clean noise free observation or for critical clean analogue waveforms to be shielded from surrounding industrial environmental interference. All of the BNC sockets are labeled on the PCB so installation engineers or development programmer can access and identify which channel and direction of the audio with each connector. For audio line IN, there are stereo left and right channels, and the same with the audio line OUT. 6.7 Power Supply NetFusion has two screw terminal DC power inlets and a single molded power receptacle. They are electrically all in parallel, but all have protection for differing voltages and overvoltage. Moreover, the polarity cannot be reversed so as to damage the baseboard either. It is generally the case that the power receptacle is commonly used on the desk and during development. The screw terminal header inlets are for the industrial deployment arena and maybe the NetFusion is sharing power with other equipment or 3 rd party bespoke DC power supplies are used. There are two screw terminal connectors in parallel to assist in the frequent and common installation practice of daisy chaining power together for multiple devices. Moreover, it can also be used if two power supplies are required to provide the current needed for NetFusion on a demanding high-bandwidth switching application. All accidental reverse polarity connection attempts are diode protected, along with over-voltage transzorb clamp protection. All three inputs can accept a wide voltage range between 9V 36V DC. The higher the voltage the lower the current sourced for the DC-DC module on the underside of the NetFusion. Please Note: a standard 18V soap-on-a-rope desk AC power supply is preferred for the receptacle inlet as this is the most optimum voltage for noise reduction for these types of supplies. Figure 20 - A Standard typical 18V DC Desk Mains Supply 56

57 6.8 Reset Button NetFusion-CAT5 Hardware Reference Guide The main reset button on the NetFusion board controls the reset sequence across the hardware. By pressing and releasing, an IP core in the FPGA fabric initiates a wave of reset flow that accurately brings up the Cortex-M3, FPGA fabric, SOM hardware and the NetFusion baseboard devices. There is no ability to distinguish different desirable resets. It s the whole environment as one. You cannot just reset the Cortex-M3 only for instance and also want to independently reset other parts of the hardware on different occasions. The reason for this is there is only one reset button and trace line routed into the SOM then into the SmartFusion2 FPGA. A solution to having NetFusion provide multiple reset signals is to use some of the available hardware on the baseboard. For instance, using the LCD buttons and re-wiring the connection inside the FPGA fabric using Libero IDE. Moreover, allowing the software to control output GPIO that is then re-wired in the fabric. 6.9 Generic Option Switches and Configuration Dials Use the option switches and the rotary switches to control and bootstrap your firmware application code. All of these signals are routed to the GPIO core inside the SmartFusion2 FPGA fabric which is memory addressable from the ARM Cortex-M3 processor. This enables software application code to use one of the UIO device drivers to ascertain the state and configuration of the option switches and the rotary switches. For instance, you can set parts of a MAC address or change fundamental MII modes. The most common usage is for user application program specific initialization settings User Buttons & LCD The LCD is not fitted as standard to a NetFusion baseboard unless you have purchased the development kit bundle. It is a 16 x 2 digit alpha-numeric screen with just black monochrome as a color. A rotary dial controls the contrast and also another dial controls the backlight power. The contents of the screen are controlled by application software via the GPIO core in the SmartFusion2 FPGA fabric. The contents of the screen survive a hardware reset which is why it must be cleared and re-initialized upon software boot-up if the screen is to re-establish an initialized message announcement. The customer/user can use the screen (if required) to show whatever content they desire and is only designed in for user purposes. The LCD buttons are just input signals available to the application code as well. 57

58 6.11 Stereo Audio Phono-Jacks The two stereo 3.5mm phono jacks provide for audio line IN and audio line OUT. The usage can obviously go beyond audio as the sampling rate of the DAC; ADC devices can extend as high as 41.5kHz. The SPI DACs sample at MHz but in practice the software pipelines for the data can only cope with khz. Figure mm Phono Plug (3-pin) Analogue waveforms incoming through both left and right channel of the audio line IN are sampled by an ADC. This is polled and read over SPI by application software. The same happens in reverse for the audio line OUT left and right channels. Line OUT impedance: 100ohms. Line IN impedance: 8K2 Note: they appear to the Linux environment as pipes of data streams from the UIO audio drivers Temperature Sensor This device does not appear as a connector on the NetFusion baseboard. Specifically, it is an on-board component that checks and monitors the state of the PCB. The temperature sensor IC is located underneath the SOM where the temperature is likely to be the hottest. This can be used by the application code and the user/customer to check for overheating and send warnings to a control station for instance. The temperature IC sends a square wave signal with an even duty cycle that has a cyclic Hz rate equal to the temperature in Kelvin degrees. So 273Hz is freezing point of water and 373Hz is 100 Celsius and this relationship continues uniformly theoretically with-in the operating limits of the industrial temperature range. The output trace from this device routes into the SmartFusion2 FPGA fabric where a counter allows user software to address how many cycles per second is occurring. From this, the UIO temperature device driver can interface with user application programs. 58

59 6.13 Voltage Monitor NetFusion-CAT5 Hardware Reference Guide This device does not appear as a connector on the NetFusion baseboard. In fact, it is an on-board component that checks and monitors the state of the PCB. An I2C device allows most of the power rails to feed in as inputs and an analogue reading is taken. A software UIO device driver reads the values over I2C and applies simple mathematics to allow the voltages to be revealed to the customer/user application programs. This can be used by the user/customer to check for malfunction or sever over-voltage conditions and send warnings to a control station for instance Real-Time Clock Although the SmartFusion2 FPGA has an in-built clock timer module in the MSS, surviving power down and maintaining good accuracy are not guaranteed. Therefore, NetFusion has incorporated a battery backed-up Real-Time-Clock (RTC) function directly on the baseboard. The battery is capable of maintaining power to the RTC device for 3 years approximately without the board being powered. The Battery charges when power is present. The RTC device is accessed via the FPGA fabric using an I2C bus. A UIO Linux device driver accesses the device and presents a time and date to user application programs or the Linux BASH script environment. This function can maintain a ticking time during power off and runs of a 32 khz crystal maintaining a good level of accuracy. If your Libero IDE NetFusion project has the on-board MSS RTC enabled, then that will be able to run in parallel and independently of this RTC hardware on the baseboard RS232 Serial Interface The first UART interface of the uclinux system in the Cortex-M3 processor is used for the USB-UART (as described early in this section). This presents itself as /dev/ttys0 in the Linux file system of devices available to use. However, for /dev/ttss1 (the second serial port) NetFusion exposes this as an industrial DB9 RS232 interface in parallel with an adjacent screw terminal header with the exact same RS232 level pins. The NetFusion uses an RS232 level-shifter to convert from the LVTTL of the SOM, and also provides 1000V isolation from induced voltages on the RS232 lines. This is very useful in the industrially deployed arena where typically NetFusion may be installed. The normal RX and TX signals are routed directly to the DB9 and the screw header terminal for statutory use but the extra DTR, DSR, CTS, RTS, RI signals go through selector switches (described early in this document), before potentially routing to the DB9 headers. The purpose of the extra LVTTL signals being switched is to give the user a choice of whether these signals are needed. They can be routed instead to the GPIO auxiliary interface to be used for other customer intended functionality. Most commonly RS232 only uses RX and TX so by switching the extra signals to the GPIO, it allows for the pins from the SOM to be re-used for other features. These extra DSR, DTR, RTS, CTS signals are not controlled in the MSS ARM UART but from the general GPIO driver in the NetFusion Linux system. The signals excluding the RX and TX route back through the SmartFusion2 FPGA fabric through a UART core which is addressable as memory from the UART device driver. However, the RX and TX are connected direct to the MSS UART. 59

60 6.16 RS485 Serial Interface NetFusion-CAT5 Hardware Reference Guide The USB and RS232 ports are not the only UART functions available to the user. Another driver has been installed to allow for an RS484 interface for much longer distances of legacy communication. As the baseboard has been designed to allow for a lot of legacy interfacing including bringing modern high speed Ethernet communications alongside old infrastructure that needs supporting, it is statutory that RS485 is at the heart of the system. Just a single screw terminal header brings the R+, R-, T+, T- 5V differential pair signal levels onto the NetFusion baseboard in which they route through 2000V isolation protection in a level shifter. LVTTL connects the level shifter IC with the SOM whereby they route through the SmartFusion2 FPGA fabric through a UART core which is addressable as memory from the UART device driver. Unlike the RS232 interface, there is only RX and TX functionality which are all handled by a single device driver which streams the received and transmitted data from the Linux environment. MAX Distance End-to-End BAUD 125m m m m m m 1200 Table 27: RS485 Distance capabilities with respect to BAUD rate 6.17 Voltage Free Relays NetFusion hosts two mains voltage relays that can be used for user general purpose activity. Each has a separate screw terminal connector for ease of installation and deployment and the voltage rating of such a switched secondary voltage is mains AC (110/230V). Although the current throughput is limited to much less than 1000mA, this mains switched voltage can be used to control further large industrial control beyond and away from NetFusion. The isolation voltage for safety purposes is rated at 3500V if transient or surge spikes affect the relay wiring. In fact, the baseboard houses an inner solid-state relay inside of the mechanical set to further protect the SOM device controlling the whole PCB. Control of the relays is obtained with an uclinux device driver for the GPIO. The ON or OFF state is driven through a core in the FPGA fabric which then routes to a set of selector switches on the PCB located in close proximity to the relays on the PCB. These selectors allow for the relay signals to be used in the GPIO interface instead if the relays are not required. If the relays are selected then the signals connect to the inner solid-state relays then to the main mechanical set. Note: normally open (NO) and normally closed (NC) controlled by other selector switches. 60

61 6.18 Analogue Contact Inputs (ACI) The most un-talked about feature of NetFusion is actually one of its best functions it can provide the user. There are 8 screw terminal connectors that individually each allow for an analogue input. The connectors are all individual as this makes wiring and interfacing in an installed and deployed environment especially in tight or restrictive spacing. Each input is biased with a 5V pull-up on the positive pin and GND on the other. This voltage applied input allows for relays of other equipment to close or keep open the input as a form of legacy communication and furthermore, the analogue orientation allows for parallel and series tamper resistors to be used to detect sabotage attempts. Other uses for these inputs could be to directly measure and monitor scaled proportional voltages of 3 rd party connected equipment. These inputs are compatible with other voltage applied equipment that assert their own 5V reference voltage as NetFusion only uses a weak pull-up resistor to its own +5V. Note: It is feasible to use these as high frequency sampling of the voltages. However new device drivers will have to be implemented in the Linux system. Each of the 8 analogue contact inputs (ACI) is read by an ADC device on the PCB which is accessed from the SmartFusion2 fabric via an I2C bus. The core in the fabric is GPIO which is memory addressable from the Cortex-M3 processor. This allows our uclinux device driver to read the voltage readings and present them to user application code. It is for the user to decide how to use these input when they tailor NetFusion as their own product and the possibilities of usage are widespread such as linking to the SQLite database in our Linux system and then displaying on a webpage for instance. Important Note: Due to sensitive analogue input levels, clamping and in-line protection to unwanted harsh electric voltage spikes, transients etc are not provided for this function. It is for the user to install their specific surge and noise suppression if it is deemed necessary. Critical: Do not expose more than 5.5V to these inputs absolute maximum rating GPIO Spare Connector A lot has been discussed and mentioned in this document about a GPIO auxiliary expansion header. It can be clearly seen on the component details and PCB diagrams earlier in the manual and forms a miniature future proofing function albeit a small one for NetFusion. There are 14 I/O lines from the SOM to the GPIO header (8 shared from the RS232 and the RELAYS via selector switches). These allow for almost any low or high speed bus or control line to be exposed off the PCB for the user to decide what they want. It is not advised to design a plug-in daughter PCB as there are not mounting holes around the header, but a ribbon cable or shield cable could be used to another external PCB. Along with the 14 signals are the NetFusion s GND and 3.3V LVTTL power rail which can provide up to 350mA of power to the auxiliary connected daughter equipment. Important Note: The header is not ultra-high speed so signal clocks and frequencies should be kept to lower than 25MHz. SPI, I2C, CAN, MDI, MII, MDIO and PCS are all protocols and buses that are applicable and can easily run over the auxiliary GPIO header but do keep in mind the cable you use in between the PCBs. 61

62 6.20 Earth and Lightning Protection Power supplies to industrially installed components should be robust and fully protected against shortcircuit and overvoltage conditions, including lightning strikes. NetFusion s legacy interfaces all have heavy-duty lightning protection devices which protect the main system board from lightning strikes, but to ensure maximum protection, the earth terminal spade on the baseboard must be connected to a goodquality earth located close by using a deep spike or lattice LED Indicators There are two RED power LEDs that indicate 2.5V rail and 5V rail levels. From this, diagnosis of a faulty baseboard is much easier if it is visual as to whether the power regulators and the DC-DC module are to blame. Dim RED power LEDs can also indicate a near-short or faulty component with the NetFusion PCB. A GREEN user LED is controlled fully by the application programs via the GPIO UIO device driver. This is for general purpose usage by the user/customer. A set of RED RX and TX LEDs are driven from the FL232 USB-UART device on NetFusion directly. These flicker and blink when data is communicating on the USB UART and this can be used to diagnose if the user is having problems with talking to the NetFusion Linux environment from their PC. Note: The USB-UART RED LEDs are driven direct from the USB device on the PCB and not the software application code. 62