TinyGv8 Production Test Instructions for Revision 2 Tester

Background and Shorthand

The following shorthand is used in these instructions:

Term | Description
-----|--------------
DUT | Device 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

#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

#Prep for a Test Run These steps need to be done at the start of each test run

• Turn on the host computer and 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 (term on OSX, or Command on Win) and navigate to your Avrdude directory

#Per-Board Instructions

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

• 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

• Go to the Coolterm

Program and Test Instructions Using Laptop Based Tester

Setup Test Rig

These steps only need to be completed once at the start of a test run.

• SETUP STEP 1 Inspect the test rig and verify against the picture above

1. Verify there is one BBB board on the test rig
2. Verify there is one TESTER board with 18 serrated head pogo pins loaded into the pogo sockets
3. Verify there is an Atmel AVRISP programmer plugged into the USB jack in the rear of the BBB
4. Verify that you have at least two 1 inch 4/40 hex standoffs available to secure the DUT to the tester

• SETUP STEP 2 Turn off DUT POWER using switch on right side of test jig and connect the AC power cord
• SETUP STEP 3 Plug in 5v wall unit and apply power to BBB board via the barrel jack located on the front, right side. The blue PWR LED next to the barrel connector should be lit.
• SETUP STEP 4 Hit reset on the BBB. Reset will take 30-40 seconds to complete. After a brief pause the 4 indicator lights should flash. Reset is complete when the right-most blue indicator LED (of the 4) is lit and the other three are not lit.

1. Verify the green LED inside the AVRISP is lit (not flashing). This verifies USB connection between the BBB and the AVRISP.

• SETUP STEP 5 Align motor flags so they all point vertically - i.e. the 12:00 position. Note: Do not attempt to position flags if green lights are lit on a DUT, as they are locked.
• SETUP STEP 6 Setup the laptop for testing using these steps:

1. Turn on laptop power using the power button at the top left
2. Once the computer has booted (Windows started) click on the CoolTerm icon to start CoolTerm. Ignore the warning that there are no serial ports. There will be once you connect a DUT to the USB (later). Click OK to ignore (Perhaps twice).
3. Connect a USB cable to the laptop (not the DUT, yet)

Setup is now complete. CoolTerm will be used for every DUT tested.

Instructions for Each TinyGv8 Board

Run these steps for each board to be programmed and tested. Each DUT should take between 2 and 3 minutes to complete.

• STEP 1 Turn off DUT POWER using switch on right side of test jig
• STEP 2 Fasten the DUT under test to top of tester. Make sure POGO pins make contact. Secure with two 4/40 standoffs though the mounting holes on the right-hand side of the DUT
• STEP 3 Connect the AVRISP programming header to DUT J10 (PDI) located in the upper left hand corner of the board. The red polarity marking should be towards the white dot labeled "PDI"
• STEP 4 Turn on DUT POWER power using switch on right side of test jig

1. Verify that the DUT blue LED D2 is lit

• STEP 5 Press PROGRAM button on the BBB. Programming takes about 10 seconds, during which time the green LED inside the AVRISP should flash and the LED on the outside of the case should turn orange. If programming is successful the following should occur:

1. The AVRISP LED inside the case will turn solid green
2. The AVRISP LED on the case will turn from orange to green
3. The TinyG board will flash D6 RED LED about 10 times, then light 4 GREEN LEDS D9 - D12 in sequence
4. LED D7 (red) will be dimly lit
5. Green LEDs D9-D12 will turn off after about 2 seconds
6. If the above occurs the DUT is now programmed. If not, execute step 5R as in Alternate Steps

• STEP 6 Disconnect the AVRISP programming header from J10 PDI
• STEP 7 Connect the USB from the laptop to the DUT. An installing message will appear in the lower left. Wait until it says "Your device is ready to use" before continuing.
• STEP 8 Click on the Options button (if not already open) and follow these steps

1. Click the "Re-Scan Serial Ports" button. There should be a COMx serial port named.
2. Click OK to exit the Options window
3. Click connect. Once connected there may be jibberish ASCII. This is OK.
4. In the input bar at the bottom of the terminal window type ? followed by Carriage Return [CR] and verify that a status report followed by the "tinyg [mm] ok> " prompt is presented. See Sample Status Report, below. You may have to enter ? more than once before getting a response.

• STEP 9 Type the following into the terminal window: $test=1 followed by RETURN. (Once you have entered this command you can use the up arrow to "find" it and re-enter on subsequent tests). 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). All 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.
2. Motor 2 does the same
3. Motor 3 does the same
4. Motor 4 does the same
5. All four motors do the same simultaneously
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
7. An LED sequence will follow, verifying operation of LEDs D5, D6 and D8. D7 should already be dimly lit after programming and throughout the test sequence.
8. A final short move on motor 1 indicates that the test sequence is complete (not all green LEDs will light)

• STEP 10 Turn off DUT POWER and wait until the blue power LED (D2) is completely off before proceeding to Step 11. A Windows "Serial Port Disconnected Error" is normal. Click OK to ignore. Ignore any other Windows errors that may occur at this point.
• STEP 11 Verify the blue power LED (D2) is completely off before removing DUT as so:

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

You can now go back to Step 1 for the next DUT board.

####Sample Status Report

Line number:         0
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:         G0  - linear traverse (seek)
Machine state:       Ready
tinyg [mm] ok> 
tinyg [mm] ok> 

Alternate Steps

• STEP 5R Recover the BBB programmer by performing the following steps

1. Verify the BBB has power applied. Verify the blue PWR LED next to the barrel connector should is lit
2. Press the RESET button located at the left of the BBB. Wait 30-40 seconds. The right-most indicator light should light solid. The other 3 indicator LEDs should be off
3. Verify the USB cable is properly connected between the BBB and the AVRISP. The USB A goes into the rear of the BBB. The USB B goes to the AVRISP
4. Verify the green LED inside the AVRISP is lit solid. The LED on the AVRISP surface may be red or some other color