Wavetec FZCO WT-AH Active Hub User Manual QC Guide of Active Hub
Wavetec FZCO Active Hub QC Guide of Active Hub
User manual
QC Guide of Active Hub Version 11.4 This Document is used to guide the QC process and applied on Active Hub PLM# 971-0003-0000 Waqas Ahmad 7/13/2011 QC Guide of Active Hub Jul. 13 Table of Contents History ...........................................................................................................................................................................4 Part Profile .....................................................................................................................................................................5 Plan of QC Activity .........................................................................................................................................................5 Parts Required ...............................................................................................................................................................7 QC Procedure.................................................................................................................................................................9 Test required on 100% of the product ............................................................................................................... 9 Burn in Test ...........................................................................................................................................................9 Power Recycling ....................................................................................................................................................9 Physical Inspection ................................................................................................................................................9 1- Sharp Edge ...................................................................................................................................................9 2- Color is uniform ............................................................................................................................................9 3- Wavetec Logo ...............................................................................................................................................9 4- Critical Item part number verification ........................................................................................................10 5- Text Printing ...............................................................................................................................................11 6- Jumper Setting ...........................................................................................................................................11 Functional Test of Active Hub with Network Scanner ........................................................................................13 1. Test Procedure of Testing Active Hub on Display Networks: .....................................................................14 2. Testing Active Hub on TSU Networks Using IN Port: ..................................................................................16 3. Testing Active Hub on TSU Networks using OUT port: ..............................................................................20 4. Test of Termination DIP Switch ..................................................................................................................20 Packaging: ...........................................................................................................................................................22 1- Packing list of parts/accessories ................................................................................................................22 2- Sticker Verification .....................................................................................................................................22 3- Carton Box ..................................................................................................................................................25 4- Power Cord.................................................................................................................................................25 Check List for Test of 100% of the product .........................................................................................................30 Test required for 1% of the product: ................................................................................................................ 31 Component Verification ......................................................................................................................................31 1- IC’s / Diodes Verification ............................................................................................................................31 2- Resistor Verification ...................................................................................................................................31 3- Capacitor Verification.................................................................................................................................32 4- Connector verification................................................................................................................................32 5- Dip Switch ..................................................................................................................................................33 QC Guide of Active Hub Jul. 13 6- Crystal ........................................................................................................................................................33 7- Inductor ......................................................................................................................................................34 8- DC Jack .......................................................................................................................................................34 9- Metal Casing Dimension verification .........................................................................................................34 Check List for 1% Test required of the Product ..................................................................................................35 QC Guide of Active Hub Jul. 13 History Date Version Description Aug 27, 2007 1.0 Initial Version Jan 16, 2008 2.0 Firmware upgrade to eqPrimeLineExtender5.hex Mar 20, 2008 3.0 New test method with TSU and Bar displays. th 4.0 Add more Test procedures. th 5.0 th 6.0 Change in the PCB, IAP (In Application Programming) feature is added, Change the Power Supply from DAJING to MEANWELL Company, having the capability to provide power to CDU’s. Also all yellow Led’s changes to blue color, WAVETEC logo is also changes to blue color and Dip switch changes from red color to blue color. Also adjust the position of the DIP Switch. Add warranty Sticker th 7.0 Make correction th 8.0 Stickers on Replaceable parts like Power Adapter. th 9.0 Change in the DIP Switch, Window size for the DIP switch is adjusted, screws changes to flat head & also the sticker which is pasted at the back of Active Hub change but the box sticker will remain same. th 10.0 th 11.0 Change the Communication IC SN75176 to ESD protected ST485ERC Change the Dip switch to Bottom Actuated Model # EPG-102AZ Change the communication IC from ST485ERC to SN75176. Add Checklist 18 Nov, 2008 27 , April, 2009 29 , April, 2009 14 ,May, 2009 08 , June, 2009 29 , June, 2009 15 , Nov , 2009 12 March, 2010 nd 22 March, 2010 th 10 June 2010 11.1 11.2 th 11.3 th 11.4 10 Dec 2010 13 July 2011 Change the communication IC from SN75176 to ST485ECDR. Change the PCB from PT0012L to PT0012M Increase the track of vcc of Gnd of RJ45 to increase the power and data transmission distance. Author Denny DENG Deng.yonghang@wavetec.com Denny DENG Deng.yonghang@wavetec.com Denny DENG Deng.yonghang@wavetec.com Zafar A. Khan/Waqas Ahmad Zafar.khan@wavetec.com/ waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com Waqas Ahmad Waqas.ahmad@wavetec.com QC Guide of Active Hub Jul. 13 Part Profile Front View Position of “Display” and “TSU” is opposite now Position of “Enable” and “Disable” is opposite now Rare View Plan of QC Activity Ensuring timely completion of Product by the CM (Contract Manufacturer): To ensure that QC activity is performed on the defined and agreed dates with the CM in accordance with the PO dates. It is important that the CM also executes the project plan on timely manner; and completes all tasks on agreed dates. So the first stage is to ensure that CM follows the defined milestones for the timely completion of the product which are; Milestone# 1 (1~3 days after P.O) Items Confirmation Day from CM for ordering the parts Active hub PCB Connector MW Adapter Power Cord Metal casing Packaging 3 Day after P.O rd 3 Day after P.O rd 3 Day after P.O rd 3 Day after P.O rd 3 Day after P.O rd 3 Day after P.O rd QC Guide of Active Hub Jul. 13 th Milestone#2 (18~20 day after P.O) Items Confirmation Day from CM for receiving the parts Active hub PCB Connector MW Adapter Power Cord Metal casing Packaging 20 Day after P.O th 20 Day after P.O 6 Weeks th 20 Day after P.O th 24 Day after P.O th 26 Day after P.O th th Milestone#3 (23~25 day after P.O) Confirm with CM for the completion of assembling. If any milestone not met, inform to supply chain department\CTO for further action. Hence to follow the above milestones, Wavetec QC staff responsible for the QC of the CM product should follow up with the CM at the end of every week to inquire if the agreed milestone is met. This will require a visit to the CM or in some cases a verbal confirmation through a phone call. A timely follow up will ensure that the QC date will be followed and there will be no unexpected delay in the end. These above milestones should be mentioned in a “PO monitoring Sheet” with proper date to follow up with respect to the PO date and hence the outcome of the discussion regarding meeting the above milestones should also be logged in that sheet. In the QC document only milestone are mentioned which should be followed. QC Activity Plan Once unit is fully assembled, and tested by the CM and verified for its full functionality, than Wavetec’s own QC staff should perform the additional QC of the product as per this document. QC activity of Active Hub will be performed in minimum two days (or more depending on the PO quantity). Day 1: On the first day QC person will visit the factory and put the entire units to “burn in” test in front of him (For detail see the section “Burn In test”) and randomly take out one unit from the batch and perform 1% Test as explain in section “Test required on 1% of the product”. Day 2: On the second day perform the QC of only those units which were put on “burn in Test” yesterday. Time Required for the QC For 100% Test, total time required for each unit is 5 minutes per unit. For 5% Test, total time required for each unit is 10 minutes.(this will not stop the QC of 100% units and can be performed in parallel with 100% QC with the help of CM staff) For 1% Test, total time required for each unit is 2 hours. Now, one can automatically calculate how much time is required for the QC of required purchase order quantity. QC Guide of Active Hub Jul. 13 Parts Required Following equipment/component required to perform the QC of Active Hub. Items Picture QTY (For 100% Test) QTY (For 5%Test) QTY (For 1%Test) Power Adapter (12V/3.34A) For network scanner Power Adapter (12V/8.4A) For Central Power CDU’s RJ45-RJ45 Straight Cable 5 cables RJ45-RJ12 Cable 5 Cable RJ12-RJ12 Cable 1 Cable Network Scanner PCB WT CDU (Central Power) QC Guide of Active Hub Jul. 13 TSU LCR meter Multi meter Magnifier Lens Soldering station with technical person who can perform soldering 1 unit 1 unit 1 unit 1 unit 1 unit 1 Set 1 station QC Guide of Active Hub Jul. 13 QC Procedure Test required on 100% of the product Burn in Test Connect the DC jack of power adapter with the Active Hub as shown in the figure below and power it “ON”. Once you power ON the adapter the Power LED’s will turn ON as shown in the figure below. Power Recycling Connect the Active Hub with main AC supply. Turn the unit “ON” and observe that power LED’s turns “ON”. Now turn “OFF” the unit and wait for 1 second and then turn “ON” and observe that power LED’s turns “ON”. Now turn it “OFF” again, Repeat this procedure 10 times and observe that every time power LED’s turns “ON”. Physical Inspection 1- Sharp Edge Make sure there is no sharp edge at the corners. Check all the corners of top and bottom enclosure. Also make sure there is no dent or any uneven spot on the metal enclosure. Check the Chassis and also the top covers before they are fitted. 2- Color is uniform Make sure color of the Active is uniform and both top and bottom enclosure are matching with each other. Color of metal casing should be black. 3- Wavetec Logo Make sure Wavetec Logo on the casing should be uniform and straight; also verify the color with pantone code “7462C” as well. QC Guide of Active Hub Jul. 13 4- Critical Item part number verification Make sure Power Adapter should be of Mean well Company Model # GS40A1-P1J (For without central Power Active Hubs). OR Make sure Power Adapter should be of Mean well Company Model # AS-120P-12 (For with central Power Active Hubs). Verify the PCB version number it should be PT0012M as shown in the figure below. 10 QC Guide of Active Hub Jul. 13 5- Text Printing Text printing of the Active Hub should be uniform as shown in the figure below. Make sure no text should not be missing and wrong printing. Alignment of the complete text is very important. It should not be tilted towards any end and should be very straight. 6- Jumper Setting Make sure following jumper should be placed on their respective positions as shown in the figure below. 11 QC Guide of Active Hub Jul. 13 12 QC Guide of Active Hub Jul. 13 Functional Test of Active Hub with Network Scanner Active Hub is capable of working on two different networks i.e. TSU and Displays. The TSU network works on 57600bps while Display network works on 115200bps. To check the functionality of Active hub, we need a network scanner device to check it on both networks. Network Scanner PCB Test Methodology of Active Hub: A. Network Scanner can scan all TSU / TDU that are connected with the Network. After the scan is completed, the IDs of all alive devices will be shown on the screen. B. Network Scanner can scan all CDU / SDU that are connected with the Network. The scanning method, for these devices, is slightly different. Network Scanner can broadcast three different messages to all the displays. Connection of Display Network to Test Active Hub: The connections of the Active Hub with Network Scanner are shown below. 13 QC Guide of Active Hub Jul. 13 To test Active Hub on Display Network, Change its DIP switch position to “Display” as shown below. Use opposite configuration as Dip switch is now bottom actuated. 1. Test Procedure of Testing Active Hub on Display Networks: When the TSU is connected with the Network Scanner PCB and the 12V DC adapter is inserted in the DC JACK of Network Scanner PCB, TSU will turn “ON”. Following screen will appear, Ver : TSU 06-1-06 After few seconds following message will appear: WAVETEC eQ www.WAVETEC.COM/EQ Then Press buttons &4 together for atleast 5 seconds or until following message is appeared. TSU3ID = 001 Welcome to TSU setup 1)TSU for eQ prime 2)TSU for eQ linux Hit Next for options Press button “Next”, following message will appear: 14 QC Guide of Active Hub Jul. 13 Welcome to TSU setup 3)Network Scanner 4)To Program TSU Press button “3”. Following message will appear: NETWORK SCANNER 1. TSU 2. TDU 5.CDU/SDU PRESS DESIRED NUMBER Now press “5” to use CDU/SDU to test Acive Hub on Display network, following message will appear. CDU/SDU SCANNER 7- SEND OK 8- SEND TEST MESSAGE MESSAGE 9- SEND BLANK MESSAGE If ‘7’ is pressed a message ‘OK’ will appear on all connected Displays. If ‘8’ is pressed a message ‘TEST’ will appear on all connected Displays. If ‘0’ is pressed all the Displays will get BLANK. In the same manner check all RJ45 Ports of Active Hub, by connecting the CDU’s to next four ports and send the message one by one. 15 QC Guide of Active Hub Jul. 13 2. Testing Active Hub on TSU Networks Using IN Port: After successful testing of Active Hub on Display network, remove the power to the Active Hub and change its DIP switch position to “TSU” and connect to the network of TSUs as shown in Figures below. Testing Active Hub on TSU Network Dip switch setting for TSU Network: Use opposite configuration as Dip switch is now bottom actuated. When the TSU is connected with the network scanner PCB and the 12V DC adapter is inserted in the DC JACK of Network Scanner PCB, TSU will turn ON and the following screen will appear, Ver : TSU 06-1-06 16 QC Guide of Active Hub Jul. 13 After few seconds following message will appear: WAVETEC eQ www.WAVETEC.COM/EQ Then Press buttons 3 &4 together for at least 5 seconds or until following message is appeared. TSU ID = 001 Welcome to TSU setup 1)TSU for eQ prime 2)TSU for eQ linux Hit Next for options Press button “Next”, following message will appear: Welcome to TSU setup 3)Network Scanner 4)To Program TSU Press button “3”. Following message will appear: NETWORK SCANNER 1. TSU 2. TDU 5. CDU/SDU PRESS DESIRED NUMBER PRESS button 1, following screen message will appear: 17 QC Guide of Active Hub Jul. 13 START ID = 01 6-UP 9-DOWN END ID = 22 7-UP 0-DOWN NEXT/OK TO SCAN Above mentioned IDs number “START ID” and “END ID” is to scan number of TSUs connected with Active Hub, in above scenario Scan ids for TSU`s goes from 0 to 22. We need to change “END ID” by pressing button “0” to decrease number of TSUs IDS and press button “7” to increase the number of TSUs IDS of TSU. In our case we need to change “END ID” to 16 because only 16 ports are available on the Active Hub. However, we can increase number of ports of Active Hub. We are testing Active Hub with only one TSU. Connect TSU with the port 1 on Active Hub, as shown in following diagram: RJ45–RJ45 Cable (Connect from scanner PCB to Active Hub “IN” Port) RJ45-RJ12 Cable (Connect from Active Hub Port to TSU RJ12–RJ12 Cable (Connect from Network scanner PCB to TSU) Connect TSU with ID 1 to port 1 on active hub; for ID change follow the procedure of section VIII and press Next/OK on network scanner TSU to test Active Hub, following message will appear: 18 QC Guide of Active Hub Jul. 13 ALIVE TSUs ARE : 01. Note: Don’t need to test all ports on TSU network , one port test is fine. How to Change TSU ID’s Once inserted Following screen message will appear for few seconds: Ver : TSU 06-1-06 After few seconds following message will appear: WAVETEC eQ www.WAVETEC.COM/EQ TSU ID can be changed or configured by the following procedure: TSU ID = 001 Press button “1” and “2” together for few seconds or until following screen is appeared on TSU: OLD TSU ID = 001 NEW TSU ID = 002 Press button “1” on TSU to increment the number of ID or Press button “5” to decrement the number of ID Once ID number has been changed to desired ID number then press button “OK” on TSU. The above selected ID will appear on Network Scanner TSU when we scan the network. 19 QC Guide of Active Hub Jul. 13 3. Testing Active Hub on TSU Networks using OUT port: Now remove the Cable from the “IN” of the Active Hub and put it into “OUT” of Active Hub and Test the Active Hub by following the procedure as described in section VII, we will get same result. 4. Test of Termination DIP Switch A) Make sure Termination DIP switch is Enable. Now connect the RJ45 connector into “IN” of the Active Hub Port as shown in figure. Use opposite configuration as Dip switch is now bottom actuated. Connect the cable on IN port of the Active Hub as shown below. Then measure the resistance between Pin 3 and Pin 6 , the resistor value be 120 ohms as shown in the figure. 20 QC Guide of Active Hub Jul. 13 Now remove cable from “IN” and place cable into “OUT” of Active Hub as shown in the figure below: Then measure the resistance between pin 3 & 6, the value should be 120ohms. B) Set the Termination DIP switch to be Disable, then measure the resistance between Pin 3 and Pin 6 on Active Hub IN&OUT port, the resistor value should be infinite. Must make sure to leave DIP setting to “Termination Enable” as shown below: Use opposite configuration as Dip switch is now bottom actuated. 21 QC Guide of Active Hub Jul. 13 Packaging: 1- Packing list of parts/accessories Following are the part needs to verify that these parts are included to every product, before the shipment of Active Hub. SN Item Qty Description Remarks Active Hub 1 piece Power Adapter 1 piece Mean well Adapter GS40A12-P1J (without central power Active Hubs) OR Mean well Adapter AS-120P-12 (with central power Active Hubs) AC Power cord 1 each British standard cord with fuse option Product Code Label 3 pieces One on the Active Hub rare side, two on the Active Hub carton box. ROHS Label 3 pieces One on the Active Hub rare side, two on the Active Hub packing box. Green Product Label 3 pieces One on the Active Hub rare side, two on the Active Hub packing box. QC Passed Label 1 piece One on the Active Hub rare side With Wavetec Logo 2- Sticker Verification Product Label for Active Hub (without Central Power)………….. 701-0002-0000 Following stickers needs to be pasted at the box of active hub. Model Active Hub(Without central Power) Input 12V / 3.34A Product ID 701 0002 0000 Rev Info 0K Batch MMDDYY(Month, Date, Year) S/N XXXX(from 0001 to 9999) Barcode Refer to Document number # 971-0001-0000 Qty: 2 pcs 22 QC Guide of Active Hub Jul. 13 Product Label for Active Hub (with Central Power)………….. 701-0002-0001 Following stickers needs to be pasted at the box of active hub. Model Active Hub(Without central Power) Input 12V / 8.4A Product ID 701 0002 0001 Rev Info 0I Batch MMDDYY(Month, Date, Year) S/N XXXX(from 0001 to 9999) Barcode Refer to Document number # 971-0001-0000 Qty: 2 pcs Product Label for Active Hub metal enclosure Following stickers needs to be pasted at the back side of metal enclosure of active hub as shown in the figure below. Model Active Hub Input 12V / 3.34A or 8.4A Product ID 701 0002 0000 Rev Info 0L Batch MMDDYY(Month, Date, Year) S/N XXXX(from 0001 to 9999) Barcode Refer to Document number # 971-00010000 Qty: 1 pcs 23 QC Guide of Active Hub Jul. 13 24 QC Guide of Active Hub Jul. 13 3- Carton Box Make sure carton box should be neat and clean from inside and outside. No stain from inside and outside. Make sure shape of the carton box is uniform. Make sure printing should be clear and uniform as shown in the figure below. The color of Wavetec logo is Black (Not Gray) 4- Power Cord Make sure Power cord should be wrapped in the bubble bag as shown in the figure below. Also make sure bubble bag used for the packing should be new one. 25 QC Guide of Active Hub Jul. 13 26 QC Guide of Active Hub Jul. 13 5- Replaceable item Sticker For without central power active hub Adapter Paste this sticker on the power adapter before packaging. Enter the production date on the Batch number. For with central power active hub Adapter Paste this sticker on the power adapter before packaging. Enter the production date on the Batch number. 27 QC Guide of Active Hub Jul. 13 Packaging for Active Hub(without Central Power) Active Hub wrapped in ESD Bubble Bag Power cord wrapped in ESD Bubble Bag Power Adapter packed in Carton Box 28 QC Guide of Active Hub Jul. 13 Packaging for Active Hub (with Central Power) Power Cord wrapped in ESD Bubble Bag Power Adapter packed in carton box Active Hub Wrapped in ESD Bubble Bag 29 Check List for Test of 100% of the product Following check list should be filled during the QC of the product. Take a print out of this checklist and filled it during the QC and after QC send a scan copy of filled checklist to Head Office with PO Number. To learn how to perform the below Testing and QC, see the relevant sections in the QC Guide. Check List for 100% Test - PO #: _______________ S/No. Burn In Test Power Recycling 1- Sharp Edge 2- Color checking Physical Inspection 4-Critical Item part 3-Wavetec number Logo verification Date: ___________ Functional Test 5-Text Printing Packaging 6-Jumper 1-Display 2-TSU Networks 3-TSU Networks 4-Termination 1- Packaging Setting Networks using IN Port using OUT port DIP Switch List 2- Sticker 3- Carton Box 4- Power cord Name:________________________________ Signature:_____________________________ Test required for 1% of the product: Take the printout of BOM of Active Hub of same revision number which is written on the P.O. Now perform the following tests. Following test needs to perform on Main controller PCB (PT0012M). Must take out 1 unit randomly from the burn In Test and do the following test. Component Verification 1- IC’s / Diodes Verification IC’s: All IC’s numbers are written on the top of IC, verify all the IC’s with the PLM BOM. Diode: All diode numbers are written on the case diodes, verify diode number with the PLM BOM. 2- Resistor Verification For all resistor needs to measure the resistance with the help of multi meter and compare it with the BOM. Don’t need to de-solder, the value found on the meter will be approximate. For Resistor R58 on main controller PCB, they are specified for 1% tolerance. Hence de-solder them and take them out. And Measure with the multi meter. The value should be R1 = 120 ohms (In between 118.8 ohms to 121.2 ohms) QC Guide of Active Hub Jul. 13 3- Capacitor Verification Electrolytic Capacitor: All electrolytic capacitor can be verified visually, values are written on the capacitor. C29, C30 are 470uf/25V. Ceramic Capacitor: C1, C2, C3, C4, C5, C6, C7, C8, C9, C10, C11,C12, C13, C14, C15, C16, C17, C18, C19, C20, C21, C22, C23, C27, C31, C32, C33 are 0.1uF capacitor randomly de-solder 2 capacitors and measure the value with the help of LRC meter and for other just visually verify that they are of same package. C26, CE1, CE2, CE3, CE4 are 10uf tantalum capacitor randomly de-solder one capacitor and measure the value with the help of LRC meter and for other just visually verify that they are of same package. In the same manner check all the ceramic capacitors, if it is used in multiple location than only de-solder one capacitor and other visual verified. 4- Connector verification Check all RJ45 block connector used in main controller PCB (PT0012M), inside of all connector “GLG” should be written as shown in the figure below. RJ45 Block Connector used in Main controller PCB Make sure on the programming connectors of Main Controller PCB should be 2.54mm pitch as shown below. 32 QC Guide of Active Hub Jul. 13 5- Dip Switch Make sure Dip switch should be piano style and bottom actuated (Arrow should pointing in downward direction). 6- Crystal Make sure crystal used in main controller PCB should be 22.1184MHz (written on the casing). 33 QC Guide of Active Hub Jul. 13 7- Inductor Make sure should be of 68uH as shown in the figure below. 8- DC Jack Make sure DC jack should be of 2.1mm pin diameter as shown in the figure below. 9- Metal Casing Dimension verification Verify the dimension of metal casing as per drawing below. Top casing Make sure thickness of the casing is 0.8mm 34 QC Guide of Active Hub Jul. 13 Bottom Enclosure Make sure thickness of the casing is 0.8mm Check List for 1% Test required of the Product Following check list should be filled during the QC of the product. Take a print out of this checklist and filled it during the QC and after QC send us scan copy of filled checklist. 35 Warning: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: -- Reorient or relocate the receiving antenna. -- Increase the separation between the equipment and receiver. -- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. -- Consult the dealer or an experienced radio/TV technician for help.
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