Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade

Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade Maestro Multi-format Master Control Field Modification Note REFERENCE ECO: 459P 075079500 October 24, 2007

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Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade Maestro Multi-format Master Control Systems Note Customers should contact Grass Valley Technical Support before performing these procedures. Purpose/Applicability This FMN addresses the following issues: 1. Checking the battery charging system on the Maestro Processor board. See page 5. 2. As described in the Maestro v1.400 Release Notes, upgrading the hardware control panel(s) requires use of the Deployment Center s FPGA/CPLD update menu. This process may not be successful if: The CP (Control Panel) Server board installed in the control panel does not allow In-System Programming (ISP). This condition will be indicated by an error message that the physical JTAG chain is broken. This FMN includes a procedure for determining the status of the board and replacement (if needed). Replacement boards should have part number 771001502A1 or newer. See page 6. The hardware control panel may report the incorrect module type in a given slot location (ID). This will be indicated by an incorrect module ID error message. This FMN describes the procedure used to set the actual location of the modules and update the gateware manually. See page 9. Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade 3

Materials Supplied Table 1. Contents of kit supplied with this FMN. Additional Materials Quantity Description Part number 1 Field Modification Note 075079500 Table 2. Additional materials Quantity Description Part number 1 per hardware control panel 1 per hardware control panel Control Panel Server board with ISP enabled Control Panel Modification Label ( ISP Enabled ) 771001502A1 335835600 Additional Documentation Release Notes, Maestro v1.400, part no. 071850604 Release Notes Addendum, Maestro v1.400, part no. 071850704 Engineering Change Order 459P. This ECO releases this FMN. 4 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade

Checking the Battery Charging System The purpose of the rechargeable backup battery, which is located in a compartment on the Processor rear panel, is to maintain the contents of the Processor s NVRAM. This avoids the need to reload system software following a power cycle. The battery is designed to maintain memory for at least 36 hours or 500 power cycles. The following procedure can be used to check the charging status of the battery. Requirements Maestro v1.400 or higher must be installed and actively running. In addition, the FPGAs and CPLDs must be upgraded as described in the v1.4 Release Notes. Procedure 1. In the Maestro Deployment Control Center window, select the Processor you wish to check for proper backup battery charging. The row for the selected Processor will have a dark background. 2. Select the Telnet button. Note Only one Telnet session to a Processsor can be open at a time. 3. In the Telnet window, type: ixgetbatterystatus [Enter] This will indicate the battery status (present, charged, discharged, etc.). Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade 5

Checking the ISP Status of the Control Panel Server Board Requirements This procedure is used to determine if the CP Server board is ISP (In- System Programming) enabled. Maestro v1.400 or higher must be installed and actively running. In addition, the FPGAs and CPLDs must be upgraded as described in the v1.4 Release Notes. Procedure 1. Using the Maestro Deployment Control Center, select ONLY the hardware control panel (i.e., the CP Panel Server) you wish to check. The row for the selected panel will have a dark background. 2. Select the Stop/Unload button. If the button is not visible, you may need to select Show Log, then the Board Comm buttons. 3. Select the Telnet button. 4. To check the ISP status of the CP Panel Server, type: xsvfscanchain...followed by [Enter]. If the system displays Error: Validation of chain failed!! then there is a problem with the physical continuity of the JTAG chain. This indicates you have the older CP Panel Server revision and the board needs to be replaced. After closing this Telnet session, refer to Control Panel Server Board Replacement on page 7 and contact Technical Support. If the system displays a list of information that includes the phrase Chain validation passed and the phrase Errors were found validating the modules, then the JTAG chain is valid and the CP Panel Server is ISP enabled. No board replacement is needed, but you must use Telnet to update the Panel Server gateware. Proceed to Using Telnet to Update Gateware in Maestro Control Panels on page 9. If the system displays a list of information that includes the phrase Chain validation passed and no errors were found, then the JTAG chain is valid and the CP Panel Server is ISP enabled. No board replacement is needed. The gateware can be updated using the Deployment Center s FPGA/CPLD Update Menu. After closing this Telnet session, refer to the v1.400 Release Notes. 5. Close the Telnet session by clicking on the X box in the upper right corner of the window. 6 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade

Control Panel Server Board Replacement In the event that the CP Server board needs to be replaced (as determined by the procedure starting on page 5), follow the steps below. CAUTION Replacing the CP Server requires the hardware control panel to be powered down. Users should consult Grass Valley Technical Support when considering an installation strategy that will minimize interruption to on-air operations. Required Tools Procedure Phillips screwdriver, #6 Nut driver 1. Disconnect the hardware control panel power, console, and LAN cables. 2. Remove the hardware control panel tub from the mounting console and flip the tub over onto a flat surface. 3. Using a Phillips screwdriver remove the eight (8) screws that attach the CP Server housing to the hardware control panel tub. See Figure 1. Figure 1. CP Panel Server board housing Hex-head lock connector screws (4) 1 2 3 8 4 7 6 5 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade 7

4. Carefully lift the housing straight away from the tub to avoid bending the connector pins between the CP server and the tub electronics. 5. Using a #6 nut driver remove the four (4) hex-head lock connector screws next to the GPIO and Console 9-pin D connectors. See Figure 1. 6. Using a Phillips screwdriver remove the two (2) screws holding the CP server printed circuit board (PCB) to the CP Server housing. The old CP Panel Server board should be returned to the factory. 7. To install the new CP Server perform the above steps in reverse order. 8. Check the status of the new board by using the procedure shown on page 5. 9. Place the hardware control panel modification label ( ISP Enabled ) on the outside bottom of the control panel or otherwise in the most convenient location for future reference. 10. The control panel gateware can now be updated using the Deployment Center s FPGA/CPLD Update Menu. For more information, refer to the v1.400 Release Notes. 8 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade

Using Telnet to Update Gateware in Maestro Control Panels Requirements As previously described, a hardware control panel may be in a state where an message such as Errors were found validating the modules appears when attempting to update gateware. The errors may be caused by incorrect reporting of module (sub panel) type and ID (location) on the control panel, especially for the Channel Control module. The following procedure uses Telnet and VxWorks commands to set the actual location of the modules and update the gateware. Maestro v1.400 or higher must be installed and actively running. In addition, the FPGAs and CPLDs must be upgraded as described in the v1.4 Release Notes. Procedure 1. In the Maestro Deployment Control Center window, select ONLY the control panel you wish to update. The row for the selected device will have a dark background. CAUTION The following step will cause the control panel to become inoperative while the update is in progress. 2. Select the Stop/Unload button. If the button is not visible, you may need to click on the Show Log, then the Board Comm buttons. 3. Select the Telnet button. 4. At the Telnet prompt, type: moduleshow...followed by [Enter]. There should be no modules listed. This indicates that the hardware control panel has been stopped and all modules have been unloaded. 5. In the Telnet window, type: cd "/ram/current" [Enter] Type the quote marks as shown. 6. List the files in this directory by typing: Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade 9

ls [Enter] The following required files should be included in the list shown. If not then a problem exists that must be fixed before proceeding. 7. Type: cp_audio_fpga.wsvf cp_ch_ctrl_fpga.wsvf cp_ch_ctrl_fpga_a1.wsvf cp_ch_ctrl_wclks_fpga.wsvf cp_keyer_fpga.wsvf cp_src_asgn_fpga.wsvf cp_src_sel_fpga.wsvf xsvfhelp [Enter]...for a brief explanation on the commands that will be used. 8. There are two methods for updating the FPGAs in the modules: 1) manually using Telnet, or 2) automatically using the Deployment Center s FPGA/CPLD update menu. To determine which method to use, type: 10 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade

xsvfscanchain [Enter] If the result displays Chain validation passed and Errors were found validating the modules, then the JTAG chain is valid but one or more modules are reporting invalid information. Carefully read what is displayed to determine which module is causing the problem. Each module description should include the module type (such as Module type = 10, <Source Control FPGA> ) and the correct slot id (position on the panel). the Module Type numbers are shown in Table 3. The slot ID positions are illustrated in Figure 2 and Figure 3. Most likely there will be a problem with the Channel Control module, which is a Module Type 4; for example, it might not be listed at all. If any other module displays problems, it can still be programmed but Technical Support should contacted. In either case, VxWorks commands must be used. Skip to Step 9 below. If the result displays Chain validation passed and displays a list of modules in the same configuration as the control panel, then the gateware can be updated using the Deployment Center s FPGA/CPLD Update Menu. After closing this Telnet session, refer to the Maestro v1.400 Release Notes. If the result displays Error: Validation of chain failed!! then there is a problem with the physical continuity of the JTAG chain that must be fixed before proceeding. Neither of the above methods will work in this case. This error can be caused by a control panel server that does not have the ISP modification implemented. After closing this Telnet session, refer to Control Panel Server Board Replacement on page 7 and contact Technical Support. Table 3. Module Type Numbers Module Type Description 0 Blank 2 Audio Control 3 Keyer Control 4 Channel Control 5 Channel Control with Clocks 6 Source Assign 10 Source Control Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade 11

Figure 2. Slot ID Numbering for 4 x 2 Panel 0 1 2 3 7 6 5 4 Slot IDs increment from left to right on the top row, then right to left on the bottom row. Any module that occupies more than one slot uses the slot number from the far left side. Figure 3. Slot ID Numbering for 5 x 2 Panel 0 1 2 3 4 9 8 7 6 5 9. Manual Configuration Method a. If the Scan Chain report shows errors, you may want to begin by writing down the actual location of the modules on the following worksheet: Table 4. Module Type and Slot Worksheet Module Type Description 0 Blank 2 Audio Control 3 Keyer Control 4 Channel Control 5 Channel Control with Clocks 6 Source Assign 10 Source Control Actual Slot ID b. Type: xsvfchangemodules [Enter] c. Follow the prompts to enter the correct module type number for each slot. 12 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade

d. To confirm your changes, type: xsvfshowmanualmodules [Enter] This will display a list of slot ID numbers modules and the respective module types. For example: Slot Id 0 type = 2: AUDIO CONTROL FPGA Slot Id 2 type = 4: CHANNEL CONTROL FPGA Slot Id 3 type = 6: SOURCE ASSIGNMENT FPGA Slot Id 4 type = 3: KEYER CONTROL FPGA Slot Id 7 type = 10: SOURCE CONTROL FPGA e. Once the slots have been configured, update the gateware by typing: xsvfmanualprogramall [Enter] Or you may update the modules individually using the following commands: xsvfmanualprogramaudio xsvfmanualprogramkeyer xsvfmanualprogramchctrl xsvfmanualprogramchctrl2 (This one is for Channel Control with Clocks) xsvfmanualprogramsrcasgn xsvfmanualprogramsrcctrl f. The Channel Control module may require an additional step: If the module displayed errors from the xsvfscanchain command (or is not listed at all), type: xsvfmanualprogramchctrl "cp_ch_ctrl_fpga_a1.wsvf" Enter the quote marks as shown. Note the entry for a1 ( a followed by the numeral one). After updating this module, the command xsvfscanchain will still report: "Errors were found validating the modules. This is normal and will not affect the operation of the control panel. 10. Once all FPGAs have been loaded reset the control panel by removing and reapplying power. It will take a moment for the panel to restart. 11. Check the control panel to ensure that every module is operational. Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade 13

14 Maestro Processor Backup Battery, CP Server, and CP FPGA Upgrade