From 261bf48bb44d60291e5c858ed7340bbbab33fc39 Mon Sep 17 00:00:00 2001 From: noise Date: Wed, 1 Jul 2026 22:11:24 -0400 Subject: [PATCH] Power stage 3: LM61460-Q1 15V->+3V3_RF 4A buck; EN from CM5 PCIE_PWR_EN - Second LM61460-Q1 (U_BUCK33R), FB 23.2k/10.0k -> 3.32V (SPICE: vfb 0.994V, inrush settles 3.32V); shared BOM with stage 2 (L 4.7uH/7A, RT 31.6k ~420kHz) - BIAS -> +3V3_RF (datasheet-valid >=3.1V, falls back to VIN below) - EN <- PCIE_PWR_EN: Module1 pin 106 NC swapped for a global label on CM5_HighSpeed + 100k pull-down (mirrors reference R14) so the Wi-Fi rail stays off until CM5 asserts it; netlist-verified 3-node net - Removed the E-key temp PWR_FLAG (#FLG33RF); buck PWR_FLAG on L33.2 is now the sole +3V3_RF driver - Verify: ERC 133->133 zero new; analyzer +49/-0 zero regressions; SPICE 17 pass / 2 benign warn / 0 fail Co-Authored-By: Claude Fable 5 --- PORT_STATUS.md | 31 +- carrier/CM5_HighSpeed.kicad_sch | 8 +- carrier/M2_Ekey.kicad_sch | 13 - carrier/Power.kicad_sch | 545 ++++++++++++++++++++++++++++++++ tools/build_ekey.py | 10 +- tools/build_power.py | 28 +- 6 files changed, 594 insertions(+), 41 deletions(-) diff --git a/PORT_STATUS.md b/PORT_STATUS.md index 7fdea73..78efabf 100644 --- a/PORT_STATUS.md +++ b/PORT_STATUS.md @@ -6,25 +6,23 @@ ## ▶ RESUME HERE (session handoff, 2026-07-01) -**State:** branch `port/strip-phase`, HEAD `fd627f5`, working tree clean (only unrelated -`refs/.history` submodule blip). Sheets in `carrier/`: root `CM5IO`, `CM5_GPIO`, `CM5_HighSpeed` -(reference, stripped), `M2_Ekey` (E-key, done), `Power` (stages 1–2 done). Baseline anchor: -`analysis/baseline/carrier_stripped.json`. +**State:** branch `port/strip-phase`. Sheets in `carrier/`: root `CM5IO`, `CM5_GPIO`, +`CM5_HighSpeed` (reference, stripped), `M2_Ekey` (E-key, done), `Power` (stages 1–3 done). +Baseline anchor: `analysis/baseline/carrier_stripped.json`. **Done:** strip phase (microSD/HDMI/MIPI/PCIe-M2); M.2 E-key sheet (PCIe ×1 to CM5); Power stage 1 (LM74700 ideal-diode input protection → `VIN_PROT`); Power stage 2 (LM61460-Q1 -15→`+5v` 5 A sync buck, SPICE-verified 5.02 V). Current whole-design **ERC = 133** (all -pre-existing types; a good edit adds **zero new**). +15→`+5v` 5 A sync buck, SPICE-verified 5.02 V); Power stage 3 (LM61460-Q1 15→`+3V3_RF` 4 A, +SPICE-verified 3.32 V; EN ← CM5 `PCIE_PWR_EN`/106 + 100k pull-down like reference R14; E-key +temp PWR_FLAG removed — buck is the sole `+3V3_RF` driver). Current whole-design **ERC = 133** +(all pre-existing types; a good edit adds **zero new**). -**NEXT ACTION → Power Stage 3: `U_BUCK33R` 15→`+3V3_RF` 4 A.** Edit `tools/build_power.py`, -append a Stage-3 block (copy the Stage-2 pattern): reuse the `CM5IO:LM61460-Q1` symbol; FB -divider for 3.3 V → ratio 2.3 → `R_FBT 23.2k / R_FBB 10.0k` (SPICE-verify vfb=1.0 V @ 3.32 V); -same L/Cin/Cout/boot/RT support. Then **(a)** delete the E-key temp `PWR_FLAG` on `+3V3_RF` -(`#FLG33RF` in `carrier/M2_Ekey.kicad_sch` via build_ekey — the buck is the real driver now), -and **(b)** wire the buck `EN` ← CM5 `PCIE_PWR_EN` (Module1 pin 106, currently NC on -`CM5_HighSpeed`) for SW radio-power control. `+3V3_RF` is a NEW net → keep it a **global** label -(no `same_local_global_label` risk, unlike `+5v`). Then Stage 4 (`+3V3_AUX`, TPS54202 28 V), -then the GPS + PPS sheet. +**NEXT ACTION → Power Stage 4: `U_BUCK33A` 15→`+3V3_AUX` ~1 A.** Candidate part TPS54202 +(28 V sync) — datasheet-verify first (KiCad has `Regulator_Switching:TPS54202DDC`). One check +that MUST pass: the SMBJ18A clamp (~29 V at rated Ipp) vs the part's VIN abs-max — if the +datasheet says <30 V abs-max, pick a 36 V-class sync part instead (LMR51430/TPS54360-class) +or justify why the surge case is acceptable. FB divider per that part's VREF; SPICE-verify. +`+3V3_AUX` is a NEW net → **global** label. Then the GPS + PPS sheet, then power-budget review. **How to build/verify (every change):** - Sheets are generated wholesale — edit `tools/build_ekey.py` / `tools/build_power.py`, then @@ -134,7 +132,8 @@ Notes that bit us (don't re-learn the hard way): 4. **Power sheet** (`carrier/Power.kicad_sch`, generated by `tools/build_power.py`) — staged, **sync + datasheet-built parts** (user choice). **Spec rating fix:** the spec's buck candidates miss its own ≥20V-Vin rule (TPS54424=17V, TPS54560=async) — selecting synchronous ≥30V parts instead (LM61460-class 6A for +5V & +3V3_RF/4A; TPS54202 28V for +3V3_AUX), each verified vs datasheet before commit. - **Stage 1 — input protection ✅ DONE.** J_PWR(15V) → D_REV `LM74700-Q1` ideal-diode + Q_REV N-FET (reverse-polarity/-current) → `VIN_PROT`; `SMBJ18A` TVS + 100µF/25V ∥ 10µF/50V bulk; C_VCAP charge-pump cap. Netlist-verified topology; ERC 133→133 (zero new); analyzer 0 regressions. **Confirm vs LM74700-Q1 datasheet:** C_VCAP value, EN-to-+15V_IN, FET pick (Vds≥30V, SOA/inrush) + optional gate R. - **Stage 2 — U_BUCK5 15→`+5v` 5A ✅ DONE.** `LM61460-Q1` (6A, 42V absmax sync; **custom symbol built from the datasheet** → `carrier/CM5IO.kicad_sym` as `CM5IO:LM61460-Q1`, fp `Package_SO:Texas_HTSSOP-14-1EP…ThermalVias`). VREF=1.0V → FB divider R_FBT5 40.2k / R_FBB5 10.0k = **5.02V (SPICE-confirmed vfb=1.0V)**. L5 4.7µH, Cout 2×47µF/16V, Cin 2×10µF/50V, Cboot 100n+Rboot 4.7Ω, RT 31.6k(~400kHz), BIAS→+5v, EN→VIN_PROT, PGOOD 100k→+5v. **`+5v` kept HIERARCHICAL** (pre-existing carrier net; global would collide `same_local_global_label`) — Power sheet exposes a `+5v` sheet pin, tied into the root `+5v` net; netlist-verified it drives Module1 + GPIO + USB. ERC 133→133 (zero new); analyzer +32 added **0 regressions**; SPICE 12/13 pass, 1 benign warn (L5/Cboot mis-detected as LC filter). **Confirm vs datasheet:** RT freq, L sat ≥7A, EP=pad15, optional EN UVLO divider. - - **Stage 3** U_BUCK33R 15→3.3V 4A → `+3V3_RF` (then REMOVE the E-key temp PWR_FLAG; wire buck EN ← CM5 `PCIE_PWR_EN`/106). **Stage 4** U_BUCK33A 15→3.3V 1A → `+3V3_AUX`. SPICE-validate each feedback divider. + - **Stage 3 — U_BUCK33R 15→`+3V3_RF` 4A ✅ DONE.** Second `LM61460-Q1` (shared BOM with stage 2: L 4.7µH/7A ripple ~1.3A=33%, Cin 2×10µ/50V, Cout 2×47µ/16V, RT 31.6k ~420kHz, Cboot 100n+Rboot 4.7). FB divider R_FBT33 23.2k / R_FBB33 10.0k = **3.32V (SPICE: vfb 0.994V, inrush settles 3.32V)**. BIAS→`+3V3_RF` (datasheet: valid ≥3.1V, auto-falls back to VIN below). **EN ← CM5 `PCIE_PWR_EN`** (Module1 pin 106: NC swapped for a global label on `CM5_HighSpeed`) + **R_EN33 100k pull-down** (mirrors reference R14 — netlist-verified `Module1.106 + U_BUCK33R.7 + R_EN33.1`) so the Wi-Fi rail is OFF until the CM5 asserts it. **E-key temp `#FLG33RF` PWR_FLAG removed** (build_ekey); the buck's PWR_FLAG on L33.2 is now the sole `+3V3_RF` driver — netlist shows buck + all 4 J_E power pins + pull-ups + decoupling on one net. Verify: ERC 133→133 zero new; analyzer +49 added **0 regressions**; SPICE 17 pass / 2 benign warn (the L/C_BOOT "LC filter" mis-detect, once per buck) / 0 fail. (Note: `kicad-cli` netlist export prints a pre-existing "annotation errors" warning — un-numbered generated refdeses like `J_E`/`J_PWR`; present at fd627f5 too, cosmetic.) + - **Stage 4** U_BUCK33A 15→3.3V ~1A → `+3V3_AUX`. SPICE-validate the feedback divider (see NEXT ACTION above for the part-selection gate). 5. **GPS + PPS distribution**: GPS connector (PPS+UART+3V3+GND); PPS → TVS → Schmitt (LVC1G17) → fan-out: CM5 `Ethernet_SYNC_OUT` (J2 pin-6 net, 3.3V, no translator) + 2 header taps. SPICE/timing check. diff --git a/carrier/CM5_HighSpeed.kicad_sch b/carrier/CM5_HighSpeed.kicad_sch index b5449f8..3e7ab23 100644 --- a/carrier/CM5_HighSpeed.kicad_sch +++ b/carrier/CM5_HighSpeed.kicad_sch @@ -12684,9 +12684,11 @@ (at 38.1 144.78) (uuid "3e94757c-62b4-5b7d-9eb9-0bce1d18da64") ) - (no_connect - (at 38.1 30.48) - (uuid "22043a85-7370-5a2b-9195-7034c3f95e65") + (global_label "PCIE_PWR_EN" + (shape input) + (at 38.1 30.48 180) + (effects (font (size 1.27 1.27)) (justify right)) + (uuid "ec1f5dd4-69da-5539-9a4f-28c69e37960f") ) (global_label "PCIE_nCLKREQ" (shape input) diff --git a/carrier/M2_Ekey.kicad_sch b/carrier/M2_Ekey.kicad_sch index 3893b18..361a872 100644 --- a/carrier/M2_Ekey.kicad_sch +++ b/carrier/M2_Ekey.kicad_sch @@ -2298,19 +2298,6 @@ (pin "1" (uuid "4b6d8ed9-33cb-576b-b25a-4d7450c86b69")) (instances (project "CM5IO" (path "/e63e39d7-6ac0-4ffd-8aa3-1841a4541b55/c57f5f03-e2c5-5c1b-ba90-8072a2a088a0" (reference "#PWRC_E3g") (unit 1)))) ) - (symbol - (lib_id 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1.27)) (hide yes))) + (property "Datasheet" "" (at 240.03 165.1 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Description" "" (at 240.03 165.1 0) (effects (font (size 1.27 1.27)) (hide yes))) + (pin "1" (uuid "84c5524c-0ff9-5213-a7c4-74c7d8feef43")) + (pin "2" (uuid "8faa8290-45a3-5c91-befe-20653856b15f")) + (instances (project "CM5IO" (path "/e63e39d7-6ac0-4ffd-8aa3-1841a4541b55/9c7ccf72-dd3e-5ed3-bb43-2939833eb069" (reference "C_OUT33a") (unit 1)))) + ) + (global_label "+3V3_RF" + (shape input) + (at 240.03 161.29 0) + (effects (font (size 1.27 1.27)) (justify left)) + (uuid "f825efc6-a599-5293-8ad7-bb35d2f7ff37") + ) + (symbol + (lib_id "power:GND") + (at 240.03 168.91 0) + (unit 1) + (exclude_from_sim no) (in_bom yes) (on_board yes) (dnp no) + (uuid "ec20a721-8c6a-571e-9f3e-d1ca8b41f544") + (property "Reference" "#PWRC_OUT33a2" (at 240.03 171.91 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Value" "GND" (at 240.03 170.91 0) (effects (font (size 1.27 1.27)))) + (property "Footprint" "" (at 240.03 168.91 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Datasheet" "" (at 240.03 168.91 0) (effects (font (size 1.27 1.27)) (hide yes))) + (pin "1" (uuid "3bad6947-dcca-5592-9aec-ffcc8a7fddeb")) + (instances (project "CM5IO" (path "/e63e39d7-6ac0-4ffd-8aa3-1841a4541b55/9c7ccf72-dd3e-5ed3-bb43-2939833eb069" (reference "#PWRC_OUT33a2") (unit 1)))) + ) + (symbol + (lib_id "Device:C") + (at 245.11 165.1 0) + (unit 1) + (exclude_from_sim no) (in_bom yes) (on_board yes) (dnp no) + (uuid "445475c3-e364-5c31-ad95-90047644c5b9") + (property "Reference" "C_OUT33b" (at 247.65 164.1 0) (effects (font (size 1.27 1.27)) (justify left))) + (property "Value" "47u/16V" (at 247.65 166.1 0) (effects (font (size 1.27 1.27)) (justify left))) + (property "Footprint" "Capacitor_SMD:C_1210_3225Metric" (at 245.11 165.1 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Datasheet" "" (at 245.11 165.1 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Description" "" (at 245.11 165.1 0) (effects (font (size 1.27 1.27)) (hide yes))) + (pin "1" (uuid "7aa57847-73b5-5c05-b767-bb62ce89d618")) + (pin "2" (uuid "69d9a762-5886-5ab1-b7ed-06843f7d57e4")) + (instances (project "CM5IO" (path "/e63e39d7-6ac0-4ffd-8aa3-1841a4541b55/9c7ccf72-dd3e-5ed3-bb43-2939833eb069" (reference "C_OUT33b") (unit 1)))) + ) + (global_label "+3V3_RF" + (shape input) + (at 245.11 161.29 0) + (effects (font (size 1.27 1.27)) (justify left)) + (uuid "9433b865-be13-549a-bfd7-1a6d376c760f") + ) + (symbol + (lib_id "power:GND") + (at 245.11 168.91 0) + (unit 1) + (exclude_from_sim no) (in_bom yes) (on_board yes) (dnp no) + (uuid "af36ee75-239f-5915-a82d-a734af60520e") + (property "Reference" "#PWRC_OUT33b2" (at 245.11 171.91 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Value" "GND" (at 245.11 170.91 0) (effects (font (size 1.27 1.27)))) + (property "Footprint" "" (at 245.11 168.91 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Datasheet" "" (at 245.11 168.91 0) (effects (font (size 1.27 1.27)) (hide yes))) + (pin "1" (uuid "a80d941d-9847-5500-bc99-f819ef1b4111")) + (instances (project "CM5IO" (path "/e63e39d7-6ac0-4ffd-8aa3-1841a4541b55/9c7ccf72-dd3e-5ed3-bb43-2939833eb069" (reference "#PWRC_OUT33b2") (unit 1)))) + ) + (symbol + (lib_id "power:PWR_FLAG") + (at 270.51 142.24 0) + (unit 1) + (exclude_from_sim no) (in_bom yes) (on_board yes) (dnp no) + (uuid "1303478c-fb2d-5112-9517-fee0895b93f1") + (property "Reference" "#FLGP33R" (at 270.51 139.24 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Value" "PWR_FLAG" (at 270.51 140.24 0) (effects (font (size 1.27 1.27)))) + (property "Footprint" "" (at 270.51 142.24 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Datasheet" "" (at 270.51 142.24 0) (effects (font (size 1.27 1.27)) (hide yes))) + (pin "1" (uuid "0e8e4211-812c-5f32-b112-8a33a94d41da")) + (instances (project "CM5IO" (path "/e63e39d7-6ac0-4ffd-8aa3-1841a4541b55/9c7ccf72-dd3e-5ed3-bb43-2939833eb069" (reference "#FLGP33R") (unit 1)))) + ) (sheet_instances (path "/" (page "5") diff --git a/tools/build_ekey.py b/tools/build_ekey.py index 4f0d08c..7989786 100644 --- a/tools/build_ekey.py +++ b/tools/build_ekey.py @@ -211,19 +211,13 @@ place_rc("Device:R", "R_E1", "10k", "Resistor_SMD:R_0402_1005Metric", g(215.0), place_rc("Device:R", "R_E2", "10k", "Resistor_SMD:R_0402_1005Metric", g(225.0), g(80.0), loc_label, "WIFI_DISABLE2#", "+3V3_RF") # decoupling caps: pin1 -> +3V3_RF ; pin2 -> GND -c_e1_pin1 = None for i, (ref, val) in enumerate([("C_E1", "10u"), ("C_E2", "100n"), ("C_E3", "100n")]): cx = g(215.0 + i * 7.62); cy = g(110.0) body.append(passive("Device:C", ref, val, "Capacitor_SMD:C_0402_1005Metric", cx, cy, ref)) - p1 = (cx, round(cy - 3.81, 2)) - body.append(glob_label("+3V3_RF", p1[0], p1[1], 90)) # pin1 + body.append(glob_label("+3V3_RF", cx, round(cy - 3.81, 2), 90)) # pin1 body.append(gnd_sym(cx, round(cy + 3.81, 2), ref + "g")) # pin2 -> GND symbol - if ref == "C_E1": c_e1_pin1 = p1 -# one PWR_FLAG to drive +3V3_RF until the power-sheet buck exists. -# Co-locate its pin directly on an existing +3V3_RF node (C_E1 pin1) so it binds. -# REMOVE this flag once the power sheet's buck drives +3V3_RF (else dual-driver ERC). -body.append(pwr_flag(c_e1_pin1[0], c_e1_pin1[1], "33RF")) +# +3V3_RF is driven by the Power sheet's U_BUCK33R (PWR_FLAG lives there). # ---- file scaffold ----------------------------------------------------------------- libsyms = "\n".join([DEV_R, DEV_C, PWR_GND, pflag, sock]) diff --git a/tools/build_power.py b/tools/build_power.py index 7d89b1b..41fa790 100644 --- a/tools/build_power.py +++ b/tools/build_power.py @@ -101,7 +101,7 @@ register_lm61460() # +5v pre-exists in the carrier as a HIERARCHICAL net (local + hierarchical labels on the CM5 # sheets) -> expose it hierarchically here (a global label collides: same_local_global_label). # +3V3_RF/+3V3_AUX are new nets introduced by this port -> global is fine. -GLOBAL_NETS = {"+3V3_RF", "+3V3_AUX"} +GLOBAL_NETS = {"+3V3_RF", "+3V3_AUX", "PCIE_PWR_EN"} HIER_NETS = {"+5v"} # from KiCad libs (renamed to full lib_id) add_from("power:PWR_FLAG", open(f"{KSS}/power.kicad_sym").read(), "PWR_FLAG") @@ -207,6 +207,32 @@ place("Device:C", "C_OUT5b", "47u/16V", "Capacitor_SMD:C_1210_3225Metric", 180, # +5v is now sourced by this buck -> PWR_FLAG co-located on L5 pin2 (+5v) p5x, p5y = pin_abs(l5, "Device:L", "2"); emit_flag(p5x, p5y, "P5V") +# ---- STAGE 3: U_BUCK33R 15V -> +3V3_RF 4A (LM61460-Q1, sync) -------------------- +# FB divider: VREF=1.0V -> Rfbt/Rfbb=2.32 -> 23.2k/10.0k = 3.32V. +# Same support set as stage 2 (RT 31.6k ~420kHz, L 4.7uH/7A: ripple ~1.3A = 33% of 4A). +# BIAS -> +3V3_RF (datasheet: BIAS>=3.1V uses output LDO path; falls back to VIN below). +# EN <- PCIE_PWR_EN (CM5 Module1 pin 106, global net) + 100k pull-down (= reference R14) +# so the Wi-Fi rail stays OFF until the CM5 asserts it. +place("CM5IO:LM61460-Q1", "U_BUCK33R", "LM61460-Q1", "Package_SO:Texas_HTSSOP-14-1EP_4.4x5mm_P0.65mm_EP3.4x5mm_Mask3.155x3.255mm_ThermalVias", + 230, 150, {'8': 'VIN_PROT', '12': 'VIN_PROT', '7': 'PCIE_PWR_EN', '1': '+3V3_RF', '2': 'VCC33', + '6': 'RT33', '5': 'PG33', '4': 'FB33', '10': 'SW33', '14': 'BOOT33', '13': 'RBOOT33', + '9': GND, '11': GND, '3': GND, '15': GND}) +l33 = place("Device:L", "L33", "4.7uH/7A", "Inductor_SMD:L_Bourns_SRP1245A", 270, 138, {'1': 'SW33', '2': '+3V3_RF'}) +place("Device:C", "C_BOOT33", "100n", "Capacitor_SMD:C_0402_1005Metric", 260, 132, {'1': 'SW33', '2': 'BOOT33'}) +place("Device:R", "R_BOOT33", "4.7", "Resistor_SMD:R_0402_1005Metric", 265, 128, {'1': 'RBOOT33', '2': 'BOOT33'}) +place("Device:R", "R_RT33", "31.6k", "Resistor_SMD:R_0402_1005Metric", 210, 158, {'1': 'RT33', '2': GND}) +place("Device:R", "R_PG33", "100k", "Resistor_SMD:R_0402_1005Metric", 255, 143, {'1': 'PG33', '2': '+3V3_RF'}) +place("Device:R", "R_FBT33", "23.2k", "Resistor_SMD:R_0402_1005Metric", 285, 150, {'1': '+3V3_RF', '2': 'FB33'}) +place("Device:R", "R_FBB33", "10.0k", "Resistor_SMD:R_0402_1005Metric", 285, 158, {'1': 'FB33', '2': GND}) +place("Device:R", "R_EN33", "100k", "Resistor_SMD:R_0402_1005Metric", 200, 165, {'1': 'PCIE_PWR_EN', '2': GND}) +place("Device:C", "C_VCC33", "1u", "Capacitor_SMD:C_0402_1005Metric", 220, 158, {'1': 'VCC33', '2': GND}) +place("Device:C", "C_IN33a", "10u/50V", "Capacitor_SMD:C_1210_3225Metric", 215, 145, {'1': 'VIN_PROT', '2': GND}) +place("Device:C", "C_IN33b", "10u/50V", "Capacitor_SMD:C_1210_3225Metric", 220, 145, {'1': 'VIN_PROT', '2': GND}) +place("Device:C", "C_OUT33a", "47u/16V", "Capacitor_SMD:C_1210_3225Metric", 240, 165, {'1': '+3V3_RF', '2': GND}) +place("Device:C", "C_OUT33b", "47u/16V", "Capacitor_SMD:C_1210_3225Metric", 245, 165, {'1': '+3V3_RF', '2': GND}) +# +3V3_RF is now sourced by this buck -> PWR_FLAG on L33 pin2 (replaces the E-key temp flag) +p33x, p33y = pin_abs(l33, "Device:L", "2"); emit_flag(p33x, p33y, "P33R") + # ---- file scaffold ---------------------------------------------------------------- libsyms = "\n".join(blk for blk, _ in LIBS.values()) sheet = ('(kicad_sch\n\t(version 20231120)\n\t(generator "eeschema")\n\t(generator_version "8.0")\n'