PowerNodeBlue-bringup

Early 2025; version 1.14 variation of the PowerNode White: order of 15 units; 25/01/23 fab date; see also this page on configuration details.

Initial Bringup / checkout

Board 001 (selected as sacrificial):

1. Optically checked soldering/board as is
2. Plug in USB-C
   1. Check 3v3 and 5v power; check red LED comes one.
   2. Check for magic smoke/things getting hot (nothing should)
   3. check detection of serial port/driver. It won't have any output at this point
3. PoE powering
   1. Solder in RJ45 connector
   2. Place solder bridges Vpwr, V5 to VPOE/VPOE5 in Source field
   3. Do not place the Vpwr/5V bridges in the PoE field - these should be better labeled: e.g. have an 'OFF' text added to them like the one just above.
   4. Plug in PoE ethernet; check voltages: 5V, 3v3 and Vpwr==5V
4. ESP32
   1. Solder in the ESP32 -- revision used:
      1. Chip is ESP32-D0WD-V3 (revision v3.1)
      2. MAC: 08:a6:f7:b0:72:ac
   2. Unplug PoE ethernet; plug in USB;
   3. Check 115200 baud visibility of ESP32 (press reset if needed). Should see

      ets Jul 29 2019 12:21:46 ... rst:0x1 (POWERON_RESET),boot:0x13 (SPI_FAST_FLASH_BOOT)

   4. Check upload with default Arduino example `Blink' app against LEDs set to OUT1/OUT2 (GPIO 16, GPIO4) with ESP32 -> ESP32-WROOM-DA module with settings and .
   5. Uploading at 115200 should work.
      1. If it fails - go drop speed
      2. For proper board with proper/non-counterfeit chips - 921600 baud works stable and well.
      3. Check the schematic for the 33 Ohm resistors that are supposed to help with the impedance/driving.
5. PoE and ESP32
   1. Remove from USB; plug into PoE and check LEDs start flashing as soon as the power LED comes on.
6. From this point on - use a Galvanic USB isolator when connecting to the board with Ethernet plugged in.
7. Solder in Buzzer, OLED display (if needed), buttons, connectors
   1. Test with plain PowerNode install & check screen & menu cycling
8. Check RDIF
   1. Holding an RFID card should cause two beeps. Use the VNA - Vector Network Analyser with this information to check.
   2. Check IP allocation on screen/serial and check web interface
9. (Optional) solder on final power selection, fuses, sensors, etc.

Problems during bringup

1. Accidental solder bridge between pin 13/14 of ESP32 made it look like the switch was not mechanically not working (stuck in 0).

Test script for the (newish) AW chip

    #include <Adafruit_AW9523.h>
    
    Adafruit_AW9523 aw;
    
    int I2C_SDA = 05; // 21 is the default
    int I2C_SCL = 15; // 22 is the default
    int IRQ_PIN =  35; // not yet tested
    
    bool _irq_seen = 0;
    void irq() { _irq_seen = true; };
    
    void setup() {
      Serial.begin(115200);
      Serial.println("Adafruit AW9523 test!");
      Wire.begin(I2C_SDA, I2C_SCL);
    
      if (! aw.begin(0x58)) 
        Serial.println("AW9523 not found? Check wiring!");
      Serial.println("AW9523 found/OK");
    
      attachInterrupt(IRQ_PIN, irq, CHANGE);
    
      for (int i = 0; i < 16; i++) {
        aw.pinMode(i, INPUT);
        aw.enableInterrupt(i, true);
      };
    }
    
    void loop() {
      if (_irq_seen) {
        _irq_seen = false;
        Serial.println("IRQ");
      };
    
      static unsigned long lst = millis();
      if (millis() - lst < 200) return;
      lst = millis();
    
      for (int i = 0; i < 16; i++) {
        Serial.print(aw.digitalRead(i));
        if (i % 4 == 3) Serial.print(".");
      };
      Serial.println();
    }

Improvements

1. Add the word 'OFF' to the labels of all bridges in the PoE field (and not just the top one)

Soldered on Features

Board Blue-001

• OLED screen, ESP32-WROOM-DA, Buzzer, override contacts
• PoE powered; VUSB allowed
• 100k Potentiometer for voltage setting
• Vpwr Voltage set to 12V
• 5A/250VAC relay; 12V coil
• Error LED, Output 1, 2 LEDs on front (all red)
• Extra LEDS:
  • LEDE Green : Heartbeat (toppost, pulses gently green in normal operation
  • LEDD Orange : Lit up on LAN/WiFi error
  • LEDC Red:
  • LEDB Red: Lit up when not paired/not functional/out of order
  • LEDA Red: Lit up on output override/error
• Normal green connector; `arrow' to the nearest side of board

Reworks

None

Board Blue-012

• OLED screen, ESP32-WROOM-DA, Buzzer, override contacts
• PoE powered; VUSB allowed
• 0R bridge replaced by fixed 27k Resistor on Vpwr; fixed to ~12Volt
• 2x12V coil, 8A/250VAC DPDT relay (Orange style) on output 1 and 2
• Error LED, Output 1, 2 LEDs on front (all red)
• Extra LEDS:
  • LEDE Green : Heartbeat (toppost, pulses gently green in normal operation
  • LEDD Orange : Lit up on LAN/WiFi error
  • LEDC Red:
  • LEDB Red: Lit up when not paired/not functional/out of order
  • LEDA Red: Lit up on output override/error
• Normal green connector; `arrow' to the nearest side of board
• ZMCT118F current coil - 68R burden; 1000:1; 0..35 Ampere; 0.7 volt/10 Ampere

Reworks

None

Board Blue-013 - Rework #2

• OLED screen, ESP32-WROOM-DA, Buzzer, override contacts
• Only YES/NO button as it replaces a white Node Bandsaw board.
• PoE powered; VUSB allowed
• 0R bridge replaced by fixed 27k Resistor on Vpwr; fixed to ~12Volt
• 1x12V coil, 8A/250VAC DPDT relay (Orange style) on output 1 ony
• Normal green connector; `arrow' to the nearest side of board
• ZMCT118F current coil - 68R burden; 1000:1; 0..35 Ampere; 0.7 volt/10 Ampere

Reworks

1. Added 100 ohm resistor and zener in the current transformer circuit
2. Removed/bridged 2x68k on opto's. May actually not be needed.