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SummerCart64/docs/06_manufacturing_guidelines.md

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Step by step guide how to make SC64

All necessary manufacturing files are packaged in every SC64.zip file in GitHub releases. Please download latest release before proceeding with the instructions.

PCB manufacturing data

  1. Locate KiCad project inside hw/pcb folder
  2. Export gerber/drill files
  3. Export BOM spreadsheet
  4. Export PnP placement files
  5. Send appropriate files to the PCB manufacturer

PCB requirements

  • Thickness: 1.2 mm
  • At least ENIG plating or better
  • PCB contains edge connector: yes
  • Beveled edge connector: yes, 45°

Components

  1. Locate interactive BOM file inside hw/pcb folder
  2. Order all parts listed in the BOM file or use PCB assembly service together with your PCB order

Plastic shell

  1. Locate .stl files inside hw/shell folder
  2. Use these files in the slicer and 3D printer of your choice or order ready made prints from 3D printing company
  3. Find matching screws, dimensions are the same as on retail N64 cartridges

Putting it together

There are no special requirements for soldering components to board. All chips and connectors can be soldered with standard manual soldering iron, although hot air station is recommended. Interactive BOM has every component and its value highlighted on PCB drawings and it's strongly recommended to use during assembly process. You can skip this step if PCB assembly service was used in previous steps.

Initial programming

For initial programming you are going to need a PC and a USB to UART (serial) adapter (3.3V signaling is required). These steps assume you are using modern Windows OS (version 10 or higher).

As for software here's list of required applications:

  • FT_PROG - FTDI FT232H EEPROM programming software
  • Python 3 - necessary for initial programming script, primer.py

Programming must be done in specific order for primer.py script to work correctly.

First, program FT232H EEPROM:

  1. Connect SC64 board to the PC with USB-C cable
  2. Locate FT232H EEPROM template in fw/ftdi folder
  3. Launch FT_PROG software
  4. Click on Scan and parse if no device has shown up
  5. Right click on SC64 device and choose Apply Template -> From File
  6. Select previously located ft232h_config.xml
  7. Right click on SC64 device and choose Program Device

Your SC64 should be ready for next programming step.

Second, program FPGA, microcontroller and Flash memory:

  1. Disconnect SC64 board from power (unplug USB-C cable)
  2. Connect USB to UART adapter to TX/RX/GND pads marked on the PCB
  3. Connect serial adapter to the PC
  4. Connect SC64 board to the PC with USB-C cable (IMPORTANT: connect it to the same computer as serial adapter)
  5. Check in device manager which port number (COMx) is assigned to serial adapter (not SC64 port number)
  6. Locate primer.py script in root folder
  7. Make sure sc64.py and dd64.py scripts are located in the same folder as primer.py
  8. Make sure sc64.upd firmware update file is located in the same folder as primer.py
  9. Run python3 primer.py COMx sc64.upd (replace COMx with port located in step 5)
  10. Follow the instructions on the screen
  11. Wait until programming process has finished

Congratulations! Your SC64 flashcart should be ready for use!

Troubleshooting

primer.py threw error on Bootloader -> SC64 FLASH step

This issue can be attributed to incorrectly programmed FT232H EPPROM in first programming step. Check again in FT_PROG if device was configured properly. Once FPGA and microcontroller has been programmed successfully, primer.py script cannot be used again. Please use command python3 sc64.py --update-firmware sc64.upd to try programming bootloader again.