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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

Please read the following instructions carefully before proceeding with 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 with pip3 - 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 serial adapter to TX/RX/GND pads marked on the PCB
  3. Connect serial adapter to the PC
  4. Check in device manager which port number COMx is assigned to serial adapter
  5. Connect SC64 board to the PC with USB-C cable (IMPORTANT: connect it to the same computer as serial adapter)
  6. Locate primer.py script in root folder
  7. Make sure these files are located in the same folder as primer.py script: requirements.txt, sc64.py, sc64_firmware.bin
  8. Run pip3 install -r requirements.txt to install required python packages
  9. Run python3 primer.py COMx sc64_firmware.bin (replace COMx with port located in step 4)
  10. Follow the instructions on the screen
  11. Wait until programming process has finished (DO NOT STOP PROGRAMMING PROCESS OR DISCONNECT SC64 BOARD FROM PC, doing so might irrecoverably break programming through UART header and you would need to program microcontroller, FPGA and bootloader with separate dedicated programming interfaces through Tag-Connect connector on the PCB)

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 EEPROM in the first programming step. Check again in FT_PROG program if device was configured properly. Once FPGA and microcontroller has been programmed successfully primer.py script needs to be run in special mode. Please use command python3 primer.py COMx sc64_firmware.bin --only-bootloader to try programming bootloader again.