Procedures PAS PowerModule V1 - thepinkmile/Enigma-NG GitHub Wiki

PAS-PWR-V1.0: Power Module Acceptance Specification

Status: Draft Version: v1.0.0 Associated Hardware Revision: Rev A Last Updated: 2026-04-20

⚠️ HINWEIS: THERMISCHE GRENZFLÄCHE (Thermal Interface)

  • The exposed ENIG zones can become extremely hot under full load (>5A).
  • PROCEDURE: Gelid-GP thermal pad MUST be applied before live testing.

1. Bare Board "Cold" Tests (Pre-Power)

  • Chassis Isolation: Confirm >1MΩ resistance between the 15V Rail and the Aluminium Tray.*
  • TCO Continuity: Confirm 0Ω across the Bourns AC72 Thermal Cutoff pads.
  • Ground Bridge: Confirm 0Ω across the 15A GND_CHASSIS diagnostic shunts.
  • Hex-Matrix: Visual check of Type VII via-capping on L4 (must be mirror-flat).

2. Live Input Verification

  • PoE Auxiliary Feed: Apply 48V to the Controller Ethernet / PoE entry; verify regulated VIN_POE_12V is present at Power Module dock J2 and reaches the PM OR-ing / eFuse input path.
  • USB-C PD: Connect 15V PD source; verify negotiated voltage and stable rail.
  • Battery: Connect 14.4V battery; verify SMBus pull-ups are active.

3. Logic & Handshake

  • Safety Glow: Confirm Amber LED illuminates at >5.1V and extinguishes at ~5.0V.
  • Discharge: Ensure < 2V at Safety Probes before handling board.
  • Logic Ready: Confirm Green "LOGIK-BEREIT" LED illuminates only when 5V/3.3V rails are stable.
  • Handshake: Verify PWR_GD on PM dock J3 goes HIGH (>3.0V).
  • UPS Hold-time: Load 15W; pull power; verify ≥33.5s uptime before dropout.

4. Header & Coupon Verification

  • Dock Orientation: Confirm J1/J2/J3 are fitted in the correct keyed orientation and align cleanly with the Controller receptacles.
  • Straight Alignment: Verify dock headers are vertical and coplanar to prevent blind-mate binding during PM insertion.
  • Adhesive Zone: Confirm RTV Silicone 'KLEBER-ZONE' is free of solder mask for maximum bond.

5. Pi-Proxy Validation

  • Handshake: Connect the Controller / CM5 assembly via the PM dock and USB-C service power path.
  • PD Check: Verify 5V/5A negotiation via vcgencmd get_throttled.
  • Telemetry: Verify I2C communication with TPS25751 PD Emulator.

6. V-Score & Coupon Inspection

  • TRENNLINIE: Verify dashed silkscreen alignment with V-groove.
  • Isolation: Confirm zero conductivity across the snap-line post-break.