Yay, no more flapping!

Tomorrow's problem: while g12 links up fine at gigabit speed, last time I tried g13 would struggle a bit then come up at 100 Mbps (verified by link partner).

That's probably a hardware issue of some sort since g12 and g13 are supposed to be identically configured. The RJ45 pinout is mirrored because of the tab-up vs tab-down jacks, but that should (famous last words) be fine because the DP83867 has a register to enable ABCD -> DCBA mirroring, which I think I've set correctly.

I made a quick pass over the schematic and nothing seemed otherwise different, it was largely copy-pasted other than the PHYADDR strap pins.

Yet another command that I wish "real" switches had.

There will of course be fancy commands that include nice detailed decodes of port state. But sometimes there's no substitute for getting close to the metal.

Well, that was a slightly larger yak than I originally expected but it's been thoroughly shaved.

SSH clients on the switch can now see log messages. For now this is enabled by default, although long term I might have this controlled by a per-unit configuration setting or off by default with a Cisco-style "terminal monitor" command to start seeing log messages.

During development I want ALL the logs so I'll leave it like this for now.

Next step will be to implement some of the commands I copied over (commented out) from the Ethernet tap board, and make any tweaks needed to support the additional PHY chipsets on the board.

In particular, I want to be able to send test patterns out both DP83867's to check for soldering issues before I debug the 100mbit-only link issue further.

Ok, I should sleep...

But on the plus side, I have the code to send test patterns working (including the three special test patterns that the DP83867 specifies in addition to the IEE-defined ones).

Won't be able to actually debug the g13 100mbit issue until tomorrow after work but I should have all the groundwork laid now.

Oh I'm sorry you wanted *less* cable spaghetti? i swear you said you wanted *more*. I even bought a new roll of ESD tape to wrangle it all.

Got the baseT test fixture cabled up so I can troubleshoot g13's link issues after work, but didn't have time to collect any data yet.

If you haven't seen it before, this is a handy dandy little gizmo consisting of two RJ45 jacks connected back to back by dual directional couplers.

This gives me 16 SMA outputs with 10 dB attenuated views of each of the 8 wires in the twisted pair cable, seen from both directions. I'm using an 8 channel PicoScope 6824E to look at all 8 lines coming out of the DP83867, ignoring the inbound data from the other side.

Hmmm.

Set up a test pattern on g13 and expected to see it coming out all pairs of the link, but only seeing it on pair A.

Thought this pointed to a soldering issue, except I'm seeing it on g12 as well (which links up just fine).

So I guess I need to read the datasheet and see if there's a test pattern mux register or something I'm missing...

Yep, there is. MMD 0x1f register 0x25, TMCH_CTRL, defaults to only sending the test pattern out pair A.

With that fixed, on g12 I'm seeing the test pattern on all pairs. So we know our register config is correct there.

And now here's what we see on g13. One of these is not like the other.

Probably a solder defect but I'll need to pull the board to investigate. Decabling this will take a while...

I wish it was a solder defect. The truth is worse.

Not sure how this got through design review...

Looking at the layout, bodging this is going to be fuuuun.

g10, g8, and g4 have pair D routed on layer 6 of 8. Getting to them (assuming I come from the back of the PCB to avoid desoldering the connector) will mean drilling down 250 μm - annoying but not too bad.

g13, g6, g2, and g0, all have pair D router on layer 3 of 8. Getting to *this* from the back side will mean drilling down almost 1.3 mm. That will be decidedly less fun.

And worst case, this isn't a fatal issue for a prototype. Having half the ports only run in 100baseTX mode, or even not work at all, would surely be annoying. But it wouldn't prevent me from using the board as a development platform for the full scale 24 port switch, which was the real goal.

But I'd like to make it fully functional if I can.

Not happening tonight, though. I've got too much else on my plate with time constraints.

Actually I might try some fixturing work and a preliminary cut while waiting for stuff to run on another project.

My microscope ring light was too fat to clear so I bodged up an LED headlamp with some tape.

First connector (on the DP83867s) bodged. Not attempting the rest (on the VSC8512) until I've brought it up.

Ended up milling all the way down and cutting the track then reconnecting on the surface. there's a small stub off a via which isn't great but it'll probably be fine on a prototype.

I'll save the other six for later. If the phy doesn't work, no point spending time reworking the RJ45s.

Initial signs of life out of the QSGMII PHY!

It's responding to MDIO with the correct address, but twice (?) and at 8 addresses (this is a 12 port PHY). Suspecting a timing issue related to the level shifters on the MDIO bus, but not sure yet. Dropping the MDIO clock frequency by 10x from 2.5 MHz to 250 kHz didn't fix it.

The actual PHY side seems OK, it links up with my laptop on every port I've tried (aside from the known pair D issue on the upper row of ports).

Also whoops I misspoke. The Ethernet test fixture is 16 dB couplers not 10. The directional coupler I use for TDR stuff is 10 dB and I mixed them up.

Too much RF hardware :p

Reading the programming guide in the VSC8512 datasheet.

Why??? IEEE has a perfectly well defined way to access up to 2^16 extended registers. You don't need to roll your own way to do it.

Loaded an FPGA bitstream that instantiates the QSGMII transceivers on the FPGA.

Power consumption climbed to 12.7W and the FPGA die temperature is up to 48.5C.

The 1V0 rail for the GTXes is sagging to 975.5 mV under load, since it's just pi filtered off of the main FPGA 1V0 rail without an independent remote sense. This is within spec... barely. But definitely something I will want to work on in the future. The full LATENTRED switch (with eight transceivers) will definitely need a dedicated SERDES power rail with independent regulation.

The FPGA 1V0 rail is doing just fine, 1.0015V at the test point and 0.996V measured by the on die ADC.

FPGA logic reports none of the QSGMII links are up.

Not entirely surprising since I've never actually tested the QSGMII block in hardware, but still a bit annoying.

I think that's it for today. Tomorrow I'll decable the whole setup (again), and probably try to bodge one or more of the VSC8512 RJ45s as long as i have it off the bench.

Then get test leads on the VSC8512 MDIO bus (to see if anything funky is happening with timing there, I still can only talk to 8 of the 12 PHYs... might be a register misconfiguration too though), and probably land a high BW probe on one or more of the QSGMII lanes to see what's happening with that.

Quick handheld probe measurement off the QSGMII TX line from the FPGA.

Definitely some logic bugs, we're supposed to have K28.1 in lane 0 and all I'm seeing is K28.5.

The eye (measured at the PHY side of the coupling capacitor) is pretty wide open, but I will definitely want to tweak driver settings given the closure in the right half. Need to check this against the QSGMII eye mask but I don't have the specs for that in ngscopeclient yet (also a job for tomorrow).

Seems like drive on my QSGMII TX is just a little bit over the top. Left eye has the transmitter mask, right has the receiver.

This is a mid-channel measurement (at the AC coupling cap) so we need to be better than the RX mask but don't need to pass the TX.

Back to the lab for the evening and continuing switch bringup.

Double checking pins on the VSC8512 and so far not seeing any issues.

I did notice that the thermal diode is tied off to ground, which is in retrospect a mistake. I should have provided a means to monitor it externally. Now I have no way to tell if the PHY is overheating other than by pointing a FLIR camera at the heatsink and adding a couple of degrees to the reading.

Signal integrity tweaking on the QSGMII.

Took initial measurements with an AKL-PT5 and a D1330, then cross checked the PT5 measurements against a D1605.

After some tweaking, the QSGMII TX waveform isn't overshooting.

But when I soldered an AKL-PT5 on, I saw a huge dip around T=25ps that I don't remember seeing in the handheld probe view (maybe it didn't have enough BW to show it?)

I repeated the same measurement with a D1605 (shown here) just in case it was an artifact of the PT5. Other than a bit less noise, the eye looked identical.

Need to check and see if the remaining QSGMII lanes have similar issues or if this is the only one, or what. It technically passes the QSGMII eye mask so it *should* work but I wouldn't want to field it looking like this!

RX drive strength is a bit higher than spec, but the FPGA will happily eat it so I'm not concerned.

Looking at the QSGMII link state, it seems that the FPGA is sending autonegotiation codeword 0x4001 (SGMII mode, no remote fault etc, no next page).

The PHY is sending K28.5 D16.2 which is IDLE 2, so I think this means it's waiting for the FPGA to go "ok, link is up"?

Reading register 19E3 from the PHY (link partner clause 37 ability) shows 0x4001, the same thing the FPGA is sending. This means that the PHY is seeing my autonegotiation traffic and decoding it correctly.

Register 17E3 is 0x0409: no SGMII alignment error or remote fault, no full duplex advertised by MAC (seems wrong), no half duplex advertised by MAC, link partner AN capable, link not connected, AN not complete, signal present.

But... bit 5 of the AN advertisement (which means full duplex capable) is *reserved, must be zero* in SGMII mode. So I'm not sure if this is a problem or not.

Fixed a bunch of bugs in the SGMII block, the QSGMII-SGMII bridge, and even in ngscopeclient.

And the TX eye still isn't very pretty, I need to investigate that more.

But the QSGMII links are now alive! Let's see if I can actually pass traffic...

And it looks like the PHY is able to receive traffic! Haven't tested if it decodes properly in the FPGA etc, but the PHY is sending well formed QSGMII, the FPGA sees the link as up, and the decode in libscopehal is making sense of it.

Not sending anything yet. A lot more work needed on the switch logic in the FPGA to make *that* happen.

Continuing switch bringup work.

All ports (except the four VSC8512 interfaces which aren't responding over MDIO) have link state/speed working and queriable via the MCU.

Something is wonky with the basic status register, it's saying the link is half duplex even though it's negotiated to full duplex (in fact, only advertising full duplex). Not sure if this is a bug or what. Might have something to do with the 8051 microcode patch I haven't yet applied?

Spent a while today debugging on live hardware and finally reproduced the issue in simulation.

Packets more than 32 128-bit words in length will max out the prefetch FIFO but I never continue to fetch traffic after that point. There's a big giant TODO comment I never implemented. Oops.

Did a bunch of timing fixes and added some more pipeline stages. Latency is higher than I'd like now and I'll definitely want to work on reducing it, but it should do for a starting point.

Also did some per-link power estimates: about 13.3W in the current test configuration (management port, SFP+ uplink, and two VSC8512 edge ports active at 1 Gbps, no packet traffic).

This climbs to about 13.8W (+0.5W, so 0.25W per interface) if looping back two DP83867 interfaces, and 14W (+0.7W, so 0.35W per interface) looping back two VSC8512 interfaces.

With all links up, I thus project that the total board power consumption would climb to about 17.3W. This would likely increase a bit further with heavy traffic due to increased toggles on the SRAM bus etc.

Not too bad for a ~16 port switch (counting management and uplink ports). I've also put zero effort into optimizing the FPGA design for power to date, so there's probably things I can do to improve there.

Off the top of my head:

* If an entire group of four baseT links is down or disabled, I can shut down the QSGMII SERDES
* If there's no traffic on the read side of the SRAM bus, I can disable the input terminations
* If there's no traffic on the write side of the SRAM bus, I might be able to tristate the bus except for control signals
* It might be possible to consolidate/optimize PLL configuration to use less PLLs
* There's definitely work to be done to use less long range high fanout clocks on the FPGA
* Improve gating of unused signals on wide buses etc to avoid propagation of toggles that don't do useful work

Always a fun day when you have to write code like this...

Hopefully this will give me a trigger condition that will let me figure out why my switch fabric is deadlocking trying to forward a packet without actually doing anything to it.

Welp. Somehow I'm trying to start forwarding from port #15.

Except I only have 15 ports (14 plus the uplink) and port numbers are zero based.

Looks like I was incrementing the round robin counter but forgot to add the "mod portcount" bit.

And apparently whatever logic Vivado synthesizes for accessing the 16th element of a 15-element vector resulted in the arbiter thinking it had data to send, entering the busy state, but then never getting a done signal.