Building a REX: Difference between revisions

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REX_Classic_bkw_6.png
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-->
=Introduction=
=Introduction=
Building a REX, BKW version.<br>
Building a REX<br>
This is essentially a REX1 with a modified pcb layout from Steven Adolph's original.<br>
 
Electrically identical.<br>
This is a version of [http://bitchin100.com/wiki/index.php?title=REXclassic Steven Adolph's REX Classic] with a modified PCB design.<br>
Software identical.<br>
It is electrically identical to REX Classic, and uses the REX Classic firmware & software.<br>
PCB shaped to snap into a 3d-printed carrier, and provide connections for power and PORT_EN for programming the CPLD.
 
The PCB layout and shape are modified to
* snap into a 3d-printed carrier to fit the Molex78805 socket
* provide connections for power and PORT_EN for programming the CPLD
 
'''[[REX:Build_(original_version)|Original version of this page, for building the original REX1]]'''


[[REX:Build_(original_version)|Original version of this page, for building the original REX1]]
[https://github.com/bkw777/REX_Classic PCB Source]<br>
[https://github.com/bkw777/Molex78802_Module Carrier Source]


=Parts & Materials=
=Parts & Materials=
* PCB: https://oshpark.com/shared_projects/DKF7eN1c
<!-- ==For Tandy 100/102/200== -->
* BOM: https://www.digikey.com/short/pbn7vw
* PCB: [https://oshpark.com/shared_projects/2aTIo5Fq OSHPark] or [https://www.pcbway.com/project/shareproject/REX_Classic__BKW_re_spin.html PCBWAY] 
* Sled: http://shpws.me/RngB
* BOM: [https://www.digikey.com/short/tj7bzf3h Digi-Key]
* Carrier: [http://shpws.me/SGNn Shapeways] or [https://www.sculpteo.com/en/print/molex78802_pcb_28-13/Bw4x3yG6 Sculpteo]
 
Note if ordering from PCBWAY: On the order page, you may have to manually change "Min tracks/spaces" to "6/6mil"<br>
All tracks & spaces are well over 6 mil (everything is 0.2mm which is almost 8 mil), and that setting drops the price from $50 to $5
 
ENIG adds a lot of cost on PCBWAY and JLCPCB lately.<br>
Currently the cheapest way to get an ENIG version for gold contacts (other than OSHPark) is [https://www.elecrow.com/ Elecrow].<br>
Upload the gerber zip from the [https://github.com/bkw777/REX_Classic/releases/latest releases], and manually select ENIG and Castellated Holes, and just use the cheapest shipping.
 
<!--
    The github includes a working re-spin REX Classic for NEC.
    REX NEC requires a different .jed file for the cpld, which is not publicly available.
    However, if you have a REX NEC, you can dump a .jed file from it, and use that to program new REX NECs.
-->
<!--
==For NEC PC-8201/8300==
* PCB: (see github)
* BOM: Same as above, but add 50 of these legs (you need 28, but 50 costs less than 28): https://www.digikey.com/product-detail/en/te-connectivity-amp-connectors/1544210-2/A117856CT-ND/4729775 Or these: https://www.digikey.com/en/products/detail/mill-max-manufacturing-corp/3121-2-00-15-00-00-08-0/436677
* No carrier needed.
-->


[[REX:flash|Other Compatible Flash Chips and how to identify them]]
[[REX:flash|Other Compatible Flash Chips and how to identify them]]


=Tools & Software=
=Tools=
[[File:DLC9G Clone.jpg|thumb]]
[[File:DLC9G Clone.jpg|thumb]]
*Cheap clone Xilinx Platform USB programmer.
*[https://www.ebay.com/sch/i.html?_nkw=xilinx+usb&_sop=15 Xilinx Platform USB programmer]
:https://www.ebay.com/sch/i.html?_nkw=xilinx+usb&_sop=15
:Cheap Chinese clone is fine.
:Look at the pictures for ones that say model DLC9G preferrably, or DLC9LP. Don't put "DLC9G" or "DLC9LP" in the search, you will only get the overpriced ones.
:Look at the pictures for ones that say model DLC9G, or DLC9LP. Don't put "DLC9G" or "DLC9LP" in the search, you will only get the overpriced ones.
:Get one that includes a "flying leads" cable, with separate loose individual wires on one end.<br clear=all>
:Get one that includes a "flying leads" cable, with separate loose individual wires on one end.<br clear=all>


[[File:Usb-ttl-cable.jpg|thumb]]
[[File:Usb-ttl-cable.jpg|thumb]]
*5v power source (actually anything 3.3 to 5v)
*[https://www.ebay.com/sch/i.html?_nkw=usb+ttl+cable&_sop=15 5v power source with dupont sockets]
:https://www.ebay.com/sch/i.html?_nkw=usb+ttl+cable&_sop=15
:A cheap usb-ttl cable is perfect. It's cheap, and already ends in loose wires with female dupont pins.
:A cheap usb-ttl cable is perfect. It's cheap, and already ends in loose wires with female dupont pins.
:Just use the red and black wires and ignore the rest.<br clear=all>
:Just use the red and black wires and ignore the rest.<br clear=all>
Line 45: Line 77:


*[http://www.microcenter.com/product/391332/12_Watt_Miniature_Corded_Soldering_Iron Soldering Iron]
*[http://www.microcenter.com/product/391332/12_Watt_Miniature_Corded_Soldering_Iron Soldering Iron]
:Do not necessarily need anything fancy. I actually used this exact one to build a few REXs, although now I use a Hakko FX-888D.
:Do not necessarily need anything fancy. I actually used this exact one to build a few REXs, although now I use a Hakko FX-888D with a T18-C2 tip.


*[http://www.microcenter.com/product/448396/No-Clean_Flux_Core_Solder_Sn63-Pb37_-_2_Ounce_Spool Solder, fine pitch, 63/37, no-clean flux or rosin core]
*[http://www.microcenter.com/product/448396/No-Clean_Flux_Core_Solder_Sn63-Pb37_-_2_Ounce_Spool Solder, fine pitch, 63/37, no-clean flux]


*[http://www.microcenter.com/product/444655/SRA_No-Clean_312_Flux_Pens No-Clean Flux]
*[http://www.microcenter.com/product/444655/SRA_No-Clean_312_Flux_Pens No-Clean Flux]
Line 61: Line 93:


[[File:1x6 1x4 shunt.jpg|thumb]]
[[File:1x6 1x4 shunt.jpg|thumb]]
*[https://www.ebay.com/sch/i.html?_nkw=2.5mm+single+row+male&_sop=15 Single-Row pin header]
*[https://www.digikey.com/short/pb0wvj Pin Headers and Shunt]
:0.1" (2.54mm) pitch
:0.1" (2.54mm) pitch single row male pin header
:You only need 10 pins. Break off a section of 6 pins, and a section of 4 pins.
:1x6
 
:1x4
*[https://www.ebay.com/sch/i.html?_nkw=2.5mm+shunt&_sop=15 A single shunt]
:one shunt
<br clear=all>
<br clear=all>


Line 72: Line 104:
*A [[Model_100_102_200_600_Serial_Cable|9F-25M-Null-Modem Serial Cable]]
*A [[Model_100_102_200_600_Serial_Cable|9F-25M-Null-Modem Serial Cable]]


*Xilinx ISE 14.7 or ISE 14.7 LabTools software
*Optional but recommended: [https://www.amazon.com/dp/B072JXQ9P5/ Ultrasonic Cleaner] and [https://www.sra-solder.com/sra-trupower-35-circuit-board-ultrasonic-cleaning-solution-1-quart saponifying PCB cleaning solution] and distilled or deionized water.
:You only need the iMPACT tool, and that is included in the Lab Tools package, which is a much smaller subset of the full ISE package. If all you want to do is program this chip, then just get Lab Tools.
 
=Software=
*Xilinx ISE 14.7 Lab Tools
:Lab Tools is a subset of ISE. You can use either ISE or Lab Tools, but you only need Lab Tools to program the REX.
:This software is old and needs special futzing to make it work, no matter what OS you are using.
:This software is old and needs special futzing to make it work, no matter what OS you are using.
:[https://drive.google.com/folderview?id=0Bys6eLbSbYyhVFBQSW1pclpjaWM Installing on Ubuntu Linux]
:[https://drive.google.com/folderview?id=0Bys6eLbSbYyhVFBQSW1pclpjaWM Installing on Ubuntu Linux]
:[https://www.micro-nova.com/xilinx-ise-win10 Installing on Windows].
:[https://www.micro-nova.com/xilinx-ise-win10 Installing on Windows].


*A DOS (aka TPDD client) for the M100
*A [[TPDD_client]] to run on the M100
:There are several dos's, and several ways to get one installed. These are a few options:
:There are several tpdd clients, and several ways to get one installed. These are a few options:
::Get [http://bitchin100.com/files/linux/dlplus.zip dlplus] and use the "teeny" installer that comes with it to install Teeny.
::For Mac, Linux, FreeBSD, any other unix: Get [http://gitlab.com/bkw777/dl2 dl2] and use the bootstrap option to install TEENY.100 or any of the other options listed by "$ dl -l"
::Get mComm for [http://www.club100.org/memfiles/index.php?action=downloadfile&filename=Setup250.EXE&directory=Kurt%20McCullum& Windows] or [http://www.club100.org/memfiles/index.php?action=downloadfile&filename=mComm181.apk&directory=Kurt%20McCullum/mComm%20Android& Android] and use the dos installer that comes with it to install either Teeny or TS-DOS.
::For Windows: Get [http://gitlab.com/bkw777/tsend tsend.ps1] and use it to install TEENY.100 or any of the clients found at https://github.com/bkw777/dl2/tree/master/clients
::Get the [http://www.club100.org/memfiles/index.php?action=downloadfile&filename=DOS100.CO.MP3&directory=Kurt%20McCullum&PHPSESSID=2rj7u8jfdrqlumb2a1q2m67lt1 ts-dos mp3] and play it from a phone into the cassette port to install TS-DOS. Go into BASIC and type: SOUND OFF:CLEAR 0,57089:RUNM "CAS:DOS100.CO"
::Play [[File:DOS100.CO.MP3]] into the cassette port to install TS-DOS. (SOUND OFF:CLEAR 0,57089:RUNM "CAS:DOS100.CO")
::Get a real tpdd and bootstrap it's utility disk to install "Floppy".
::Get a real tpdd and bootstrap it's utility disk to install "Floppy".


*A [[TPDD_server]] to run on a modern host machine
:For Mac, Linux, FreeBSD, any unix: [http://gitlab.com/bkw777/dl2 dl2]
:For Windows: [http://bitchin100.com/wiki/index.php?title=LaddieCon#LaddieAlpha LaddieAlpha]
<!--
  This is all still true, but most people will not have any problem. It depends on how slow the host machine is, and most are fast enough.
  So it's not worth cluttering up and complicating the directions which are already complicated enough.
  The bug is definitely in the RF#49.CO util rather than in the other tpdd emulators, because for one thing, RF*49.CO does not work with an *actual TPDD drive*.
  This also only started with build 254. Build 162 works fine.
*[http://bitchin100.com/wiki/index.php?title=LaddieCon#LaddieAlpha LaddieAlpha]
*[http://bitchin100.com/wiki/index.php?title=LaddieCon#LaddieAlpha LaddieAlpha]
The rex firmware updater needs a TPDD server. dlplus and mComm above are both tpdd servers, which come with tpdd client installers, and previously you used to be able to just use those for the tpdd server as well. But there is a bug in the latest REX build 254 files, such that it only works (reliably) with LaddieAlpha as the TPDD server. But LaddieAlpha does not come with any dos installer, and so right now it's a bit inconvenient. You have to get one of the above packages just to use it's dos installer, and then you have to get LaddieAlpha also and use it for the rest of the rex setup process.
:The rex firmware updater needs a TPDD server.
:dl2 and mComm above are both tpdd servers, which come with tpdd client installers, and previously you used to be able to just use one of those packages for everything.
:But there is a bug in the latest REX build 254 files, such that it only works (reliably) with LaddieAlpha as the TPDD server.
:But LaddieAlpha does not come with any dos installer.
:So, right now it's a bit inconvenient. You have to get one of the above packages just to use it's dos installer, and then you have to get LaddieAlpha also, and use it for the rest of the rex setup process.
-->
 
*[http://www.club100.org/memfiles/index.php?action=downloadfile&filename=rex_0110_April24%202011_no%20RST.jed&directory=Steve%20Adolph/REX/info& REX1 CPLD Jedec file]
 
*[http://bitchin100.com/wiki/index.php?title=REX REX1 firmware]
:Start there, and follow the links to whatever is the latest "REX Release x.x Rebuild Package" zip file.


=Directons=
=Procedure=
==Prep the Bare PCB==
==Prep the Bare PCB==
Lay a piece of medium grit (100-200) sandpaper face up on a hard flat surface like a cutting board.
Lay a piece of medium grit (100-200) sandpaper face up on a hard flat surface like a cutting board.
Line 103: Line 156:


:U1 = XCR3064XL
:U1 = XCR3064XL
:U2 = 29F800 (on the back side)
:U2 = 29F800
:U3 = LP2980
:U3 = LP2980-3.3
:R1 = 10K ohm
:R1 = 10K
:C1 = 1.0 uF
:C1 = 1uF
:TP1 & TP2 = right-angle pin (optional)
:TP1 & TP2 = right-angle pin (optional)


Line 113: Line 166:
Another example: https://youtu.be/09qb0KY_IF4
Another example: https://youtu.be/09qb0KY_IF4


The TP1 and TP2 pins are only needed if you think you will ever perform the hardware modification required to use the [http://bitchin100.com/wiki/index.php?title=Main_ROM_Management_Feature main rom management feature].
The TP1 and TP2 pins are only needed if you think you will ever perform the hardware modification required to use the [http://bitchin100.com/wiki/index.php?title=Main_ROM_Management_Feature main rom management feature]. See [[FlexROM_100]] or [[FlexROM_102]] to facilitate this.
<br clear=all>
<br clear=all>
<!--
===NEC===
For the NEC version, do the DIP legs the same way as [[FlexROM_100]].
:Cut 2 strips of 14 pins each
:Cut the top (larger end) off of all the pins using ordinary scissors, leaving a simple "comb" of pins.
:Insert the "comb" into the top of the pcb and poke the legs down through about 1/2 way. The frame holding all the pins together should be on the top side of the pcb, 2-3mm above the pcb. The legs sticking out the bottom of the pcb should be 4 to 6 mm long.
:Adjust the leg on one end of the row and solder that leg.
:Adjust the leg on the opposite end of the row so the row is even, and solder that leg.
:Solder all remaining legs.
:Examine the legs for excess solder on the bottom of the pcb and along the length of the legs. If there is any solder built up on the legs, use flux and solder wick to remove it.
:When you are sure the legs are all good, use flush cutters and cut the top of each leg off flush with the top of the pcb.
[[File:FlexROM_100-12.jpg|thumb]]
<br clear=all>
-->


==Clean the Finished PCB==
==Clean the Finished PCB==
Even "No-Clean" flux should still be removed as much as possible after soldering. But without an ultrasonic cleaner, it is just about impossible to get the flux cleaned out from under the chips. So, using no-clean just means the flux that inevitably isn't removed, won't be too harmful. Use 99% isopropyl alcohol and a small paint brush to wash the flux off.
Even "No-Clean" flux should still be removed as much as possible after soldering.
 
The best is to use an ultrasonic cleaner and saponifying pcb cleaning solution.
 
If you don't have that, then at least make sure your flux and solder are both "no-clean", and then use 99% isopropyl alcohol and a brush. This will still leave flux trapped under the chips no matter how much you soak it or wash it, but for no-clean flux it's not ideal but ok.


==Program the CPLD==
==Program the CPLD==
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</gallery>
</gallery>


*[https://drive.google.com/open?id=10KIFE5Zo7FUw-gWCkEibTjgq-EmEbtgugif0lVh8Q2I Use iMPACT to program the .jed file]
*[https://docs.google.com/document/d/10KIFE5Zo7FUw-gWCkEibTjgq-EmEbtgugif0lVh8Q2I/edit?usp=sharing Use iMPACT to program the .jed file]


==Snap the PCB Into the Carrier==
==Snap the PCB Into the Carrier==
Place the end of the PCB without the hole into the carrier first, then snap the rest of it in.
<gallery>
<gallery>
Rex in carrier start.jpg
REX_and_carrier.jpg
Carrier finish.jpg
REX_in_carrier.jpg
</gallery>
</gallery>


==Flash the Firmware==
==Flash the Firmware==
Install the REX into a Model 100, 102, or 200.
Follow the REX 4.9 update directions to load the firmware onto the REX.<br>
The original directions for that are here: [http://bitchin100.com/wiki/index.php?title=REX_Release_4.9 4.9 update directions].
 
Here are explicit/literal example directions to do that using [https://github.com/bkw777/dl2 dl2] on a Mac, Linux, FreeBSD, or other unix pc.<br>
 
(For Windows: instead of dl2,
:Download & unzip the various files manually with a browser instead of cutting & pasting the wget & unzip commands.
:use [https://github.com/bkw777/tsend tsend.ps1] for the bootstrap in place of "dl -v -b FILE.100"
:use [http://bitchin100.com/wiki/index.php?title=LaddieCon#LaddieAlpha LaddieAlpha] for the TPDD server in place of "dl -v -u")
 
Back up any files off of M100. M100 will be wiped.
 
Cold reset the M100  (ctrl+pause+reset)
 
Power off the M100
 
Install the REX in the M100's Option ROM socket
 
Connect the [[Model_T_Serial_Cable|serial cable]] between M100 and PC
 
Power on the M100
 
'''Install dl2 on a PC:'''<br>
On the PC, in a terminal window.
$ git clone git@github.com:bkw777/dl2.git
$ cd dl2
$ make all && sudo make install
 
'''Install TEENY onto the M100:'''<br>
On the PC:
$ dl -vb TEENY.100
 
Follow the prompts on the PC and on the M100 screen...
 
On the M100:
:BASIC
RUN "COM:98N1ENN"
 
On the PC:
:Enter
:wait...
 
On the M100:
:Enter
NEW
?HIMEM:CALL9643
:Look at the <code>Top: #####</code> number.
:A 32k machine should say 62213.
:Yours may say something else.
: Use that number in the following CLEAR command.
CLEAR 0,62213
MENU
 
On the PC:
:Enter
:should be back at a shell prompt now


Follow the [http://bitchin100.com/wiki/index.php?title=REX_Release_4.9 4.9 update directions] to load the firmware.
<!--
<!--
[http://www.club100.org/memfiles/index.php?&direction=0&order=&directory=Steve%20Adolph/REX%204.9%20Beta 4.9 update files]
There is a timing/race-condition bug in the TPDD routines in the REX flasher util, in versions after 4.9 build 162, whereby it doesn't work reliably with all TPDD emulators on all host machines. In fact, it also does not work with a real TPDD drive.
 
Steve has admitted that he only tests against LaddieAlpha himself, and so that is the only TPDD server that is garanteed to work (or rather, it's the only one he's likely to care about any bug reports). This is unfortunate, because for instance it complcates bootstrapping directions like these, because LaddieAlpha does not include any DOS bootstrapper. So you have to use dl2 or mComm to get TEENY or TS-DOS installed, and then use LaddieAlpha just for RF*49.CO
 
MOST of the time, any TPDD server will actually work fine as long as the host machine isn't slow. But I have an old pentium-m laptop runing ubuntu 18.04 that would not work with anything but LaddieAlpha. dl2 actually worked fine for everything else, it's only RF149.CO that didn't work, and only versions after build 162.
 
So, for simplicity I'll use dl2 in the visible directions below, but for reference, here are directions to use LaddieAlpha for this stage.
 
$ mkdir LaddieAlpha
$ cd LaddieAlpha
$ sudo apt install mono-complete
$ wget http://bitchin100.com/files/linux/LaddieAlpha.EXE
$ wget http://bitchin100.com/wiki/images/3/38/R49_M100T102_260_rebuild.zip
$ wget http://bitchin100.com/wiki/images/6/63/M100_OPTION_ROMS.zip
$ unzip R49_M100T102_260_rebuild.zip
$ unzip M100_OPTION_ROMS.zip
$ mono ./LaddieAlpha.EXE /dev/ttyUSB0 6
-->
-->


The directions for the 4.9 update state that you use any tpdd device to serve the 3 files to the M100/T102/T200, but in fact at least at present, it does not work with actual tpdd1 or tpdd2 drives at all, and is not reliable with just any tpdd server either. You must use specifically [http://bitchin100.com/wiki/index.php?title=LaddieCon#LaddieAlpha LaddieAlpha].
'''Download the REX Classic setup files'''
$ mkdir rex_setup
$ cd rex_setup
$ wget http://bitchin100.com/wiki/images/3/38/R49_M100T102_260_rebuild.zip
$ wget http://bitchin100.com/wiki/images/6/63/M100_OPTION_ROMS.zip
$ unzip R49_M100T102_260_rebuild.zip
$ unzip M100_OPTION_ROMS.zip
 
'''Use dl2 to start a TPDD server'''
$ dl -vu
 
'''Copy RF149.CO to the M100, then run it.'''<br>
On the M100:
:should be at menu
:TEENY.CO
> L RF149.CO
> Q
:should be at menu
:BASIC
CLEAR 0,55000
MENU
:should be at menu
:run RF149.CO
:Answer Y
:Wait...
:should be at menu
 
'''Reset the M100 to clear out TEENY and RF149.CO'''
:ctrl+pause+reset
:should be at menu, ram wiped
 
The flash memory on the REX is now formatted and loaded with REXMGR and a TS-DOS option rom image.
 
'''Install REXMGR from the REX itself'''
:BASIC
CALL 63012
 
:should be at menu, REXMGR should appear in menu
 
REX is now ready to use, and empty except for TS-DOS.


TODO: Document this more fully, but here is a bullet list.
'''Now install an option ROM image. Example: Ultimate Rom II'''
:REXMGR
:press TAB once
:screen should say "TS-DOS* ------"
:press right-arrow once, highlight should move to "------"
:press F2
Loading from image filename: UR2100
Hit any key when TPDD ready.
Loading 0:UR2100.BX    ####
:now it should say "TS-DOS* UR2100 ------"


*Get a proper [[Model_100_102_200_600_Serial_Cable|serial cable]]
UR2 is now loaded into REX, but not currently selected/active, TS-DOS is.<br>
*Install a TPDD client on the M100/T102/T200: Any, teeny, floppy, ts-dos. If you don't have anything already, then get the "dlplus" zip file and run the teeny installer that comes with it.
What this means is, If you were to go back to BASIC and run <code>CALL 63012</code> right now, it would load TS-DOS, as if you had a TS-DOS option rom in the option rom socket.<br>
*Get LaddieAlpha onto a PC.
To run UR2, you have to select it in REXMGR first.
*Get the 3 update files.
*Run LaddieAlpha in the dir with the 3 update files.
*Use whatever TPDD client you installed on the M100 to copy rf149.co to the M100.
*Run rf149.co on the M100.


Until this part of the directions is improved, there are several pictures of the full process here: https://photos.app.goo.gl/aNfjvB1XucSehPGB9
:right-arrow to highlight UR2100
:press enter
:Y
 
UR2 is now the active option rom image. Additionally, the equivalent of <code>CALL 63012</code> was already done for you by REXMGR just as a convenience to skip a step.
 
F8 back to menu.
 
Leave dl2 running on PC while you load more rom images.
 
Ctrl+C to exit dl2 when you're done with it.


=Done!=
=Done!=
That was the last step. You're done! Consult the [http://bitchin100.com/wiki/index.php?title=Special%3ASearch&search=rex&fulltext=Search REX docs] to start using it!
That was the last step. You're done! Consult the [http://bitchin100.com/wiki/index.php?title=Special%3ASearch&search=rex&fulltext=Search REX docs] to start using it!
=Main ROM Management=
[http://bitchin100.com/wiki/index.php?title=Main_ROM_Management_Feature Main ROM Management]
*For 100, see [[FlexROM_100]]
*For 102, see [[FlexROM_102]]
*For 200, no FlexROM for 200 yet. See the regular REX docs.
<!--
*For NEC, you can use FlexROM_102 in NEC, but there is almost no reason to. The main advantage to FlexROM is the ability to deactivate/re-activate an internal main rom without taking the computer apart. In the NEC, the main rom socket is accessible, so you can just pop the standard main rom back in any time you need to.
-->


=References=
=References=
[https://photos.app.goo.gl/aNfjvB1XucSehPGB9 Version c6 pcb, pcb is obsolete, but has pics of the Firmware flash process]
[https://github.com/bkw777/REX_Classic KiCAD source files for the PCB]


[https://photos.app.goo.gl/EzncfFFAvmRmq5Mt6 Version c8 pcb, more pics of building the current version]
[https://github.com/bkw777/Molex78802_Module OpenSCAD source files for the carrier]


[http://bitchin100.com/wiki/index.php?title=REX User Manual]
[https://photos.app.goo.gl/aNfjvB1XucSehPGB9 Version c6 pcb] This version of the pcb is obsolete, but has pics of the firmware flashing process.


[http://www.club100.org/memfiles/index.php?PHPSESSID=0iltg2un40287et7flm4m54387&direction=0&order=&directory=Steve%20Adolph Original sources and support files]
[https://photos.app.goo.gl/EzncfFFAvmRmq5Mt6 Version c8 pcb] This version is also now obsolete, but the only difference is the pcb dimensions and matching carrier.


[https://drive.google.com/open?id=0Bys6eLbSbYyhV3NEdjhvWFlYMDg Copies of some of the sources and support files, and new sources for some things modified from the originals]
[http://bitchin100.com/wiki/index.php?title=REX User Manual]


[http://www.club100.org/memfiles/index.php?PHPSESSID=0iltg2un40287et7flm4m54387&direction=0&order=&directory=Steve%20Adolph Original sources and support files from Steven Adolph]


<!-- [https://github.com/aljex/REX1 pcb on github] -->
[https://drive.google.com/drive/folders/0Bys6eLbSbYyhV3NEdjhvWFlYMDg?resourcekey=0-MKkAnbTYHoSeNHfjYqjsIQ&usp=sharing Backup copies of some of the sources and support files]

Latest revision as of 03:24, 13 November 2023

Introduction

Building a REX

This is a version of Steven Adolph's REX Classic with a modified PCB design.
It is electrically identical to REX Classic, and uses the REX Classic firmware & software.

The PCB layout and shape are modified to:

  • snap into a 3d-printed carrier to fit the Molex78805 socket
  • provide connections for power and PORT_EN for programming the CPLD

Original version of this page, for building the original REX1

PCB Source
Carrier Source

Parts & Materials

Note if ordering from PCBWAY: On the order page, you may have to manually change "Min tracks/spaces" to "6/6mil"
All tracks & spaces are well over 6 mil (everything is 0.2mm which is almost 8 mil), and that setting drops the price from $50 to $5

ENIG adds a lot of cost on PCBWAY and JLCPCB lately.
Currently the cheapest way to get an ENIG version for gold contacts (other than OSHPark) is Elecrow.
Upload the gerber zip from the releases, and manually select ENIG and Castellated Holes, and just use the cheapest shipping.


Other Compatible Flash Chips and how to identify them

Tools

Cheap Chinese clone is fine.
Look at the pictures for ones that say model DLC9G, or DLC9LP. Don't put "DLC9G" or "DLC9LP" in the search, you will only get the overpriced ones.
Get one that includes a "flying leads" cable, with separate loose individual wires on one end.
A cheap usb-ttl cable is perfect. It's cheap, and already ends in loose wires with female dupont pins.
Just use the red and black wires and ignore the rest.
  • PC with at least one usb port, and a COM port or usb-serial adapter.
  • Sandpaper, medium grit (120 or so), and a hard flat surface like a cutting board.
Do not necessarily need anything fancy. I actually used this exact one to build a few REXs, although now I use a Hakko FX-888D with a T18-C2 tip.
Or the strongest reading glasses you can get at a local drug store. 3.00x or higher.
0.1" (2.54mm) pitch single row male pin header
1x6
1x4
one shunt


  • A Tandy Model 100, 102, or 200.

Software

  • Xilinx ISE 14.7 Lab Tools
Lab Tools is a subset of ISE. You can use either ISE or Lab Tools, but you only need Lab Tools to program the REX.
This software is old and needs special futzing to make it work, no matter what OS you are using.
Installing on Ubuntu Linux
Installing on Windows.
There are several tpdd clients, and several ways to get one installed. These are a few options:
For Mac, Linux, FreeBSD, any other unix: Get dl2 and use the bootstrap option to install TEENY.100 or any of the other options listed by "$ dl -l"
For Windows: Get tsend.ps1 and use it to install TEENY.100 or any of the clients found at https://github.com/bkw777/dl2/tree/master/clients
Play File:DOS100.CO.MP3 into the cassette port to install TS-DOS. (SOUND OFF:CLEAR 0,57089:RUNM "CAS:DOS100.CO")
Get a real tpdd and bootstrap it's utility disk to install "Floppy".
For Mac, Linux, FreeBSD, any unix: dl2
For Windows: LaddieAlpha
Start there, and follow the links to whatever is the latest "REX Release x.x Rebuild Package" zip file.

Procedure

Prep the Bare PCB

Lay a piece of medium grit (100-200) sandpaper face up on a hard flat surface like a cutting board.

Sand the edges of the PCB on the sandpaper just enough to clean off the panelization break-away points.

Use magnification to look closely at the castellated edge contacts for copper or gold "flags" hanging on the edge of most contacts. Scrape them off with an xacto knife.

Solder the Electronic Components

Solder these parts onto the matching labeled locations on the pcb.

U1 = XCR3064XL
U2 = 29F800
U3 = LP2980-3.3
R1 = 10K
C1 = 1uF
TP1 & TP2 = right-angle pin (optional)

Don't be too intimidated by the tiny legs on that TSOP-48 chip.
Just use magnifying glasses, lots of flux, and the DRAG TECHNIQUE.
Another example: https://youtu.be/09qb0KY_IF4

The TP1 and TP2 pins are only needed if you think you will ever perform the hardware modification required to use the main rom management feature. See FlexROM_100 or FlexROM_102 to facilitate this.

Clean the Finished PCB

Even "No-Clean" flux should still be removed as much as possible after soldering.

The best is to use an ultrasonic cleaner and saponifying pcb cleaning solution.

If you don't have that, then at least make sure your flux and solder are both "no-clean", and then use 99% isopropyl alcohol and a brush. This will still leave flux trapped under the chips no matter how much you soak it or wash it, but for no-clean flux it's not ideal but ok.

Program the CPLD

Now we need to flash the CPLD (Xilinx) with the .jed file. This configures the blank CPLD into a functional circuit that actually does something.

  • Get the .jed file from here.
  • Connect the jtag, 5vdc, and PORT_EN jumper.

Snap the PCB Into the Carrier

Flash the Firmware

Follow the REX 4.9 update directions to load the firmware onto the REX.
The original directions for that are here: 4.9 update directions.

Here are explicit/literal example directions to do that using dl2 on a Mac, Linux, FreeBSD, or other unix pc.

(For Windows: instead of dl2,

Download & unzip the various files manually with a browser instead of cutting & pasting the wget & unzip commands.
use tsend.ps1 for the bootstrap in place of "dl -v -b FILE.100"
use LaddieAlpha for the TPDD server in place of "dl -v -u")

Back up any files off of M100. M100 will be wiped.

Cold reset the M100 (ctrl+pause+reset)

Power off the M100

Install the REX in the M100's Option ROM socket

Connect the serial cable between M100 and PC

Power on the M100

Install dl2 on a PC:
On the PC, in a terminal window.

$ git clone git@github.com:bkw777/dl2.git
$ cd dl2
$ make all && sudo make install

Install TEENY onto the M100:
On the PC:

$ dl -vb TEENY.100

Follow the prompts on the PC and on the M100 screen...

On the M100:

BASIC
RUN "COM:98N1ENN"

On the PC:

Enter
wait...

On the M100:

Enter
NEW
?HIMEM:CALL9643
Look at the Top: ##### number.
A 32k machine should say 62213.
Yours may say something else.
Use that number in the following CLEAR command.
CLEAR 0,62213
MENU

On the PC:

Enter
should be back at a shell prompt now


Download the REX Classic setup files

$ mkdir rex_setup
$ cd rex_setup
$ wget http://bitchin100.com/wiki/images/3/38/R49_M100T102_260_rebuild.zip
$ wget http://bitchin100.com/wiki/images/6/63/M100_OPTION_ROMS.zip
$ unzip R49_M100T102_260_rebuild.zip
$ unzip M100_OPTION_ROMS.zip

Use dl2 to start a TPDD server

$ dl -vu

Copy RF149.CO to the M100, then run it.
On the M100:

should be at menu
TEENY.CO
> L RF149.CO
> Q
should be at menu
BASIC
CLEAR 0,55000
MENU
should be at menu
run RF149.CO
Answer Y
Wait...
should be at menu

Reset the M100 to clear out TEENY and RF149.CO

ctrl+pause+reset
should be at menu, ram wiped

The flash memory on the REX is now formatted and loaded with REXMGR and a TS-DOS option rom image.

Install REXMGR from the REX itself

BASIC
CALL 63012
should be at menu, REXMGR should appear in menu

REX is now ready to use, and empty except for TS-DOS.

Now install an option ROM image. Example: Ultimate Rom II

REXMGR
press TAB once
screen should say "TS-DOS* ------"
press right-arrow once, highlight should move to "------"
press F2
Loading from image filename: UR2100
Hit any key when TPDD ready.
Loading 0:UR2100.BX     ####
now it should say "TS-DOS* UR2100 ------"

UR2 is now loaded into REX, but not currently selected/active, TS-DOS is.
What this means is, If you were to go back to BASIC and run CALL 63012 right now, it would load TS-DOS, as if you had a TS-DOS option rom in the option rom socket.
To run UR2, you have to select it in REXMGR first.

right-arrow to highlight UR2100
press enter
Y

UR2 is now the active option rom image. Additionally, the equivalent of CALL 63012 was already done for you by REXMGR just as a convenience to skip a step.

F8 back to menu.

Leave dl2 running on PC while you load more rom images.

Ctrl+C to exit dl2 when you're done with it.

Done!

That was the last step. You're done! Consult the REX docs to start using it!

Main ROM Management

Main ROM Management

References

KiCAD source files for the PCB

OpenSCAD source files for the carrier

Version c6 pcb This version of the pcb is obsolete, but has pics of the firmware flashing process.

Version c8 pcb This version is also now obsolete, but the only difference is the pcb dimensions and matching carrier.

User Manual

Original sources and support files from Steven Adolph

Backup copies of some of the sources and support files