Z3 Technology Z3-DM8168-DVR-RPS User manual

User Instructions
Multi-Channel H.264 HD Multimedia System
DM8168-DVR Rapid Prototyping System
Model Name: Z3-DM8168-DVR-RPS
DOC-USR-0014-03
Manual Version 1.0.5
Software Version 0.0.1
July 16, 2015
Before attempting to connect or operate this product, please read these instructions carefully and save the manual for future use.
® Z3 Technology, LLC. All rights reserved. This document contains proprietary and confidential information of Z3 Technology, LLC ("Z3"). This
document may not be used, reproduced, disclosed, or disseminated to anyone without the prior written approval of an authorized representative
of Z3.

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Revision History
Version
Date
Change Note
Author
1.0.0
2/27/13
Original DM8168-DVR System
PS
1.0.1
2/28/13
Formatting & Review
MC
1.0.2
3/1/13
Minor Updates
PS
1.0.3
5/2/13
Cleanup
NB
1.0.4
6/26/13
Corrections by NB and RC
MC
1.0.5
7/16/15
Added SATA2 note. Updated formatting
KA

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TABLE OF CONTENTS
1.0 GENERAL DESCRIPTION.................................................................................................4
2.0 FEATURES ................................................................................................................5
2.1 Supported Input Resolutions .......................................................................................5
3.0 APPLICATIONS ...........................................................................................................6
4.0 THERMAL CONSIDERATIONS............................................................................................7
5.0 SERIAL INTERFACE CONTROL ..........................................................................................8
5.1 Serial Connection to PC.............................................................................................8
5.2 Main Menu ............................................................................................................8
6.0 USING THE Z3-DM8168-DVR-RPS ......................................................................................9
7.0 INSTALLING RELEASED MATERIALS .................................................................................. 11
7.1 Building the Code.................................................................................................. 11
8.0 CONFIGURING THE TARGET FOR YOUR OWN DEVELOPMENT ENVIRONMENT.................................. 12
8.1 U-boot Startup Scripts ............................................................................................ 13
8.2 U-boot Update Scripts ............................................................................................ 13
9.0 BUILDING THE CODE.................................................................................................. 14
10.0 UBIFS .................................................................................................................. 16
11.0 DEPENDENCIES ....................................................................................................... 17
12.0 NAND RECOVERY PROCEDURE...................................................................................... 18
12.1 Purpose ............................................................................................................ 18
12.2 General Description.............................................................................................. 18
12.3 Overview of the Process......................................................................................... 18
12.4 Reloading the Flash .............................................................................................. 20
12.5 Flash Programming Setup ....................................................................................... 20
12.6 Test and Programming Setup.................................................................................... 21
12.7 Log of Successful Flash Programming.......................................................................... 22
13.0 TROUBLESHOOTING ................................................................................................. 26

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GENERAL DESCRIPTION
The Z3-DM8168-DVR-RPS development system consists of both hardware and software. The hardware
provided includes one Z3-DM816x-MOD system on module card and an example carrier or application
board, the Z3-DM8168-APP-11, which provides advanced video input capabilities with 16 channels of
composite inputs. The bundled software includes all necessary components for the user to develop their
own advanced multimedia, graphics and/or DSP applications.
Measuring 88 x 108 mm, the Z3-DM816x-MOD is a compact OEM module, supporting encode and stream,
decode from stream or store in applications such as real time transcoding, broadcast video encoding and
decoding, digital signage and video kiosks, medical and industrial video, video conference terminal and
MCU and high definition embedded video sub-systems. The Z3-DM816x-MOD features a unique expansion
interface comprised of five high density connectors providing access to the greatest majority of interface
signals available from the DM8168 processor. Figure 1 below shows the Z3-DM8168-DVR-RPS.
An example application board, Z3-DM8168-APP-11, is available from Z3 Technology and is included with
the Z3-DM8168-DVR-RPS system.This application board uses the I/O expansion capability of the Z3-
DM816x-MODto implement additional functions not present in the base module. The Z3-DM8168-APP-11
application board has two 16-channel DB25 inputs (J6 = video/BNC, J7 = audio/RCA), one DB9 serial
output, one HDMI output, and one SD card slot.
A Linux-based media SDK license, additional design services and support are available from Z3 Technology.
Please contact Z3 at http://www.z3technology.com or e-mail at [e-mail].
*Note: Z3 does not warrant modules that are operated outside the specified scope of operation per Texas
Instruments datasheets or errata for the DM816x processors. This includes but is not limited to the SATA2
interface. Per specifications from Texas Instruments, only SATA2 drives are supported.
Figure 1 Z3-DM816x-MOD

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FEATURES
High Density connectors to interface to all signals
Supports output of video and audio at up to 1080p60 resolution
1024MB DDR3 (MOD-2X) or 512MB DDR3 (MOD-0X)
256MB NAND Flash
16-channel Composite video input
RJ45 jack from on-module PHY, supporting 1GB Ethernet
Dual SATA interface supporting 3Gbps drives
Dual USB 2.0 type A (host) jacks
RS232 serial console port
JTAG debug port
2.1 Supported Input Resolutions
Composite: 16 channels of D1 NTSC

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APPLICATIONS
The Z3-DM816x-MOD is designed to facilitate the implementation of video and audio functions on media-
embedded applications such as broadcast video encoding and decoding, real time transcoding at 1080p60,
video security and industrial DVR, medical and industrial video and video conferencing terminal and MCU.
Its versatile design allows the system designer to focus on the end application, with confidence that the
Z3-DM816x-MOD will handle all audio and video media operations required with little or no additional
engineering effort.
Whether the end application requires encode or decode media from storage or streaming, the readily
available, production-ready Z3-DM816x-MOD will simplify the overall system design, reducing time to
market and costs.

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THERMAL CONSIDERATIONS
The main processor on the Z3-DM816x-MOD generates a large amount of heat, and is cooled by a fan heat
sink type cooler. The heat sink may reach temperatures in excess of 75°C during work. Please make sure
that the airflow for the heat sink is free and unimpeded at all times. Hot air must have a place to escape
to allow for room air to be used to cool the chip. Failure to cool the processor may result in permanent
damage to the processor.
The maximum continuous power consumption by the whole DM8168-MOD system during normal operation
should be less than 18W, with up to 12W dissipated by the main processor. Please plan the cooling strategy
appropriately.

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SERIAL INTERFACE CONTROL
5.1 Serial Connection to PC
(1) Plug-in a supplied serial cable from the Z3-DM816x-MOD to your PC
(2) Set up Teraterm on the PC for 115k, 8, N, 1, N, 1ms/char, 50ms/line
(3) Connect to the proper COM port
(4) Connect the supplied 12V power to the Z3-DM816x-MOD
(5) Power-on the Z3-DM816x-MOD
(6) Power-on the Z3-DM8168-APP-11
(7) Output should come immediately to the Teraterm console
5.2 Main Menu
Z3 Technology, LLC DM8168-MOD v1.00.01
H.264 multichannel demo
+==============================================================+
| Current |
| P - Change local IP address 192.168.0.81
| N - Change netmask 255.255.0.0
| G - Change default gateway 192.168.0.1
|
| N - Number of Channels 16
|
| 1 - Change H.264 channel config
| URL: rtp://225.1.2.3:5004
| VBRATE: 2000000
| VFRATE: 30
| VDELAY: 2000
|
|
+--------------------------------------------------------------+
| S - Start streaming |
| W - Write configuration to flash |
| X - eXit to prompt |
+==============================================================+

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USING THE Z3-DM8168-DVR-RPS
The software demo can support inputs from 16 independent composite video sources. The connections are
labeled below.
The Z3-DM8168-APP-11 can support 16 simultaneous video inputs on J6.
The Z3-DM8168-DVR-RPS can be controlled via the serial port.
(1) Plug in the supplied serial cable and NULL modem adaptor from Z3-DM816x-MOD to PC’s COM port.
(2) Setup teraterm on PC for 115k, 8, N, 1, 0ms/char, 100ms/line.
(3) Connect the other end of the serial cable to the console port on Z3-DM816x-MOD board.
The console port is the 2.5mm jack next to the power switch.
(4) Connect power supply to Z3-DM816x-MOD.
(5) Power on Z3-DM816x-MOD.
(6) Power on Z3-DM8168-APP-11.
(7) Connect HDMI out of Z3-DM8168-APP-11 to HDMI in of TV.
(8) Connect composite video sources to DB25 cable connected to J6 on Z3-DM8168-APP-11.
(9) Connect audio sources to DB25 cable connected to J7 on Z3-DM8168-APP-11.
(10) Open up a serial console window.
Audio
Video Port
Figure 2 Z3-DM8168-DVR-RPS Connections

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(11) After booting up and running through the beginning of the sequence, a menu will appear. You will
have the option to manually change the behavior of the system. Below is a screenshot of a
terminal console of the system with the default prompt. Use the computer keyboard to operate
the Z3-DM8168-DVR-RPS.
Z3 Technology, LLC DM8168-MOD v1.00.01
H.264 multichannel demo
+==============================================================+
| Current |
| P - Change local IP address 192.168.0.81
| N - Change netmask 255.255.0.0
| G - Change default gateway 192.168.0.1
|
| N - Number of Channels 16
|
| 1 - Change H.264 channel config
| URL: rtp://225.1.2.3:5004
| VBRATE: 2000000
| VFRATE: 30
| VDELAY: 2000
|
|
+--------------------------------------------------------------+
| S - Start streaming |
| W - Write configuration to flash |
| X - eXit to prompt |
+==============================================================+
(12) Press “S” to start the demo.
You can change the parameters by pressing 1 and then paging through the parameters as they are
presented. You can select a file-based url if you want to save the stream to file. A valid file url is
“file://path/file” or just “path/file”. For example, to save to a USB drive, you might select
“file:///media/sda1/video” or “/media/sda1/video”. The framework will append a channel
number and extension on each file created. One file is created for each channel.

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INSTALLING RELEASED MATERIALS
The software provided will allow you to re-create the pre-installed software of the DM8168-MOD starting
from the source code included.
On a PC running Linux, create a directory where the released materials are going to be located,
such as /home/z3/z3-netra:
# mkdir /home/z3/z3-netra
Copy the released tar archive to that directory.
# cp z3-dm8168-version.tar.bz2/home/z3/z3-netra
Untar the archive
# tar -xjf z3-dm8168-version.tar.bz2
A directory with the release name and a set of sub-directories should have been created as follows:
z3-dm8168-version/
build-tools
Contains some scripts that simplify the setup
filesys
Contains the root file system for the DM8168 target
kernels
The kernel source tree, w/ added support for the Z3-DM8168-MOD HW
images
Binary images needed by the target
toolchain
ARM compilers, binutils and other build tools
u-boot
The u-boot source tree, with support for the Z3-DM8168-MOD HW
z3apps
Optional software licensed by Z3 Technology
7.1 Building the Code
Follow the directions in Section 0. When the build completes successfully, an “images” directory will be
created at the project level. All images and executables will be located in the "images" directory, ready
to be transferred to the target.

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CONFIGURING THE TARGET FOR YOUR OWN DEVELOPMENT ENVIRONMENT
The best way to develop for the Z3-DM8168-DVR-RPS system is to use the HDD of a Linux PC to serve as the
root file system for the target. It is also productive to allow the DM8168 system to fetch the Linux kernel
from the PC using the network, so all the software that is being run by the DM8168 is in effect coming from
the PC. To accomplish this, follow the steps below.
(1) Run a TFTP server on the Linux PC. The target system will need to access files from the "images"
directory via TFTP. Depending on your Linux distribution you will need to download and set up the
server.
(2) The DM8168 module is pre-setup so that it will TFTP from the path "z3/z3-netra/images". This path
is defined in the target by the u-boot environment variable "tftp_root".
(3) Enable NFS on the Linux PC. The target DM8168 will need to mount the root file system using NFS.
Usually it is sufficient to add the desired path in the /etc/exports file, and restart the NFS service
(as root) with:
# service nfs restart
(4) Copy the file .../u-boot/u-boot-env-netra.txt to the Windows PC running Teraterm. Edit the file and
change the following variables to match your own system and network. Note: Use a Windows
editor; it is important to Teraterm to have CR-LF instead of just LF.
setenv ipaddr 192.168.0.56
IP address of the target system
setenv gatewayip 192.168.0.1
Usually the router in your network
setenv netmask 255.255.0.0
As per your network parameters
setenv serverip 192.168.0.6
The computer with the TFTP server
setenv tftp_root z3/z3-netra/images
Loc of the images folder in TFTP space
setenv nfs_root /home/z3/z3-netra/filesys/fs
Loc of the root file system
(5) Reboot the DM8168-MOD and press the space bar to make it stop in the u-boot prompt.
Make sure that your terminal is pausing for 120ms or more at the end of each line. This is
important because the serial port does not have hardware flow control.
(6) Go into the Teraterm "Setup" menu, select "Serial port...".
Set the "Baud rate" to 115200, "Data" to 8 bit, "Parity" to none, 1 stop bit and flow control to
"none." At "Transmit delay", enter 120 in the box next to "msec/line", then click OK.
(7) Now upload the new environment variables to the board.
In Teraterm, go to the "File" menu and click on "Send file...". Select the file with the variables
that was just edited.

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(8) When you get the u-boot prompt again, enter the commands below. This will enable mounting the
rootfs using NFS and booting the kernel by TFTP.
Z3-DM8168-MOD# setenv bootcmd run boot-nfs
Z3-DM8168-MOD# saveenv
(9) Make sure that the DM8168 is connected to your network and power cycle.
If all went well, the DM8168 system will boot the kernel obtained via TFTP from the Linux PC,
mount a root file system using NFS, and present a "#" prompt. If not, then troubleshoot the
connections, IP addresses and server settings. Look in the .../images directory and make sure
that the code is there. The root file system for the target will be at .../filesys/fs.
8.1 U-boot Startup Scripts
The following u-boot startup scripts are available. Each set up the u-boot variables for a specific
behavior. To make the settings permanent, run 'saveenv'.
setenv bootcmd run boot-nfs
Obtains root file system from NFS, kernel from TFTP
setenv bootcmd run nand_boot_nfs
Obtains root file system from NFS, kernel from NAND
setenv bootcmd run nand_boot_jffs2
Obtains root file system from NAND (JFFS2 format), kernel
from NAND
setenv bootcmd run nand_boot_ramdisk
Obtains root file system from ramdisk, kernel from NAND
setenv bootcmd run nand_boot_ubifs
Obtains root file system from NAND (UBIFS format), kernel
from NAND
8.2 U-boot Update Scripts
The following U-boot update scripts are available. These scripts just update the images - you must also
set the bootcmd above to use the proper image.
run update-uboot
Update U-Boot bootloader in NAND
run update-kernel
Update Linux kernel image
run update-env
Update U-Boot environment settings
run update-ramdisk
Update root filesystem ramdisk
run update-jffs2
Update jffs2 image (requires mtd-utils on host)
run update-ubifs
Update jffs2 image (requires ubi utils on host)

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BUILDING THE CODE
Instructions to setup and build the full code base for the Z3-DM8168-MOD.
You will need sudo privileges in order to build the code. Make sure that the user account you are working
from is in the /etc/sudoers file and that you have the password.
The various variables of the system are all set up by default as if you are using the user account "z3". If you
create a "z3" account and use it to build the code then you will be able to execute the results of your build
without changing paths in the target system or elsewhere. It is not necessary to do so, but starting at the
right place can shorten the startup time.
First create a work directory (if you have not already done so) and cd to it.
mkdir ~/z3-netra
cd ~/z3-netra
Place release tar file in new directory and untar archive.
cp /your_tar_file_location/z3-dm8168-version.tar.bz2
tar -xjf z3-dm8168-version.tar.bz2
Un-tarring the release should have created an intermediate directory with the release name (such as "z3-
dm8168-1.0.0-20110209"), please cd into it. In order to build the code, the current directory must contain
the project subdirectories "build-tools", "dvsdk", "kernels", "u-boot", etc.
Then run the following command to build the system executables.
./makeall.sh
Now all the executables are built and ready to run. All binaries and executables are in the images/
directory.

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The target board must be able to access the files placed in the “images” directory of the project. Since
the default u-boot variables point to /home/z3/z3-netra, it is just easier to make a symbolic link from
there to the project you are currently working on. If un-tar'ring the release created an intermediate
directory with the release name (such as "z3-dm8168-version”), then create symbolic links as shown below
so that the target default settings can find the images:
cd /home/z3/z3-netra
ln -s z3-dm8168-version/images images
ln -s z3-dm8168-version/filesys filesys
Make sure that the u-boot environment variables set on the target board match the locations of the
executables on your work directory and run the target board. By default, using the factory settings, the
target expects that the kernel image is available at z3/z3-netra/images/ (assuming that the root path set
at the TFTP server is /home) and that a root file system is available for mounting with NFS at
/home/z3/z3-netra/filesys/fs/.
It is important that you have the shell environment variables of the Linux PC you are working on set
correctly as set by the included batch file "z3-env". Every time you start a new shell you should set the
environment by running “source z3-env”. Among other things, this will set the environment variables
$PRJROOT and $ROOTFS to the appropriate paths.

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UBIFS
Follow this procedure to flash the development NFS root filesystem onto the target NAND using the UBIFS
filesystem format:
(1) Boot the board from NFS in U-Boot:
Z3-DM8168-MOD# run boot-nfs
(2) Erase partition
flash_eraseall /dev/mtd3 # Run this the first time
OR
ubiformat /dev/mtd3 # Run this to preserve wear-leveling data
(3) Attach UBI device
Ubiattach /dev/ubi_ctrl -m 3 -O 2048
(4) Create UBI volume named 'rootfs' on device ubi0
ubimkvol /dev/ubi0 -N rootfs -s 128MiB
(5) Mount clean copy of NFS root filesystem
mkdir /tmp/mynfsmnt
mount -o nolock 192.168.0.6:/home/z3/z3-netra/filesys/fs /tmp/mynfsmnt
(6) Mount UBIFS on empty filesystem
mkdir /mnt/ubifs
mount -t ubifs ubi0:rootfs /mnt/ubifs
(7) Copy all files from clean NFS mount to UBIFS
cp -a /tmp/mynfsmnt/* /mnt/ubifs/.
(8) Unmount filesystems
umount /mnt/ubifs
umount /tmp/mynfsmnt
Reboot the board and stop at the u-boot prompt. In U-Boot then enter the commands:
Z3-DM8168-MOD# setenv bootcmd run nand_boot_ubifs
Z3-DM8168-MOD# saveenv

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DEPENDENCIES
The build system counts on the availability of a few packages, all installed by default by most Linux
distributions. If the build aborts with an error then most likely your installation is lacking one or more of
these packages.
mtd-utils:
JFFS2 and UBI utilities.
For Ubuntu 10.x, use the following command to install the needed packages:
sudo apt-get install bison flex mtd-utils liblzo2-dev uuid-dev zlib1g-dev libpcre3-dev
For Fedora Core, use the following command to install the needed packages:
sudo yum install bison flex mtd-utils mtd-utils-ubi lzo-devel libuuid-devel pcre-devel

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NAND RECOVERY PROCEDURE
12.1 Purpose
This procedure is used to recover the Z3-DM816x-MOD-24 module using BOOTP. These procedures are
necessary in order to load the initial software into the Flash.
12.2 General Description
The Z3-DM816x-MOD is an original equipment manufacturer (OEM) ready module based on the
TMS320DM816x DaVinci™ video processor from Texas Instruments™. The Z3-DM816x-MOD features a
unique expansion interface comprised of five high density connectors providing access to the greatest
majority of interface signals available from the TMS320DM816x video processor.
12.3 Overview of the Process
All Z3-DM816x-MOD modules contain a NAND flash chip for storage of firmware and data, including
sections necessary for the board to boot. The Flash also stores the Linux kernel and filesystem. In order
to allow the module to boot, the Flash needs to contain at least the u-boot code and its environment
variables.
The Flash chip is initially blank. The various software components that are to be loaded into the flash
are stored in a server on the network. The module can be configured to boot from the network using
BOOTP protocol so that the initial load is provided from the server. This initial load will cause the
subsequent blocks of data to be loaded into the Flash. When the load process is complete a status
message will be printed to the console. If the software load was performed without errors, the message
will be “NAND update SUCCESS”.
After the flash content is successfully programmed, the manufacturing tests must be performed. When
the functional test completes without issues, the module will display a success message on the serial
console port.
Note that the same process can be used to recover a module that had the content of its Flash
compromised and no longer boots.
Once the flash is programmed, the module can be subject to further functional tests. Such tests can be
run from a USB memory stick plugged into one of the module’s USB ports or by connecting the
manufacturing jumper option.

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In summary, the following steps are used to program the Flash and verify the assembly process:
(1) Reconfigure jumpers on 1-2, 3-4, and 5-6 of jumper block J20.The factory default is 5-6, 9-10, and
15-16.
(2) Power up the system.
This will automatically start the Flash programming step procedure described in section 8.
Since the Flash is initially empty, the module retrieves its IPL code from the BOOTP server.
The IPL code runs and retrieves various other portions of software from the TFTP server.
(a) Get the file “u-boot-uartboot.bin.scr” from the server and write to Flash.
(b) Get the file “u-boot-env.scr'” from the server and write to Flash.
(c) Get the file “u-boot.bin.img” from the server and write to Flash.
(d) Get the file “uImage” from the server and write to Flash.
(e) Get the file “ubifs-image” from the server and write to Flash.
(3) Once all sections of the Flash are written successfully, a success message is displayed.
If the test succeeds, then proceed to the next step, otherwise troubleshoot.
(4) Turn power off.
(5) Next run the functional tests as described in section 7 below.
Insert the manufacturing jumper or use a pair of tweezers to place the board into manufacturing test
mode and turn power on again to start the functional tests.
When the jumper or tweezers is detected correctly, the message “Factory jumper detected." is
displayed. At this point you can remove the tweezers.
(6) The manufacturing functional verification tests will execute in an endless loop.
(7) If the test is successful, then remove the manufacturing jumper (if one was used) and the module is
good for shipping.
Otherwise, troubleshoot the module or the process.

CONFIDENTIAL DOC-USR-0014-03
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12.4 Reloading the Flash
Once the Flash is programmed, the module will no longer attempt to boot from the BOOTP server on
power on. Instead, it will boot much quicker from the internal Flash. The consequence is that the
module will no longer be able to re-flash itself by following the steps described above. There are two
possible methods to force the module to boot to the BOOTP server and therefore reload the Flash
contents.
(1) One method is to erase the contents of the Flash. Once the Flash is empty, the module will once
again try to boot from the BOOTP server. Erasing the Flash is possible if the module gets to the u-
boot prompt or pressing space during boot to force the module to stop at the u-boot prompt. Once
at the u-boot prompt, the command below will erase the Flash:
Z3-DM8168-MOD# nand erase
Once the Flash is erased, turn power off and on again to start the Flash procedure.
(2) Another method to force booting from the BOOTP server is to set the module boot jumpers to
default to a BOOTP boot. This is accomplished by placing jumper blocks on pins 1-2, 3-4 and 5-6 of
the J20 header. The board will boot from the BOOTP server and complete the flash procedure.
Once the Flash initialization is successful, the jumper blocks need to be returned to their default
positions on pins 5-6, 9-10 and 15-16 of the J20 header.
12.5 Flash Programming Setup
12.5.1 Procedure
To run the procedure and install the firmware in the flash; verify the test environment is setup and
the system is connected according to the instructions in section 14.6. Simply turn the power switch
to the “ON” position. In about 4 seconds, the initial BOOTP will complete and the programming
will start. The entire procedure is complete in about 40 seconds.