Help request! If any reader has experience taking a hobby-scale electronics project to an outside vendor for assembly, I’d love to hear from you. I’ve been talking with the fab in China that makes the Floppy Emu PCBs, and they can do the full assembly process for a reasonable price. That means making the PCBs, ordering all the components, and doing 95% of the assembly. I’ll add the DB-19 connector and LCD myself. But I’m stuck on determining what kind of testing to request from them, if any. It seems like a simple question, but I don’t have the experience to know what kind of failures to test for or what failure rate is typical.

The vendor will send me hardware that passes whatever tests I specify. If a board fails a test, it’s up to them to find out the problem and fix it. Ideally they’d do a full functional test – the same test I do before shipping a Floppy Emu – but that’s not practical for several reasons. I’d have to ship several vintage Macs to Shenzhen, and give them instructions on how to use old System 2.0 software and perform a non-automated series of file copy tests. Assuming they were even willing to do this, it would be expensive and time-consuming, and I’m not sure I’d even trust them to do it correctly.

At the other end of the spectrum, they could do a basic power-on test. Apply power, and confirm that the power LED turns on. But that wouldn’t really prove much except that there are no power-to-ground shorts. There could be all kinds of horrible problems with the board, but the LED would still turn on and the test would still pass. Furthermore, it’s not so easy to “power on” a Floppy Emu without having a Mac, since it’s meant to be powered through the floppy port. I’d have to build them some kind of power adapter, or they’d need to connect test leads to specific pins on the board to power it.

A mid-level test would be for them to flash the AVR firmware, then confirm that the status LED blinks three times at power-on (the normal behavior). That would at least show that the AVR was working correctly. But it wouldn’t do anything to test the SD card interface, or the CPLD, or the LCD interface. And there would still be the same challenge of powering the hardware without having a Mac to connect with it.

What makes this difficult is not knowing what kind of failure rate is typical, nor what kind of failures. If I specified no tests at all, and they installed an IC backwards in all the boards, I could get a 100% failure rate. Would something like that be my responsibility, or theirs? If I didn’t provide any tests at all, they could theoretically send me anything and have still met their obligation.

Lastly, the cost of testing time is somewhat expensive relative to the cost of the hardware. For a run of 50 units, for each 1 minute per unit spent on testing, it’s the same cost as if they did no testing and 1 unit was defective and discarded. For example if they spent 5 minutes per unit on testing, I could afford to have 5 of the 50 units be defective and unusable – a 10% failure rate – for the same cost. Since 5 minutes of testing still wouldn’t guarantee a 0% failure rate anyway, the cost of testing begins to look questionable unless the typical failure rate is high.

Working out testing details with someone who’s on the other side of the planet and who’s not a native English speaker can be difficult. I tried to find an electronics assembler in the United States, but had terrible results. One place actually contacted me, after reading the blog, but they later said they couldn’t handle my order and referred me to a second US vendor. I contacted the second vendor, but they never responded. A third US vendor was referred to me by a friend of a friend. I sent them a detailed description of the project and some questions about their process, but heard nothing for more than a week. Finally they wrote back with a generic reply, without quoting any price or answering any of the questions I’d asked. A fourth US vendor was referred to me by another retro-computer enthusiast I know, but so far I’ve had no response from that vendor either. In contrast, the Chinese shop sent me a detailed quote within 24 hours of my first inquiry, and was happy to have my business.

In a perfect world I’d have a test that was easy to run, quick, required no extra equipment, and could catch near 100% of the possible problems. But I don’t have that, or even anything close. So I’m leaning towards no testing, but my nightmare scenario is to spend lots of money and receive 50 units that are all broken, due to some kind of systematic assembly problem.

Has anyone else been through this process before? What was your experience?

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With the missing parts finally on hand, I was able put in some quality soldering time this weekend and build a whole pile of Floppy Emus. If you’ve been waiting, then wait no longer: they’re available now on the Floppy Emu page. It was a soldering ultra-marathon, and wow, was it tedious! I’ll definitely be looking into options for having an electronics shop assemble boards in larger batches in the future. I wish there were an easy way to hand-off the programming, testing, and order fulfillment too, as those tasks are surprisingly time-consuming. Many assembly shops can do programming and testing too, but when your test routine begins with “turn on the Macintosh Plus”, the conversation doesn’t go very well.

Most of the new batch of Floppy Emus were sold within 12 hours of putting them out for sale, before I’d even had a chance to mention it here on the blog, so hopefully there will still be some left by the time you read this. In fact, the level of interest remains surprisingly high for such a niche product, and to be  honest I’m a little bewildered by it. Sure it’s a neat little gizmo, but I never would have guessed there were so many people out there with Mac SE/30′s rattling around in their closets, looking for a floppy emulation solution. Who are you people? Don’t you have anything better to do? You’re crazy! But I love you anyway.

With this batch of hardware, I’m also introducing a new variant of the Floppy Emu. For an extra $13, you can get the DB-19 floppy connector on a 36 inch extension cable, instead of having it built-in directly to the Floppy Emu board. This provides some extra flexibility for positioning the Floppy Emu where it’s convenient for you to see it and press the menu buttons. It’s similar to what you’d get with IEC’s cable, only now you can get it at the same time that you purchase the emulator.

The extension cable uses a tiny circuit board to adapt the DB-19 floppy connector to a standard IDC-20 header, then adds an IDC-20 to IDC-20 cable. Using a custom circuit board here seems a little like overkill, but I was unable to find a DB-19 shrouded header anywhere. The whole cable assembly is hand-built by me. This new extension cable Floppy Emu variant is an experiment, and I’ll be looking to see how popular it becomes, and how tedious it is to make the cables. If the experiment doesn’t go well, I’ll probably return to selling only the original variant with the built-in DB-19 floppy connector, and let IEC have the extension cable business for those who want one.

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Where and how do you find the parts needed to build your hardware? Selling Floppy Emu on a small scale has introduced me to the difficulties of managing a supply chain, and I’ve discovered it’s more difficult than it looks. Doing it wrong means higher costs, more risk, and a danger of running out of key parts at the wrong time. Due to my own poor planning, Floppy Emu has been stuck at “out of stock” for far too long, and I can’t even say for certain when it will be back.

Choosing a vendor from whom to buy parts seems like it should be easy: just use a search engine like Octopart to find the vendor with the lowest price. Sadly it’s not that simple. Some guy on eBay may have the lowest price, but how can I know if his parts are good quality, or if they’re recycled, relabeled, or even counterfeit? Is the savings enough to be worth the risk? And then there are “overstock” vendors like Arrow, Avnet, and Verical, who often have very good prices but require minimum orders of 100+ parts. Are they worth it?

Even if it’s clear which vendor is best for a specific part, it becomes less clear when all the parts are considered together. Floppy Emu is built from about 15 different types of parts, and if I ordered each one from a different vendor, the combined shipping costs from all those vendors would kill me. It’s a balancing act, and it’s often necessary to buy a part from a vendor whose price isn’t the best, so I can combine it with other parts in the same order from that vendor.

Mapping all this out is a pain, but at least it only needs to be done once, right? Wrong. The vendor prices are constantly changing, and less commonly the minimum order sizes change as well. So every time I go to order more parts, I have to start the analysis over again.

I struggle the most with determining how many parts to order. Virtually every vendor has a sliding price scale, where the per-part cost decreases as the number of parts ordered goes up. So there’s an incentive to make orders for large numbers of parts to drive down the average cost, but there’s also a risk. If I order 100 ATMEGA1284 microcontrollers, and then interest in Floppy Emu dries up, I could be left with $1000 worth of useless chips sitting on a shelf. But if I order them 10 at a time, I’ll not only be paying more per chip, I’ll also be reordering nearly every week and risking running out of parts if demand temporarily spikes up.

Out of Stock

My current problems are due to Floppy Emu’s LCD display. In mid-January I thought I had two boxes of LCDs remaining, when in reality I only had one. When I discovered the truth, I only had about six LCDs left. I placed an order for more LCDs on January 29, from the same Chinese vendor I’d used in the past. But then Chinese New Year hit, and nothing happened for a week. The package finally shipped on February 6. Meanwhile, I ran out of LCDs on February 8 and put Floppy Emu into “out of stock” status.

My last order from this vendor took 10 days to arrive from China, so I expected the new LCDs to appear around February 16. But that day passed with nothing in my mailbox, nor the next, nor the next. Time ticked by. As I waited, I accumulated enough Floppy Emu back orders so that the new supply of LCDs would already be nearly exhausted by the time it arrived, so I placed a second order for even more LCDs.

When I checked back on the first order, I saw the vendor was now quoting 25 to 30 working days for delivery. What?! That’s like a month and a half! I’m not sure if this was a change in policy, or the 10-day delivery time I had earlier was just an outlier, but they were now giving me an estimated delivery date of March 7-15. Somehow the second LCD order was estimated to arrive earlier, on February 28 to March 6, despite being ordered three weeks after the first LCDs and being shipped by the same method. And there’s no tracking info on either shipment, so there’s nothing to do but wait.

 

 

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Burning through my 15 minutes of fame, I was the featured guest on this week’s episode of the RetroMacCast show – listen to it here. RetroMacCast is a weekly podcast about vintage Macintosh systems, software, and collectibles. Hosts James and John have been doing this since (at least) 2008! They were kind enough to invite me to this week’s show, where we discussed Floppy Emu, Plus Too, Tetris Max, and my other Apple-related hacks.

This recording prompted an interesting side-discussion: have I been mispronouncing “Floppy Emu” for the past two years? Is it “emyoo” (short e + myoo, as in ‘emulator’), ”eemyoo” (long e + myoo, a flightless Australian bird), or ”eemoo” (long e + moo, an electronic cow sound)?

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The Apple Hard Disk 20 (HD20) was an external 20 MB hard drive for the Macintosh, introduced in 1985. This was during the earliest days of the Mac’s history, before the introduction of SCSI support, so the HD20 connected to the Mac’s floppy port. Despite sharing the same DB-19 connector as a floppy drive, the HD20 used an entirely different communication method, making it something of a hardware freak. When SCSI support was introduced in 1986, external hard drive solutions quickly adopted the new standard, and the HD20 faded into obscurity.

During the long course of Floppy Emu’s development, several people have suggested that it might be possible to emulate the HD20 using the same hardware. In theory it should only require changes to the CPLD and AVR firmware, since the HD20 uses the same physical interface with the same pins as a floppy drive. But in practice, no documentation of the HD20 communication protocol existed, and reverse engineering it looked to be such a daunting task that it wasn’t worth it.

Circumstances changed last fall, when a couple of HD20 specification documents surfaced on the internet. Who knows where they came from – probably rescued from the bottom drawer of an ex-Apple engineer’s desk in a questionable release of company confidential information. But it’s hard to imagine anyone getting upset over documents nearly 30 years old, detailing a long obsolete peripheral for a long obsolete computer. The two most interesting documents are the specifications for “directly connected disks”, one dated March 1985 and a later revision dated May 1985. The DCD standard was planned to support a variety of device types, but ultimately the HD20 was the only product to ever use it. With these two documents and a careful examination of the HD20 driver routines contained in the Mac’s ROM, it looked like it might finally be possible to emulate the HD20.

Into the Abyss

So how does it work? First off, we can assume that raw data bytes are sent and received in serial fashion using NRZI encoding on the ReadData and WriteData lines of the floppy connector. While the DCD documents don’t specifically mention this anywhere, it’s a safe assumption because the floppy interface is powered by the Mac’s IWM chip (Integrated Wozniak Machine), which is hard-wired to send and receive data this way. So the main questions surround exactly what data bytes are sent and received, and when, and how the other lines on the floppy connector are used.

The DCD docs describe a state-based protocol that’s mercifully straightforward, compared to the oddities of the floppy drive interface. The Phase0, Phase1, and Phase2 lines on the floppy connector (sometimes called CA0, CA1, CA2) are used as a 3-bit state ID, to control the workings of a state machine governing Mac to DCD communications. At boot up, the Mac cycles through states 6, 7, and 5 in that order, checking the value on the ReadData line after each state transition. If it sees the values 1, 1, and 0, then it concludes that a DCD is connected to the floppy port, rather than a standard floppy drive.

HD20 communication is always a two-way exchange, with a command from the Mac followed by a response from the drive. From state 2 (idle), the Mac transitions to state 3 to indicate it wants to send a command. Seeing this, the DCD pulls /HSHK (the ReadData line) low to indicate that it’s ready to receive the command. The Mac then transitions to state 1 and sends the command, after which it transitions to state 3 to signal that it’s done. The DCD then brings /HSHK high again to acknowledge the end of the transfer, after which the Mac transitions back to the idle state.

When the DCD is ready to send a reply, while in the idle state, it pulls /HSHK low to indicate that it wants to send. The Mac then switches to state 1, and the DCD sends the reply bytes. After the last byte, the DCD brings /HSHK high again, and the Mac transitions back to the idle state.

Commands follow a fairly simple structure. A read command and response are shown above. The command begins with $AA, which functions as a sync byte and start of command marker. The next byte is the command id. In this case, $00 means it’s a read command. Following that are the number of 512-byte blocks to read, a three byte block address, a padding byte, and a checksum.

The reply looks similar to the command. Again there’s an $AA sync byte, followed by the command id. The command id in the reply is always the command id from the request plus $80, though I’m not sure the reason for this. After that is the sequence number of the block being sent, a status byte (zero means OK), more padding, the actual block data, and a checksum.

The HD20 carries over the concept of tag bytes that originated with the Apple Lisa, and that are also present (but unused) on Macintosh floppies. Each block has 20 tag bytes, so from a low-level point of view, blocks are essentially 532 bytes instead of 512, and 532 bytes of data will be returned in reply to a read request. The Mac throws away the 20 tag bytes, however, and only the last 512 bytes are treated as disk data. From the point of view of an emulator, only those 512 bytes need to be filled from a disk image file, and 20 bytes of zeroes can be prepended for the tags.

Because of the way the IWM works, the MSB of every transmitted byte must always be 1, so in effect there are only seven usable bits per transmitted byte. The DCD standard uses a 7-to-8 technique in which data is collected into groups of seven bytes, and then repackaged and transmitted as eight bytes with an MSB of 1 for every byte. This technique right shifts each of the seven bytes by one bit, chopping off the LSB, and setting the MSB to one. Then all of the chopped off LSBs are collected into an 8th byte. At the other end of the line, the receiver applies the reverse process to recover the original seven data bytes.

From Theory to Practice

That’s how it’s supposed to work, anyway, but there are many gaps and inconsistencies in the documents. One of the biggest concerns is that the March version of the doc differs in major ways from the May version. For example, the handshaking method described in the March doc is completely different than what I described in the previous section, based on the May doc. If there was that much change in the space of two months, it’s likely that the spec continued to evolve after that, and the May doc may not reflect the final version as it was eventually implemented.

Some important details just aren’t mentioned at all. What’s the checksum algorithm used? Nobody knows. An appendix also mentions a couple of dozen diagnostic commands, without describing what the parameters mean, or how the DCD should reply. Answering these kinds of questions requires a combination of educated guesswork, experimentation, and good old reverse engineering.

The code used by the Mac to communicate with the HD20 is contained in the ROM of the Mac Plus and other early Macs. Unfortunately this is raw 68000 machine language, so it’s difficult to read and understand what it’s doing. With the help of disassembler tools, the ROM data can be converted into 68000 assembly mnemonics, and symbolic names can be substituted for some known memory addresses, resulting in a code listing like this one:

L4772: MoveQ.L $4, D0
L4773: DBF D0, L4773
       Move.L D6, D0
       Add.L $810081, D0
       Move.B $-56, $400(A0)
L4774: Tst.B (A3)
       BPL L4774
       Move.B D0, (A0)
       Swap D0
L4775: Tst.B (A3)
       BPL L4775
       Move.B D0, (A0)

That’s not very instructive. But after long hours of studying and examining other nearby sections of code, some sense of structure does slowly emerge. For example, from looking at where A3 is set previously, I can tell that those Tst.B (A3) instructions are checking to see if the IWM is busy. And the Move.B D0, (A0) instructions are each writing a new byte to the IWM. Other clues are provided by the literal value $-56 appearing in the code, which when expressed as an unsigned byte is $AA – the sync byte. So what we have here is something that does a short busy loop, then adds $810081 to an unknown value from D6, and stores the 32 bit result in D0. Then it writes the $AA sync byte, waits for the IWM, writes the low byte of D0, waits for the IWM, and writes the high byte of D0. So it looks like it’s the preamble to sending a command to the DCD.

This is the kind of “deep in the weeds” analysis that’s needed to fill in the blanks for an emulation project. It’s something I’ve spent a lot of time doing for Floppy Emu and for Plus Too before that, so I’ve gotten pretty good at it, but I can’t really say it’s fun.

And a Progress Report

Armed with all this information, I began by hacking up the firmware on a Floppy Emu to identify itself as a DCD, and observe the proper handshaking rules for the various states. No data was actually sent or received. That was enough to get a noticeable reaction from the Mac: at bootup it froze for a long time, then when it finally did boot (from a SCSI drive), it complained that an attached disk was uninitialized and needed to be formatted. Then I wrote a simple test program to read arbitrary blocks from the DCD. The program always reported error -17 (driver can’t respond to this call). That was logical, but a little disappointing, as I could see from the ROM disassembly that there were many other more specific error codes that might be returned to give better feedback on what was and wasn’t working. I was hoping I might get an error like 64, no response received, or 33, timeout waiting for sync byte.

I spent a while tinkering with things, trying to get a more specific error than -17, but without success. I also tried using MacsBug to debug the HD20 driver routines while they were executing, but that appeared to create some new timing-related problems that messed things up even worse. Finally I decided to change course, and attack the other end of the problem by looking at what was happening on the Floppy Emu when the error -17 occurred.

I started with just displaying the current state number on the Floppy Emu LCD. I could see it go through states 6, 7, and 5 at bootup, just as the docs say it should. Then it went through states 2, 3, 1, 3, and 2, which looked like an attempted Mac to DCD command transmission. That seemed promising, so I leveraged the existing write code for Floppy Emu to try to collect the data bytes sent by the Mac, and display them on the LCD. That’s when I got the first payoff, as the received bytes were:

AA 81 B1 C1 81 80 80 80 80 80 FE

There was the $AA sync byte. And if you looked at the last eight bytes (beginning with $C1), it looked like a valid 7-to-8 encoding. Decoding those bytes yielded:

03 00 00 00 00 00 FD

That was command id 3 (drive status, according to the doc), with a bunch of padding and a checksum of FD. The sum of all the bytes mod 256 was 00, so that’s likely the checksum algorithm.

But wait, what were the second and third bytes for, 81 B1? Those shouldn’t have been there, according to the doc. Help! Truthfully I’m still not sure what those are, but after long examination of the ROM routines, I’m about 90% sure the first byte is the size of the data being sent, and the second byte is the size of the expected reply. Both sizes are expressed as a number of 7 byte groupings, then added to $81. In fact, the code that outputs those two bytes is the snippet I analyzed in the previous section.

So for the example above, the size of the data being sent was zero (no data payload for a drive status command), and the size of the expected reply was $30 groups of 7, or 336 bytes. Probably these size bytes were added to the DCD protocol late in the development process in an attempt to provide some amount of forward compatibility, so a device could gracefully handle an unknown command and send back a dummy reply of the correct size.

That’s where things stand today. With a little more experimentation, I’m hoping I can send back a valid drive status reply, or at least one that’s close enough to generate a more specific error code than -17. Then things will start to get very interesting.

 

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