Finally done testing and reworking the PCB v1.1 . The PCB design is good, nothing need to be change. The new ESD array chips I used are a lot easier to work with. In any case the next batch will be assembled by professionals. I will keep those boards for my own personal tests.
I followed the following checklist while testing and reworking the boards. It's very helpful to not forget any step!
|Check for short between supply and ground||VBUS_C, VBUS, 3V3_USB, 1V8, 3V3|
|Check U2 alignment and pin short||Visualy with magnifying glass.|
|Check U3 for short.||Make sure 3 pins are not short with multimeter.|
|Check U4 for short.||Visualy with magnifying glass.|
|Check U6 for short.||Visualy with magnifying glass.|
|Test USB||Validate LED is on and that PC detect both UART. In FT-Prog utility validate EEPROM is detected.|
|Check U7, U10, U11, U12, U13 for short on internal side.||Check with multimeter on ESP32 side.|
|Check U7, U10, U11, U12, U13 for short on external side.||Check with multimeter on connector contacts.|
|Check U1 for short.||Check with multimeter between each adjacent pins.|
|Check U7, U10, U11, U12, U13 continuity between connector & ESP32.||Use multimeter to measure resistance. Should 100 Ohm.|
|Program ESP32 via USB UART.||Place jumper on TX & RX on UART header. Place power jumper on VBUS.|
Validate programming is done without requiring any press on switches. Check USB TX & RX LEDs. Validate Green power led is ON.
|Test Switches||Hold reset switch, validate error LED is on, release reset and validate error switch goes off. Press Boot switch and validate message appear in UART logs.|
|Test JTAG||Program JTAG FW & populate JTAG jumpers. Test connection.|
|Test SD card.||Reprogram regular FW, insert SD card & validate no error in logs.|
|Connect 7 Bluetooth controllers||Make sure radio is working fine.|
|Try will all supported systems||Test with DC, Saturn, N64, NGC, NES, SNES & JVS.|