Card Booting Failure Detected in Cyclone V Device

[ArunkumarSC]

We are writing to you today regarding a critical issue we are experiencing with the FPGA Cyclone V MPN: 5CSEMA5U23I7N  and DDR used as MPN: MT41K256M16TW-107IT:PTR. 

We have observed a widespread card booting failure across a significant portion of our recent batch of these cards. While a few cards are booting successfully and operating as expected, the majority of the cards are consistently failing to boot.

Specifics of the Issue:

• Problem: Card booting failure. The cards do not initialize  correctly within the FPGA system.

• Observation: Out of 13 cards, approximately 8 are exhibiting this failure. Only 5 cards are booting successfully.

• Impact: This issue is severely impacting our "production schedule," "testing phase," "development efforts" and is causing significant delays.

Troubleshooting Steps Taken :

• We have verified the power supplies and connections.

• We have attempted x-rays multiple times of Cyclone V and DDR3

Given the high failure rate and the critical nature of these components to our systems, we urgently request your immediate assistance in diagnosing and providing a solution for this problem.

Could you please advise on the next steps for troubleshooting, potential causes, and a plan for resolution ?

Thank you for your prompt attention to this critical matter. We look forward to your swift response and support.

[Fakhrul]

Hi ArunkumarSC,

Thank you for your detailed report regarding the boot failures on your Cyclone V and DDR3 cards.

Based on the Cyclone V Device Handbook and your observations, please review and provide the following to help us pinpoint the issue:

Configuration Signals:

• Monitor nCONFIG, nSTATUS, and CONF_DONE pins during power-up. Are there differences between working and non-working cards?
• Confirm correct MSEL settings and configuration mode.

Power Supplies:

• Ensure all FPGA power rails ramp up within spec and in the correct sequence (per handbook recommendations).
• Share oscilloscope captures if possible.

DDR3 Interface:

• Check that DDR3 initialization and PHY calibration complete successfully.
• Confirm correct pinout, I/O voltages, and termination.

Programming & Assembly:

• Verify the same FPGA image is used on all cards.
• Consider cross-swapping FPGA/DDR3 between working and failed units to isolate the fault.
• Inspect for subtle soldering issues (even if X-ray looks OK).

JTAG Access:

• Can you connect to failed cards via JTAG for further diagnosis?

Please provide your findings from the above. If you have oscilloscope traces or error/status codes, sharing them will help accelerate resolution.

Thank you for your cooperation, looking forward to your update.

Best regards,

Fakhrul

[Fakhrul]

As we haven't received a response to our previous notification, this thread will be transitioned to community support. We hope all your concerns have been addressed. If you have any new questions, please feel free to open a new thread to receive support from Intel experts. Otherwise, community users will continue to assist you here. Thank you.