Manufacturing & Supply Chain

SOP 01: WiFi Router Setup Procedures

Definitions:

• WISP (Wireless ISP) Mode: The router connects to an upstream WiFi network (e.g., hotel/venue WiFi) as its internet source, then creates its own local network for Pod devices.

• DHCP: Dynamic Host Configuration Protocol -- automatically assigns IP addresses to devices on the local network.

• NAT (Network Address Translation): Allows multiple local devices to share a single upstream IP address. "Virtual Server" / "Port Forwarding" is a NAT feature that routes incoming traffic on specific ports to a specific local device.

• WPA/WPA2-PSK: WiFi security encryption standards. WPA2 is preferred. PSK = Pre-Shared Key (password-based).

• SSID: The visible (or hidden) name of a WiFi network.

Steps:

Part A -- Hardware Selection & Preparation

1. Confirm the router model fits physically inside the Pod electronics box. Approved models:
• TP-Link MR3020
• TOTOLINK N200RE\_V5
• GL-iNet AXT1800

Note: Other models may work if they support WISP mode, DHCP, and NAT/Virtual Server. Physical dimensions are the constraint.

1. If the router has been used before, RESET it to factory defaults using the physical reset button (hold 10 seconds) or via the admin interface.
2. Connect a laptop to the router using a LAN cable. Refer to the router's user manual for which LAN port to use and the default login credentials.

Part B -- Router Configuration (Core Settings)

1. Log in to the router's admin page from the laptop browser:
• TOTOLINK: http://172.19.199.1 (after LAN IP is set) or default IP per manual
• GL-iNet: http://192.168.199.xx/#/ (xx = Pod IP)
• TP-Link: per manual (usually http://192.168.0.1)
• Default password for all Pod routers: "Pod\_00001"
2. Set the Operation Mode to "WISP" (Wireless ISP / Repeater mode).
3. Configure Internet Settings:
• Connection Type: "Dynamic IP"
• IP Address: Assigned by parent router (automatic)
• Subnet Mask: Assigned by parent router (automatic)
• Gateway: Assigned by parent router (automatic)
• DNS Mode: "Dynamic"
• Primary DNS: Leave blank or assigned by parent router
• Secondary DNS: Leave blank or assigned by parent router

IMPORTANT: Do NOT hard-code DNS to a specific parent router IP -- this will fail outside that specific network. Always use Dynamic IP assignment.

1. Configure LAN Settings:
• IP Address: 172.19.199.1
• Subnet Mask: 255.255.255.0
• DHCP Server: Enable
• DHCP Start: 172.19.199.100
• DHCP End: 172.19.199.199
2. Configure Wireless Settings:
• SSID: "Regenesis Studio XY" (where XY = the Pod ID number, e.g., "Regenesis Studio 13")
• Encryption: Enable -- WPA/WPA2-PSK
• Wireless Password: "Pod\_00001"
• Hidden SSID: Enable (SSID will not broadcast publicly)
• Guest Network: Disable
3. Configure NAT / Port Forwarding / Virtual Server:
• Set up port forwarding rules as required for Pod services (Anydesk, VerneMQ, etc.)
• Refer to the Pod Network Port Map (maintained by Fahmy) for the current list of ports and target local IPs.

Note: The NAT configuration interface differs by router brand. Consult the router manual or screenshots in the original SOP document for brand-specific steps.

1. Configure Remote Management:
• Allow management from LAN only
• DENY management from WAN (external access to router admin must be blocked)

Part C -- Testing & Verification

1. Disconnect the laptop LAN cable from the router.
2. On the laptop, connect to the Pod SSID ("Regenesis Studio XY") using password "Pod\_00001".
3. Open a browser and navigate to 172.19.199.1 to confirm access to the router admin page.
4. Verify the router shows an active upstream connection to the venue WiFi (check the WISP status page).
5. Connect the Pod's internal PC to the Pod SSID and confirm it receives an IP in the 172.19.199.100-199 range.
6. From the laptop, use Anydesk to remotely access the Pod PC. Confirm the connection works.
7. Use telnet from the laptop to test each port-forwarded service:
• Open a terminal/command prompt
• Run: telnet 172.19.199.1 \[port\] for each forwarded port
• Confirm each port responds (connection established, not refused/timed out)
8. Attempt to access the router admin page from the WAN side (e.g., from a device on the venue's network, not the Pod network). Confirm access is DENIED.

Materials Required:

Tools Required:

• Router is in WISP mode and connected to venue WiFi

• Pod SSID is broadcasting (hidden) with correct name and password

• Pod PC receives a DHCP address in the 172.19.199.100-199 range

• All port forwarding rules are verified via telnet

• Anydesk remote access to Pod PC works through the router

• Remote management is confirmed blocked from WAN

• Router admin page is accessible from LAN at 172.19.199.1

• Router won't connect to venue WiFi: Verify the venue SSID and password are correct. Ensure the router is within WiFi range. Try moving the Pod closer or using a WiFi extender. Check that WISP mode (not AP mode) is selected.

• Pod PC doesn't get an IP address: Confirm DHCP is enabled on the router (Step 7). Check that the PC's network adapter is set to "Obtain IP automatically." Restart the router.

• Port forwarding not working: Double-check the target local IP and port numbers match the Pod Network Port Map. Ensure the target device is powered on and the service is running. Confirm NAT/Virtual Server is enabled (not just saved but not applied).

• Can't access router admin page: Confirm you are connected to the Pod SSID, not the venue WiFi. Try 172.19.199.1 in a private/incognito browser window. Clear browser cache.

• Router admin accessible from WAN: Immediately disable WAN management. Re-check remote management settings (Step 10). This is a security risk -- do not leave the Pod deployed until fixed.

• Escalation: Contact Fahmy (IoT Lead) for router issues, or Jeddy/Nathan for Pod PC network integration issues.

Reference Tables:

Standard Pod Network Settings:

Approved Router Models:

Port Forwarding Map:

v2 Suggested Update -- April 2026

Original: Google Drive > 11-Partnerships > SOP DOCUMENT V3

Rewritten to Regenesis SOP Standard (Finance SOP format)

Pending review by: Tav, Matt, Barrie, Ausi

Google Doc: https://docs.google.com/document/d/1nIel3tE2bW-PKZiOI\_0z5chQojk90DsQ8DNm0mJJ4Lg/edit

SOP 02: PC Setup with Pod Disk Image

Definitions:

• Clonezilla: Disk cloning software used to copy a pre-configured disk image onto a new PC

• Ventoy: Bootable USB tool that can launch multiple ISO files from a single drive

• Wireguard: VPN protocol used to securely connect the Pod PC to the Regenesis network

• VerneMQ: MQTT message broker that handles communication between Pod modules

• BIOS: Basic Input/Output System — firmware that initializes hardware on boot

• Anydesk: Remote desktop software used by the Tech Team to configure the PC remotely

• MQTT: Message Queuing Telemetry Transport — lightweight messaging protocol for IoT devices

Steps:

Part A -- Preparation

1. Download the current Pod disk image from the team Google Drive:

https://drive.google.com/file/d/1lgQ6NXIrF\_bYjgWTcI5f6\_PdIh6BTaFO/view?usp=sharing

IMPORTANT: Confirm with Jeddy/Nathan that this is the latest image before using it. The URL in the original SOP may be outdated.

1. Copy the disk image to an external SSD drive.
2. Prepare a USB bootable drive using Ventoy, containing the Clonezilla ISO.
• Ventoy download: https://www.ventoy.net
• Clonezilla ISO download: https://clonezilla.org/downloads.php
• Copy the Clonezilla ISO file onto the Ventoy USB drive (just drag and drop -- Ventoy handles booting).

Part B -- Disk Image Restoration (Clonezilla)

1. Insert the Ventoy USB drive into the new PC.
2. Power on the PC.
3. As the PC starts, press the appropriate key to enter the boot menu. Common keys:
• F12 (most common)
• Esc
• Del / F2

The exact key depends on the PC's motherboard manufacturer.

1. Select the USB drive from the boot menu to boot from it.
2. Ventoy will display available ISOs. Select the Clonezilla ISO.
3. Clonezilla will start. Once Clonezilla Live loads, select the default boot mode (press Enter) or choose an alternative if needed using arrow keys.
4. Choose your preferred language (English recommended for consistency).
5. Select "device-image" mode -- this clones from a disk image file to a physical disk.
6. Choose "local\_dev" as the image source. Use the spacebar to select it (an asterisk marks the selection), then press Enter.
7. Connect the external SSD containing the Pod disk image when prompted. Clonezilla will detect it.
8. Select the external SSD as the source device containing the image.
9. Choose the directory for the Clonezilla image:
• Navigate to "/ Top\_directory\_in\_the\_local\_device"
• Press spacebar to select, then Enter
• Review the disk usage report, then press Enter to continue.
10. Select "Beginner" mode to use all default parameters.
11. Choose "restoredisk" -- this installs the clone image onto the new PC's internal disk.
12. Select the Pod disk image file from the list.
13. Select the target disk in the new PC (the internal drive to write to).

WARNING: All data on the target disk will be permanently erased. Double-check you are selecting the correct disk by verifying the disk size and model name.

1. Clonezilla will display a summary of the operation. Carefully review:
• Source image name is correct
• Target disk is correct
• Disk size matches expectations
2. Type "Y" to confirm and start the cloning process.
3. Wait for the cloning process to complete. Do not interrupt or power off.
4. When cloning is complete, type "Y" to confirm. Choose "Reboot" or "Poweroff" as appropriate.
5. Remove the Ventoy USB drive and the external SSD before rebooting.

Part C -- Post-Installation: BIOS Configuration

1. Power on the PC and enter BIOS setup (typically F2, Del, or F10 during startup).
2. Navigate to the power management settings and enable "Restore After AC Power Loss" (also called "Wake after power cut off" or "S0 state"):
• Set to "Power On" (so the Pod PC automatically restarts after a power outage)

TBD -- to be confirmed by Nathan: Exact BIOS navigation path and screenshots for the current PC model.

1. Save BIOS settings and exit.

Part D -- Post-Installation: Network Verification

1. Boot into the operating system.
2. Verify the PC is connected to the internet:
• Open a terminal application (Konsole on Linux)
• Run: ping 8.8.8.8
• If you see replies with ms times, the connection is working
• If you see "destination host unreachable" or "request timeout", the PC is NOT connected -- go back to SOP 01 (WiFi Router Setup) and verify router configuration
3. Verify DNS resolution:
• Run: ping google.com
• If the IP resolves and replies come back, DNS is working
• If "ping: unknown host", check DNS settings on the router

Part E -- Post-Installation: Remote Access (Anydesk)

1. Open Anydesk on the PC (it should be pre-installed in the disk image).
2. Note the Anydesk ID displayed on the main screen.
3. Send the Anydesk ID to the Regenesis Tech Team (Jeddy/Nathan) via the team communication channel.

TBD -- to be confirmed by Jeddy/Nathan: Exact steps for Anydesk configuration (unattended access password, display name, address book entry).

Part F -- Post-Installation: VPN & Service Configuration (Remote by Tech Team)

1. Provide the Regenesis Tech Team with:
• Anydesk ID (from Step 32)
• Pod ID number
• The PC's Bluetooth MAC address:

Open terminal and run: bt-adapter -l

Output example: pod (E8:C8:29:EE:F6:87) -- copy the MAC address value

1. The Regenesis Tech Team (Jeddy/Nathan) will configure the following remotely via Anydesk:
• Wireguard VPN: Contabo server connection + Mas connection

TBD -- to be confirmed by Jeddy/Nathan: Wireguard configuration file contents, server endpoints, keys

• VerneMQ configuration:

• nodename

• listener

• bridge settings

TBD -- to be confirmed by Jeddy/Nathan: Exact VerneMQ config values and file locations

• Bluetooth MAC address: Copy the MAC address from Step 34 into soundcards.json

TBD -- to be confirmed by Jeddy/Nathan: Full path to soundcards.json and the JSON structure

• Audio sound card name configuration

TBD -- to be confirmed by Jeddy/Nathan: How sound card names are detected and where they are configured

1. After remote configuration is complete, verify with the Tech Team that all services are running:
• Wireguard VPN is connected
• VerneMQ broker is reachable
• Audio system responds to test commands

Materials Required:

Tools Required:

• Pod disk image is successfully cloned to the new PC's internal drive

• BIOS is configured for auto-restart after power loss (S0 state)

• PC boots into the operating system without errors

• PC has internet connectivity (ping 8.8.8.8 succeeds)

• Anydesk ID has been sent to the Tech Team

• Tech Team confirms: Wireguard VPN connected, VerneMQ configured, Bluetooth MAC registered, audio configured

• PC is ready for Pod integration

• Clonezilla doesn't detect the USB drive: Try a different USB port (preferably USB 2.0). Check that the BIOS boot order includes USB. Re-create the Ventoy USB if corrupted.

• Clonezilla doesn't detect the external SSD: Reconnect the SSD. Try a different USB port. Ensure the SSD is formatted with a filesystem Clonezilla supports (ext4, NTFS, FAT32).

• Cloning fails midway: Check the external SSD for errors. Verify the disk image is not corrupted (compare file size with the original). Retry the process. If it fails again, re-download the image.

• PC doesn't boot after cloning: Enter BIOS and verify the boot order -- the internal drive should be first. If the OS doesn't start, the image may be incompatible with the hardware. Contact Jeddy/Nathan.

• No internet after boot: Follow SOP 01 to verify router setup. Check that the PC's WiFi adapter is enabled. Run: ip link show -- verify the WiFi interface is UP.

• Anydesk not installed: Download from https://anydesk.com/en/downloads/linux and install manually. Contact Jeddy/Nathan if the disk image is missing expected software.

• Escalation: Contact Jeddy or Nathan for disk image issues, Fahmy for router/network issues, Tav for hardware decisions.

Reference Tables:

Disk Image Details:

BIOS Settings:

Network Verification Commands:

v2 Suggested Update -- April 2026

Original: Google Drive > 11-Partnerships > SOP DOCUMENT V3

Rewritten to Regenesis SOP Standard (Finance SOP format)

Pending review by: Tav, Matt, Barrie, Ausi

Note: Multiple sections marked "TBD -- to be confirmed by Jeddy/Nathan" require input before this SOP is complete.

Google Doc: https://docs.google.com/document/d/1VIfFWafOLMwqCTR1qmwR1KtuffJvR9aW3xxaaisEE64/edit

SOP 03: Flash Firmware Amplifier (JAB5)

Definitions:

• JAB5: The amplifier board model used in Regenesis Pods. Each Pod contains two JAB5 boards: one Slave and one Master.

• ADAU1701: The Analog Devices audio DSP (Digital Signal Processor) chip on the JAB5 board. Firmware is written to its E2PROM.

• E2PROM: Electrically Erasable Programmable Read-Only Memory -- the non-volatile memory chip that stores the firmware. Data persists after power off.

• ICP3: The In-Circuit Programmer hardware tool used to connect a PC to the JAB5 board for firmware flashing via I2C protocol.

• I2C: Inter-Integrated Circuit -- a serial communication protocol used between the ICP3 programmer and the ADAU1701 chip.

• SigmaStudio: Analog Devices software used to compile and download firmware to ADAU1701 DSP chips.

• JIG Audio Tester: The custom test fixture/jig that holds JAB5 boards in position and provides power connections during flashing and testing.

SAFETY WARNINGS:

• Always connect PSU power BEFORE connecting AC mains power.

• Never touch the amplifier boards while AC power is connected.

• Ensure the fuse button is pushed up (engaged) before connecting AC power.

• If any component smells burnt, produces smoke, or makes unusual sounds, immediately disconnect AC power at the wall and do NOT proceed. Report to Ade.

• Handle boards by edges only -- avoid touching components directly (ESD risk).

Steps:

Part A -- Hardware Setup

1. Place the JIG Audio Tester on a clean, dry work surface.
2. Insert the JAB5 Slave amplifier board into the Slave position on the JIG Tester.
3. Insert the JAB5 Master amplifier board into the Master position on the JIG Tester.

Note: Ensure boards are seated firmly in the correct positions. The Slave and Master positions are labeled on the JIG.

1. Connect the Slave PSU (24V) cable to the Slave amplifier board.
2. Connect the Master PSU (24V) cable to the Master amplifier board.
3. Push UP the fuse button on the JIG Tester (this engages the fuse protection).
4. Connect the AC power cord to mains power.
5. Verify both amplifiers turn on -- you should see LEDs blinking on both boards.

If LEDs do not blink: Check all cable connections. Verify PSU outputs 24V. Check fuse.

Part B -- Flashing the Slave Amplifier

1. Connect the ICP3 programmer to the PC via the USB-A to USB-C cable.
• The ICP3 LED should turn on, confirming USB connection.
• If the LED does not turn on: Try a different USB port. Try a different cable. Check that SigmaStudio recognizes the ICP3.
2. Connect the ICP3 to the Slave amplifier board via the I2C cable.
3. On the PC, open SigmaStudio.
4. Open the SLAVE firmware project file.

CONFIRM WITH TEAM: Exact file name and file path for the current Slave firmware project. Where are firmware files stored? (Local PC folder? Shared drive? Version-controlled repository?)

1. Click "Link Compile Download" in SigmaStudio.
• If compilation is successful, you will see "Active Download" text appear in the bottom-right corner of the SigmaStudio window.
• If compilation fails: Check the SigmaStudio output/log panel for error messages. Verify the correct firmware file is open. Contact Ade.
2. Right-click on "ADAU1701" in the SigmaStudio project tree.
3. Select "Write Latest Compilation to E2PROM" from the context menu.
4. When prompted for the communication interface, select "I2C", then click OK.
5. Wait for the progress bar to complete. Do NOT disconnect cables or power during this process.
• Typical flash time: 30-60 seconds.
• If the progress bar stalls or an error appears: See troubleshooting section below.
6. Verify the flash was successful:
• SigmaStudio should display a success message or return to the normal project view without errors.

CONFIRM WITH TEAM: Is there a specific verification step? (e.g., read-back verification, LED behavior change, audio test tone?)

Part C -- Flashing the Master Amplifier

1. Disconnect the I2C cable from the Slave amplifier.
2. Connect the I2C cable from the ICP3 to the Master amplifier board.
3. In SigmaStudio, open the MASTER firmware project file.

CONFIRM WITH TEAM: Exact file name and file path for the current Master firmware project.

1. Click "Link Compile Download" in SigmaStudio.
• Verify "Active Download" appears in the bottom-right corner.
2. Right-click on "ADAU1701" in the project tree.
3. Select "Write Latest Compilation to E2PROM".
4. Select "I2C", then click OK.
5. Wait for the progress bar to complete. Do NOT disconnect cables or power.
6. Verify the flash was successful (same verification as Step 18).

Part D -- Cleanup

1. Disconnect the I2C cable from the Master amplifier.
2. Disconnect the USB cable from the PC.
3. Disconnect AC power from mains.
4. Disconnect the Slave and Master PSU cables.
5. Remove both JAB5 boards from the JIG Tester.
6. Label or mark both boards as "Firmware Flashed" with the date and firmware version.

CONFIRM WITH TEAM: What labeling system is used? Sticker? Marker? Digital log?

1. Store the flashed boards in the appropriate staging area for Pod assembly.

Materials Required:

Tools Required:

• Both Slave and Master JAB5 boards have been flashed with the latest firmware

• SigmaStudio reported success for both E2PROM writes (no errors)

• Both boards are labeled with flash date and firmware version

• All cables disconnected and boards removed from JIG

• Boards stored in staging area for Pod assembly

• CONFIRM WITH TEAM: Any additional verification step? (audio test, power consumption check, etc.)

• ICP3 not detected by PC: Try a different USB port. Reinstall SigmaStudio USB drivers. Try a different USB cable. Check Device Manager for the ICP3 device.

• Compilation fails in SigmaStudio: Verify you opened the correct firmware file (Slave vs Master). Check SigmaStudio version compatibility. Contact Ade for firmware file issues.

• E2PROM write fails or stalls: Disconnect I2C cable, wait 10 seconds, reconnect. Ensure ICP3 LED is on. Check that the correct board (Slave/Master) is connected. Power cycle the JIG Tester and retry. If it fails 3 times, the board may be defective -- set aside and report to Ade.

• LED does not blink after power on: Check PSU connections (24V). Verify fuse button is UP. Check AC power. If PSU is confirmed working and LED still off, the board may be defective.

• Wrong firmware flashed to wrong board (Slave firmware on Master or vice versa): Re-flash with the correct firmware. The E2PROM can be overwritten safely.

• Escalation: Contact Ade (Electrical Lead) for all firmware and hardware issues. Contact Tav for board replacement decisions.

Reference Tables:

Firmware Files:

Hardware Specifications:

Flash Procedure Checklist (Quick Reference):

v2 Suggested Update -- April 2026

Original: Google Drive > 11-Partnerships > SOP DOCUMENT V3

Rewritten to Regenesis SOP Standard (Finance SOP format)

Pending review by: Tav, Matt, Barrie, Ausi

Note: Several sections marked "CONFIRM WITH TEAM" or "TBD" require input from Ade before this SOP is complete. The original SOP was very brief (17 steps, no troubleshooting, no safety warnings, no firmware file details). This rewrite expands significantly but needs team validation.

Google Doc: https://docs.google.com/document/d/1sbMlnHIwoCU56YufE-rjVK8H\_kfMf\_qZBxVG\_\_O0xmo/edit

Google Doc (v2): https://docs.google.com/document/d/1ZfWhnDCrkWJLzUPdB89KDlQKweKlzds0ZpdKbxg1cMk/edit

SOP 03.2: Testing Audio Box (Integration Audio Test)

Doc Version: 20250321-03.2 → v2 Suggested Update — April 2026

PURPOSE

Verify that all audio channels inside an assembled Audio Box produce correct output power at specification before the unit proceeds to POD integration.

DEFINITIONS

• DAC: Digital-to-Analog Converter — converts digital audio signal to analog for amplification

• Vrms: Volts Root Mean Square — standard measurement of AC voltage used to verify output power

• IPQC: In-Process Quality Control — inspection performed during manufacturing before final assembly

• NR1 UI: Software interface for the NR1 audio measurement device used to control volume channels

• Dummy Load: Resistor that simulates a speaker for safe testing without connecting actual speakers

• JCALLY: Brand of USB DAC adapter used as a soundcard for audio output

PREREQUISITES

• MiniPC powered on with NR1 UI software installed

• All soundcard DACs connected and recognized by MiniPC

• Oscilloscope calibrated and functional

• Audio WAV test file (100 Hz sine wave) available on MiniPC

• IPQC Form / Checklist printed or open digitally

MATERIALS REQUIRED

TOOLS REQUIRED

PROCEDURE

STEP 1: Setup MiniPC and DACs

1.1 Power on MiniPC

1.2 Connect JCALLY and UGREEN soundcard DACs via USB

1.3 Confirm both DACs are recognized in Windows Sound settings

STEP 2: Connect Audio Box to Test JIG

2.1 Connect RCA cable from DAC output to JIG Tester input

2.2 Connect Aux cable as required for secondary audio path

2.3 Connect USB Micro cable to the Audio Box

2.4 Connect all integration harness cables from JIG Tester to Audio Box

— Ensure all connectors are fully seated

STEP 3: Power On

3.1 Push up the Fuse button on the JIG Tester

3.2 Connect AC power cord to mains supply

3.3 Verify power indicator on Audio Box is active

STEP 4: Test Left and Right Speakers

4.1 Connect Oscilloscope Probe 1 to LEFT Speaker Dummy Load on JIG

4.2 Connect Oscilloscope Probe 2 to RIGHT Speaker Dummy Load on JIG

4.3 Set up Oscilloscope:

— Measurement mode: Vrms

— Enable Pass/Fail function

— Set threshold per Reference Table below

4.4 Open Audio WAV 100 Hz file on MiniPC and press Play

4.5 Open NR1 UI software and set ALL volume channels to 100%

4.6 READ Vrms on oscilloscope for both channels

4.7 PASS if signal exceeds threshold value (see Reference Table)

AND audible tone is present on oscilloscope speaker output

STEP 5: Test Subwoofer

5.1 Connect Oscilloscope Probe 1 to Subwoofer Dummy Load

5.2 READ Vrms on oscilloscope

5.3 PASS if signal exceeds threshold value (see Reference Table)

AND audible tone is present

STEP 6: Test Transducers

6.1 Connect Oscilloscope Probes 1, 2, 3 to all Transducer Dummy Loads

6.2 READ Vrms on oscilloscope for each transducer

6.3 PASS if ALL signals exceed threshold value (see Reference Table)

AND audible tone is present on each channel

STEP 7: Test Binaural Channels

7.1 Connect Oscilloscope Probes 1, 2 to Binaural Dummy Loads

7.2 READ Vrms on oscilloscope for both channels

7.3 PASS if signal exceeds 2.5 Vrms on both channels

STEP 8: Record Results

8.1 Record ALL power measurement results on IPQC Form / Checklist

8.2 Compare results to pre-integration data (from SOP 03.3 firmware test)

8.3 If any channel shows significant reduction vs. pre-integration values:

→ STOP — refer to Integration Troubleshooting Manual

8.4 If all channels pass → sign off IPQC Form and move unit to next station

REFERENCE TABLE: Pass/Fail Threshold Values (Vrms at 100 Hz)

\\ CRITICAL: All "TBD" values must be confirmed by Ade before this SOP is approved for production use. \\

\\ The original SOP states "over the threshold value" but never specifies what that threshold is. \\

DONE WHEN

• All 8 channels (L, R, Sub, Trans x3, Binaural x2) show Vrms above threshold on oscilloscope

• Binaural channels confirmed above 2.5 Vrms

• IPQC Form is fully completed with measured values for every channel

• Results compared against SOP 03.3 pre-integration baseline — no significant deviation

• Audio Box is labeled PASS and moved to next station

IF SOMETHING GOES WRONG

REVISION HISTORY

v2 Suggested Update — April 2026, pending review by team

Google Doc (v2): https://docs.google.com/document/d/1o6LnGMe1CQB9MlL6mjek8GIgp5acRjp1NOtjKBnUTGE/edit

SOP 03.3: Power Measurement All Channel after Flash Firmware

Doc Version: 20250321-03 → v2 Suggested Update — April 2026

PURPOSE

Verify that all audio amplifier channels produce correct output power after firmware has been flashed, BEFORE the amplifier is integrated into an Audio Box. This establishes the pre-integration baseline that SOP 03.2 compares against.

DEFINITIONS

• PSU: Power Supply Unit — provides 24V DC power to the amplifier boards

• PCB: Printed Circuit Board — the input board that receives and routes audio signals

• Vrms: Volts Root Mean Square — standard measurement of AC voltage used to verify output power

• Potentiometer: Variable resistor used to adjust signal levels (volume control for each channel)

• DAC: Digital-to-Analog Converter — converts digital audio signal to analog for amplification

• Oscilloscope: Instrument for measuring electrical signal waveforms and verifying output levels

PREREQUISITES

• Amplifier board has passed SOP 03 (Flash Firmware Amplifier) successfully

• MiniPC powered on with audio playback software installed

• Oscilloscope calibrated and functional

• Audio WAV test file (100 Hz sine wave) available on MiniPC

• IPQC Form / Checklist printed or open digitally

• Slave and Master PSU 24V power supplies available and tested

MATERIALS REQUIRED

TOOLS REQUIRED

PROCEDURE

STEP 1: Setup MiniPC and DAC

1.1 Power on MiniPC

1.2 Connect JCALLY soundcard DAC via USB

1.3 Confirm DAC is recognized in Windows Sound settings

STEP 2: Connect DAC to JIG Tester

2.1 Connect Aux 3.5mm cable from DAC output

2.2 Connect RCA end to JIG Tester input

STEP 3: Connect Power Supplies

3.1 Connect Slave PSU 24V to Slave Amplifier

3.2 Connect Master PSU 24V to Master Amplifier

3.3 Do NOT power on yet (fuse stays down)

STEP 4: Connect Amplifier Inputs

4.1 Connect Slave Connector Input cable to Slave Amplifier

4.2 Connect Master Connector Input cable to Master Amplifier

4.3 Connect both Slave and Master Connector Input cables to PCB Input board

STEP 5: Connect Potentiometers

5.1 Connect Slave Potentiometer cable to Slave Amplifier

5.2 Connect Master Potentiometer cable to Master Amplifier

5.3 Ensure both potentiometers are turned fully counter-clockwise (minimum / 0%)

STEP 6: Connect Outputs to PCB

6.1 Connect Output Cable Slave A to PCB

6.2 Connect Output Cable Slave B to PCB

6.3 Connect Output Cable Master to PCB

STEP 7: Power On

7.1 Push up the Fuse button

7.2 Connect AC Power cord to mains supply

7.3 Verify amplifier turns on — LED should blink on both Slave and Master

STEP 8: Test Left and Right Speakers (Master)

8.1 Connect Oscilloscope Probe 1 to LEFT Speaker Dummy Load

8.2 Connect Oscilloscope Probe 2 to RIGHT Speaker Dummy Load

8.3 Set up Oscilloscope:

— Measurement mode: Vrms

— Enable Pass/Fail function

— Set threshold per Reference Table below

8.4 Open Audio WAV 100 Hz file on MiniPC and press Play

8.5 Turn Master Potentiometer clockwise to maximum (100%)

8.6 READ Vrms on oscilloscope for both channels

8.7 PASS if signal exceeds threshold value (see Reference Table)

AND audible tone is present on oscilloscope speaker output

STEP 9: Test Subwoofer (Slave POT3)

9.1 Connect Oscilloscope Probe 1 to Subwoofer Dummy Load

9.2 Turn SLAVE POT3 potentiometer clockwise to maximum (100%)

9.3 READ Vrms on oscilloscope

9.4 PASS if signal exceeds threshold value (see Reference Table)

AND audible tone is present

STEP 10: Test Transducers (Slave POT4)

10.1 Connect Oscilloscope Probes 1, 2, 3 to all Transducer Dummy Loads

10.2 Turn SLAVE POT4 potentiometer clockwise to maximum (100%)

10.3 READ Vrms on oscilloscope for each transducer

10.4 PASS if ALL signals exceed threshold value (see Reference Table)

AND audible tone is present on each channel

STEP 11: Record Results

11.1 Record ALL power measurement results on IPQC Form / Checklist

11.2 These values become the PRE-INTEGRATION BASELINE for SOP 03.2

11.3 If all channels pass → sign off IPQC Form, label amplifier PASS

11.4 If any channel fails → see troubleshooting below

REFERENCE TABLE: Pass/Fail Threshold Values (Vrms at 100 Hz)

\\ CRITICAL: All "TBD" values must be confirmed by Ade before this SOP is approved for production use. \\

\\ The original SOP states "over the threshold value" but never specifies what that threshold is. \\

\\ Note: Binaural channels are NOT tested at this stage — they are tested in SOP 03.2 (integration test). \\

POTENTIOMETER MAPPING

DONE WHEN

• All 6 channels (L, R, Sub, Trans x3) show Vrms above threshold on oscilloscope

• LED blink confirmed on both Slave and Master amplifiers

• IPQC Form is fully completed with measured Vrms values for every channel

• Amplifier board labeled PASS with measured values recorded (these become SOP 03.2 baseline)

• Unit moved to Audio Box assembly station

IF SOMETHING GOES WRONG

REVISION HISTORY

v2 Suggested Update — April 2026, pending review by team

Google Doc (v2): https://docs.google.com/document/d/1S4dLsuHoiFCNtI6vKQla-Gih28\_LXy7PimSfzwgSttg/edit

SOP 03.4: Testing Audio POD (Room Measurement)

Doc Version: 20250321-03.4 → v2 Suggested Update — April 2026

PURPOSE

Measure and verify the in-POD frequency response of the audio system using a calibrated microphone and REW analysis software, confirming the assembled POD meets the acoustic specification before delivery.

DEFINITIONS

• REW: Room EQ Wizard — acoustic measurement software used to analyze frequency response

• RTA: Real-Time Analyzer — displays frequency content of audio in real time

• Frequency Response: How evenly a system reproduces all audio frequencies across the spectrum

• Smoothing: Averaging technique applied to measurement data to reduce noise and make trends clearer

• SPL: Sound Pressure Level — loudness measured in decibels

PREREQUISITES

• POD fully assembled with Audio Box installed and tested (SOP 03.2 passed)

• POD powered on and all audio channels functional

• MiniPC with Audacity + REW software installed

• Daytona Audio UMM-6 microphone calibration file loaded in REW

• Acoustic specification document available for comparison

\\ NOTE: The original SOP references "specification given by Indonesian team" — this document must be obtained and attached to this SOP. TBD — to be confirmed by Ade / Tav. \\

MATERIALS REQUIRED

TOOLS REQUIRED

PROCEDURE

STEP 1: Position Microphone

1.1 Attach Daytona Audio UMM-6 microphone to the stand/holder

1.2 Place microphone and stand INSIDE the POD

1.3 Position microphone 1 meter in front of the speakers

1.4 Ensure microphone is at ear height (seated position) and pointing toward speakers

— CONFIRM WITH TEAM: Is 1 meter the correct distance? Is there a specific height? Is the mic aimed at one speaker or centered between L+R?

STEP 2: Configure Recording Software

2.1 Open Audacity on MiniPC

2.2 Select recording device: "Microphone UMM-6" from the audio input dropdown

2.3 Verify input levels show signal when tapping the microphone gently

2.4 Set sample rate to 48 kHz (or as specified — CONFIRM WITH TEAM)

STEP 3: Play Test Signal

3.1 Open Node-RED on MiniPC

3.2 Load the "testing room measurement" audio file

3.3 Set audio volume to 100%

3.4 Set vibrate volume to 100%

3.5 Initiate playback through Node-RED

STEP 4: Record Measurement

4.1 In Audacity, click the RECORD button to begin capturing

4.2 Allow the full test signal to play through completely

4.3 Click STOP when the test signal finishes

4.4 Visually inspect the waveform — it should show clear signal, not flat or clipping

STEP 5: Export Recording

5.1 In Audacity: File → Export Audio (or Export → Export as WAV)

5.2 File name: Use POD number as filename (e.g., "POD\_001.wav")

5.3 Format: WAV audio file

5.4 Save to designated measurement results folder on MiniPC

— CONFIRM WITH TEAM: What is the standard folder path for saving measurement files?

STEP 6: Analyze in REW

6.1 Open REW software on MiniPC

6.2 Click the "RTA" (Real-Time Analyzer) button

6.3 Open / import the WAV file exported from Step 5

6.4 The frequency response curve will display

STEP 7: Compare Against Specification

7.1 Apply smoothing to the frequency response graph

— CONFIRM WITH TEAM: What smoothing level? (1/3 octave, 1/6 octave, 1/12 octave?)

7.2 Compare the measured frequency response to the acoustic specification

7.3 Check that ALL frequency bands fall within the acceptable tolerance

7.4 Record PASS or FAIL for the POD

REFERENCE TABLE: Acoustic Specification (Frequency Response Targets)

\\ CRITICAL: The original SOP says "compare to the specification given by Indonesian team" but this \\

\\ specification document does not exist in the SOP folder and has never been attached. \\

\\ This table MUST be populated with actual target values before this SOP is approved for production. \\

\\ Action: Ade and/or Tav to provide the frequency response specification document. \\

RECORDING SETTINGS REFERENCE

DONE WHEN

• Measurement WAV file saved with correct POD number filename

• REW frequency response analysis completed and compared to specification

• ALL frequency bands within acceptable tolerance (per specification)

• POD marked PASS on QC checklist

• Measurement file archived in standard folder for traceability

IF SOMETHING GOES WRONG

OPEN ITEMS (Must Be Resolved Before Production Use)

1. Acoustic specification document — must be provided by Ade / Tav / Indonesian team
2. Microphone position details — exact height, angle, centering
3. REW smoothing level — which octave smoothing to apply
4. Recording sample rate — confirm 48 kHz or other
5. Standard folder path for saving measurement WAV files
6. Pass/fail frequency response tolerance values for each band

REVISION HISTORY

v2 Suggested Update — April 2026, pending review by team

Google Doc (v2): https://docs.google.com/document/d/1OCzNcYqFHYmOWy0ApDlpRSbmHjHyqYQyAYA009mLpNU/edit

SOP 04: Module ESP32 Initial Firmware Flash

Doc Version: v2 Suggested Update — April 2026

PURPOSE

Flash the correct firmware binary files onto each ESP32 module board, verify successful write via serial terminal, and confirm heartbeat operation — ensuring each module is ready for POD integration.

DEFINITIONS

• ESP32: Microcontroller module with built-in WiFi and Bluetooth used in each Pod module

• MinIO: Open-source object storage server — used to store and distribute firmware files on the workshop LAN

• esptool: Command-line utility for flashing firmware onto ESP32 microcontrollers

• COM Port: Serial communication port used to connect the ESP32 to a laptop for flashing and debugging

• Baud Rate: Data transmission speed in bits per second — esptool uses 115200, QCOM uses 230400

• Binary File: Compiled firmware file (.bin) ready for flashing onto the ESP32

• Heartbeat: Periodic signal sent by a flashed module to confirm it is running correctly

PREREQUISITES

Before starting, confirm ALL of the following:

\\ NOTE: MinIO is on the local workshop network. You MUST be connected via VPN or physically \\

\\ on the workshop LAN to access the firmware repository. \\

MATERIALS REQUIRED

TOOLS REQUIRED

MODULE REFERENCE TABLE

\\ IMPORTANT: Always flash Module 500 (Motherboard) FIRST. Modules 505, 506, and 507 \\

\\ cannot be tested without the motherboard connected. \\

PROCEDURE

PART A: Download Firmware from MinIO

STEP 1: Access MinIO Repository

1.1 Ensure you are on the workshop LAN or connected via VPN

1.2 Open browser and go to: http://10.20.10.3:9001

1.3 Log in with your MinIO credentials

STEP 2: Navigate to Firmware

2.1 Go to: http://10.20.10.3:9001/browser/regenesispodfirm

2.2 Select the folder matching the target POD version

2.3 Enter the module folder (e.g., 500/ for motherboard)

2.4 Enter the "new\_firmware" subfolder

STEP 3: Download Binary Files

3.1 Download ALL THREE binary files for each module:

— bootloader.bin

— partitions.bin

— module\_firmware.bin (name varies by module)

3.2 Save to a known folder on your local computer

3.3 Repeat Steps 2.3–3.2 for ALL 9 modules

3.4 Open File Manager and verify all downloads are present

PART B: Flash Firmware to ESP32

STEP 4: Flash Motherboard Module (500) FIRST

4.1 Connect the ESP32 board for the MOTHERBOARD module to laptop via USB micro cable

4.2 Open Device Manager and note the COM port number assigned

4.3 Open Command Prompt / Terminal

4.4 Navigate to the folder containing the motherboard binary files

4.5 Run the flash command (SINGLE LINE):

esptool --port  --baud 115200 write_flash 0x1000  0x8000  0x10000 

Where:
—            = COM port (e.g., COM3)
—  = full path to bootloader.bin
—  = full path to partitions.bin
—    = full path to module firmware .bin file

4.6  Wait for flashing to reach 100%
4.7  Verify the terminal displays "Hash of data verified" / success message

STEP 5: Verify Motherboard via QCOM

5.1 Open QCOM serial terminal

5.2 Set configuration:

— COM Port: (same as used for flashing)

— Baud Rate: 230400

5.3 Click "Open Port"

5.4 SUCCESS: Port opens, ESP32 output is readable, heartbeat starts running

5.5 FAILURE: Output shows unreadable/garbled characters → reflash (see troubleshooting)

STEP 6: Flash Remaining Modules

6.1 For each remaining module (501–508):

a. Connect the ESP32 board for that module via USB

b. Note the COM port

c. Run the esptool flash command with that module's binary files

d. Wait for 100% completion

e. Verify success message

STEP 7: Test Independent Modules (501, 502, 503, 504, 508)

7.1 For each independent module:

a. Open QCOM

b. Select the COM port for that module

c. Set Baud Rate: 230400

d. Click "Open Port"

e. Verify: output is readable AND heartbeat is running

7.2 Record PASS/FAIL for each module

STEP 8: Test Dependent Modules (505, 506, 507)

8.1 These modules require the MOTHERBOARD (500) to be connected simultaneously

8.2 Connect the motherboard ESP32 to laptop via USB

8.3 Connect the dependent module ESP32 to laptop via another USB port

8.4 In QCOM:

a. Select the COM port of the MOTHERBOARD (not the module)

b. Set Baud Rate: 230400

c. Click "Open Port"

d. Wait for the dependent module's heartbeat to appear in the motherboard's output

8.5 If heartbeat appears and runs → PASS

8.6 If no heartbeat appears → see troubleshooting

** NOTE: When testing dependent modules ALONE (without motherboard), QCOM will show **
** "port open" but only unreadable output and NO heartbeat. This is EXPECTED behavior **
** — it does NOT mean the flash failed. You MUST connect the motherboard to test. **

FLASH COMMAND QUICK REFERENCE

Template:

esptool --port COM# --baud 115200 write\_flash 0x1000 bootloader.bin 0x8000 partitions.bin 0x10000 firmware.bin

Examples:

esptool --port COM3 --baud 115200 write\_flash 0x1000 .\\bootloader.bin 0x8000 .\\partitions.bin 0x10000 .\\motherboard\_fw.bin

esptool --port COM5 --baud 115200 write\_flash 0x1000 .\\bootloader.bin 0x8000 .\\partitions.bin 0x10000 .\\door\_fw.bin

Memory Addresses:

0x1000 → bootloader.bin

0x8000 → partitions.bin

0x10000 → module firmware .bin

QCOM Settings:

Baud Rate: 230400

COM Port: (as recognized by Windows)

DONE WHEN

• All 9 module ESP32 boards flashed with correct firmware for target POD version

• All independent modules (500, 501, 502, 503, 504, 508) show readable output + heartbeat in QCOM

• All dependent modules (505, 506, 507) show heartbeat when connected alongside motherboard

• All results recorded on QC checklist

• All modules labeled with POD number and module number

IF SOMETHING GOES WRONG

DRIVER DOWNLOAD LINKS

REVISION HISTORY

v2 Suggested Update — April 2026, pending review by team

SOP 05: Quality Control -- Pod System QC Inspection

Definitions:

• MQTT: Message Queuing Telemetry Transport — lightweight IoT messaging protocol used for communication between Pod modules

• SSH: Secure Shell — encrypted remote terminal access used to inspect backend logs on the Mini PC

• pm2: Process manager for Node.js applications — used to run and monitor backend services on the Pod

• Kiwi TCMS: Test Case Management System — tool for organizing, executing, and tracking test cases

• UAT: User Acceptance Testing — final testing performed by stakeholders to confirm the Pod meets requirements

• Scrcpy: Screen mirroring tool for Android devices — used to view and control the Pod tablet display from a PC

• Regression Testing: Re-testing previously passed test cases after fixes to ensure nothing broke

Scope:

• UI Application (Big Screen and Small Screen)

• Hardware Components (output verification of each module)

• Integration of Software and Hardware (MQTT messaging and backend logs)

Tools: Kiwi TCMS, ClickUp, Google Sheets, MQTT Explorer, Scrcpy, Node-RED UI, SSH terminal

Procedure Summary (7 Phases):

1. Test Preparation -- load Kiwi TCMS test cases, confirm Pod is ready
2. MQTT Integration Verification -- connect to broker, verify message flow
3. Backend Log Inspection -- SSH into Mini PC, check pm2 logs
4. UI Application Testing -- execute all 25 test cases from Kiwi TCMS
5. Regression Testing -- re-run affected tests after fixes
6. UAT -- coordinate stakeholder testing
7. Test Run Reporting -- generate Kiwi TCMS report

• All 25 test cases executed and recorded

• MQTT message flow verified for all hardware modules

• Backend logs reviewed with no unresolved errors

• All defects logged in ClickUp

• Test Run Report generated and attached

Full document: Google Drive - v2 Gold Standard

v2 Suggested Update -- April 2026 | Maintainer: Tav

SOP 06: Training -- Electro-Acoustic Tester

Definitions:

• DSP: Digital Signal Processor — chip that processes audio signals (EQ, crossover, delay)

• I2C: Inter-Integrated Circuit — communication protocol between chips on the amplifier board

• E2PROM: Electrically Erasable Programmable Read-Only Memory — chip that stores firmware settings on the amplifier

• Vrms: Volts Root Mean Square — standard measurement of AC voltage used to verify output power

• Crossover: Circuit that splits an audio signal into frequency bands for different speakers (e.g., bass to subwoofer, mids to main speakers)

• Potentiometer: Variable resistor used for volume and level control on the amplifier

• RCA: Connector type for audio cables — used to connect DAC output to test equipment

Scope:

• Hardware Components: output level verification on each amplifier channel

• Integration (Middleware & Hardware): volume control via Node-RED and manual console

• Acoustic Performance: in-Pod frequency response measurement

Hardware: Wondom JAB5 (4x100W), Wondom PAM8803 (2x2W), Focal ES100K, Tang-Band T1, Focal ISUB, Sonic Immersion VT200-I BEAM, GM89 mic

Instruments: Rigol DHO914S oscilloscope, Dayton Audio UMM-6 measurement mic

Software: Sigma Studio, REW, Audacity, Node-RED UI

Procedure (4 Phases -- each cross-references its detailed SOP):

1. Flash Firmware to Amplifiers >> See SOP 03
2. Power Level Measurement (All Channels) >> See SOP 03.3
3. Integration Audio Box Test >> See SOP 03.2
4. Final Assembly -- Pod Audio System Test >> See SOP 03.4

Includes: 18-row troubleshooting table covering raw material, integration box, volume control, and Pod UX sound issues.

• Trainee completes all 4 phases under supervision

• Trainee can independently perform each phase

• Trainee can identify and troubleshoot common problems

• Training record signed and filed

Full document: Google Drive - v2 Gold Standard

v2 Suggested Update -- April 2026 | Maintainer: Tav

SOP 07: UPS Monitoring -- Graceful PC Shutdown via NUT & Eaton 5P 1150i G2

Definitions:

• NUT: Network UPS Tools — open-source software suite for monitoring and managing UPS devices

• UPS: Uninterruptible Power Supply — battery backup that provides power during outages and enables graceful shutdown

• USB-HID: USB Human Interface Device — protocol used by the Eaton UPS to communicate status to the connected PC

• upsmon: NUT daemon that monitors UPS status and triggers shutdown actions when battery is critical

• upsd: NUT daemon that serves UPS data to network clients and monitoring tools

• systemctl: Linux command for managing system services — used to start, stop, and enable NUT services

• LB: Low Battery — UPS status flag indicating the battery is nearly depleted and shutdown is imminent

Prerequisites: Eaton 5P 1150i G2 UPS, Linux PC (Debian/Ubuntu), USB Type-A to Type-B cable, sudo access

Procedure (7 Steps):

1. Hardware Connection -- connect UPS to wall, PC to UPS, USB cable between them, verify with lsusb
2. Software Installation -- apt-get install nut nut-client nut-server
3. Driver Configuration -- /etc/nut/ups.conf with usbhid-ups driver
4. Set NUT Mode -- /etc/nut/nut.conf set MODE=standalone
5. Configure NUT Daemon -- /etc/nut/upsd.users with monitoring user
6. Configure Monitoring Client -- /etc/nut/upsmon.conf with MONITOR line and SHUTDOWNCMD
7. Start and Enable Services -- systemctl start/enable nut-server and nut-client

Verification: upsc eaton returns valid UPS data; services show active (running)

• UPS detected by lsusb

• NUT packages installed and configured

• Services running and enabled on boot

• upsc eaton returns valid status data

• Graceful shutdown tested (recommended)

Full document: Google Drive - v2 Gold Standard

v2 Suggested Update -- April 2026 | Maintainer: Tav