Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

Function Specification
Star Bus Electronics

Product: Starbus
Spec Type: Functional Specification
Author: Jeff Chang
Revision: 01

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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

Table of Contents
1 Scope ......................................................................................................................................................................................... 4
2 Definitions .................................................................................................................................................................................. 4
2.1 Common Terms .................................................................................................................................................................... 4
2.2 Circuit Boards and Components ........................................................................................................................................... 4
3 Starbus Description .................................................................................................................................................................... 5
4 Reference Documents ............................................................................................................................................................... 6
5 Starbus Features........................................................................................................................................................................ 7
6 Architecture .............................................................................................................................................................................. 10
6.1 Starbus Typology................................................................................................................................................................ 10
6.2 Starbus Platform for NG Cabinets and Accessories ........................................................................................................... 12
6.3 Starbus Port to Cabinet and AUX Mapping ........................................................................................................................ 13
6.4 Cabinet PCBA and Wiring Configuration ............................................................................................................................ 14
6.5 Top Switch .......................................................................................................................................................................... 15
6.6 Zone Boards ....................................................................................................................................................................... 16
6.7 Wiring Harnesses ............................................................................................................................................................... 17
6.8 Future Proofing ................................................................................................................................................................... 18
7 Electrical Specifications ........................................................................................................................................................... 19
7.1 Common Recommended Features [MRD #18]................................................................................................................... 19
7.2 PC interface Requirements................................................................................................................................................. 23
7.3 Bus Signaling Requirements .............................................................................................................................................. 23
7.4 ESD Requirements ............................................................................................................................................................. 24
7.5 Testing Requirements ........................................................................................................................................................ 24
8 Mechanical Specifications ........................................................................................................................................................ 24
9 Deliverables and Milestones .................................................................................................................................................... 24
9.1 Verification Test .................................................................................................................................................................. 24
9.2 Validation Test .................................................................................................................................................................... 24
9.3 Release Date ...................................................................................................................................................................... 25
9.4 Life Expectancy .................................................................................................................................................................. 25
10 Manufacturability and Sourcing ................................................................................................................................................ 25
10.1 Board Manufacturing ..................................................................................................................................................... 25
10.2 Parts Selection and Sourcing......................................................................................................................................... 25
10.3 Support Tools and Test Requirements .......................................................................................................................... 26
11 Serviceability, Installability, and Support Plan .......................................................................................................................... 26
11.1 Customer Servicing and Installation .............................................................................................................................. 26
11.2 Design for Improved Component Serviceability ............................................................................................................. 27
12 Environmental Considerations ................................................................................................................................................. 27
13 Regulatory Compliance ............................................................................................................................................................ 27

Revision History
Date Revision Description of changes
11/03/2014 00 Document created
12/29/14 0.1 Linked to MRD
Ready for Initial HWE review.
01/02/2015 0.2 Modifications after HWE Review
01/19/2015 01 Submitted as ECO# 10217

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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

MRD Cross Reference

#001 ...................................................................................................................................................... 6, 25
#002 ....................................................................................................................... 7, 8, 9, 15, 23, 24, 25, 26
#003 .................................................................................................................................................. 8, 9, 16
#004 .......................................................................................................................................... 8, 15, 16, 26
#005 ............................................................................................................................................ 8, 9, 15, 26
#008 .................................................................................................................................................... 25, 26
#009 .................................................................................................................................................... 25, 26
#012 ........................................................................................................................................................ 6, 7
#014 ..................................................................................................................... 7, 8, 12, 15, 16, 17, 24, 26
#015 ....................................................................................................................... 7, 8, 9, 12, 15, 16, 24, 26
#016 ........................................................................................................................................................ 7, 9
#017 .......................................................................................................................................................... 27
#018 .............................................................................................................................................. 16, 19, 26
#019 ............................................................................................................................. 6, 8, 9, 12, 15, 16, 26
#020 ............................................................................................................................. 6, 8, 9, 15, 16, 26, 27
#021 .......................................................................................................................................................... 26
#026 .......................................................................................................................................................... 24
#050 .................................................................................................................................................... 25, 26
#051 .......................................................................................................................................................... 27
#052 .............................................................................................................................................. 25, 26, 27
#054 .......................................................................................................................................................... 26
#061 .......................................................................................................................................................... 16
#064 .......................................................................................................................................................... 26
#065 .......................................................................................................................................................... 25
#066 .......................................................................................................................................................... 25
#070 ........................................................................................................................................................ 7, 8
#077 .................................................................................................................................................. 7, 9, 27
#078 ...................................................................................................................................................... 8, 27
#081 .......................................................................................................................................................... 27
#084 .....................................................................................................................................8, 12, 15, 25, 26
#085 ............................................................................................................................................ 7, 8, 26, 27
#101 .......................................................................................................................................................... 12
#121 .......................................................................................................................................................... 27
#133 .......................................................................................................................................................... 16
#134 .......................................................................................................................................................... 16
#135 .......................................................................................................................................................... 16
#157 .................................................................................................................................................... 7, 8, 9
#159 .................................................................................................................................................. 7, 9, 10
#179 .......................................................................................................................................................... 12
#180 .......................................................................................................................................................... 12
#181 .......................................................................................................................................................... 12
#184 .......................................................................................................................................................... 18
#185 .......................................................................................................................................................... 18

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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

1 Scope

1.1.1 This document describes the functional design specifications for the NG communication
platform at the physical layer. This specification encompasses the current iteration of
prototype PCBAs and cable harnesses.
2 Definitions
2.1 Common Terms
Controller The Starbus controller is a piece of software running on the PC which is the only
component which can communicate downstream and receive upstream
communications from nodes. This is the interface between Omnicell software and
hardware.
Switch PCBA which connects multiple nodes together and controls which node has access to
the upstream link. If the switch is the first switch encountered from the PC, then it is
considered the “Primary Switch.” If the switch is at the top of the cabinet and fans out
Starbus to each cell, then the switch is considered a “Top Switch.”
“Top” Switch The highest layer switch in any frame whether it is an Aux, headless, wireless, or
directly off of the PC. In tall cabinets, the physical placement is also at the very top of
the machine.
“Primary” Switch Primary is the role served by the single highest switch in a domain of bus devices that
can be discovered using only a Starbus-compliant bus scan. Any switch board serves
the primary role when there are no Starbus switches in the path upstream to the
controller.
Starbus Node Each endpoint on Starbus is defined as a node. Nodes receive commands, and
respond upstream with responses and event signals
Starbus Sub-node Each Starbus node could be composed of many sub-circuits or modules, eg button
bars or dispensers.
RU “Rack Unit”, defined as 59mm increments, denotes incremental pitch of drawer slides
in a drawer zone. Each zone is defined as 10 RU in height.

2.2 Circuit Boards and Components

Components Function Location
Top Switch Provide Starbus fan-out from one Starbus port to 15 Top of Cabinet
ports (9 internal and 6 external). Also provide power
distribution to all cabinet zones.
Expansion Switch Provide additional 8 Starbus ports to additional AUX Top of Cabinet
cabinets. Does not provide power.
Pharmacy Section Provide Starbus switching to each drawer. Provides Each drawer section.
Board 14 pin connector at RU pitch to each drawer. This
board will not be built in production.
Shelf Section Board Starbus node which provide data and power Each supply section
connections to supply shelves and button bars. 10
RU variant will be built for all shelf sections.
Mixed Zone / Hybrid / PCBA combining the connectors and features of the Each drawer or supply
Combo Board Supply Section and the Pharmacy Section board. 10 zone.
RU and 5 RU variants for drawer and mixed zone
configurations. This board will be built instead of the
pure Pharmacy Section board.

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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

Power Harness Provides redundant 12V power rails to each Starbus Spine of each cell.
board.

3 Starbus Description

3.1.1 Starbus is a custom, proprietary communication bus enabling the Controller software to
control and communicate with a population of connected hardware nodes within one or
more co-located Omnicell products such as automated dispensing cabinets (ADCs).

3.1.2 At the physical layer, packets are broadcast from the Controller (software) directly to all
nodes through the downstream half of a full duplex, 1 Mbps RS422 link. In response, one
or more nodes send packets directly to the Controller through the upstream half of the
same link. Upstream collisions are prevented by hardware arbitration circuits called
Switches that grant only a single node access to the upstream link at a time. Upstream
flow control is a simple handshake using two additional signals outside of the RS422 data
paths. Each node with a packet to send to the Controller would drive a request line and
transmit only when a switch responds with a grant signal.

Upstream Upstream Upstream Upstream

Switch Switch Switch Switch
Request

Request

Request

Request
Grant

Grant

Grant

Grant
Data

Data

Data

Data
Node Node Node Node

Figure 1: Upstream Data Handshaking Process

3.1.3 The arbitration and hardware-based flow control performed by switches aren’t visible to the
Controller. Packets are not buffered, repeated, monitored, or interpreted by any
intermediate hardware between the Controller and nodes, in either direction. After the
Controller initializes communications by performing a bus scan, every bit sent over the bus
arrives at its destination port(s) with a fixed, near zero latency due to short electrical
propagation delays.

3.1.4 The Bus consists of a series of switch devices that divide the serial line into many lines
(similar to a network switch). These switches can be controlled by the software to enable
(unblock) and disable (block) specific connection points. This allows the SW to

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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

communicate with one, several, or all connected nodes and switches at a time. The
switches also have logic built in to detect hot insertion of new devices and emit event
packets to notify the controller. [MRD #19, #20]

3.1.5 The bus is easily scalable. A system could contain as few as one node, or thousands of
switches and nodes. For practical purposes, the number of nodes and levels of switch
interconnect will likely be limited in the Controller Software. [MRD #1, #12]

4 Reference Documents
• 62-16001_Specification,Communications Protocol, Starbus
• 62-16003_Specification, PCBA, 16 Port Top Switch, Starbus
• 62-16004_Specification, PCBA, Shelf Section, 10RU, Starbus
• 62-16005_Specification, PCBA, Combo Board, 10RU, Starbus
• 62-16006_Specification, PCBA, Combo Board, 5RU, Starbus
• Apollo MRD v4

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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

5 Starbus Features
Table 1: Legacy and Starbus Comparison [MRD #16]

Legacy Bus Star Bus

Topology Single shared channel using two Star shaped network of point to point
conductors (Data+, Data-) connections, (Downstream, Upstream,
Request, Grant). Any issues on nodes
are limited to single, point-to-point,
connection and will not affect the rest of
the bus. [MRD #2, #15, #159]
Maximum 13 Cabinets (3 Cell) supporting Theoretical maximum of 3.86 billion
Number of maximum of 702 Drawers and 39 nodes (combinations of Drawers and
Nodes Supply Zones. Shelf Sections). Actual limit depends on
software addressing scheme. [MRD
#12]
Control Multi-master (potentially hundreds) on Single master (the PC) with RS422
RS485
Routing Scheme Broadcast only - from all to all. Unicast, Multicast, Broadcast or hybrid
of all of these depending on SW usage
Collision Not guaranteed. Transmit when quiet. Guaranteed by full duplex and upstream
Protection arbiter.
Bandwidth None. Free for all. Fair sharing. Every node will get a
Limits for any predictable turn even if every other
Node node was designed to saturate the bus.
An optional, programmable time-out can
be configured to bump any node
spending too long on the bus before
relinquishing control to the Arbiter.
Failure Scope & Entire bus can fail due to problem at Only downstream nodes are affected by
Opportunities any node. bus faults (ex: shorts). [MRD #159]
Locating On site disassembly for Bus failure location self-evident from
Failures connect/disconnect experiments, with problem definition, and can be isolated
intermittent failures to complicate and remotely. LEDs on PCB indicate certain
cause re-visits. error conditions. [MRD #2, #14,
#15,#77, #159]
Bandwidth 9.6 kbps, half duplex (minus turn- 1.0 Mbps, full duplex (> 200x effective
around times) BW)
Data Error No. CRC in protocol.
Detection
Supply Zone Dip switches Auto-detect. [MRD #2,#14, #15, #70,
Addressing #85]
Drawer location Manual SW/installer sequence, with Auto-detect. [MRD #2,#14, #15, #85,
or addressing configuration details entered in dialog #157]
boxes of PC.
Terminations Manual steps critical to prevent Built in everywhere needed, invisible to
intermittent behavior. installers and users.

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Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

Legacy Bus Star Bus

Drawer physical On the hard drive, copied to server. Inherently stored in the hardware, with
addresses copies always available to the disk and
storage server. [MRD #5]
Button bar info No Yes. [MRD #2, #5, #85]
(presence, type
and location)
stored in HW
Door presence No Yes. [MRD #2, #85]
and location
stored in HW
Node (drawer, No. Can’t even poll due to BW Yes, of button bars, drawers, zones,
button bar, shortage and lack of user input (ex: cabinets. An unsolicited command can
zone, etc.) button bars) be triggered, if desired, by any bus
disconnect disconnect at any level of the star.
alarm
Addressing Not easily. Yes.
works with
Carousels, other
shapes
Bus and nodes Configuration dependent. Requires Built in. A continuous bus scan should
stress test setup, scripting, heuristics. be able to detect and flag any
availability. differences. Every node is exercised.
Hacker Yes. Off the shelf HW, easy sniffing, No. Custom electronics needed for
susceptibility lots of entry point connectors, trivial arbiter control signals, uncommon baud
protocol rate, difficult reverse engineering,
access only to downstream bus
segment (nothing if accessing at a
node), instant detection of the attempt,
more complex protocol, etc.
Cabinet Frame, No. Stickers and on disk drive image. Yes. If the disk or Ebox moves, the
boards have If the disk or Ebox moves, the cabinet next initialization scan will show the new
electronically ID follows. cabinet type, serial number,
readable ID in manufacturing date, and all of its nodes
HW information as well. [MRD #2, #5, #84,
#85]
Suitable for Plug No. Dipswitch and termination Could be detected. Any hardware that
and play or hot changes, manual configuration entry gets added, removed or relocated is
swapped HW at a GUI, etc. reported to the cabinet along with the
node type and globally unique IDs.
[MRD #2, #3, #4, #14, #15, #19, #20,
#70, #78, #157]
Hardware No. Disassemble and inspect for Yes, more. The SW/HAL can
traceability many types of information. Some determine, “The PCBAs with p/n xx-
within a cabinet information can be extracted from xxxx Rev C or earlier are in Aux 2, Zone
SAP for identifying the parent cabinet 4, Nodes 2 and 5 only.” Even using a
of some HW. fresh gold drive. [MRD #2, #5,#84, #85,
#157]
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Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

Legacy Bus Star Bus

Remote Powercom and Enhanced Drawers All node microcontrollers that are
Firmware only. directly accessible by Starbus have
Update capability to be remotely updated.
Switch CPLDs currently cannot be
updated remotely. [MRD #2, #3, #15]

Table 2: Fault Tolerance and Detection Summary [MRD #16]

Legacy HOW does NG design Cost

Comparison isolate failure? Increase
Button bar or Drawer Can't tell Detected Inseparable
removed. [MRD #2, #5, #157]]
Button bars or drawers No traceability. Movements can be tracked Inseparable
swapped or moved to new by Controller.
shelf. [MRD #2, #5, #19,#20,
#157]
Power overloaded/shorted Cabinet-wide failure. Isolated to switch, drawer, 20 cents
or node.
[MRD #2, #159]
Shorts on data lines Undetectable failure Isolated; Detectable <20 cents
of data bus; no [MRD #2, #77, #159]
failure isolation
Open circuits: Any non- Intermittent Failure identified with Inseparable
redundant output operation with timeouts.
undefined results. [MRD #2, #77]

Table 3: Limitation of Failure Diagnostics

Legacy Limitations of new design

Switch stuck open No visibility No visibility
Switch stuck closed No visibility Specific button bar/drawer and button
identifiable, blockable via software
Short within node PCBA No visibility Specific node or switch identifiable
LED fails dark No visibility No visibility

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6 Architecture
6.1 Starbus Typology

6.1.1 Starbus is flexible enough to be used in multiple ways. The star typology provides
maximum failure tolerance, where all drawers and shelves are organized under switches.
Single failures of sublayers or nodes would not affect nor disable the rest of the system.
[MRD #159]

UPSTREAM
Down
Starbus Adapter USB, PCIe, or LAN

Down

Down

Down

Down

Down

Down

Down

Down
UPSTREAM UPSTREAM UPSTREAM UPSTREAM UPSTREAM UPSTREAM UPSTREAM

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Node Down Node Down Node Down Node Down Node Down Node Down Node

Down Down Down Down Down Down Down

Down Down Down Down Down Down Down

Figure 2: Star Typology

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6.1.2 Starbus could also be used in a less robust daisy-chained scheme, as cabinets are
currently configured. However, there may be a software limit on number of layers.

Starbus USB, PCIe, or LAN

UPSTREAM
Adapter
Down

Down

Down

Down

Down

Down

Down

Down

Down
Node

Node

Node

Node

Node

Node
UPSTREAM

Down
UPSTREAM

Down Node Down UPSTREAM

Down
Down Node Down Node UPSTREAM

Node Down Node Down UPSTREAM

Down Node Down

Down UPSTREAM
Down Node Down Node
Down Node Down Node
Down
Down Node UPSTREAM
Down Node Down Node
Down Node Down Node

Down Node Down Node Down

Down Node Down Node
Down Node Down Node
Down Node Down Node
Down Node
Down Node Down Node
Down Down Node
Down Node Down Node
Down Node
Down Down
Down Node Down Node

Down Node Down Node

Down Node
Down
Down Down Node

Down Node Down Node

Down Node
Down Down

Down
Down Node Down Node
Down

Down
Down Down Node

Down Down

Down

Figure 3: Daisy Chained Typology (cf Current Shipping Configuration)

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6.2 Starbus Platform for NG Cabinets and Accessories

6.2.1 Overall, Starbus is intended to connected to drawers and supply zone boards (button bars)
within the cabinet, as well as provide data connections to six Aux cabinets, and up to two
cabinet mounted (and internally powered) ERBs. An additional 8 port expansion board can
be added at a later date to expand to 13 AUX cabinets. [MRD #101, #179, #180, #181]
MAIN Cabinet

Frame ID
“Primary” Top Switch

Expansion AUX Cabinet AUX Cabinet AUX Cabinet

Switch
(Optional
Addon) Top Switch Top Switch Top Switch

Button Bar Button Bar Button Bar

10RU Shelf Section Board

10RU Shelf Section Board

10RU Shelf Section Board

Button Bar Button Bar Button Bar

Button Bar Button Bar

Button Bar Button Bar

Console

Button Bar Button Bar

1U Drawer 1U Drawer AUX Cabinet AUX Cabinet AUX Cabinet

1U Drawer 1U Drawer

1U Drawer 5U CSD 1U Drawer Top Switch Top Switch Top Switch

10 RU Combo Board
10 RU Combo Board

10 RU Combo Board

1U Drawer 1U Drawer

ERB 1U Drawer 1U Drawer ERB

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer
10 RU Combo Board

1U Drawer
10 RU Combo Board

10 RU Combo Board

1U Drawer 1U Drawer 1U Drawer

1U Drawer 1U Drawer 1U Drawer Key:

1U Drawer 1U Drawer 1U Drawer Internal Starbus Port
1U Drawer 1U Drawer 1U Drawer Internal Power Port
1U Drawer 1U Drawer 1U Drawer External (Isolated) Starbus Port
1U Drawer 1U Drawer 1U Drawer Starbus Data
1U Drawer 1U Drawer 1U Drawer Optional Starbus Data
Cell 3 Cell 2 Cell 1 Starbus Power

Figure 4: Example Starbus Connection Diagram for Three Cell Cabinet

6.2.2 On startup, software controller will scan through the entire bus to detect and configure all
Starbus components. No jumpers or DIP switch settings will be necessary. In the event of
a new device being “hot-plugged,” the Starbus switches should be able to detect the new
device and emit event for software to handle. [MRD #14, #15, #19, #84]

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6.3 Starbus Port to Cabinet and AUX Mapping

Port # Board and Direction 1 Main + 6 AUX 1 Main + 13 AUX

1 Top Switch (Internal) Cell 1, Zone 0 Cell 1, Zone 0
2 Top Switch (Internal) Cell 1, Zone 1 Cell 1, Zone 1
3 Top Switch (Internal) Cell 1, Zone 2 Cell 1, Zone 2
4 Top Switch (Internal) Cell 2, Zone 3 Cell 2, Zone 3
5 Top Switch (Internal) Cell 2, Zone 4 Cell 2, Zone 4
6 Top Switch (Internal) Cell 2, Zone 5 Cell 2, Zone 5
7 Top Switch (Internal) Cell 3, Zone 6 Cell 3, Zone 6
8 Top Switch (Internal) Cell 3, Zone 7 Cell 3, Zone 7
9 Top Switch (Internal) Cell 3, Zone 8 Cell 3, Zone 8
10 Top Switch (External) AUX 1 AUX 1
11 Top Switch (External) AUX 2 AUX 2
12 Top Switch (External) AUX 3 AUX 3
13 Top Switch (External) AUX 4 AUX 4
14 Top Switch (External) AUX 5 AUX 5
15 Top Switch (External) AUX 6 To Expansion Board
1 Expansion Switch AUX 6
2 Expansion Switch AUX 7
3 Expansion Switch AUX 8
4 Expansion Switch AUX 9
5 Expansion Switch AUX 10
6 Expansion Switch AUX 11
7 Expansion Switch AUX 12
8 Expansion Switch AUX 13

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6.4 Cabinet PCBA and Wiring Configuration

Figure 5: Wiring Within 2 Cell Cabinet

6.4.1 Figure 4 is a rendering of the configuration for two Shelf Section at the top (one above the
console), and six Pharmacy Sections in the lower sections of the cabinet. Boards will be
mounted in the back of the frame, behind the drawers and shelves. Wiring will be routed
through openings at the top of each cell and routed alongside the Starbus boards.

6.4.2 This configuration has been chosen after careful consideration with regards to mechanical
structure and overrides, PCBA and cabling costs, and installability and serviceability.
Please refer to the Starbus Wiring Alternatives Study for further details.

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6.5 Top Switch

6.5.1 The Top Switch routes Starbus data from a single entering port to nine internal ports and
six external facing ports. The Top Switch will provide power monitoring and distribution to
all components within the cabinet (including up to two side-mounted ERBs).

Powercom/ Powercom/
Topswitch/ Power Supply
Adapter

12V Power x2
Data

Top Switch LEDs Indicators

Arbitration, Power Distribution,
CPLD Monitoring, Protection
Control,
Diagnostics Logic Frame ID Connector

ERB Power x2

External 1 External 2 External 3 External 4 External 5 External 6

Or
Zone1 Zone 2 Zone 3 Power Zone 4 Zone 5 Zone 6 Power Zone 7 Zone 8 Zone 9 Power
Expansion
12V Power x2

12V Power x2

12V Power x2

Data

Data

Data

Data
Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data
Figure 6: Top Switch Block Diagram

6.5.2 Each external facing Starbus port will be shielded, and have LED indicators to denote valid
Starbus connection and data transmission. This will allow service and customers to get a
quick visual indicator of correct operation. [MRD #14]

6.5.3 Top switch board logic will recognize when new Starbus nodes or switches are plugged in,
even detecting hot-plug events and will be able to emit events to the controller software for
further action. [MRD #19, #20]

6.5.4 An expansion switch board can also be added in the future to expand the number of
external ports available [MRD #4].

6.5.5 A data interface will be provided to connect to the frame ID board, which will give each
frame a unique ID number, which would be reportable to the controller software. The frame
ID board should also have some capability to indicate status of the top switch through the
top of the frame. [MRD #2, #5, #14, #84]

6.5.6 Power ports and rails will be monitors for shorting conditions, with the capability to turn off
the offending power rail. This affords some recovery in case of hardware issues. This
redundancy should improve the reliability of the hardware. [MRD #15].

6.5.7 Please refer to 62-16003 for complete functional specification for testing.
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 Functional Specification, Star Bus Electronics 01/19/15 62-13002 Rev 01

6.6 Zone Boards

3-Cell

1/2

1/4

S C
h o
e m c
l b o
f o m
b
o

Figure 7: Starbus Configuration Across Product Line

6.6.1 Figure 5 shows the three types of boards which will be installed in each cabinet. For Shelf
Sections, a 10 RU Shelf Section board will be used to connect shelves (button bars) to
Starbus. For Pharmacy Sections, a 10 RU Combo board will be used. The Combo board
combines the drawer switching components and the shelving interface components into
one board. This would allow easy future upgrades for the customer from Shelf to Pharmacy
Sections. A 5RU Combo board will be used for the ½ height sections in the Quarter Height
and Half Height frames. Thus, this set of three boards can accommodate all configurations
of cabinets of varying sizes across the product line. [MRD #4, #18, #61, #133, #134, #135]

6.6.2 On each Combo board, each switch port and each button bar port will be monitored and hot
plugged peripherals will emit an event to the controller and await further action. [MRD #19,
#20]

6.6.3 Power connections to each button bar and drawer will be fused and monitored. Dual
redundant power rails will be provided, and on failure of one rail, the node can still be
powered. This redundancy should improve reliability of the hardware. [MRD #15].

6.6.4 Each board will have LED indicators to help with quick diagnostics or failures. These
indicators will either be directly on the boards for immediate feedback, or will route the
appropriate event signals up to the controller software. [MRD #3, #14].

6.6.5 Please refer to 62-16004 and 62-16005 for full functional specifications for testing.

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6.7 Wiring Harnesses

Figure 8: Top Switch and Cabling (Top View)

6.7.1 Starbus data lines require 4 twisted pairs for upstream and downstream data and
handshaking. Starbus data cables will run from the top switch to each cabinet zone.
External Starbus connections will also use CAT5E and will be routed through a port in the
back top of the cabinet. Data cabling uses CAT5E due to the low cost and abundant
availability. The CAT5E could also be leveraged for future upgrades. This will also enable
field service and customers to quickly add or replace cabling, in case of damage or in case
of relocating AUX cabinets. [MRD #14]

6.7.2 Data connections between button bars and Shelf Section boards, and Pharmacy Section
and drawers will use ribbon cables.

6.7.3 Internal power cabling will require custom harnesses to be built. However, the connectors
specified will be fairly simple to construct and could be done without the need of an
expensive crimping tool.

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6.8 Future Proofing

6.8.1 Starbus is designed to be highly reconfigurable and upgradable. [MRD #184, #185]
• There is currently expansion room at the top of the cabinet to support embedded controllers
for expanded functionality.
• There is currently expansion room at the top of the cabinet to support Starbus adapters, to
support control by standalone AIO computer.
• Each shelf or pharmacy section board could be swapped out with new technology as they
are released.
• Cabling uses CAT5E, which can be directly upgradable to Ethernet. Extra CAT5E cabling
could be installed in manufacturing to provide parallel data access for future high bandwidth
requirements.
• Shelf section button bars communicated over a subnode standard, so any number of low
bandwidth devices could be added in place of a button bar, including RFID and other
sensors.

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7 Electrical Specifications
The following specifications are top level requirements for all Starbus boards. Please refer to each
PCBA’s specific specification document for detailed specifications.
7.1 Common Recommended Features [MRD #18]
7.1.1 Microcontrollers and related features:
7.1.1.1 Either PIC16F1947 or PIC16LF1947 microcontrollers should be used on Starbus
facing hardware so that common firmware libraries could be reused.
7.1.1.2 PIC16F1513 microcontrollers should be used as sub-node controller.
7.1.1.3 Microcontroller should use internal oscillator, unless additional clocks are necessary.
7.1.1.4 Programming connector shall be Molex 0855135002, if space (and height clearance)
permits, or Molex 0022053061 for low profile. Extra through-hole test-points should
be placed on data and clock pins for manufacturing use.
7.1.1.5 In case PCB space and UART pins are available and unused, the serial port should
be pulled out and used for serial debugging. TTL lines should be brought to header
pins for external conversion to USB signals.
7.1.1.6 Top switch shall include a 4 pin I2C interface to connect to a frame ID board,
providing cabinet ID from a ATSHA204 chip.

7.1.2 CPLD:
7.1.2.1 5M570ZT144 shall be used for Prototyping. 5M240ZT144 should be considered for
cost savings.
7.1.2.2 Programming port for CPLD should follow Altera specifications.
7.1.2.3 CPLD should use internal RC oscillator.

7.1.3 Starbus:
7.1.3.1 All Top Switch Starbus connections providing switching to nodes within a cabinet
(internal) shall use an unshielded R/A RJ45 jack (Molex 44620-0001 or equivalent),
with no magnetics necessary. ESD protection should be added if requirements
exceed what transceivers provide.
7.1.3.2 All Top Switch Starbus connections providing switching to nodes outside a cabinet
(external ports to AUXs) shall use shielded jacks with built in LEDs. Shielded jack
with LEDs should use Amphenol RJHSE-5385, or equivalent.
7.1.3.3 All Top Switch Starbus connections to nodes outside the cabinet (external ports to
AUXs) should be isolated.
7.1.3.4 All Starbus connectors on the Shelf and Pharmacy Section boards which are
receiving data downstream from the Top Switch shall use the unshielded RJ45

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connector. ESD protection should be added if requirements exceed what

transceivers provide.
7.1.3.5 All Starbus connectors providing Starbus signals to drawers shall use a vertical 14
pin shrouded 0.100” pitch header without locking latches.
7.1.3.6 All Button Bars shall connect to the Supply Zone board using a vertical 10 pin
shrouded 0.050” pitch header without locking latches(CNC Tech 3220-10-0100-00,
Samtec SHF or ESHF series, or equivalent).
7.1.3.7 Starbus connector on Pharmacy section boards shall be 14 pin, 2mm pitch, IDC
headers. Drawers shall have matching 2mm pitch IDC headers.
7.1.3.8 RS422 drivers and receivers shall be rated for ESD protection (15kV Air, 8kV
Contact). TI AM26LV31EIRGYR and AM26LV32EIRGYR shall be used for Prototype
1. Transceivers selected in future prototypes or cost reduction measures shall
conform to the same operational modes as the TI parts selected, including 1Mbps,
I/O levels during operation, failure, and sleep state.
7.1.3.9 RS422 receivers shall be terminated with a 120 ohm, ¼W, termination resistor,
placed right before the receiver input pins.
7.1.3.10 Drawers shall have 10k resistor across two pins to allow detection and soft power
start.
7.1.3.11 Starbus upstream signals shall be inverted in the microcontroller UART peripheral.
This is inverted back at the Starbus to USB converter right before the PC.
7.1.3.12 Starbus RJ45 jacks shall follow the following pinout:

Pin Signal
1 Down+
2 Down-
3 Up+
4 Grant+
5 Grant-
6 Up-
7 Request+
8 Request-
7.1.3.13 Starbus nodes shall operate and respond in accordance with the latest protocol
specifications.
7.1.3.14 Starbus nodes shall obey the handshaking protocols for upstream transmission. All
nodes should relinquish bus control after upstream data transmission within time
specified by the latest protocol specification. Any violations and errors shall be
detected by the upstream switch(es) and reported to the controller.
7.1.3.15 Any failure or shorts on Starbus data lines shall only affect downstream operations.
Upstream ports which are shorted should be blocked at the switch level.

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7.1.3.16 All Starbus nodes shall put RS422 driver in sleep mode, until startup routines are
finished successfully. On completion, microcontroller shall enable the RS422 driver,
to indicated to the upstream port that node is plugged in and operational.
7.1.3.17 All Starbus switch should have the ability to detect when a hardware device has
been plugged into the system.

7.1.4 PCBA Power:

7.1.4.1 All power connectors on any PCBs should use 4 Pin locking connector (TE 640389-
4 or equivalent), and shall have the following pinout.

Pin Signal
1 +12V (Primary)
2 Ground (Primary Return)
3 Ground (Secondary Return)
4 +12V (Secondary)

7.1.4.2 Power connections shall be rated for up to 10A, aggregate.

7.1.4.3 All power rails shall have primary and secondary power rails. 12V should be
supplied as primary and secondary rails to each board. 3.3V should be supplied as
primary and secondary rails to each button bar.
7.1.4.4 All power rails should be fused with resettable fuses, at some level on each board, to
be tolerant of shorts on either power rails.
7.1.4.5 Powercom board should supply, at minimum, 7A (+/-10%) at 12V (+/-10%) to the
Top Switch board, aggregate, on the primary and secondary rails.
7.1.4.6 All Starbus boards shall be able to operate from either primary or secondary rails.
7.1.4.7 Voltages on primary and secondary rails on all node boards, after input protection
and filter circuitry, shall be greater than 10.75V.
7.1.4.8 Power traces on each power rail should be sized to support 10A of current.
7.1.4.9 The voltage drop on the primary and secondary rails through the Top Switch should
not be greater than 1 V.
7.1.4.10 The MCU or power management IC (using LTC4221CGN or equivalent) shall
monitor the primary and secondary rails on the Top Switch and shall react to short
circuit conditions. The monitored power should then be branched out to the outgoing
power connectors to the cells. The MCU should generate a Starbus event in case of
over-current condition on any of the power rails providing power to each cell.
7.1.4.11 Top Switch shall provide three output power connectors for each cell of the cabinet.
Filtering should be added on each rail to attenuate EMI.

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7.1.4.12 Top Switch shall provide two output power connectors for ERBs, and should be
placed on opposite sides of the board at the 3 and 9 o’clock positions. Filtering
should be added on each rail to attenuate EMI.
7.1.4.13 Top Switch should provide one output power connector for expansion board power.
Filtering should be added on each rail to attenuate EMI.
7.1.4.14 Each board should use a diode circuit to “OR” the 12V inputs for on-board 3.3V
generation.
7.1.4.15 Each PCBA shall use high efficiency switching regulators to provide 3.3V (+/-10%)
for sub circuitry, as well as to supply sub-nodes.
7.1.4.16 The Shelf board should monitor the current load on the 3.3V output(s). LEDs should
be the first level indicator of shorting condition. MCU should also be able to read
status and generate an event to the controller.
7.1.4.17 Combo board should monitor each drawer connector to detect new hardware and
soft-start power to control inrush current.

7.1.5 LED Indicators:

7.1.5.1 On Top Switch, for external facing ports, 2 LEDs should be used to indicate:
7.1.5.1.1 Should show solid green for Starbus connection valid or enumerated.
7.1.5.1.2 Should show blinking green for any TX/RX activity
7.1.5.1.3 Should show solid orange for Switch error
7.1.5.1.4 Should show blinking orange for TBD fuction
7.1.5.2 On Top Switch, Red/Green LEDs (Kingbright WP59EGW or equivalent) should be
used to denote power and status.
7.1.5.2.1 Should show solid green for 12V good
7.1.5.2.2 Should show blinking red for short circuit condition on any of three power distribution
connectors.
7.1.5.3 On all boards, LEDs should be used to indicate communication status.
7.1.5.3.1 Should include one flashing green LED for any TX activity.
7.1.5.4 Should include one flashing green LED for any RX activity.SMT LEDs should be
used for other diagnostic purposes, as indicators, or which would be helpful in
debugging (detect over current conditions, etc).
7.1.5.4.1 Should include LEDs on power good or fault pins for current monitoring
7.1.5.4.2 Should include LEDs to denote proper operational status (Button Bar Inserted and
configured)
7.1.5.4.3 Should include LEDs for MCU to denote proper operation – blink after startup?
7.1.5.4.4 Should include LEDs to show state of switch operation?

7.1.6 Cable Harnesses

7.1.6.1 Starbus Data
7.1.6.1.1 Majority of Starbus should use CAT5 cabling. Each cell should have one bundle of
three CAT5 cabling of proper lengths. CAT5 was chosen specifically because it is

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cheap and readily available anywhere and replacements can be easily obtained by
field personnel in most electronics stores. [MRD #2]
7.1.6.1.2 Starbus data connection to drawers should use a 14 conductor ribbon cable,
terminated with 0.100” pitch IDC connectors. Pinouts are TBD.
7.1.6.2 Starbus Power Harness
7.1.6.2.1 Power cable harness shall use TE 3-644878-4 (or equivalent) on end connectors,
and TE 3-644465-4 (or equivalent) connectors in line.
7.1.6.2.2 18 AWG wire should be used for power. Yellow wire shall be used for 12V, and black
wire for ground.
7.1.6.2.3 Total length of cable harness will be estimated 410cm in length, with 3 pinch points
and service loops to connect to zone.
7.1.6.3 Button Bar Cable
7.1.6.3.1 Power and signal cable harness should be 10 position, 0.025” pitch, ribbon cable
(3M 3749/10-100 or equivalent) terminated by 0.050” IDC sockets (CNC 3230-10-
0103-00 or equivalent).
7.1.6.4 Drawer Cable
7.1.6.4.1 Power and signal cable harness should be 14 position, 1mm pitch, ribbon cable
terminated by 2mm IDC sockets.

7.2 PC interface Requirements

7.2.1.1 The Star Bus data path shall be implemented using the RS422 standard.
7.2.1.2 A USB to Starbus adapter should be built into the Powercom board.
7.2.1.3 The PC COM port shall be able to support:

Baud Rate 1 Mbps

Data Bits 8
Start Bits 1
Stop Bits 1
Parity No

7.3 Bus Signaling Requirements

7.3.1 At the physical layer, upstream flow control is a simple handshake using two handshaking
signals. Each node with a packet to send to the Controller would drive a request line and
wait until the grant signal is asserted to transmit. Any data driven on the data line before
grant is given would result in a fault condition, and reported by the upstream switch.
Timeout for holding data lines are set and controlled through Starbus commands to each
Starbus switch.

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7.4 ESD Requirements

7.4.1 Starbus boards should be designed to tolerate ESD up to 15kV air discharge, and 8kV
contact discharge on all user accessible or touchable areas. [MRD #15]
7.5 Testing Requirements
7.5.1 Starbus PCBAs should reference each PCBA’s functional specification document for
detailed test requirements.
8 Mechanical Specifications
For complete mechanical specifications, please refer to the following documents:
• 62-16003_Specification, PCBA, 16 Port Top Switch, Starbus
• 62-16004_Specification, PCBA, Shelf Section, 10RU, Starbus

8.1.1.1 In general, each 10 RU board will attach to the frame using multiple standoffs which
mount to slots on the board, and will only require two screws to secure to the frame.
This makes the board very easy to remove from the back of the frame. [MRD #2,
#14]
8.1.1.2 5RU boards will attach to the frame using the same standoff pitch, and will require
one screw to secure to the frame.
8.1.1.3 Mounting holes should be sized for M4 fasteners.
8.1.1.4 The drawer connectors should be purposely differentiated from the shelf and button
bar connectors by size and orientation. This should minimize mistakes and make
field and customer upgrades cleaner and simpler. [MRD #2, #14]

9 Deliverables and Milestones

9.1 Verification Test

9.1.1 At least two phases of prototypes will be made to execute Engineering Verification Test
(EVT). Engineering will be responsible for performing EVT and review test results with
other departments. [MRD #26]

9.2 Validation Test

9.2.1 Minimum one phase of pilot production will be provided for the External Validation [EV] and
regulatory agency tests and environmental tests. Engineering will be responsible for
regulatory agency test and environmental tests. EV team will be responsible for running
validation test. [MRD #26]

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9.3 Release Date

9.3.1 All Starbus components should be ready for production release to market in 2017. [MRD
#1]

9.4 Life Expectancy

9.4.1 All Starbus components should be selected, where available, for target life expectancy of
ten years after product release, through 2027. [MRD #8, #9]

9.4.2 Since not all parts should have a 10 year life-span, HWE will create the list of critical single
source components and procurement group shall engage with vendor to early forecast the
EOL of items.

10 Manufacturability and Sourcing

10.1 Board Manufacturing

10.1.1 Boards should be designed to have parts on a single side to minimize production
complexity and time. BGA style packages should not be used if alternate footprints are
available and board space is available. QFN type parts should be used sparingly. Surface
mount passives should be 0402 or larger. Debug ports should be clearly marked out.
Boards should be designed to facilitate bed-of-nails production test fixtures, with surface
mount or through-hole pads on the bottom side of the board to break out signals of interest.
PCBs shall be manufactured to be ROHS compliant. [MRD #2, #50, #52]

10.1.2 Most Starbus boards shall be less than 20” in length. However, the button bars have to be
23” in length, and cannot be shortened. However, the 20” length is typically specified for
maximum length of area accessible by the SMT machine, and not the maximum FR4
material panel size. The parts of all boards will be limited to within a 20” maximum length of
the board. [MRD #66]

10.1.3 PCBs shall have space designated for part numbering (p/n) and bar code labels (s/n). The
serial number The MCU of the board will also have serial number programmed in memory
by manufacturing. [MRD #65, #84]

10.2 Parts Selection and Sourcing

10.2.1 Digi-key and Mouser should be primary sources for prototyping. Part selection will be
optimized for quantity available and multiple sources (eg pick RJ45 jack which has parts
available from multiple vendors with same footprint and dimensions). Production parts will
be sourced in bulk from reputable vendors by Procurement.
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10.2.2 Common parts should be selected for all major electronics components (microcontroller,
connectors, etc) to drive COGs down. [MRD #18]

10.2.3 All parts selected shall be ROHS compliant. [MRD #50, #52]

10.2.4 Parts should be selected with long product life, where ever possible, targeting EOL 2027.
[MRD #8, #9]. This should also boost the reliability of the hardware and minimized part
failures. [MRD #15]

10.3 Support Tools and Test Requirements

10.3.1 Test sets shall be produced for testing all components. Two prototype phases (including
verification tests), as well as EV testing will precede final production.

10.3.2 Testing should focus on Starbus reliability and long operational life with minimal failures.
ESD will be targeted for customer facing components. Testing will also be performed to
assure that the manufacturing of the PCBAs is robust and repeatable.

11 Serviceability, Installability, and Support Plan

11.1 Customer Servicing and Installation

11.1.1 Starbus boards should designed to be simple to install. The Top Switch will be accessed
from the top of the cabinet. The Pharmacy and Shelf Section boards will require removal of
groups of 5RU or 10RU of the drawers or shelves from the cabinet to access the boards.
The one benefit of this placement of the Starbus board is that it makes the Starbus boards
harder to access by unauthorized personnel. [MRD #54]

11.1.2 Starbus shall support self-detection of all components through the bus scan. This enables
customers to move drawers to other cabinets and have hardware and software work
together to identify such events has happened, including automatically updating where the
drawer has been moved to. [MRD #2, #4, #5, #19, #20, #84, #85]

11.1.3 Starbus boards shall also have basic diagnostic LEDs to indicate certain failure modes.
This will allow customers and/or service personnel to quickly ascertain and report errors.
[MRD #14]

11.1.4 Starbus boards should be designed to use minimum numbers of screws (two) so that
manufacturing can install quickly, and field service can quickly swap out boards. [MRD #21,
#64]

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11.2 Design for Improved Component Serviceability

11.2.1 Component serviceability is hinged upon the design of all the components that go into a
frame. Starbus boards are located to facilitate easy interfacing to drawers and shelves. In
the current location, the boards are not very easily serviceable. However, the benefits of
Starbus will help mitigate this concern. The advantage of Starbus is the ability to detect
where errors are occurring, so that servicing can target the problem directly. This improves
the service time by minimizing the debugging process needed to locate errors. [MRD #20,
#77, #78, #81, #85, #121

12 Environmental Considerations
12.1.1.1 Operating Temperature shall be between 0° - 40° C
12.1.1.2 Storage Temperature shall be between -40° - 85° C
12.1.1.3 Operating Input Voltage shall be 12V DC, +/-10%.

13 Regulatory Compliance

13.1.1 Since all Starbus components are receiving power from the Console, all regulatory
requirements for conducted emissions would be satisfied through the console. [MRD #17]

13.1.1.1 All components must meet the Restriction of Hazardous Substances (RoHS)
directive 2011/65/EU and China RoHS [MRD #51, #52]
13.1.1.2 EMC: FCC and CE testing shall pass Class B.
13.1.1.3 Safety: Designed for IEC 60601-1 – Medical Grade Safety, tested to 61010-1
standard for Electrical Equipment for Measurement, Control, and Laboratory Use.

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