Nexus Apollo Hardware Setup Guide

System Overview

The Nexus Apollo platform runs on a Raspberry Pi 5 with specialized I/O boards and AI acceleration hardware for real-time HVAC monitoring and control.

Hardware Components

Core System

Raspberry Pi 5 (8GB RAM)
- 2.4GHz quad-core ARM Cortex-A76 CPU
- 8GB LPDDR4X-4267 SDRAM
- Dual-band 802.11ac Wi-Fi
- Bluetooth 5.0 / BLE
- Gigabit Ethernet with PoE+ support

Storage

256GB NVMe SSD
- Connected via PCIe M.2 HAT
- Houses OS, databases, and models
- 3500MB/s read, 2500MB/s write speeds

AI Acceleration

Hailo-8 AI Accelerator
- 26 TOPS performance
- PCIe Gen 3.0 interface
- Sub-100ms inference for all models
- 2.5W typical power consumption

I/O Expansion

Sequent Microsystems MegaBAS-V4
- 8x relay outputs (10A @ 250VAC)
- 8x digital inputs (3-24V)
- 4x analog inputs (0-10V or 4-20mA)
- RS485 Modbus RTU interface
- I2C communication with Pi
Sequent Microsystems MegaIND-V4
- 4x analog inputs (0-10V/4-20mA)
- 4x analog outputs (0-10V/4-20mA)
- 8x digital I/O configurable
- Industrial temperature range

Power Supply

Mean Well DIN Rail Power Supply
- 24VDC, 5A output
- 85-264VAC input range
- DIN rail mounting
- Over-voltage/current protection

Cooling

Active Cooling System
- 40mm PWM fan for Pi 5
- Heatsinks for CPU and Hailo-8
- Temperature-controlled operation
- Target: <65°C under load

Physical Installation

1. Mounting Configuration

DIN Rail Layout (left to right):
[Power Supply] [Circuit Breaker] [MegaBAS] [MegaIND] [Pi5+Hailo]
     150mm          35mm           90mm      90mm       120mm

2. Wiring Diagram

Power Distribution:
AC Mains ──► Circuit Breaker ──► Power Supply
                                       │
                                       ├──► 24V to MegaBAS
                                       ├──► 24V to MegaIND
                                       └──► 5V to Pi5 (via buck converter)

I2C Bus:
Pi5 GPIO ──► MegaBAS (addr: 0x48) ──► MegaIND (addr: 0x50)
   SDA: Pin 3
   SCL: Pin 5
   GND: Pin 9
   3.3V: Pin 1

Modbus Network:
Equipment ──► RS485 A/B ──► MegaBAS RS485 ──► USB-RS485 ──► Pi5

3. Sensor Connections

Temperature Sensors (RTD PT100)

Connect to MegaBAS analog inputs
Use 3-wire configuration
Calibrate offset in software

Pressure Transducers (4-20mA)

Connect to MegaIND analog inputs
250Ω shunt resistor for current-to-voltage
Supply 24V from DIN rail PSU

Current Transformers

Split-core CTs on compressor lines
0-5A secondary to 0-10V converter
Connect to MegaBAS analog inputs

Digital Inputs

Compressor status (24V)
Fan status (24V)
Alarm contacts (dry contact)
Flow switches (dry contact)

Software Installation

1. Operating System Setup

# Flash Raspberry Pi OS (64-bit) to NVMe
sudo rpi-imager

# Initial configuration
sudo raspi-config
# Enable: I2C, SPI, Serial, SSH
# Disable: Bluetooth (if not needed)
# Set: GPU memory split to 16MB

# Update system
sudo apt update && sudo apt upgrade -y

2. Install Dependencies

# System packages
sudo apt install -y \
  nodejs npm \
  postgresql postgresql-contrib \
  nginx \
  python3-pip python3-dev \
  i2c-tools \
  git curl wget \
  build-essential cmake

# Node.js 20.x
curl -fsSL https://deb.nodesource.com/setup_20.x | sudo -E bash -
sudo apt install -y nodejs

# PM2 process manager
sudo npm install -g pm2
pm2 startup systemd -u pi --hp /home/pi

3. Hailo-8 Setup

# Install HailoRT
wget https://hailo.ai/downloads/hailort_4.17.0_arm64.deb
sudo dpkg -i hailort_4.17.0_arm64.deb

# Install PCIe driver
sudo apt install -y hailort-pcie-driver
sudo modprobe hailo_pcie

# Verify installation
hailortcli fw-control identify

# Expected output:
# Hailo-8 device found
# Device ID: 0000:01:00.0
# Firmware version: 4.17.0

4. Sequent Microsystems Drivers

# MegaBAS installation
git clone https://github.com/SequentMicrosystems/megabas-rpi.git
cd megabas-rpi
sudo make install

# MegaIND installation
git clone https://github.com/SequentMicrosystems/megaind-rpi.git
cd megaind-rpi
sudo make install

# Test I2C communication
i2cdetect -y 1
# Should show devices at 0x48 (MegaBAS) and 0x50 (MegaIND)

# Test relay control
megabas 0 relay write 1 on
sleep 1
megabas 0 relay write 1 off

5. Database Setup

# PostgreSQL configuration
sudo -u postgres psql
CREATE DATABASE apollo_nexus;
CREATE USER DevOps WITH ENCRYPTED PASSWORD 'Invertedskynet2$';
GRANT ALL PRIVILEGES ON DATABASE apollo_nexus TO DevOps;
\q

# Import schema
psql -U DevOps -d apollo_nexus < /home/pi/apollo-nexus/schema.sql

# SQLite for high-frequency data
mkdir -p /home/pi/apollo-nexus/data
sqlite3 /home/pi/apollo-nexus/data/sensor_data.db < sensor_schema.sql

6. Application Deployment

# Clone repository
cd /home/pi
git clone https://github.com/yourusername/apollo-nexus.git
cd apollo-nexus

# Install backend dependencies
cd portal
npm install --legacy-peer-deps
cp .env.example .env
# Edit .env with your configuration

# Install frontend dependencies
cd ../apollo-ui
npm install --legacy-peer-deps
npm run build

# Start services with PM2
pm2 start ecosystem.config.js
pm2 save

Network Configuration

1. Ethernet Setup

# Static IP configuration
sudo nano /etc/dhcpcd.conf

interface eth0
static ip_address=192.168.1.100/24
static routers=192.168.1.1
static domain_name_servers=192.168.1.1 8.8.8.8

2. Cloudflare Tunnel

# Install cloudflared
wget https://github.com/cloudflare/cloudflared/releases/latest/download/cloudflared-linux-arm64
sudo mv cloudflared-linux-arm64 /usr/local/bin/cloudflared
sudo chmod +x /usr/local/bin/cloudflared

# Configure tunnel
cloudflared tunnel login
cloudflared tunnel create nexus-apollo
cloudflared tunnel route dns nexus-apollo nexus.automatacontrols.com

# Create config file
nano ~/.cloudflared/config.yml

tunnel: YOUR_TUNNEL_ID
credentials-file: /home/pi/.cloudflared/YOUR_TUNNEL_ID.json

ingress:
  - hostname: nexus.automatacontrols.com
    service: http://localhost:80
  - service: http_status:404

3. Nginx Configuration

# /etc/nginx/sites-available/apollo
server {
    listen 80;
    server_name nexus.automatacontrols.com localhost;

    # Frontend
    location / {
        proxy_pass http://localhost:3000;
        proxy_http_version 1.1;
        proxy_set_header Upgrade $http_upgrade;
        proxy_set_header Connection 'upgrade';
        proxy_set_header Host $host;
        proxy_cache_bypass $http_upgrade;
    }

    # Backend API
    location /api {
        proxy_pass http://localhost:8001;
        proxy_http_version 1.1;
        proxy_set_header X-Real-IP $remote_addr;
        proxy_set_header X-Forwarded-For $proxy_add_x_forwarded_for;
        proxy_set_header Host $host;
    }

    # WebSocket
    location /socket.io {
        proxy_pass http://localhost:8001;
        proxy_http_version 1.1;
        proxy_set_header Upgrade $http_upgrade;
        proxy_set_header Connection "upgrade";
    }
}

Calibration and Testing

1. Sensor Calibration

// calibration.js
const { exec } = require('child_process');

// Read analog input
function readAnalog(channel) {
  return new Promise((resolve, reject) => {
    exec(`megabas 0 aread ${channel}`, (error, stdout) => {
      if (error) reject(error);
      resolve(parseFloat(stdout));
    });
  });
}

// Calibrate temperature sensor
async function calibrateTemp(channel, actualTemp) {
  const rawValue = await readAnalog(channel);
  const offset = actualTemp - rawValue;
  console.log(`Channel ${channel} offset: ${offset}`);
  // Save to database
}

2. Relay Testing

#!/bin/bash
# test_relays.sh

echo "Testing all relays..."
for i in {1..8}; do
  echo "Relay $i ON"
  megabas 0 relay write $i on
  sleep 0.5
  megabas 0 relay write $i off
  sleep 0.5
done
echo "Relay test complete"

3. Modbus Communication Test

#!/usr/bin/env python3
# test_modbus.py

import minimalmodbus
import serial

# Configure instrument
instrument = minimalmodbus.Instrument('/dev/ttyUSB0', 1)
instrument.serial.baudrate = 9600
instrument.serial.timeout = 1

# Read holding registers
try:
    temp = instrument.read_register(0, 1)  # Address 0, 1 decimal
    print(f"Temperature: {temp}°F")
except Exception as e:
    print(f"Modbus error: {e}")

Monitoring and Maintenance

1. System Health Monitoring

# Create monitoring script
nano /home/pi/scripts/health_check.sh

#!/bin/bash

# CPU Temperature
cpu_temp=$(vcgencmd measure_temp | cut -d'=' -f2 | cut -d"'" -f1)

# Hailo-8 Status
hailo_status=$(hailortcli fw-control identify 2>&1)

# Memory usage
mem_usage=$(free -m | awk 'NR==2{printf "%.1f%%", $3*100/$2}')

# Disk usage
disk_usage=$(df -h / | awk 'NR==2{print $5}')

# Service status
pm2_status=$(pm2 status --no-color)

echo "System Health Report - $(date)"
echo "CPU Temp: ${cpu_temp}°C"
echo "Memory: ${mem_usage}"
echo "Disk: ${disk_usage}"
echo "Hailo-8: ${hailo_status}"
echo "Services: ${pm2_status}"

2. Automated Backups

# Daily backup script
nano /home/pi/scripts/backup.sh

#!/bin/bash

BACKUP_DIR="/media/backup"
DATE=$(date +%Y%m%d)

# Backup databases
pg_dump -U DevOps apollo_nexus > ${BACKUP_DIR}/postgres_${DATE}.sql
cp /home/pi/apollo-nexus/data/sensor_data.db ${BACKUP_DIR}/sqlite_${DATE}.db

# Backup configuration
tar -czf ${BACKUP_DIR}/config_${DATE}.tar.gz \
  /home/pi/apollo-nexus/.env \
  /home/pi/.cloudflared/config.yml \
  /etc/nginx/sites-available/

# Keep only last 30 days
find ${BACKUP_DIR} -name "*.sql" -mtime +30 -delete
find ${BACKUP_DIR} -name "*.db" -mtime +30 -delete
find ${BACKUP_DIR} -name "*.tar.gz" -mtime +30 -delete

3. Log Rotation

# Configure logrotate
sudo nano /etc/logrotate.d/apollo

/home/pi/apollo-nexus/logs/*.log {
    daily
    rotate 14
    compress
    delaycompress
    missingok
    notifempty
    create 644 pi pi
    sharedscripts
    postrotate
        pm2 reloadLogs
    endscript
}

Troubleshooting

Common Issues

I2C Communication Failure

# Check I2C devices
sudo i2cdetect -y 1
# Reset I2C bus
sudo rmmod i2c_bcm2835
sudo modprobe i2c_bcm2835

Hailo-8 Not Detected

# Check PCIe
lspci | grep Hailo
# Reload driver
sudo rmmod hailo_pcie
sudo modprobe hailo_pcie

High Temperature

# Check thermal throttling
vcgencmd get_throttled
# Increase fan speed
echo 255 > /sys/class/hwmon/hwmon2/pwm1

Database Connection Issues

# Check PostgreSQL status
sudo systemctl status postgresql
# Check connections
sudo -u postgres psql -c "SELECT * FROM pg_stat_activity;"

Performance Optimization

1. CPU Governor

# Set to performance mode
echo performance | sudo tee /sys/devices/system/cpu/cpu*/cpufreq/scaling_governor

2. Memory Management

# Increase shared memory for PostgreSQL
sudo sysctl -w kernel.shmmax=268435456
echo "kernel.shmmax=268435456" | sudo tee -a /etc/sysctl.conf

3. Network Optimization

# Increase network buffers
sudo sysctl -w net.core.rmem_max=134217728
sudo sysctl -w net.core.wmem_max=134217728

Security Hardening

1. Firewall Configuration

# Install and configure UFW
sudo apt install ufw
sudo ufw default deny incoming
sudo ufw default allow outgoing
sudo ufw allow 22/tcp  # SSH
sudo ufw allow 80/tcp  # HTTP
sudo ufw allow 443/tcp # HTTPS
sudo ufw enable

2. SSH Hardening

# Disable password authentication
sudo nano /etc/ssh/sshd_config
# Set: PasswordAuthentication no
# Set: PermitRootLogin no
sudo systemctl restart sshd

3. Fail2ban Setup

sudo apt install fail2ban
sudo cp /etc/fail2ban/jail.conf /etc/fail2ban/jail.local
sudo systemctl enable fail2ban
sudo systemctl start fail2ban

Support Resources

Hardware documentation: /home/pi/docs/hardware/
Sequent Microsystems support: https://sequentmicrosystems.com
Hailo support: https://hailo.ai/developer-zone/
System logs: journalctl -u apollo-nexus
Application logs: pm2 logs

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