verigy v93000 service training module 4: low level diagnostic

Verigy V93000Service Training

Module 4:Low Level Diagnostic

04 - Low Level Diagnostic

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Diagnostic Subsystem Introduction

The Verigy V93000 system has a diagnostic subsystem (DIS), which allowstroubleshooting of the power system and communication problems.The diagnostic subsystem allows:

1. Read error information out of hardware registers:• EMO condition• Pressure failure• Cooling unit failure

2. To measure all parameters vital for the test system:• AC input voltage• Ground failure current• Water delta pressure

3. Check Fibre optic communication path.

• Over temperature condition• AC input voltage failure• DC output voltage failure

• All DC voltages and trim voltages (DC/DC boards)• All DC currents (DC/DC boards)• DC voltages (auxiliary supplies)• Board temperatures


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System stand-by offoff off

After ‘ON’ LED is pressed (checks cooling unit, leakage and EMO) offoff off

Front Panel LED States

Problems which occur during the system start procedure are indicatedby the LEDs at the ON/OFF unit.

When starting the system, watch these LEDs.

Status

Starting cooling, connecting AC/DCs and switched power outlets

Starting DC/DC Converters

System running, cooling regulation warning

System shutdown, hardware failure

System OK

Green Red

off

blinking fast

off

off

off

off

on

on off

Yellow

on

off

on

off

offblinking slow


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Process Structure

Fiber Link

PC Test Head

RS232Rack Interface

Board

Control Board

DIS Bus

Computer Interface Card

Support Rack

USB-to-RS232

Adapter


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• Due to the obsolescence of the RS232 port on future controllers, a USB-to-RS232 adapter is required with all LINUX controllers.By default the software assumes that the RS232 cable from the test system is connected to this adapter (see picture below) and the adapter is connected to a USB port on the controller.

NOTE: If adapter is lost or damaged, a temporary work around is explained below:• Attach the RS232 cable to the serial port (COM1) directly. You need to set the

environment variable DI_RS232 before PDIAG (SmarTest) is started: export DI_RS232=ttyS0

• This will point the software to look for the tester on the RS232 (COM1) port. Make sure to set this environment variable for allonline users by placing the above command in every users “.bash_profile”

Part No: 0960-2437

USB to RS232 Adapter


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Diagnostic Subsystem

Frontplane

CAN bus

Power Control Board

Primary Power

400V Motherboard

Rack I/FBoard

Ribbon cables

Support Rack

DC/DCConverter

DC/DCConverter

Connector board

Clock Board

Clock Board

Clock Board

Clock Board

Cardcage 1

Cardcage 2

Cardcage 3

Cardcage 4

CAN bus

CAN bus

Test Head

Backplane

RS232

On board power supply

24 VDC5 VDC+15 VDC-15 VDC+30VDC

Pwr c

ntl c

able

2Pw

r cnt

l cab

le 1

CAN bus

Active Control Board

Passive Control Board

Control BoardJumper


Passive Control Board

Control BoardJumper

AC/DCConverter


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LTH

Pwr c

ntl c

able

1

Frontplane

CAN bus

Power Control Board

Rack I/FBoard

Support Rack

Connector board

Clock Board Active Control Board


Clock Board

Cardcage 1

Cardcage 2

CAN bus

Test Head

Backplane

CAN

bus

CAN bus

Cooling Unit

CAN Nodes

Can Node STH

Rack interface board 1Power control board 4Active Control board 2

184

CTH

121


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No

Yes

No

Warning MessageCan not establish connection to Diagnostic Subsystem via RS232.RS232 retry mechanism disabled.IC-Test system normal operation is not restricted ! Please see Service Manual.

Success?

PDIAGRunning

Disable RS232

Warning Message

< 20 Retries?

Wait 5 sec.Establish RS 232 Connection

Start PDIAG

Starting PDIAG


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Troubleshooting PDIAG Problem

Warning MessageCan not establish connection to Diagnostic Subsystem via RS232.RS232 retry mechanism disabled.IC-Test system normal operation is not restricted ! Please see Service Manual.

Check if UI-report window indicates below warning message;

DIUI window also appears without any components related to power systems (missing red bubbles for AC/DC, DC/DC, Power Ctrl. Bds.)


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No

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Troubleshooting PDIAG Problem

Shut down SmarTest or PDIAG

Connect / Check RS232 cable

OK?

Restart PDIAG

Restart PDIAG

Restart PDIAG

OK?

OK?

Power cycle Test System

Reboot WS Power cycle Test Head

Call Expert


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Diagnostic User Interface Screen

Two different possibilities to start Low-Level-Diagnostic and run functional tests: Via GUI Command line

steve.prassel

new window capture for CTH


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Starting Diagnostic User Interface (DIUI)

Low-Level programs directory: /opt/hp93000/soc/pws/bin

• Enter: “./DIUI”

• This command will check automatically if SmarTest or PDIAG process is running:

• If PDIAG is not running the software will show up a selection menu.

• Follow the instructions on the screen and the known Diagnostic window will start up.

• Enter into Service-Mode and select required DIS test.


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Starting LLD From Command LineLow-Level programs directory: /opt/hp93000/soc/pws/bin

• ./PDIAG -n -t <4/8> (-n: system S/W not running, -t: number of testhead cardcages)• ./DIFT

• load tcf file: >l /opt/hp93000/soc/pws/data/di_files/all_dd.tcf• execute a DIS test: >T xxxx xxxx: mnemonics of DIS tests

• tail –f /var/opt/hp93000/soc/diagnostic/di_log_file.<date_time>


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Sequence of LLD Tests

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

TroubleshootFailures





Start PDIAG and DIFT

Run T DSAC OK? OK?

OK?

OK? OK?

Run T DSPC Run T DVAC

Run T DPCI,DPCE, DCLK

Run T DADR,DFOC, DCIC,DFLT

Quit DIFT and PDIAG

Start SW

Check TH Card Voltages

Check TH CardCommunications

Checks Support Rack VoltagesChecks Support Rack Power System Checks TH Power System

Use Only When the Red Light is On!Use Only When

Green Light is On!


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LLD Tests

Run these 2 tests when there isa red light <power on> condition,but only 1 at a time.

List of Tests:DSAC: DIS status AC/DC testDVAC: DIS voltage AC/DC testDSPC: DIS status power control testDPCI: DIS power ctrl volt 1 test (internal ADC)DPCE: DIS power ctrl volt 2 test (external ADC)DCLK: DIS clock bd volt 1 testDFLT: DIS fiber-link testDCIC: DIS computer interface card test (no FW allowed)DFOC: DIS fiber optic test (optical cable needed, needs user interaction; no FW allowed)DADR: DIS address & data bus test (no FW allowed)PCON: DIS power consumption test


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Low-Level-DiagnosticBest practice

• When DIUI startup fails with message: “Cannot find PDIAG process”; just re-enter again command DIUI, which will most likely startup Diagnostic GUI.

• When DIUI startup fails with message: “another PDIAG process is already running”; search for PDIAG process by using command: ps –ef | grep PDIAG and manually stop this running process: kill -9 <process-id-number of PDIAG>

• With each Low-Level-Diagnostic run only select a single subtest each.

• Sometimes Rule-Interpreter (DIRI) is not able to display a meaningful result:“Sorry, no information in knowledgebase found”, please continue in the list of Low-Level-Diagnostic subtests; just select the next test.

• Close Low-Level-Diagnostic GUI only by selecting: FILE > Close and Exit PDIAG and DIFT

• Each Diagnostic run creates the known result files; for easy navigation use the command: ll –lart to list the files by their date, when they have been created.


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T DSAC : DIS Status AC/DC Test


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T DSAC : di_value_file

diagnostic directory: /var/opt/hp93000/soc/diagnostic

• Turn on value loggingbefore running test

• Di_value_file gives moreinformation than di_log_file


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T DSPC : DIS Status Power Control Test


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T DSPC : value vs. log

diagnostic directory: /var/opt/hp93000/soc/diagnostic

• Turn on value loggingbefore running test

di_log_file

di_value_file


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T DVAC : DIS Voltage AC/DC Test


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T DPCI : DIS Power Control Voltage 1 Test


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T DPCE : DIS Power Control Voltage 2 Test


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T DCLK : DIS Clock Board Voltage Test


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T DFLT : DIS Fiber-Link Test

The purpose of this test is to check the fiber optic connection between the controller and the test head.

Clockboard

CardCage 1

CardCage 5

Largetest head

Active controlboard

Connectionboard

CardCage 7

Card Cage 3

CardCage 6

CardCage 2

CardCage 4

Card Cage 8

Clockboard

Clockboard

Clockboard

Active controlboard

Active controlboard

Active controlboard

Control cable

Standard support rack

Rack interfaceboard

RS232cable

Power backplane

Power controlboard

Powercontrolboard

Powercontrolboard

Power controlboard

Termination

Supply onlyTo

Man

ipul

ator

Fiber Optic Communications


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T DCIC : Computer Interface Card Test

This test checks the computer interface card of the controller. During the test the CIC is set into the ‘Loopback’ mode which is an internal short circuit between transmit path and receive path.


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T DFOC : Fiber Optic Test

The purpose of this test is to check the fiber optic cable.

Optic CouplerFiber Optics


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T DADR : Address & Data Bus Test

The multiplexed address/data bus in the testhead are checked for stuck-at-0 and stuck-at-1 failures. RS232 DIS Bus

Fiber Optics


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verigy v93000 service training module 4: low level diagnostic

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