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Verigy V93000 Service Training Module 4: Low Level Diagnostic Diagnostic Subsystem Introduction The Verigy V93000 system has a diagnostic subsystem (DIS), which allows troubleshooting 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 • Over temperature condition • AC input voltage failure • DC output voltage failure 2. To measure all parameters vital for the test system: • • • AC input voltage Ground failure current Water delta pressure • All DC voltages and trim voltages (DC/DC boards) • All DC currents (DC/DC boards) • DC voltages (auxiliary supplies) • Board temperatures 3. Check Fibre optic communication path. Verigy Restricted Page 2 04 - Low Level Diagnostic Front Panel LED States Problems which occur during the system start procedure are indicated by the LEDs at the ON/OFF unit. When starting the system, watch these LEDs. Status Green Yellow Red System stand-by off off off After ‘ON’ LED is pressed (checks cooling unit, leakage and EMO) off off off Starting cooling, connecting AC/DCs and switched power outlets blinking slow off off Starting DC/DC Converters blinking fast off off System OK on off off System running, cooling regulation warning on on off System shutdown, hardware failure off off on Verigy Restricted Page 3 04 - Low Level Diagnostic Process Structure PC Computer Interface Card Test Head Fiber Link Control Board DIS Bus USB-toRS232 Adapter RS232 Support Rack Rack Interface Board Verigy Restricted Page 4 04 - Low Level Diagnostic USB to RS232 Adapter • 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 Part No: 0960-2437 • This will point the software to look for the tester on the RS232 (COM1) port. Make sure to set this environment variable for all online users by placing the above command in every users “.bash_profile” Verigy Restricted Page 5 04 - Low Level Diagnostic Diagnostic Subsystem 400V Motherboard Primary Power DC/DC Converter AC/DC Converter Connector board Ribbon cables On board power supply 24 VDC 5 VDC +15 VDC -15 VDC +30VDC CAN bus CAN bus Power Control Board Rack I/FBoard DC/DC Converter Frontplane Clock Board CAN bus Cardcage 1 Clock Board Cardcage 3 RS232 Clock Board CAN bus Cardcage 2 Support Rack Clock Board Test Head Cardcage 4 Backplane Active Control Board Control Board Jumper Passive Control Board Active Control Board Control Board Jumper Passive Control Board Verigy Restricted Page 6 04 - Low Level Diagnostic CAN Nodes Frontplane CAN bus Connector board CAN bus CAN bus Power Control Board Clock Board Cardcage 1 Clock Board Rack I/FBoard Support Rack CAN bus Backplane Cardcage 2 Test Head Active Control Board Active Control Board Cooling Unit Can Node Rack interface board Power control board Active Control board CTH 1 2 STH 1 4 LTH 1 8 1 2 4 Verigy Restricted Page 7 04 - Low Level Diagnostic Starting PDIAG Start PDIAG Establish RS 232 Connection Success? Yes Wait 5 sec. Warning Message No No < 20 Retries? Yes Can not establish connection to Diagnostic Subsystem via RS232. RS232 retry mechanism disabled. IC-Test system normal operation is not restricted ! Please see Service Manual. Warning Message PDIAG Running Disable RS232 Verigy Restricted Page 8 04 - Low Level Diagnostic Troubleshooting PDIAG Problem 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.) Warning Message Can not establish connection to Diagnostic Subsystem via RS232. RS232 retry mechanism disabled. IC-Test system normal operation is not restricted ! Please see Service Manual. Verigy Restricted Page 9 04 - Low Level Diagnostic Troubleshooting PDIAG Problem Shut down SmarTest or PDIAG Connect / Check RS232 cable OK? No Power cycle Test System Yes OK? No Reboot WS Power cycle Test Head Yes OK? No Call Expert Yes Restart PDIAG Restart PDIAG Restart PDIAG Verigy Restricted Page 10 04 - Low Level Diagnostic Diagnostic User Interface Screen Two different possibilities to start Low-Level-Diagnostic and run functional tests: - Via GUI - Command line Verigy Restricted Page 11 04 - Low Level Diagnostic 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. Verigy Restricted Page 12 04 - Low Level Diagnostic Starting LLD From Command Line Low-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> Verigy Restricted Page 13 04 - Low Level Diagnostic Sequence of LLD Tests Use Only When Green Light is On! Use Only When the Red Light is On! Checks Support Rack Power System Start PDIAG and DIFT Run T DSAC Yes OK? Checks TH Power System Run T DSPC OK? No Checks Support Rack Voltages Yes Run T DVAC No Troubleshoot Failures Troubleshoot Failures OK? No Troubleshoot Failures Yes Quit DIFT and PDIAG Yes OK? No Start SW Troubleshoot Failures Run T DADR, DFOC, DCIC, DFLT Check TH Card Communications Yes OK? Run T DPCI, DPCE, DCLK Check TH Card Voltages No Troubleshoot Failures Verigy Restricted Page 14 04 - Low Level Diagnostic LLD Tests Run these 2 tests when there is a red light <power on> condition, but only 1 at a time. List of Tests: DSAC: DIS status AC/DC test DVAC: DIS voltage AC/DC test DSPC: DIS status power control test DPCI: DIS power ctrl volt 1 test (internal ADC) DPCE: DIS power ctrl volt 2 test (external ADC) DCLK: DIS clock bd volt 1 test DFLT: DIS fiber-link test DCIC: 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 Verigy Restricted Page 15 04 - Low Level Diagnostic Low-Level-Diagnostic Best 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 LowLevel-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. Verigy Restricted Page 16 04 - Low Level Diagnostic T DSAC : DIS Status AC/DC Test Verigy Restricted Page 17 04 - Low Level Diagnostic T DSAC : di_value_file diagnostic directory: /var/opt/hp93000/soc/diagnostic • Turn on value logging before running test • Di_value_file gives more information than di_log_file Verigy Restricted Page 18 04 - Low Level Diagnostic T DSPC : DIS Status Power Control Test Verigy Restricted Page 19 04 - Low Level Diagnostic T DSPC : value vs. log di_value_file diagnostic directory: /var/opt/hp93000/soc/diagnostic • Turn on value logging before running test di_log_file Verigy Restricted Page 20 04 - Low Level Diagnostic T DVAC : DIS Voltage AC/DC Test Verigy Restricted Page 21 04 - Low Level Diagnostic T DPCI : DIS Power Control Voltage 1 Test Verigy Restricted Page 22 04 - Low Level Diagnostic T DPCE : DIS Power Control Voltage 2 Test Verigy Restricted Page 23 04 - Low Level Diagnostic T DCLK : DIS Clock Board Voltage Test Verigy Restricted Page 24 04 - Low Level Diagnostic T DFLT : DIS Fiber-Link Test To Manipulator The purpose of this test is to check the fiber optic connection between the controller and the test head. Fiber Optic Communications RS232 cable Card Cage 8 Card Cage 7 Large test head Card Active Cage 3 control board Clock board Supply only Card Cage 1 Clock board Termination Standard support rack Power control board Clock board Control Connection Card board cable Cage 4 Power backplane Rack interface board Power control board Active control board Active Card Card control Cage 2 Cage 6 board Power control board Card Cage 5 Clock board Power control board Active control board Verigy Restricted Page 25 04 - Low Level Diagnostic 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. Verigy Restricted Page 26 04 - Low Level Diagnostic T DFOC : Fiber Optic Test The purpose of this test is to check the fiber optic cable. Fiber Optics Optic Coupler Verigy Restricted Page 27 04 - Low Level Diagnostic T DADR : Address & Data Bus Test The multiplexed address/data bus in the testhead are checked for stuck-at0 and stuck-at-1 failures. RS232 DIS Bus Fiber Optics Verigy Restricted Page 28 04 - Low Level Diagnostic Verigy Restricted Page 29 04 - Low Level Diagnostic