1. Verigy V93000 Service Training
Module 4:
Low Level Diagnostic
Module 4: Low Level Diagnostics
Objective:
Given:
Service Guide I
Study Guide
Quiz
Answer questions about the V93000 low level diagnostics. 90% correct answers are required to get credit for this module.
References:
Service Guide I Chapter 3, “Diagnostic”

2. 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:
Read error information out of hardware registers:
EMO condition
Pressure failure
Cooling unit failure
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
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 off off off off
System starting cooling and connecting mains to low frequency blinking off off
AC/DC converters and auxiliary supplies.
System starting DC/DC converters high frequency blinking off off
System okay on off off
System running, cooling regulation warning on on off
System shut down due to an error off off on
04 - Low Level Diagnostic

3. 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
04 - Low Level Diagnostic

4. Computer Interface Card
Process Structure PC
Test Head
Fiber Link
Computer Interface Card
Control Board
DIS Bus
USB-to-RS232 Adapter
Support Rack
RS232
Rack Interface Board
04 - Low Level Diagnostic

5. 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
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”
Part No:
Reason for the introduction for this USB to RS232 adapter is that the serial (COM) ports might get obsoleted soon.
The environment variable is read by the PDIAG program at start-up.
04 - Low Level Diagnostic

6. Diagnostic Subsystem Support Rack Test Head Pwr cntl cable 2
Frontplane
CAN bus
Power Control
Board
Primary
Power
400V Motherboard
Rack I/FBoard
Ribbon cables
Support Rack
DC/DC
Converter
Connector board
Clock Board
Cardcage 1
Cardcage 2
Cardcage 3
Cardcage 4
Test Head
Backplane
RS232
On board power supply
24 VDC
5 VDC
+15 VDC
-15 VDC
+30VDC
Pwr cntl cable 2
Pwr cntl cable 1
CAN bus
Active Control Board
Passive Control Board
Control Board
Jumper
AC/DC
The diagnostic subsystem is powered by the +5/±15V/+24V from the Support DC/DC board. The presence of the +5 V can be checked on the control board. If the green LED labeled 5VCL lights, the diagnostic subsystem is powered up.
On the control board another green LED indicated, if the CAN bus is working. The LED is located close to the 5VCL. If it blinks, the CAN bus is up and running. If it is continuously turned on or off, the CAN bus is not working and you can not perform low-level Diagnostic.
The Rack interface board includes the DIS controller and the CAN to RS232 conversion circuitry. The RS232 interface is connected to the workstation. When SmartTest or the PDIAG process is started, the RS232 link to the workstation will be established.
The diagnostic subsystem allows 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 (support DC/DC board)
Board temperatures
04 - Low Level Diagnostic

7. CAN Nodes Frontplane CAN bus Power Control Board Rack I/FBoard
Support Rack
Connector board
Clock Board
Active Control Board
Cardcage 1
Cardcage 2
Test Head
Backplane
Cooling Unit
Pwr cntl cable 1
Can Node
CTH
STH
LTH
Rack interface board 1 1 1
Power control board 2 4 8
Active Control board 1 2 4
The diagnostic subsystem bases on the CAN (controller area network) architecture. The rack interface board, the power control boards and the control board represent the CAN nodes. A CAN node has read/write access to the CAN bus.
After switching on the line switch, the CAN nodes registers themselves on the CAN bus. Therefore, the CAN node number may vary each time the system is turned on. The maximum number of CAN nodes is depending on the size of the test head. A 512pin test head holds 6 nodes and a 1024 pin test head 12 nodes.
04 - Low Level Diagnostic

8. Starting PDIAG Warning Message Start PDIAG Establish RS 232 Connection
Wait 5 sec.
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. No
< 20
Retries?
Success? No
Yes
Yes
Warning
Message
PDIAG
Running
Disable
RS232
Starting SmarTest forks the PDIAG process automatically. The PDIAG process tries to establish the RS232 connection to the workstation.If it fails, PDIAG will retry. After 20 retries the RS232 retry mechanism will be disabled. Therefore, neither low-level Diagnostic can be started nor the DIS tests can be performed. A warning message in the report window informs the user about the problem establishing the RS232 connection.
04 - Low Level Diagnostic

9. 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.
04 - Low Level Diagnostic

10. Troubleshooting PDIAG Problem
Shut down SmarTest or PDIAG
Connect / Check RS232 cable No
Power cycle Test System
OK?
Yes No
Reboot WS
Power cycle Test Head
OK?
Yes
Call Expert
OK? No
Yes
Restart PDIAG
Restart PDIAG
Restart PDIAG
After rebooting the workstation the test system must be powercycled. The workstation writes non-defined pattern to the RS232 interface during the boot phase. These pattern set the DIS controller on the rack interface board to a non-defined state. Powercycling of the support rack resets the DIS controller.
On workstations it can happen that the ports A and B of the RS232 are swapped. In this case please enter the following comands after looging into the system as root:
mv /dev/tty0p0 /dev/tty0p0.old
mknod /dev/tty0p0 c 1 0x010000
chmod 666 /dev/tty0p0
chown bin:bin /dev/tty0p0
Please reboot the workstation upon completion of this procedure.
Please note that the second RS232 might not be useable for remote support after this procedure. Therefore it is advised to keep Port B as the port for the diagnostic subsystem on C200 and C360 workstations.
04 - Low Level Diagnostic

11. Diagnostic User Interface Screen
Two different possibilities to start Low-Level-Diagnostic and run functional tests:
Via GUI
Command line
04 - Low Level Diagnostic

12. 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.
04 - Low Level Diagnostic

13. 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>
04 - Low Level Diagnostic

14. Sequence of LLD Tests Use Only When Green Light is On!
Use Only When the Red Light is On!
Checks Support Rack Power System
Checks TH Power System
Checks Support Rack Voltages
Start PDIAG and DIFT
Run T DSAC
Yes
OK?
Run T DSPC
Yes
OK?
Run T DVAC No No
Troubleshoot
Failures
Troubleshoot
Failures
OK?
Troubleshoot
Failures No
Yes
Run T DADR,
DFOC, DCIC,
DFLT
Yes
Check TH Card
Voltages
Quit DIFT and PDIAG
Yes
Run T DPCI,
DPCE, DCLK
OK?
OK? No
Check TH Card
Communications No
Troubleshoot
Failures
Troubleshoot
Failures
Start SW
The tests T DSAC and T DSPC are checking the error latches on the power control and the rack interface board. Therefore it is important not to cycle power on the tester if a failure condition occurred. Only if these two tests pass the results of the remaining tests are meaningful. Detail for the rest of the slides will be explained in the following slides.
04 - Low Level Diagnostic

15. LLD Tests List of 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
04 - Low Level Diagnostic

16. 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 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.
04 - Low Level Diagnostic

17. T DSAC : DIS Status AC/DC Test
04 - Low Level Diagnostic

18. T DSAC : di_value_file diagnostic directory: Turn on value logging
/var/opt/hp93000/soc/diagnostic
Turn on value logging
before running test
Di_value_file gives more
information than di_log_file
04 - Low Level Diagnostic

19. T DSPC : DIS Status Power Control Test
04 - Low Level Diagnostic

20. T DSPC : value vs. log diagnostic directory: Turn on value logging
di_value_file
diagnostic directory:
/var/opt/hp93000/soc/diagnostic
Turn on value logging
before running test
di_log_file
04 - Low Level Diagnostic

21. T DVAC : DIS Voltage AC/DC Test
04 - Low Level Diagnostic

22. T DPCI : DIS Power Control Voltage 1 Test
04 - Low Level Diagnostic

23. T DPCE : DIS Power Control Voltage 2 Test
04 - Low Level Diagnostic

24. T DCLK : DIS Clock Board Voltage Test
04 - Low Level Diagnostic

25. 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.
Fiber Optic Communications
Clock
board
Card
Cage 1
Cage 5
Large test head
Active control
Connection
Cage 7
Cage 3
Cage 6
Cage 2
Cage 4
Cage 8
Control
cable
Standard support rack
Rack interface
RS232
Power
backplane
control
Termination
Supply only
To Manipulator
This test does not require a running software. If the firmware is not running, the CIC device file is opened and the transceiver checks the energy level of all fiber optic links. If a control board is found during the start of the diagnostic subsystem, the segment number is derived from a hard coded binary value on the wireboard. This is done via the clockboard in the same quadrant as the control board since the control board has no direct connection to the frontplane and the wire board. This value is written in a register on the control board. This register is read by the DIS controller and the transceiver unit. The information is then simultaneously transmitted over the RS232 and the fiber optic cable to the workstation. There the values are compared and a mismatch detected.
For checking the connection in the other direction, the now known segment number is transmitted back to the control board via the fiber optic link. The register on the control board is read and the result transmitted via the DIS bus to the rack interface board and then via the RS232 to the workstation. Here the value is again compared with the expected value.
04 - Low Level Diagnostic

26. 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.
04 - Low Level Diagnostic

27. T DFOC : Fiber Optic Test
The purpose of this test is to check the fiber optic cable.
Fiber Optics
Optic Coupler
The Firmware must not run while executing the test. The user is asked to short circuit the optical outputs 1 & 2 of the computer interface card. The signal transmitted from output 1 is now measured at output 2 and vice versa. If the energy level is above the required threshold, a violation character is sent in both directions that needs to be detected by the opposite receiver. The test has to be repeated for both optical fiber cables.
04 - Low Level Diagnostic

28. 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
The test opens the device file to get access to the hardware. Each link is initialized. For every installed fiber link connection all boards are disconnected from the address/data bus. The next read access from the bus should deliver a logical ‘1’ for each address/data line (open collector bus).
In the next step each channel board is accessed sequentially. Every channel module on the channel board must drive a 0xAA pattern first followed by a 0x55 pattern.
04 - Low Level Diagnostic

29. 04 - Low Level Diagnostic