1. Verigy V93000 Service Training
Module 22:
Troubleshooting
Tools & Tips
Module 22: Troubleshooting Tools & Tips
Objective:
Given:
Study Guide
Quiz
Answer questions concerning software tools and tips for troubleshooting problems with the V93000 test platform. 90% correct answers are required to get credit for this module.

2. Undocking the Test Head (With system powered down)
Accessing the pneumatic valves
Valves for soft docking
Valves for hard docking
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3. Undocking the Test Head (With system powered down)
Valves for soft docking
Turn red tap to cut off compressed air and bleed off pressure at the interface
Press blue buttons to open/close valves manually
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4. Undocking the Test Head (With system powered down)
Valves for hard docking
Press blue buttons to open/close hard docking valves
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5. AC/DC Problems AC/DC All AC/DC fail in the low level diagnostic
All AC/DC LEDs for AC/DC Power Units installed on the Power Backplane are lit
Fault Isolation :
Check the +/-15V LED on power backplane (voltage generated on Rack Interface)
22 - Troubleshooting

6. DC/DC Problems Failure Condition
All DC/DCs fail in the low level diagnostics
All LEDs on the power control board don’t indicate a failure
Fault Isolation
Check the +/- 15V by measuring the voltage directly on the power control board capacitors (voltage generated on Rack Interface)
-15VDC
+15VDC
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7. DC/DC vs. DPS Baseboard Problems
DPS cannot be recognized
Fault conditions
Raw power of the DPS is missing (possible defective 12V source from DC/DC; Replacement of DC/DC may be necessary) OR
DPS was in over-current state and switched off by the SW (Power cycle the system and restart the V93000 s/w. If this does not clear the problem DPS baseboard replacement may be necessary)
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8. Sequencer Time Outs Failure Condition Repair Recommendation
SW hangs during bootup for a given amount of time, ~2 min.
Once SW resumes, missing channels are seen in the channel lists.
Repair Recommendation
If single channel missing, replace channel module.
If all four channels on channel module missing, replace interface module.
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9. DCOM Issues Failure Condition Fault Isolation
Tester shuts down in red light condition after SW startup.
Red ‘Ground Offset’ LED on power backplane is lit.
Fault Isolation
Manually measure DCOM to chassis, nominal 5k ohm.
Inspect interface module LED’s on channel boards for
fault condition.
Run low level diagnostics.
Pull boards from card cage.
Other possibilities: shorted pressure sensor, power
control board.
Once hardware has been identified with grounding
issue, repair or replace.
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10. Fatal Errors SW crash from time to time during running production
Starting V93000 software ends with a Fatal error in the report window
Prerequisite:
System can be powered-up
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11. Fatal Errors During SW Boot
This kind of “Fatal error” can be generated by:
Defective Channel module
Defective Clock board
Defective Master Clock Ring
Defective Data & Address Bus of the Backplane/Control Boards
Defective Communication Path
Steps to find this failure:
Run several DIS Tests (DFLT & DCIC & DADR)
Bring the tester down to the minimum configuration, CS1 Only CC (CC1 & CC5) CC (CC1 & CC3)
Verify physical connections of the clock ring cables on front planes.
Possibility of catching failures with which method:
This will catch up to ~95% of the failures
Run several DIS Tests (67/68/70)
Use Crash dump variables with grep-tool
Successive Approximation with ignoring boards
This will catch up to ~5% of the failures
Bring the tester down to the minimum configuration (separate CC)
This will catch up to ~0.5% of the failures
Defective clock ring (~1% possibility)
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12. Fatal Errors During SW Boot
Run DIS tests
DFLT DIS Fiber Link Test
DCIC DIS Computer Interface card
DADR* DIS Address & Data Bus Test
You must manually verify that all installed hardware is identified in this test. It will pass even if some hardware is missing. You must also cycle power on the system after running this test.
NOTE: View di_log_file for results of above tests even if you get a passing result.
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13. Minimum Configuration
Failure tracing to the card cage (CC) level:
Remove all the jumper boards between the CCs except between
CC1 & CC5 in 8CC TH and CC1 & CC3 in 4CC TH.
2a. Disconnect all fiber-optic lines from the control boards, except 1 line (CC1 on 512 TH or CC5 of 1024 TH).
2b. Boot the SW and look for fatal errors. If there are no errors, add cards (control board, channel cards, clock, DPS, DC/DC) from other card cages, 1 card cage at a time.
2c. When you find the cards that causes the error proceed to step 3
3. Try replacing the suspect control board/backplane assembly.
4. Remove all of the channel cards in the suspect card cage and reinstall them one at a time.
5. Try replacing the clock board in the suspect card cage.
22 - Troubleshooting

14. Backplane Assembly Installation
NOTE: It’s a must to use two ‘T’ handles
for even insertion of all connectors.
If only one ‘T’ handle is used, one must
switch between top and bottom screws every
3 turns.
CAUTION: Once top and bottom connectors
have engaged, stop tightening and check for
proper alignment on all slots before continuing.
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15. Monitor Tool Run Monitor Tool Select “update control”
to choose options.
Click to change
temperature
readout.
Click on ‘details’ to get actual measurements, reported in UI Report Window
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16. High Performance Pogo Pin Replacement
Products Covered:
PS3600
HSM
PinScale HX
BIST Assist BAA
MCC E
Pogo Pin Kit contains: 20 Signal Pins 40 Ground Pins
Signal Pin
Ground Pin
WARNING: Signal pins are one use only. If a signal pin is damaged, do not remove pogo pin from
a good pogo cable as a replacement. The pogo pin will be damaged upon removal from the pogo block.
22 - Troubleshooting

17. Toolset E7995-68602 Overview Ground Pin Tourque Meter with Insert
Ground Pin Extractor (0,8mm left hand drill with chuck)
Signal Pin Insertion Tool
Signal Pin Extraction Tool (M 0,9 tap with chuck)
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18. Extracting broken ground pins
Use the ground pin extractor (left hand drill bit 0,8mm with chuck)
Place the drill on the broken ground pin, use little pressure and turn counterclockwise to remove the broken pin.
NOTE: The drill is very fragile, please handle with the utmost caution.
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19. Inserting a new ground pin
Insert a new ground pin and gently screw in the pin with the bit.
Use the torque meter and tighten the pin to 3cNm.
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20. Removing a broken signal pin
There are 2 ways a signal pin can break:
Signal pin breaks ~3mm above the isolator.
Signal pin breaks right at the isolator.
For case 1, just use needle nosed pliers
and pull the pin.
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21. NOTE: The tool is very fragile! Please handle with the utmost caution.
Removing a broken signal pin
For case 2:
Use the signal pin extractor and place the tip of the tap on the isolator of the signal pin.
Turn the tap until you reached around 3-4 mm. (3-4/32“)
Pull out the pin
NOTE: The tool is very fragile! Please handle with the utmost caution.
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22. Inserting a new signal pin
Insert a signal pin
Press-in the signal pin with the Pin Insertion Tool.
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23. One thing not to be forgotten!
Some of the tools break easily, so please work with them as if you were a watchmaker.
22 - Troubleshooting