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.

Undocking the Test Head (With system powered down) Accessing the pneumatic valves Valves for soft docking Valves for hard docking 22 - Troubleshooting

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 22 - Troubleshooting

Undocking the Test Head (With system powered down) Valves for hard docking Press blue buttons to open/close hard docking valves 22 - Troubleshooting

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

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 22 - Troubleshooting

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) 22 - Troubleshooting

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. 22 - Troubleshooting

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. 22 - Troubleshooting

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 22 - Troubleshooting

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. 8CC (CC1 & CC5) 4CC (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) 22 - Troubleshooting

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. 22 - Troubleshooting

Minimum Configuration Failure tracing to the card cage (CC) level: 1. 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

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. 22 - Troubleshooting

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 22 - Troubleshooting

High Performance Pogo Pin Replacement Products Covered: PS3600 HSM PinScale HX BIST Assist BAA MCC E7995-68513 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

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) 22 - Troubleshooting

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. 22 - Troubleshooting

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. 22 - Troubleshooting

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. 22 - Troubleshooting

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. 22 - Troubleshooting

Inserting a new signal pin Insert a signal pin Press-in the signal pin with the Pin Insertion Tool. 22 - Troubleshooting

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