System Monitor/Controller
Contents
1. 1 Check IP settings on the computer 2 Check Ethernet cable and link LED between the computer and the SMC 3 Replace the SMC Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 320f33 SMC Unit Troubleshooting Reference Continued Symptom Action Test power switch es inoperative or one or more panel LEDs inoperative with all power on 2 Replace the affected switch panel replace as indicated 4 Replace the SMC 1 Compare inoperative panel operation to the panel on the opposite side 3 Inspect cables and connections from the switch panels to the SMC Repair or Note If the Test Power On LED is flashing the SMC has stopped the system Use the Maintenance window and the tester_status file to diagnose the failure The SMC communicates with the tester computer over a dedicated Ethernet link using the standard TCP IP protocol stack The SMC connection is at J12 and the computer connection is at the SMC Ethernet controller card The SMC has a dedicated IP ad dress of 10 0 0 2 and the tester computer SMC Ethernet board is set to 10 02. SMC Unit Troubleshooting Reference Symptom Action No SMC input power 1 Verify and repair the 48V supply SWPS1 2 If 48V is present at the SMC replace the SMC Missing one or more of the SMC power outputs 1 Verify input power from the 48V SWPS1 2 Measure supplies shown as defective at appropriate cable connectors with a voltmeter 3 Replace SMC Note LA703 power is switched and is fully active only with test power on SMC trips the EMO 1 Verify that the support cabinet is the affected EMO circuit 2 Verify that the support cabinet EMO loop thermostats and EMO buttons is intact 3 Restore power if possible and review EMO error messages in the tester_status file or in the SMC tab of the Maintenance window Repair any problems as indicated 4 Replace SMC SMC related fault or warning is displayed in the status log or Maintenance window 1 Verify that the fault or warning is related to the SMC and not to an external instrument or sensor 2 Evaluate warnings for severity and cause 3 Evaluate faults for source and occurrence frequency 4 Replace SMC instrument or sensor as indicated No instruments seen by the SMC 1 Verify SMC power outputs 2 Check SMC LON cables and connections 3 Reduce the system by replacing all instruments with filler cards Only the Support Cabinet node should be seen 4 Replace the SMC No SMC communications with the test computer
3. Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a 0 HOME HELP System Monitor Controller SMC Troubleshooting Page 11 of 33 gt The SMC shuts down the system due to BRDS_INSTA fault Is the test head door closed YES Are all instrument and filler boards installed YES Verfiy operation of door switch with an ohmmeter Close the test head door Install all instrument and filler boards Does door switch and wiring pass continuity test Repair or replace door interlock switch and or wiring YES Perform continuity checks on each board Replace defective instrument or filler board YES Replace master support board Boards Installed Flowchart Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 12 of 33 gt Note The primary purpose o
4. IP Address AA Subnet Mask s s o a o s 2 gt 255 255 255 0 Default Gateway 5 re Ethernet adapter Local Area Connection Connection specific DNS Suffix i teradyne com IP Address e cam a a aa 161 186 116 Subnet Mask e gt s o o e s a 255 255 0 A E AA Default Gateway 1 101 186 254 A i a Rev 0406
5. 0 1 with a subnet mask of 255 255 255 0 See the figure Verifying the SMC Computer IP Ad dress and Mask Settings If the tester computer fails to see or log the SMC but the test system operates normally then that is a symptom of a communications failure Trou bleshoot by checking the Ethernet cable and connections at both ends first Next ver ify that the computer settings are correct for the SMC Ethernet card Then observe the Ethernet activity indicator If the LED is actively blinking that is a good indicator of com munication integrity See the figure SMC Ethernet Link Light The SMC acts a power source for the system clock module When test power is off the clock is supplied with only those voltages needed to maintain stability When test power is activated the remaining supplies needed for clock operation are powered up Both the SMC and the clock are equipped with monitoring LEDs The LEDs on the clock monitor the internal voltages of the clock If the LED on the SMC is illuminated but the corresponding LED on the clock is not a faulty clock is the most probable cause of failure A bad cable is also a possible cause of failure Rev 0406 gt ntr er SMC Troubleshooting Page 33 of 33 i E lim WINNT System32 cm Microsoft Windows 2000 Version 5 66 2195 lt C gt Copyright 1985 2000 Microsoft Corp C gt ipconfig Windows 2666 IP Configuration Ethernet adapter SMC Connection Connection specific DNS Suffix
6. Page 29 of 33 gt FAN MON PWR Shows the state of the 5V line that goes to a the fan sensors located in the fan body This is a fused output pr 7 coming from the main 5V on the SMC assembly and goes to connectors J3 J4 and J5 This LED should come on with FAN MON _ PWR i i main power 48V This LED indicates the status of the main 48V supply that powers the SMC assembly This line is fused and the LED is located after the fuse This LED should come on with main power LA703 12V Indicates the status of the 12V line that powers the crys tal oscillator located on the LA703 assembly This LED LA7O3 comes on with main power 12V 15V 15V 5V 5 2V These LEDs indicate the status of 15V 15V the rest of the power supplies that power auxiliary circuits 5V 5 2V contained in the LA703 These LEDs will come on with test SC 5V ua system power None of the LA703 outputs are fused TH 5V p SC 5V This LED indicates the status of the 5V supply that powers the SMC assembly It will come on with main power TH 5V Indicates the status of the 5V supply that powers the SMC rider boards located on the test head channel cards TH 5V gt F This LED will come on with test system power It is not fused TH 5V Indicates the status of the 5V supply that powers the SMC rider boards located on the test head channel cards This LED will come on with test system power It is not fused sc 5
7. 805 251 12_0249 dat SMC Ver 0183 0238 SupportBoard Slave B IG XL13 60 13153MC1805 003 11_0238 dat 1 ers 018 4o 4 D D n a MO SD so 03 31 03 15 26 12 SMC CRITICAL FAULT FO SCN N A EMO GENERATED SCN N A PDU_VO 028 Lo 0 843 Val 49 685 Hi 3 000 Volts 03 31 03 15 26 12 SMC CRITICAL FAULT FO SCN N A EMO GENERATED SCN N A PDU_VO 028 Lo 0 843 Val 49 685 Hi 3 000 Volts E 03 31 03 15 26 19 SMC STATUS SN N A SMC Test Power turned ON 03 31 03 15 32 03 Pinging System Node Average RTT 15 304 mseconds Max RTT 30 088 mseconds Min RTT 14 805 mseconds ER dc IE m For Help press F1 fa a FO Critical Fault Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 170f33 Faults SMC faults can be systemwide or localized to the instrument sometimes referred to as F1 and F2 faults respectively F1 and F2 faults cause the test power to shut down F1 and F2 faults have the same effect as pressing the test power button The system shuts down but the test power button LED remains blinking The blinking LED informs the ope
8. ADERS ARE UPLOADED TO SYSTEM NODE y SMC ENABLES 48 VOLT TEST POWER VIA PDU SMC ENABLES SWITCHED AC POWER BLOWER BEGINS ROTATION IS 48 VOLT POWER PRESENT AT SPEED AND IS BOARDS IN DOOR CLOSED YES v INSTRUMENT CARDS BEGIN POWER UP SEQUENCES TEST POWER LED GOES TO STEADY STATE y SMC MONITORING BEGINS FOR ALL INSTRUMENTS FOUND EMO TRIPPED EMO YES ERROR NO gt NO GENERATED WARNING NO Lo y SMC Operational Flow WARNING LOGGED Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 230f33 SMC General Troubleshooting Symptom Action EMO Fault 1 Check the manual EMO buttons thermostats and other EMO sources Verify that these items have not caused the EMO event Refer to the EMO section for more information on EMO troubleshooting 2 Reset EMO with main breaker and attempt to re power 3 If re power is OK check the SMC log for cause 4 If unable to power remove all instruments from
9. CMO Tane Tiara fem aA arr For Help press F1 Fault F1 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 190f33 gt Warnings Each node that the SMC monitors can produce warning messages also referred to as F3 warnings These messages are triggered when a preprogrammed warning speci fication limit is exceeded The warning message is received by the SMC on its next polling loop and stored These messages are also forwarded to the test computer and are stored in the tester_status file in the tester tester status directory The specific trig ger levels are stored in tabular form on each node and are duplicated in a file that re sides on the computer Instrument trigger levels are informational in nature and do not necessarily call for the instrument to be replaced Operators should evaluate the sys tem at the time of the warning instead of evaluating the level value to determine caus es and possible effects See the figure Warning for an example warning from the tester_status log In this case the voltage readings are slightly out of the expected range and the SMC issu
10. FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 1 of 33 SMC Troubleshooting In general use the maintenance software for troubleshooting the FLEX system moni tor controller SMC Refer to Maintenance Software If further troubleshooting is required or if the maintenance software is not functioning use the SMC flowchart to troubleshoot SMC assembly failures This topic consists of the following sections e Checking the System e Using the SMC Assembly Checks and Flowchart Note In addition to using the SMC flowchart for troubleshooting SMC assembly faults use the flowchart after a fault has been corrected to verify that there are no other SMC assembly faults in the system When performing further troubleshooting you can also refer to specific pinouts and wiring and signals information Checking the System Test your system before you use the troubleshooting procedures that are specific to the SMC assembly Verify that the FLEX continuity check passes Refer to Maintenance Software Re solve any failures before continuing Rev 0406 F a System M
11. IB Interface troubleshoot this type of failure perform the following Field Replaceable Units 1 Open the Maintenance window Refer to the Maintenance Window Description ernie topic for more information Maintenance softvara 2 View the tester_status log file These data sources contain the information needed Manipulator to localize the problem a iomad Dee 3 Refer to the table SMC General Troubleshooting Find the type of fault listed under PAS the Symptom heading and perform the associated procedures listed under the pei Action heading Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a Rev 0406 HOME HELP FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 22 of 33 TEST POWER ON BUTTON IS PUSHED 5 VOLT SMC POWER IS SUPPLIED BY SCN TO BOTH HALVES OF THE TEST HEAD SYSTEM CLOCK IS ACTIVATED TEST POWER LED BEGINS FLASHING y SMC POLLS FOR AND MAPS INSTALLED INSTRUMENTS y EACH INSTRUMENT SENDS ANY PREVIOUSLY STORED ERRORS y LIMIT TABLE HE
12. Unite D System Node SMC O Local MSV 11 25 05 25 19 PM 547 5 216 4519 Vols E Support Cabinet SMC 1 Local_P5V 11 25 05 25 19 PM 477 4 996 5 477 Volts Option Monitors SMC 2M10V_MON 11 25 05 25 19 PM 10 254 8 292 6 825 Volts O 7SupportBoard SME 3P10V MON 11 25 05 25 19 PM 6 825 8 787 10 254 Vots 1 20SupportBoard SMC 4 200MV_REF 11 25 05 25 19 PM 0 164 0 189 0 202 Volts pa SMC 5 2 5V_FEF 11 25 05 25 19 PM 2 431 2 497 257 Volts o SMC 6 1 25V_REF 11 25 05 25 19 PM 1 199 1 232 1 269 Volts 0 24HS0100 SMC 7 LA703_P12 11 25 05 25 19 PM 11 347 12 042 12673 Vols SMC amp SMCTH_PSV 11 25 05 25 19 PM 477 5 299 5 672 Volts SMC S P5V_TH_Ise 11 25 05 25 19 PM 0 0 403 3 042 Amps SMC 10 SMCTH_MSV 11 25 05 25 19 PM 5 672 5 366 4 519 Volts SMC 11 LA703_P5 11 25 05 25 20 PM 4 728 4 974 5 28 Volts SMC 12LA703 M15 11 25 05 25 20 PM 16304 14 911 14023 Volts SMC 13LA703 M5 11 25 05 25 20 PM 5613 5 133 4312 Vols SMC 14SMC_SC_MBV 11 25 05 25 20 PM 547 5214 4519 Vots SMC 15 SMC_SC_P5V 11 25 05 25 20 PM 477 5 003 5 477 Volts SMC 1624V_P_GOOD 11 25 05 25 20 PM 0 39 1 669 1 38 Volts SMC 17 P5V_SC_ISE 11 25 05 25 20 PM 0 1 292 2 001 Amps SMC 1833 FPGA 11 25 05 25 20 PM 3011 3 311 4584 Volts SMC 19 intemal use 11 25 05 25 19 PM 1 98 2 615 3 537 N A SMC 20intemal use 11 25 05 25 19 PM 0 1 673 1 38 N A SMC 21 internal use 11 25 05 25 19 PM 0 1 665 1 98 NA SMC 22intemal use 11 25 05 25 19 PM 0 1 668 0 39 N A SMC 23intemal use 11 25 05 25 19 PM 1001 538 39 734 3720 N A SMC 24
13. V Fns SC 5V This LED indicates the status of the 5V supply that s powers the SMC assembly It will come on with main power TSP ON This LED will mirror the operation of the test system power LED located on each tester control panel PDU 5V This LED indicates the status of the 5V rail that powers the optoisolators located in the PDU This line is PDU 5V gt fused The LED should come on with main power i SMC LEDs Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 300f33 For example if an LED on the SMC is illuminated but the matching LED on the clock is not then clock replacement is most likely indicated The interconnecting cable is also a possibility The SMC provides independent power to all the nodes on all instruments This allows the SMC to operate even with test power off A split cable delivers power to each hemi sphere of the test head from the SMC at J9 Failure to read all of the SMC nodes on one or both sides of the test head are symptoms of cable or power failures The SMC uses the LON as the communication protocol The LON prov
14. cal operating net work LON nodes to monitor and control system functions Each LON node reports to the SMC assembly The SMC system node processes the information the SMC as sembly receives The system node instructs the SMC assembly to take control of the entire system when necessary Under certain circumstances the system node directs the SMC to shut down test power system power or to display a warning to the oper ator Before replacing the SMC assembly it is necessary to review any information logged in the software maintenance window and in the system log file Ethernet 386EX Single LON Bus ma Board Computer Support Cabinet Interface Node Main Board Rev 0406 System Monitor Controller SMC Troubleshooting Page 4 of 33 pe Ef FLli SMC related faults are usually symptoms of other failures For example a failing pow er board on an instrument may generate an F2 fault via the SMC subsystem The fault results in the SMC assembly shutting down test power The operator may believe the SMC assembly is causing the power down However the SMC assembly is just a symptom of the fault and not the cause of the fault So before troubleshooting for an SMC problem it is recommended to rule out other components and field replaceable fos units first Calibration The SMC troubleshooting section is divided into two parts to reflect the distinction be Computer tween faults seen and acted on by the SMC and faults that are interna
15. e Faults YES Repair for Indicated Fault and Retest Is Test Power LED On Turn Test Power On or Troubleshoot for Test Power Will Not Come On YES Trouble shoot PDU Power Shuts Off During Run or Power Comes On and Then Goes Off Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 260f33 Troubleshooting the SMC Overview The SMC can be a source of EMO faults SMC faults and or SMC warnings The trou bleshooting information in this section outlines the possible causes for these types of problems The SMC operates as a power supply for itself the LA703 clock module and all test system nodes The SMC board monitors these components and can produce messag es or take actions based on these measurements The interface for these monitors is through the support cabinet node SCN Refer to the table Support Cabinet Node Monitors for a list of these monitors The SCN is a rider card not a field replaceable unit mounted on the SMC main board See the figure LEDs on the Rider Card SCN The SMC acts as the controller for the test power on and of
16. e SMC main board M10V_MON Derived from Local_M5V and Local_P5V used by node P10V_MON Derived from Local_M5V and Local_P5V used by node 200MV_REF 200 mV reference that the A D converter uses on the node 2 5V_REF 2 5V reference that the A D converter uses on the node 1 25V_REF 1 25V reference that the A D converter uses on the node Support Cabinet Node Monitors The support cabinet node SCN part of the SMC assembly monitors SMC power central power to all nodes power to the clock module main blower rotation and PDU functions The SCN monitors can be viewed at the SMC tab of the maintenance win dow See the table Support Cabinet Node Monitors and the figure SMC Monitor Win dow in the Maintenance Window The SCN resides on the SMC assembly but is not a field replaceable unit See the fig ure SMC Assembly Failure of the SCN requires replacement of the SMC assembly The SCN also contains the standard set of node monitors See the table Standard Set of Node Monitors Rev 0406 System Monitor Controller SMC Troubleshooting Page 7 of 33 gt FLE Support Cabinet Node Monitors Monitor Name Description LA703_ P12 12V to clock Cables SMCTH_P5V 5V to all nodes Calibration P5V_TH_lIse Current sense for 5V node power computer SMCTH_M5V 5V to all nodes Cooling DIB Interface P5V_SC_lse Current sense for 5V support cabinet p
17. ents The test computer is used primarily to receive display and record information from the SMC main board SMC information can be viewed in near real time delayed by node polling loop time in the SMC tab of the Maintenance window Information is recorded to the tester_status file that is accessible through the view menu of the maintenance soft ware Refer to the Maintenance Window Description topic for more information The maintenance software provides a convenient view menu that allows the field engineer to access this file without the need to search through directory trees Critical Faults Messages and faults that are displayed and recorded fall into three classes The most severe is a critical fault sometimes referred to as an FO critical fault When generated by the SMC FO faults disable system power FO faults have the same effect as push ing an EMO button The FO fault message is received by the SMC on its next polling loop and stored Depending on the power down speed and sequence messages may not be forwarded before the EMO disables power for the computer If the messages are forwarded they are stored in the tester status file in the tester tester status directory If the messages are not forwarded they are retained by the source and forwarded when power is restored This has important implications for troubleshooting because a message indicating the fault type may not be visible to the operator The specific trigger levels fo
18. es a PDU maintenance warning Note A warning is an informational message only and not a mandate to replace an instrument Rev 0406 System Monitor Controller SMC Troubleshooting Page 20 of 33 D FLE B Tester Status0303 txt WordPad BoE pisla ala al elo al Cables Calibration Computer Cooling DIB Interface 03 31 03 15 06 04 SMC WARNING F3 SCN N A PDU maintenance signal Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety ml SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide 03 31 03 15 06 04 SMC WARNING F3 SCN N A PDU maintenance signal 03 31 03 15 06 10 SMC STATUS SN N A SMC Test Power turned OFF sl Warning a Rev 0406 HOME HELP System Monitor Controller SMC Troubleshooting Page 21 of 33 E an i Troubleshooting Guidelines Operators should be aware of the following troubleshooting scenarios for SMC record ed faults e The operator observes a recorded warning e The test system powers down during operation Cables e Test power fails to power up Calibration e An SMC controlled EMO system power down occurs Computer Normal SMC operational flow is shown in the figure SMC Operational Flow as a trou Cooling bleshooting aid The illustration can be used to localize a symptom to its cause To D
19. est head door or failure to install a filler card when an instrument is removed Before troubleshooting do a visual examination and try to understand the activities that preceded the shut down Replace any instruments or filled boards that were removed prior to the shutdown Examine the door and inter lock switch for proper operation Continuity checks can be performed on each instru ment and filler card The entire loop may be evaluated by removing the test interface plate to obtain access to the backplane and conducting continuity checks with the in terface removed Refer to the Boards Installed Flowchart for troubleshooting Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a 0 HOME HELP System Monitor Controller SMC Troubleshooting Page 10 of 33 BACKPLANE SLOTS 8 13 MASTER SB i on if SLOTS 1 6 rd LON to SMC Main Board via J27 and 866 162 00 Ny Door Interlock Switch Normally Open SLOTS 14 19 SLAVE SB SLOTS 21 26 NOTE Slot ranges indicate multiple boards Pin numbers are the same on each board Signal Block Diagram Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface
20. f switches and provides status feedback to the user by controlling the LED indicators on the operator interface panels Common SMC problems include a failure to respond to a power switch being pressed or failure of an indicator to light As a result of a key press requesting that test power be turned on or off or as a result of an SMC fault the SMC board may enable or disable the test power by controlling the PDU No monitors are provided for these functions Line frequency input voltage for each phase and output current of the PDU are monitored on the SMC board Refer to the table Support Cabinet Node Monitors for a list of these monitors Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 27 of 33 ss LEDs on the Rider Card SCN The SMC may activate the EMO upon receipt of critical errors This presents a difficult troubleshooting scenario because all power is removed from the system preventing viewing of source messages in the Maintenance window Troubleshooting in this case involves restoring power if possible to retrieve any messages The SMC is the hub
21. f the test head interlock switch is to disable test system power if the test head door is opened during operation Opening the test head door reduces the effectiveness of the cooling system The interlock switch is monitored by the SMC which interrupts test power when the switch is activated This switch is not designed as an electrical safety feature Additional monitor points are the digital signal processor DSP and Picoclock power supplies and presence indicators Refer to the table Support Board Monitors for de scriptions of the support board monitors The table shows the master support board monitors the slave support board monitors are a subset there are no P48V_IN or BRDS_INSTA monitors The monitors can be viewed in the maintenance window by selecting the SMC tab See the figure Support Board Monitor Window in the Mainte nance Window Support Board Monitors Instrument Monitors Description P48V_IN Main 48 VDC power to instrument from the PDU P3 3V_MAIND 3 3 VDC instrument power derived from the 48V mains by the power converters on the support board power section P5V_Shared Support board 5V DSP1_PRESE DSP module present signals DSP3_PRESE DSP3_PRESE DSP4_PRESE Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Supp
22. ides the data link to all nodes in the system Cable integrity of the LON and correct pin 1 orientation at the SMC are necessary to provide good data communications Communication fail ures have symptoms such as intermittent operation or loss of visibility of nodes The J1 connector on the SMC is the EMO control loop It is a normally closed output during operation Opening this connection causes a support cabinet S C EMO to trip The SMC is a controller and an interface for the power panel switches and indicators The SMC receives these signals through the J10 connector Indicator and switch fail ures are symptoms of a problem in the cable or J10 connector Begin troubleshooting by observing the control panel on the opposite side of the test system If the switch or indicator operation corresponds to the failed panel then look for cable faults or replace the SMC If the two panel sides have different indications troubleshoot and repair the cable or replace the power panel See the table SMC Unit Troubleshooting Reference Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 310f33
23. igital A D converter a control micropro cessor and communications circuits The node contains standard self monitoring cir cuitry and it is customized for each instrument type Each instrument may route parameters that are of interest to the node for monitoring These parameters differ be tween instrument types The node also acts as a power on sequence controller for each instrument The power sequence and monitor levels are stored in a programmable table on the node and on the test computer Saving tables on the test computer eliminates the need to upload a full copy of an instrument s table every time test power is cycled The functional soft ware communications and conversion routines for the node also resides on the node See the table Standard Set of Node Monitors Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 6 of 33 Standard Set of Node Monitors Monka Description Code Local_M5V 5V SMC node power Provides operating power to the node from the SMC main board Local_P5V 5V SMC node power Provides operating power to the node from th
24. l to the SMC Cooling subsystem A common problem is determining whether to troubleshoot with the SMC DIB Interface or troubleshoot the SMC Operators should attempt to troubleshoot with the SMC first Field Replaceable Units e Troubleshooting with the SMC Instruments e Troubleshooting the SMC Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide Rev 0406 HOME HELP FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 5 of 33 gt Troubleshooting with the SMC Overview The first step in troubleshooting an SMC problem is to distinguish between SMC ob served faults and SMC induced problems This section provides procedures and flow charts to troubleshoot SMC monitored faults Generic Node Monitors Each instrument board is equipped with an SMC node This node is mounted on a rider card that resides on the power board section of each instrument The node consists of a small multiplexer a calibrated analog to d
25. ntemal use 11 25 05 25 19 PM 0 1 667 1 98 N A SMC 25intemal use 11 25 05 25 19 PM 0 1 666 0 39 N A SMC 26 intemal use NoData 39 734 0 520 8 N A SMC 27 BLOWER 11 25 05 25 19 PM 940363 1372611 3000 RPM SMC 28 PDU_VO 11 25 05 25 19 PM 45 216 47 92 55 024 Volts SMC 29PDU_1 11 25 05 25 19 PM 1 265 11 777 175 Amps SMC 30 PDU_I2 11 25 05 25 19 PM 1 265 1 265 175 Amps SMC 31 PDU_V1 11 25 05 25 19 PM 45198 48 066 54997 Volts SMC 32 PDU_V2 11 25 05 25 19 PM 45 198 48 128 54 997 Volts SMC 33PDU_VAB 11 25 05 25 19 PM 180 013 208 836 240 017 VAC SMC 34 PDU_VAC 11 25 05 25 19 PM 180 013 207 426 240 017 VAC SMC 35 PDU_VBC 11 25 05 25 19 PM 180 013 205 882 240 017 VAC SMC 3 amp PDU_FREQ 11 25 05 25 19 PM 46006 60 64094 HZ Tester Faults Measured Value Upper Limit Units Testina Completed Status PASSED DIB OFF Power ON A SMC Monitor Window in the Maintenance Window Support Board Monitors The master support board MSB monitors the 48V system power that the PDU pro duces at the test head The board also is the communications point for the boards in signal chain The boards in chain is a physical series loop that passes through each instrument and filler card as well as the test head door interlock switch All instruments and filler cards must be inserted in their slots and the test head door must be closed or the test head door interlock switch monitor will signal a failure Rev 0406 FLE Cables Calibration Comp
26. of the SMC local network communications The SMC relays mes sages to the system computer by a dedicated Ethernet connection Troubleshooting in this area involves isolating network faults and replacing any defective cables or components General Troubleshooting Instructions Before troubleshooting SMC problems open the maintenance window and read any error messages there Refer to the SMC Window Description section for more infor mation A review of the tester_status log file can also be helpful The tester_status file is accessible through the view menu of the Maintenance window Relate any error messages displayed to the problem being addressed Verify that the fault displayed is a cause rather than a side effect Next determine if the source is external or internal to the SMC Troubleshoot external errors to their source and repair as indicated Inter nal errors require the replacement of the SMC assembly Rev 0406 System Monitor Controller SMC Troubleshooting Page 28 of 33 D pe Ef i As an aid to diagnosis the SMC assembly is equipped with a series of LED indicators that give a quick representation of many of the SMC monitor points An illuminated LED is an indication of a signals presence but it should not be relied on to confirm a value See the SMC LED Table and the figure SMC LEDs The SMC acts a power source J7 for the system clock module When test power is off the clock is supplied with only those voltage
27. onitor Controller SMC Troubleshooting Page 2 of 33 Ef Using the SMC Assembly Checks and Flowchart Use the SMC assembly checks and flowchart to troubleshoot the SMC assembly as follows 1 Run the quick or full SMC assembly checks 2 Ifa check fails follow the SMC assembly flowchart to determine the cause of the failure Cables 3 Replace the board or other appropriate hardware Calibration 4 Run the checks again samputar 5 Run the FLEX continuity check Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a 0 HOME HELP Bales FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 3 of 33 SMC Troubleshooting Introduction The SMC subsystem controls and monitors the system operations The SMC sub system includes a set of standard nodes located on each instrument board The SMC assembly shown in the figure SMC Assembly uses the lo
28. ort Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a 0 HOME HELP System Monitor Controller SMC Troubleshooting Page 13 of 33 Support Board Monitors Continued Instrument Monitors Description DSP1_S_1 8 DSP2_S_1 8 DSP3_S_1 8 DSP4_S_1 8 DSP1_S_2 5 DSP2_S_2 5 DSP3_S_2 5 DSP4_S_2 5 DSP supply P_15_UVP_DC M15_UVP_DC P75 UVP_DC M75_UVP_DC P_15_OVP_DC M15_OVP_DC P75_OVP_DC M75_OVP_DC Monitors the overvoltage and undervoltage protection feedback voltage of the 15V and 75V converters on the support board power section These signals will appear out of range if the converter is being steered due to an undervoltage or overvoltage condition TCO_GA1V8 HUB_GA1V8 XPT_GA_1V5 XPT_GA_2V5 DDR_SD_2V5 Voltage monitors for TCIO HUB and cross point FPGA supplies BRDS_INSTA Boards installed and test head door series loop Rev 0406 System Monitor Controller SMC Troubleshooting Page 14 of 33 FLE Support Board Monitors Continued Instrument Monitors Description P15V_pico Positive and negative 15V PicoClock supply M15V _pico Cables Calibration E A Computer Buick Check Cooling DIB Interface ile ee PEE Field Replaceable Units 11714 042850 PM 11 14 04 26 50 PM Instruments a
29. os naman Maintenance Software 9 5v_Pico Manipulator haa MAND Power ea 11 14 04 26 51 PM i A 15 XPT_GA_2V5 11 14 04 26 51 PM Preventive Maintenance te SD AS J11 DA ESTEM Safety e al S M c A 11 14 04 26 50 PI 2a0sra PRESE Support Board 2505315725 11714042850 PM Ops 18 11714 042650 PM Support Cabinet 2BDSP4_S_25 11 14 04 26 50 PM Test Head ri oc ninina 32M75_UVP_DC 11 1404 Troubleshooting SAPTE IVP DE 11714 042650 35 P75_0VP_DC 11 14 04 26 50 PM 36 M15_UVP_DC 11714 04 26 50 PM Tra l n in g 37 M15_0VP_DC 11 14 04 26 50 PM Product Integration Manuals Site Prep Guide Install amp Checkout Guide a Support Board Monitor Window in the Maintenance Window HOME HELP none FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 15 of 33 3 Critical Faults Faults and Warnings Each node communicates with the SMC main board SCN over the SMC local oper ating network The SMC main board acts independently on the information it receives No interaction with the test system computer is required the test computer can be turned off and the SMC will still monitor and control instrum
30. ot 009 SMC Ver 0183 0229 DC_30 IG XL13 60 1315MC1805 002 00_0229 dat Slot 019 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 131 SMC 805 251 12_0249 dat Slot 020 SMC Ver 0183 0238 SupportBoard Slave B IG XL 3 60 13 SMC 805 003 11 0238 dat Slot 021 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 1315MC1805 251 12_0249 dat Slot N A SNC Ver 0237 0234 SMC System Node Slot N A SMC Ver 0183 0234 Support Cabinet IG XL 3 60 13 5NC 866 848 00 0234 dat 03 31 03 14 50 00 SMC STATUS SN N A SMC Test Power turned ON 03 31 03 14 50 00 SMC SYSTEM WIDE FAULT F1 CCN 007 TEST POWER SHUTDOWN CCN 007 BRDS_INSTA 030 Lo 0 000 Val 2 614 Hi 1 649 Volts 03 31 03 14 50 00 SMC SYSTEM WIDE FAULT F1 CCN 007 TEST POWER SHUTDOWN CCN 007 BRDS_INSTA 030 Lo 0 000 Val 2 614 Hi 1 649 Volts 03 31 03 14 SMC STATUS SN N A SMC Test Power turned OFF 03 31 03 14 50 55 SMC STATUS SN N A SMC Test Power turned ON 03 31 03 14 50 57 SMC SYSTEM WIDE FAULT F1 CCN 007 TEST POWER SHUTDOWN CCN 007 BRDS_INSTA 030 Lo 0 000 Val 2 612 Hi 1 649 Volts 03 31 03 14 50 59 SMC STATUS SN N A SMC Test Power turned OFF 03 31 03 14 55 34 SMC STATUS SN N A SMC Test Power turned ON 03 31 03 14 55 34 SMC SYSTEM WIDE FAULT F1 CCN 007 TEST POWER SHUTDOWN CCN 007 BRDS_INSTA 030 Lo 0 000 Val 2 612 Hi 1 649 Volts NMa 21 102 44 06 99 ewe erario OCM entre ay
31. ower Field Replaceable Units LA703_ P5 5V to clock Instruments LA703_M15 15V to clock Maintenance Software LA703_M5 5V to clock Manipulator Power SMC_M5V Support cabinet 5V Preventive Maintenance SMC_P5V Support cabinet 5V Safety 24V_P_GOOD SWPS1 24V wie 3 3V_FPGA SMC 3 3V Support Board a Support Cabinet BLOWER Speed of main system blower Test Head PDU_VO PDU AC voltage phase 1 Troubleshooting PDU_I1 Current drawn on 48V connector 1 Training PDU_l2 Current drawn on 48V connector 2 Product Integration Manuals Site Prep Guide PDU_V1 PDU AC voltage phase 2 Install 8 Checkout Guide PDU_V2 PDU AC voltage phase 3 PDU_VAB PDU input voltage phase 1 PDU_VAC PDU input voltage phase 2 a PDU_VBC PDU input voltage phase 3 a HOME HELP Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 8 of 33 Ele View Options Run System Tools Help E Fut check Tal gt mT ey system 7 K ERADYNEJ jf ah Jn EDO Maintenance Calbration SMC Slot Monitor Time Lower Limit Measured Value Upper Limit
32. r an SMC EMO are stored in tabular form on each node and are duplicated in a file that resides on the system computer For exam ple the figure FO Critical Fault shows 48V applied after the SMC has commanded the 48V to be shut off Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 16 of 33 B Tester Status0303 txt WordPad BEE File Edit View Insert Format Help oela Sle aa raes aj List of discovered SMC nodes Slot 002 SMC Ver 0183 0229 DC_30 IG XL 3 60 13 SMC 805 002 00_0229 dat Slot 004 SMC Ver 0183 0229 DC_30 IG XL 3 60 13 SMC 805 002 00_0229 dat Slot 005 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 1315MC1805 251 12_0249 dat Slot 006 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL 3 60 13 SMC 805 251 12 0249 dat Slot 007 SMC Ver 0183 0238 SupportBoard Master B IG XL13 60 1315MC1805 003 10_0238 dat Slot 008 SMC Ver 0183 0249 H5D 200 Rev B D2 L3 IG XL13 60 1315MC1805 251 12_0249 dat Slot 009 SMC Ver 0183 0229 DC_30 IG XL13 60 1315MC1805 002 00_0229 dat Slot 019 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 13153MC1
33. rator the SMC has initiated the shutdown The F1 and F2 warning messages are received by the SMC on its next polling loop and stored These faults are also for warded to the tester computer and are stored in the tester status file in the tester tester status directory The specific trigger levels for each warning are stored in tabular form on each node and are duplicated in a file that resides on the system computer See the figure Fault F1 for an example fault from a tester status log In this example the test head door is open or a board is not installed Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page 18 of 33 D Tester Status0303 txt WordPad MAE File Edit View Insert Format Help oela aln sal Slot 005 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 1315MC1805 251 12_0249 dat Slot 006 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 1313MC1805 251 12 0249 dat Slot 007 SMC Ver 0183 0238 SupportBoard Master B IG XL13 60 1315MC1805 003 10_0238 dat Slot 008 SMC Ver 0183 0249 HSD 200 Rev B D2 L3 IG XL13 60 1315MC1805 251 12_0249 dat Sl
34. s needed to maintain time stability Cables When test power is activated the remaining supplies needed for clock operation are Calibration turned on Both the SMC and the clock are equipped with monitoring LEDs The LEDs Computer on the clock monitor the clock s internal voltages Cooling DIB Interface Field Replaceable Units SMC LED Table Instruments T ERE Maintenance Software p Manipulator FAN MON PWR Power to blower rotation monitor Power 48V Power to SMC from SWPS 1 Preventive Maintenance LA 703 12V Clock Power Safety SMC LA 703 15V Clock Power Support Board LA 703 5V Clock Power Support Cabinet LA 703 5 2V Clock Power Taai Mean SC 5V SMC 5V S rt Cabinet Nod Troubleshooting See eee Training TH 5V Test Head Instrument Node Power 5V Product Integration Manuals TH 5V Test Head Instrument Node Power 5V Site Prep Gules SC 5V SMC 5V Support Cabinet Node Install amp Checkout Guide TSP ON Test System Power On PDU 5V 5V to PDU Control Circuits a D HOME HELP Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting
35. the affected instrument Training 6 If a support cabinet monitor detects the fault determine whether the fault was Product Integration Manuals generated by an external entity such as the PDU blower or the BRDS_INSTA Site Prep Guide signal Install amp Checkout Guide 7 Troubleshoot accordingly and repair or replace the affected cables or devices The figure Power Shuts Off During Run or Power Comes On and Then Goes Off depicts the troubleshooting flow Refer to Troubleshooting the SMC if no fault sources are found or if an SMC supply generates the fault y Rev 0406 HOME HELP FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a 0 HOME HELP System Monitor Controller SMC Troubleshooting Page 25 of 33 Power Shut Off Durring Run Is Main Circuit Breaker Tripped Trouble shoot PDU Is Power Available LED On YES YES YES y y Reset Main Circuit Breaker and Retest Reset EMO and Retest Is AC Power LED On Trouble shoot PDU Is 48 Volt Power Available LED On Is Test Run Maintenance Power Software and Observe LED for Both Logged and Blinking Activ
36. the test head and replace with filler cards to prevent possible damage Bypass the SMC EMO loop at J1 with the provided jumper When main power is restored verify SMC input power with the SMC LEDs View the log file to narrow down the possible errors 5 Repair or replace components indicated by failures in the log files 6 Replace the SMC board SMC Fault 1 Verify that the SMC has caused test system power to be shut down The Test Power LED should be blinking if this is the case 2 Open the SMC tab in the Maintenance software window and view the output window or view the tester status log file in the tester tester_status directory for fault source information 3 Repair or replace components indicated by failures in the log files SMC Warning 1 Open the SMC tab in the Maintenance window and view the output window or view the tester status log file in the tester tester_status directory for warning source information 2 Warnings do not mandate component replacement Evaluate the warning s effect on expected performance Possible indications are continued monitoring SMC table updating or instrument replacement Rev 0406 System Monitor Controller SMC Troubleshooting Page 24 of 33 gt E Boa Recorded Warnings Warnings can be generated by any input to any monitor node in the system pro grammed by table to do so Generally the warning should be investigated by observ ing the warning message in the Maintenance windo
37. uter Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install 8 Checkout Guide a D HOME HELP System Monitor Controller SMC Troubleshooting Page90f33 OVERVIEW The MSB monitors the boards installed loop known as BOARDS_INS This serial sig nal chain loops from the MSB SMC node through the backplane and all of the instru ments in the system and through the micro switch located on the test head door See the figure Signal Block Diagram The purpose of the loop is to prevent operation in the event that any instruments or filler cards are not installed in the test head slots or if the test head door is left open Because leaving a slot empty or opening the test head door disrupts the cooling air flow This disruption may be severe enough to cause instru ment failures or shorten components expected life due to overheating TROUBLESHOOTING GUIDE Failure of the boards installed loop results in a system shutdown by the SMC Exami nation of the tester status file or the SMC status window will reveal a fault on the BRDS_INST line of the MSB in slot seven The value will be greater than 1 7V approx imately if the loop is open and less than 1 7V approximately if it is closed The most common cause of failures are an open t
38. w For more information about the maintenance software see the topic Maintenance Software Each warning is recorded to the tester_status file that is accessible through the view menu of the maintenance Cables software Refer to the Maintenance Window Description topic for more information Calibration Warnings are informational in nature Each should be evaluated carefully to determine Computer the appropriate action needed Repairs may range from continued monitoring of a val Cooling ue to replacing the entire instrument DIB Interface Symptom The test system powers down during operation or starts and then shuts off Field Replaceable Units gio Action Instruments Maintenance Software 1 Determine whether the SMC shut down the test power Manipulator 2 Observe the Test Power LED on either of the operator interface panels If the LED Power is blinking the SMC shut down the test power in a controlled manner Preventive Maintenance 3 Open the SMC tab on the Maintenance window and observe the recorded errors Safety Using the monitor feature of the SMC tab allows direct examination of a particular SMC value or values from the sensor that triggered the shutdown This is useful in Support Board qualitative analysis of the fault Support Cabinet 4 Examine the error log in the tester_status file in the tester tester_status directory Test Head to determine whether the fault has occurred before Troubleshooting 5 For instrument related errors replace
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