System Hardware Overview

Lecture Introduction

18/01/2000

Course Outline

System Hardware Overview

Series III System Installation
Documentation and Configuration Overview
Confirmation / Diagnostics and AutoAdjust
Overview
Cards, Subsystems, and Associated Diagnostics
Miscellaneous Hardware and System Level
Troubleshooting
Applications Software Overview
Site Preparation / Support Issues
18/01/2000

System Overview

HP 3X7X Family
Subsystems
Software
Fixturing

18/01/2000

HP 307X Series III Family Choices

Powered / Unpowered / Telecom / Pay-Per-Use
Number of Modules / Nodes
Up to 4 modules / 5184 nodes (full double density 307X)
2592 nodes (full single density 307X)

Vector Application Rate

6 MP/s, 12 MP/s, or 20 MP/s

Software
Incircuit, Combinational, Functional, Special Applications,
Pay-Per-Use

18/01/2000

HP 317X Series III Family Choices

Powered / Unpowered / Telecom / Pay-Per-Use
Number of Modules / Nodes
Up to 2 modules / 2592 nodes (full double density 317X)
1296 nodes (full single density 317X)

Vector Application Rate

6 MP/s, 12 MP/s, or 20 MP/s

Software
Incircuit, Combinational, Functional, Special Applications,
and Pay-Per-Use

18/01/2000

HP 327X Series III Family Choices

Powered / Unpowered / Telecom / Pay-Per-Use
Number of Modules / Nodes
1 module/1296 nodes (full double density 327X)
748 nodes (full single density 327X)

Vector Application Rate

6 MP/s, 12 MP/s, or 20 MP/s

Software
Incircuit, Combinational, Special Applications, and Pay-PerUse

18/01/2000

3X73
3074
3174

Functional
Combinational
Process Test
Pay-Per-Use
Communications

20
M .0
Pa
tte
rn
s

Incircuit

12
M .5
Pa
tte
rn
s

PIN card vector

application rate

6.2
M 5
Pa
tte
rn
s

Family Overview

3X75/6

3X75/12

3X75/20

3X72
3070
3170
3X79/6

3070
3170

3070
3170

3X79/12

3X79/20
18/01/2000

HP 3070 Family History

Products and Applications
HP 3173

HP 3070
Platform
Introduced

HP 3073
Advanced InHP 3070
Combinational circuit

1/89

Short-wire
Automation
Axx.xxx
Software

HP 3175
Lower Cost
Lower node
count
HP 3079
systems Telecom
HP 3075 High
Performance
HP 3074
Combinational
20MP/s
Functional

9/90

11/91 1/92

VXI Integration
ICT B.Scan

Test Jet
3072
3172

4/93

HP InterconnectPlus

(IEEE 1149.1)
HP
Throughput
(IEEE 1149.1)
Hi-Performance Multiplier
CTE Test
HP PanelTest
Fixturing
Tools

HP Series II
Platform
Introduced
725/50

HP327X
712/60
725/100

5/94

9/95

Bxx.xxx
Software

18/01/2000

HP 3070 Family History

HP 3070
Series III
Platform
Introduced
B180/C240

B.03.10

6/98

B.03.xx
Software

8/99

B.03.20

B.03.40

18/01/2000

Major Differentiators

Testhead Platform
Controllers
Card Types
Software
Theory
Hardware theory of operation is almost identical for all
systems in the 3070 family

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10

Series I Analogy
307X Platform
Up to four modules
l Separate support bay
with Power subsystem
l 115V module fans
l

317X Platform
Up to two modules
l Power subsystem in
testhead
l 230V module fans
l

Both systems support all single density PIN electronics!

18/01/2000

11

Series I
307X Power distribution
317X Power distribution
l one fan / module (in)
307X MPUs in support bay
317X MPUs in testhead
l gas springs
l Longer MPU cables
l Series 300 controller (outside
testhead)
l GPIO system card
l Single density PINs / mother
cards
l

Series II
3X7X testhead Power distribution
/ support bay
l 2 fans / module (out)
l All MPUs in testhead
l

rotator motor / gas spring

l Much Shorter MPU cables
l Series 700 controller (inside
testhead pod)
l LAN system card
l Double density PINs / mother
cards
l

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12

Series III

Similar power distribution as in Series II

2 stacked fans
New MPU in testhead
Rotator motor / gas spring
Same shorter MPU cables
B180/C240 controllers
LAN system card and control cards
Programmable (6/12/20) Double Density
HybridPlus cards

18/01/2000

13

Module Cards
Series I
Series II
Control Cards
03066-66510 (12MP/s)
E1038-66615 (6MP/s)
03066-66511 (6/12/20)
l ASRU Cards
03066-66530 (6/12)
03066-66531 (6/12/20)
l PIN Cards (Digital)
Hybrid
Channel
Serial (Telecom)
l Analog
E1172-66524 (ALL)
E1121-55626 (ALL)
l

Control Cards
03066-66511 (ALL)

ASRU Cards
03066-66532 (ALL)

PIN Cards (Digital)

Hybrid (Double Dens.)
Channel (Same)
- Serial (Telecom / Same)
l Analog
E4000-66542 (ALL DD)
l

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14

Series III Module Cards

ControlXT cards
use testhead LAN
E4000-66512

ASRU same as in Series II

Programmable HybridPlus DD
E4000-66550

Analog DD same as in Series II

18/01/2000

15

Service Issues
Configuration Constraints
System will not boot if configuration file / codewords
specifies wrong card speed. (6/12/20 MP/s)
A single system cannot run different control cards
Hybrid PIN cards of different speeds can not be mixed
Diagnostic Tests vary (6/12/20/DD)
Lanic ID wrong in etc/bootptab file

Instant Ignition from the factory

Field Service Inventory (order the correct part)
Billing and Contract Questions (last day)
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16

Subsystems Introduction
Power Subsystem
Control Subsystem
Analog Subsystem
TestJet

Digital Subsystem
Merged Analog/Digital Subsystem
Vacuum Subsystem
Fixture Pull-Down Subsystem

18/01/2000

17

Power Subsystem

AC

+5 / +24 V
Power
Supplies

DC

STC +5V Supply

DC

(3X79 only)

To System Card

Enable
DC

Contactors

Optional
Test Equipment

AC
"Mains"
DC

Control
MPU (1 of 4)

Enable
EMO Branch
Control

Other
Daughter
Cards

STC Card

PDU

ASRU Card

DUT
Power Supply

DC Power Distribution...
Module Mother Card
(1 of 4)
18/01/2000

18

Abbreviations to Remember
PDU = Power Distribution Unit
MPU = Module Power Unit
DUT = Device Under Test

18/01/2000

19

Series III Control Subsystem

Controller

I/O

Graphics
PS/2

To Monitor
To Keyboard, Mouse, Bar Code Scanner

RS-232

To Modem, Strip Printer

RS-232

PPU Button Adapter

EFS Board Handler
EFS Bar Code Reader
Repair Terminals

SCSI

E3788A SCSI to RS-232

LAN

To Site LAN, Line Printer, Plotter

HP-IB

To DUT Power Supplies, Optional Test Equipment, VXI

Testhead Modules
in
Control Card 0 out

Black
Box

Disk
DDS Tape

Testhead
LAN

System
Card

Control Card 1
Control Card 3

High-Speed
Link

Control Card 2
LAN Termination
To Footswitch
18/01/2000

20

Series II Control Subsystem

Testhead Controller

Built-in
I/O Ports

Plug-in
I/O Cards

Graphics
HP-HIL / PC
RS-232 #1
RS-232 #2
LAN AUI

To Monitor
To Keyboard, Mouse, Bar Code Reader(725/50 only)

To Modem
To Strip Printer(ThinLAN transceiver/HP-IB Gateway (on 712 only))
To Site External LAN
SCSI Single Ended
(Central Data SCSI/RS232 MuxConverter)

Parallel
HP-IB

To PPU Button Adapter, Line Printer

To DUT Power Supplies, Optional Test Equipment

RS-232 MUX

(Optional)
Testhead Modules

Internal
System
LAN

Control Card 0
System
Card

Control Card 1

Disk

Control Card 3

DDS Tape

Control Card 2

in
out

High-Speed
Link

18/01/2000

21

Control Subsystem Rolls

Controller Rolls
Speed
SCSI vs. HP-IB
Monitor size
Cost
HP-HIL / PCMCIA / OS-2

Software Revisions

18/01/2000

22

Series III Measurement Subsystem

Communication Paths
New
50 S SMB
New LAN Cable
50 BNC
Termination New LAN Cable E4000-61630 Short or BNC Tee Termination
1250-2076 E4000-61629 44607-61601 Long
1250-0781 1250-0207

15.3.112.5
Mod. 1
ControlXT

15.3.112.4
Mod. 0
ControlXT

15.3.112.6
Mod. 2
ControlXT

15.3.112.7
Mod. 3
ControlXT

15.3.112.2
System Card

Testhead
Controller
Existing LAN cable
8120-5371
New Adapter Cables
E4000-61631

New High-Speed Link Cables

E4000-61627

Existing System Card to Control Card

Control Cables
E1170-61604
18/01/2000

23

Series II Measurement Subsystem

Communication Paths
50 BNC
BNC Tee Termination
1250-0781 1250-0207

15.3.112.5 15.3.112.4 15.3.112.6

Mod. 1
Mod. 0
Mod. 2
ControlXT ControlXT ControlXT

15.3.112.7
Mod. 3
ControlXT

15.3.112.2
System Card

Testhead
Controller
Existing LAN cable
8120-5371

High-Speed Link Cables

03066-61603

System Card to Control Card Control Cable

E1170-61604

18/01/2000

24

Analog Subsystem
DUT
Control Card

CPU

Seq

Pin Card
Drive
r

ASRU Card
MOA

Receiver

Formatter

MU
X

MU
X

Control

Det

Control

Analog Bus
Control Bus
Mother Card
18/01/2000

25

TestJet Measurement Theory

Power
and
Signal
Ground

1000X
Amp

To Signal
Conditioner Board

Electronics Board

Sensor Plate
Capacitance

TestJet Probe

IC

Lead Frame

PC Board

AC Signal

Ground

18/01/2000

26

TestJet Subsystem
Fixture Top
Signal
Conditioner
Board

MUX

Signal
Amp

+6Vdc
Power

BPF

Gnd

MUX Control

TestJet Probe

Signal

Gnd

Ribbon
Cable

DUT
Fixture
Bottom
L
O

H
I

Gnd +6V

Verify

Mother

Debug Lines

Pin
Card

PSD
Primary
Source
8192 Hz
200 mVrms

Auxiliary DC
Source Detector

ASRU Card

Control
Card

18/01/2000

27

Digital Subsystem
DUT
Control Card

CPU

ASRU Card

Pin Card
Drive
r

Seq

MO
A

Receiver

Formatter

Control

MU
X

MU
X

Det

Control

Digital Bus
Control Bus
Mother Card

18/01/2000

28

Merged Analog / Digital Subsystem

DUT

Control
Card

CPU

Pin Card
Drive
r

Seq

MO
A

Receiver

Formatter

Control

Separate
Channels
for D-A

ASRU Card

MU
X

Det

MU
X

Formatter Control

Analog Bus
Digital Bus
Control Bus
Mother Card

18/01/2000

29

System Block Diagram

To Site LAN

To Module 0

Car
System
d

Testhead LAN

To Module 1
To Module 2
To Module 3
Vacuu
m and
Air
Control

+5/+24 V
AUX Ports

High-Speed Link IN

DU
T
Supply

Pin Card
8

Pin Card

DC

Pin Card

EM
O
Contro
Branch
l

MP
U
(1 of 4)

Pin Card

AC
"Mains"

PDU

Pin Card

Testhead Fans

Pin Card

AC
from
PDU

ASRU Card

Probe

Control Card

DDS Tape

High-Speed Link OUT

Pin Card

Optiona
l T/
E

Pin Card

Disk

Pin Card

Controlle
r

10

11

Module 0 Mother Card (1 of 4)

Enable
Debug
Ports

18/01/2000

30

Vacuum Subsystem
+24V
Power
Supply

+
-

J60b

System Card

Auxiliary Relays

15
16

J3
Auxiliary Ports

1
2
+
AUX1

3
4
+
AUX2

5
6
+
AUX3

7
8
+
AUX4

9
10
+
AUX5

Relay 1

Relay 2

Relay 3

Relay 4

Relay 5

Twisted Pair Wires To Auxiliary Ports

*
*
Vacuum Source
*
* Air-piloted solenoids
also need a source of
compressed air

11

12
Remote Emergency
Shutdown Jumper

Vacuum Ports
on Testhead for
Modules 0,1,2,3
2

*
Vacuum Solenoids

Flexible
Vacuum Hoses

18/01/2000

31

Air Pull-Down Subsystem

To Handler

Fixture Pull-down Towers

To Solenoid

Input

Air Output
(for Board Handler)

Regulator
(Top View)

Air Lines
Air Input
Test
Button

Pull-down Line
Release Line

Control
Wires

Air Regulator
03066-67911

Solenoid
Valve
03066-67910
Fan Power
J560a

J561

1
2

Bracket in rear of testhead

below the modules

Drain Valve
Fixture Pull-down
Relay
J60b
15
+
16
-

+24V
Power
Supply

System Card

18/01/2000

32

System Software
1: HP-UX
2: LAN
2

3: BT-BASIC

4: Diagnostics

5: Customer's
Application

18/01/2000

33

HP-UX

Install Reference
Useful Commands
Vi Editor
Operates in a multi-windows
Device Files

18/01/2000

34

HP-UX Lecture Continued

18/01/2000

35

LAN
Installation
covers MTD systems only
covers trouble-free" site LAN installation

Troubleshooting the MTD LAN boot process

18/01/2000

36

BT-BASIC / Customer's Application

Insight into corner-case failures
The system passes diagnostics but fails customer's boards

BT-BASIC commands that manipulate hardware

Install guide

Familiarity with user environment

18/01/2000

37

Testhead Boot Process

(see appendix A)
Starts process managers
System Card
Control Card(s)

Required for system operation

Communication
Module Power

Available from several software packages

From HP-UX: boot1
From BT-BASIC: testhead power on
From Diagnostics: softkeys

18/01/2000

38

Test Development Software

IPG Test Consultant

Data Entry Software

Program Generation Software
Fixture Construction Software
Program Debug Software
Production Testing Software

18/01/2000

39

Diagnostics
This course provides the knowledge and skills
necessary to enable the student to isolate and correct
80% of the hardware related failures on an HP 307X
system using Diagnostics software.

18/01/2000

40

Fixturing Solutions

SimPlate Test Fixture

SimPlate Express Test Fixture
XG-50 Test Fixture
Test Jet Test Fixture
Express Fixturing System
Express Cassette Test Fixture

Pin Verification Fixture (PVF)

18/01/2000

41

HP SimPlate Fixture
Board Support
Plate
Probe
Plate
Hinge

Pin
Plate
Pin
Block
18/01/2000

42

HP SimPlate Express Fixture

Tooling
Pin

HP Spring
Seal

PC
Board

Support
Plate

Probe
Plate
Personality
Pin
Single Plane
Wiring

Built-in Vacuum
Port

Testhead Interface
Pins

Alignment
Plate

18/01/2000

43

XG-50 Fixture
HP Spring
Seal

Tooling
Pin

PC
Board

Support
Plate

Probe
Plate
Ground
Personality Pin

Built-in Vacuum
Port

Testhead Interface
Pins

Single
Plane
Wiring

Alignment
Plate

18/01/2000

44

HP Express Cassette Fixture

Top Side
Probe

Latch
Post

Push
Rod

Transfer
Probes
Latch
Plate

Tooling
Pin
HP SimPlate
Express

18/01/2000

45