1. Verigy V93000 Service Training
Module 3:
Support Rack &
Power Subsystem
Module 3: Support Rack and Power Subsystem
Objective:
Given:
Service Guide II
Study Guide
Quiz
Answer questions about the V93000 support rack and power infrastructure. 90% correct answers are required to get credit for this module.

2. Power Block Diagram – LTH & STH
Support Rack
Power Backplane
Test Head
355V DC
Trim DC out Voltage
V AC To
Controller (RS232)
Cooling Unit
Manipulator Motor
Leakage Sensor
Pressure Sensor
DIS
Temp.
Sensors
Sense
DC output to each card slot
Temp / DC
Monitor
Power Control
From
Mains Power/ Auto Transformer
V AC AC DC
Control
Primary Power Box ,
AC Dist Box
AC/DC Power Unit
Rack Interface Board
ON/OFF Unit
DC/DC Power Unit
Power Control Bd
Power Subsystem Key Components K1
This block diagram shows the functional blocks and the main connections of the power subsystem. Most parts are in the support rack, the DC/DC power units and the power control board are in the test head.
This block diagram will lead through this training module.
03 - Support Rack

3. Power Block Diagram - CTH
Power Subsystem Key Components
Compact Test Head
From
Mains Power
V AC
Power Backplane AC DC
Control
Primary Power Box ,
AC Dist Box
V AC
DC output to each card slot K1
DC/DC Power Unit
AC/DC Power Unit
355V DC
Trim DC out Voltage
Rack Interface Board
Monitor
Temp/ DC
Sense
Power Control Bd
Power Control
DIS
Temp.
Sensors
DIS
Pressure Sensor To
Controller (RS232)
Cooling Unit
ON/OFF Unit
This block diagram shows the functional blocks and the main connections of the power subsystem.
Most parts are in the compact test head. The On/Off unit is external.
03 - Support Rack

4. Front View
On/Off Unit
Emergency Off button, illuminated ON and STANDBY switches, and an additional warning lamp. The unit is integrated into the front panel of the support rack. A ribbon cable connects it to the power back plane
Air Intake+Cooling Fan for Rack Interface Board & Power Backplane
Rack Interface Board – controls the system start and shutdown procedures and contains vital parts of the diagnostic subsystem (DIS). Also contains power supplies for the DIS. Rack interface board is accessible from front side.
Air Intake for Support Rack
AC/DC Power Units
Up to eight water cooled AC/DC units, which supply the test head with 355V DC. AC/DC units are accessible from front side.
Test Head Cooling Water Hoses
Test Head Power & Fiber-Optic Cables
The most visible difference to the Single Density Support Rack are the two air intakes on the front side.
The main functional difference are the AC/DC Power Units which can supply up to 2048 digital channels in a double density system.
The On/Off Unit is identical to single density.
The connections to the rack are compatible with single density test heads.
03 - Support Rack

5. Rear View Space for additional equipment Primary Power Box
Connection to mains power, the system’s line switch, and the line breaker
AC Distribution Box and Power Backplane
AC Distribution Box – Fuses and individual breakers for switched outlets, non-switched outlets, additional support racks, and the rack interface board.
The switched and non-switched outlets for auxiliary equipment provide output V AC.
Power Backplane – A board placed behind the AC Distribution Box. There are one DC-out connector and two fuses per card cage. There are several other connectors for WS, Cooler, Manipulator, EMO, DIS, etc. Temperature sensors also exist.
Fiber-Optic Cables
Compressed Air Connector
Water Hose Inlet/Outlet to Cooling Unit
The rear view shows the connectors:
Mains Power
Fiber Optic Cables, for the connection to the system controller
Compressed Air, needed for the docking mechanism
Cooling Water
03 - Support Rack

6. CTH - Bottom/Maintenance View
AC/DC Power Box
On/Off Unit
Rack Interface Board
Passive Control Board
CC2
AC/DC Power Units
Jumper Board
Active Control Board
CC 1
Optical link
03 - Support Rack

7. CTH – End View Connections
Low Level Diagnostic Cable RS232
ON/OFF Unit cable
Optical link
Cooler Control
Nitrogen
Main breaker
Compressed air
Mains power inlet
Air Pressure
Governors &
Guages
Cooling water in
Mains power out
(Cal Robot)
Cooling water out
03 - Support Rack

8. Primary Power Box and AC Distribution
Primary Power Box (PPB)
Contactor
Disconnect mains power controlled by the signal from rack interface board in case that the system detects hardware failure
Main Breaker
Connection Point of Main Power Cable (3-phase)
Connection Point of Main Power Cable (PE/Neutral)
AC Distribution Box
Non-switched Power Outlets
Switched Power Outlets
Breakers for Additional Support Racks
03 - Support Rack

9. Primary Power Distribution
Mains power is distributed to:
AC/DC Power Units
3 switched and 3 non-switched power sockets
Additional support racks
Rack Interface Board
Primary Power Box is configurable to 3-phase delta 208V and to 3-phase star 400/230V. As shipment default, configured to the European power option of star 400/230V.
Primary Power Box
Power Backplane
AC Dist. Box
From
Mains (3 phase)
Delta 208 V
Star 230/400 V
From Rack Interface Board
To Non-switched Power Outlets
200 – 230 V AC
To Rack Interface Board
To Additional Support Racks
To Switched Power Outlets
To Card Cages
355 V DC
Main Breaker
ON/OFF
Contactor
AC/DC
03 - Support Rack

10. Power Options with Autotransformer
The Autotransformer E8005A is required for systems with:
Small or Large test head, if the primary voltage is 440V or 480V.
Large test head, if the primary voltage is 200V/208V AND power consumption exceeds 36kVA. Currently this is the case if more than 42 digital channel boards (of any type) are installed.
Analog boards can be neglected.
1 Additional Support Rack is equivalent to 5 channel boards.
Example: For systems with 2 Additional Support Racks up to 32 channel boards are supported without the transformer.
The E8005A can be pro-actively ordered for large test head systems to allow for later upgrades.
03 - Support Rack

11. Autotransformer Front and Back Views
Control Transformer
Fan Power Supply PE
Primary Power
Connections
Power Output Cable
Power On Lamp
Output Breaker ST2
Emergency Off Button
Power Cable Outlet
Cooling Fan
Primary Power
Cable Inlet
Cooling Fan
Input Breaker ST1
FRONT
BACK .
03 - Support Rack

12. Primary Power – Star 400/230V – LTH & STH
Line Filter
Power
Backplane
Rack
Interface
F50
F51
NOTE: Newer HD support racks will have the new line
Configuration going to the RIB. This will include the addition
Of fuses F50 and F51 (PN ), bypassing the S3 breaker.
NOTE: LTH systems require an autotransformer (E8005A) if the primary voltage is 200V/208V AND power consumption exceeds
36kVA (Currently this is the case if more than 42 digital channel boards (of any type) are installed).
In star configuration the AC/DC power units, rack interface board and outlets are connected between a phase and the neutral.
03 - Support Rack

13. Primary Power – Delta 208V – LTH & STH
Line Filter
Power
Backplane
Rack
Interface
F50
F51
NOTE: Newer HD support racks will have the new line
Configuration going to the RIB. This will include the addition
Of fuses F50 and F51 (PN ), bypassing the S3 breaker.
In delta configuration the AC/DC power units, rack interface board and outlets are connected between two phases.
03 - Support Rack

14. Primary Power – Star 400/230V – CTH
03 - Support Rack

15. Primary Power – Delta 208V – CTH
03 - Support Rack

16. Primary Power Configuration – LTH & STHPE
Star Configuration 400/230V Delta Configuration 208V
Note
Select suitable cable clamp according to cable diameter
Torque Specification at Breaker: 15Nm
Star to Delta reconfiguration is described in Installation Guide
The Main Breaker has two dials for setting the trip current and the inrush current multiple:
Configuration Trip current (yellow dial):
STH Delta 208V 125A
STH Star /230V 80A
LTH Delta 208V 125A
LTH Star /230V 110A
The Inrush current multiple (red dial) is always set to x 6
03 - Support Rack

17. Primary Power Configuration – CTH
Phase
terminals L3 L2 L1
N terminal
(Star config. only)
PE terminal
03 - Support Rack

18. Breakers for additional Rack #3 #1 #2
Additional Support Rack Connections
Cable number are different between old and new racks:
E9695A (old)
E9695B (new)
Left
2 & 3
2 & 6
Right 1 4
Power cable clamps for additional support racks
The left side terminal of the breaker always connects two wires.
The right side terminal connects one wire to Neutral in Star configuration or to another phase in Delta configuration.
The supply voltage for the additional racks is: 200V..230V
Breakers for additional Rack #3 #1 #2
03 - Support Rack

19. Fuses and Breakers – LTH & STH
Breaker / Fuse
Location (ID)
Purpose
Main Breaker
Primary Power Box (S1)
For disconnect mains power completely.
Contactor
Primary Power Box (K1)
For remotely disconnect mains power controlled by the signal from rack interface board in case that the system detects hardware failure.
Switched power line breaker and fuses
AC Distribution Box (S2/F10/F11)
1 breaker 13A and 2 fuses 45A for switched power sockets
Non-switched power line breaker and fuses
Primary Power Box (S3)
AC Distribution Box (F4/F5)
1 breaker 13A and 2 fuses 45A for non-switched power sockets, power back plane and rack interface board
Additional support rack breakers and fuses
AC Distribution Box
(Rack 1: S5/F34/F35)
(Rack 2: S6/F36/F37)
(Rack 3: S4/F26/F27)
1 breaker 16A and 2 fuses 45A for each additional support racks (max. 3 racks)
AC/DC fuses
(AC/DC 1: F12/F13, AC/DC 2: F20/F21)
(AC/DC 3: F30/F31, AC/DC 4: F14/F15)
(AC/DC 5: F22/F23, AC/DC 6: F32/F33)
(AC/DC 7: F16/F17, AC/DC 8: F24/F25)
2 fuses 45A for each AC/DC unit
DC Out fuses
Power Backplane
2 fuses 10A for each Card Cage
gray: Used for 8CC test head only
03 - Support Rack

20. Fuses and Breakers – CTH
Breaker / Fuse
Location (ID)
Purpose
Main Breaker
Power Distribution Unit (S1)
For disconnect mains power completely.
Contactor
Power Distribution Unit (K1)
For remotely disconnect mains power controlled by the signal from rack interface board in case that the system detects hardware failure.
Switched power line breaker and fuses
Power Distribution Unit (S4/F1/F2)
1 breaker 16A and 2 fuses 10A for switched power sockets
Rack Interface Board line breakers
Power Distribution Unit (F3/F4))
2 fuses 3A for rack interface board
AC/DC line breakers
Power Distribution Unit
(AC/DC 1: S2, AC/DC 2: S3)
1 breaker 50A for each AC/DC unit
03 - Support Rack

21. Fuses and Breakers Maintenance
Indicator
: Blown fuse
: Good fuse
Fuse Exchange
There is a Fuse Extractor available to remove the thermal fuse.
Part number: E S3 S2
GFCI test button (GFCI – Ground failure Current Interrupter)
Perform GFCI test with appropriate procedures (see speaker note) every 6 months. Incorrect procedures damage the components in the test head.
For Exchange:
Use a flat screwdriver to pull out tab under the breaker
Check continuity by using multimeter. Blown fuse shows open connection.
Test Point
GFCI test procedures (S3 and S2 breakers require different procedures)
To test S3 (upper location):
Turn on main breaker (S1).
Press GFCI test button (S3). Check if S3 breaker trips. Do not press ON button of ON/OFF unit in front panel. It may damage front-end IC on Pin Scale 3600 card.
To test S2 (lower location):
Press ON button of the front panel.
Press GFCI test button (S2). Check if S2 breaker trips.
03 - Support Rack

22. Block Diagram AC/DC Power Unit LC Line Filter PFC AC/DC- Converter
Output
Power
3kW
6kW
350V
355V
360V
Uout
Block Diagram
AC/DC Power Unit
LC Line Filter
PFC
AC/DC- Converter
DC/DC-
Converter
AC1
DC+
Vac
Uout = Vdc
100K
AC2
DC -
Disable
Disable PE
EEPROM
Control
PWR-OK
100ms
Temp.
Monitor
DIS
TEMP-OK
AC-OK
INSTALL*
The AC/DCs provide isolation between AC input and DC output. The outputs are connected with a high resistor of 100k to PE.
This isolation results in similar noise performance as a Power Conditioner.
03 - Support Rack

23. AC/DC Power Unit Filling Order
Output power from all AC/DC units are connected in parrallel.
Filling Order of AC/DC unit:
Minimum configuration:
Required number of AC/DC units is determined by the power calculation. (See below)
(Number of ACDC) = (Power Summation of HW Resources) / 6000
Example: 8CC test head with 24 Pin Scale DPS
(8 x x x 695 ) / 6000 =  Requires 4 AC/DC’s
Minimum Configuration
Installable Slot
8CC: 51627384
4CC: 1234
8CC: 5 and 1
4CC: 1
HW Resource
Power per unit
Clock(214) + CC power margin
414 W
DPS (GP, HV, HC)
457 W
DC Scale DPS, VI
650 W
Utility DPS
30 W
Digital I/O (PS800)
600 W
Digital I/O (PS400, PS3600)
RF Card (Griffin)
124 W
AV8 (MCA, MCB)
298 W
PinScale HX
300 W #5 #6 #7 #8 #1 #2 #3 #4 #1 #2 #3 #4
8CC CC
03 - Support Rack

24. Unit Exchange Use the hose extraction tool for the cooling hoses
LTH & STH
CTH
Support the weight of
the AC/DC power unit
while pulling it out.
15kg / unit
03 - Support Rack

25. RIB Location and Components – LTH & STH
Rack interface board is the heart of the power subsystem. It contains a part of the diagnostic subsystem (DIS).
Residual charge warning LEDs
Thermal (Bimetal) switch with release button
Locating pin
Connectors to Power Backplane
Rack Interface State Machine and error latches
DIS Controller and CAN bus interface
Accessible from front side of the support rack
In case of problems, always check the “release button” on the temperature switch (bimetal switch)
03 - Support Rack

26. RIB Location and Components – CTH
Residual charge
warning LEDs
Water cooled heat sink
Thermal (Bimetal) switch with release button
Accessible from the back side of the CTH
Locating pin
Prototype
Connectors to Power Backplane
Rack Interface State Machine and error latches
DIS Controller and CAN bus interface
Fan
In case of problems, always check the “release button” on the temperature switch (bimetal switch)
03 - Support Rack

27. Block Diagram Rack Interface Board Functions of the board:
Executing the system start procedure
ON/OFF Unit interface
Monitoring the system status
Controlling the contactor K1
Providing the diagnostic interface to the controller (via RS232)
Controlling the manipulator, soft and hard docking
Generating support voltage
Monitoring pressure, leakage, and cooling fan
Monitoring temperature for AC/DC, Rack Interface Board, and Power Backplane
Monitoring AC/DC supply voltage
DIS controller with RAM banks and CAN Bus interface
DIS and RS232 interface
To (+24V)
Manipulator and Docking
Rack Interface Board
Connections to test head
CAN Bus DIS Power +5V, ±15 V , - 12 V To
(+24VC)
Contactor
Rack Interface State Machine
&
support circuits
Pressure Sensors
Leakage Sensor
ON/OFF Unit
Cooling Unit
External EMO
Signal Lamps
Manipulator
System Controller (RS232)
DIS
Controller
Support Voltage
+30 V
+24 VC
+15 VC
+5 VC
-15 VC
+24V
Connections to external units
Bi-metal Switch
230 VAC
from
Main
Breaker
AC/DC Monitor
Temperature Monitor
RS232
03 - Support Rack

28. Support Rack Cooling Fan
The Fan operation is monitored by the Rack Interface Board
Cooling fan for Rack Interface Board and Power Backplane
Connector to Power Backplane
The cooling fan is located on top of the rack interface board. The fan also cools the power backplane, which is warmed up from the high currents of the primary power distribution.
03 - Support Rack

29. ON/OFF and EMO – LED and Circuit
EMO Circuit
+24 V
Interlock
(jumper as default)
Emergency Off (EMO) Button
ON Button
/ SYS OK LED
Warning LED
STANDBY Button / SYS FAIL LED
EMO Button
Cooler
On/Off
Contactor
From Rack Interface Bd.
At Front Panel
External EMO connector on Power Backplane
Cooler control connector on Power Backplane
External EMO
EMO to Cooler
System Status by LED
Status
Green
Yellow
Red
System stand-by
Off
Starting cooler, connecting AC/DC power units, and switched/non-switched power outlets
Blinking Slow
Starting DC/DC power units
Blinking Fast
System OK On
System running, cooler warning
System shutdown, hardware failure
State Diagram:
03 - Support Rack
For more information, refer to the System Start Problems section of the Service Guide 1.

30. System Start-Up States
State Name
Description
LED’s
state_off
System in stand-by
AC/DC power units disconnected from the mains power supply 1
state_start_1
Cooling unit is started
Timeout counter for the cooling unit startup is set for 20 sec.
Green LED blinks with low frequency 2
state_half_on
Contactor closed. AC/DC power units connected to mains power
DC/DC power unit still inactive
Timeout counter for the AC/DC power units set 3
state_start_2
Enable DC/DC power units by setting Start_PWR
Timeout counter for DC/DC power units set to 1.3 sec.
Green LED blinks with high frequency 4
state_on
Green LED on 5
state_half_off
DC/DC power units disconnected in sequence
AC/DC power units disconnected from mains power supply
Cooling unit is shutdown
‘EMO’ Engaged
Leakage detected
Cooling failure 6
state_fail
Turn on red LED
03 - Support Rack

31. Power Backplane - Location
Cables to
AC Fuses
Fuses for
DC Out
DC Out
Connectors
03 - Support Rack

32. Power Backplane – LTH & STH
Rear Side Front Side
EEPROM
Over-temperature Sensors
LED & Connectors
(See next slide)
Rack interface Board Connectors
AC/DC Power Unit Connectors
+5VC for TH(J114)
Manipulator Motor(J142) *
TH Power Control(J113)
External EMO Sense / Interlock(J130)
24V2, 24VC2 for TH(J135)
Cooler Control (EMO and On/Off)(J107) *
LED’s, Connectors and Fuses for DC Out
Cooling Loop Cooling Loop 2 Leakage Sensor
(J140) (J141) (J143)
* Must be connected for
system installation.
03 - Support Rack

33. Connectors and LEDs (front side)
Installation:
Connect the RS232 cable to the system controller for low level diagnostic.
The LEDs on the power backplane are very helpful to get a first overview of the power system status. Short descriptions are printed on the board. For more detailed explanations of the LEDs see Service Guide 2.
Detailed troubleshooting can be done by the low level diagnostic. For details see Service Guide 1.
03 - Support Rack

34. RS232 for low level diagnostic
Power Backplane - CTH
LED’s
(See Next Slide)
Cooler Control
RS232 for low level diagnostic
ON/OFF Unit with EMO
Rack Interface Board Connectors
AC/DC Power Unit Connectors
03 - Support Rack

35. LEDs (front side)
Remove cover to check LEDs
03 - Support Rack

36. Support Rack to Test Head Connections

37. Manipulator and Docking Control
+24V
Open
Close
Magnetic Valve
(Hard Docking)
Override
Enable
Test Head
Up/Down
DUT Undock
DUT Dock
Hard Undock
Hard Neutral
Hard Dock
GND
Interface dock
Interf. undock
Hard dock
Hard undock
Motor on
Up / Down
Idle
Override
+24V when
undocked
Hard Docking
Sensor
Beeper
Board
Remote Control Connector
+24V
Open
Close
Magnetic Valve
(Interface)
+5V when
undocked
Interface
Micro Switch
Test Head
Support Rack
Manipulator
Motor
Power Backplane
Up / Down
24VDC
Up -
Up+
Motor on
Rack Interface Board
The remote control unit controls the up/down movement of the test head and operates the hard-docking and DUT- interface docking mechanisms. It is held by a magnet to the side of the test head.
The remote control unit transmits two signals to the rack interface board: up/down and motor_on.
The up/down signal switches two relays that reverse the polarity of the manipulator control voltage.
The motor_on signal activates the control voltage, which controls the manipulator driver circuit. The driver circuit is powered by +24 V provided by the rack interface board.
The remaining signals are passed to the test head and control the compressed air solenoids that operate the docking mechanism.
The beeper board is a small board inside the test head which is used as a connector interface between the remote control, valves, sensors and the cable to the power backplane. It also contains a beeper to warn the user when the manipulator is moved by the motor.
03 - Support Rack

38. DC/DC Power Unit 8 DC/DC Power Units are in a 4CC TH
Back plane address, data , control bus interface.
8 DC/DC Power Units are in a 4CC TH
16 DC/DC Power Units are in a 8CC TH
The DC/DC Power Units step down the 355 VDC from the AC/DC boards to different low voltages required by the TH boards. The DC/DC Power Unit modules are mounted to water-cooled heat sinks.
Each card cage contains two identical DC/DC Power Units.
A DC/DC Power Unit consists of two DC/DC conversion units which are screwed onto both sides of a common heat sink.
DC/DC Power Unit generates voltages for the following modules: Channel boards, Analog module, Clock boards, Device power supplies and Control boards.
Two types of DC/DC Power Units are available:
Digital DC/DC Power Unit,
Analog DC/DC Power Unit(generate 16V for analog channel boards).
355 VDC from the AC/DC boards, low voltages for the following modules: Channel boards, Analog module, Clock boards, Device power supplies and Control boards.
DC/DC Power Units serve to supply the half of the system boards in this card cage.
DC/DC Power Units for digital and analog card cages are different and these are coded with different colored coding pins. Digital DC/DC Power Unit boards have blue colored coding pins , while analog DC/DC Power Unit boards have pink ones.
Each DC/DC Power Unit contains 10 DC/DC Convertors to supply the different voltages .
The DC/DC Power Units are controlled by the power control board, which is plugged onto the CC’s frontplane board. The power control board enables the converters at power on and disables them when the system is switched off.
Circuits on the power control board also compare the output voltages with references and generate trim voltages for the DC/DC Power Units to achieve the desired output.
Reference Voltages for Power control Board:
There is one diff-amp on the 16V- DC/DC-bd (Analog) for the +16V and one for the -16V.
The first one transforms the +16V (referenced to AGND) to 3.3V (referenced to DGND of the frontplane).
The second one makes the same, it uses the -16V and creates 3.3V.
The power control board sees no difference between both boards, that is
necessary for compatibility reasons.
Max. tolerance of output voltage is +-2%.
03 - Support Rack

39. Universal DC/DC (blue coding key) Analog DC/DC (pink coding key)
DC/DC Power Unit
There are 2 DC/DC power units per card cage in the test head. Each DC/DC power unit occupies 2 slots.
Each DC/DC power unit is composed of two boards. Each board has 5 DC/DC converters mounted to one water-cooled heat sink. These DC/DC converters supply required voltages to all test head boards.
Each converter has sense lines that adjust the output level roughly to its nominal level (without control circuitry).
Output levels are monitored and regulated by monitoring circuits to nominal levels in case of load variations.
The temperature of the heat sink is measured. The contactor K1 is disabled as soon as the temperature exceeds 57°C.
Each DC/DC converter has an enable input, which is used to switch on/off the converter. A certain switching sequence is followed in order not to damage sensitive components (ADC and bus driver).
Universal DC/DC only powers up, if PinScale or BIST Assist cards are detected.
CAUTION: Putting the analog DC/DC in a digital card cage might damage the channel boards. See supply voltage difference in the table.
Backplane Connectors
Frontplane Connectors
Universal DC/DC (blue coding key)
Analog DC/DC (pink coding key)
Single Density
E , +3.3V, For P/C/Ce/NP/BAA/PPS, Strap: black
E , ±16V, For all analog, Strap: blue
High Density
E , +6V +12V, For Pin Scale/BAA, Strap: orange stripe
03 - Support Rack

40. Power Control Board 4 Power Control boards in a 4CC test head
The task of the Power Control board are to:
Provide a defined power ON/OFF sequence
Measure the DC output voltages and generates trim voltages, which are applied to the converters.
Monitor the trim voltages
Monitor the temperatures of all boards in its card cage
Contain a DIS controller and DIS interface
DC/DC Power Unit output voltages, trim voltages, temperatures of all boards in its quadrant, DIS controller and DIS interface.
Via the DIS interface, the power control board can communicate with the rack interface board. It is able to receive commands from the rack interface board and to transmit messages to the rack interface board. The DIS interface allows Diagnostics to access each power control board.
The power control boards are powered by the auxiliary power supply via the rack interface board. Thus, Diagnostics can communicate with the DIS controllers even if the system has shut down due to a problem.
03 - Support Rack

41. Power Control Board - Location
LTH
STH
CTH
Each card cage has a Power Control Board, which is plugged into the front plane board.
The power control board controls and monitors the DC/DC power units.
03 - Support Rack

42. Voltages & Temp. Signals
Block Diagram
Functions of the Power Control Board:
Contains a DIS controller which is connected to all other DIS controllers in the system via the CAN Bus.
Powered by +5 V / ±15 V / - 12 V from the Rack Interface Board
The supply voltages are present as soon as the main breaker is ON. Thus, the diagnostic hardware is accessible even if the system was shut down by a hardware failure.
The State Machine provides a defined power ON/OFF sequence.
Controls and monitors the DC/DC converters on the DC/DC Power Units.
Monitors the temperatures (reference: 57 degree C) of all cards in each card cage.
For PinScale channel cards only: Detects the coding resistors and monitors the DC/DC converters on the PinScale channel cards.
Power Control Board
Error Logic
&
State Machine
DIS Controller
Rack
Interface
Board
DIS
Status LEDs
Power Control
CAN Bus
Channel Cards
Select
Temp DC
Voltages & Temp. Signals
Coding
Trim DC out Voltage
Enable DC/DC
DC/DC Power Units
+ 5 V ±15 V V
03 - Support Rack

43. DC/DC vs. PinScale IO Type Compatibility
301/ PS3600
303/ PS3600
305/ PS800
307/ PS800
101/ PS3600
107/ PS800
105/ PS800
103/ PS3600
301/ PS800
303/ PS800
107/ PS3600
105/ PS3600
Possible Configuration:
DC/DC unit hosts a pair of same card
Impossible Configuration:
DC/DC unit doesn’t host Pin Scale 3600 and 800 pair.
301/ BAA
303/ BAA
305/ BAA
307/ BAA
BIST Assist 6.4 can co-exist with any of Pin Scale card.
PS3600 has priority to PS800.
301/ Digital
303/ Digital
305/ Digital
307/ Digital
101/ Digital
107/ Digital
105/ Digital
103/ Digital
DC/DC E8003A
Power Distribution in a Cage 8 7 6 5 4 3 2 1
For slot 7&8
For slot 5&6
For slot 3&4
For slot 1&2
Examples at Group1, CC 3
03 - Support Rack

44. Card compatibility table
PS400
PS800
PS3600
PS HX
Bist-
Assist
DPS32
VI32
MB AV8
6G QS
Port Scale RF
AV 8
Griffin
Bist-Assist
AV8
cards can sit side-by-side
cards cannot sit side-by-side
analog DCDC
universal DCDC
Which board can pair up with which other board
The following board types can be operated with both kind of DC/DC (analog or universal):
- MBAV8
- 6GHz Sampler (Multi-site Sampler)
- Port Scale RF
03 - Support Rack

45. Power-up Sequence PinScale Single Density Disable Enable
Voltage Analog
Voltage Digital PS800
Voltage Digital PS3600
Distribution Route
- 12 V
Frontplane
+ 14 V
+12V
Backplane
±16 V
+ 12 V
+ 12↓6 V
+ 5 V
+5↑6.5 V
- 6 V
- 6 V
+ 10 V
+ 8 V
+ 5 V
+ 5 V
+ 3.3 V
Frontplane (for DPS)
Single Density
Voltage Analog
Voltage Digital
Distribution Route
-12 V
- 12 V
Frontplane
+14 V
+ 14 V
±16 V
+3.3 V
Backplane
+5 V
+ 5 V
- 6 V
- 6 V
+ 10 V
+10 V
+ 5 V
+ 3.3 V
Frontplane (for DPS)
Enable
Disable
During power-up and power-down the state machine enables/disables the DC/DC converters in a defined sequence by activating the enable signal for the DC/DC converters.
NOTE: The red numbers indicates voltage differences.
03 - Support Rack

46. Power Control Board – LED’s
Descriptions OK
System is switched on and power is ok
UVPb
UVPd
Under voltage detected (b: channel bd 5 – 8, d: -12V for DPS)
UVPa
UVPc
Under voltage detected (a: channel bd 1 – 4, c: +12V for DPS)
OVP
Over voltage detected
SPWR
Start power (on for 1.3 second during start up)
OVT1
OVT2
Over temperature detected (OVT1 is on and OVT2 is off)
DC/DC failure on channel board (OVT1 and OVT2 are on)
OFF
DC off (system switched off, mains present)
MISMATCH A
Incompatible Channel Boards in Slots 1 / 2
MISMATCH B
Incompatible Channel Boards in Slots 3 / 4
MISMATCH C
Incompatible Channel Boards in Slots 5 / 6
MISMATCH D
Incompatible Channel Boards in Slots 7 / 8
The Mismatch LED is on if two adjacent channel cards are not power compatible, for example a Pin Scale 800 and a Pin Scale 3600 card.
All water-cooled boards in the test head have a temperature sensor mounted to the heat sink. Analog comparators on the power control boards compare the output levels of the temperature sensors to a reference level of 57°C.
If an over-temperature condition occurs, the red OVT LED on the power control board of this card cage is lit and all DC/DC converters and the contactor are disabled.
The signal Start_PWR clears all error latches for a new system start.
03 - Support Rack

47. RS232 and CAN Bus System (CTH)
controller
Rack
interface board
Power
control
board
Clock
RS232
cable
Power
control
board
board
Control Cable 2
Control Cable 1
Active control
board
Card Cage 2
Card Cage 1
To Manipulator
Wiring Board
Termination
Power backplane
CTH
This picture shows the routing of the CAN bus, shown from the frontplane side. The arrow points towards the manipulator.
The CAN bus starts on the rack interface board and is terminated on the power backplane. It connects all 4 DIS controllers on:
1 rack interface board,
2 power control boards and
1 active control board
For Linux controllers a USB to RS232 converter is used for the diagnostic cable.
03 - Support Rack

48. RS232 and CAN Bus System (STH)
Standard support rack
Rack interface board
RS232
cable
Clock
board
Active control
Card Cage 2
Card Cage 4
Card Cage 3
Card Cage 1
Power control board
Power
control
Power control board
Power control board
Connection
Termination
STH
System
controller
Control
backplane
To Manipulator
This picture shows the routing of the CAN bus, shown from the frontplane side. The arrow points towards the manipulator.
The CAN bus starts and ends on the rack interface board. It connects
all 7 DIS controllers on:
1 rack interface board,
4 power control boards and
2 active control boards
For Linux controllers a USB to RS232 converter is used for the diagnostic cable.
03 - Support Rack

49. RS232 and CAN Bus System (LTH)
Clock
board
Card
Cage 1
Cage 5
LTH
Active control
Connection
Cage 7
Cage 3
Cage 6
Cage 2
Cage 4
Cage 8
Control
cable
Standard support rack
Rack interface
RS232
System
controller
Power
backplane
control
Termination
Supply only
To Manipulator
This picture shows the routing of the CAN bus, shown from the frontplane side. The arrow points towards the manipulator.
The CAN bus starts and ends on the rack interface board. It connects
all 13 DIS controllers on:
1 rack interface board,
8 power control boards and
4 active control boards
For Linux controllers a USB to RS232 converter is used for the diagnostic cable.
03 - Support Rack