Agilent 3070 User Fundamentals

Module 8: Fixture I
Table of Contents
The Test Development Process ............................................................................................... 2 The Test Fixture ...................................................................................................................... 3 The Test Probe................................................................................................................. 3 The Personality Pin.......................................................................................................... 4 The connection process.................................................................................................... 4 Simplate Fixture (above left) ........................................................................................... 5 Simplate Express Fixture (above right) ........................................................................... 5 Issues ....................................................................................................................................... 6 Fixture Electronics........................................................................................................... 7 TestJet Probe ........................................................................................................................... 8 Agilent IPG Test Consultant & the Fixture ........................................................................... 10 The Individual Parts of the Fixture Generation Software.............................................. 11 Board Placement ............................................................................................................ 11 Probe Select ................................................................................................................... 13 Allocating Power Supply resources............................................................................... 15 Module Pin Assignment ........................................................................................................ 17 Module Pin Assignments Inputs & Outputs................................................................. 18 Fixture Tooling...................................................................................................................... 19 Extra Personality Pins.................................................................................................... 20 Fixture Tooling Outputs ................................................................................................ 21 The Files for the Fixture Builder ........................................................................................... 22 Bank Row Column ................................................................................................................ 24 Fixture Verification ............................................................................................................... 25 Running Test Consultant Multiple times............................................................................... 28 Re-running Fixturing Software BEFORE a fixture is built ........................................... 28 Rerunning Fixturing Software AFTER a fixture is built ............................................... 29 Examine the fixture/details file .................................................................................. 30 Glossary................................................................................................................................. 31 Appendix ............................................................................................................................... 32 fixture/fixture.o details....................................................................................................... 32 fixture/summary - after Board Placement .................................................................. 33 fixture/details.............................................................................................................. 33 fixture/summary - after Probe Select ......................................................................... 33 fixture/fixture.o output - after Module Pin Assignment ............................ 34

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Test Development Flowchart

Process
1 2

Files
board

Tools
CAMCAD Translator BT-BASIC Board Consultant Part Description Editor Digital Setup Editor IPG Test Consultant PushButton Debug

Translate CAD Describe board & system

board_xy config Custom libraries

3 4 5 6

Generate Test & Fixture files Build & Verify test Fixture Turn-On / Debug all Tests Release to Production & Long Term Support

testability.rpt Fixture Files Individual Test Files testplan

ECO

Generates

Modify
1

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The Test Development Process

During previous modules, you: Created the config file, Translated the CAD into a board description, Completed the board description using Agilents Board Consultant, Part Description Editor, Digital Setup Editor, Generated and evaluated the testability.rpt, Generated the fixture and test files using Agilent IPG Test Consultant. Regenerated and reevaluated the testability.rpt

Now, the development continues with an overview of fixture types, the fixture files, the parts of the fixture and fixture verification. Later in the class, the Agilent Fixture Consultant will be examined. For now, it will be skipped so you can concentrate on a general overview of the entire fixture process.

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The Fixtures
Tooling Pin Vacuum Gasket

Personality Pins

Simplate Express
Pins

Alignment Plate

Simplate
Board Support Plate Probe Plate
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The Test Fixture

The goal of fixturing is to connect the testhead resources to the PC board with the minimum of impedance, reactance or inconvenience. There are two basic fixture types: Simplate Simplate Express

During this class the focus is on the Simplate Express or short wire fixture. The Simplate or long-wire fixture is also described. Two other fixture types are not described as they are only seldom used. The Express Cassette fixture was used in the EFS Board Handler. The EFS is no longer in production, having been replaced by more modern automated board handling equipment. The XG-50 fixture was used to propagate higher frequency signals. As with the EFS, more modern test techniques have all but made this fixture obsolete.

The Test Probe

The test probe is a four part assembly. The socket is press-fit into the Probe Plate. The height of the socket is carefully controlled. This ensures the probe can compress more than the fixture, to make sure the probe is not damaged during test. The tail of the socket is a wire wrap post.

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Agilent Technologies The test probe assembly is inserted into the socket during the fixture build process. This probe will last many months but can be replaced easily. The probe assembly consists of three parts. A sleeve, a spring and the probe itself. The spring is mounted inside the sleeve. The probe inserts into the sleeve and attaches to the spring. The probe assembly is then inserted into the socket. Together these are generically referred to as the probe even though it is really the probe assembly and socket. During test, the probe tip lightly scratches the surface of the solder or copper when the fixture compresses. This scratch is usually sufficient to clear away oxidation or surface contamination thus ensuring good electrical contact during test. It is usually not enough to pit the surface. There are dozens of different point types for fixture probes. As with the different probe point types, there are a number of different spring forces, probe lengths, probe diameters, etc. Most people try several variations and qualify one or two types of probes for their applications and environments. NOTE: Caution should be used when cleaning the probes. Any solvent that penetrates between the probe and the spring/sleeve assembly will dry out the lubricants within the sleeve and the probe will fail prematurely.

The Personality Pin

The Personality Pin (or P-Pin for short) is used to connect to the testhead resource. It has a plastic top that is press fit into the bottom of the Probe Plate at specific coordinates (defined by the fixture software). The post is simply a wire wrap pin that will hold at least three wires.

The connection process

The test Operator loads the board to test onto the fixture. Tooling Pins mounted in the Probe Plate, but extend through the Support Plate ensure a quality alignment. The board rests on a combination of vacuum gaskets around the parameter of the board and spacers or pads scattered evenly around the interior of the board. The system asserts vacuum to the fixture. This creates a vacuum chamber between the printed circuit board and the Probe Plate. Vacuum holds the printed circuit board to the Support Plate. Springs holding the Support Plate to the Probe Plate compress pulling it and the board toward the Probe Plate. The test probes are also spring loaded and they compress as the board pushes them toward the Probe Plate. The board travels to a physical stop. The probes, resisting that travel embed their points into the solder on the test points of the board.

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Agilent 3070 User Fundamentals The 3070 generates a signal. That signal is propagated from its source on a Pin Card, to the fixtures test Pin. Through the fixture wiring to the Probe. Through the probe to the test point on the printed circuit board. The signal travels through parts and traces on the printed circuit board. The test circuit is completed when the signal is returned, via a separate Probe, wire and Pin from the printed circuit board back to a Pin Card. The returned signal is measured and evaluated with pass/fail criteria.

The final detail about this fixture is the use of spacers, pre-loaded board springs and gaskets to prevent warping of either the PC board or the Support Plate when vacuum is applied or released.

Simplate Fixture (above left)

This older fixturing technique, the Simplate or long wire fixture has been used for about the last 20 years. This test fixture features three plates. Issues Long wire lengths can introduce excessive inductive and/or capacitive loading on the printed circuit board. In high speed applications, the wire can act as a coil with potentially damaging energy. Twisted pair, coaxial wire and/or Ferrite beads can minimize the impact of some of these issues, but not all. The only real solution is to make the wires shorter. The printed circuit board rests on the Support Plate. The Probe Plate has test probes mounted at specific coordinates. These make contact to the printed circuit board during test. These test probes give the fixture its bed-of-nails name. The third plate has test pins mounted in it. These pins connect to predefined locations in the testhead. The connection from the test probes to the test pins is made with wire wrap wire. You will notice that the fixture is hinged so it can open. The typical fixture uses wires that range from 16 to 36 inches.

Simplate Express Fixture (above right)

This style fixture offers typical wire lengths that range from 1.0 to 9 inches. It uses three plates also, but in a very different manner. The Support Plate is the same as the long wire fixtures. The Probe Plate holds not only the test probes, but also the test pins, called Personality Pins. By putting both probes and pins on the same plate, the wire length required to complete the connections are very short. The Alignment Plate is used to ensure proper alignment between the testhead and the personality pins. It consists of rows of funnels that help direct the pins into the proper locations.

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Issues
Because the probes and pins are on the same plate, conflicts became a concern. If a probe has to be at a particular location, and a pin needs to occupy that same space, what happens? The answer, the probe wins! (Because they are assigned first.) Why? Because there is a limited number of probe sites for a given node. But that means one of the testhead resources is blocked. Perhaps, but not necessarily. If a pin is blocked, it is usually not a serious problem because there are lots of testhead resources. But there are ways to un-block pin locations: Ideally, the personality pin is installed so it aligns straight through the Alignment Plate without interfering with a probe. But what happens if a probe and a personality pin both need to occupy the same space? There are three methods for overcoming this limitation of the Express Fixture. All of these are done automatically by the fixturing software. The first is to simply use a different location for the personality pin. Few testhead resources truly require a personality pin be located at a specific location. If a personality pin cannot be used it is considered blocked. The probe remains at its location; the testhead resource (BRC) below this Alignment Plate funnel is flagged as non-usable. The second method is to locate the personality pin as close as possible (without causing a short) to the probe. Then bend the pin so that when the Alignment Plate is installed it ensures the bent personality pin aligns properly to the testhead. Personality pins may be bent up to 0.1. However, they may only be bent in the Y direction (in parallel with the alignment plate funnels). The third method involves an offset personality pin. It allows a personality pin to be located close to the blocking probe, then to transfer its signal to a very small plated printed circuit board that is mounted to the Alignment Plate. The effect is to bypass the probe that is blocking that particular system resource. The use of offset personality pins is not recommended for signals that are sensitive to added impedance. A fourth, manual technique, uses Agilents Fixture Consultant. This tool, detailed later in the class, allows you to manually reposition the printed circuit board on the fixture. The software then evaluates blocked testhead resources. By spending a few minutes with this interface, you can frequently minimize the number of blocked testhead resources.

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Fixture Electronics

Add a load inside the fixture Hang a pullup inside the fixture Board Under Test Add a printed circuit assembly to the top of the fixture. - Cover it with a protective housing. - Connect it to the Board Under Test using a cable and connector

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Fixture Electronics
Fixture Electronics are sometimes needed to assist in testing your board. There are two typical methods for including fixture electronics in a test fixture. One is to suspend those components within the fixture on nothing more than the wire-wrap wire. This will work if you are adding a resistor or other simple component. Any exposed, conductive surfaces should be enclosed in heat-shrink or electrical tape to prevent shorting. For more complex fixture electronics, a printed circuit board (breadboard) should be assembled. This board may be mounted on the top of the Probe Plate where it should be enclosed with a housing or shield to prevent it from being shocked (ESD) or damaged in handling. The Fixture Electronics board should be connected to the rest of the fixture through a connector. In this way, you can easily swap to a backup board if the primary board becomes faulty. Agilents Fixture Consultant provides tools for describing fixture electronics and even extending these parts into tests so you know the electronics continue to function normally.

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The TestJet Probe

Top Plate PCB Support & Probe Plates

Small TestJet or Polarity Check Probe

Sensor Plate Electronics Board TestJet Pins

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TestJet Probe
The TestJet probe consists of three parts: The Sensor Plate, An Electronics board The TestJet Pins

TestJet Test Theory During the test, one lead of the device is driven. This signal is capacitively coupled to the sensor plate. The capacitively coupled signal is amplified by the electronics board. The resulting signal is sent to the Multiplex card (not shown) and is relayed to the ASRU for analysis. Installation of the TestJet Probe Because TestJet measures the capacitive coupling between the lead and the die of an integrated circuit, the TestJet probe must be physically very close to the device under test. Touching is acceptable. Given: A device mounted on the bottom of the board to be tested with TestJet. When you enabled TestJet testing, you also described the outside radius of the device. The fixture software uses this radius to create a keepout region. This region defines an area where no probes or personality pins should be installed. Given: A device mounted on the top of the board to be tested with TestJet.

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Agilent 3070 User Fundamentals When you enable the TestJet test, you must also enable the use of a Top Plate. This custom built plate holds the TestJet probes mounted above the device. To load and unload the printed circuit board, this Top Plate must be hinged. It is opened to load the board, closed to test and reopened to remove this board and load the next.

The Small TestJet probe is used to test polarized capacitors (through-hole or surface mount) or small surface mount integrated circuits. The pins are 100 mil probes with a special end that saddle-mounts onto the edge of the electronics board. These are soldered together using a special tool provided with the fixturing kit. The electronics board is similar to the standard TestJet electronics board, but because of the mounting differences, they are not interchangeable. The Small TestJet sensor plate is very different. It is basically a folded metal plate with mounting pins that you solder to the electronics board (again using the special tool provided in the fixture kits). The sensor plate is coated to prevent shorting. The Foam-mounted TestJet Sensor is designed to test large devices including connectors and integrated circuits. Because it is so long (up to 6), the use of mounting pins is not practical. Therefore, adhesive backed foam pads are used to mount the sensor above the device to be tested. It mounts on the top plate only, where vacuum is not required.

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Agilent IPG Test Consultant

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Agilent IPG Test Consultant & the Fixture

Notice that there are two Fixturing Processes shown. The Initial Fixturing tasks are: Board Placement, which defines where the board will be located on the fixture. Probe Select, which locates all possible probing locations for each node. After the initial fixturing process, the test software writes the individual tests for each device. A part of this process defines the resources required to test each device. The Final Fixturing tasks are: Module Pin Assignment that chooses which testhead resource to connect to which probe. Fixture Tooling that determines the wire length, number of wires, color and size of wires, etc. The fixture builder uses this information. Fixture Tooling also defines several additional wire connections needed within the fixture. These are discussed in greater detail later in this module.

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The Parts of Fixture Generation

Board Placement
Probe Select Module Pin Assignment Fixture Tooling Generation of Fixture Plots
Fixture Origin (0,0 point) Board Origin (0,0 point)

Board Placement:

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The Individual Parts of the Fixture Generation Software

The Fixturing Software associated with Test Consultant consists of five pieces of code: Board Placement Probe Select Module Pin Assignment Fixture Tooling Plot File generation

Board Placement
Board Placement operates on a set of assumptions, some of which may not be valid for your application. It always places the longer edge of the board at the front edge of the fixture. The board is placed just above the lower left vacuum port in Bank 2. The boards placement is based on the lowest and left most location on the printed circuit board. This allows the software to define all coordinate values as positive values. (NOTE: This does not necessarily place the origin on the corner of the board, it is simply a point that is more left and lower than any other point on the board.

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Agilent Technologies The Fixture 0,0 point (not the board 0,0) is located on the left boundary about mid-way between top and bottom of the fixture. This provides an asymmetrical midline so the fixture plates can be aligned on the drilling machine. There are two mounting holes drilled on this mid-line. These are drilled into the Probe Plate while the plate is being shaped and is therefore under precise control. Output of Board Placement The board placement software creates three files. fixture/fixture.o Board Placement created the fixture directory and the fixture.o file automatically. This file currently contains only preliminary information about the PC board obtained from the board_xy file. The fixture/fixture.o file is an object file and is not user readable. Therefore a de-compiler has been created to allow you to see these files when desired. To convert the object into a text file: list object fixture/fixture.o to fixture/fixture fixture/details fixture/summary These files contain warning and error messages generated during the development process. Other software will augment the fixture/fixture.o, fixture/details and fixture/summary files. The BT-BASIC command list object <file.o> to <file> can be used to decompile five object files. Four files (board.o, board_xy.o, wirelist.o and fixture.o) are covered in this course. The fifth file (states.o) is covered in an advanced class. No other object files can be regenerated to their original source file states. fixture/fixture.o The fixture/fixture.o file contains several elements. The board outline Tooling pin locations Keepout areas if any were specified Global information including: Fixture type Autofile code

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Fixturing: Probe Select

R1 500K U1 U2 R3 R2 3.9 Ohms 10K

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Probe Select
The basic function of Probe Select is to determine where each node will be probed. When the probe locations have been defined, the software can visualize the Probe Plate and the numerous holes that have been placed in it both actual probe locations and the blind hole or partially drilled holes Default Criteria The default criteria takes over after allocating the critical and mandatory locations. Electrical considerations Digital pins defined as dynamic for flash programming. Digital output pins are preferred over inputs or non-digital devices. Probe directly on small value resistors. (< 10ohms) Probe directly on large value capacitors. (>1uf) Probe directly on small value inductors (< 10mH) Fixture density considerations If the probe density default maximum threshold for a specific area of the board has been reached, no additional probes are assigned to that area.

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Agilent Technologies Board edge clearance A probe that is within the gasket area or within 0.125 inches of the board edge will be considered among the last choices. Only unreliable and no_probe nodes have lower evaluations. Collision Considerations Probes that will be located too close together (physically) are not allowed. 100 and 75 mil probe locations are preferred. 50 mil probe locations are second best. Tooling pins are allocated with a keepout band also, this to prevent shorts to the tooling pins. Testhead considerations For scarce testhead resources, warnings are issued if these are blocked. There are 12 ground pins on each Double Density Hybrid card. It is possible to block all these grounds with probe locations. If this happens, Fixture Tooling software will output a warning that this card is not usable due to blocked resources. The last consideration for each node is that of access. If a node has only one access point its priority is increased. Topside probing is not used often, and will only be used if the Board Consultants Global Options have the Top Electrical Probes enabled. This will require a fixture top probe plate.

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Probe Select
Power Wiring
There are 1203 nodes on this board. If: +5V draws 2.2 Amps +12V draws 0.8 Amps How many +5V, +12V and GND wires are required? +5V 3 1 1 5 +12V 1 1 1 3 GND 4 2 2 38 46

1 wire per amp: 1 per supply 1 for sense Node Count / 32 Total:

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Allocating Power Supply resources

From board.o, the Probe Select software receives the user requirements for power supplies. During the assignment of nodes, the power nodes received some of the wires needed for testing, but not the wires needed for carrying the current specified in the Power Options Menu of Board Consultant. These additional wiring requirements are added after other nodes have been assigned. A quick look at the Power Supply wiring scheme for the Ground node, (we are counting ground wires): The current (I) value of each power supply in rounded up to the next higher integer. One wire is required for each amp (2.1Amps requires 3 wires). The number of supplies needed for this PC board are added to this number. Add one ground return for every 32 nodes (rounding up).

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Fixturing:
Requirements are generated and evaluated
Vcc R1

En
U1

U2 Large ASIC

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The Fixturing Process is done in two disjointed steps Board Placement places the board on the test fixture. Probe Select identifies the best probing location. Test Consultant writes the individual tests. For Node En: Pins & Shorts test will require a G bus. Analog Incircuit test of R1 will need an S or I bus. Digital test for U1 will require a Digital Driver. Digital test for U2 will require a Digital Driver to disable U1 The individual tests are compiled This creates requirements or .r files. These list the resources needed for this test to function properly Module Pin Assignment runs. MPA gathers all the requirements for the node En and identifies a BRC as close as possible to the probe location that provides all the resources needed by the various .r files. If MPA cannot find one BRC, it assigns two. Fixture Tooling runs: Given the probe location and the BRCs assigned, Fixture Tooling defines the wiring scheme.

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The Parts of Fixture Generation

Board Placement Probe Select

Module Pin Assignment

Fixture Tooling Generation of Fixture Plots

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Module Pin Assignment

Module Pin Assignment evaluates how each node will be used to determine: Which testhead resource(s) needs to be paired with each node MPA selects the appropriate testhead resource The goal, place the Personality Pin as close as possible to the test Probe. This will ensure the shortest possible wire. MPA knows that a personality pin can be bent up to 0.10 inches or the Offset Kit can be used if necessary. When selecting the appropriate resource MPA makes sure there are no multiplexing conflicts Module Pin Assignment then writes the wirelist.o file that is used by subsequent software. The wirelist.o file lists: Each test The nodes used in that test The nodes BRC number Which internal multiplexed bus that node needs to contact. To read the wirelist.o, de-compile it with the list object command: list object wirelist.o to wirelist Module Pin Assignment follows a criterion similar to the one used by Probe Select when assigning Personality Pins:

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Agilent Technologies Some testhead resources were identified as being blocked as probes were assigned; therefore, MPA no longer has access to these resources. Assign critical nodes first. Scan all the nodes, looking for those that the user marked critical. Assign those resources that are limited Clocks: There are several clock resources on the Control Card. These are important, but not covered in the User Fundamentals class. They are described in detail in the Advanced Digital class. External Instrumentation: Typically external instruments can connect to the board under test, but in a limited number of locations. Therefore, these personality pins are assigned early in the sequence. The powered test resources are assigned next. Resources that involve clusters rather than the individual parts. Large pin-out devices, these need to be assigned early before channels are loaded with potential multiplexing conflicts with smaller devices. (The smaller pin count devices can be assigned more easily.) Next, nodes that are involved with both powered and unpowered tests. These nodes are allocated after the digital resources but before purely analog nodes. The purely analog nodes are assigned next. The analog multiplexing scheme is rather complex, but completely different from the digital assignments made so far. While these nodes are assigned late in the process, earlier steps do consider the analog multiplexing and assign their resources breath first using as many test cards as possible, filling as few channels on any one card as possible. This means that analog distribution is more easily implemented. The final allocation goes to nodes that are only tested in the shorts test. These might include nodes on the output of a digital gate that is not used on the board, or devices marked no-test in the board file.

Module Pin Assignments Inputs & Outputs

MPA uses the test.r files, testorder, config.o and fixture/fixture.o files as input. These provide the software with the information needed about each test. Notice that Module Pin Assignment deals with the fixture based on tests, not on devices. Module Pin Assignment does not augment the fixture file. Instead it creates a new file, wirelist.o. This lists each of the tests and the specific resources used for that test. Module Pin Assignment adds information to the fixture/summary and fixture/details files. The information is initially identical in the two files:

The efficiency value is a measure of the number of nodes that required more than one wire. If multiple modules are used, there will be cases where each module needs access to a node on the board (for example: Vcc or Ground). In this case, one probe will have multiple wires. This is reflected as a lower efficiency value. (This value is lower in Powered test systems where a node maybe connected to both analog and digital resources.)

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The Parts of Fixture Generation

Board Placement Probe Select Module Pin Assignment Fixture Tooling Generation of Fixture Plots

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Fixture Tooling
Fixture Tooling does some resource management for you. Fixture Tooling determines the length of wire needed for each wire-wrap operation. It counts the number of wires connected to each probe or personality pin. The maximum number of wires is three. The software adds the inter-module wiring required in all fixture applications of more than one module. Fixture Tooling also adds additional personality pins to the fixture. These might be needed in the future if an ECO occurs. The Fixture Tooling software generates reports and files that describe how to build the fixture and files that will assist in troubleshooting any fixturing problems in the future. Inter-module Wires added by Fixture Tooling Autofile When a fixture is loaded, the Autofile is automatically read by the system. It identifies the board file associated with the fixture, msis to that directory, loads and runs the testplan. The standard Fixture wiring includes the Autofile. The system will generate an Autofile code automatically or you can define your own. The system starts with the number 4094 and counts down toward the minimum value of 11. Fixture I 8 - 19

Agilent Technologies Other autofile codes are reserved for diagnostics fixtures and other Agilent applications. Each fixture must have a unique autofile code. Fixture Enable The jumper, Fixture Enable must be installed for the test to run. If this jumper is sensed by the testhead, it accepts the fixture as being present and loaded correctly. If the enable jumper is not found, the operator is given a prompt about the fixture being misloaded. Safety Disable The Safety Disable jumper must be present in the fixture for the power supplies to be powered. If this jumper is not present, the power supplies are disabled. There are applications where this jumper is very handy such as in the event that a board needs to have a safety shield to prevent dangerous shock to the operator. XL & XG module interconnections When an ASRU tests a device on the PC board, it needs access to all nodes associated with that device. The software provides the S and I bus connections to the device under test. But guard points might be in another module, with a different ASRU card. The modules need to be interconnected. The GOUT (guard bus) and LOUT (guard sense bus) connections in each module must be tied together. The Fixture Tooling software identifies which modules need to be interconnected. It then assigns the appropriate personality pins and wires.

Extra Personality Pins

Fixture Tooling also allocates additional personality pins. These are provided to make ECOs easier to accomplish. When the allocations are complete extra locations are added by Fixture Tooling. The software will keep track of these resources and when a fixture change is required, these extra personality pins will be used. The algorithm does not assign a fixed number or percentage of extra p-pins, but typically, it is on the order of 10%.

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Fixture Tooling Outputs

Fixture Tooling modifies the following files: fixture/fixture.o fixture/details fixture/summary

The fixture/details file includes: A list of the Test Cards used in testing this PC board. A summary of the fixture wiring. If the mean wire length is 12 inches, there is probably a problem. If the standard deviation of the wire length is nearly equal to or greater than the mean value, there may be a problem. If the overall fixturing efficiency is less than 85%, there is probably a problem. A table shows the ground wire length for test cards that had critical connections associated.

The fixture/summary file includes: The information that appears in the Test Consultant Message Window along with additional information that is not displayed. This includes: A summary of the fixturing resources (number of pins, probes, wire length...).

The Fixture Tooling software amends the fixture/fixture file: Each node now shows the location of the personality pin with the PINS statement. It also adds the WIRES information that lists the Bank/Row/Column where the personality pin is located, the color wire, its gauge and length.

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fixture/ trace
!----------------------------------------------------! AGILENT FIXTURE TRACE REPORT <date & time> ! fixture/trace !----------------------------------------------------FIXTURE TYPE: Agilent Simplate Express ... !----------------------------------------------------(Pin) [Probe] <Length> !----------------------------------------------------Node Name 1A Probe [2 11.77 44.7] On Device: u1.1 Wire Color: Blue Guage: 28 Path (2 20.00 61.0) <6.5> [2 11.77 44.7] Use Digital Drv. ASRU Detector Shorts Test ... Node Name Probe Wire Path Use ...
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CLOCK_ENABLE [2 16.84 27.1] On Device: r5.2 Color: Blue Guage: 28 (2 18.00 48.0) <3.5> [2 16.84 GP Relay

27.1]

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The Files for the Fixture Builder

These files are also important to the programmer who has to modify a fixture. trace This file combines all the information about the fixture in a single file and is used during troubleshooting. The information includes the probes location (X-Y and device.pin), the number of wire-wrap wires connected to it, the color of those wires and where those wires should go. If there were a fixture verification error, use the trace file to debug the fixture. drill An Excellon Format 2, version2 file that most machine shops will recognize and use in the construction of a fixture, specifically, drilling the Probe Plate. It includes the probe locations (completely through the Probe Plate), the alternate locations (partially through the Probe Plate), the personality pin locations and locations for Tooling Pins. drilltop Another Excellon file, this one is dedicated to drilling the Top Plate in the event top side TestJet Probes are used and you used the Test Consultant software to determine the exact locations for these probes. It only includes holes in the Top Plate, no other information. If the fixture does not include top side test probes, there will not be a drilltop file.

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drillsup Another Excellon file, this one is dedicated to drilling the Support Plate. The major difference between this one and the drill file, is that the drill file includes information on drilling blind holes and holes for the personality pins. The drillsup has only the list of drill locations to match the probe sites on the board and tooling pin locations. inserts Lists information to assist in the loading of the drilled Probe Plate. It tells which holes receive probe sockets, which ones receive personality pins and which Tooling pins to use. In the case of different spring force probes, it defines which force probe to install in which receptacle. wires This file is designed for the people who actually do the wire-wrapping. There are two styles of presentation (defined in Board Consultant). Manual: The wiring operations start at the center of the board and work out from the center to limit the number of wire-wraps that will require the operator to dig for the pin among previously installed wires. Automated: The wiring order is based on the length, gauge and color of the wire. Automated wire-wrap machines center the wire-wrap gun over the target pin so that there is no need to dig for the pin. difference The difference report is part of the details file. This report lists all the wiring changes as wires to remove and wires to add. Note: If you have not built a fixture yet, if you see the software removing wires and adding wires, you are forcing it to adapt to a fixture that does not exist. This is not as efficient as letting the software create the fixture without any limitations.

During the lab, review the fixture/trace and fixture/wires files. The trace file contains the maximum information possible about each node.

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Testhead Numbering
BRC: Bank Row Column
Bank 2
Column 78 Row 1
MOTHER BOARD Slot 1: ASRU

Bank 1
1 78
Module 0
Slot 6: Control Slot 1: ASRU

1 Row 1
MOTHER BOARD

Row 23

1A at:

2 20 61 2 18 48

CLOCK_ENABLE at:

3070 User Fundamentals Module 8: Fixturing

Bank Row Column

The BRC or Bank Row Column reference is a way of navigating the fixture and testhead. The numbers reflect which Bank is involved, which Row in that bank and which column on the row. Thus the node 1A, described at BRC 22061 is in Bank 2, Row 20, Column 61. Likewise, Clock_Enable has a connection at BRC 21848 or Bank 2, Row 18, Column 48. For the Double Density Pin Card, this original numbering scheme did not work very well. Therefore, the numbering on the Double Density cards uses the original numbering scheme for the original row of pins, and inserts an extra 1 into the pattern for the second row of pins. Thus if these were Double Density Pin Cards, BRC 220161 would refer to Bank 2, Row 20, Double Density row 1, Column 61. The Bank1 node at 11848 is shown as a white dot on the drawing, at Slot 6 of Bank1. Notice it is on the Control Card. Notice this is a different resource than the corresponding pin in Bank2. The resources on the cards are numbered from the Mother Board. Therefore, the 48th pin from the Mother Board in Bank1 is not the same resource as the 48th resource from the Mother Board in Bank2. The 48th pin in Bank2 is a General Purpose Relay (GP1H, H for high) The 48th pin in Bank1 is a Ground Connection. See the On-Line Documentation for details about the resources. See the Cards In Testhead manual.

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Module 3

Slot 6: Control

Slot 1: ASRU

Row11 Row 13

Module 2

Slot 6: Control

Module 1
Slot 6: Control Slot 1: ASRU

Row11 Row 13

Row 23

Double Density node at: Bank 1 Node:

2 20 1 61 1 18 48
14

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Agilent 3070 User Fundamentals

Fixture Verification

Missing Probes Miswires Opens and Shorts

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Fixture Verification
There are several tools available to assist in verifying the correct wiring of a fixture. Some of these will not be detailed until later modules, but the majority can be explained here. Board Graphics Before starting verification, you should start the Board Graphics display. If enabled before starting the fixture verification, the Board Graphics Display will highlight all the positions where the probe can be placed to access a node, or the specific device.pin that the command wants you to probe. Auto Start AutoStart is associated with the Special Function Key F7. It has two modes of operation, the default is manual start meaning you must press either the foot switch or the START key to initiate a fixture verification test (detailed below). If you choose to use auto start the hardware looks for a continuous contact between the hand-held probe and any point on the fixture. When the software has detected a continuous contact, it automatically invokes the START key for you. To use the Board Graphics Display: in a BT-BASIC window: msi to the board directory Execute the command board graphics In the same BT-BASIC window, issue the desired verification command.

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Agilent Technologies verify The verify command places the guided probe on a location, applies a 100mv source and measures where that signal goes. The verify command options: verify node_name You enter the command with a specific node name. The system provides a list of device.pins where the node can be found. The testhead applies the 100mv source. It measures all nodes to see where the signal actually goes. If it goes to the expected point(s) only, it passes. If it goes to additional locations, these are reported. If it does not go to the expected destination, that is reported too. verify all This command tells the system to test all points on the board, This command will cause the verification software to sequence through each component in board asking you to place the guided probe on each pin of the component to verify the connection. verify all nodes This command tells the system to test all nodes on the board (but not all points that tests each node several times). This command sequences through all the nodes in the board file having you verify each node. verify all from device.pin Allows you to stop the verify all verification. The software records the current device.pin being verified so that you can return later and resume verification without missing any points or having to retest locations. verify nodes from node-name Allows you to stop the verify all nodes verification. The software records the current node being verified so that you can return later and resume verification without missing any nodes or having to retest nodes. verify all testjet probes This command sequences through all TestJet probes on the board. verify testjet probes device_name This command tests the TestJet probe associated with the specified device. verify testjet probes from device_name Allows you to stop the verification process and resume without having to retest or miss testing any probes. Fixture I 8 - 26

Agilent 3070 User Fundamentals verify all mux cards The software runs without your interaction. It tests each of the multiplexing cards associated with TestJet Probes. Because the TestJets electronics board can be mounted incorrectly, this test also verifies the assembly of each TestJet probe. (The test does not check the polarity of the sensor plate, that is done by the verify testjet probes command.) verify mux <mux#> port <port#> module <module#> Tests the TestJet Probe associated with the targeted mux/port/module. find pins find pins: The function is similar to verify except you do not specify a location or node. find pins Put the hand-held probe on a point and press F1: START. The 100mv signal is applied to the hand-held probe and the system looks for which node is receiving the signal. When it finds that node, it reports it to you. If there are multiple node contacts, all are reported. Because the signal is on the entire node, the system cannot report which device.pin the guided probe is on, but it does list the device.pins on the node in contact with the hand probe. find testjet probes Put the hand-held probe on the test via of the TestJet Probe The software does a serial poll of all the TestJet Probes looking for the one that you are probing. When the poll is completed, you receive a prompt, including the address (module, mux, port) and associated device for that TestJet Probe. probe <device-name> The probe command displays a representation of the device specified. probe <device> When the hand held probe is touching a pin, that pin is shown as a P indicating the 100mv signal is currently present of the pin in question. When that lead is released, the display shows it as T for tested. Any lead that is not touched, will show an asterisk (*). Any lead that does not have a probe in the fixture (marked no_probe in board_xy) will be identified with a period (.).

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Agilent Technologies

Running Fixture Generation

Multiple Times

Fixture has NOT been built

Remove Fixture Files Run Agilent IPG Test Consultant - Software sees no evidence of fixture therefore, creates a new one without provision for non-existent fixture.

Fixture has been built

Keep Fixture Files Run Agilent IPG Test Consultant - Software sees the fixture. - Software decides if a wire can be added or removed based on existing tests and fixture.

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Running Test Consultant Multiple times

There are two fundamental reasons for running the Fixturing Software again. The first is that the previous run resulted in errors, poor test coverage, excessive number of blocked resources or something that you decided would not allow the process to continue until that was corrected. In these cases, the fixture has not been built yet. The other case is if there is an Engineering Change to the board. In this case, the fixture has been built.

Re-running Fixturing Software BEFORE a fixture is built

If the reason for running the software again was identified before a fixture was actually built, Test Consultant needs to know that the fixture does not exist. The key is that the Fixturing Software believes in magic. It assumes that as soon as its reports are generated, a fixture is built. When the fixture reports are in existence, the fixture exists too. Any subsequent software run assumes that there is a tangible fixture sitting on a shelf. Given this, the software will work with the existing fixture, modifying it rather than recreating it. This leads to a very inefficient fixture design.

Fixture I 8 - 28

Agilent 3070 User Fundamentals To illustrate what can happen, an example: Test Consultant was run, including the fixturing software. Fixture reports were generated, the software assumes a fixture exists. You discover a data entry error on a digital device. The correction is made. Test Consultant is run again. The fixture files describe a fixture (that has not been built) that has several conflicts with the newly entered digital device. In one case, the software might recognize the conflicts, issue warnings and mark that lead of the device as not being accessible. In another case, the new device needs a personality pin, but all the ppins in the immediate area have either been allocated or will not work due to multiplexing conflicts. Therefore the closest available personality pin must be used, unfortunately it happens to be 12 inches away. The moral of this story, if there is no fixture yet, do not let the system think there is.

How do you tell tell the software that the fixture does not exist? By removing the wirelist.o and fixture/fixture.o files. Use a BT-BASIC window to unlink the files: unlink wirelist.o | unlink fixture/fixture.o

Rerunning Fixturing Software AFTER a fixture is built

If Test Consultant is being re-run with an existing fixture due to an ECO, the wirelist.o and fixture.o files are the only way the system software can know what the existing fixture looks like. Given these resources, the fixturing software may generate a modified version of the fixture. It may write new wirelist.o and fixture.o files and add a difference report to the details file. The difference report contains details about any wires that need to be removed and about wires that need to be added.

If there is a fixture, but the wirelist.o and fixture.o files are removed, the existence of the real fixture is likewise removed. Now the fixturing software will start all over again. It is likely that the new version of the fixture will be very similar to the actual fixture but there will definitely be differences. Therefore, never remove these files if a fixture has been built.

Fixture I 8 - 29

Agilent Technologies The ECO process The process followed when Test Consultant runs with an existing fixture. The software first removes all resources that are no longer needed. It moves these resources to an internal list of available-resources. When additional resources are needed, all available resources are evaluated for the best match. This evaluation starts with the list of availableresources created or augmented in the first step.

Make two archive tapes of your development. Send one to the people who build your fixture. Save / Protect the other. Many programmers also make copies of the wirelist.o and fixture.o files and save them in the board directory, perhaps as wirelist_orig and fixture/fixture_orig. Exceptions to the Rule Having built the fixture you may discover the need to add wires to improve test accuracy. This need may not be seen until you are well into the debug process. There are two basic alternatives to achieving the needed modifications. You can manipulate the fixture semi-manually using Fixture Consultant. Fixture Consultant (discussed later) allows you to make changes while the software only shows alternatives based on multiplexing requirements. You can modify your test development descriptions in Board Consultant and rerun Test Consultant. Using this technique, the software will manage all aspects of the actual modification.

Examine the fixture/details file

Look for changes to the fixture findn "Diff": -------------------------------------------------------3070 FIXTURE WIRE DIFFERENCE REPORT <date & time> /home/user1/class_bd/fixture/details -------------------------------------------------------| From | To | From | To Length|Ga|Color|(b r c ) |(b r c )| X Y | X Y ------|--|-----|----------------|---------------|-----|-----|-----|---Remove 2.8 26 Blue (2 23.00 63.0) (2 22.00 61.0) 4211 -227 5801 -281 Add 4.3 26 Blue (2 23.00 63.0) (2 16.00 62.0) 4211 -227 4361 -327 Remove Add 1 1

If a wire is removed from a fixture, the old test may no longer execute properly. This means the old version of the board will no longer be testable. Use Multiple Board

Fixture I 8 - 30

Agilent 3070 User Fundamentals Versions software to keep the existing tests and testhead resources in place while adapting to a new version of the board. This is discussed next week.

Glossary
There are some additional terms and expressions that you should be aware of before continuing. Simplate Fixture: Long wire fixture using one plate for probes and a second for pins. Simplate Express Fixture: Short wire fixture using a single probe/pin plate. Probe: Spring loaded nail that connects the fixture to the PC board. Personality Pin: Pin that connects the fixture to the testhead. Vacuum Fixture: These are vacuum actuated fixtures. A vacuum is applied so the PC board is pulled tightly against the Support Plate and together these are pulled down onto the test probes. Support Plate: The plate that the PC board rests on. It has a vacuum gasket between it and the Probe Plate and a vacuum gasket between it and the PC board. Probe Plate: The plate that contains the test probes. On the Express Fixture, it also has Personality Pins loaded in it. Alignment Plate: On Simplate Express fixtures only - aligns Personality Pins to testhead. Tooling Pins: Pins that the operator mounts the PC board over. These ensure quality registration between the PC board and the overall fixture. BRC: The testhead resources are numbered as Bank/Row/Column values or BRCs. There are two formats. The single density pin cards use B RR CC. The double density pin cards use the format B RR 1 CC. e.g.: 11311 would be Bank 1, row 13 column 11. or 214122 would be Bank 2, row 14, column 22 on the double density cards second row. ECO: Engineering Change Order. The basic modification of the existing board to include new features, cost reductions, re-engineering modifications, etc.

Fixture I 8 - 31

Agilent Technologies

Appendix

fixture/fixture.o
! -----------------------------------------------------------! FIXTURE DESCRIPTION LISTER <date & time> ! fixture/fixture.o ! -----------------------------------------------------------OPTIONS Fixture Type EXPRESS; Fixture Size BANK2; ... BOARD angela_bd !Note: This name must match the board directory PLACEMENT 19486, -77677 0.0; OUTLINE 0, 0 115750, 0 115750, 128500 0, 128500 0, 0; TOOLING 3750 3750 KEEPOUTS
3070 User Fundamentals Module 8: Fixturing

2500, 6500; 113410, 121450;

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fixture/fixture.o details
For an Express fixture, you must define several details during the data entry phase of Board Consultant. Board Consultant copies this information to the board_xy file. Fixture Option information such as the fixture type and size. The command line BOARD, the name entered must match the name of the directory. In this case the angela_bd directory and file. If the outline of the board includes several notches, slots or other irregularities, you can simplify that by selecting a single plane and using it as the board edge. However, before you over-simplify the board outline, check with your fixture builder to confirm that they understand you are simplifying the outline. The location of Tooling Holes is important to the fixture building process. The software includes keepout regions adjacent to tooling pins because the pin has a shoulder that prevents probes or personality pins from being mounted immediately adjacent to the tooling pin. The software expects you to define two Tooling Pin locations. You define keepout areas to prevent the placement of probes and/or personality pins in a specific region of the fixture. The reasons for defining a keepout area will vary, among the most common are to allow for TestJet probes (done by the software) or to allow for components mounted on the edge or bottom of the board.

Fixture I 8 - 32

Agilent 3070 User Fundamentals

fixture/summary - after Board Placement

The fixture/summary file contains all ERRORS and WARNINGS generated by the software while evaluating the board and board_xy files. The information scrolling across Test Consultants message window while the software runs, is the same information found in the fixture/summary file. NOTE: The fixture/summary file is cumulative. The original file generated by the first run of fixturing software will be kept and subsequent runs of the fixturing software will append information to the end of the file. If you want to review the latest run of the fixturing software, you will need to skip past the earlier runs and find the most recent information. -------------------------------------------------------3070 BOARD PLACEMENT <date & time> /home/user1/class_bd/fixture/summary -------------------------------------------------------... The board angela_bd was placed at X = 19486, Y = -77677 with a rotation of 0.000 degrees.

fixture/details
The third file is the fixture/details file. After Board Placement the summary and details files are identical. As the fixture software continues to run, the two files become distinct.

fixture/summary - after Probe Select

The fixture/summary file now includes a description of fixture requirements, number of probes, number of pins, etc. -------------------------------------------------------3070 Probe Select <date & time> /home/user1/class_bd/fixture/summary -------------------------------------------------------Nodes that are inaccessible or need more probes = 0 Maximum probe force density (oz./sq.in.) = 104 Number of probes exceeding density threshold = 0 ... Nodes added to the fixture = 101 Nodes marked NO_PROBE or NO_ACCESS in board_xy = 0 ... The fixture/details file now includes: Testhead resources defined as inaccessible or as blocked pins

Fixture I 8 - 33

Agilent Technologies Personality Pin locations and the probes that block them are listed. Having several Personality Pins blocked is not uncommon and is generally not a major concern. During incremental runs of the fixture software, Probe Select might make changes. To see any changes, review the fixture/details file.

fixture/fixture.o output - after Module Pin Assignment

!----------------------------------------------------! FIXTURE DESCRIPTION LISTER <date & time> ! fixture/fixture.o !----------------------------------------------------OPTIONS ... BOARD angela_bd PLACEMENT 13111, 38073 -90.0; OUTLINE ... TOOLING ... NODE ADDR0 PINS 22136 -676; PROBES P50 70380, 22980 u302.9; ALTERNATES 80380, 26980 u303.5; WIRES 22136 TO P50 Blue 28 1.00; ... NODE CCLK PINS 22032; PROBES P110 80880, 75480 j301.1; ALTERNATES 75880, 65480, u302.18; 61880, 66480, u301.2; 52880, 48480, ar309.1; WIRES 22032 TO P110 Blue 28 1.00; OTHER PINS 21329 BLOCKED; ... 22341 SOCKETED; ... 21805 DRILLED; . . .

Fixture I 8 - 34