QIT for Fusion 2

QIC session QIC session

Subject : Tester Stability Subject : Tester Stability Improvement.Improvement.

Author: C.S.Tu (Author: C.S.Tu ( 涂俊勝涂俊勝 ))

Root Causes on Root Causes on FusionFusion

1. 1. Bad stability of cooling Bad stability of cooling system.system. 2. 2. Bad stability of Digital DC power Bad stability of Digital DC power

supply.supply. 3. Low 3. Low reliability of relay on pin reliability of relay on pin card .card .

Top 3 problems !

Cooler introductionCooler introduction

Controller

Filter

Purge Tank.

External coolingwater!

FARMNT !到 的 水 管

!到 測 試 頭 冷 卻 水 水 管

Cooler stability problem

It could not be cooled effectively !

Flow sensor Filter Snubber Air in the waterLeak

CoolerCooler stability problem stability problem

Cooler couldnot cool the

waterevvectively

Sensoris bad !

Filter/snubberbe blocked !

Leak !

To much air !

真 因

This sensor measurethe flow rate of

cooling water inside the cooler.

Filter , it is filtering the water and remove

some of its impurities.

Snubber :It protect the

sensor .Leak : it damage Pin card,

FARMNT board and T/H backplane

Too much air in the cooling water, would

decrease its effect!

Five problems analysis Five problems analysis 五大問題分析五大問題分析

故 障 年 度 Seneor Filter Snubber Leak Air in the water

2001年總數 17 117 205 67 27

17

117

205

67

27

0

50

100

150

200

250

年度總次 數

Seneor Filter Snubber 漏 水 空氣問題

項目

2001年總次數 Cooler problem

Seneor4% Filter

27%

Snubber48%

Leak15%

Air in thewater6%

How to find the solutions of cooler problem ?How to find the solutions of cooler problem ?

對Cold Plate影響Coolant Advantage Defect

Distill water and bleach Prevent Biological growth! Bleach cause corrosion of ColdPlate , and get impurites !

Distill water only No corrosion and less impurities! Can not prevent Biological growth!

Pure water (non ion) Less impurities ! Can not prevent Biological growth, acidic water will corrode coldplate!

Pure water (non ion)and bleach Prevent Biological growth,less impurities ! Bleach and acidic water will corrode coldplate!!

原廠鋁質原廠鋁質 ColdPlateColdPlate 與不同水質之驗證與不同水質之驗證

According to LTX stand servicemanual, use distill water and

bleach could prevent the

Biologicalgrowth.

What we should improve is this

What kind of Cold Plate is good for What kind of Cold Plate is good for distill water and bleach ?distill water and bleach ?

Material of Cold Plate The result after it use distill water and bleach Aluminum Be easy to corrode and make impurities !

Aluminum be electroplated Better than pure Aluminum.Plastics It is hard to corrode and less impurities.

What is the advantage What is the advantage when we use Plastics Cold Platewhen we use Plastics Cold Plate??

Cold Plate Snubbertype Snubber Live time Filter live timeOrigional Type 2 months 2 months

Aluminum G type 2.5 2

E type 3 2

Type 1 3 3.5Aluminum be electroplated G type 3 3.5

E type 3 3.5

Type 1 no no

Plastics G type no no

E type 4 5

• Less impurities will help to improve the Less impurities will help to improve the life time of snubber and filter !life time of snubber and filter !

• We expect !We expect !

What we should do now about Leak ?What we should do now about Leak ?

>>Corrosion on Corrosion on Cold plate and Cold plate and connector . connector .

>MCM leak .>MCM leak .

•What was the cause of theWhat was the cause of the leak ? leak ?

•SoluctionSoluction: :

>Replace them with >Replace them with Vendor ASAPVendor ASAP!!

DC power supplyDC power supply

•The quality of fan would decide the stability and life The quality of fan would decide the stability and life time Dtime DC power supplyC power supply..

2123.1

24.6

28.6

34.235.9 36.7 37 37.1 37.2 37.3 37.4 37.5 37.6 37.6

2123.4

25.9

30.6

37.238.9

40.141.4 42.1 42.3 42.5 42.6 42.7 42.7 42.7

0

5

10

15

20

25

30

35

40

45

Tem

pera

ture

Fan Temperature

Improvement: Replcae the fan made of plastics with metal

,and with high performance.Notice: Cooperate with LTX to upgrade the fan .

Relay problem on digital pin cardRelay problem on digital pin card

RESULT PIN ACTUAL TARGET LOWER UPPER======== ==== ============= ======= ===== ========= 7 655.17377m 750m 0 2.000000 8 622.421988m 750m 0 2.000000**FAIL** 9 2.600212 750m 0 2.000000 10 644.60327m 750m 0 2.000000

•The The reliability of relay is bad , it always reliability of relay is bad , it always make some functional /open-shortmake some functional /open-short problem problem ..

•Improvement: Replcae the relay Improvement: Replcae the relay ..

•Other action : When do the PM ,run the Other action : When do the PM ,run the relay checker too!relay checker too!

•Why do we want to improve this Why do we want to improve this ??

StandardizationStandardization

Item PM Before improvement .

Cold Plate Aluminum or Aluminum be electroplated.Filter Monthly PM check it, ,quarterly PM replace it ,but actually it is impossible !

Snubber No define !Relay checker No define !

Item PM after improvement

Cold Plate Use Plastics Cold Plate.Filter Get the standard ,Monthly PM check it, ,quarterly PM replace it,or >>25PSI.

Snubber Check every week, replcae it every quarterly PM .Relay checker Check it every monthly PM .

ConclusionConclusionCooler down : Cooler down : 27 times/year -> 1 times/year27 times/year -> 1 times/year Saving : $ 33,340 / yearSaving : $ 33,340 / year

Power Fan Defect :Power Fan Defect : 15 times/year -> 0 time/year15 times/year -> 0 time/year Saving : $ 3250/yearSaving : $ 3250/year

Relay Repair: ,Relay Repair: , 57 times/year -> 1 times/year57 times/year -> 1 times/year Saving : $ 68,400/yearSaving : $ 68,400/year

The End .The End .