The Rev 5.0 Production Page, 2004

Running Totals for Delivered boards:

For delivery totals, Ask Azriel, or Bill Edwards (totals to Wisconsin, Zeuthen and Sweden)
For assembly house delivery totals, ask Azriel, or Jimmie
For testing rejects, ask Azriel, or Billie, or George to get the numbers out of the database...

Analysis Pending	Repaired Pending	Repaired Shipped	Software Test Only	Unrecoverable
53	16*	222	25	2

Updated 12/5/04

Actions Taken

Repeat problems, and production issues have prompted certain actions. Description: Here
As noted in the description of repeated problems, several could be solved by changes to software, or changes to firmware. No rework was required on these boards. Boards recovered by software and firmware fixes make up a substantial fraction of board problems.28

Rev 5.0 DOM Main Board Repair History

The boards entered in this list failed either an inspection, or a performance test.

* This list isn't comprehensive; it does not include boards diagnosed in the test lab, and routed for replacement of ATWDs, and serial ADCs, or that were recovered by software or firmware enhancement.
The analysis and repair work on Non-Conforming is summerized below.
The details links are based on the Template Repair Record form; Report forms are here.

Repair records for DOM MBs debugged in the first year

#694 September 10, 2004 -- ATWD A Ch2 Baseline failure at the beginning of cold test (Mainstream)

#626 September 10, 2004 -- ATWD A Ch2 Baseline failure, and communications/boot failure cold (Mainstream)

#589 August 20, 2004 -- Communications/Boot failure (Software test)

#208 December 10, 2004 -- ATWD A and B Ch2 failures at elevated temperature(in-process)

#195 December 10, 2004 -- LVDS Start slow start (Return to Wisconsin)

#342 August 16, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#655 September 9, 2004 -- Flat Flasher board Waveform (Mainstream)

#655 September 10, 2004 -- Baseline ATWD B Multiple problems (Pending retest)

#689 July 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#727 July 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#737 July 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#748 September 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#658 September 10, 2004 -- Baseline ATWD A Ch 2 Baseline jumps (Software Test)

Details An interesting case

#727 October 27, 2004 -- Baseline ATWD A Ch 2 Baseline jumps (Software test)

Details An interesting case

#655 September 10, 2004 -- Fails ATWD B Ch 1 and Ch2 baseline, and Ch2 noise (Pending low temperature profile)

#655 September 9, 2004 -- Flasher flat with two different flasher boards (Mainstream)

#613 November 18, 2004 -- Flasher board Slow Start due to LVDS repeater slow turn-on (Return to Wisconsin directly)

#640 October 27, 2004 -- Baseline ATWD A Ch 2 Baseline jumps (Mainstream)

#498 August 6, 2004 -- Fails most ATWD tests, both A and B due to Faulty DAC (Mainstream)

#498 September 30, 2004 -- Baseline ATWD A Ch 2 Baseline jumps (Mainstream)

#429 September 10, 2004 -- Baseline ATWD A Ch 2 Baseline jumps (Mainstream)

#412 August 31, 2004 -- Baseline ATWD A Ch 2 Baseline jumps, and Oscillator failure (Mainstream)

#404 August 31, 2004 -- Baseline ATWD A Ch 2 Baseline jumps (Mainstream)

#352 August 22, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#323 July 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

#345 July 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Hold)

#192 July 30, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Hold)

#142 August 25, 2004 -- Failed ATWD B tests (Hold)

#142 September 24, 2004 -- Failed ATWD B tests AGAIN (Hold)

#142 November 8, 2004 -- Failed ATWD B tests (Hold)

#142 November 20, 2004 -- Failed ATWD B tests (Hold)

#131 July 13, 2004 -- Current Fluctuations (Mainstream)

#492 July 28, 2004 -- ATWD A, B and fADC pulser test failures. Disc Scan failures (Mainstream)

#466 September 1, 2004 -- ATWD A, B and fADC pulser test failures (Under study)

Details

#415 August 24, 2004 -- ATWD pulser and fADC Pulser (Mainstream)

Details

#521 July 30, 2004 -- Serial ADC ch 18, 19 anomylous (Mainstream)

Details

#353 August 5, 2004 -- Clock waveform missing from ATWD a and B(Mainstream)

Details (an interesting case)

#446 July 27, 2004 -- ATWD "B" tests fail (Mainstream)

Details

#668 August 30, 2004 -- ATWD "B" waveforms flat (Mainstream)

Details

#489 August 6, 2004 -- ATWD "A" and "B" tests fail (Mainstream)

Details

#143 September 7, 2004 -- No pulser waveforms (Mainstream)

Details

#687 September 7, 2004 -- ATWD "A" tests fail (Mainstream)

Details

#289 August 5, 2004 -- fADC pulse, baseline and pedestal failures
#289 November 8, 2004 -- Failed Local Coincidence Loop-back test
#289 November 17, 2004 -- Fails local coincidence Loop-back test during Burn-In (Not For Deployment)
#289 November 20, 2004 -- Serial ADC 0 tests fail at low temperature

Details

#634 September 1, 2004 -- Multiple ATWD and pulser failures (Mainstream)

Details

#571 August 20, 2004 -- Boot failure, cold. (Mainstream)

Details

#538 August 9, 2004 -- On-board LED flasher event count incorrect. (Mainstream)

Details

#340 August 9, 2004 -- On-board LED flasher event count incorrect. (Mainstream)

Details

#537 August 9, 2004 -- On-board LED flasher event count incorrect. (Mainstream)

Details

#380 September 1, 2004 -- On-board LED flasher no-light too high. (Mainstream)

Details

#631 September 3, 2004 -- Boot failures. (Mainstream)

Details

#458 September 27, 2004 -- ATWD B (Mainstream)

Details

#738 November 10, 2004 -- ATWD A Channel 2 Baseline Jumps. (Mainstream)

#738 September 27, 2004 -- Boot failure at high temperatures in HASS. (Mainstream)

Details

#725 September 27, 2004 -- Boot failure during HASS (Mainstream)

Details

#703 November 8, 2004 -- Boot failure at room temperature STF(Mainstream)

#703 September 27, 2004 -- Boot failure during HASS (Mainstream)

Details

#636 September 3, 2004 -- Boot failure during HASS (Mainstream)

Details

#406 September 27, 2004 -- Boot failure during Purn In. (Mainstream)

Details

#753 September 27, 2004 -- Boot failure during HASS. Power Problem. (Mainstream)

Details

#722 August 7, 2004 -- Boot failure at Burn In (Debugging Deferred)

Details

#707 September 27, 2004 -- Boot failure during HASS (Mainstream)

Details (an interesting case)

#528 August 7, 2004 -- Boot failure (Mainstream)

#528 October 27, 2004 -- Baseline ATWD A Ch 1 Baseline jumps (Mainstream)

Details

#709 September 28, 2004 -- Broken component (Mainstream)

Details

#673 September 22, 2004-- Serial ADC and No 'on all'. Boot sweep test. (Mainstream)

Details

#695 August 31, 2004 -- Intermittant Communications Cold. . (Mainstream)
#695 October 17, 2004 -- Intermittant boot failure cold (Mainstream)

Details

#327 August 4, 2004 -- No 'on all' before STF. (TBD)

Details

#714 September 27, 2004 -- No 'on all' in HASS. (Debugging Deferred)

Details

#206 July 28, 2004 -- High power load at input.(TBD)
#206 -- Communications Failures due to bad inductors (TBD)
#206 -- Intermittant boot failure due to faulty U8, or soldering. (Mainstream)

Details

#637 September 4, 2004 -- ADC 0 all 1023 at room temperature (Mainstream)

Details

#242 August 4, 2004 -- ATWD 0 still bad after replacement (Software Testing)

Details

#465 August 11, 2004 -- Fell on floor. High power consumption on +5 (Software Testing)
#465 August 9, 2004 -- Low temperature boot failure (Mainstream)

Details

#410 September 14, 2004 -- Boot failure. (TBD)

Details

#721 September 24, 2004 -- LC Loopback. Z1 (Mainstream)

Details

#417 August 25, 2004 -- High power consumption. High reading from ADC3 Serial DAC U31 suspected (Mainstream)

Details

#219 August 4, 2004 -- SDRAM Load Failure; EPXA4 SDRAM controller suspected (on hold)

Details

#635 September 4, 2004 -- ADC 14 High Reading. Suspect U6 metastable states. (Possibly not a good candidate for mainstreaming)

Details

#530 October 27, 2004 -- Failure to communicate at beginning of cold test. (Possible Mainstream)

#530 August 6, 2004 -- Failure to communicate at end of HASS; Fell on floor with no obvious adverse effects. (TBD)

Details

#625 September 7, 2004 -- On-Board LED flasher malfunction; Crashes MB.(Mainstream)

Details

#388 August 31, 2004 -- On-Boarde LED flasher malfunction; Constant light level(Software Testing)

Details

#387 September 2, 2004 -- On-Board LED Flasher malfuncton; Brightness too high.(under study)

Details

#686 September 16, 2004 -- On-Board LED Flasher malfunction; Brightness too high.(Mainstream)

Details

#188 July 7, 2004 -- Failure to communicate cold. Oscillator failed.(Mainstream)

Details

#171 September 20, 2004 -- Slow readout. Faulty trace (Software Testing)

Details

#460 August 5, 2004 -- Does not hold voltage(?). Excessive power consumption.Faulty Capacitor(Mainstream)

#460 September 30, 2004 -- ATWD A Channel 2 Baseline Jumps. (Mainstream)

Details

#409 December 7, 2004 -- Boot failure. (Software Test)

#409 September 20, 2004 -- CPLD Load/Verify failure. (Software Test)

#409 September 16, 2004 -- Boot failure. (Mainstream)

Details

#539 August 5, 2004 -- Load/Verify failure for Configuration memory (Mainstream)

#539 September 27, 2004 -- Serial ADC Load Failure at End of HASS (cold).; (Mainstream)

Details

#285 August 5, 2004 -- Load/Verify failure for Configuration memory; Boot failure. (Debugging Deferred)

#285 September 29, 2004 -- Boot failure (Software test)

Details

#401 August 24, 2004 -- Local Coincidence Loopback test failure. (Mainstream)

Details

#565 September 13, 2004 -- Cloudy Solder mask (Software Testing)

Details

#619 September 13, 2004 -- Load/Verify failure for Configuration memory (Mainstream)

Details

#561 September 13, 2004 -- Cloudy Solder mask (Software Testing)

Details

#629 September 2, 2004 -- Load failure. Boot failure. Power problem. (Software Testing)

Details

#646 August 27, 2004 -- Boot failure after software load. (Mainstream)

#646 September 22, 2004 -- Boot failure during burn-in. (Under Study)

Details

#506 September 2, 2004 -- Load/Verify failure for Configuration memory (Mainstream)

Details (an interesting case)

#569 September 13, 2004 -- Cloudy Solder mask, and front-end failures.(Software Testing)

Details

#567 September 13, 2004 -- Cloudy Solder mask (Software Testing)

Details

#405 August 24, 2004 -- CPLD load problem (under study)

Details

#517 August 11, 2004 -- Local Coincidence Loopback test failure. (Mainstream)

Details

#332 August 11, 2004 -- Boot Race condition. Firmware fixed. (Mainstream)

Details

#111 September 10, 2004 -- Sub-Class II via; < 270 ° coverage. (Software Testing)

Details

#165 August 17, 2004 -- Sub-Class II via; < 270 ° coverage. (Software Testing)

Details

#621 August 3, 2004 -- Local Coincidence Loopback test failure (Mainstream)

#621 September 16, 2004 -- Intermittant (Software test(?))

Details (an interesting case)

#544 August 3, 2004 -- Serial ADC and Local Coincidence Loopback test failure (Mainstream)

#385 August 25, 2004 -- Local Coincidence Loopback test failure (Mainstream)

#588 August 25, 2004 -- Local Coincidence Loopback test failure (Mainstream)

#471 August 7, 2004 -- Temperature related Local Coincidence Loopback test failure. (ATWD_testing)
#471 August 11, 2004 --

#267 July 27, 2004 -- Local Coincidence Loopback test failure (Mainstream)

#267 September 16, 2004 -- Boot failure. (Mainstream)

#232 July 27, 2004 -- Local Coincidence Loopback test failure (Mainstream)

#467 August 17, 2004 -- Local Coincidence Loopback test failure (Software test)

#304 August 13, 2004 -- Local Coincidence "Failures during HASS cycles but Not at end"; Forensics needed.

#183 August 3, 2004 -- Board failed Via inspection... One sub Class II via.

#105 August 3, 2004 -- Board failed Via inspection.

#127 July 5, 2004 -- Board would not communicate with computer @ the "on all" command. Board does not boot. Non problem.

#119 July 2, 2004 -- Board would not communicate with computer @ the "on all" command. Board does not boot. Non problem.

#119 July 7, 2004 -- Failed ATWD Pedestal noise and problem. and discriminator scan.

#119 July 8, 2004 -- Fails to boot into IceBoot

#119 July 28, 2004 -- Fails fADC baseline test

#123 June 24, 2004 -- Config Boot Loaded, Flash Loaded and Verified (via Config-boot). Board does not boot. Bad via.

History of "Non-delivered" boards

Non-delivered boards are those forwarded to LBNL after failing to pass post-production testing at the PC loading house.
The analysis and repair work on Non-delivered is summerized below. Where apropriate, a details page, based on a Template Repair Record form is included for every board in this set. Some boards from this set may be funneled back into the main production stream, however, only one details page will exist for it. For instance, a non-delivered board can be routed back into the production stream, to later be officially delivered. If that board then becomes non-conforming, it will have an entry in both the delivered non-conforming list and the non-delivered list.

Some boards in this subset can be reworked into boards suitable for test and development systems in the northern hemisphere.
Some boards in the subset will not be recoverable.

Non-Delivered by Assembly house:	4
Abandoned
Recovered by Rework
Returned to production stream
Pending	4

#170. July 2, 2004 -- Open circuit betweek JP9.18, and R95.6. Confirmed. Reworkable.

#137. July 2, 2004 -- Open circuit between U50.xxx, and Rx.x. Open circuit between U50.xxx and U37.45. Confirmed. Probably not reworkable.

#168. July 2, 2004 -- Anomylous readings around U8, the switching power supply chip. Power supplies operated properly. Routed back into production stream
Details.

#102. July 2, 2004 -- Short from -5V net to GND. Pending
Details