Series 2040D Test Systems 2040D Maintenance Manual Part Number #4200-0181 Version 1.
Table Of Contents System Overview ......................................................................................... 3 SYSTEM MAINTENANCE OVERVIEW ................................................ 5 Selftest & Calibration .................................................................................. 7 SELFTEST AND CALIBRATION OVERVIEW ........................................ 8 Purpose Of Calibration ........................................................... 8 When To Calibrate ...................
CONTACT SPRING REPAIR ............................................................. 63 USE OF PATCHBOARD SPRING REMOVAL TOOL (0000-2746) ...... 64 CONTACT SPRING REPLACEMENT (Conventional Method) .
Series 2040 Maintenance Manual V2.
Maintenance Overview 4 Series 2040 Maintenance Manual V2.
Series 2040 Maintenance Manual V2.00 Maintenance Overview SYSTEM MAINTENANCE OVERVIEW The Series 2040 Test System has been designed with extensive diagnostics and self testing capabilities. Each module and circuit board includes additional circuitry for calibration and self testing programs. In addition, a Selftest Assembly is provided to calibrate and functionally test every component in the test system.
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Selftest & Calibration Series 2040 Maintenance Manual V2.00 SELFTEST AND CALIBRATION OVERVIEW Calibration on the Series 2040 Functional Test System is completely automated. All calibration is based on high precision references built into the system Testhead and the Selftest Assembly. A high precision Temperature Compensated Crystal Oscillator (TCXO) on the Time Measurement System Board (TMS) is used as a frequency/time reference.
Series 2040 Maintenance Manual V2.00 Selftest & Calibration SELFTEST Selftest on the Series 2040 Test System is an automated procedure. The programs that comprise Selftest are organized under the Selftest Executive in a test menu called “Functional”. These programs exercise the hardware functions available to the user through the hardware functional calls.
Selftest & Calibration Series 2040 Maintenance Manual V2.00 Utilities” dialog box in shown on the next page will appear. This box contains three separate ways of reporting the data collected during the tests. Data may be stored to a file, displayed on the screen and/or printed. In addition, each of these three reporting functions can report “All Data”, “Fail Data” or “No Data”. “All Data” includes all of the pass or fail sequences from the test.
Series 2040 Maintenance Manual V2.00 Selftest & Calibration 4) Once the type(s) of reporting is completed, click on “OK” to return to the Selftest Executive menu. Select “Functional” from the Selftest Executive screen, and the Functional menu will appear as shown below. The Functional test menu has been organized so that tests closely related are blocked together in groups. If only one test is to be run, use the mouse to select that particular test.
Selftest & Calibration Series 2040 Maintenance Manual V2.00 “:” (Colon) signifies that the following number indicates the amount of iterations to perform of the previous sequence. ‘,’ (Comma) shares the definition of ‘E’ as a separator between sequences. ‘-’ (Dash) signifies inclusive or ‘through’. EXAMPLE: E1-3:5,6-100:2,1-5 This sequence executes tests 1 through 3 five times, tests 6 through 100 two times, and tests 1 through 5 once.
Series 2040 Maintenance Manual V2.00 Selftest & Calibration check the Selftest assembly’s cable for damage. UUT POWER SUPPLIES OFF - Make sure the UUT Power Supplies are on. TESTHEAD POWER SUPPLY FAULT - Check the Testhead Power Supply Controller’s indicator LEDs. If any of the LEDs are not lit, reset the system and recheck. MISALIGNED PINS ON PATCHBOARD RECEIVER - Remove the Selftest Assembly and carefully inspect the alignment of the Patchboard receiver pins.
Selftest & Calibration Series 2040 Maintenance Manual V2.00 Selftest Failure Analysis 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) 36) 37) 38) 39) 40) 41) 42) 43) 44) 45) 14 Test Name SELF_dig-f th_config_tst ams_dig_f ams_mode_f ams_sig3_f #1 #2 #3 Selftest TH Cont/CPU TH P/S Cont Testhead configuration does not match the stored configuration.
Series 2040 Maintenance Manual V2.
Selftest & Calibration Series 2040 Maintenance Manual V2.00 CALIBRATION Whenever a Testhead board is replaced, or any time that Selftest determines a failure, a calibration must be performed. If a unit passes the complete Functional Selftest routine, a calibration is not necessary. When Calibrate is selected from the Selftest Executive, the screen shown to the right is displayed. The Calibrate menu operates under the same basic rules as the Functional menu.
Series 2040 Maintenance Manual V2.00 Selftest & Calibration Any type of failure during calibration could indicate a hardware problem. If a failure during Functional was the reason that a calibration is being run, refer to the Selftest Failure Analysis sheet on page 8 of this section.
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Series 2040 Maintenance Manual V2.
Diagnostics Series 2040 Maintenance Manual V2.00 DIAGNOSTIC TOOLS SelfTest EXaminer (STEX) for Microsoft Windows 95 Overview The STEX program may be used to help graphically interpret the results of any diagnostic output file generated by Digalog System’s SelfExec program run on the Series 2040 testers.
Series 2040 Maintenance Manual V2.00 Diagnostics Selection of the ‘Diagnostic’ option for file output will create a file with all the information required by STEX to analyze the system. This information includes the tester type being run, a listing of the Testhead resources as recorded in the ‘resource.ini’ file or the Registry, and a listing of all tests run along with any problems encountered during the tests. These results will be written into a file in the ‘digalog\bin\’ directory.
Diagnostics Series 2040 Maintenance Manual V2.00 All tester resources, by default, are either gray-colored or on gray background. The one to three resources calculated to be most likely causing the fault(s) will be highlighted in red. Also, the ‘Results:’ box on the lower portion of the form displays the information regarding these three tester resources.
Series 2040 Maintenance Manual V2.00 Diagnostics If any failure(s) or problem(s) are found in a valid diagnostic file, the menu item ‘Report Details’ will be enabled to show some details about those tests. See item ‘Report Details’ for more information. If the diagnostic file is examined, and no fails or other problems were found with this test, the ‘Results:’ box will display the message: “No Problem Found” on a green background.
Diagnostics Series 2040 Maintenance Manual V2.00 error. If a test listed did not have any slot information listed in the results, the slot will be listed as ‘Unknown’. To view the details of each individual fail or system error number from the test results, use the ‘View Log File’ menu item. Refer to the Selftest documentation to aid in interpreting these test results.
Series 2040 Maintenance Manual V2.00 Diagnostics TRMAN (Tester Resource Manager) The Tester Resource Manager is used to track and manage the tester resources including all the boards in the Testhead and the UUT power supplies. Information about these resources can be automatically generated or manually defined, and is used to generate a Patchboard Interface Map and define the pin locations of these resources at the Patchboard. This information can be saved to a project specific file called resource.
Diagnostics file in the \Digalog\include\ directory. Series 2040 Maintenance Manual V2.00 menu. It has selections for a New configuration, Load an existing configuration, Save a configuration, Save an existing configuration As another file, and Exit. The Print Utility as shown below will be discussed later in this section. For the purposes of this explanation, the file being used for illustrations is the standard resource.
Series 2040 Maintenance Manual V2.00 Diagnostics Manual Generation - If Manual generation is selected, the screen below will be displayed.
Diagnostics Series 2040 Maintenance Manual V2.00 configuration table. From this utility, any system configuration may be generated. It is the users responsibility to make sure the generated configuration is valid. The Programmable variable power supplies (maximum of five) may be defined in terms of maximum voltage and current once a Programmable Power Supply is selected (up/down button). With Volts or Amps selected, the jog shuttle located to the right modifies the selected value.
Series 2040 Maintenance Manual V2.00 Diagnostics The table is directly linked to the slot drop-down menu, therefore any slot changes in either place will be reflected in the other. View Testhead Configuration - This utility displays the entire Testhead configuration in an organized format. An example of a typical Testhead configuration is shown below.
Diagnostics Series 2040 Maintenance Manual V2.00 View Pin Definitions - This utility from the Options menu explains the mnemonics used in the Patchboard map as shown to the right. View Power Supply Configuration - If this option is selected, a grid is displayed showing all of the power supplies present, along with the type, name, device designation, and Patchboard connection for each supply as shown below.
Series 2040 Maintenance Manual V2.00 Diagnostics TESTHEAD - PATCHBOARD - UUT P/S BUILT-IN DIAGNOSTICS When a malfunction is suspected in either the Testhead Internal or Patchboard Power Supply system, the LED status indicators should be examined. The top LEDs are labeled for their respective power supplies as shown on page 14. The legend for the four lower LEDs is shown below.
Diagnostics Series 2040 Maintenance Manual V2.00 Breakers and Test Points + 5VDC TH + 48V TH DC1+ DC1- - 40VDC TH + 40VDC TH - 19VDC TH + 19VDC TH - 15VDC TH + 15VDC TH - 5.
Series 2040 Maintenance Manual V2.00 Diagnostics FAULT LOOP The Series 2040 Test System incorporates a “fault loop” for troubleshooting and self-diagnostics. The cable between the UUT Power Supply Controller and the Testhead, besides providing a path for the power supply output, contains the fault loop. If the fault loop is broken, it will cause the controller to shut down and report an error to the computer (the next time the computer tries to give it a command).
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Series 2040 Maintenance Manual V2.00 Diagnostics GPIB/HPIB POWER SUPPLIES The Series 2040 Test System may also contain one or more GPIB/HPIB Power Supplies. These supplies communicate with each other and the computer via an IEEE-488 bus. In addition, they use a Fault/Inhibit loop for voltage/current protection and this loop also connects to the Testhead Power Supply Controller. Some of these supplies may have more than one output channel.
Diagnostics Series 2040 Maintenance Manual V2.00 For a system containing “n” number of HP power supplies, the PSC board drives the +Inhibit (input) line of HP P/S #n low relative to its -Inhibit (input) line. When this power supply detects that its +Inhibit input signal is low, then it drives its +Fault (output) signal low relative to its -Fault (output) signal. These fault output lines are connected to the inhibit input connections of HP P/S #(n-1).
Series 2040 Maintenance Manual V2.00 Diagnostics 1) Verify on the relay controller board (0000-5X44) that pin #3 relative to pin #4 of connector P3 (PSC Port) is low or at a logic “0.” If not, a problem exists on the PSC board, in the fault/inhibit cable from the PSC board to connector P3, or with connector P3 . 2) Otherwise, verify that pin #3 relative to pin #4 of connector P5 which mates to the first relay disconnect board is low or at a logic “0.
Diagnostics Series 2040 Maintenance Manual V2.00 and verify that each wire is connected to the proper terminal on the HP power supply. The HP power supply may be configured to use its inhibit input pins as simply digital I/O pins. Consult its operating manual to determine the correct position of the internal configuration jumper shunt for “Fault/Inhibit” operations, and then remove its cover to confirm the shunt’s proper placement.
Series 2040 Maintenance Manual V2.00 Diagnostics the PSC board itself. Note: If there are no wires in the fault/inhibit cable of the HP power supply for the fault and inhibit signals (pins 1-4 on connector P2), then jumper shunts #9-10 (Fault/Inhibit Bypass) must be installed.
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Certification X Series 2040 Maintenance Manual V2.
Series 2040 Maintenance Manual V2.00 Certification CERTIFICATION System certification ensures that the system standards that are used for Selftest and calibration are accurate, and can be traced to the National Institute of Standards and Technology (NIST). There are two elements of the Series 2040 Functional Test System that need to be certified: 1) The TDAC high precision digital to analog converter on each Selftest unit.
Certification Series 2040 Maintenance Manual V2.00 Calibration Station. Finally, connect the GPIB port from the 2040 console to the GPIB port on the Calibration Station. To run the program select the certification icon from the Atart/ Programs/Digalog program group, and the screen to the right will appear prompting for the type of calibration. Select the TDAC, and the screens in the right column on both this page and the following page will appear in the order shown.
Series 2040 Maintenance Manual V2.00 Certification screen shown below. When this portion of the certification is complete, the TCXO frequency must be checked. The procedure for the frequency certification is identical, except for the final screen displaying the frequency counter. The user should wait until the frequency is stable, and then click on certify to start the test. Again, the results and a pass/fail condition are displayed.
Certification Series 2040 Maintenance Manual V2.00 If the TCXO fails the preset calibration limits, it will also require a manual adjustment. Again, contact Digalog Systems should this occur. The procedure for the Selftest PPS current feedback circuit is almost identical to the first two certification procedures. Follow the instructions displayed on the screen. The fourth procedure certifies the ICAM Selftest current measurement circuitry, and the last certification screen is shown below.
Series 2040 Maintenance Manual V2.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 REPAIR AND REPLACEMENT PROCEDURES Upon determining that a part is defective, the customer should: 1) Contact Digalog Systems at (414) 797-8000 to obtain an RMA (Return Materials Authorization) number and be prepared to supply the part number and serial number of the defective part. If the part is not covered under warranty or a support contract, the customer must provide a method of payment for the repairs.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement COMPUTER ASSEMBLY When it is determined that a problem exists in the computer assembly itself, the entire assembly must be sent back for repair. To remove the computer assembly, proceed as follows: 1) Ensure that the main power cord is unplugged from the wall outlet. 2) Remove the two side panel mounting screws from the console as shown to the right. 3) Lift up the side panel and remove it.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 INTERNAL AND PATCHBOARD POWER SUPPLY OVERVIEW The Testhead Power Supply Controller monitors Testhead power supplies for overvoltage with OVP crowbar IC’s. When an overvoltage is detected, the OVP IC quickly short circuits the offending power supply. This produces an undervoltage state on that power supply. This is, in turn, sensed by an optoisolated comparator to produce a digital fail signal.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement TESTHEAD & PATCHBOARD POWER SUPPLY REPLACEMENT WARNING! Remove main power from tester before proceeding. 1) Ensure that the main power cord is unplugged from the wall outlet. 2) Remove the two side panel mounting screws from the console as shown to the right. 3) Lift up on the side panel and remove it. 4) Remove the two screws from the front edge of the inner panel and swing it out to reveal the four power supplies.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 +5VDC Testhead Power Supply The Testhead cooling fan assembly contains the main +5VDC Power Supply for the Testhead. If it is determined that the supply is faulty, the recommended procedure would be replacement of the entire assembly as described below: 1) Remove the four screws on the sides of the Testhead cooling fan assembly, and draw the assembly towards you 2 to 3 inches.
Series 2040 Maintenance Manual V2.00 Testhead Boards Module Repair and Replacement Retaining Screws Remove the assembly through this opening. 6) Disconnect the AC fan power cord from the Testhead section of the AC Distribution box. 7) Remove and replace the assembly through the Testhead bay, taking care to route the wiring for the new Testhead fan assembly exactly as the old wiring was routed. 8) To reinstall the supply, reverse steps 1 - 7.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 UUT POWER SUPPLIES - Description Contained in the middle rack of the unit are the product power supply controllers. Each one controls a single product supply. The controllers are arranged PCS2, PCS1, and PCS0 from left to right. (This is a typical installation. Individual systems may vary.) To the right of the controllers, PS2, a Kikusui PDA110-1.5L, completes the top power supply rack.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement UUT POWER SUPPLY CONTROLLER REPLACEMENT WARNING! Remove main power from tester before proceeding. To remove a controller, remove the upper and lower retaining screws from the front of the console. The controller should slide directly forward. Place the controller to be installed on the floor directly beside the controller being replaced. Place it in the same orientation to make the process simpler.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 UUT POWER SUPPLIES WARNING! Remove main power from tester before proceeding. The removal process for UUT Power Supplies and GPIB/HPIB Power Supplies is almost identical. However for both types of supplies, extreme caution should be exercised due to the considerable weight of the supplies.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement GPIB/HPIB POWER SUPPLIES 1) Remove the left side panel (side opposite the computer) to gain access to the rear of the power supplies. 2) Disconnect the AC power cords from the AC/DC Distribution Box, and disconnect the GPIB cable, Fault/Inhibit cable, and power output cable from the rear of the supply. 3) If the faulty supply is the lower of two GPIB/HPIB supplies, it may be easier to remove the upper supply first.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 UUT - GPIB/HPIB POWER SUPPLY DISCONNECT AT TEST BAY From top to bottom: PS0 PS1 PS2 PS3 - Jumper PS4 - Jumper All unused power supplies must be jumpered. This is a typical installation. Individual systems may vary. Also note, the GPIB/HPIB power supplies may be externally connected to the fixture/UUT.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement CIRCUIT BOARD REPLACEMENT PSC The illustration below shows the positions of the boards in a typical Series 2040 Test System. The MDE, TMS, and AMS are always the last three on the left side of the tester (as viewed from the rear of the Testhead) and are dedicated to those slots shown. The PSD (Power Supply Distribution) assembly always occupies Slot 0, while the PSC (P/S Controller) occupies its own slot on the far right.
Module Repair and Replacement Spread these tabs. Series 2040 Maintenance Manual V2.00 Spread these tabs. Pin Guide To reinstall a board, first check the positioning of the black plastic pin guide to ensure that the beveled openings are aligned with the receptacles on the board. Position the board’s leading edge in the top and bottom card guides for the Testhead slot and carefully insert the board until resistance is felt.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement CONTACT SPRING REPAIR Alignment of the contact springs (pins) in the Patchboard receiver of the Digalog Series 2040 Test System is critical. Misaligned or bent pins can cause failures in the system. It is possible that one or more contact springs may become damaged in one way or another. If the springs are bent, and the bend is horizontal (lateral), the springs may be repairable.
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 position to ensure that they all have the proper spring tension. If so, you must then place the comb on the opposite side of the contact springs and bend them back to the normal position. Individual contact springs can be aligned using a suitable non-metallic tool (e.g. the eraser end of a pencil). Simply reposition the bent contact spring so that it is aligned with the properly positioned springs in the same row.
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement Retract the plunger of the spring removal tool and position the sleeve of the tool so that the flat side of the “D”-shape formed by the end of the sleeve is aligned with the latching tab of the damaged Patchboard spring (Testhead card Board Side of Patchboard “D”shaped latching tab “D” shaped sleeve Plunger Patchboard side of the Patchboard).
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 1. Remove the termination from the rear of the spring. (Remove the Testhead card.) 2. With a slow and steady pressure, bend the one side of the “U” in far enough to clear the board opening. Then, in the same manner, bend the other side of the “U” in far enough to permit the contact spring to pass freely though the board cavity. CAUTION: To prevent chipping of the cavity, double check that the “U” will clear the cavity opening. 3.
