TRICOR Systems Inc. Contents 1 INTRODUCTION ................................................................................. 2 SETUP AND INTERCONNECTION .................................................... 2.1 Hardware ..................................................................................... 2.2 PC Connection ............................................................................. 2.3 Software....................................................................................... 2.
TRICOR Systems Inc. SECTION 1 INTRODUCTION The Model 921A Displacement - Force (DF) Test Station operation is similar to the highly acclaimed Models 951A and 961A Test Stations. The high accuracy and many of the features of the 951A and 961A have been incorporated in the 921A. Testing on the 921A is performed using remote test fixtures similar to the 961A. The remote operation permits testing a wide variety of components/devices and also allows the 921A to operate as part of a fully automated test line.
TRICOR Systems Inc. TABLE 1-1 MODEL 921A DISPLACEMENT - FORCE TEST STATION SPECIFICATIONS Power Requirements 115/220 V ac, 50/60 Hz, 230 VA Test Cycle Time 6 to 10 seconds typ Resistance Test Current 10 mA standard* Resistance Measurement Channels One (Optional) Displacement* Range: Resolution: Abs Accuracy†: 6.25 to 62.51 mm (0.246 to 2.461 inches) standard* 0.00254 mm (0.0001 inch) programmable ±0.00762 mm (±0.0003 inch) max ±0.00254 mm (±0.0001 inch) typ ±0.00762 mm (±0.0003 inch) max ±0.
TRICOR Systems Inc. The test sequence is initiated by pressing the TEST switch or externally by the PC. During the test sequence, sensor data is logged in 921A memory. Test data is then analyzed, parameters are calculated, and the results are compared with the configuration criteria to determine a pass or fail status. The PASS or FAIL indicator then illuminates. Upon completion of the test sequence, the 921A is ready to test the next device.
TRICOR Systems Inc. K J 2-204-3 F G H I FRONT PANEL C D A B E BACK PANEL 2-204-4 Figure 1.1 921A Controls and Indicators 1.
TRICOR Systems Inc. TABLE 1-2 CONTROLS AND INDICATORS (Refer to Figure 1.1) A - Back Panel Connector J1 — the serial communication channel connector used to connect the 921A to a PC using the supplied serial cable (Figure 1.4 or 1.5). B - SERVICE/RUN Select Switch — active only when power is first applied to the 921A. This switch is placed in the RUN position for normal operation.
TRICOR Systems Inc. TABLE 1-2 CONTROLS AND INDICATORS (Cont.) E - Back Panel Resistance Connector J2 (optional) — the electrical resistance connector used with the resistance cable PN 921-112 to connect 921A to generic or user nests. F - TEST STATUS PASS Indicator — illuminates green after a test cycle in which the device being tested passes all of the specified parameters (within tolerance).
TRICOR Systems Inc. TABLE 1-6 CONTROLS AND INDICATORS (Cont.) J - POWER Indicator — illuminates green when the 921A is turned on with power applied. K - SYSTEM STATUS Operator's Display — contains two 40character lines which supply information about 921A operation, such as the part number and version of the device configuration being tested. This display also prompts the operator concerning necessary actions, such as "Install Device and Press Ready," etc. 1.
TRICOR Systems Inc. 2-204-5 Figure 1.2 Resistance Cable 15-Pin M/F Sub D (Optional) PN 921-112 2-204-8 Figure 1.3 Precision Drive Mechanism Showing Corrugated Cable and 37-Pin Connector 2-204-7 Figure 1.4 25-Pin M/F Sub D Serial Cable PN 905-390-101 1.
TRICOR Systems Inc. 2-204-6 Figure 1.5 25 Pin M/ 9-Pin Female Serial Cable PN 905-390-102 2-204-9 Figure 1.6 Two-Clip Generic Nest Assy PN 921-140-101 2-204-10 Figure 1.7 Four-Clip Generic Nest Assy PN 921-140-102 1.
TRICOR Systems Inc. SECTION 2 SETUP AND INTERCONNECTION 2.1 HARDWARE The power entry module (C-Figure 1.1) must be set for the user's facility power. The 921A is normally supplied configured for 110-120 V ac, 60 Hz. To reconfigure the 921A for 220-240 V ac, 50-60 Hz rotate the slideout voltage selector and position it accordingly. Plug the power cord into the 921A power entry module and into a properly grounded outlet. 110-120V 220-240V 2.
TRICOR Systems Inc. WARNING Set up unit for facility power (115 or 220 Vac) prior to connecting to facility power (see paragraph 2.1). 110 - 120 VAC OR 220 - 240 VAC 15-PIN MALE MODEL 921A DF TEST STATION J2 J1 RESISTANCE CABLE 15-PIN FEMALE GENERIC NEST PN 921-140(OR USER NEST) 25-PIN MALE SERIAL CABLE SERIAL COM CHANNEL PC 25-PIN FEMALE (9-PIN OPTIONAL) PRECISION DRIVE MECHANISM Figure 2.1 921A DF Test Station Interconnect 2.
TRICOR Systems Inc. 2.4 PRECISION DRIVE MECHANISM SETUP/CONNECTION A suitable test fixture or vice should be used to hold the device for test. The drive mechanism force sensor must be centered over the device button, dome, etc., to which force is to be applied. The sensor must not be in contact with the device for test (allow at least a 1/16-inch gap).
TRICOR Systems Inc. 2.5 ELECTRICAL RESISTANCE CONNECTION (OPTIONAL) The 5-foot 15-pin Subminiature "D" Male/Female connector cable supplied with the resistance option is used to connect either the supplied generic nest assembly or the user's nest to the 921A (refer to Figure 1.2). 2.6 GENERIC NEST ASSEMBLY CONNECTION (OPTIONAL) Two types of Generic Nest Assemblies are available: a two-clip version and a four-clip version. The type must be specified when ordering.
TRICOR Systems Inc. Table 2-1 J2 Connector Wiring PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Notes: SIGNAL INSTALL CH1 SENSE + CH1 SENSE - CH1 SRC+ CHASSIS GROUND SIGNAL GND CH1 SRC - 1. Pin 9, chassis ground is provided for shield termination. If userdesigned nests have wire lengths in excess of 8 inches, those wires should be shielded. If the user nest is to be used in an electrically noisy environment, the wiring should be metal enclosed with the metal enclosure chassis grounded. 2.
TRICOR Systems Inc. WARNING Care must be taken whenever handling the force transducer. These transducers are easily damaged. The 2.0 kg, 3.6 kg and 50 lb transducers are supplied with protective stops for overload under compression. However, tension or rotational forces applied in excess of 150% of fullscale rating will permanently damage the transducer. The 2.0 kg, 3.6 kg and 50 lb force transducers are supplied with two tips (small and large, refer to Figure 2.3).
TRICOR Systems Inc. CAUTION If users design their own tips, the mass and length must be kept at a minimum (comparable to the large tip supplied) or performance may be impaired. 2.8.2 75 g, 360 g and 750 g Transducer Tips WARNING Care must be taken whenever handling the force transducer. These transducers are easily damaged. Compression, tension or rotational forces applied in excess of 150% of full scale rating will permanently damage the transducer.
TRICOR Systems Inc. WARNING DO NOT TOUCH THE TRANSDUCER TIP DURING HANDLING OR INSTALLATION/REMOVAL OR PERMANENT DAMAGE MAY RESULT. Use proper ESD Handling procedures during installation/removal and handling/packaging (antistatic) the force transducer assembly. Failure to comply may result in damage to the equipment. The transducer assembly consists of the force transducer, the force transducer circuit card assembly (CCA) and the CCA/transducer interconnect cable.
TRICOR Systems Inc. The remaining two tie down areas are not critical for performance. The cable should be tied down to these as shown in Figure 2.9 to provide the service loop for operation. Be sure sufficient slack in the cable is provided so that the precision drive mechanism limit switch (the furthest extended outward position) is actuated with some slack remaining. When the platform is in the home position (furthest retracted inward position) there must also be some slack remaining in the cable. 2.
TRICOR Systems Inc. Screws (5) 2-204-15 2-204-16 Figure 2.5 Figure 2.6 Screws (4) Screws (2) 2-204-19 2-204-18 Figure 2.7 Tie downs Tie downs Figure 2.8 Screws (2) 2-204-17 Figure 2.9 2.
TRICOR Systems Inc. SECTION 3 CONFIGURATION WARNING Set up unit for facility power (115 or 220 Vac) prior to connecting to facility power. After the 921A has been set up as described in section 2, it is ready for power. 3.1 TURN-ON The power ON-OFF switch is located on the back panel as part of the power module (C-Figure 1.1). Place this switch in the ON position. The green POWER indicator should illuminate and all other indicators should remain off.
TRICOR Systems Inc. SECTION 4 OPERATION After the 921A has been configured, it is ready for operation. Turn on the 921A and allow it to perform its self-test routine and enter the Calibration Mode. The operator's display contains two lines of information. The first line provides data about the device test configuration, i.e., the device part number, the version of the device configuration, and the work order (if applicable).
TRICOR Systems Inc. If the configuration uses resistance, then the Generic Nest Assembly (or equivalent) must be connected to the DF for calibration. If the four-clip version, PN 921-140-102 is used, the Red clips (I+ and S+) must be connected together and the black clips (I - and S -) must be connected together for the purpose of calibration. The red and black clips cannot be shorting together or to a metal surface.
TRICOR Systems Inc. This message indicates that a calibration cycle has been initiated. If an operator accidentally pressed the MODE switch, he/she now has the option to abort the calibration cycle by pressing the CAL switch. The 921A will retain the former calibration values and be prepared to test another device. Whenever a different Configuration is installed, the display may instruct the operator to recalibrate.
TRICOR Systems Inc. SECTION 5 SERVICE & ADJUSTMENTS 5.1 SERVICE MODE WARNING The Service Mode operates the moving platform at some service mode steps. Never operate the unit without the platform properly setup with the drive mechanism height adjusted to provide a suitable stop for the platform force transducer. The Service Mode provides a means to periodically test and adjust the 921A internal measurement circuits.
TRICOR Systems Inc. 5.1.2 Resistance Offset (Resistance Option Only) This step allows adjusting the resistance offset electronics and verifying the internal resistance gain calibration value, as well as, verifying the resistance readings. Appendix C provides the detailed instructions for adjustment/verification of the resistance electronics. If the operator wants to proceed to a different service mode step, press TEST/READY, as required. 5.1.
TRICOR Systems Inc. If the operator wants to proceed to the next service mode step, press TEST/ READY, as required. 5.1.6 Displacement Verification This step allows verifying the system displacement accuracy. Appendix D provides the detailed instructions for verification of the system displacement. If the operator wants to proceed to the next service mode step, be sure the platform is properly setup (see warning above), then press TEST/READY, as required.
TRICOR Systems Inc. SECTION 6 TROUBLESHOOTING User troubleshooting of the 921A is limited to replacing fuses. Before returning the unit to TRICOR for service, check the following: 1) Verify that the power outlet has power. Plug in and turn on the 921A. 2) Does the POWER indicator illuminate? Yes - Go to step 3. No - Remove power plug from outlet. Remove slideout panel from power entry module (C-Figure 1.1). Check the two 2-A fuses. Replace defective fuse(s). Reapply power.
TRICOR Systems Inc. Remove the back panel (Refer to Appendix C Warnings and Step 1) prior to removing panel. Check the 4-A fuse (see Figure 5.1) on the power supply CCA (located on the right side of the base beneath the operator's display) . Replace defective fuse, if any, with proper type. Reapply power. If fuse blows or unit still does not operate properly, return it to TRICOR for service. 4-A Fuse 2-204-20 Figure 5.1 4A Fuse Location on Power Supply CCA 6.
TRICOR Systems Inc. APPENDIX A RESTRICTIONS AND WARNING / PROBLEM / FAILURE MESSAGE DESCRIPTIONS Max Force Restriction Max Force parameter will establish the end of inward travel (bottomout). Max Force should be set to a reasonable value for the device under test. If the Max Force is set to small, the inward test range may not reach the desired bottomout point of the device under test. If the Max Force is set to large excessive force may be applied to the device under test.
The Force measured by the Force Transducer exceeds the acceptable limit. If Force Transducer is in contact with Nest, press and hold "TEST" to back up platform from Nest. If Force Transducer is not in contact with Nest, check Force Gain/Offset calibration. If problem persists -- consult factory. The 921A Analog-to-Digital Converter is not operating properly -- consult factory. A/D CONVERSION (EOC) FAILURE WARNING!!! FORCE LIMIT EXCEEDED.
Force limit exceeded or Limit switch contacted during platform travel. Typical cause is Maximum Force parameter in configuration file set too high (near limit of transducer). Reduce Maximum Force parameter value. Other causes are hardware failures -- consult factory. RS-232 serial communication with PC interrupted. Possible cause is loose or disconnected cable between 921A and PC or PC being turned off during communication. If necessary, power down 921A and retry operating unit.
TRICOR Systems Inc. APPENDIX B Force Transducer CCA Calibration Test Tool Required: Force Calibration Fixture PN 905-810 WARNING Service is to be performed by qualified personnel only. Use only plastic adjustment tools. Failure to comply may result in damage to the equipment. Step 1 Power down the unit. Remove the cover from the drive mechanism assembly (12 screws, Figure B.1). The force transducer CCA is located on the left side of the drive mechanism.
TRICOR Systems Inc. Step 5 There are two types of force transducer CCAs which are illustrated in Figures B.5a and B.5b. Examine your unit's force transducer CCA to determine which type is on the unit. Reference figure a or b accordingly to perform the adjustments of steps 6, 7, and 8. Step 6 Adjust the force transducer CCA potentiometer labeled "offset" on Figure B.5 until the offset value displayed on the unit is as close to the nominal value listed below for your transducer type.
TRICOR Systems Inc. Step 8 Press the TEST/READY switch once. When the platform mechanism stops moving power down the unit. Repeat steps 4 through 8 until the step 6 offset is within acceptable range and the step 7 Measured Value is within adjustment tolerance without requiring further potentiometer adjustment, at steps 6 and 7. It typically takes performing steps 4 through 8 at least three times to achieve correct adjustment.
TRICOR Systems Inc. Screws (12) 2-204-21 Figure B.1 Drive Mechanism Assembly Cover Removal B.
TRICOR Systems Inc. 2-204-22 2-204-24 Figure B.2 L Bracket/Gauge B.
TRICOR Systems Inc. 2-204-23 Figure B.3 Force Gauge with Tip B.
TRICOR Systems Inc. 2-204-25 Figure B.4 Center Gauge to Transducer Tip B.
TRICOR Systems Inc. OFFSET GAIN 2 GAIN 1 2-201-43 Figure B.5a Resistance Pot Locations Force Transducer CCA Type 1 2-204-26 GAIN 2 GAIN 1 OFFSET Figure B.5b Resistance Pot Locations Force Transducer CCA Type 2 B.
TRICOR Systems Inc. APPENDIX C Resistance Adjustment/Verification (Resistance Option Only) Test Tool Required: Resistance Verification Fixture PN 921-811-XX (See Table C-1 for the complete part number of the fixture required based on the Resistance Option Type installed in the Model 921A) Table C-1 Resistance Option Type 4 5, 10mA 4 5, 25mA 16 k5, .25mA 1 k5, 1 mA 4 V, 4.
TRICOR Systems Inc. WARNING The Service Mode operates the moving platform at some service mode steps. Never operate the unit without the platform properly set up with the test fixture height adjusted to provide a suitable stop for the platform force transducer. Step 1 Power down the unit. Disconnect the ac power cord from the primary power source. Remove the rear panel from the unit (four screws - figure C.1) and lay down on a flat surface.
TRICOR Systems Inc. Rear Panel Mounting Screws (4) 2-204-4 Figure C.1 921A Rear Panel Press TEST/READY again - The platform returns to the home position. The resistance Offset Adjustment Mode message is displayed. Install the Offset/Gain Jumpering Connector (part of PN 921811-XX) on the Resistance Cable (PN 921-112) P2 Connector. Do not remove the jumpering connector until instructed to do so by this procedure. Step 5 Press the TEST/READY switch once.
TRICOR Systems Inc. 2-204-27 OFFSET POT R21 Figure C.2 Resistance CCA Offset Pot Location C.
TRICOR Systems Inc. Resistance Type 4 5, 10 mA Channel Offset 4 5, 25 mA Channel Offset 16 k5, .25 mA Channel Offset 1 k5, 1 mA Channel Offset 4 V, 4.99 k Pullup Channel Offset Acceptable Range 0.010 to 0.030 0.004 to 0.012 0.001 to 0.030 0.001 to 0.030 0.001 to 0.030 Step 7 Press the TEST/READY switch once. The unit displays the GAIN Calibration Resistance Value message. Press the TEST/ READY switch again. The unit displays the GAIN Calibration Value (GV).
TRICOR Systems Inc. Table C.2 4 5, 10 mA or 25 mA Resistance Option using Resistance Fixture PN 921-811-09 Resistance Switch Position 1 (0 5) 2 (1 5) 3 (2 5) 4 (3 5) 5 (3.8 5) 6 (.025 5) 7 (.050 5) 8 (.075 5) Displayed Value (5) 0.000 1.000 2.000 3.000 3.800 0.025 0.050 0.075 Tolerance ±.010 ±.010 ±.010 ±.010 ±.010 ±.010 ±.010 ±.010 Table C.3 16 k5, .
TRICOR Systems Inc. Table C.5 4 V, 4.99k Pullup Resistance Option using Resistance Fixture PN 921-811-02 Resistance Switch Position 0 (0 V) 1 (1 V) 2 (2 V) 3 (3 V) 4 (4 V) Displayed Value (Volts) 0.000 1.000 2.000 3.000 4.000 Tolerance ± 0.040 ± 0.040 ± 0.040 ± 0.040 ± 0.040 Consult the factory if any of the resistance values fail to meet the specified requirement. This completes the resistance calibration/verification. Step 10 Power down the unit.
TRICOR Systems Inc. APPENDIX D Displacement Verification Procedure Test Tool Required: Force/Displacement Gauge Fixture PN 905-378 Displacement Gauge: Mitutoyo PN 543-146 (or Equivalent) Align Parallel 2-204-28 Figure D.1 Fixture with Gauge WARNING The Service Mode operates the moving platform at some service mode steps. Never operate the unit without the platform properly setup with the test fixture height adjusted to provide a suitable stop for the platform force transducer.
TRICOR Systems Inc. Step 2 Connect the Drive Mechanism to the rear panel connector per section 2 of the 921A User's Manual. Connect the ac power cord to the unit and to primary power source. Place the SERVICE/RUN switch on the unit rear panel in the SERVICE position. Turn on the unit. The Service Mode is used to perform the calibration/adjustment. The Service Mode requires pressing the TEST/READY switch on the front panel to increment or step through the various service mode display screens.
TRICOR Systems Inc. (approximately 1/16-inch) when contacting the Force Transducer Assembly (adjust the height of the drive mechanism, as necessary) as shown in Figure D.2. Figure D.2 Step 5 2-204-29 Prior to proceeding with the displacement test, the operator needs to become familiar with the test method. Table D.1 provides the approximate displacement locations to test. When the TEST/READY switch is pressed and released, the drive mechanism will begin incrementing (moving) into the displacement gauge.
TRICOR Systems Inc. Step 6 With the Displacement Verification Mode message displayed on the unit, turn on and zero the fixture gauge. Be sure the fixture gauge reads zero, or re-zero the gauge as necessary until the gauge reads zero before proceeding. Press, then release, then press and hold in the TEST/READY switch. This is the approximate zero reading. If the unit display still reads zero, then re-zero the fixture gauge (if necessary).
TRICOR Systems Inc. Table D-1 Displacement Verification Table Approximate Displacement Unit Measurement Mitutoyo Measurement 0.0000 0.0125 0.0250 0.0500 0.0750 0.1000 0.1250 0.1500 0.1750 0.2000 D.
