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HP 2040D User's Manual

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2. 1 2 ddnS inn LP ol Series 2040 Test System 34 Diagnostics Series 2040 Maintenance Manual V2 00 35 pue Burejos 159 Buuimiel oiiuo9 AK ddn S NIOV 00186801 anis 9 9 iex LLHSUId vf 910N SUId pf 910N vr O N peeuse peeusel Lr Series 2040 Test System Series 2040 Maintenance Manual V2 00 Diagnostics zAjddnsioamog 05 159 LSd anis 1 8 LL SUId f 910N O N vr peeusel el Series 2040 Test System 36 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 als
3. Fail Data or No Data All No Data Data includes all of the pass or fail sequences from the test Data includes only information on the tests that failed No Data disables that reporting function To select merely use the mouse to check or uncheck each reporting function If a reporting device is unchecked the options under that device appear shosted indicating that they are disabled For diagnostic purposes enable the Printer and File options and select the Fail Data option Under the File section click the Diagnostic File check box Disable the Window reporting functions Series 2040 Test System Series 2040 Maintenance Manual V2 00 Selftest amp 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 1 Tests Test Sequence Configuration Summary Test Summary File Fail Data Diagnostic Cycle Window Fail Data Menu Printer No Data Program Log Not Selected Total Fails 2 th config tst 22 brst 42 tms evnt f 62 3 ams dig f 23 arb ext 43 tms test f 63 4 44 45 dio 46 ext 47 int 7 8 S afet rtt 9 4 69 jo 30 mde 50 70 11 mrly dig f 31 mde ditm
4. 51 f 71 12 f 32 mde f 52 72 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 If a related group of tests is to be run they may be selected using only the mouse For example if the Measurement Display Electronics group is to be selected place the mouse pointer on test 30 and hold the left button down and drag the mouse down to test 38 The entire MDE group is now selected If a random series of tests is desired place the mouse pointer on the box under Run sequence When the Windows text tool appears click the left mouse button At the blinking cursor any sequence of tests can be entered The test numbers however must follow this syntax E Execute signifies the beginning of a sequence or acts as a separator between sequences Series 2040 Test System 11 Selftest amp Calibration Series 2040 Maintenance Manual V2 00 12 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 If a single test or a group o
5. 53 Jumper 54 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 5 5 5 51 5l 5lf5lrsls5lrslslrslrslrslrs TETE olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo olo PSO PS1 PS2 _ Jumper Jumper 60 Series 2040 Test System Series 2040 Maintenance Manual 2 00 Module Repair and Replacement CIRCUIT BOARD REPLACEMENT 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 5 S gt o x
6. 3 Remove the screws in the front panel holding the lower rack in place and slide the entire rack forward out of the cabinet The rack assembly is very heavy so proceed with caution 4 Remove the faulty supply from the rack and return for repair Upper Power Supplies PDA110 1 5L Repeat the above procedure except that the supply can just be removed by removing the small upper and lower retaining brackets No rack assembly needs to be removed 58 Series 2040 Test System Series 2040 Maintenance Manual 2 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 CPIB 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 4 Remove the faulty supply and return for repair GPIB HPIB LT Supplies PAD115 1 5L Kikusui PD 35 20 Kenwood PD 35 20 Kikusui PD55 10 or Kenwood PD56 10 This illustration shows a typical installation Individual systems may vary from this example Series 2040 Test System 59 Module Repair and Replacement Series 2040 Maintenance Manual V2 00 UUT GPIB HPIB POWER SUPPLY DISCONNECT AT TEST BAY From top to bottom PSO PS1 PS2
7. Mounted on the 2040 3 A printer if a hard copy certificate is desired The Calibration Station contains a precision digital multimeter and a precision counter timer Both instruments are equipped with a GPIB interface so that the certification process in terms of instrument setup and measurement processing is completely automatic Setup A number of connections between the 2040 and the Calibration Station must be made before continuing These are 1 Installation of the Selftest assembly See page 2 1 2 Power connections for the Calibration Station 3 GPIB IEEE 488 communication link between the 2040 and the Calibration Station 4 Connections between the TDAC port on the Selftest assembly and the multimeter 5 Connections between the 10MHz output of the TMS in the Testhead and the counter timer Using the interconnect on the left page hook a BNC cable from the 10MHz connector on the back panel of the 2040 Console to the A input of the Frequency counter of the Calibration Station Using another BNC cable connect the TDAC signal from the Selftest unit to the Multimeter on the Series 2040 Test System 45 Certification Series 2040 Maintenance Manual V2 00 Calibration Station Finally connect the port from the 2040 console to the port on the Calibration Station To run the program select the certification icon from the Atart of Calibration Programs Digalog program group and the screen to the righ
8. SEU ss 45 Module Repair amp Replacement ss 49 REPAIR AND REPLACEMENT PROCEDURES 50 COMPUTER ASSEMBLY ai persi e Ro ee 51 INTERNAL AND PATCHBOARD P S OVERVIEW 52 TESTHEAD amp PATCHBOARD P S REPLACEMENT 53 5VDC Testhead Power Supply seems 54 UUT POWER SUPPLIES Description x 56 UUT POWER SUPPLY CONTROLLER REPLACEMENT 57 UOT POWER SUPPLIES ss ero brote emer bd astres 58 GPIB HPIB POWER SUPPLIES m ena 59 UUT GPIB HPIB P S DISCONNECT AT TEST BAY 60 CIRCUIT BOARD REPLACEMENT ecce cete etr e EDU Ree COS ga ede i adn 61 CONTACT SPRING REPAIR USE OF PATCHBOARD SPRING REMOVAL TOOL 0000 2746 CONTACT SPRING REPLACEMENT Conventional Method 65 Series 2040 Maintenance Manual 2 00 Maintenance Overview System Overview Series 2040 Test System 3 WVHOVIG 0018 0802 Series 2040 Maintenance Manual 2 00 Maintenance Overview
9. To remove the computer assembly proceed as follows Mounting 1 Ensure that the main power cord is screws 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 4 Remove the two screws from the front edge of the inner panel and swing it out to expose the computer assembly 5 Carefully remove all of the cables from the rear of the computer assembly noting where each individual cable was connected 6 The computer assembly is held in place by four bolt assemblies with rubber bumpers on them Relieve the tension on all four bolt assemblies until the computer moves easily forward and backward 7 Remove the computer assembly from the front of the tester and send it to Digalog for repair To reinstall the computer assembly reverse this procedure Series 2040 Test System 51 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 opto isolated comparator to produce a digital fail signal This digital signal is latched in the control circuit and removes the AC line power from t
10. board one will be numbered over and above those of board number zero In other words for a Relay Multiplexer Board containing sixty four channels board zero channels would be labeled zero through sixty three and board one channels would be labeled sixty four through one hundred and twenty seven Series 2040 Test System Series 2040 Maintenance Manual 2 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 Test Head Configuration x SLOT Code Number Board description Description of pins soro sor e 0 fAms soaz je o0 fAndogSeuceBoad DAO andARBOT Hai CENE as Daun huayFET channels 64 127 channels 0 63 0 po oa j Open CollectorlX O B pe ___ y ais ely ais Fe ais Fela mplitude Measurement ime Measurement pin definitions easurement display No pin definitions irF r o r ot 10 ot 11 ot 12 4 bis lot 15 ot 16 lot 17 ot 18 lot 19 ot20 5 5 5 5 8 CIAM CM Lu a lt e 5 e E e E lot 21 ot 22
11. 3 QVdA33 1 IXW C120 1808 HOLINON 892 X zOL 21 OL aido EO LV Zvr Nou do 31A8A9SZ OL 3 I3NH3Hl3 001 0 d SAG ISOS Y va wm Series 2040 Maintenance Manual 2 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 This assembly attaches to the fixture interface to provide the best accuracy and reliability for calibration and self diagnostics The Certification program uses a Calibration station containing a Digital Voltmeter DVM and Universal Counter Timer which are certified by the National Institute of Standards and Technology as a Transfer Standard to calibrate the internal precision references of the tester The Selftest Assembly uses a 18 bit D A converter TDAC as an internal precision voltage standard The internal precision time standard is a Temperature Compensated Crystal Oscillator located on the Time Measurement System board The Calibration and Selftest routines calibrate the remainder of the system to the tester s internal precision references Calibra
12. Channel nnn 7 Xnnn Relay Matrix Channel nnn X prefix will be ommitted if channel exceeds 999 8 Bn m Relay Matrix Bus n Board m 9 Cbbd OCIO byte bb data bit d 10 Knnn OCIO bank nnn external rail reference 11 Power32 Relay Channel nnn Print Utility When this utility is selected from the File menu a small inputbox is displayed prompting for a specific serial number for the printout to be generated If a specific tester s configuration is to be generated enter the serial number in the textbox If not merely select the OK command button press Enter on the keyboard or select Cancel After this inputbox is satisfied select an individual printout to be generated or select all three options Series 2040 Test System 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 In case of a power supply malfunction the power supply that has shut down first will be indicated by its respective LED being extinguished If you are diagnosing the case of no power at the Patchboard and the status indicators the lower four LEDs are all lit then an over under vol
13. e gt gt on p 2 x a x u g g BB 25 55 5 lt ee lt lt O lt L lt lt Z nnnnnun Eee 5 lo 26 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 To remove a circuit board grasp the white tabs on the corners of the board and spread them outward towards the sides of the Testhead as shown on the next page Series 2040 Test System 61 Module Repair and Replacement Series 2040 Maintenance Manual V2 00 these tabs Spread these co 71 7 o oj gt a 8 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 inse
14. evaluate possible problems with the tester resources based on failed test data and or system errors during testing STEX will use these results to decide what the top three most likely resource problems are in the tester based on Selftest output information These results will be shown graphically on the STEX interface highlighting and identifying the potentially problematic resources in the tester STEX can be very useful in aiding an operator who is troubleshooting possible problems in the Digalog testers by providing a graphical depiction of the location of potentially faulty tester resources These resources include all Testhead boards the Testhead power supplies the variable power supplies and their controller modules the computer with its Testhead controller card and the Selftest unit itself Creating the Diagnostic File for STEX To use STEX to analyze Selftest data the proper information must be recorded in the Selftest output file first A new user selection under SelfExec s output configuration has been added to provide this information To obtain a diagnostic file for use in STEX follow these steps when running SelfExec Bi Utities r File Options Fail Data Log Summary 1 Under the File menu select 5 2 Configuration ere Fail Data Log Summary All Data 2 On configuration form under Fi
15. is or is not required If you find that all Selftest programs run without failures there is no need to recalibrate any portion of the tester The recommended guideline is to calibrate every 3 months Whenever a temperature change of more than five 5 degrees Celsius occurs or a Testhead board swap is made the 2040 should be recalibrated 8 Series 2040 Test System Series 2040 Maintenance Manual V2 00 Selftest amp 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 To perform Selftest proceed as follows 1 Install the Selftest unit on the Patchboard assembly as shown below A Pull the locking handle towards the front of the unit until it is vertical B Slide the pins on the rear of the Selftest unit into the Patchboard and rotate the Selftest unit forward until it is vertical and sets into the Patchboard C The ribbon assembly should be installed in the receptacle behind the Selftest with the colored edge of the ribbon on the left side while viewing the front of the unit D Rotate the locking handle back to it s original position to lock the Selftest into place 2 Enter the Selftest Executive by selecting double clicking on the SelfExec
16. that it is aligned with the properly positioned springs in the same row Alignment of the contact springs can be visually checked by looking straight through the holes of an empty Patchboard with the Patchboard in operating position When making such a visual check be sure that the contact springs are positioned within the range shown If a contact spring is severely bent or bent vertically replacement of the contact spring is recommended Should the bend be minor and in the horizontal lateral plane the contact spring may be repairable CONTACT VIEWED THROUGH FRONT BOARD HOLE OPTIMUM ALIGNMENT HIGHEST USEABLE LOWEST USEABLE USE OF PATCHBOARD SPRING REMOVAL TOOL 0000 2746 Determine the slot in which the damaged spring is located If there is a Testhead card in that slot it will need to be removed Be sure to use a wrist strap when removing or inserting the card and be sure to place the card into a static bag while it is out of the tester Turn off Testhead power and open the Testhead Remove the card if necessary put it into a static bag and set it safely aside Determine the location of the damaged spring Observe on the top fixture mating side of the Testhead that each spring has a pair of small metal tangs at the base opposite the finger of the spring The latching tab on the bottom Testhead card side is on the same side of the spring as the tangs 64 Series 2040 Test System Series 2040 Maintenance Manual 2 0
17. 0 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 z D shaped sleeve EUER _ lunger Patchboard side of the Patchboard Carefully lower the sleeve over the spring until it is fully seated and the sleeve is resting against the Patchboard The stinger of the spring will slide into the hollow end of the plunger A flashlight may be needed to provide adequate lighting especially if there are Testhead cards on either side of the slot The latching tab of the spring should be fully depressed inside the tool sleeve Be sure that the tool is held straight in line with the spring Apply steady careful pressure on the handle Do NOT push sharply and do NOT strike or tap the end of the handle Resistance will be felt as the spring slides out of the Patchboard Continue to apply steady pressure until the plunger handle bottoms out If these precautions are ignored it is possible to damage the tool or the Patchboard material itself The ejected Patchboard spring will be protruding from the top fixture mating side of the Patchboard Simply grasp it and pull it free of the Patchboard After replacing the spring in the Patchboard re install the Testhead card and close
18. Manual 2 00 Diagnostics TESTHEAD POWER SUPPLY CONTROLLER 11 12 11 12 11 12 UUTPOWERSUPPLY gt 5 5 2 TYPICAL POWER SUPPLY FAULT LOOP CONFIGURATION 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 The fault loop is broken by the controller itself whenever the controller detects an error This signals to the other controllers that they too should shut down If a controller for a power supply channel is unresponsive and the Ext Fault LED on the Testhead Power Supply Controller is on a communication problem exists between the CPU and the controller If the LED is out the fault loop is probably broken The power supplies may be isolated for diagnostics as shown in the following pages If a supply is isolated and fails to power up it is most likely the problem If a supply is isolated and powers up it can b eliminated as the cause of the failure Series 2040 Test System 33 Series 2040 Maintenance Manual V2 00 Diagnostics
19. Series 20400 Test Systems 2040D Maintenance Manual Part Number 4200 0181 Version 1 0 Table Of Contents System Overview 3 SYSTEM MAINTENANCE OVERVIEW sovi save i povabi uvedene 5 Selitest amp Calibration sana stana sans verd io pake 7 SELFTEST AND CALIBRATION OVERVIEW 8 Purpose Obs suede thee been oki ie 8 When Brate erepto ii bed veta ed 8 SBECTES To ai 9 Selftest Failure Analysis znasa 14 CALIBRATION apis vb EE o Me ERN 16 ite SR 19 DIAGNOSTIC NOUS a dents 20 SelfTest EXaminer STEX for Microsoft Windows 95 20 GC 20 Creating the Diagnostic File for 20 Analyzing SelftesF Datsun 21 TRMAN Tester Resource Manager errant noe ttt 25 MENU 25 TESTHEAD PATCHBOARD UUT P S BUILT IN DIAGNOSTICS 31 Breakers and Test Points pp 32 aes Rees EE aet 32 GPIB HPIB POWER SUPPLIES sostiene porem orte 37 Troubleshooting Hewlett Packard Power Supplies 37 ee v da berto OI 43 CERTIFICATION a sou ata epe eeu Ce etes 45
20. TEX Analyzing Selftest Data When starting the STEX program the graphics show the Testhead as being empty Under the menu item File are the selections Open for EXam View Log File Report Details Close and Exit Open for EXam Selecting this menu item opens up a file selection window showing the files available in the digalog bin directory with the dxx extension Highlight the desired filename and Click on the Open Upenjar Een button to select for analysis under STEX STEX will then Te Hon Fs open that file and examine it to see if it is a valid file for this program If the file is not valid for STEX a message box will inform the user of this and the graphics will Exit return to their default condition If it is valid the tester resource information will be read in for analysis The boards listed in the Registry will be placed in the proper slots in the Testhead graphic and the file will be inspected for any fail data from the tests listed If fail data or system errors are found the program will analyze those results using information about the tests located in STEX database digalog include stex mdb The program will then use this information to calculate the three most likely tester resources that could cause the problems found in this diagnostic file Report Details Close Series 2040 Test System 21 Diagnostics Series 2040 Maintenance Manual V2 00 All tester resources b
21. ceeding 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 One by one remove each of the cables cords from the back of the controller being removed installing them in the exact same locations on the replacement controller To reinstall reverse the removal process Move AC in to AC in v gt Move P S in to P S in Serialinto Serialin Serialoutto Serialout Move UUT out to UUT out gt Move AC out to AC out From To Series 2040 Test System 57 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 Lower Rack Power Supplies Kikusui or Kenwood PD 35 20 Kikusui PD55 10 and Kenwood PD56 10 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 remove the Power Output Programming cables from the UUT Controllers
22. ed as being at fault as a result of this file s analysis The test config test examines and compares the contents of the Testhead to the recorded listing in the Registry If a problem is found with this test it cannot be automatically known where the source of the problem is without further investigation Therefore the user should refer to the Tester Resource Manager TRMAN section of this manual to proceed in troubleshooting this problem 22 Series 2040 Test System Series 2040 Maintenance Manual 2 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 The proper configuration for the Testhead will be displayed but the menu item Report Details will be disabled since there are no failing tests on which to display information View Log File Selecting this menu item opens a file selection window showing the available files similar to the Open for EXam item Selecting a filename here will start the Microsoft Windows text editor program WordPad and open the diagnostic file for viewing Here individual test results may be viewed to provide further possible insight into any proble
23. elay controller board in the fault inhibit cable from the PSC board or on Series 2040 Test System 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 Series 2040 Test System 41 Diagnostics Series 2040 Maintenance Manual V2 00 42 Series 2040 Test System Series 2040 Maintenance Manual V2 00 Certification Certification Series 2040 Test System 43 Certification Series 2040 Maintenance Manual V2 00 10 2 EXTCLEXTEVENT PRINTER x ETHERNET 5 KEYBOARD 44 Series 2040 Test System 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 2 The TCXO precision oscillator on the Time Measurement System TMS in the 2040 Testhead To perform a certification the following equipment is necessary 1 A Digalog Calibration Station 2 A Digalog Selftest assembly
24. ere a 0 causes the Patchboard Power Supplies to shut down without a detected fault condition A 1 enables the Patchboard Power supplies The Patchboard Power is removed when a Testhead reset is issued See the TCLEAR functional call in the Programming Manual When the Patchboard Power Supplies are shut down they are also disconnected from the Patchboard via relays 52 Series 2040 Test System Series 2040 Maintenance Manual 2 00 Module Repair and Replacement TESTHEAD amp PATCHBOARD POWER SUPPLY REPLACEMENT WARNING Remove main power from tester before proceeding 1 Ensure that the main power cord is Mounting unplugged from the wall outlet screws 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 5 Locate the proper Testhead or Patchboard power supply connector for the supply to be replaced and disconnect it from the Testhead Power Supply Controller Use the legend below 6 Remove and replace the faulty power supply taking care to route new cable SNO exactly the same as the old E PENES one 19 5VDC 1 J7 5VDC 15VDC Save J8 5 2VDC 15VDC J9 19VDC 15VDC J13 5VDC SVDC 1 zm Series 2040 Test Sy
25. etects a fault from some other source such as the proximity switch proceed with the following troubleshooting procedure 38 Series 2040 Test System Series 2040 Maintenance Manual 2 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 If not a problem exists on the relay controller board 3 Otherwise on the first relay disconnect board verify that pin 3 relative to pin 4 of connector which mates to the relay controller board is low or at a logic 0 If not a problem exists either with connector P1 or else with connector P5 on the relay controller board 4 Otherwise verify that pin 3 relative to pin 4 of connector P3 which mates to the next relay disconnect board is low or at a logic 0 If not a problem exists between connectors PT and on the relay disconnect board 5 Otherwise on the second relay disconnect board verify that pin 3 relative to pin 4 of connector P1 which mates to the first relay disconnect board is low or at a logic 0 If not a problem exists either with connector P1 or else with connector P3 on the first relay disc
26. f selected tests is to be run once 10 times or 100 times use the mouse to select the appropriate button on the upper left If the test or group is to be run at some other number place the mouse pointer in the box to the direct left of the stop button and the Windows text tool will appear in place of the mouse pointer Click the left mouse button while texttool is displayed in the box and a blinking cursor appears in the box The user can now enter any number from 1 to 999 for the number of times a test should run For diagnostic purposes click the mouse button on the small box in the upper left corner of the menu next to Tests Select the 1 button and the program will run all of the functional tests once while reporting the data to wherever it was directed from the Report Utilities box For diagnostics this path should include the File and Printer categories and the Fail Data and Diagnostic File options m functional File T 00 trao Tests If any of the Functional programs fail check these common problems SELFTEST ASSEMBLY IMPROPERLY INSTALLED Check to make sure the assembly is properly installed on the Patchboard Also Series 2040 Test System Series 2040 Maintenance Manual V2 00 Selftest amp 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 S
27. fy that pin 1 relative to pin 2 of connector P2 on the relay disconnect board is low or at a logic 0 If not a problem exists in the HP power supply in the fault inhibit cable for this supply on the relay disconnect board for this supply on the relay disconnect board for the previous supply in the fault inhibit cable for the previous supply or in the previous HP power supply itself 11 Otherwise verify that pin 1 relative to pin 2 of connector which mates to the previous relay disconnect board is low or at a logic 0 If not a continuity problem exists on the relay disconnect board 12 Otherwise on the previous relay disconnect board verify that pin 1 relative to pin 2 of connector P3 which mates to the next relay disconnect board is low or at a logic 0 If not a problem exists either with connector P3 or else with connector P1 on the next relay disconnect board 13 Repeat steps 8 12 for each previous relay disconnect board up to and including the first relay disconnect board 14 Otherwise on the relay controller board verify that pin 1 relative to pin 2 of connector P5 which mates to the first relay disconnect board is low or at a logic 0 If not a problem exists either with connector P5 or else with connector P1 on the first relay disconnect board 15 Otherwise verify that pin 1 relative to pin 2 of connector PSC Port is low or at a logic 0 If not a problem exists on the r
28. g menu It has selections for a New configuration Load an existing configuration Save a configuration Save an existing configuration As another file Load Config from File Save Config to File and Exit The Print Utility as shown Print Testhead Configuration below will be discussed later in this Printer Setup Print Power Supply Configuration Exit Print Patchboard Map section For the purposes of this explanation the file being used for illustrations is the standard resource ini file in the Digalog include directory Options Menu When the Options menu is Deme selected a pull down menu will be displayed FLN ETES prompting for a choice of the following Auto Automatic Generation matic generation Link to tester Manual Manual Generation eration View pin Definitions and View Testhead configuration Each of these options 26 View Testhead Configuration 4 p View Power Supply Configuration along with the Print utility from the File menu Pin Definitions will be briefly discussed Link to Tester This item will toggle the link between the application and a tester When checked the application assumes a Testhead is present and enables Automatic generation When using Tester Resource Manager on a development computer that is not connected to a Digalog tester this item should never be checked as it could lead to corruption of certain memo
29. he Testhead Internal and or Patchboard Power Supplies The state of all comparators is indicated by the LEDs mounted on the top edge of the controller circuit card An illuminated LED in the power supply group indicates a normal condition The PBON RESET PROX and EXTERNAL FAULT LEDs when all are illuminated indicate that power is applied to the patchboard The extinguishing of any LED shows the reason for the loss of power to the Patchboard and or the Testhead A dedicated power supply on the controller circuit card maintains its function without regard to the monitored supplies The result of the logical OR of any Testhead Internal Power Supply failure is logically OR d with any Patchboard Power Supply failure The result of this is provided as a current loop signal through an opto isolator to the UUT Power Supply Controller Therefore when a fault is detected in the Testhead Internal Power Supply all power supplies are shut down If the fault originates in the Patchboard Power Supply the Testhead Internal Power Supply remains on The Testhead Power Supply Controller also responds to three external logic signals They are the Patchboard Open Sensor CPU ON OFF command and Reset A proximity detector located near the Patchboard senses the release of the Patchboard and causes a shutdown of the Patchboard Power Supplies and indirectly the UUT Power Supplies The CPU ON OFF command see the functional call POWER is a programmed command wh
30. her Trigger Matrix board 15 Selftest amp Calibration Series 2040 Maintenance Manual V2 00 CALIBRATION Whenever a Testhead board is nami 1 File replaced or any time that Selftest jo determines a failure a calibration AN Tests Sop deseen Configuration Summary r Test Summary must be performed If a unit Fic Fal Data Gle Printer No Data Program passes the complete Functional Log Not Selected Total Fa 1 21 41 61 81 Selftest routine a calibration is 2 lone sie 22 not necessary When Calibrate is B 26 46 66 86 selected from the Selftest 27 47 67 87 8 dio c 28 48 68 88 Executive screen shown to m Za s zl go the right is displayed iz 52 z sz 13 mde 33 53 73 93 14 34 54 74 34 Rs 7 The Calibrate menu operates 9 s under the same basic rules as 5 s a Functional menu For installation purposes use the mouse to select the Tests box and select the 1 button for the number of times to be run See page 6 Ensure that the Printer and Fail Data are selected so that any failures will be printed automatically The following is a list of the calibration programs located in the Calibrate menu in the Se
31. htened with an Alignment Comb Digalog part number 0000 2745 designed for this purpose When several contact springs of a single row are out of position straighten them with the alignment comb to attain uniformity Use the comb as follows 1 De energize the system and remove the Patchboard fixture to expose the contact springs 2 Determine the contact springs to be straightened You can do this by placing a non metallic straight edge vertically along the row to be straightened CAUTION Be sure the contact springs you are aligning are either all left hand or all right hand springs 3 Place the bottom edge of the teeth of the comb between two vertical rows of contact springs REISEN COMB TEETH ANCHORED ON THIS ROW OF CONTACTS 4 Place the bottom edge of the teeth against N the base of the contact springs in the row adjacent to those being straightened 5 Push against the top of the contact springs with the comb It may be necessary to bend the contact springs beyond the normal Series 2040 Test System 63 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
32. ion does not match the stored configuration AMS TH Cont CPU P S Cont AMS MSP ISO ASB AMS MSP ISO TH P S Cont Arly AFET TH Cont CPU TH P S Cont Arly AFET RMUX AMS AFET RMUX AMS MRLY Selftest TH Cont CPU MRLY RMUX AMS RMUX TH Cont CPU P S Cont RMUX AMS Selftest RMUX AMS MDE ASB TH Cont CPU P S Cont ASB AMS MDE ASB AMS MDE ASB AMS MDE ASB AMS MSP ISO ASB AMS MDE ASB AMS MSP ISO MDE TMS AMS MDE TMS AMS MDE TMS AMS MDE TMS AMS MDE TMS AMS MDE TMS AMS MDE TMS AMS AMS MDE TMS AMS MDE TMS TMS TH Cont CPU P S Cont TMS MDE AMS TMS MDE TH P S Cont DIO Selftest TH P S Cont Series 2040 Test System Series 2040 Maintenance Manual V2 00 dio ext f iamp dig f inst f amp cmrr f isoamp f pwr mon f ptest f th iso f msp ser f ocio dig f ocio f ocio rail f adio f adio ext f ams int f dms dig f dms mem f psc dig f Series 2040 Test System DIO INST INST INST MSP ISO Power Supply Selftest amp Calibration Selftest TH P S Cont TH Cont CPU P S Cont ASB AMS RMUX AMS ASB AMS TH P S Cont MSP ISO UUT Controller AMS RMUX Selftest Scope Connected MSP OCIO OCIO OCIO ADIO ADIO AMS DMS DMS PSC Internal coax short TH Cont CPU P S Cont TH Cont CPU P S Cont Selftest TH Cont CPU Selftest TH Cont CPU Selftest TH Cont CPU Selftest TH Cont CPU MDE TH Cont CPU Selftest TH Cont CPU TH Cont CPU P S Cont Any ot
33. ition of the D within the board cavity 4 Place the end of a medium size screwdriver against the end of the barrel at the base of the blade Then press with a slow and even pressure until the ears are seated on the board As the ears reach the surface of the board you will feel the locking tab snap into the locked position 5 Check the replacement contact spring to see that it is properly aligned with the adjacent springs 66 Series 2040 Test System
34. le r Printer Options Options select either Fail Data Only or O Fai Data Log Summary 5 OAI Data Footer Only Data and select Diagnostic G No Data 3 desired calibration and function tests 20 Series 2040 Test System Series 2040 Maintenance Manual 2 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 in the digalogibinY directory The filename is the date on which the test was run with the file extension dxx where xx is an incrementing number starting at 01 and going through 99 For example if the diagnostic file was written on January 20 1997 the file name would be jan2097 d01 If a second file were created on the same day its name would be jan2097 d02 and so on The first SelfExec file written each day would carry the extension d01 If SelfExec s file option is not set to Diagnostic the file extension would be 001 002 and so on These files do not contain the configuration information required by STEX and will not be accepted as proper files for analysis by S
35. lftest Executive with the three most likely boards or assemblies that could cause failures Test Name 1 2 3 1 AMS RMUX 5 RMUX MSP ISO 2 5 SIC3 c AMS MSP ISO RMUX 3 AMS DIFF AMS RMUX ICAM 4 DMS c DMS 5 ASB MSP ISO AMS 6 vc ASB MSP ISO AMS 8 c DIO TH CONT CPU Selftest 9 ADIO c ADIO TH CONT CPU Selftest 10 ADIO dac c ADIO AMS RMUX 12 c TMS AMS 13 MDE TGDC c MDE TMS AMS 15 POWER c UUT Cont AMS RMUX Selftest 17 ISOAmp c MSP ISO AMS RMUX 16 Series 2040 Test System Series 2040 Maintenance Manual V2 00 Selftest amp 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 Series 2040 Test System 17 Selftest amp Calibration Series 2040 Maintenance Manual V2 00 18 Series 2040 Test System Series 2040 Maintenance Manual 2 00 Diagnostics Diagnostics Series 2040 Test System 19 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 STEX uses the results of the diagnostic output file to show the configuration of the tester and
36. lot 23 ot 24 lot 25 lot 26 a a E ojojo S e a configuration is shown below Series 2040 Test System 29 Diagnostics 30 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 Power Supply Configuration Unit Patchboard Connection 55v 105 Serial 0 Serial 1 FES Channel 1 DEVW5 Series 2040 Maintenance Manual V2 00 Patch Board Pin Definitions ATOS eee 1 AGND Analog ground DGND Digital ground Wire all product digital signal low s to DGND Wire all product analog signal low s to AGND AGND and are tied in the tester do not tie on the PatchBoard If the UUT has analog and digital grounds tied it cannot be helped 2 Dn ASBs XRnn are the Extemal Reference inputs for the DAs DAs are paired and only the first channel of the pair is listed KRO4 is external ref input for 4 and Da 5 ete 3 On DIOs Dnnn are drivers and are receivers 4 Mnnn Relay Mux Channel nnn 5 Annn Aux Relay Channel nnn B Annn Aux Fet
37. ly will program its output s to 0 0V 9 0 0A disable its output s and assert its fault output signal If an HP power supply detects an internal error condition it will then drive its Fault output line low to signal the next HP power supply positioned below it in the loop Eventually the fault signal will reach HP P S 0 and it in turn will trigger the PSC board The PSC board will then latch HP P S fault condition and drive all of its fault output connections including that for the HP power supplies This will fault all of the HP power supplies positioned after the one which detected the internal error condition The initial faulting HP power supply will also have its Inhibit input connection driven low the power supply following it To determine which HP power supply detected an internal error condition press the Local button and then the Prot button on each HP power supply All of the HP power supplies that were faulted by their following brethen via their inhibit input lines will display the letters which stands for Remote Inhibit in its LCD display The single HP power supply that displays something other than RI in its LCD display is the power supply that detected an internal error condition Consult its operating manual to determine the cause of the internal error condition If some or none of the HP power supplies are disabled via their fault inhibit loop connections when the PSC board d
38. m the test results use the View Log File menu item Refer to the Selftest documentation to aid in interpreting these test results Close Selecting this menu item closes the currently selected diagnostic file and clears all result information from the program s windows This clears the on screen Testhead board configuration and removes any individual test results from the Report Details window This menu item is provided only for the convenience of the user It is not mandatory to Close one test before opening another for exam However it may be used to provide an obvious separation in the examination of different test result sets Exit Selecting this menu item closes the current diagnostic file clears configuration information from the program and closes and exits the program D DIGALOG BINWan2997 d01 File Help o 0 o 0 0 o 5 5 E jes Testhead Power Supply o 9 oS Product HE Power Supply AA UA m Controller Computer 7 Controller Problems Found 24 Series 2040 Test System Series 2040 Maintenance Manual 2 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 ge
39. ms with the tester Viewing the individual failures of a test may aid in troubleshooting an individual board Examining any system error messages and referring to documentation for the source and or meaning of the error may also help in resolving the problem with the tester resources While viewing this file the user may also elect to print the file contents IMPORTANT The file being examined SHOULD NOT be edited Changing any information in these files could render the information inaccurate or useless for diagnosing any problems with the tester Report Details This menu item is only available while there is a valid diagnostic file with fail information opened for examination Report Details is a listing of the individual Selftest programs that show at least one fail or system error during its execution Selecting this menu item will bring up a separate window Fie with a list of the failed test Test Name Slot Number Fault Type programs This list gives the name of the Selftest which had the problem the slot number of the board being examined by that test and whether the problem with the test was a test fail or a system afet rft f Unknown Failis Series 2040 Test System 23 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 fro
40. nerated 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 ini and can be used by other Digalog System s applications Specifically the software is capable of printing out a Patchboard Map containing Patchboard pin mnemonics by either automatically interrogating the tester for its resources or by asking the programmer to define the tester s resources When the configuration is performed manually it allows the programmer to configure additional resources beyond what the tester physically contains In this manner a programmer has the additional resources to generate programs and fixtures for any tester Tester Resource MANager d digalog include resource ini File Options Help 3 4 4 5 5 J K L M AGND DA12 DGND AGND DA13 016 AGND 14 R16 AGND 0 15 D17 AGND DA16 R17 AGND 041 D D18 AC M SR AGNo ma 11 AGND 0 23 D21 13 Mi kam om wm opu 14 AGND 20 6 R22 A16 m ma Al ae 08 024 18 18 R8 R24 Menu Bar File Menu The TRMAN File menu is similar to the standard Windows file Series 2040 Test System 25 Diagnostics Series 2040 Maintenance Manual V2 00 New Config Read Config from Registry Register Confi
41. o connects to the Testhead Power Supply Controller Some of these supplies may have more than one output channel In these situations each separate output of each supply is assigned its own channel or unit number Programming is accomplished using Digalog s PowerUUT functional call Over under voltage current limits for these supplies and channels are listed in the resource cat file For programming purposes these power supplies act in the same manner as the Digalog UUT Product Power Supplies Troubleshooting Hewlett Packard Power Supplies The fault inhibit loop for the Hewlett Packard power supplies links each HP power supply serially with each other and with the PSC board It is completely independent of the UUT P S controllers external fault loop and the fault loop for each non HP GPIB power supply The PSC board will recognize a fault generated by the HP fault inhibit loop only if the registered power supply configuration set up by TRMAN contains at least one HP power supply whose resource cat entry has its Fault Capable property set to 1 The LED on the PSC board will turn off whenever an HP power supply has either detected an internal error condition such as overvoltage or has been faulted by the PSC board but only after a HP power supply has been programmed following a Testhead power up or the TClear event The fault signal driving the HPF LED on the PSC is not latched Also if the rese
42. onnect board 6 Repeat steps 4 5 for the second and all subsequent relay disconnect boards up to and including the last relay disconnect board 7 Jumper shunts 7 8 which connect the corresponding inhibit and fault signals on the last relay disconnect board must be installed Verify continuity from pin 3 of connector through jumper shunt 8 to pin 4 of connector P2 which connects to fault inhibit cable for the HP power supply Verify continuity from pin 4 of connector P1 through jumper shunt 7 to pin 3 of connector P2 8 Otherwise verify that pin 74 relative to pin 3 of connector P2 is low or at a logic 0 If not a problem exists on the relay disconnect board in its fault inhibit cable or with the HP power supply s inhibit input pins Verify the continuity of each wire in the fault inhibit cable Series 2040 Test System 39 Diagnostics Series 2040 Maintenance Manual V2 00 40 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 1 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 9 Otherwise verify that an arrow exists above the word Prot on the LCD display If not the HP power supply itself is faulty 10 Otherwise veri
43. program from the Windows Explorer The Selftest Executive menu will be displayed as shown on the next page 3 From the File menu select Configure and the small Report Series 2040 Test System 9 Selftest amp Calibration Series 2040 Maintenance Manual V2 00 10 EXECUTIVE RUN TIME 1 10 100 Continuous FH Stop Configuration Summary Test Summary 34 File No Data Cycle Window Fail Data Menu Printer No Data Program Log Not Selected Total Fails 1 calibrate 41 61 81 2 Jfunctional 42 62 82 3 43 63 83 4 44 64 84 5 45 65 85 6 46 66 86 47 67 87 8 48 68 88 3 49 69 89 10 50 70 90 1 51 71 91 12 52 72 92 13 53 73 93 14 54 74 94 15 55 75 95 16 56 76 96 17 57 77 97 18 58 78 98 19 59 79 99 20 60 80 100 Utilities dialog box in shown on the pep next page will appear This box contains pie Options three separate ways of reporting the Fail Data C Log Summary Data 0 Footer Only data collected during the tests Data O No Data may be stored to a file displayed on the window Options Fail Data Log Summary screen and or printed O No Data In addition each of these three Printer Options O Fail Data O Log Summary reporting functions can report All OAI Data O Footer Only Data
44. quency time reference A precision digital to analog converter TDAC contained within the Selftest Assembly is used as a voltage reference for system calibration Purpose Of Calibration Calibration of the functional tester is necessary to obtain gain and offset terms for all signal paths that exist within the system and to determine timing for the MDE s Measurement Display Electronics sweeps delays triggers and measurement mark Since potentiometers are used in only a few instances where factory calibration is required the majority of the calibration is done by taking measurements and calculating calibration terms which can be referenced at a later time These terms are used by the hardware functional calls to account for gains offsets and timing discrepancies and their use is transparent to the user In all calibration programs limits are set on what values any given calibration term may take on If a calculated value is outside of the allowable range a failure will result and be displayed printed to the designated output device When To Calibrate Selftest is the best guide to determine if calibration is required The battery of Selftest programs is designed to test all functions of the 2040 to their specifications If any failures occur during Selftest especially borderline failures calibration should be carried out before proceeding to troubleshoot the system Running through Selftest periodically can tell you if calibration
45. rt the board until resistance is felt At this time it is crucial to ensure that the pointed ends of the Patchboard pins are properly aligned with the receptacles on the board When the alignment is correct a slight give will be felt as the pins begin to seat At this point place your thumbs on the white tabs and firmly seat the board Ensure that it is fully seated by comparing the position of the rear edge of the board with the rear edge of neighboring boards If excessive resistance is encountered or a high pitched metallic noise is heard stop and remove the board or damage to the pins and or receptacles may occur CAUTIONI Repeat the procedure from the beginning y Observe Precautions ForHandling In some cases temporary removal of boards 4 Electrostatic in adjacent slots may be helpful sensitive Devices 62 Series 2040 Test System Series 2040 Maintenance Manual 2 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 If the springs are severely bent or bent vertically they must be replaced When damage to the springs is minor and repairable they may be straig
46. ry locations Automatic Generation If Automatic Generation is selected the program scans the tester for its resources and then updates the map of the Patchboard as shown on the next page Tester resources required to generate the Patchboard map plus any other tester resources can also be saved to a resource file on the hard drive resource ini stored in the Registry or printed out All programmers writing code for the system should be familiar with this map since it is the actual physical configuration of the Patchboard Series 2040 Test System Series 2040 Maintenance Manual 2 00 Diagnostics Tester Resource MANager d digalog include resource ini Options Help Manual Generation If Manual generation is selected the screen below will be displayed Note that the Power Supply Distribution board is always in slot O and therefore does not show in the Testhead Manual Configuration F sito z Testhead P S Cont with Trigger Matrix Series 2040 Test System 27 Diagnostics Series 2040 Maintenance Manual V2 00 28 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 selec
47. stem 53 Module Repair and Replacement Series 2040 Maintenance Manual V2 00 5VDC Testhead Power Supply 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 Fasteners 2 Remove the five fasteners for the filter housing plate as shown above and remove the plate from the cooling fan assembly 3 Loosen the two Testhead retaining screws located along the back of the black Testhead cover by turning them 1 4 turn counterclockwise Using the handle lift the Testhead into the position shown on the next page 4 Remove the hazard cover from the Testhead by removing the mounting screw from each end of the cover 5 Disconnect the supply wiring harness from connector J13 on the Testhead Power Supply Controller board 54 Series 2040 Test System Series 2040 Maintenance Manual 2 00 Module Repair and Replacement Testhead Boards Retaining P 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
48. t jumper shunt on the PSC board is installed only the Proximity Switch LED will turn off when the Patchboard fixture handle is disengaged It will then turn back on when the handle has re engaged The PSC board will drive its HP fault inhibit loop connection low every time that it detects a fault from any source whether or not any HP power supplies are registered or even present Series 2040 Test System 37 Diagnostics Series 2040 Maintenance Manual V2 00 For a system containing 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 Upon its detection that HP P S n has driven its Inhibit input signal low HP P S n 1 will then fault HP P S n 2 using its fault output connections Thus each HP P S in the fault loop will fault the power supply preceding it in the loop all the way to HP 5 0 The Fault output lines of HP P S 0 connect to the PSC board which allows that power supply to signal the PSC board that an error has been detected by one of the HP power supplies Upon detection of an internal error condition such as overvoltage or the external inhibit input signal the HP power supp
49. t 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 The first screen prompts for the user s name the serial number of the 8840 Fluke multimeter in the Calibration Station This number can be found on a Digalog tag inside the Calibration Station next to the meter It also prompts for the Selftest Assembly serial number and the serial number of the tester itself Confirm Info When the information is entered the last setup screen will appear requesting a verification of the information that was entered If any of the information is incorrect it can be modified or changed at this time The operator s name Selftest serial number and Fluke 8840A meter serial number must be entered and verified before the unit can be certified Click on the Certify button and the program checks the TDAC signal Test results and a pass fail condition are displayed in the 46 Series 2040 Test System Series 2040 Maintenance Manual V2 00 Certification screen shown below Fil Certification of TDAC in Assembly 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
50. tage fault has occurred in a Patchboard power supply The power supply causing the fault will have it s respective LED extinguished Power could also have been removed from the Patchboard without generating a fault condition In this case the reason that the power has been removed is indicated by one or two of the lower four status LEDs being extinguished CASE PROX PBON Ext Fault Reset Power Call on off on on TCLEAR on off on off Patchboard removed off on on on UUT Power Fault on on off on When a power supply cannot be restored by resetting the unit the circuit breaker for the offending supply should be checked for continuity A graphic of the circuit breakers on the edge of the Testhead Power Supply Controller board is shown on page 14 of this section If any of these breakers continually trips the associated power supply must be replaced Series 2040 Test System 31 Diagnostics Series 2040 Maintenance Manual V2 00 Breakers and Test Points LED Indicators 5VDC TH 48VDC TH DC1 DC1 GPIB 3 GPIB 2 Hen GPIB 1 GPIB 0 DENS 40VDC 40VDC 40VDC TH 40VDC TH 5VDC TH 19VDC TH 19VDC TH 15VDC TH 15VDC PB 15VDC PB 15VDC TH 5 TPS 5VDC PBF ave 15VDCTH HP Fault Fa DES PROX PBON TP3 Ext Fault Common Reset 15VDC PB 3 1 15VDC 15VDC l TPAZ 1 5VDC PB 32 Series 2040 Test System Series 2040 Maintenance
51. ted the jog shuttle located to the right modifies the selected value The option buttons under the jog shuttle control determine what position in the serial loop that the supply being defined occupies However the variable supplies must be filled in a contiguous manner from 0 to 74 The spin control on the upper left corner of the dialog is used to determine which programming channel is being configured If a GPIB or HPIB power supply is being defined or added the channel and type can be selected and the upper right of the dialog changes to allow the programmer to select a power supply type a GPIB HPIB Device number and what Relay Control board will be used The spin control on the middle left of the dialog Patchboard Connection is used to define which of the five Patchboard connections are connected to which supply or if a GPIB HPIB supply will use an external output i e the supply s output does not physically appear on the Patchboard The rest of the Testhead is displayed in table format by slot number The Description and Board Number drop down menus are directly linked to and will modify the table The Clear All button will clear all configuration items Board Codes are specific identifiers for the particular type of board selected for that slot Board Numbers are used to define the resources of that particular board For example if there are two of the same type of board in the system board numbers zero and one the resources of
52. tem Series 2040 Maintenance Manual 2 00 Module Repair and Replacement Module Repair amp Replacement Series 2040 Test System 49 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 2 Return the defective part and reference the RMA number All equipment being returned to Digalog Systems should be shipped prepaid and insured at the customer s expense 3 All circuit boards to be returned to Digalog Systems must be shipped in static shielding bags and packed in anti static packaging material Digalog Systems will pay the return freight within the continental United States on a warranty issue Digalog Systems is not liable for consequential shipping damages 4 Out of warranty repairs will be done on a time and materials basis or may be covered under a Support Agreement 50 Series 2040 Test System Series 2040 Maintenance Manual 2 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
53. the Testhead CONTACT SPRING REPLACEMENT Conventional Method To remove a damaged contact spring when the removal tool is not available use the following procedure Series 2040 Test System 65 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 0 will clear the cavity opening 3 Face the front of the board and grasp the damaged contact spring across the chevron with a needle nosed pliers With a steady even pressure pull straight out on the contact spring until it is free and clear of the board and then destroy the contact spring immediately To install a new contact spring in the board the following steps are recommended 1 Be sure that you have the proper contact spring right hand or left hand whichever is required the chevron contact area should be facing the general direction of the bottom left or bottom right corner of the frame 2 The Digalog part numbers for the springs are as follows Right Hand 2825 1011 Left Hand 2825 1012 3 Orient and start the contact spring by hand according to the pos
54. the wiring for the new Testhead fan assembly exactly as the old wiring was routed 8 To reinstall the supply reverse steps 1 7 Series 2040 Test System 55 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 PCSO 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 Directly beneath a second rack contains from left to right PS1 a Kikusui or Kenwood PD 35 20 and a Kikusui PD55 10 Kenwood PD56 10 The bottom rack is heavy so care is suggested in handling it The three power supply controllers are identical To adapt them to the different characteristics of each supply a configuration card unique for each supply is inserted into the front of each controller To replace a configuration card ensure that the power to the controller is shut off and pull the black tabs and remove the card To install reverse the process Programmable Power Supply Controllers Power Supplies 56 Series 2040 Test System Series 2040 Maintenance Manual 2 00 Module Repair and Replacement UUT POWER SUPPLY CONTROLLER REPLACEMENT WARNING Remove main power from tester before pro
55. then click on certify to start the test Again the results and a pass fail condition are displayed For the portion dealing with the the measured value must not from the programmed value by more than the designated limits or failure will result If this happens manual adjustment must be made Contact Digalog Systems should this occur Series 2040 Test System 47 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 im ICAM SELFTEST BOARD CERTIFICATION 92 4381 910 4392 9126 783 90905 457 912377 45 9009916 4 Connect the ICAM Certification cable from the white connector on the ICAM Selftest board to the Fluke 8840 Multimeter The ICAM IMON measurement certification tests the circuitry over six different ranges with the results displayed to the right of the dialog The result of the current certification is also displayed If any of these readings are out of range the small box adjacent to the result will appear red instead of green 48 Series 2040 Test Sys
56. tion constants are derived during Calibration These constants are used during runtime to maintain system accuracy The Calibration constants are stored on the hard drive and reloaded at powerup Complete system auto calibration is achieved without any pots to adjust The Selftest programs use the Selftest Assembly to test all circuits to their published specifications and assure that all paths and modules are functional The System Maintenance guide is written for troubleshooting to the module and circuit board level The tester shall be disconnected from all power sources before it is opened for any adjustment replacement maintenance or repair If service repairs performed under power become necessary the repairs shall be performed by a skilled technician who is aware of the hazard involved Series 2040 Test System 5 Maintenance Overview Series 2040 Maintenance Manual V2 00 6 Series 2040 Test System Series 2040 Maintenance Manual V2 00 Selftest amp Calibration Selftest amp Calibration Series 2040 Test System 7 Selftest amp 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 fre
57. upply 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 Adjust any pins that are misaligned remount the Selftest Assembly and re test After the common problems have been eliminated a failure in Functional Selftest can indicate a hardware problem Since a failure in Functional Selftest could also be caused by calibration recalibrate the unit and run Functional Selftest again If calibration or Functional Selftest fails now a hardware problem most likely exists Refer to the Selftest Failure Analysis on the next two pages Series 2040 Test System 13 Selftest amp Calibration Selftest Failure Analysis Test Name 1 SELF dig f 2 th config tst 3 ams dig f 4 ams mode f 5 ams sig3 f 6 7 arly dig f 8 arly f 9 afet rft f 10 11 mrly dig f 12 mrly f 13 14 rmux dig f 15 rmux f 16 rmux prt f 17 18 19 20 21 arb mem f 22 arb brst f 23 arb ext f 24 arb freq f 25 arb mon f 26 ref f 27 da ref f 28 29 30 mde dlmd f 31 mde dltm f 32 mde expm f 33 mde freq f 34 mde mrkp f 35 mde msmk f 36 mde pmes f 37 mde tgfl f 38 mde tglv f 39 40 41 tms dig f 42 tms evnt f 43 tms test f 44 45 dio f 14 Series 2040 Maintenance Manual V2 00 1 2 3 Selftest TH Cont CPU TH P S Cont Testhead configurat
58. y 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 If the resource is a board in the Testhead an arrow with a number 1 3 according to its gg IUUUUUUUUUUUI Choice 1 Info Choice 2 Info Choice 3 Info AMS Part Number 5002 Serial Number 1018 Serial Number 1022 relative importance 1 being greatest will point to the location of the board An information box with the same number will display the board s description Digalog part number and serial number if this information is available in the diagnostic file If the tester resource is not a board in the Testhead the resource s graphic will be highlighted in red with a label indicating which Choice it is in relative importance The information box with the Choice information will have resource s description and other optional information regarding that resource If the SelfExec test TH config test has logged fails in the current diagnostic file a message box will be shown informing the user that this fault exists Also the Results box will display the message Config problems found on a red background The configuration of the Testhead will be displayed but no specific tester resources will be tagg

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