Digalog Systems 2040D Series Maintenance Manual

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Series 2040D Test Systems

2040D

Maintenance

Manual

Part Number #4200-0181

Version 1.0

Table of Contents

Summary of Contents for Digalog Systems 2040D Series

Page 1 Series 2040D Test Systems 2040D Maintenance Manual Part Number #4200-0181 Version 1.0...
Page 2: Table Of Contents
Table Of Contents System Overview ... 3 SYSTEM MAINTENANCE OVERVIEW ... 5 Selftest & Calibration ... 7 SELFTEST AND CALIBRATION OVERVIEW ... 8 Purpose Of Calibration ... 8 When To Calibrate ... 8 SELFTEST ... 9 Selftest Failure Analysis ... 14 CALIBRATION ...
Page 3 CONTACT SPRING REPAIR ... 63 USE OF PATCHBOARD SPRING REMOVAL TOOL (0000-2746) ... 64 CONTACT SPRING REPLACEMENT (Conventional Method) . 65...
Page 4: System Overview
Series 2040 Maintenance Manual V2.00 Maintenance Overview System Overview Series 2040 Test System...
Page 5 Maintenance Overview Series 2040 Maintenance Manual V2.00 Series 2040 Test System...
Page 6: System Maintenance Overview
Series 2040 Maintenance Manual V2.00 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.
Page 7 Maintenance Overview Series 2040 Maintenance Manual V2.00 Series 2040 Test System...
Page 8: Selftest & Calibration
Series 2040 Maintenance Manual V2.00 Selftest & Calibration Selftest & Calibration Series 2040 Test System...
Page 9: Selftest And Calibration Overview
Selftest & Calibration Series 2040 Maintenance Manual V2.00 SELFTEST AND CALIBRATION OVERVIEW Calibration on the Series 2040 Functional Test System is completely automated. All calibration is based on high precision references built into the system Testhead and the Selftest Assembly. A high precision Temperature Compensated Crystal Oscillator (TCXO) on the Time Measurement System Board (TMS) is used as a frequency/time reference.
Page 10: Selftest
Series 2040 Maintenance Manual V2.00 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:...
Page 11 Selftest & Calibration Series 2040 Maintenance Manual V2.00 Utilities” dialog box in shown on the next page will appear. This box contains three separate ways of reporting the data collected during the tests. Data may be stored to a file, displayed on the screen and/or printed.
Page 12 Series 2040 Maintenance Manual V2.00 4) Once the type(s) of reporting is completed, click on “OK” to return to the Selftest Executive menu. Select “Functional” from the Selftest Executive screen, and the Functional menu will appear as shown below. The Functional test menu has been organized so that tests closely related are blocked together in groups.
Page 13 Selftest & Calibration Series 2040 Maintenance Manual V2.00 “:” (Colon) signifies that the following number indicates the amount of iterations to perform of the previous sequence. ‘,’ (Comma) shares the definition of ‘E’ as a separator between sequences. ‘-’ (Dash) signifies inclusive or ‘through’. EXAMPLE: E1-3:5,6-100:2,1-5 This sequence executes tests 1 through 3 five times, tests 6 through 100 two times, and tests 1 through 5 once.
Page 14 Series 2040 Maintenance Manual V2.00 check the Selftest assembly’s cable for damage. UUT POWER SUPPLIES OFF - Make sure the UUT Power Supplies are on. TESTHEAD POWER SUPPLY FAULT - Check the Testhead Power Supply Controller’s indicator LEDs. If any of the LEDs are not lit, reset the system and recheck.
Page 15: Selftest Failure Analysis
Selftest & Calibration Selftest Failure Analysis Test Name SELF_dig-f th_config_tst Testhead configuration does not match the stored configuration. ams_dig_f ams_mode_f ams_sig3_f arly_dig_f arly_f afet_rft_f mrly_dig_f mrly_f rmux_dig_f rmux_f rmux_prt_f arb_mem_f arb_brst_f arb_ext_f arb_freq_f arb_mon_f arb_ref_f da_ref_f mde_dlmd_f mde_dltm_f mde_expm_f mde_freq_f mde_mrkp_f mde_msmk_f mde_pmes_f...
Page 16 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 Selftest INST TH Cont/CPU INST INST RMUX MSP/ISO Power Supply TH P/S Cont UUT Controller AMS/RMUX Scope Connected? Internal coax short?
Page 17: Calibration
Selftest & Calibration CALIBRATION Whenever a Testhead board is replaced, or any time that Selftest determines a failure, a calibration must be performed. If a unit passes the complete Functional Selftest routine, a calibration is not necessary. When Calibrate is selected from the Selftest Executive, the screen shown to the right is displayed.
Page 18 Series 2040 Maintenance Manual V2.00 Selftest & Calibration Any type of failure during calibration could indicate a hardware problem. If a failure during Functional was the reason that a calibration is being run, refer to the Selftest Failure Analysis sheet on page 8 of this section. Series 2040 Test System...
Page 19 Selftest & Calibration Series 2040 Maintenance Manual V2.00 Series 2040 Test System...
Page 20: Diagnostics
Series 2040 Maintenance Manual V2.00 Diagnostics Diagnostics Series 2040 Test System...
Page 21: Diagnostic Tools
Diagnostics 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 evaluate possible problems with the tester resources based on failed test data and/or system errors during testing.
Page 22: Analyzing Selftest Data
Series 2040 Maintenance Manual V2.00 Diagnostics Selection of the ‘Diagnostic’ option for file output will create a file with all the information required by STEX to analyze the system. This information includes the tester type being run, a listing of the Testhead resources as recorded in the ‘resource.ini’...
Page 23 Diagnostics Series 2040 Maintenance Manual V2.00 All tester resources, by default, are either gray-colored or on gray background. The one to three resources calculated to be most likely causing the fault(s) will be highlighted in red. Also, the ‘Results:’ box on the lower portion of the form displays the information regarding these three tester resources.
Page 24 Series 2040 Maintenance Manual V2.00 Diagnostics If any failure(s) or problem(s) are found in a valid diagnostic file, the menu item ‘Report Details’ will be enabled to show some details about those tests. See item ‘Report Details’ for more information. If the diagnostic file is examined, and no fails or other problems were found with this test, the ‘Results:’...
Page 25 Diagnostics Series 2040 Maintenance Manual V2.00 error. If a test listed did not have any slot information listed in the results, the slot will be listed as ‘Unknown’. To view the details of each individual fail or system error number from the test results, use the ‘View Log File’ menu item. Refer to the Selftest documentation to aid in interpreting these test results.
Page 26: Trman (Tester Resource Manager)
Series 2040 Maintenance Manual V2.00 Diagnostics TRMAN (Tester Resource Manager) The Tester Resource Manager is used to track and manage the tester resources including all the boards in the Testhead and the UUT power supplies. Information about these resources can be automatically generated or manually defined, and is used to generate a Patchboard Interface Map and define the pin locations of these resources at the Patchboard.
Page 27 Diagnostics file in the \Digalog\include\ directory. Options Menu - When the Options menu is selected, a pull-down menu will be displayed prompting for a choice of the following: Auto- matic generation, Link to tester, Manual Gen- eration, View pin Definitions, and View Testhead configuration.
Page 28 Series 2040 Maintenance Manual V2.00 Manual Generation - If Manual generation is selected, the screen below will be displayed. Note that the Power Supply Distribution board is always in slot 0 and therefore does not show in the Testhead Series 2040 Test System Diagnostics...
Page 29 Diagnostics 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).
Page 30 Series 2040 Maintenance Manual V2.00 The table is directly linked to the slot drop-down menu, therefore any slot changes in either place will be reflected in the other. View Testhead Configuration - This utility displays the entire Testhead configuration in an organized format. An example of a typical Testhead configuration is shown below.
Page 31 Diagnostics 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.
Page 32: Testhead - Patchboard - Uut P/S Built-In Diagnostics
Series 2040 Maintenance Manual V2.00 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.
Page 33: Breakers And Test Points
- 19VDC TH + 15VDC TH + 19VDC TH - 15VDC PB + 5VDC TH + 15VDC PB + 5VDC PBF +/- 15VDC TH HP Fault Patchboard Power Ext. Fault + 5VDC +/- 15VDC Series 2040 Test System DC1 - PROX...
Page 34 Series 2040 Maintenance Manual V2.00 Diagnostics FAULT LOOP The Series 2040 Test System incorporates a “fault loop” for troubleshooting and self-diagnostics. The cable between the UUT Power Supply Controller and the Testhead, besides providing a path for the power supply output, contains the fault loop.
Page 35 Diagnostics Series 2040 Maintenance Manual V2.00 Series 2040 Test System...
Page 36 Series 2040 Maintenance Manual V2.00 Diagnostics Series 2040 Test System...
Page 37 Diagnostics Series 2040 Maintenance Manual V2.00 Series 2040 Test System...
Page 38: Gpib/Hpib Power Supplies
HP power supply whose “resource.cat” entry has its “Fault Capable” property set to “1.” The “HPF” 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”...
Page 39 Thus, each HP P/S in the fault loop will “fault” the power supply preceding it in the loop all the way to HP P/S #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.
Page 40 #3 of connector P1 through jumper shunt #8 to pin #4 of connector P2 (which connects to the 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.
Page 41 Diagnostics and verify that each wire is connected to the proper terminal on the HP power supply. The HP power supply may be configured to use its inhibit input pins as simply digital I/O pins. Consult its operating manual to determine the correct position of the internal configuration jumper shunt for “Fault/Inhibit”...
Page 42 Series 2040 Maintenance Manual V2.00 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.
Page 43 Diagnostics Series 2040 Maintenance Manual V2.00 Series 2040 Test System...
Page 44: Certification
Series 2040 Maintenance Manual V2.00 Certification Certification Series 2040 Test System...
Page 45 Certification Series 2040 Maintenance Manual V2.00 10MHz TDAC 10 M H Z E X T C L K E X T E V E N T G P IB P R IN T E R E T H E R N E T C O M 1 K E Y B O A R D GPIB...
Page 46: Certification
Series 2040 Maintenance Manual V2.00 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.
Page 47 Certification Series 2040 Maintenance Manual V2.00 Calibration Station. Finally, connect the GPIB port from the 2040 console to the GPIB port on the Calibration Station. To run the program select the certification icon from the Atart/ Programs/Digalog program group, and the screen to the right will appear prompting for the type of calibration.
Page 48 Series 2040 Maintenance Manual V2.00 Certification screen shown below. When this portion of the certification is complete, the TCXO frequency must be checked. The procedure for the frequency certification is identical, except for the final screen displaying the frequency counter. The user should wait until the frequency is stable, and then click on certify to start the test.
Page 49 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.
Page 50: Module Repair & Replacement
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement Module Repair & Replacement Series 2040 Test System...
Page 51: Repair And Replacement Procedures
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.
Page 52: Computer Assembly
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement COMPUTER ASSEMBLY When it is determined that a problem exists in the computer assembly itself, the entire assembly must be sent back for repair. To remove the computer assembly, proceed as follows: 1) Ensure that the main power cord is unplugged from the wall outlet.
Page 53: Internal And Patchboard P/S Overview
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.
Page 54: Testhead & Patchboard P/S Replacement
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement TESTHEAD & PATCHBOARD POWER SUPPLY REPLACEMENT WARNING! Remove main power from tester before proceeding. 1) Ensure that the main power cord is unplugged from the wall outlet. 2) Remove the two side panel mounting screws from the console as shown to the right.
Page 55: 5Vdc Testhead Power Supply
Module Repair and Replacement +5VDC Testhead Power Supply The Testhead cooling fan assembly contains the main +5VDC Power Supply for the Testhead. If it is determined that the supply is faulty, the recommended procedure would be replacement of the entire assembly as described below: 1) Remove the four screws on the sides of the Testhead cooling fan assembly, and draw the assembly towards you 2 to 3 inches.
Page 56 Series 2040 Maintenance Manual V2.00 Module Repair and Replacement Testhead Boards Retaining Screws Remove the assembly through this opening. 6) Disconnect the AC fan power cord from the Testhead section of the AC Distribution box. 7) Remove and replace the assembly through the Testhead bay, taking care to route the wiring for the new Testhead fan assembly exactly as the old wiring was routed.
Page 57: Uut Power Supplies - Description
Module Repair and Replacement Series 2040 Maintenance Manual V2.00 UUT POWER SUPPLIES - Description Contained in the middle rack of the unit are the product power supply controllers. Each one controls a single product supply. The controllers are arranged PCS2, PCS1, and PCS0 from left to right. (This is a typical installation. Individual systems may vary.) To the right of the controllers, PS2, a Kikusui PDA110-1.5L, completes the top power supply rack.
Page 58: Uut Power Supply Controller Replacement
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement UUT POWER SUPPLY CONTROLLER REPLACEMENT WARNING! Remove main power from tester before proceeding. To remove a controller, remove the upper and lower retaining screws from the front of the console. The controller should slide directly forward. Place the controller to be installed on the floor directly beside the controller being replaced.
Page 59: Uut Power Supplies
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.
Page 60: Gpib/Hpib Power Supplies
Series 2040 Maintenance Manual V2.00 Module Repair and Replacement GPIB/HPIB POWER SUPPLIES 1) Remove the left side panel (side opposite the computer) to gain access to the rear of the power supplies. 2) Disconnect the AC power cords from the AC/DC Distribution Box, and disconnect the GPIB cable, Fault/Inhibit cable, and power output cable from the rear of the supply.
Page 61: Uut - Gpib/Hpib P/S Disconnect At Test Bay
Module Repair and Replacement UUT - GPIB/HPIB POWER SUPPLY DISCONNECT AT TEST BAY From top to bottom: PS3 - Jumper PS4 - Jumper All unused power supplies must be jumpered. This is a typical installation. Individual systems may vary. Also note, the GPIB/HPIB power supplies may be externally connected to the fixture/UUT.
Page 62: Circuit Board Replacement
Series 2040 Maintenance Manual V2.00 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.
Page 63 Module Repair and Replacement Series 2040 Maintenance Manual V2.00 Spread these tabs. Spread these tabs. Pin Guide To reinstall a board, first check the positioning of the black plastic pin guide to ensure that the beveled openings are aligned with the receptacles on the board.
Page 64 Series 2040 Maintenance Manual V2.00 Module Repair and Replacement CONTACT SPRING REPAIR Alignment of the contact springs (pins) in the Patchboard receiver of the Digalog Series 2040 Test System is critical. Misaligned or bent pins can cause failures in the system. It is possible that one or more contact springs may become damaged in one way or another.
Page 65 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.
Page 66 Series 2040 Maintenance Manual V2.00 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 “D”shaped latching tab Patchboard...
Page 67 Module Repair and Replacement 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”...