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HP (Hewlett-Packard) 2040D manual

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Table of contents for the manual

  • Page 1

    Series 2040D T est Systems 2040D Maintenance Manual P art Number #4200-0181 V ersion 1.0[...]

  • Page 2

    T able Of Contents System Overview ......................................................................................... 3 SYSTEM MAINTENANCE OVERVIEW ................................................ 5 Selftest & Calibration .................................................................................. 7 SELFTEST AND CALIBRA TION OVERVI[...]

  • Page 3

    CONT ACT SPRING REP AIR ............................................................. 63 USE OF P A TCHBOARD SPRING REMOV AL TOOL (0000-2746) ...... 64 CONT ACT SPRING REPLACEMENT (Conventional Method) . 65[...]

  • Page 4

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Maintenance Overview 3 System Overview[...]

  • Page 5

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Maintenance Overview 4[...]

  • Page 6

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Maintenance Overview 5 SYSTEM MAINTENANCE OVERVIEW The Series 2040 T est 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 Assemb[...]

  • Page 7

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Maintenance Overview 6[...]

  • Page 8

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 7 Selftest & Calibration[...]

  • Page 9

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 8 SELFTEST AND CALIBRA TION OVERVIEW Calibration on the Series 2040 F unctional T est System is completely automated. All calibration is based on high precision references built into the system T esthead and the Selftest Assembly . A high precision T emperature[...]

  • Page 10

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 9 SELFTEST Selftest on the Series 2040 T est System is an automated procedure. The programs that comprise Selftest are organized under the Selftest Executive in a test menu called “F unctional”. These programs exercise the hardware functions available to th[...]

  • Page 11

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 10 Utilities” dialog box in shown on the next page will appear . This box contains three separate ways of reporting the data collected during the tests. Data may be stored to a file, displayed on the screen and/or printed. In addition, each of these three rep[...]

  • Page 12

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 11 4) Once the type(s) of reporting is completed, click on “OK” to return to the Selftest Executive menu. Select “F unctional” from the Selftest Executive screen, and the F unctional menu will appear as shown below . The F unctional test menu has been o[...]

  • Page 13

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 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 ‘thro[...]

  • Page 14

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 13 check the Selftest assembly ’s cable for damage. UUT POWER SUPPLIES OFF - Make sure the UUT P ower Supplies are on. TESTHEAD POWER SUPPL Y F AUL T - Check the T esthead P ower Supply Controller’s indicator LEDs. If any of the LEDs are not lit, reset the [...]

  • Page 15

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 14 Selftest F ailure Analysis T est Name #1 #2 #3 1 ) SELF_dig-f Selftest TH Cont/CPU TH P/S Cont 2) th_config_tst T esthead configuration does not match the stored configuration. 3) ams_dig_f A M S TH Cont/CPU TH P/S Cont 4) ams_mode_f A M S M SP /I S O A S B [...]

  • Page 16

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 15 46 ) dio_ext_f DIO Selftest TH P/S Cont 47) 48) iamp_dig_f INST TH Cont/CPU TH P/S Cont 49 ) inst_f INST A SB A M S 50) amp_cmrr_f INST RMUX AM S 51) isoamp_f MS P/ ISO A SB A M S 52) 53) pwr_mon_f P ower Supply TH P/S Cont MS P/ISO 5 4) ptest_f UUT Controll[...]

  • Page 17

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 16 CALIBRA TION Whenever a T esthead board is replaced, or any time that Selftest determines a failure, a calibration must be performed. If a unit passes the complete F unctional Selftest routine, a calibration is not necessary . When Calibrate is selected from[...]

  • Page 18

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 17 Any type of failure during calibration could indicate a hardware problem. If a failure during F unctional was the reason that a calibration is being run, refer to the Selftest F ailure Analysis sheet on page 8 of this section.[...]

  • Page 19

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Selftest & Calibration 18[...]

  • Page 20

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 19 Diagnostics[...]

  • Page 21

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 20 DIAGNOSTIC TOOLS SelfT est 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[...]

  • Page 22

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 21 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 T esthead resources as recorded in the ‘ resource.ini’ fil[...]

  • Page 23

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 22 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 [...]

  • Page 24

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 23 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 pr[...]

  • Page 25

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 24 error . If a test listed did not have any slot information listed in the results, the slot will be listed as ‘Unknown ’. T o view the details of each individual fail or system error number from the test results, use the ‘ View Log F ile’ menu item. Refer to the Sel[...]

  • Page 26

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 25 TRMAN (T ester Resource Manager) The T ester Resource Manager is used to track and manage the tester resources including all the boards in the T esthead and the UUT power supplies. Information about these resources can be automatically generated or manually defined, and is[...]

  • Page 27

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 26 menu. It has selections for a N ew configuration, L oad an existing configuration, Sa v e a configuration, Sav e an existing configuration As another file, and E x it. The P rint Utility as shown below will be discussed later in this section. For the purposes of this expla[...]

  • Page 28

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 27 Manual Generation - If Manual generation is selected, the screen below will be displayed. Note that the P ower Supply Distribution board is always in slot 0 and therefore does not show in the T esthead[...]

  • Page 29

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 28 configuration table. F rom 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 [...]

  • Page 30

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 29 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 T esthead Configuration - This utility displays the entire T esthead configuration in an organized format. An example of a typical T es[...]

  • Page 31

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 30 View Pin Definitions - This utility from the Options menu explains the mnemonics used in the P atchboard 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 t[...]

  • Page 32

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 31 TESTHEAD - P A T CHBOARD - UUT P/S BUIL T -IN DIAGNOSTICS When a malfunction is suspected in either the T esthead Internal or P atchboard P ower Supply system, the LED status indicators should be examined. The top LEDs are labeled for their respective power supplies as sho[...]

  • Page 33

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 32 LED Indicators +48VDC TH DC1 - DC1 + GPIB 3 GPIB 2 GPIB 1 GPIB 0 - 40VDC (ICAM) + 40VDC (ICAM) - 5.2VDC TH + 5VDC TH - 19VDC TH + 19VDC TH - 15VDC TH + 15VDC TH - 15VDC PB + 15VDC PB + 5VDC PBF HP F ault PROX PBON Ext. F ault Reset Breakers and T est Points + 5VDC PB + 15V[...]

  • Page 34

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 33 F A UL T L OOP The Series 2040 T est System incorporates a “fault loop ” for troubleshooting and self-diagnostics. The cable between the UUT P ower Supply Controller and the T esthead, besides providing a path for the power supply output, contains the fault loop. If th[...]

  • Page 35

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 34[...]

  • Page 36

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 35[...]

  • Page 37

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 36[...]

  • Page 38

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 37 GPIB/HPIB POWER SUPPLIES The Series 2040 T est System may also contain one or more GPIB/HPIB P ower Supplies. These supplies communicate with each other and the computer via an IEEE-488 bus. In addition, they use a F ault/Inhibit loop for voltage/current protection and thi[...]

  • Page 39

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 38 F or a system containing “n ” number of HP power supplies, the PSC board drives the +Inhibit (input) line of HP P/S #n low relative to its -Inhibit (input) line. When this power supply detects that its +Inhibit input signal is low , then it drives its +F ault (output) [...]

  • Page 40

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 39 1) V erify on the relay controller board (0000-5X44) that pin #3 relative to pin #4 of connector P3 (PSC P ort) 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)[...]

  • Page 41

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 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 I/O pins. Consult its operating manual to determine the correct position of the internal configurati[...]

  • Page 42

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 41 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 (F ault/Inhibit Bypass) must be installed.[...]

  • Page 43

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Diagnostics 42[...]

  • Page 44

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Certification 43 Certification[...]

  • Page 45

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Certification 44 ETHERNET PRI NTE R GPI B Z Y X 10M HZ EX TC LK EX TEV ENT KEYB OARD COM1 MODEM 10MHz TDAC GPIB[...]

  • Page 46

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Certification 45 CERTIFICA TION 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 T echnology (NIST). There are two elements of the Series 2040 F unctional T est Syst[...]

  • Page 47

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Certification 46 Calibration Station. F inally , connect the GPIB port from the 2040 console to the GPIB port on the Calibration Station. T o run the program select the certification icon from the Atart/ Programs/Digalog program group, and the screen to the right will appear prompting for[...]

  • Page 48

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Certification 47 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 [...]

  • Page 49

    Series 2040 Test System Series 2040 Maintenance Manual V2.00 Certification 48 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 [...]

  • Page 50

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 49 Module Repair & Replacement[...]

  • Page 51

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 50 REP AIR 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 n[...]

  • Page 52

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 51 COMPUTER ASSEMBL Y When it is determined that a problem exists in the computer assembly itself , the entire assembly must be sent back for repair . T o remove the computer assembly , proceed as follows: 1) Ensure that the main power cord is unplugged from[...]

  • Page 53

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 52 INTERNAL AND P A T CHBOARD POWER SUPPL Y OVERVIEW The T esthead P ower Supply Controller monitors T esthead power supplies for overvoltage with OVP crowbar IC’s. When an overvoltage is detected, the OVP IC quickly short circuits the offending power supp[...]

  • Page 54

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 53 TESTHEAD & P A T CHBOARD POWER SUPPL Y REPLACEMENT 1) Ensure that the main power cord is unplugged from the wall outlet. 2) Remove the two side panel mounting screws from the console as shown to the right. 3) Lift up on the side panel and remove it. 4[...]

  • Page 55

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 54 +5VDC T esthead Power Supply The T esthead cooling fan assembly contains the main +5VDC P ower Supply for the T esthead. If it is determined that the supply is faulty , the recommended procedure would be replacement of the entire assembly as described bel[...]

  • Page 56

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 55 6) Disconnect the AC fan power cord from the T esthead section of the AC Distribution box. 7) Remove and replace the assembly through the T esthead bay , taking care to route the wiring for the new T esthead fan assembly exactly as the old wiring was rout[...]

  • Page 57

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 56 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 instal[...]

  • Page 58

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 57 UUT POWER SUPPL Y CONTROLLER REPLACEMENT T o 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 t[...]

  • Page 59

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 58 UUT POWER SUPPLIES The removal process for UUT P ower Supplies and GPIB/HPIB P ower 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 Supp[...]

  • Page 60

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 59 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, F ault/Inhibit cable, an[...]

  • Page 61

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 60 UUT - GPIB/HPIB POWER SUPPL Y DISCONNECT A T TEST BAY F rom top to bottom: PS0 PS1 PS2 PS3 - Jumper PS4 - Jumper All unused power supplies must be jumpered. This is a typical installation. Individual systems may vary . Also note, the GPIB/HPIB power suppl[...]

  • Page 62

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 61 CIRCUIT BOARD REPLACEMENT The illustration below shows the positions of the boards in a typical Series 2040 T est 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 T esthead) and are ded[...]

  • Page 63

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 62 T o 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. P osition the board’s leading edge in the top and bottom card guides for the T esthead s[...]

  • Page 64

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 63 CONT ACT SPRING REP AIR Alignment of the contact springs (pins) in the P atchboard receiver of the Digalog Series 2040 T est System is critical. Misaligned or bent pins can cause failures in the system. It is possible that one or more contact springs may [...]

  • Page 65

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 64 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-meta[...]

  • Page 66

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 65 Plunger Patchboard “D” shaped sleeve “D”shaped latching tab Board Side of Patchboard 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 a[...]

  • Page 67

    Series 2040 T est System Series 2040 Maintenance Manual V2.00 Module Repair and Replacement 66 1. Remove the termination from the rear of the spring . (Remove the T esthead 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[...]