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921B

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2. 1000 O 4 000 x 0 010 Resistance Displayed Value x 250 O C 6 Table C 5 4 V 4 99k Pullup Resistance Option using Resistance Fixture PN 921 811 02 Resistance Switch Position Displayed Value Volts Tolerance Step 10 Step 11 Step 12 0 0 V 0 000 0 040 1 000 0 040 2 000 0 040 3 3 V 3 000 0 040 4 000 0 040 Consult the factory if any of the resistance values fail to meet the specified requirement This completes the resistance calibration verification Power down the unit Disconnect the ac power cord from the primary power source Disconnect Test Tool PN 921 811 09 from the Resistance Cable P2 connector If the potentiometer was adjusted apply a small amount of Glytol to the potentiometer adjustment screw being sure some Glytol is applied between the screw and the body of the potentiometer If no further internal adjustments are to be made install the rear panel on the unit using the four screws removed in step 1 C 7 APPENDIX D Displacement Verification Procedure Test Tool Required Force Displacement Gauge Fixture PN 905 378 Displacement Gauge Mitutoyo PN 543 146 or Equivalent Align Parallel 2 204 28 Figure D 1 Fixture with Gauge WARNING The Service Mode operates the moving platform at some service mode steps Never operate the unit without the platform properly setup with the test fixture height adjusted to provide a suitable stop for the platform force
3. 2 204 8 Figure 1 3 Precision Drive Mechanism Showing Corrugated Cable and 37 Pin Connector y 2 204 7 Figure 1 4 25 Pin M F Sub D Serial Cable PN 905 390 101 1 8 2 204 6 Figure 1 5 25 Pin M 9 Pin Female Serial Cable PN 905 390 102 2 204 9 Figure 1 6 Two Clip Generic Nest Assy PN 921 140 101 2 204 10 Figure 1 7 Four Clip Generic Nest Assy PN 921 140 102 1 9 SECTION 2 SETUP AND INTERCONNECTION 2 1 HARDWARE The power entry module C Figure 1 1 must be set for the user s facility power The 921A is normally supplied configured for 110 120 V ac 60 Hz To reconfigure the 921A for 220 240 V ac 50 60 Hz rotate the slideout voltage selector and position it accordingly Plug the power cord into the 921A power entry module 110 120V 220 240V and into a properly grounded outlet 2 2 PC CONNECTION The 921A must be connected to a PC to upload configuration data to the station or download test data to the PC Connect a PC with an open communication channel to the 921A using the serial communication cable supplied with the unit see Figure 1 4 or 1 5 between the PC Serial COM port connector and 921A connector J1 A Figure 1 1 Tighten the connector securing screws to ensure a secure connection Ifthe cable supplied with the 921A is not long enough a generic 1 1 25 pin D type extension cable can be used with the cable supplied 2 3 SOFTWARE Refer to DFR Operations Software Manual Typ
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5. SERVICE RUN switch on the unit rear panel in the SERVICE position Turn on the unit The Service Mode is used to perform the calibration adjustment The Service Mode requires pressing the TEST READY switch on the front panel to increment or step through the various service mode display screens The TEST READY switch must be depressed and held for at least 1 second prior to release to ensure the unit will recognize that the switch is pressed After successful completion of the power up self test the unit displays the Force Calibration Mode message The Force Calibration will not be performed as part of this procedure However the unit must be sequenced through the service mode Force Calibration screens by pressing the TEST READY switch on the front panel Press TEST READY once Force Offset Value displayed Press TEST READY again Platform moves until Force Cal value is reached and stops C 2 Step 5 Step 6 Rear Panel Mounting Screws 4 2 204 4 Figure C 1 921A Rear Panel Press TEST READY again The platform returns to the home position The resistance Offset Adjustment Mode message is displayed Install the Offset Gain Jumpering Connector part of PN 921 811 XX on the Resistance Cable PN 921 112 P2 Connector Do not remove the jumpering connector until instructed to do so by this procedure Press the TEST READY switch once The unit displays the offset values for the resistance current source channel Fig
6. and press READY The message CALIBRATION IN PROCESS vwill be displayed The sensor will move in to the block or vice clamp and back out twice This process provides the exact positioning force and resistance data required to accurately test a device When the calibration cycle is complete the READY indicator will illuminate the CAL indicator will extinguish and the message INSTALL DEVICE THEN PRESS READY will be displayed This message indicates that the calibration cycle is complete All references have been obtained and the 921A is ready to test the selected device The calibration cycle can be run whenever desired by pressing the MODE Switch This is useful if the operator suspects the original calibration has changed For example if the sensor has been moved by more than 1 inch the original calibration will be invalid and a new calibration cycle will be necessary to reestablish calibration After the MODE switch has been pressed the message INSTALL DISTANCE REFERENCE GAUGE or ENSURE PEDESTAL SETUP for CAL PRESS READY WHEN INSTALLED PRESS CAL TO ABORT will be displayed 4 2 This message indicates that a calibration cycle has been initiated Ifan operator accidentally pressed the MODE switch he she now has the option to abort the calibration cycle by pressing the CAL switch The 921A will retain the former calibration values and be prepared to test another device Whenever a different Configuration is installed the di
7. and the new device configuration requires a different calibration Whenever the 921A is in Calibration Mode only the CAL indicator is illuminated Press the Mode CAL switch to enter the Calibration Mode If the configuration parameters include a Reference Block Size Ref BIk Size value other than zero refer to the DFR Operations Software Manual for details the display will prompt for installation of the Distance Reference Gauge at this point then to press test See restrictions Appendix A If the Ref BIk Size value is zero or not applicable in the configuration then the message Ensure Pedestal Setup for CAL is displayed Press TEST when ready 4 1 If the configuration uses resistance then the Generic Nest Assembly or equivalent must be connected to the DF for calibration If the four clip version PN 921 140 102 is used the Red clips l and S must be connected together and the black clips I and S must be connected together for the purpose of calibration The red and black clips cannot be shorting together or to a metal surface Failure to properly setup the Generic Nest or equivalent will result in a calibration failure message when calibration is attempted The calibration process corrects out all system offsets and hardware deviations so that the device to be tested is the only unknown Install the block or tighten the vice clamp together Position the sensor approximately 1 2 inch above the block or vice clamp
8. be within the range listed below for your transducer type for proper calibration Type Nominal Acceptable Range 3 6 kg 0 075 kg 0 025 to 0 200 kg 360 g 7 59 2 5 to 20 0 g 759 1 69 5 to 4 2g 2 0 kg 0 038 kg 0 012 to 100 kg 750 g 159 5 to 42g 50 Ib 1 04 Ib 35 Ib to 2 80 Ib 20 Ib 0 38 Ib 0 12 to 1 00 Ib Turn on the force gauge Select the units kg or g and zero the force gauge Press the TEST READY switch once The unit drive mechanism will operate until the unit force transducer is in contact with the force gauge and reaches the calibration force level The unit displays the adjust force pot s message for Force Gauge value and displays Force Measured Value Refer to Figure B 5 and adjust the GAIN 1 and or the GAIN 2 potentiometer until the unit force Measured Value is equal to the force gauge value within the tolerance listed below for your transducer type Adjustment Specification Type Tolerance Tolerance 3 6 kg x 003 kg 010 kg 360 g 0 4g 2 0g 759 0 1g 0 5g 2 0 kg x 002 kg x 005 kg 750g 0 8g 3 89 50 Ib 0 04 Ib 0 25 Ib 20 Ib 0 02 Ib x 0 10 Ib B 2 Step 8 Step 9 Step 10 Press the TEST READY switch once When the platform mechanism stops moving power down the unit Repeat steps 4 through 8 until the step 6 offset is within acceptable range and the step 7 Measured Value is within adjustment tolerance without requiring further potentiometer adjustment at steps 6 and 7 It typically tak
9. connector from the Resistance Cable P2 connector Connect the Resistance Test Box Part of PN 921 811 XX connector to the Resistance Cable P2 Connector Tables C 2 through C 5 provide the switch settings and verification criteria for the different Resistance Option types Use the appropriate table for the Resistance Option installed in the 921A Set the Resistance Test Box Resistance switch to each position listed in the appropriate table below and verify that the value displayed by the unit CH1 equals the corresponding value listed in the table within the tolerance specified C 5 Table C 2 4 O 10 mA or 25 mA Resistance Option using Resistance Fixture PN 921 811 09 Resistance Switch Position Displayed Value O Tolerance 1 0 Q 0 000 010 2 10 1 000 010 3 20 2 000 010 4 3 Q 3 000 010 5 3 8 Q 3 800 010 6 025 Q 0 025 010 7 050 Q 0 050 010 8 075 Q 0 075 010 Table C 3 16 kO 25 mA Resistance Option using Resistance Fixture PN 921 811 01 Resistance Switch Position Displayed Value Tolerance 0 0 kO 0 000 x 0 010 1 4 kQ 1 000 x 0 010 2 8 kQ 2 000 x 0 010 3 12 kQ 3 000 x 0 010 4 16 kQ 4 000 x 0 010 Resistance Displayed Value x 4000 Q Table C 4 1 kO 1 mA Resistance Option using Resistance Fixture PN 921 811 07 Resistance Switch Position Displayed Value Tolerance 0 0 Q 0 000 x 0 010 1 250 Q 1 000 x 0 010 2 500 Q 2 000 x 0 010 3 750 Q 3 000 x 0 010 4
10. switch or externally by the PC During the test sequence sensor data is logged in 921A memory Test data is then analyzed parameters are calculated and the results are compared with the configuration criteria to determine a pass or fail status The PASS or FAIL indicator then illuminates Upon completion of the test sequence the 921A is ready to test the next device The 921A stores test criteria for one device configuration and up to 32 test results PC operating mode in non volatile memory so that once loaded the station will retain the test criteria even upon power down Device configurations are identified by device part numbers The operator s display indicates which device is currently being tested by displaying the part number of the device in the left hand corner of the display For a complete description of operating modes configuration parameters test results test algorithms and the details for creating configurations and viewing results refer to the DFR Operations Software Manual 1 3 Hi FRONT PANEL E BACK PANEL Figure 1 1 921A Controls and Indicators 2 204 4 1 4 TABLE 1 2 CONTROLS AND INDICATORS Refer to Figure 1 1 A Back Panel Connector J1 the serial communication channel connector used to connect the 921A to a PC using the supplied serial cable Figure 1 4 or 1 5 B SERVICE RUN Select Switch active only when power is first applied to the 921A This switch is placed in
11. transducer Step 1 Adjust the height of the Drive Mechanism to provide a suitable stop for the drive mechanism force transducer D 1 Step 2 Step 3 Step 4 Connect the Drive Mechanism to the rear panel connector per section 2 ofthe 921A User s Manual Connect the ac power cord to the unit and to primary power source Place the SERVICE RUN switch on the unit rear panel in the SERVICE position Turn on the unit The Service Mode is used to perform the calibration adjustment The Service Mode requires pressing the TEST READY switch on the front panel to increment or step through the various service mode display screens The TEST READY switch must be depressed and held for at least 1 second prior to release to ensure the unit will recognize that the switch is pressed After successful completion of the power up self test the unit displays the Force Calibration Mode message The Force Calibration will not be performed as part of this procedure However the unit must be sequenced through the Service Mode Force Calibration screens by pressing the TEST READY switch on the front panel Press TEST READY once Force Offset Value displayed Press TEST READY again Platform moves until Force Cal Value is reached and stops Press TEST READY again The platform returns to the home position If the unit is equipped with the Resistance Option Resistance Offset Mode is displayed If not the Lamp Test Mode message is displayed Press T
12. 0mA 921 811 09 4 Q 25mA 921 811 09 16 kQ 25mA 921 811 01 1 kO 1 mA 921 811 07 4 V 4 99k Pullup 921 811 02 Each fixture consists of The Resistance Test Box a 37 pin to 15 pin adapter cable and the Offset Gain Jumpering Connector Resistance Test Box Offset Gain Jumpering Connector WARNING DANGER There is 115 V or 230 V ac voltages present within the unit Service is to be performed by qualified personnel only Use only plastic adjustment tools Do not touch or come in physical contact with any wires components or assemblies within the unit or severe injury or death can result C 1 Step 1 Step 2 Step 3 Step 4 WARNING The Service Mode operates the moving platform at some service mode steps Never operate the unit without the platform properly set up with the test fixture height adjusted to provide a suitable stop for the platform force transducer Power down the unit Disconnect the ac power cord from the primary power source Remove the rear panel from the unit four screws figure C 1 and lay down on a flat surface Adjust the height of the Drive Mechanism to provide a suitable stop for the platform force transducer Connect the Drive Mechanism and Resistance Cable PN 921 112 to the rear panel connectors per section 2 of the 921A User s Manual however do not connect P2 of the resistance cable to a nest Connect the ac power cord to the unit and to the primary power source Place the
13. Contents as INTBODUETION ee 2 SETUP AND INTERCONNECTION eeeeeeee eene 2 1 Hardware nenne each 22 EEN uper ER PRO NR tates 2 3 SOIN EE 2 4 Precision Drive Mechanism Setup Connection 2 5 Electrical Resistance Connection Optional 2 6 Generic Nest Assembly Connection Optional 2L User cT 2 8 Force Transducer Tips 2 8 1 Interchangeable Force Transducer Tips 2 8 2 75 g 360 g and 750 g Transducer Tips 2 9 Changing Force Transducer Assemblies 3 CONFIGURA TIO N BE Ca DM KE E WEE CP SO KE EE A OPERATION BE 4 1 Calibration Mode EE 5 SERVICE amp ADJUSTMENTS eeice rien eene conn rr xen Rana andan 9 1 296r VIC B leie EE 5 1 1 Force GallbFallOlza secet us oa aee xc Pee dut tera a de bog uon 5 1 2 Resistance Offset Resistance Option Only e E EE le REH 5 1 4 Resistance CCA Code Switch Installed Resistance Option Only sssssssesss 5 1 5 Pressure Code Agen 5 1 6 Displacement Verification sseeeesessessssss P TROUBLESHOOTING tne ccu c c cur co ecce aco an Appendix A Restrictions and DF Warning Problem Failure Message Descriptions Appendix B Force Transducer CCA Calibration Appendix C Resistance Adjustment Verification Appendix D D
14. EST READY switch as required until the Displacement Verification Mode message is displayed then proceed to step 4 Assemble the Displacement Gauge to Fixture PN 905 378 as shown in Figure D 1 using the bolt provided Be certain the gauge is mounted with the plunger parallel to the side of the fixture see Figure D 1 Install the assembled fixture with gauge on the 921A baseplate optional or equivalent such that the displacement gauge plunger is slightly depressed D 2 Step 5 approximately 1 16 inch when contacting the Force Transducer Assembly adjust the height of the drive mechanism as necessary as shown in Figure D 2 Prior to proceeding with the displacement test the operator needs to become familiar with the test method Table D 1 provides the approximate displacement locations to test When the TEST READY switch is pressed and released the drive mechanism will begin incrementing moving into the displacement gauge The 921A displacement value is presented on the unit display The drive mechanism is incremented until the displacement reaches 0 2000 inch standard 0001 inch lead screw or until the TEST READY switch is pressed and held in The drive mechanism will remain stationary as long as the TEST READY switch is held in actuated By monitoring the displacement value on the unit display and pressing holding the TEST READY switch the operator can stop the platform at the approximate displacement points listed i
15. The READY indicator illuminates when the 921A is ready for another device test sequence The indicator extinguishes when a test sequence is initiated or if the 921A is not ready to accept a device for test 2 The TEST switch is a pushbutton switch which when illuminated is pressed to initiate a test sequence This switch is also used to initiate a calibration cycle when the 921A is in Calibration Mode NOTE The READY indicator does not indicate when to press the TEST switch Its function is only to indicate that the 921A is ready for another test cycle H TEST STATUS FAIL Indicator illuminates red after a test sequence in which a device fails one or more of the specified test parameters out of tolerance MODE Switch CAL Indicator has two functions 1 The MODE switch is used to initiate a calibration cycle 2 The CAL indicator illuminates green when the 921A is in the Calibration Mode 1 6 TABLE 1 6 CONTROLS AND INDICATORS Cont J POWER Indicator illuminates green when the 921A is turned on with power applied K SYSTEM STATUS Operator s Display contains two 40 character lines which supply information about 921A operation such as the part number and version of the device configuration being tested This display also prompts the operator concerning necessary actions such as Install Device and Press Ready etc 1 7 Figure 1 2 Resistance Cable 15 Pin M F Sub D Optional PN 921 112
16. ble Force Transducer Tips 2 0 kg 3 6 kg and 50 Ib Transducers 2 4 Notes 1 Table 2 1 J2 Connector Wiring PIN SIGNAL 1 INSTALL 2 CH1 SENSE 3 CH1 SENSE 4 5 6 7 8 CH1 SRC 9 CHASSIS GROUND 10 11 12 13 14 SIGNAL GND 15 CH1 SRC Pin 9 chassis ground is provided for shield termination If user designed nests have wire lengths in excess of 8 inches those wires should be shielded If the user nest is to be used in an electrically noisy environment the wiring should be metal en closed with the metal enclosure chassis grounded Pin 1 INSTALL signal provides a device installed interlock for testing The test cycle will not initiate unless the Install signal is grounded connected to Pin 14 The user designed nest can incorporate a switch which is actuated when a device is in stalled in the nest thereby grounding the Install signal The user s nest design can defeat the interlock by jumpering Pin 1 to Pin 14 if the interlock function is not required 3 Pin 3 CH1 SENSE applies only to the 4 O resistance options 2 5 WARNING Care must be taken whenever handling the force transducer These transducers are easily dam aged The 2 0 kg 3 6 kg and 50 Ib transducers are supplied with protective stops for overload under compression However tension or rota tional forces applied in excess of 150 of full scale rating will permanently damage the trans ducer The 2 0 kg 3 6 kg and 50 Ib fo
17. e 921A is turned on it has no reference for measurement and must perform a calibration cycle as discussed in paragraph 4 1 to establish measurement references If the display indicates a mismatch the system setup and device are not compatible with the stored configuration See Appendix A 3 1 SECTION 4 OPERATION After the 921A has been configured it is ready for operation Turn on the 921A and allow it to perform its self test routine and enter the Calibration Mode The operator s display contains two lines of information The first line provides data about the device test configuration i e the device part number the version of the device configuration and the work order if applicable This information is dependent upon the device test parameters stored in memory for the configuration The second line of the display provides instructions for the operator Note A valid configuration must be previously installed using the PC DFR Operations Software If not refer to the DFR Operations Software Manual and create install a configuration in the 921A prior to proceeding 4 1 CALIBRATION MODE The Calibration Mode is used to obtain measurement references and is automatically entered upon the successful completion of a self test routine It can also be entered by pressing the MODE switch on the front panel whenever the operator s display indicates READY The 921A will also enter the Calibration Mode if the Configuration is changed
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19. e transducer assembly Bubble wrap and protect the force transducer tip Place the transducer assembly in an antistatic bag for ESD protection Install the new transducer on the precision drive mechanism in the reverse order of removal above Be sure to secure the transducer interconnect cable to the tie downs with tie wraps as shown in Figure 2 7 The critical tie down area is the first tie down nearest the transducer The cable must be secured to this tie down using two 2 tie wraps 90 to each other and tightened securely The cable should not be able to be slide through this tie down if pulled with moderate force The cable from the transducer to this tie down also cannot drag or come in contact with any surface during platform move ment or the system will not operate properly 2 8 The remaining two tie down areas are not critical for performance The cable should be tied down to these as shown in Figure 2 9 to provide the service loop for operation Be sure sufficient slack in the cable is provided so that the precision drive mechanism limit switch the furthest extended outward posi tion is actuated with some slack remaining When the platform is in the home position furthest retracted inward position there must also be some slack remaining in the cable 2 9 Screws 5 2 204 16 2 204 15 Figure 2 5 Figure 2 6 Screws 2 Screws 4 2 204 19 Figure 2 7 Figure 2 8 Screws 2 Tie downs Tie d
20. es performing steps 4 through 8 at least three times to achieve correct adjustment Apply a small amount of Gilytol to the potentiometer adjustment screw being sure some Glytol is applied between the screw and the body of the potentiometer This completes the force transducer calibration Install the cover on the head assembly with the screws removed in step 1 Remove the L bracket with force gauge from the baseplate Remove the force gauge from the L bracket Store force gauge and tip in original shipping case for protection B 3 Screws 12 2 204 21 Figure B 1 Drive Mechanism Assembly Cover Removal B 4 Figure B 2 L Bracket Gauge 2 204 22 2 204 24 B 5 n S i ork m n r d a I S SC aem Ri x RUNS Figure B 3 Force Gauge with Tip 2 204 23 B 6 Figure B 4 Center Gauge to Transducer Tip B 7 OFFSET GAIN2 GAIN 1 2 201 43 Figure B 5a Resistance Pot Locations Force Transducer CCA Type 1 2 204 26 GAIN2 GAIN1 OFFSET Figure B 5b Resistance Pot Locations Force Transducer CCA Type 2 B 8 AFFENDIA v Resistance Adjustment Verification Resistance Option Only Test Tool Required Resistance Verification Fixture PN 921 811 XX See Table C 1 for the complete part number of the fixture required based on the Resistance Option Type installed in the Model 921A Table C 1 Resistance Option Type Resistance Fixture PN 4 Q 1
21. f the opening in the rear panel Carefully mate the cable connector with the connector recessed in the rear panel opening Secure with the two screws removed above 2 Screws NEED ER Figure 2 2a Figure 2 2b 2 3 2 5 ELECTRICAL RESISTANCE CONNECTION OPTIONAL The 5 foot 15 pin Subminiature D Male Female connector cable supplied with the resistance option is used to connect either the supplied generic nest assembly or the user s nest to the 921A refer to Figure 1 2 2 6 GENERIC NEST ASSEMBLY CONNECTION OPTIONAL Two types of Generic Nest Assemblies are available a two clip version and a four clip version The type must be specified when ordering PN 921 140 101 Two Clip Version Resistance channel source and sense plus red clip are connected together and channel source and sense minus black clip are con nected together This nest does not allow 4 wire resistance measure ment PN 921 140 102 Four Clip Version Resistance channel source l and sense S plus are separated and supplied with red clips Resistance channel source I and sense S minus are separated and supplied with black clips This nest allows performing 4 wire Kelvin resistance measurements with the 4 Q resistance options 2 7 USER NESTS Table 2 1 shows the wiring of the 15 pin connector J2 on the rear of the unit This information is provided for users who wish to wire their own nests 2 8 FORCE TRANSDUCER TIPS 2 8 1 Interchangea
22. from baseplate Remove and store gauge in original shipping case for protection D 4 Table D 1 Displacement Verification Table Approximate Unit Measurement Mitutoyo Displacement Measurement D 5
23. g 400 g 75 g etc However each force transducer assembly must be specifi cally calibrated on the 921A unit on which it is used Transducer assemblies calibrated on the same unit can be interchanged without recalibration Refer to section 5 1 for transducer calibration information 2 7 WARNING DO NOT TOUCH THE TRANSDUCER TIP DUR ING HANDLING OR INSTALLATION REMOVAL OR PERMANENT DAMAGE MAY RESULT Use proper ESD Handling procedures during installation removal and handling packaging anti static the force transducer assembly Failure to comply may result in damage to the equipment The transducer assembly consists of the force transducer the force trans ducer circuit card assembly CCA and the CCA transducer interconnect cable To remove the transducer assembly from the precision drive mechanism remove the cover from this assembly as described in Appendix B step 1 Remove the five 5 screws holding the left side plate to the back plate of the precision drive mechanism Figure 2 5 Loosen the two 2 screws securing the harness connector to the force transducer CCA then disconnect this connector Figure 2 6 Remove the four 4 screws securing the force trans ducer CCA to the side plate Figure 2 6 Carefully cut the tie wraps securing the force transducer assembly interconnect cable to the platform tie downs Figure 2 7 Support the force transducer and remove the two 2 mounting screws Figure 2 8 Carefully remove th
24. g points outward With the 0001 lead screw this is approximately 25 of travel in and out when operating in the 1 step log mode Note that this travel is the test range travel free position to bottomout and not total platform travel If the test travel range exceeds the 2 500 data log points more than approx 25 then invalid results will occur The configuration must be changed to increase the steps log i e 2 steps log provides 5 test travel with the standard 0001 lead screw The user must configure the parameters properly for the device under test to ensure the test travel does not exceed the logging capacity of the system or the test results data will be invalid Ref BIk Size Restriction Two restrictions apply to the Distance Reference Gauge and Ref BIk Size One is the combination of the platform travel and the Ref BIk size cannot exceed 6 5535 inches The other is the location or reference point established during the calibration cycle using the Distance Reference Gauge and Ref BIk Size must occur further inward than device bottomout during device testing In other words the reference point must be further more travel away from the platform home position than the device bottomout point during testing Failure to comply with these restrictions will cause invalid results A 1 uapej3nsuoo sisisieduuego dd J uonexre PSYO UIED 9204 POEL ISON Ui PUO ur3ou si Jjeonpsuei 93104 J ESOU dn gt peq a 1S3 L pou pu
25. ical Test Fixture Setup 2 1 WARNING Set up unit for facility power 115 or 220 Vac prior to connecting to facility power see paragraph 2 1 110 120 VAC OR 220 240 VAC 15 PIN MALE MODEL 921A 15 PIN FEMALE RESISTANCE CABLE L J DFTESTSTATION 32 PES GENERIC NEST PN 921 140 OR USER NEST 25 PIN MALE SERIAL CABLE SERIAL COM CHANNEL PRECISION DRIVE 25 PIN FEMALE MECHANISM 9 PIN OPTIONAL Figure 2 1 921A DF Test Station Interconnect 2 2 2 4 PRECISION DRIVE MECHANISM SETUP CONNECTION A suitable test fixture or vice should be used to hold the device for test The drive mechanism force sensor must be centered over the device button dome etc to which force is to be applied The sensor must not be in contact with the device for test allow at least a 1 16 inch gap If the optional platform was purchased the height of the force sensor above the device for test can be easily adjusted by loosening the knobs and raising and lowering the Precision Drive Mechanism to the desired position and tightening the knobs WARNING Support the Precision Drive Mechanism when loosening the knobs or the mechanism will slip on the post possibly damaging the force transducer and or the device under test The Precision Drive Mechanism cable connector connects to the rear of the 921A electronic unit using the two screws provided Refer to Figure 2 2 Carefully remove the two screws at the sides o
26. isplacement Verification Procedure SECTION 1 INTRODUCTION The Model 921A Displacement Force DF Test Station operation is similar to the highly acclaimed Models 951A and 961A Test Stations The high accuracy and many of the features of the 951A and 961A have been incorporated in the 921A Testing on the 921A is performed using remote test fixtures similar to the 961A The remote operation permits testing a wide variety of components devices and also allows the 921A to operate as part of a fully automated test line Keyboards springs switches and other components requiring measurement of displacement force or resistance one channel optional can be tested manually individually or with automatic feed The 921A is also ideally suited for engineering investigation and new product development Table 1 1 lists the specifications of the 921A When interfaced with a personal computer PC the resulting test data can be viewed analyzed and printed The 9214 stores test criteria for one test configuration To assure simplicity of operation and efficient effective error free use by anyone the test station displays operator prompts and provides a minimum of operator controls a MODE switch and a TEST switch Three operating modes are featured 1 Local a pass fail indication is provided during standalone operation test results are not stored 2 PC a PC interfaces with the test station and is used to configure device test criteria and vie
27. l the assembled L bracket with force gauge on the 921A baseplate or equivalent such that the force gauge tip is centered under the 921A drive mechanism assembly force transducer refer to Figure B 4 Place the SERVICE RUN switch on the unit rear panel in the SERVICE position The Service Mode is used to perform the calibration adjustment The Service Mode requires pressing the TEST READY switch on the front panel to increment or step through the various service mode display screens The TEST READY switch must be depressed and held for at least 1 second prior to release to ensure the unit will recognize that the switch is pressed Turn on the unit After successful completion of the power up self test the unit displays the FORCE CALIBRATION MODE message Press the TEST READY switch once The message to Adjust Force Pot and the Offset value is displayed The force transducer offset adjustment is performed using this display B 1 Step 5 Step 6 Step 7 There are two types of force transducer CCAs which are illustrated in Figures B 5a and B 5b Examine your unit s force transducer CCA to determine which type is on the unit Reference figure a or b accordingly to perform the adjustments of steps 6 7 and 8 Adjust the force transducer CCA potentiometer labeled offset on Figure B 5 until the offset value displayed on the unit is as close to the nominal value listed below for your transducer type The force offset adjustment must
28. n Table D 1 and compare the unit displayed displacement to that of the fixture gauge D 3 Step 6 Step 7 Step 8 With the Displacement Verification Mode message displayed on the unit turn on and zero the fixture gauge Be sure the fixture gauge reads zero or re zero the gauge as necessary until the gauge reads zero before proceeding Press then release then press and hold in the TEST READY switch This is the approximate zero reading Ifthe unit display still reads zero then re zero the fixture gauge if necessary Ifthe unit reads other than zero any difference should be noted and subsequent fixture gauge readings corrected for the initial zero difference Release the TEST READY switch monitor the unit displacement until the next approximate displacement point then press and hold the TEST READY switch Compare the fixture gauge to the unit displayed value The unit value must be within 0 0003 inch of the corrected gauge value for each displacement check for acceptance Repeat until all displacement points listed in Table D 1 prior to the last displacement point have been checked The unit will automatically stop at the last displacement point Do not press TEST READY switch for this point Check the unit displacement to the gauge at this point as well Press TEST READY switch again The drive mechanism will retract and go to the home position This completes the displacement verification Power down unit Remove fixture
29. nnected to the unit the SW Install Status should indicate TRUE if it is disconnected it should indicate FALSE If the operator wants to proceed to the next service mode step press TEST READY as required 5 1 5 Pressure Code This step displays the Pressure Force Transducer Code value The Pressure Code identifies the specific transducer type installed on the unit 5 2 If the operator wants to proceed to the next service mode step press TEST READY as required 5 1 6 Displacement Verification This step allows verifying the system displacement accuracy Appendix D provides the detailed instructions for verification of the system displacement If the operator wants to proceed to the next service mode step be sure the platform is properly setup see warning above then press TEST READY as required In this case the next step is again Force Calibration para 5 1 1 The sequence can be repeated as often as desired 5 3 SECTION 6 TROUBLESHOOTING User troubleshooting of the 921A is limited to replacing fuses Before returning the unit to TRICOR for service check the following 1 2 Verify that the power outlet has power Plug in and turn on the 921A Does the POWER indicator illuminate Yes Go to step 3 No Remove power plug from outlet Remove slideout panel from power entry module C Figure 1 1 Check the two 2 A fuses Replace defective fuse s Reapply power If fuse s blow return uni
30. owns ve 2 204 17 Figure 2 9 2 10 SECTION 3 CONFIGURATION WARNING Set up unit for facility power 115 or 220 Vac prior to connecting to facility power After the 921A has been set up as described in section 2 it is ready for power 3 1 TURN ON The power ON OFF switch is located on the back panel as part of the power module C Figure 1 1 Place this switch in the ON position The green POWER indicator should illuminate and all other indicators should remain off If the POWER indicator does not illuminate see section 6 Troubleshooting 3 2 SELF TEST Upon application of power the 921A performs a series of self tests to verify that it is functioning properly If any of the self tests fail see section 6 Troubleshooting The message PERFORMING SYSTEM SELF TEST TESTING CHECKSUM will appear on the operator s display Areas tested during self test include CHECKSUM CPU RAM RAM 1 RAM 2 and RAM 3 The name of each of these areas is displayed as it is tested During the self test routine either a message is briefly displayed stating that an area has passed or the self test routine stops and a message is displayed stating what area has failed If a failure occurs the 921A will not allow further operation The reason for failure must be corrected before continuing See Appendix A After a successful self test the CAL indicator will illuminate indicating that the station has automatically entered the Calibration mode When th
31. rce transducers are supplied with two tips small and large refer to Figure 2 3 To change tips on the force transducer use the allen wrench provided and carefully loosen the set screw holding the tip refer to Figure 2 4 04 13 Figure 2 3 Typical Tips Install the desired tip until it seats bottoms out in the transducer opening and carefully tighten the set screw with the allen wrench 2 204 14 Figure 2 4 3 6 kg 2 0 kg 50 Ib Tip Setscrew Location 2 6 CAUTION If users design their own tips the mass and length must be kept at a minimum comparable to the large tip supplied or performance may be im paired 2 8 2 75 g 360 g and 750 g Transducer Tips WARNING Care must be taken whenever handling the force transducer These transducers are easily dam aged Compression tension or rotational forces applied in excess of 150 of full scale rating will permanently damage the transducer The 75 g 360 g and 750 g transducers are supplied with a 4 40 setscrew as the transducer tip This setscrew should not be removed If the user requires a different size tip the user tip should be designed to thread onto the 4 40 setscrew CAUTION If users design their own tips the mass and length must be kept at a minimum since performance of the system may be impaired by the additional mass length 2 9 CHANGING FORCE TRANSDUCER ASSEMBLIES The 921A allows changing force transducer assemblies i e 3 6 kg 2 0 k
32. re the unit will recognize that the switch is pressed 5 1 1 Force Calibration This step allows adjusting the force offset and gain electronics on the force transducer assembly Appendix B provides the detailed instructions for adjustment calibration of the force transducer assembly If the operator wants to proceed to a different service mode step be sure the platform is properly setup see warning above then press TEST READY as required 5 1 5 1 2 Resistance Offset Resistance Option Only This step allows adjusting the resistance offset electronics and verifying the internal resistance gain calibration value as well as verifying the resistance readings Appendix C provides the detailed instructions for adjustment verification of the resistance electronics If the operator wants to proceed to a different service mode step press TEST READY as required 5 1 3 Lamp Test This step allows verifying that the PASS FAIL READY and CAL indicators are operational Pressing the CAL switch will alternately turn all these indicators on and off If the operator wants to proceed to the next service mode step press TEST READY as required 5 1 4 Resistance CCA Code Switch Installed Resistance Option Only This step displays the Resistance CCA code RCCA value and the switch installed status The RCCA code indentifies the specific optional Resistance CCA type installed in the unit If the Generic Nest Assembly is co
33. splay may instruct the operator to recalibrate The 921A will automatically prompt the operator if a calibration is required due to a configuration change 4 3 SECTION 5 SERVICE amp ADJUSTMENTS 5 1 SERVICE MODE WARNING The Service Mode operates the moving platform at some service mode steps Never operate the unit without the platform properly setup with the drive mechanism height adjusted to provide a suitable stop for the platform force transducer The Service Mode provides a means to periodically test and adjust the 921A internal measurement circuits Adjustments should be performed on a regular basis as determined by the user s requirements The Service Mode adjustments calibration should be performed at least on an annual basis The SERVICE RUN switch is located on the back panel B Figure 1 1 Turn off the 921A and place the switch in the SERVICE position Install a Calibration Force Gauge under pressure transducer before turning on the 921A Ensure that the serial communication cable is disconnected from the 921A Turn on the 921A It will perform its self test routine and enter the Service Mode automatically The message FORCE CALIBRATION MODE PRESS READY TO CONTINUE will be displayed The Service Mode requires pressing the TEST READY switch on the front panel to increment or step through the various service mode display screens The TEST READY switch must be depressed and held for at least 1 second prior to release to ensu
34. t to TRICOR for service Otherwise allow 921A to perform its self test routine Does the operator s display indicate Self Test Yes Go to step 4 No Return unit to TRICOR for service Does Self Test pass Yes Go to step 5 No Return unit to TRICOR for service Does Calibration mode cycle complete No Remove plug from power outlet Note If the unit is under warranty contact TRICOR prior to proceeding 6 1 Remove the back panel Refer to Appendix C Warnings and Step 1 prior to removing panel Check the 4 A fuse see Figure 5 1 on the power supply CCA located on the right side of the base beneath the operator s display Replace defective fuse if any with proper type Reapply power If fuse blows or unit still does not operate properly return it to TRICOR for service 4 A Fuse Figure 5 1 4A Fuse Location on Power Supply CCA 6 2 APPENDIX A RESTRICTIONS AND WARNING PROBLEM FAILURE MESSAGE DESCRIPTIONS Max Force Restriction Max Force parameter will establish the end of inward travel bottomout Max Force should be set to a reasonable value for the device under test If the Max Force is set to small the inward test range may not reach the desired bottomout point of the device under test If the Max Force is set to large excessive force may be applied to the device under test Test Range Travel Restriction The system can store a maximum of 2 500 data log points inward and 2 500 data lo
35. the RUN position for normal operation When the switch is placed in the SERVICE position the 921A is in the Service Mode where internal instrumentation circuits can be adjusted and various system functions checked C Power Switch Back Panel Input Power Module consists of the following 1 Input power voltage selection permits selecting 110 120 V ac or 220 240 V ac operation by positioning the slideout voltage selector as Slideout Panel indicated in section 2 1 2 The slideout voltage selector panel contains two fuses Remove the slideout panel to access the fuses 3 Contains the male connector for the power cord 4 Contains the power On Off switch D Precision Drive Mechanism includes the motor lead screw and precision guide and sensor used to apply the force to the device under test The connector on the corrugated cable of this assembly is connected to the rear D of the 921A electronics unit Precision Drive Mechanism Cover Removed Force Sensor 1 5 TABLE 1 2 CONTROLS AND INDICATORS Cont E Back Panel Resistance Connector J2 optional the electrical resistance connector used with the resistance cable PN 921 112 to connect 921A to generic or user nests F TEST STATUS PASS Indicator illuminates green after a test cycle in which the device being tested passes all of the specified parameters within tolerance G TEST Switch READY Indicator has two functions 1
36. ure C 2 identifies the location of the offset potentiometer pot and the corresponding pot designator which is displayed by the unit The resistance offset value must be within the acceptable range listed below If necessary adjust the offset pot until the offset value displayed by the unit is within the acceptable range C 3 iauss ray Mm b ORL 06 pys 2 204 27 OFFSET POT R21 Figure C 2 Resistance CCA Offset Pot Location CA Step 7 Step 8 Step 9 Resistance Type Acceptable Range 4 Q 10 mA Channel Offset 0 010 to 0 030 4 Q 25 mA Channel Offset 0 004 to 0 012 16 kQ 25 mA Channel Offset 0 001 to 0 030 1 kQ 1 mA Channel Offset 0 001 to 0 030 4 V 4 99 k Pullup Channel Offset 0 001 to 0 030 Press the TEST READY switch once The unit displays the GAIN Calibration Resistance Value message Press the TEST READY switch again The unit displays the GAIN Calibration Value GV The Gain Values displayed should be in the range 3 800 100 These are not adjustable values Consult the factory if the GV value is not within this range Press the TEST READY switch once The unit displays the Contact Resistance Value Mode message Press the TEST READY switch again The unit displays the measured resistance for the resistance channel The value displayed must be 4 095 This is the open circuit condition Consult the factory if the channel is not equal to this value Remove the Offset Gain jumpering
37. w stored test results and 3 Engineering test data is logged for every 0 0001 inch of travel and is available for viewing at the PC The 921A features a precision lead screw drive mechanism used to trip the device under test which serves to guarantee repeatability of results Prior to testing the operator must perform a calibration cycle refer to section 4 1 Testing cannot be initiated until a calibration cycle has been performed 1 1 TABLE 1 1 MODEL 921A DISPLACEMENT FORCE TEST STATION Power Requirements Test Cycle Time Resistance Test Current Resistance Measurement Channels Displacement Range Resolution Abs AccuracyT Force Range Resolution Abs Accuracy Repeatability Resistance Optional Range Resolution Abs Accuracy Repeatability Other ranges available T Related to free position SPECIFICATIONS 115 220 V ac 50 60 Hz 230 VA 6 to 10 seconds typ 10 mA standard One Optional 6 25 to 62 51 mm 0 246 to 2 461 inches standard 0 00254 mm 0 0001 inch programmable 0 00762 mm 0 0003 inch max 0 00254 mm 20 0001 inch typ 0 00762 mm 20 0003 inch max 0 00254 mm 20 0001 inch typ 0 to 3 6 kg 0 to 8 Ib standard 1 g 0 035 oz 0 25 of fsc max 0 2 of fsc typ 0 1 of fsc max 0 05 of fsc typ 0 to 4 Q standard 1mQ 0 25 of fsc max 0 1 of fsc typ 0 1 of fsc max 0 05 of fsc typ 1 2 The test sequence is initiated by pressing the TEST

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