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iTest - Bilt System

1. parameter value at reset general purpose value comment signal name BE437 connector pin number current ImA 100mA clamping voltage 20mV 2V resistance trigger level 6 250 100mQ min pulse duration 20ns lus input filter 10ns 100ns min drift amplitude 500mQ 0 1mQ min threshold level 0Q 0Q max threshold level 0Q 10mQ active threshold no yes Then a major choice has to be discussed The use of individual group for each contact under test will allow to drive independent tests Then time base can be mismatched between the different samples of the batch The use of groups of several contacts up to 12 within one group will allow to drive synchronous test Then the reports will use the same time base If separated groups are uses BE421 temperature and frequency module has to be duplicated in each of them When the groups are formed it s time to create the memories associated to each module BE437 CONTACT TESTING MODULE J t 3 t Model A review 7 BE437 Arev7 odt 26 07 12 Page 16 25 A INNOVATIVE TEST SYSTEMS i 6 3 Memory configuration The event memory has to be created in order to enable contact interruption monitoring Create memory Type PenodDelay fi Number of points eu Parameters PULSe Required memory 4096 octets Avalaible memory 2066 912 octets Cancel Then DC Resistor monitoring can be cr
2. A BE437 CONTACT TESTING MODULE t t Model A review 7 BE437 Arev7 odt 26 07 12 Page 1 25 INNOVATIVE TEST SYSTEMS ER BE437 CONTACT TESTING MODULE Technical specification and user manual References BE432 Contact testing module technical specification BE432Brev9 amp BE432B TPrevs Bilt system complete technical documentation review option A rev 1 dated 17 11 2008 initial review option A rev 2 dated 10 02 2009 development completed option A rev 3 dated 27 02 2009 calibration software completed option A rev 5 dated 13 03 2009 resistance trigger level update option A rev 6 dated 29 04 2009 accuracy test update option A rev 7 dated 26 07 2012 simulator box TE437C update Contents 1 Mant CA CUERS seirer E sees 2 2 ADDICION PRE PE PEER en RE EP 3 3 SPECE PAN Cis esse ss EAEE E 4 4 Electrical DOE IORI AN COG iso esens su essdebenss baie ose ssss pete desnen cents nos ee esneuetere ct 5 4 1 Impedance balancing cable SILC Cl ss sscis citcanadvennasnvewetsncextsanheslenes osuahicoieocsnteuey sehd act anndeae ueotatbe Eaa EEEE 5 4 2 DG Characteristic resistor Measurement sessicnnaccosicecenacasscasenenseacandnronsessaconaniasseoasaneasunozecansiososnaeanpeeceseaeconcane 6 4 3 Contact interruption trigger 16VEl o c1 124sssavcshscsactedecddsssbdessabaeedasssvcdsenssaaneanadedntsexstnandenesaataaeebaesasebtbiarseanceeeens 8 4 4 Current source D CORS ve deh ven se EEEE seen es
3. pa When powered on the TE437 box is set to A3 T3 P3 the large step 10us pulse at 1Hz rate is enabled a BE437 CONTACT TESTING MODULE d t t Model A review 7 BE437 Arev7 odt 26 07 12 Page 21 25 2 INNOVATIVE TEST SYSTEMS TER RARES 8 3 Operating test examples Using the TE437 simulator box allows to test all the operating conditions of the BE437 module DC resistance variation recording slow step 100mQ 125mQ 1 135 mR TE437 Amplitude Al small drift box Time resolution 130 mR t sem P Pattern P4 steady state 125 mR Connection setup Thin 3m wire 1Q sonia Current 100mA 115 mR Clamping Voltage 2 5V 110 mR BE437 Trigger level 120mQ 12mV H module o 105 mR Input filter 10ns 100 mR AR min 0 01Q 95 mR Echelle amp s div 5 mR div Min 95 mR Max 145 mR Time RESistor PULSe WIDth TEMP FREQ Cause 1 OOOOHOOMO0Os 0 100929 O O 20 3 O Start 2 OOOOHOOM32s 0 12632 O O 20 0 O RESI 3 0000h01m14s 0 10172 O O 19 9 O RESI 4 O000h01m43s 0 101193 O O 19 9 O Stop Pulse detection calibrated lus pulse 100mQ 2Q at 1 Hz rate low level detection Tek Run SOOMS s Sample DATH fs 00 00 voc g 7 T TE437 Amplitude A2 medium step box Time resolution T2 1us du Pattern P3 pulse 1Hz Connection setup SMB cable scope Current 100mA then 10mA Clamping Voltage 2 5V BE437 Trigger level 1 042 then 100mQ mod
4. EasyStress software display window colour code green start stop blue new informations red alarm stop EZ M1 BE437 Memon EVENT 128 points PULSe Avalaible Time RESistor PULSe WIDth TEMPerat FRE Quenc Cause Memories OO00hOOm00s 100 269 mA Os 13 9 L 0 Hz Start EVE OO00hOOm36s 125 493 mA Os 20 4 C O Hz RESI OO00hOOm41s 100 632 mA Os 20 1 C O Hz RESI OO00hO m 100 335 mA 1 90 nz 19 6 C 0 Hz PULS OO00hO1m30s 100 407 mA 3 40 nz 20 1 C O Hz PULS Create OO00hO mtrs 100 335 mA 7 110 nz 19 6 C 0 Hz PULS Delete Copy Lave as OOOOhO2nO2s 100 401 mA 11 1 24 ps TATE 0 Hz PULS BILT SYSTEM 100 MEMORY FILE Backup memory file format Unit 02 BILT 2 Group 1 1 Module 1 BE437 EasyStress software allows to download the Group properties memory files onto the PC either for single Step No 38 channel or for the complete system Step duration 1000h00m00s Test Time OhOOm02s Using Excel compatible format the memory Group History file contains all the data related to the test of 95 02 09 17 31 46 0000h00m00s Start one channel first including general Memory Type EVENT informations _ pa Data Memory channel position Time RESistor PULSe WIDth TEMPeEQuer Cause Run step information duration 0000h00m00s 0 100269 0 0 199 O Start group history list of major events related 0000h00m36s 0 125493 0 0 204 0 RESI to th f modul 0000h00m
5. VLI1 01 software revision oO o Ce Input Filter f Tps Current voltage setup tab Current clamping voltage computed voltage trigger level display value only resistance trigger level setup value min pulse duration input filter M1 BE437 i ITEST BE 437A Resistor setup tab 103 22 mQ CONTACT RESISTOR a TEST minimum drift amplitude 64 pulses W108 SNOC 001 LCO000 min threshold level 10 ns YL403 max threshold level threshold activation delay after start activation of threshold control a Event Memorization Minima Drift Amplitude 10 mid Warning Threshold Level Mir O mi Max 200 mtd Delay 150 me Active Threshold OF Cancel Bug BE437 CONTACT TESTING MODULE test Model A review 7 BE437 Arev7 odt 26 07 12 Page 15 25 INNOVATIVE TEST SYSTEMS EE FE DT 6 2 Creating your own software setup Before defining a test setup the user has to identify the following basic test conditions parameter general purpose value comment contact resistor typical value 2mQ cable bandwidth 10MHZ using general purpose twisted pairs cable resistor per lead 300mQ 3 m length Shaker frequency range 5Hz 500Hz synchro signal available logic level connection Oven temperature range 20 C 85 C thermocouple K The complete setting of the first module has to be performed and tested
6. lt Accurate amplifier The module BE437 comes in replacement of the previous BE432 module while providing compatible SUBD connection and software driver The main performance improvements are Event monitoring bandwidth The new time resolution is 10ns Wide bandwidth connections Internal circuitry includes 2 terminal 50Q loads and fully differential monitoring at sense terminal The front panel is both fitted with general purpose SUBD connector and two additional SMB coaxial connectors useful for high bandwidth amp low voltage installation Clamping accuracy is 2mV and minimum available level is lower down to 20mV which is useful for dry contact testing Using a fast linear regulator the clamping action operates with respect to the remote voltage level within a response time shorter than us Fast comparator threshold accuracy is 2mV with respect to the remote voltage level and minimum available level is lower down to 5mV The trigger level is setup using the resistance value ranging from 50mQ up to 15Q Then voltage level is computed according to the current level and the load resistor Bandwidth limitation for very low voltage level In order to operate down to 10mV levels without using coaxial cables a switchable filter is available at the input of the fast comparator 100ns or I us Typical resistance measurement accuracy of 0 1mQ is maintained while using both long cables and 50Q load resistors USB isolated ne
7. LIM CLEar Thresholds reset LIM FAIL Reading of alarm status related to the selected channel NO No alarm LOW Resistor LOWer software threshold occurred HIGH Resistor UPPer software threshold occurred FULL maximum pulse count OVER maximum force voltage 300mV PULSe BANDwidth val Input filter setup 0 or H 10ns l or M 100ns 2 or L Ips PULSe COUNT Pulse counter read back max 65535 PULSe COUNt CLEar Pulse counter clear PULSe WIDth val Pulse duration read back PULSe WIDth MINimum val Minimum pulse duration setup RESistance STEP val Minimum resistor drift amplitude requested to trig event memorization IDATA Complete data read back N instrument State Lim Fail Meas res Pulse count Pulse width meas res cable
8. 0 01 40 70 90 contr le suivi 100 carts maximums a C K 1 00242 b C K 1 639E 4 CGUD1 3 595E 5 COUD1 2 463E 3 marge pr cision corrig e 81 CGUD1 3 604E5 COUD1 2 627E 3 marge de r glage id al 6 936E 6 id al 0 000E0 limite 5 00 150 LSB 1 040E 3 marge marge 0 10 0 08 0 06 0 04 0 02 0 00 0 02 0 04 0 06 0 08 0 10 0 20 40 60 80 100 0 10 0 08 0 06 0 04 0 02 0 00 0 02 0 04 0 06 0 08 0 10 0 20 40 60 80 100 0 10 0 08 0 06 0 04 0 02 0 00 0 02 0 04 0 06 0 08 0 10 0 20 40 60 80 100 1 50 1 00 0 50 0 00 oo 0 50 1 00 1 50 0 20 40 60 80 100 Ite st INNOVATIVE TEST SYSTEMS 8 5 Main SCPI commands BE437 CONTACT TESTING MODULE Model A review 7 BE437 Arev7 odt 26 07 12 Page 25 25 Command Comments idn ee ce identification of the module BE437A module type hardware revision letter CONTACT RESISTOR TEST function description VC101 FPGA revision SN01 008 serial number LCO8 52 last calibration date VL1 01 software revision CURRent val ren setup 100mA range including update of VOLT LEV providing constant RES LEV value Use of m u n coefficient allowed Example c
9. 2 EEE LE AL o A E E AEE E A E E E E 20 8 3 Operating test examples eee ee ee nee EE E me E E aE eee 21 8 4 CADRE ONIE ee eee dd A E E EEE E 23 Main SCPI commands ccccccccccceccecceccccecceccecccccuceecsceccecuecuccecsececeesscuecececusescceesuscuseseesececuceeueess 25 a BE437 CONTACT TESTING MODULE It e gt st Model A review 7 BE437 Arev7 odt 26 07 12 Page 2 25 INNOVATIVE TEST SYSTEMS 1 Main features The module BE437 is designed for testing at the same time contact interruption and contact resistance drift The module incorporates all the functions necessary for the test of one contact gt a fast and accurate linear source provides the constant current requested to bias the contact under test the constant voltage clamping requested when the contact opens gt a fast comparator followed by a synchronous logical circuit provides minimum pulse width control in order to reject too short pulses number of pulse counting pulse duration measurement gt a low level amplifier provides accuracy for DC measurement of the contact resistance BE437 module menon oane OUT 1R current A setup es Fast current source OUT Sense voltage A clampin DAC ping Fast clamping regulator contact under switchable i test low pass filter glitches WwW IR monitorin Omn GND Sense he O Fast A comparator threshold setup DAC GND 1R resistance monitoring lt ADC
10. AS GNDsense F 3 terminals d back read ba Multimeter threshold setup resistance monitoring ADC lt lt Accurate amplifier 50R The strap which connects the internal 50Q resistor at sense input must be removed As no current flows into external cable and connexions the voltage displayed by the voltmeter will be equal to the amplifier input s Easystress control sheet displays the computed resistance value but no the straightforward voltage input values Then using dedicated SCPI commands see section 8 5 it is possible to display the voltage measurements both at force output and at sense input the comparator state The complete calibration requests 4 steps gt The current setup is tested while ranging from 1mA up to 100mA with the ampere meter using a shunt lower than 1Q The actual source current is computed using the formula Imeas Isetup Vforce 50Q gt The voltage clamping setup is tested while ranging from 20mV up to 2 5V The current setup is fixed to 100mA gt The low level voltage measurement used for ohmmeter function is tested using the voltage clamping setup ranging from 20mV up to 100mV gt The comparator threshold setup is tested using only DC levels without any pulse In order to track the toggling point the comparator level is fixed and the actual voltage level is raised using the clamping setup ranging from 20mV to 1V The comparator output state is displayed by the front panel
11. LED see section 7 2 An automatic accuracy test bench 1s used by iTest for the purpose of initial test and periodical check on customer request The next page is a partial copy of the main sheet of the Excel control file used for BE437 module test a d BE437 CONTACT TESTING MODULE t t Model A review 7 BE437 Arev7 odt 26 07 12 Page 24 25 INNOVATIVE TEST SYSTEMS marge de r glage Error level 7 consigne Mesure Ref _ mesures annexes cart consigne 0a OA initial comig 0 0 O 4 789E 02 _5 0000E 02 0 055 0 050 0 00 0 00 0 9 5776 02 9 9997E 02 0 111 0 101 0 00 0 00 carts maximums a C K 1 00012 b C K 8 758E 6 CGI 6 998E 6 COI 3 13E 04 marge pr cision corrig e 97 CGl 6 997E 6 cor 3 21E 04 marge de r glage 42 id al 6 936E 6 id al 0 00E 00 limite 5 00 80 LSB 5 549E 4 82 42 0 10 0 08 0 06 0 04 0 02 0 00 0 02 0 04 0 06 0 08 0 10 0 20 40 60 80 100 consigne Mesure Ref mesures annexes cartmesue ov ow vi com 1 o romeo romeo 004 0 002 0 0 30 3 021E 02 3 021E 02 0 000 0 001 60 _6 041E 02 6 041E 02 0003 0 002 100 1 007E 01 to07e 01 Tf 0 001 0 001 carts maximums a M K 1 00005 b M K 2 147E 6 MGUS 3 219F 6 MOUS 4 999E 4 marge pr cision corrig e 97 MGUS 321
12. The comparator output is sampled each 10ns duration measurement Each time a pulse occurs the time counting 1s A ae ee ee enabled clamping level MORE DE ra RS SE EE e e l I I Then if the pulse ends before the minimum duration i i value the counter is cleared and the wait state meshed i hysteresis resumes ee een ee a eee eee rn RE sssedmsssass 6 amp AR When the pulse remains longer than the specified minimum duration value the number of pulse counter is incremented and the total pulse duration is Count 1 measured using the 10ns sample rate resolution Once a pulse has been triggered the measured duration is latched until main micro controller asks for memory update according to a rate of 1Hz Then during the remaining time the system is able to count any other pulses with respect to specified minimum duration but it will be unable to measure a new duration The event memory is updated only when an event occurs If several pulses occurs during the same interval of 1s the record will contains only the total number of pulse and the duration of the first one threshold level In this example five pulses occurred within 1s As d2 d4 and d5 were too short only 2 pulses were counted As dI was the first pulse within this sample interval Count 4 Count 1 of 1 s only the time value d1 was recorded 5 2 Resistance variation recording principle Moreover the DC Resistance value 1s
13. do not comply with this system requirements BE437 CONTACT TESTING MODULE y Model A review 7 BE437 Arev7 odt 26 07 12 Page 6 25 A INNOVATIVE TEST SYSTEMS TS 4 2 DC characteristic resistor measurement gt Internal parallel 509 load resistors effect This DC characteristic plot shows the actual current and voltage when the resistance of the contact varies from 2 5mQ up to 2 5kQ The working point is plotted depending on the current source setup value Ic using the maximum value Ic 100mA and the minimum value Ic 10mA l A Rcontact 2 5mR 25mR lo 100mA gt 5 oe 2R a jt oe Fu A 4 A 4 Pa 1 Ic 10mA Le A A a d go 250R S P Ic Rcontact RVA 1mA resistance measurement D 2 5K 100mV range of 4 4 4 100UA 4 al 25UV 250uV 25mV 25mV 250mV 2 5V As the DC source is internally biased by the two 50Q load resistors the current remains nearly constant into the contact as long as it remains closed The software keeps accuracy of the resistance measurement by subtraction of the current bias into the two internal 50Q resistors When the resistor increases above 1Q the voltage saturates up to the value Ic 25Q gt External cable resistor effect The external maximum cable resistance per lead is specified up to Rw 1Q This serial resistance combined to the 50Q load at the amplifier input introduces a gain error contact under test current source sense amp The
14. not interrupted e If an emergency stop is required the threshold control has to be activated at the group level button activate desactivate threshold The emergency stop is proceeded for all the modules includes in the same group In addition a threshold control is proceeded on the force output voltage which must stays under 300mV The BE437 module can produce 4 different alarm messages mnemonic event Enable disable action LOW Resistor Min software threshold occurred at module level and at warning or emergency stop HIGH Resistor Max software threshold occurred group level depending Do aa level activation OVER DC voltage at force output over 300mV only at group level FULL pulse count is over 65 535 no only warning The first alarm which occurs is latched into the alarm memory buffer This buffer 1s readable when recovering from abnormal state Clearing of the buffer is requested before restarting In addition a programmable delay can be added after the start of the module before activation of the threshold control 7 2 Front panel features BE43 front panel view The force output signal and the sense input signals are available on both SubD9 and 2 coaxial SMB connectors ae Force d i Force A third SMB connector provides a 200ms logic level r B i senset pulse each time a valid contact interruption is counted ne This pulse is intended for oscilloscope triggering gnd Force Th
15. 00ns setu P Pattern P2 burst 4 pulses Connection setup SMB cable scope Current 50mA Clamping Voltage 2 5V BE437 Trigger level 2 65Q 120mV module setup Min Width Ons 10ns 20ns 40ns 80ns Input filter 10ns 100ns lus AR min Time RES PULS WIDth start 1 O000h00m00s 1 0 0 0 2 0000h00m04s 1 4 1 00E 08 pulse acquisition using different values of input filter 0 3 0000h00m06s 1 8 1 00E 08 Filter Time RES PULS WIDth 10ns 4 0000h00m18s 1 11 2 00E 08 start 1 0000h00m00s 1 0 0 10ns 5 0000h00m20s 1 14 3 00E 08 no 2 0000h00m19s 1 4 2 00E 08 20ns 6 0000h00m34s 1 16 5 00E 08 no 3 0000h00m25s 1 8 1 00E 08 20ns 7 0000h00m36s 1 18 5 00E 08 100ns 4 0000h00m34s 1 9 9 00E 08 40ns 8 0000h00m50s 1 20 5 00E 08 100ns 5 0000h00m39s 1 10 8 00E 08 40ns 9 0000h00m52s 1 22 5 00E 08 100ns 6 0000h00m42s 1 11 9 00E 08 80ns 10 0000h01m07s 1 23 1 00E 07 a BE437 CONTACT TESTING MODULE t gt st Model A review 7 BE437 Arev7 odt 26 07 12 Page 23 25 2 SENS INNOVATIVE TEST SYSTEMS 8 4 Calibration test The calibration of the module involves testing separately voltage and current For this purpose the sense connexions are shorted and the BE437 module is connected to a general purpose digital multimeter BE43 module source current setup Fast current source voltage i DAC clamping Fast clamping regulator T OUTsense force voltage monitoring strap removed ee comparator CF sey
16. 4 Current source performances The current source provides fast response time during resistor voltage transitions The current recovers within 50ns and 2 overshoot when a small step occurs 200mV The current recovers within 100ns and 20 overshoot when a large step occurs 2V coaxial SMB cable coaxial SMB cable transition 0 1Q to 2Q 100mA transition 0 1Q to 200 100mA Chanl sense voltage 100mV div Chanl sense voltage 1V div Chan2 internal current shunt voltage SmA div Chan2 internal current shunt voltage 10mA div Tek CEE SOOMS ss 9 s FS 00 00 voc Tek CIE SOOMS 5 42 Acgs 71 00 00 voc 60m 4 5 Input filter This test is proceeded using the burst of 4 pulses with duration in progression 12ns 25ns 5Ons 100ns The fast comparator is able to trig pulses as short as 12ns Then the module is able to count and or to verify the duration of each pulse of the burst of 4 pulses The displayed values are rounded to 10ns Using the medium filter with 100ns time constant the same burst will trig only one time displaying a 300ns duration Of course when using the lower filter with lus time constant no trig will occur with such a burst coaxial SMB cable coaxial SMB cable Burst from 2Q up to 30 50mA Burst from 2Q up to 30 50mA Chanl Sense voltage 50mV Div Chanl Sense voltage 50mV Div Chan2 fast comparator output threshold 120mV Chan2 100ns filtered comparator output th 120mV Tek CE SOOMS 75 10 a4cg
17. 41s 0 100632 0 0 201 0 RESI O tne group ot module 0000h01m09s 0 100335 1 9 00E 08 19 8 0 PULS 0000h01m30s 0 100401 3 4 00E 08 20 1 0 PULS 0000h01m47s 0 100335 7 1 1e 07 198 0 PULS 0000h02m02s 0 100401 11 1 24e 06 199 0 PULS BE437 CONTACT TESTING MODULE Y t aD t Model A review 7 BE437 Arev7 odt 26 07 12 Page 13 25 2m INNOVATIVE TEST SYSTEMS Ts 5 4 DC measurement memory principle DC Resistance temperature and frequency can be plotted using the same time scale with EasyStress general purpose memory system ROLL memories allow to plot the drift within a shifting constant time interval INFINITE memory allow to plot the drift within the whole test duration using a constant number of point thus corresponding to an extensible time interval Data compression is performed by the software each time the test duration doubles Please refer to EasyStress User Manual for the detailed specification of these kind of memories SUME ag oe ee D ES D a ES OS D ES ec a ae eas aa Fe D E ae en ere mer E aes a een Seer eee oes eee ew a SC id Exemple of resistance TE gad ume Wea ae de a measurement using a 128 point en ee ee ee ee ee ee ROLL memory 2 ee oe oe oe or ee ee ee ee er A ae ely aa age ge nc ce ae a Ce a ig Agee a a a e e us 0 2m08s Echelle 8s div 4 mR drv Min 40 mR Max 80 mR BILT SYSTEM 100 MEMORY FILE Unit 02 BILT 2 Group 1 1 Example for backup memory file format Module 1 BE457 i
18. 956 MOUS 4 978E 4 marge de r glage 48 id al 3 179E6 id al 0 limite 5 0 300 LSB 9 537E 4 marge 75 marge 48 consigne Mesure Ref mesures annexes cart consigne PSV SV init corrig niveau Cumax Tstab KU spec 008 1 oO 250202 000 0 00 30 o 7497601 001 0 01 60 o 1500E 00 000 0 01 90 o 2250E 00 f 0 00 0 00 carts maximums a C K 0 99999 b C K 7 354E 5 CGU 1 685E 4 COU 0 0 marge pr cision corrig e 89 CGU 1 685E 4 COU 9 031E 4 marge de r glage id al 6 936E 6 id al 0 limite 5 00 10 LSB 6 936E 5 marge marge D consigne Mesure Ref mesures annexes cartmesure PSV VT initial cortige niveau Cumax Tstab MUF KU __ spec 0 10 10 0 3 010E 02 3 011E 02 000 0 00 40 O 1 200601 1200 01 __ 000 0 00 70 0 2100 01 2100E 01 000 0 00 0 E carts maximums 90 0 270 0 00 0 00 contr le suivi 5 a C K 1 00003 b C K 1 159E 5 MGUF 9 82666 MOUF 1 591E 3 MGUF 9 826E 6 MOUF 1 603E 3 id al 9 781E 6 id al 0 limite 3 0 200 LSB 1 956E 3 marge 85 marge 18 marge pr cision corrig e 98 marge de r glage 18 consigne Mesure IV Step 0 0005 S Nbre 20 intai corrig 5 CUMAX niveau spec 0 20 20 0 100 0 090 0 110 0 00
19. D9 cable for general purpose test Maximum length 1 ohm resistive cable for sense voltage test coaxial SMB cables for high frequency and or low level test For the purpose of high frequency and or low level test the internal 50 Q load of the BE437 module should be manually disconnected in order to connect the scope with coaxial cable with the 50 Q load at the scope input The TE437 box is supplied by the 25V voltage available into the safety stop connector located on the BE603 main input board front panel Bilt unit SCOPE BE43 module Ce SENSE OUT o current setup A DAC gt KD Y Fast current source voltage t7 clampin DAC ping DAC Fast clamping regulator switchable low pass filter glitches WL te lt fo Fast t comparator threshold DAC setup DAC resistance monitoring ADC Accurate amplifier OUT Sense O puise qe Al 2 3 4 generator a 1123 wpe P1 2 5 4 GND Sense O ont ong mama 0 1 wor ofofo BE603 pl 25 V power supply ph TE437 i simulator box BE437 CONTACT TESTING MODULE J t eo t Model A review 7 BE437 Arev7 odt 26 07 12 Page 20 25 at INNOVATIVE TEST SYSTEMS 8 2 Simulator set up A 2 The test signal is defined according to 3 parameters A2 P2 cp wO gt ons amplitude low high time resolution pattern 4 Each parameter setup is selected with a push button re ane sie A T amp P resolut
20. Group properties The contents of the report file is similar to the Step No 43 one of the event memory ha Salat a Group History 05 02 09 17 58 58 0000h00m0O0s Start 05 02 09 18 01 08 0000h02m10s Stop Memory Type ROLS Parameter RESistor Data Memory 1 0 050662 2 0 050563 3 0 050531 4 0 050563 5 0 050563 6 0 050563 7 0 050695 8 0 050563 9 0 050563 10 0 050596 q BE437 CONTACT TESTING MODULE lt t t Model A review 7 BE437 Arev7 odt 26 07 12 Page 14 25 BRET ites INNOVATIVE TEST SYSTEMS irae 6 EasyStress user interface As this paragraph contains only BE437 specific informations please refer to EasyStress User Manual in order to find general purpose informations and tricks useful for this matter 6 1 Dedicated BE437 control window The black area indicates tr M1 BEA37 the resistance measurement 9 T s T7 9 1 m m i an the min max threshold state 32 pulses the pulse count 10 ns TEST WCT04 SNO1 002 LCOS VL40 the max count state the last pulse width the cable resistance per lead Current Voltage Pulse Detection Source Setup r z og Trigger Level Tem Y The right area indicates the reni mA complete identification of the module 120m 2 BE437A module type hardware Clamping Voltage Min Pulse Width 10n s revision letter VC101 FPGA revision SNO1 008 serial number LC08 52 last calibration date T TE
21. Voltage setup 5mV 1000mV comparator Voltage resolution 0 32mV Voltage accuracy 2mV Voltage hysteresis 6mV resolution 10ns time measurement 10ns 650us Minimum pulse width setup Ons 40us Glitches Time meas Hold off Is monitoring Pulse counting 0 65535 Comparator response time No input filter 5ns 10ns 63 RC time constant Medium input filter 100ns 63 RC Time constant Slow input filter lps Voltage range At differential sense input 0 100mV DC Voltage resolution 3uV resistance Voltage accuracy SuV 0 1 of the value monitoring Saturation resistance value Whatever the current setup value 19 Resistance accuracy 10 mQ 100mA see table 4 2 0 05mQ 0 5mQ Response time Is DC Force voltage At module output GND 0 300mV Bias Internal resistance both at sense input and force output 50 Q External cable resistance per lead 300m Q 10 a BE437 CONTACT TESTING MODULE d t t Model A review 7 BE437 Arev7 odt 26 07 12 Page 5 25 INNOVATIVE TEST SYSTEMS Se 4 Electrical performances 4 1 Impedance balancing cable effect The equivalent schematic of BE437 module connected to the contact through the cables can be simplified as following 3 m lengh 3 m lengh coaxial contact coaxial force connection under test sense connection current source monitoring A jo ff as The signal to be monitored starts from the middle of the transmission line and both terminations of the line can produce reflexions which will degrade the signal shape at th
22. d current source Io 100mA Then computed voltage trigger level is U 100mA 70 25Q 546mV If the user modifies the current level Io then the software will update the trigger voltage level Using Io 10mA the voltage trigger level U becomes 54mV thus maintaining 7Q constant resistance level gt trigger level accuracy checking When testing trigger level accuracy down to ImV care should be taken with the 6mV hysteresis gap The fast comparator is calibrated with respect to the rising edge of the pulse and the accuracy of 1 mV 1s related to the level requested to trig at the beginning of the pulse But in order to stop the time counting at the end of the pulse the signal have to decrease 6mV under the programmable trigger level LED YELLOVY ON trigger level clamping f f leve The trigger level accuracy is easy to test at any time using a DC voltage level close to the trigger level while reading the comparator state on the front panel LED see 7 2 Assuming large enough contact resistor including open circuit the actual output voltage will be controlled by the clamping voltage setup Then tuning this setup it is possible to go through the trigger voltage level providing enough accuracy to meet the 6mV hysteresis gap Of course actual noise level at sense input will be included into the decision of the comparator BE437 CONTACT TESTING MODULE Itest INNOVATIVE TEST SYSTEMS 4
23. e amplifier input As the contact resistance ranges from zero to infinite the only way to reduce oscillations is to use properly terminated transmission lines 50Q internal load resistors are integrated into the BE437 module both at current source output and monitoring amplifier input Using a squared calibrated pulse simulator it is possible to highlight the cable effect onto the transmitted signal The 50Q coaxial cable insures accurate shape monitoring at sense input while the twisted pair slows down 2 coaxial SMB cable 1 m length Twisted pairs cable 3 m length transition 0 1Q to 2Q I00mA transition 0 1Q to 2Q I00mA Chanl sense input Chan2 force output Chanl sense input Chan2 force output Tek ME 500MS 5 57 aqs SJ 00 00 voc Tek GEILE 500MS ss 16 Acgs GT 00 00 voc T KARRAR RAARAAAA RARA PEAN ARARE ANA RANAR RANARNARNAAAKRAANA T T T T 16m 16m Coaxial cables are useful for both high speed performances and low voltage amp low noise performances General purpose twisted pair cables feature impedance within the range of 90Q up to 1200 Then 50Q loads will provides additional attenuation of the signal rise time which is not so bad because the noise level will be slightly higher than the coaxial s level Nevertheless twisted pair cable features the minimum level of noise immunity and signal integrity required for the purpose of this equipment Using separated and individual wires without any ground screen
24. e right LED indicates the on off state of the module ences The left LED indicates 3 different states 50R strap When OFF the input level is lower than the setup voltage threshold level grc trigger out When ON and YELLOW continuously the input level is continuously greater than the setup Led pulse Led on off voltage threshold level Each time a valid contact interruption is counted this LED blinks GREEN during 200ms BE437 CONTACT TESTING MODULE p ia Model A review 7 BE437_Arev7 odt 26 07 12 Page 18 25 A INNOVATIVE TEST SYSTEMS EN 7 3 External 50Q load connection For the purpose of displaying on the oscilloscope the actual sense input signal the internal 50Q load can be removed using a strap located closed to the SMB connector Then the 50Q load requested at sense input will be located at the scope input providing full bandwidth If omitted there will be no damage running the BE437 module without the sense input 50Q load except a loss of accuracy 7 4 Temperature and frequency monitoring For the purpose of monitoring temperature and frequency the 13th position of the BILT unit has to be fitted with a BE421 module e Measuring temperature Sensor type K thermocouple Range from 50 C to 250 C Resolution 0 1 C with typical accuracy of 1 C maximum 3 C over the entire range Connector standard K type thermocouple Measuring the frequency of the shaker unit The shaker unit should de
25. eated using either ROLL SAMPLE or INF SAMPLE with resolution from 128 points up to 4096 points Create memory Type INF_SAMPLE Petiod Delay i Humber of points Parameters RE Sistor Required memory 2 046 octets Avalaible memory 2 O64 352 octets OK Then for future comparison and data compilation Temperature memories have to be created in the BE421 module using same type and same resolution memories as for BE437 Resistor The recommended memory setup for BE437 module associated to common BE421 module is Module Name aL Memos tone Tape ditandai eae so BE 437 EVET EVENT 126 PULSe BE43 ROLI FOULS 126 RE Sistor BE43 INF INFS 512 RE Sistor BE 421 ROLI ROLS 126 TEMPerat BE 421 INF INFS 512 TEMPerat a BE437 CONTACT TESTING MODULE lt t D t Model A review 7 BE437 Arev7 odt 26 07 12 Page 17 25 Ann TRS INNOVATIVE TEST SYSTEMS 7 Miscellaneous information 7 1 Software threshold control on resistance value and maximum count As others Bilt instruments the BE437 module software proceeds to a min max threshold control with the actual resistance measurement value This control operates at 1Hz rate and trigs only with DC events e If required this control has to be activated at the module level option active threshold Then when the actual resistance values goes outside the range MIN MAX a warning message is delivered at the group level but the test is
26. f the value typical resistance measurement error 20 15 This plot is obtained using typical maximum error amplitudes 2 10mA AU 5uV 0 05 of the measured value D o 4 0 10 _ AI 10uA 0 05 of the measured value 5 0 1 10 100 1000 resistance value mQ gt Resistance measurement accuracy test The simplest way to check the accuracy of resistance measurement is to connect a 4 terminal precision shunt onto the SUBD connector Then using different current level and or length resistance of the cable it is easy to highlight the accuracy limits Example using a 2m length cable with 330mQ per lead Current setup measurement of a 10m shunt measurement of a 2m shunt 100mA 10 02mQ 2 05mQ 33mA 10 12mQ 2 12mQ 10mA 10 3 1mQ 2 36mQ 7 BE437 CONTACT TESTING MODULE lt t gt t Model A review 7 BE437 Arev7 odt 26 07 12 Page 8 25 INNOVATIVE TEST SYSTEMS TEN 4 3 Contact interruption trigger level gt Actual resistance and voltage trigger levels The trigger level is defined using Rc the resistor value when the contact opens ranging from 50mQ up to 15Q Then the software computes the corresponding actual voltage level U as a function of both the current source setup value lo and the parallel 25Q internal load resistor The result has to be a voltage within the range of 5mV up to IV example Setup contact resistance trigger level Rc 7Q an
27. ion Each time the button is pressed the selected value yellow LED is shifted to the next position The output is enabled by pushing the last button X The green LED blinks at each pulse Amplitude Low High setup button A amp led A1 A2 A3 A4 test purpose Low level Low voltage level High level load High voltage level load 100mA 100mA Al small resistance drift 100mQ 10mV 100mQ 25mA 12mV A2 medium step 100mQ 10mV 2Q 200mV A3 large step 100mQ 10mV 209 2V A4 small step amp high speed 2Q 200mV 2Q 22mA 250mV Time resolution setup button T amp led T1 T2 T3 A master clock performs 3 different time resolutions 12 5ns 125ns amp 1 25us Then according to the time setup command the length of the main generated pulses will be T1 100ns T2 lus T3 10us Pattern setup button P amp Led P1 P2 P3 P4 P1 one shoot pulse one clean pulse is generated each time the push button X is pressed P2 one shoot burst of 4 pulses duration in progression one burst each time X is pressed P3 same pulse as P1 but continuously repeated at 1Hz rate starts stops when push button X is pressed P4 steady state value at output state toggles each time push button X is pressed 100ns Ips 10us P1 12 5ns 25ns 50ns 100ns 125ns 250ns 500ns ipus 1 25ps 2 5us 5us 10us gt le laje La r a P2 100ns 100ns ipus 1us 10us 10us pf ot 1s
28. liver a trigger signal synchronous of its power output Typical input logic level 3 3V to 5V The BE421 module performs a simple counting within a 1s window Measurement range from 2Hz to 3KHz with resolution and accuracy 1 Hz Filter limiting input signal frequency to 3 5KHz Connector SUBD 9 pin 3 input pin 7 amp 8 GND BNC adaptor is available This two measurements are to be memorized together with the resistance measurement of each BE437 module using their own time base For this purpose the BE421 module will be duplicated into each group of BE437 module Please refer to EasyStress User Manual for the detailed operation of the group function q BE437 CONTACT TESTING MODULE It e gt st Model A review 7 BE437 Arev7 odt 26 07 12 Page 19 25 INNOVATIVE TEST SYSTEMS 8 Test tools 8 1 Operating test using the TE437 simulator box The TE437 simulator box is designed for the purpose of BE437 module operating test Connected straight to the module with a short SUBD9 cable it is useful for training or for on site verification Moreover it will useful for the characterization of the module and the demonstration of its dynamic performances The TE437 simulator box is not designed for resistance measurement accuracy test as low contact resistance 1s simulated by saturated transistors subject to drift Depending on what will be tested it will be requested to use the proper cable 4 wires twisted pairs SUB
29. n order to compensate wire resistance The rapid detection of low amplitude pulses requires the use of coaxial or twisted pair cables In order to reduce the oscillations resulting from the length of the cables which deform the signal observed during glitches two 50Q resistances connected in parallel are included one at at the sense input and one at the force output of the module Although the BILT unit is fitted with many computer interfaces RS422 RS232 GPIB USB and Ethernet the first one RS422 is well suited to provide isolated interface between each Bilt unit and the computer Close to the shaker this will prevent any disturbance around multiple ground connections from introducing noise into fast comparator inputs jtest INNOVATIVE TEST SYSTEMS 3 Specification table BE437 CONTACT TESTING MODULE Model A review 7 BE437 Arev7 odt 26 07 12 Page 4 25 resistors Parameter conditions Min Typ Max Setup range 10mA 100mA Current resolution 6 3uA source accuracy Load resistance lt 25mQ 10uA 0 1 of the value Response time Transition 0 1Q 20Q 100mA 100ns setup 20mV 2 59 Voltage resolution 0 16mV clamping accuracy 2mV Response time Transition 0 1Q 20Q 100mA Ips overshoot With respect to the clamping level 0 5V Resistance setup 50mQ 162 Trigger Resistance accuracy 1Q 100mA 20mQ level
30. recorded together with the glitches into the event memory Each time the variation of the resistance is greater than a programmable minimum drift amplitude a new recording is initiated 10h The sampling rate is 1 Hz In this example 4 recordings were initiated one for the initial value and then 3 times along the test duration when the variation was greater than the smR ImQ minimum drift amplitude Recorded values minimum drift amplitude 1mR to 2h30mn10s 4h05mn01s 6h00mn30s BE437 CONTACT TESTING MODULE t aD t Model A review 7 BE437 Arev7 odt 26 07 12 Page 12 25 A INNOVATIVE TEST SYSTEMS TE 5 3 Event memory principle The Event memory is dedicated to BE432 BE437 contact interruption modules It allows three types of event to be displayed chronologically in the same table Cause pulse when a new glitch or a burst of glitches is detected Cause resistance when a DC resistance variation is detected Cause start stop Initial and final values are included at the beginning and end of the table The table can record a maximum of 128 event lines and when full an alarm is triggered Temperature and Frequency recording requires that the BE421 module is installed at position 13 Whatever the nature of the event each line of the table contains the following information Test time accumulated number of glitches duration of glitch DC resistance temperature frequency and cause
31. s GS 00 00 voc Tek GEILE 500M5 fs 66 acas G 00 00 voc T A ARARE ARA AARAA ARAR ANNA R ARA ANA AARAA ARRA RHAR KANAR ANANK q BE437 CONTACT TESTING MODULE It e gt st Model A review 7 BE437 Arev7 odt 26 07 12 Page 10 25 INNOVATIVE TEST SYSTEMS 4 6 Voltage clamping performances The clamping voltage regulator is able to regulate to remote voltage in the range of 2 5V down to 20mV But it needs a response time of lus Meanwhile a fast schotky diode will clamp the overshoot at 0 5V above the setup level When using very low clamping level in order to avoid time measurement errors due to transient voltage it 1s recommended to use filtered input 100ns and or min pulse duration gt 1 us clamping level 10us pulse from 100mQ up to 200 100mA 10us pulse from 100mQ up to 20Q 10mA voltage clamping 20mV scope 20mV div voltage clamping 20mV scope 50mV div Tek Run ee Sample Eo 00 00 voc Tek Run a Sample MAFA Eo 00 00 voc 10us pulse from 100mQ up to 200 100mA lus pulse from 100mQ up to 209 100mA voltage clamping 1V scope 500mV div voltage clamping 1V scope 200mV div Tek Run zens is Sample E 00 00 voe SJ 00 00 vor q BE437 CONTACT TESTING MODULE a t D t Model A review 7 BE437 Arev7 odt 26 07 12 Page 11 25 INNOVATIVE TEST SYSTEMS 5 Monitoring and memorization 5 1 Glitches recording principle The fast comparator trigs when the input goes above the programmable threshold level
32. se EE EE 9 4 5 d E OA O 9 4 6 Voltage clamping perlorman CES a5 os csctasesenxdesnehavnssdantesduachdaaosdnadebeenasndesboonqasa E EEEE Ea ANENE 10 5 Monitoring and memorization esossecccossecossseccssecccssecocssecosseecosseeoossecsoseeeosseesscsseosess 11 5 1 Glitches recording principle sssrinin aea EE EEE E EE a E EEEE 11 32 Resistance variation recording Principle 2 ea 2 nE di come tdeie teen de deemeeto mens 11 5 3 EVENT memory principle rene i ee resort ie een 12 5 4 DC measurement memory principle sprs orinni in n nn ERE adassaansgdadaaneaeatesdiseiseacaasesaaseeeeess 13 6 Easy OUT CSS NC Or ACO iior EE EE E titi 14 6 1 Dedicated BEA F contol Wi OW Ed ne n ea a E aT 14 6 2 Creating your own software SOUP ias cctonntassescedpsceueeseatindvsansantbeantosseadiencacbientdesusledensssineaibos ba A EEN ANE 15 6 3 Memory conii NOs seen sere sete EEE EATE OE EA E SAAE E EER 16 7 Mis ellancous MIO LIMMAUION ss isceecatsicad ecb scasasdvcesesaccuewlesdsaceosussascavesbssassescedassicosaswetessbessseeens 17 7 1 Software threshold control on resistance value and maximum count 17 7 2 Frontpancl Oaie enansar AE A E N es eae anapeeoesenees 17 7 3 External 3509 OAC HNC COM en ae ea ee entr es oh the 18 7 4 Temperature and Tequemey MONO sia ennemies en centre du 18 8 D RER A GOONS E A E E E E T O cease 19 8 1 Operating test using the TE437 simulator DOX 0 0 0 0 cece eccccccccccccceceeeeeeeeeeseeeeeeceeeeeeeeesseeaaaeeeeeeeeeeeeeseeeeeeeas 19 8
33. software keeps accuracy of the resistance measurement by measuring the force output voltage Vf with an auxiliary measurement amplifier computing the actual value of Rw and at last compensating of the gain error For this purpose it is requested to use the same length and the same size of cables for both force and sense connections The computed wire resistor value Rw 1s displayed onto the BE437 control window q BE437 CONTACT TESTING MODULE e d t D t Model review 7 BE437 Arev7 odt 26 07 12 Page 7 25 gt TITRE INNOVATIVE TEST SYSTEMS HN gt Resistance over range values In order to prevent displaying and memorization of corrupted values the computed resistance value is forced to 1Q when either e the sense voltage Vs exceeds the 100mV measurement range e the force voltage Vf exceeds 300mV 100mV maximum sense voltage 200mV maximum wire resistance 1Q per led 100mA e the computed resistance value is greater than 1Q When outputs are shorted giving voltage measurement lower than 10uV or slightly negative the computed resistance value is forced to 0Q gt Resistance measurement accuracy versus current source set up At last accuracy of the resistance measurement 1s strongly limited when using low current values Example Measuring of a 10mQ contact resistance using a 10mA current will introduce an error up to 5 of the value According to the hereafter plot a 100mA current will reduce the error down to 0 5 o
34. twork PC serial JE gt bus a BE437 CONTACT TESTING MODULE It e 3 gt t Model A review 7 BE437 Arev7 odt 26 07 12 Page 3 25 INNOVATIVE TEST SYSTEMS 2 Application Endurance test bench for connectors mounted on a shaker unit under thermal stress controller fitted with BE7 17 Rs422 setup counting amp event memory converter connector yy under test 110 220 AC main BN100 lt i 20m lengh cable 3m lengh cable Stand alone multichannel system A Bilt unit fitted with 12 BE437 modules and one BE421 module can monitor 12 contacts The embedded micro controller unit performs reliable memorization of the test whatever the state of the remote computer which is running the dedicated Bilt EasyStress software The software allows either independent or synchronised channel operation Several units can be controlled simultaneously by the same PC using an RS422 isolated network Stress conditions monitoring Temperature and vibration patterns are performed by equipment that is independent of the Bilt system The additional BE421 acquisition module performs only temperature and vibration frequency recording It needs a thermocouple K and a trigger signal delivered by the shaker As recording is performed using the same time base occurrences of contact failure can be correlated with stress conditions Wiring precautions A four wire cable is requested i
35. ule 100mV then 10mV setup Min Width 50ns Input filter 10ns AR min Chanl 100mV Div sense voltage 100mA ChanA 10mV Div_ sense voltage 10mA a BE437 CONTACT TESTING MODULE lt t D t Model A review 7 BE437 Arev7 odt 26 07 12 Page 22 25 7 TT INNOVATIVE TEST SYSTEMS FREE Current source with voltage clamping 10us pulse 100mQ 20Q at 1 Hz rate Tek GEILE 125M5 fs Tacs FJ 00 00 Vic The threshold voltage is only 5mV above the steady voltage re SRI MERE which is 10mV 100mA x 100m Then pulses are counted properly whatever the clamping voltage which is set to 4 different levels e 2 5V no clamping square pulse 100mA x 20Q 2V e 1V with 1 5V overshoot same picture e 100mV with 0 5V overshoot same picture e 20mV in this case the scope is set to 10mV chi Soom s50m LEJ soomy 2s Amplitude A3 large ste TE437 P ee aes Time resolution T3 10us Tek Run 125 S s Sample ith Ee 00 00 oc setu P pattern P3 pulse 1Hz Connection setup SMB cable scope Current 100mA Clamping Voltage 2 5V 1V 100mV 20mV 437 Trigger level 150mQ 15mV module setup Min Width lus Input filter 100ns 27mY AR min High speed detection 12ns to 100ns burst pulse 2Q 3Q Tek Run SOOMSss Sample Eo 00 00 voc T Amplitude A4 high speed TE437 P pn se box Time resolution T1 1
36. urr 47 5 m curr 415E 4 curr 0 0415 VOLTage LEVel val Voltage trigger level setup 1V range including automatic update of RES LEV RESistance LEVel val Resistance trigger level setup 109 range including automatic update of VOLT LEV VOLTage MAXimum vall Clamping voltage setup 2 5V range MEASure VOLTage SENSe Reading of the voltage at sense input 100mV range MEASure VOLTage FORCe Reading of the voltage at force output 300mV range MEASure VOLTage Reading of the voltage measurement at remote sense point including wire resistance compensation 100mV range MEASure RESistance Reading of the computed DC contact resistor 12 range MEASure RESistance CABle Reading of the computed cable resistor per lead using sense and force voltage measurement 19 range OUTPut on off Enabling Disabling output LIMit STATe on off Enabling Disabling of the software thresholds monitoring LIM UPP val LIM LOW val Resistor High low threshold programming Any values are accepted without any warning message if out of range It s then possible to disable one threshold monitoring using any inaccessible out of range value imit upp 10m low 1000 state on set only UPP threshold to 10mQ LIM DELay val Setting of delay before applying thresholds 0 60000 ms This delay start at OUTP ON or P STATE ON received

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