Model TR-4/6 Automated Test System INSTRUCTION MANUAL. CheckSum, Inc. P.O. Box 3279 Arlington, WA (360) Web Site:

Transcription

1 Model TR-4/6 Automated Test System INSTRUCTION MANUAL CheckSum, Inc. P.O. Box 3279 Arlington, WA (360) Web Site:

2 P/N Revision 12/2003 Copyright CheckSum, Inc. - all rights reserved Litho in U.S.A. Specifications and operational characteristics of the System are subject to change. CheckSum, Inc. cannot take responsibility for any direct or consequential damages arising from use of this manual or the related product. IBM-PC, IBM-XT, and IBM-AT are trademarks of International Business Machines, Inc. MS-DOS is a trademark of Microsoft Inc. OrCad is a trademark of OrCad Systems Corp. CadStar is a trademark of Racal-Redac.

3 Table of Contents Chapter 1 Introduction Getting Started 1-1 System Overview 1-2 Chapter 2 Operational Overview Installation 2-1 Connection to the UUT 2-4 Creating a Spec File 2-5 Testing an Assembly 2-7 Chapter 3 Specifications Model TR-4 MDA System 3-1 Model TR-6 Functional Test System 3-6 Model TR4/6 CheckSum Test System Software 3-13 Model RM-1 Relay Module 3-15 Model GPIB IEEE-488 Interface 3-15 System Configuration 3-18 Chapter 4 Theory of Operation Model TR-4 Overview 4-1 Current Mode 4-2 Voltage Mode 4-6 Model TR-6 Overview 4-11 Measurement Guidelines 4-16 Chapter 5 Installation Instructions Overview 5-1 Model TR-4 System Module Installation 5-3 Model MPX-3-200/TR-4-1D MPX Module Installation 5-6 Model TR-6 System Module Installation 5-9 Model TR-6-1 Relay MPX Module Installation 5-9 Accessory Module Installation 5-10 Completing the Hardware Installation 5-13 CheckSum Test System Software Installation 5-14 Connection to the UUT 5-19 CheckSum Model TR-4/6 Manual Page i

4 Chapter 6 Testing an Assembly Overview 6-1 Selecting the Proper Spec Data 6-4 Performing the Test 6-8 Concluding the Test 6-12 Chapter 7 Learning an Assembly Overview 7-1 Assembly Learn Menu 7-3 Assigning Connection Information 7-6 Enter/Edit Spec Data 7-8 Autolearn/Autoguard Use and Configuration 7-13 QuickGuard Configuration 7-16 Measurement Analysis 7-18 Nominal Fit 7-22 Dynamic Point Analysis 7-25 Edit/Enter Continuity Test Data 7-28 Edit/Enter IC Test Data 7-33 DMM Interactive Control 7-36 UCT Interactive Control 7-38 Assigning Operator Messages 7-40 Global Spec File Operations 7-42 Edit/Enter Fixture-Check Data 7-45 Special Features 7-46 Assign Other Measurement Characteristics 7-48 Auto Programming 7-50 Translating Spec Data To and From an ASCII File 7-54 Assign Measurement Characteristics 7-56 Assign Operator Setup Screen 7-58 Printing Specification or Wire List Data 7-60 Testing Multi-PCB Panels 7-61 Multi-PCB Panel Configuration 7-65 Testing Digital Logic 7-69 Chapter 8 CAD Data Conversion Overview 8-1 Generating the Spec File 8-2 CAD Conversion Selections Menu 8-4 Enter/Edit Reference Designator Template 8-8 Selective Spec Data Generation 8-9 Notes on P-Cad Data Conversion 8-12 Notes on Mentor Data Conversion 8-14 CheckSum Model TR-4/6 Manual Page ii

5 Chapter 8 CAD Data Conversion, continued Notes on OrCAD Data Conversion 8-16 Notes on HP-BCF Data Conversion 8-18 Notes on Cadence Data Conversion 8-19 Notes on Racal-Redac Data Conversion 8-20 Notes on ViewLogic Data Conversion 8-22 Notes on Tango Data Conversion 8-24 Notes on ComputerVision Data Conversion 8-26 Notes on Pads2000 Data Conversion 8-29 Notes on Schema Data Conversion 8-31 Notes on Scicards Data Conversion 8-32 Notes on Fabmaster Data Conversion 8-33 Chapter 9 Statistical Analysis Statistical Process Control Reporting 9-1 Chapter 10 Configuring the System Overview Model TR-4 Module Configuration Model TR-6 Module Configuration Other Hardware Configuration Assign Passwords and Password Privileges Configure Test Environment Configure SPC Logging & Automatic Reporting Configure Test Reports Chapter 11 Test Type Descriptions Analog Measurement Test Types Analog Stimulus Test Types Digital Test Types Transfer of Control Test Types Message Test Types User-Defined Tests Memory Manipulation Test Types General Purpose Interface Bus I/O Miscellaneous Tests Wiring Diagrams Appendix A Sample Reports Appendix B Command Line Parameters Appendix C In Case of Problems Appendix D Error Messages Appendix E Glossary Appendix F Example Spec File Segments Appendix G Index CheckSum Model TR-4/6 Manual Page iii

6 CheckSum Model TR-4/6 Manual Page iv

7 Figures & Illustrations Figure Title Page Number Figure 1-1 System Block Diagram 1-3 Figure 2-1 Module Orientation 2-2 Figure 4-1 Current Mode Block Diagram 4-2 Figure 4-2 External Sensing Diagram 4-3 Figure 4-3 Circuit with Parallel Components 4-5 Figure 4-4 Circuit with Current Guarding 4-5 Figure 4-5 Voltage Mode Block Diagram 4-6 Figure 4-6 Series LR Model 4-7 Figure 4-7 Parallel RC Model 4-7 Figure 4-8 Series RC Model 4-8 Figure 4-9 Offset 4-8 Figure 4-10 Circuit with Voltage Guarding 4-10 Figure 4-11 Choosing Voltage Mode Guards 4-18 Figure 4-12 Choosing Current Mode Guards 4-18 Figure 5-1 Module Configuration 5-2 Figure 5-2 CheckSum Module Base Address Jumpering 5-3 Figure 5-3 Aux I/O Pinout 5-5 Figure 5-4 Model MPX-3/TR-4-1D MPX Installation 5-8 Figure 5-5 System Menu 5-16 Figure 5-6 Configure/Install System Menu 5-17 Figure 5-7 Model MPX-3/TR-4-1D Test Point Pin-Out 5-19 Figure 5-8 Model TR-6-1 Test Point Pin-Out 5-20 Figure 5-9 Model TR-6 System Module Pin-Out 5-21 Figure 6-1 System Menu 6-2 Figure 6-2 File Selection Menu 6-4 Figure 6-3 File Selection List 6-6 Figure 6-4 Spec File Execution Parameters 6-7 Figure 6-5 Testing Display 6-8 Figure 6-6 Halt on Failure for Continuity Screen 6-11 Figure 6-7 Test Completed Menu 6-12 Figure 7-1 Assembly Learn Menu 7-3 Figure 7-2 Assign Connection Information Screen 7-6 Figure 7-3 Enter/Edit Spec Data Screen 7-8 Figure 7-4 Autolearn Configuration 7-13 Figure 7-5 Select QuickGuard Points Screen 7-16 CheckSum Model TR-4/6 Manual Page v

8 Figure Title Page Number Figure 7-6 Measurement Analysis Display 7-19 Figure 7-7 Nominal Fit Display 7-22 Figure 7-8 Dynamic Point Analysis Screen 7-25 Figure 7-9 Edit/Enter Continuity Test Data Screen 7-30 Figure 7-10 Edit/Enter IC Test Data 7-34 Figure 7-11 DMM Interactive Control Menu 7-36 Figure 7-12 UCT Interactive Control Menu 7-38 Figure 7-13 Assign Operator Messages Screen 7-40 Figure 7-14 Global Spec File Operations Menu 7-42 Figure 7-15 Edit/Enter Fixture-Check Data Screen 7-45 Figure 7-16 Special Features Menu 7-46 Figure 7-17 Assign Other Measurement Characteristics Menu 7-48 Figure 7-18 Autoprogram UUT Menu 7-51 Figure 7-19 Autoprogram UUT Parameters 7-52 Figure 7-20 Resistance Measurement Characteristics Screen 7-56 Figure 7-21 Operator Setup Entry Screen 7-58 Figure 7-22 Spec File Report Device Selection List 7-60 Figure 7-23 Testing Display with Multi-PCB Panels 7-61 Figure 7-24 Skip PCBs in Panel 7-62 Figure 7-25 Test Completed Display with Multi-PCB Panels 7-63 Figure 7-26 Multi-PCB Panel Configuration Menu 7-65 Figure 7-27 Panel Configuration Screen 7-67 Figure 7-28 PCB Wiring Assignments Screen 7-68 Figure 7-29 Example Circuit for Logic Test 7-71 Figure 7-30A Logic Test File for Test Steps of Example Spec File 7-72 Figure 7-30B Example Logic Spec File in ASCII Format 7-72 Figure 7-31 G-80-ODM Input/Output Pin Mapping When 7-73 Connected to a Model G-80 Figure 8-1 CAD Conversion Selections Menu 8-4 Figure 8-2 Example Fixture Wiring List 8-5 Figure 8-3 Example Exception Report 8-7 Figure 8-4 Enter/Edit Reference Designator Template Screen 8-8 Figure 8-5 Selective Spec Data Generation Menu 8-10 Figure 8-6 P-Cad Net List Format 8-12 Figure 8-7 P-Cad Materials List Format 8-13 Figure 8-8 Mentor Net List Format 8-14 Figure 8-9 Mentor Component List Format 8-15 Figure 8-10 OrCAD Cross-Reference File Format 8-16 Figure 8-11 HP-BCF File Format 8-18 CheckSum Model TR-4/6 Manual Page vi

9 Figure Title Page Number Figure 8-12 Cadence Net List Format 8-19 Figure 8-13 Racal-Redac Net List Format 8-20 Figure 8-14 Racal-Redac Materials List Format 8-21 Figure 8-15 ViewLogic Net List Format 8-23 Figure 8-16 Tango Net List Format 8-25 Figure 8-17 ComputerVision Net List Format 8-27 Figure 8-18 Modified Mentor Component List Format 8-28 Figure 8-19 Pads2000 Net List Format 8-29 Figure 8-20 Pads2000 Component List Format 8-30 Figure 8-21 Scicards CAD Data Format 8-32 Figure 8-22 Fabmaster Net List Format 8-33 Figure 8-23 Fabmaster Materials List Format 8-34 Figure 8-24 Fabmaster Nails File Format 8-35 Figure 9-1 Statistical Analysis Menu 9-1 Figure 10-1 Configure/Install System Menu 10-1 Figure 10-2 Model TR-4 Module Configuration Screen 10-4 Figure 10-3 Model TR-6 Module Configuration Screen 10-7 Figure 10-4 Model TR-6 Calibration Screen 10-9 Figure 10-5 Other Hardware Configuration Screen Figure 10-6 Configure Accessories & Fixture Screen Figure 10-7 Password Access Menu Figure 10-8 Configure Test Environment Menu Figure 10-9 Configure SPC Logging & Automatic Reporting Menu Figure Configure Test Report Menu Figure Configure Test Report Header Items Menu Figure Column Test Report Fields Menu CheckSum Model TR-4/6 Manual Page vii

10 CheckSum Model TR-4/6 Manual Page viii

11 Limited Warranty CheckSum, Inc. products, exclusive of fixturing products, are covered by a one-year limited parts and labor warranty for defects in materials and workmanship from time of original product shipment. Fixturing products (Model TR-3/TR-5/TR-7 series and Model GS-850) include a 90-day limited warranty. This warranty extends only to the original purchaser and excludes products or parts that have been subject to misuse, neglect, accident, or abnormal conditions of operations. CheckSum, Inc. reserves the right to replace the product in lieu of repair. If the failure has been caused, as determined by CheckSum, by misuse, neglect, accident, or abnormal conditions of operation, repairs will be invoiced at a nominal cost. In such case, an estimate will be submitted before the work is started, if requested. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IM- PLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHAN- TABILITY, FITNESS, OR ADEQUACY FOR ANY PARTICULAR PURPOSE OR USE. CHECKSUM, INC. SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, WHETHER IN CONTRACT, TORT, OR OTHERWISE. In the event of a failure of a product during the warranty period: 1. Contact CheckSum for a returned material authorization number (RMA). 2. Pack the product in its original packing material or suitable equivalent and return it postage-paid to CheckSum, Inc.. Mark the package clearly with the RMA number. 3. CheckSum will repair the product and return it postage-paid. Repairs are typically completed within two working days of receipt. In the event that expedited repair is necessary, call CheckSum for information. In many cases a replacement module can be provided immediately. CheckSum Model TR-4/6 Manual Page ix

12 CheckSum Model TR-4/6 Manual Page x

13 Introduction Getting Started This instruction manual is for use with the CheckSum Model TR-4 Manufacturing Defects Analyzer (MDA) System, the CheckSum Model TR-6 Functional Test System, or the combined Model TR-4/6 Test System. Since these Systems are based on a common hardware and software architecture, most descriptions are shared. Programming and use is very similar between the Systems, with the most significant exception being that test commands (Chapter 11) for controlling measurements and stimuli are specific to each of the Systems. In order to best serve your long-term needs, the Model TR-4 Manufacturing Defects Analyzer System and Model TR-6 Functional Test System contain a number of features and capabilities. Because of this, it may take you some time before you want (or need) to use all the features of the System. To help you get your System up and testing as quickly as possible, you might want to expedite your initial reading of the manual. The manual has been organized to support you in doing so. First, read this Introduction. You also might want to look over Appendix F, the Glossary, to become accustomed to the terminology used with the System. Then read through the next section of this manual, the Operational Overview. By this time, you will have a good general knowledge of what the System can do and how to navigate your way around. Finally, using the remainder of the manual as reference material, you can install your hardware and software, and begin experimenting with the System as you become familiar with its use. Check the software disk enclosed with your System. If it has a READ.ME file, print the READ.ME file for any last-minute information about System updates. If you run into problems or have questions, don t hesitate to call CheckSum for assistance. We are here to help you. CheckSum Model TR-4/6 Manual Page 1-1

14 System Overview The CheckSum Model TR-4 Manufacturing Defects Analyzer System allows an IBM PC (or compatible) to efficiently test assemblies (such as cables, components and bare or assembled circuits) to find manufacturing defects such as opens, shorts, and incorrect or misoriented components. The System makes high-speed measurements for opens and shorts, resistances, capacitances, inductances, voltages and semiconductor junctions. For each test it makes a measurement of a pair of test points in the unit-under-test (UUT) and compares the outcome against individual, user-specified upper and lower test limits. The CheckSum Model TR-4 MDA Core System contains the System electronics for making measurements, CheckSoft Software, and this Instruction Manual. Test points are added in 200-test point increments (with Model TR-4-1 MPX Modules) to a maximum of 1600 test points. The Model TR-6 Functional Test System provides the capability to power- up the UUT and to apply stimulus and make measurements while powered-up. This can be used to confirm that the UUT s circuitry is functioning properly. The Model TR-6 Core System is comprised of a single, full-sized module that contains a DMM, Counter/Timer, Function Generator, Digital I/O, sixteen relay test points, fused power outputs, and four undedicated relays. The Model TR-6-1 Relay MPX Module expands the relay switching of the Model TR-6 in 50-test-point increments. Relay switch points are used when measuring low resistances or when the test points are subject to voltages greater than +/-12 volts (with respect to the PC chassis). The Model TR-6-2 Fixture Interface allows you to provide special functions near the UUT to help facilitate functional testing. These functions include switching high power to the UUT, buffering and conditioning of signals (e.g. frequency-dividing and redriving an oscillator signal from the UUT), and switching or disconnecting signals near the UUT to reduce capacitive loading or to support special signal cabling requirements. The Model-GPIB allows a Model TR-4 or TR-6 to use external IEEE-488 instrumentation to supplement testing operations. The software is designed to support the specific GPIB module supplied by CheckSum. The Model TR-4 and TR-6 Base Systems each provide eight digital I/O bits that can be used for control of external solid-state relays (such as those produced by Opto-22) for input or output, or for LS-TTL or CMOS-compatible logic for purposes of functional testing of the UUT. The Model TR-6 digital I/O can also directly control relays (it is open-collector). The TR-6 also supports output of DC voltages directly to several simultaneous test points (up to 16) through the Model TR-4 test points. These can be used to supply digital signals. CheckSum Model TR-4/6 Manual Page 1-2

15 If additional digital I/O points are needed, 96 more digital bits can be added with an optional CheckSum Model G-80 Digital I/O Module. The Model TR-6 or TR-4 can either be used on a standalone basis, or can be used in combination. When this is the case, the test points and other capabilities can be shared by the two Systems. The Model TR-6 can also be used with Model TR-4-1 (or TR-4-1D) MPX modules, even if a Model TR-4 Base System is not used. Figure System Block Diagram You can provide your own fixturing that is compatible with the 50-pin ribbon cables provided with the System or purchase a fixture from CheckSum: 1. The CheckSum Model TR-3 Vacuum Fixture System provides bed-of-nails capability for testing bare or assembled PCBs. It uses a GenRad 2270-style receiver interface for interchangeable test heads. 2. The CheckSum Model TR-5 Mechanical Fixture Systems provide bed-of-nails capability for testing small bare or assembled PCBs. These mechanical fixtures are used for PCBs with up to 150 test points to provide a low-cost, compact fixture without the requirement for a vacuum source or fixture receiver. CheckSum Model TR-4/6 Manual Page 1-3

16 3. The CheckSum Model GS-850 Fixture System provides an interface to edge connectors or sockets that mate to the UUT. Each Model GS-850 Fixture can accommodate up to 240 test points via two removable adapter boards. Adapter boards are available prewired for common connector types or in breadboard format that you can customize for your UUT. Other System options include controllers (PCs) of various speeds and a foot switch that can provide operator input to the System. The System software provides the ability to program ( learn ) the test sequence for a UUT. The System can self-learn the opens and connections for a UUT, then allows you to easily add the component tests. The initial test data can also be entered via compatible CAD data if available. Once the UUT is learned, you may save the information (called the specification file, or spec file for short) on your System disk. It can be recalled later to test UUTs. Once a UUT is tested you may generate various types of test reports or gather statistics to help control the manufacturing process. CheckSum Model TR-4/6 Manual Page 1-4

17 Operational Overview This section guides you through typical complete sequences for each major use of the System. These sequences include: Installation Fixturing Creation of a Spec File for a UUT Testing a UUT Read through this section to get an overview of each activity. Complete detail is not given in this section, so you will probably want to refer to the individual sections of the manual that describe each action in detail as you perform the task. Installation The Model TR-4/6 controller (PC) minimally requires an processor with a full-sized slot available for each module system or MPX module. The modules can be installed in either 8-bit or 16-bit slots. Figure 2-1 shows a suggested ordering of the modules, cable installation overview, and default base addresses. For a Model TR-4 MDA system, the Model TR-4 System Module is first installed in your PC. As delivered from CheckSum, it is jumpered to base address 768 (300 hex). For a Model TR-6 Functional Test System, the Model TR-6 System Module is first installed in your PC. As delivered from CheckSum, it is jumpered to base address 816 (330 hex). For a combined TR-4/6 System, install both the TR-4 and TR-6 modules in the order shown in Figure 2-1. Install a short 16-pin bus cable from the TR-4 connector (JP-1) to the TR-6 connector (JP-2). For every additional 50 test points of relay switching that are to be used (for Systems with a Model TR-6), install a Model TR-6-1 Module. The default base addresses for these CheckSum Model TR-4/6 Manual Page 2-1

18 modules are 832 (hex 340), 848 (hex 350), and so on. Install a two-wire bus connecting the TR-6 (JP-5) to each of the TR-6-1 modules (JP-2). For every 200 test points of solid-state switching that are to be used, an MPX (MPX or TR-4-1D) Module is installed. As shipped, the first MPX module is set to a base address of 672 decimal (2A0 hex, JP2 jumpers on positions 9, 7, and 5) and a Board Select setting of 1 decimal (1 hex, JP3 jumper on position 0). The TR-4-1D Modules are jumpered to 776 (hex 308), 780 (hex 30C), and so on. Connect the 16-pin bus cable to JP-1 on each MPX module. For a TR-4 System, connect the end of the cable to JP-1 on the TR-4 system module. For a System with a Model TR-6, connect the end of the 16-pin cable to JP-3 on the TR-6 system module. Note Plug the modules into your PC, taking normal safety and electrostatic discharge (ESD) precautions: turn off power and ground your body to the PC prior to installation. Ensure that the 50-pin test point ribbon cables are installed with each MPX Module during the installation. You might find it easier to install the MPX modules first to allow easier routing of the 50-pin cables. Module Installation (16-pin bus) JP-1 JP-2 JP-3 Viewed from top of controller TR-4 System Module (Base 768) TR-6 System Module (Base 816) TR-6-1 Relay MPX Modules (Base 832, 848,...) TR-4-1 MPX Modules (Base 776, 780,...) JP-1 " (2-pin bus) JP-5 JP-2 JP-2 B a c k o f P C Test Points , JP-1 Other Modules (Model GPIB, RM-1) " , Figure Module Orientation Once the hardware is installed, install the CheckSoft Software in your PC. If you have a hard disk, put the CheckSoft disk into A:, assign A:, then run the INSTALL program (type INSTALL[Enter]). If you don t have a hard disk, back up the CheckSoft disk (using CheckSum Model TR-4/6 Manual Page 2-2

19 DISKCOPY or similar tools), then put the CheckSoft disk into A: and assign it (A: followed by [Enter]). Start the CheckSoft Software by typing MDA[Enter]. At this point, you will see the System menu which is the hub of all System operations. When first installing the System, it is necessary to run a self-test. This ensures that the hardware is installed properly. It also performs some special accuracy and speed enhancement functions that allow your System to operate properly. Self-test is executed by selecting Configure/Install System from the System menu ([F4]), then [F1] Model TR-4 module configuration, and/or [F2] Model TR-6 module configuration as necessary. Once in the applicable module configuration screen, individually select each module installed in the System and press [F1] Self-test module. Once self-test has started, press the keys as prompted to sequence through the self-test. Once the System Modules are completed, test each MPX Module that is installed by selecting each at a time. As part of the MPX (MPX-3 and TR-4-1D) self-test process, the System will ask you to install a shorting fixture to each 50-pin ribbon cable in sequence. The shorting fixture is included with the TR-4 System and can be connected onto each cable, then removed with its ejection levers. As the MPXs are shorted, the System measures the zero-offset values associated with each test point. This is necessary to ensure full accuracy is achieved. Once self-test is completed, select Save configuration data on disk ([F8]) to save the setup information determined during the self-test for use next time the System is used. Saving configuration data on disk saves the current value for most selections of the Configure/Install System menu and its submenus. Saved values include most of the System operating characteristics such as self-test determined data, report configuration, active ports, and measurement characteristics. The Model TR-4 and TR-6 can be tested against external standards if desired. This can be used to meet standards of traceability for the Systems. The optional Model CM-3 Calibration Module provides software and hardware to test Model TR-4 Test System operation against values external to the System. You can confirm/characterize the values of the components on the Calibration Module in your calibration facility if desired. The Model TR-6 can be calibrated to external standards using a DMM and Multifunction Calibrator. This process determines calibration constants for the system to obtain full accuracy. This process is described in Chapter 10 of this Manual. CheckSum Model TR-4/6 Manual Page 2-3

20 Connecting to the UUT The System s measurements are made via test points available at the end of the 50-pin ribbon cables that come from the back of the Model TR-6 System Module, MPX-3-200/TR-4-1D Modules, and TR-6-1 MPX Modules. Each pin is called a port or test point. Each test point is completely universal in nature and can be connected to any UUT test point, although selection of test points between relay test points (TR-6) and solid state MPX points (TR-4) should be separated based on the nature of the UUT. Also, if you are using Model TR-4-1D modules, the first 16 points on each module are special in that they can be switched to digital points. The MPX does not support digital I/O. For MDA testing (or TR-6 testing through the Model TR-4-1D test points), all MPX (MPX-3-200/TR-4-1D) test points (points ) are electrically equivalent and can be wired randomly. If you are not concerned with detailed pin and connection names for operator interaction and reports, it is not even necessary to know how the UUT is connected to the System for doing MDA opens and shorts testing. The System can self-learn a UUT without concern for user-assigned pin and connection names. For functional testing, you should use Model TR-6 (and TR-6-1) relay test points for nodes on the UUT that exceed +/- 12V with respect to the computer chassis, or points that you want to use for low-resistance TR-6 DMM measurements. You should use MPX-3/TR-4-1D test points whenever possible since they have the widest spectrum of capabilities (e.g., continuity testing, guarded measurements, signal sourcing). The pin-out of the MPX-3-200/TR-4-1D MPX Module is shown in Appendix A. Note that test points 1, 51, 101, and 151 are at the bottom of JP9, JP8, JP7, and JP6 respectively. Test points are on the first MPX Module shown in the Set I/O module configuration display of the Configure/Install System menu. Test points are contained on the second MPX Module shown in the display, and so on. If you are not sure about the pin out, use the Probe a pin feature available from the [F3] Assign Connection Information selection of the Assembly Learn menu. If you enable this feature, then touch a grounded probe to the port in question, the System will display the test point number. The Model TR-6 System Module signals are available at the back panel of the module. The TR-6 system module can be differentiated from the Model TR-6-1 MPX modules because the back panel connector is a special color (typically blue). The pin-out of this module is shown in Appendix A of this manual. The 16 test points available from this module are numbers Note The Model TR-6 System Module back panel connector contains power supply voltages that could harm your fixture or UUT. Ensure that you do not route this cable to the wrong spot on your fixture. CheckSum Model TR-4/6 Manual Page 2-4

21 The Model TR-6 Relay MPX modules have 50 test points available at each back panel. These test points are numbered as , , and so on. Creating a Spec File The specification file (spec file) tells the System how to test an assembly (also called the unit-under-test or UUT). The spec file is typically generated once, saved on the disk, then used each time one or more of the same UUTs are tested. The spec file consists of a number of test steps, most of which can generate test results. Typical test types include CONT for continuity, RES for resistance tests, DMM for voltage and resistance measurements, UCT for frequency and time measurements, CAP for capacitance tests, INDUC for inductance tests and DIODE for semiconductor junction tests. For most of these test types, the test step contains upper and lower test limits, the two test point numbers and names, the measurement range, and a test title describing the component being tested. In addition, the spec file contains pin names (optionally assigned), the measurement characteristics (e.g., samples averaged for each reading), active ports, the assembly name (optional) and operator comments (optional instructions to the operator). Generating a spec file can be performed in several ways. All are available from the Learn an Assembly ([F2]) selection of the System menu. You may use the System in random sequences of configuration, learning, testing, and other operations. When you are satisfied that your PC s memory contains the proper spec data, save it to disk. Following is a typical programming sequence: The Assign Connection Information ([F3]) selection of the Assembly Learn menu allows you to enter names specific to your UUT into the System. When you do this, the System displays and reports will contain the names that you enter. Each pin name can be up to eight characters. The System can automatically assign sequential pin names as you probe the fixture, making this process quick and easy. The Assign Connection Information selection also allows you to specify which test points are active and inactive (ignored) when learning CONTinuity for an assembly. Once you have assigned pin names, you can use the [F8] Output Wire List Report selection of the Learn menu selection to generate a wiring list for the UUT. Use the Enter/Edit Spec Data screen ([F2] from the Assembly Learn menu) to enter a test type of CONT (continuity). Then select [F5] to get the Enter/Edit Continuity Test Data screen. Finally, use the [F6] selection to automatically learn the UUT s opens and shorts. Once the connections are learned, [ESC] back to the Enter/Edit Spec Data menu. For each component in the UUT, press [INS]sert, enter the two test point numbers ( from and to port numbers) or pin names, the test type (e.g., RES, CAP, INDUC CheckSum Model TR-4/6 Manual Page 2-5

22 or DIODE), and the component name in the test title (e.g., R101). Then press [F5] for the System to measure the points, assign the range and test tolerances. Note that at times the measurement values will be different from the nominal values of the components that you are measuring. This is a normal case caused by interference from associated circuitry on the UUT. Even though the test limits may not represent the nominal value of the component, the System will still efficiently find most manufacturing faults because differences from the learned value are detected. These measurement differences can be minimized by careful selection of ranges and polarities used in the measurements, guarding, and the use of zero/scale values. The uses of these advanced features are described in detail in the Learning an Assembly chapter. The Theory of Operation chapter describes how the System makes measurements to allow you to make the best measurements if you run across problem components. Once the MDA tests are completed, you can use the Model TR-6 to power up the UUT, apply stimulus and make measurements of various signal points on the UUT. The Assign operator set-up screen, accessed from [F4], can be used to create a screen of text that the operator sees prior to beginning a test for each UUT. This text can be used for precautions, connection information, or other things that you would like to convey to the operator. Once you have entered the spec data, you will want to run a batch of UUTs through the System to verify that the tolerances are appropriate to meet the UUT-to-UUT and measurement variances. As you do this, if you encounter a failure that is not caused by a fault in the UUT, press the [F5] key while observing the failure. The System will adjust the test tolerances to accommodate the UUT that you are testing. Note that the [F5] key is hidden in the Testing display so that operators won t have a tendency to use it during production testing (it is also password-protected). You can use data logging in conjunction with the X-Bar/Sigma Control Report to help determine appropriate tolerances by analyzing the readings from the first few batches of UUTs tested. Output spec data report ([F7]) lists information about the spec data presently in memory. It may be sent to the CRT, a disk file or a printer. Output wire list report ([F8]) outputs a report that shows the correlation between tester port numbers and pin names that you have assigned. The report is sorted by both port numbers and pin names. Save spec data to disk ([F9]) is used to save the spec data for future use. This information is on the System disk. Consequently, when the spec file is loaded in the future this information will be restored to match the conditions when the spec file was saved. CheckSum Model TR-4/6 Manual Page 2-6

23 Testing an Assembly Once you have generated a spec file for a UUT, the UUT may be tested. To test a UUT, select Test an Assembly ([F1]) from the System menu. You are then presented with the Select Spec Data File menu. Either enter [F2] and type in the spec file name or use the Select Spec Data File From List ([F3]) to choose the proper spec file. Once the proper spec file is loaded into memory, select Start Test With Present File ([F1]) to actually start the test. You may elect to single step or halt on failure from this display if you wish. If the test fails any points (and you have selected halt on fail), you are presented with a display describing the failure. You may either continue, abort or retry the test. Once the test is completed or aborted, you see the Test Completed menu. This menu allows you to either continue on to the next assembly in this run or to retest the present assembly. At any point you may also generate a report. The test report ([F3]) contains the actual measurements for the UUT. A failure-only report ([F4]) lists only the test values that failed. The batch report ([F5]) gives a summary of all of the UUTs tested in this run. CheckSum Model TR-4/6 Manual Page 2-7

24 CheckSum Model TR-4/6 Manual Page 2-8

25 Specifications Model TR-4 MDA System Voltage Technique Resistance Measurement Characteristics Frequency: DC, 100 Hz or 1 KHz sine wave Output Voltage into Open: 200 mv or 2 V Output Impedance: 600 Ω Max Current Through Unknown: 2V range: 3.3 ma 200 mv range: 33 ma Typical Accuracy: 0-10 KΩ: 2% of reading Ω 10 KΩ - 1 MΩ: 3% of reading 1 MΩ - 19 MΩ: 10% of reading Approximate Measurement Speed: DC: 12 msec 1 KHz: 18 msec 100 Hz: 130 msec Current Mode Full Range Volts (Full Range) Current Typical Accuracy 190 Ω 0.2 V 1.0 ma ± 0.5 Ω 1.9 KΩ 2 V 1.0 ma ± 9 Ω 19 KΩ 2 V 0.1 ma ± 190 Ω 190 KΩ 2 V 10.0 µa ± 4.5 KΩ 1.9 MΩ 2 V 1.0 µa ± 95 KΩ 19 MΩ 2 V 0.1 µa ± 1.9 MΩ Full-range values shown applicable for externally sensed measurements. Reduce value by 20 Ω when using internally sensed measurements. Reduced accuracy with other 200 mv ranges. CheckSum Model TR-4/6 Manual Page 3-1

26 Test speed is 4 msec per test point switching, measurement, and evaluation time when measuring a value less than 190 Ω. Worst-case time of 50 msec when autoranging from 0 Ω to a measurement on the 19 MΩ range. System uses internal Kelvin measurements for compensation of switching resistance with an offset stored for lead and contact resistance from that point. Readings can be externally sensed at device being measured if desired. Voltage Mode Capacitance Measurement Characteristics Frequency: 100 Hz or 1 KHz sine wave Output Voltage into Open: 200 mv or 2 V Output Impedance: 600 Ω Max Current Through Unknown: 2V range: 3.3 ma 200 mv range: 0.33 ma Usable Range: 100 Hz: 10 pf to 20,000 µf 1 KHz: 0 pf to 2,000 µf Typical Accuracy: 5% with zero-offset compensation Usable Resolution: 0.5% (minimally 5 pf) Approximate Measurement Speed: 1 KHz: 18 msec 100 Hz: 130 msec Current Mode Six-decade ranges from.05 µ to 5,000 µf, providing a usable range of 500 pf to 20,000 µf. Typical Accuracy: ± 5% (Reading accuracy may degrade if capacitor being tested has significant leakage.) Resolution: 1% of range Technique: Inject DC current, measure rise characteristics of voltage across unknown. Stimulus: 0.1 µa to 1 ma in decade ranges. 2 V or 200 mv full-range voltage across unknown. CheckSum Model TR-4/6 Manual Page 3-2

27 Inductance Measurement Characteristics Frequency: 100 Hz or 1 KHz sine wave Output Voltage into Open: 200 mv or 2 V Output Impedance: 600 Ω Max Current Through Unknown: 2V range: 3.3 ma 200 mv range: 0.33 ma Usable Range: 6 µh H Typical Accuracy: 5% with zero-offset compensation Usable Resolution: 0.5% (minimally 0.5 µh) Approximate Measurement Speed: 1 KHz: 18 msec 100 Hz: 130 msec Voltage Measurement Characteristics Range: 0 to 9.9 V Typical Accuracy: ± 200 mv Speed: 1-2 msec/measurement Continuity Measurement Characteristics Connection and open thresholds are separately programmable from 2 Ω to 50 Ω. Each test point pair can be specified as open, connection or not tested. Maximum open/short test time for 200 test points is 6.8 sec.. Each measurement takes approximately 330 µsec. The worst-case total time to test a block of n test points can be calculated as: T = 330 µs n ( n 1 ) 2 The System uses optimizations to increase speed of continuity testing. In most cases test speed is much faster than the times listed above. For example, a CONT test for a typical 200-test point assembly executes in less than a second. CheckSum Model TR-4/6 Manual Page 3-3

28 Semiconductor Measurement Characteristics Technique: Source constant-current in decade values (1 ma through 0.1 µa), measure voltage. Typical Accuracy: 0-2 V: ± 2 mv V: ± 20 mv Speed: 1-2 msec/measurement Digital I/O Capabilities Eight individually bi-directional digital bits, each of which can be tri-stated or configured for input or output. One of the bits is used for control of vacuum if the Model TR-3-VALVE is configured into the System. Sink capability of 24 ma per bit. Source capability of 2.6 ma per bit. Each 74LS-TTL bit is configured with a 10 KΩ pull-up resistor for TTL/CMOS compatibility. The System can be expanded by 96 bits of digital I/O by addition of an optional CheckSum Model G-80 Digital I/O Module. Guarding Capabilities General: Up to 6 guard points can be simultaneously selected. Each guard point can be externally sensed. AC/DC Voltage Guarding: Usable to ratios of approximately 100:1 (impedance of measured component divided by impedance of guarded path). Guard point is driven to low test point potential (ground). DC Current Guarding: Up to 15 ma of total guarding current. Guard point is driven to potential of high test point. Unguarded Measurement: Since the System makes complex impedance measurements, even without guarding, it can make measurements of components with parallel impedances with a ratio down to 20:1. For example, when using external sensing at 100 Hz, it can directly measure either a 10 KΩ resistor or a 3 µf capacitor that are directly wired in parallel. CheckSum Model TR-4/6 Manual Page 3-4

29 Zener Measurement Characteristics General: The Zener measurement function is available at TR-4-1D test points only. Use the Diode (Semiconductor) measurement technique if a TR-4-1D is not installed. Technique: Source approximately 10 ma constant current. The positive test point is current limited with 12 V compliance and the negative test point is set to -10 V. Two terminal measurements are made up to 18 V. Accuracy: ± 5%, ±.3 V Approximate Measurement Speed: 2 msec External Verification The Model TR-4 can be tested against external standards to confirm proper operation. The optional Model CM-3 provides hardware and software for this purpose. The external calibration may be executed semi-annually to assure full confidence. CheckSum Model TR-4/6 Manual Page 3-5

30 Model TR-6 Functional Test System Digital Multimeter The DMM is used to make voltage and resistance measurements on the UUT. It can make voltage measurements through the TR-6 test points (up to ± 250 volts) or through the TR-4 test points (up to ± 12 volts). Low resistance measurements, through the back panel or TR-6 test points, augment the Model TR-4 MDA resistance measurement capabilities. DC Voltage Measurement Ranges: 200 mv, 600 mv, 2V, 6V, 20V 60V, 200V, 600V (max input 250V), autorange Accuracy: 0.5% of range Resolution:.05% of range AC Voltage Measurement Ranges: 200 mv, 600 mv, 2V, 6V, 20V, 60V, 200V, 600V (max input 250V RMS), autorange Accuracy: 2% of range (40 Hz to 1 KHz) 5% of range (1 KHz to 10 KHz) Resolution: 0.05% of range Input: AC or AC+DC Coupled Resistance Measurement Ranges: 2, 6, 20 Ω, autorange (including lead resistance) Resolution:.05% of range Accuracy: 3% of range (using zero offset) Ohms Source: 100 ma DMM General Voltage levels: The DMM can take fully floating differential measurements on the ranges up to 6V. Neither input can exceed ± 8 from the computer chassis. On the 20V and higher ranges, measurements are ground-referenced. Measurement Speed: ~60mSec (AC readings and filtered DC readings ~500mSec) CheckSum Model TR-4/6 Manual Page 3-6

31 Counter/Timer The counter/timer is used to measure frequencies and periods. It is typically used to measure UUT oscillator frequency and other UUT signal frequencies. Inputs can be taken from the unswitched back panel connector, the TR-6 switching, or through the TR-4 test points. The DMM input (usable to 50 KHz) can be accessed for low-level differential inputs through the TR-6 test points. The optional Model TR-6-2 Interface can be used to buffer, and divide frequency signals in close proximity to the UUT. Frequency range: DC to 10 MHz (higher frequencies can be prescaled by Model TR-6-2 in fixture - see accessories) Channels: 2 plus DMM input Triggering: Programmable threshold -2.2V to +2.2V Input Level: 300 mv to 5 V (60 mv to 250 V through DMM channel) Coupling: AC/DC Common: Ground-referenced (except on differential input ranges of DMM) Frequency Ranges: Resolution: Accuracy: Period: Range: Resolution: Accuracy: Totalize: Range: Pulse Width: Specifications Function: 5KHz, 50 KHz, 500 KHz, 5 MHz, 10 MHz.0015% of range.01% ± 2 counts 12.8 µs Sec (in 8 decade ranges).0015% of range.01% ± 2 counts 1 to 65,535 counts (up to 5MHz input) Same as period Start and stop slope selectable CheckSum Model TR-4/6 Manual Page 3-7

32 Function Generator The Function Generator is used to provide UUT stimulus. It can provide DC-V, sine and square waves. Both square wave output levels are separately programmable to provide full flexibility. The stimulus is available at unswitched Model TR-6 back panel outputs, or at Model TR-4 MDA test points. All three stimuli are available simultaneously with some limitations (sine and square frequencies must match, square wave must be ground-referenced). When switched through the Model TR-4 test points, the total path resistance is 1 Kohm or less. Each function generator output can source up to 10mA into low impedances, but the current/voltage is limited by the switch resistance. Functions: DC Voltage / Sine Wave / Square Wave Frequency Range: DC, 2 Hz - 40 KHz in 56 discrete steps Common: Ground-referenced Frequency Accuracy:.01% Harmonic Distortion: 1% Amplitude Accuracy: 1% of scale (DC) 5% of scale (25 Hz to 1 KHz) 10% of scale (1 KHz to 20 KHz) Sine Amplitude: 100 mv to 20 Vpp (.1dB steps) Square Wave Amplitude: Each level programmable from -10V to +10V (5mV steps) DC V Amplitude: Programmable from -10V to +10V (5mV steps) Power Outputs The Model TR-6 makes PC-power available at the back panel connector. Each supply is fused on the TR-6 with a plug-in fuse. Fuse status is determined by system self-test. The power outputs can be used to power UUTs with limited current requirements. The power outputs can be switched to the UUT with use of the undedicated relay switches on the Model TR-6. Fixed outputs: +12V fused at 1A -12V fused at.1a +5V fused at 1A GND unfused CheckSum Model TR-4/6 Manual Page 3-8

33 Digital I/O The Model TR-6 provides digital capabilities which allow you to perform low-speed digital input and output for test of UUT functionality. The digital I/O capability can also be used to drive relays or send and receive digital signals and switch closures controlling test flow. The standard Model TR-6 includes eight bits of digital I/O capabilities. These bits are available at the TR-6 back panel. Open-collector outputs can directly control external relays requiring up to 100mA when used with an external source. The digital outputs can be left floating, or jumper-connected on the TR-6 through pull-ups to either +5V or + 12V. The status of the eight bits can be read back by the system. The digital I/O capability of the system can be expanded by 96 non-multiplexed bits with the addition of a Model G-80 Digital I/O Module. Each bit on this module is individually bidirectional and can sink up to 24mA. When used in conjunction with Model TR-4-1D MPX modules, the system provides an additional 16-bits of digital I/O per MPX module. On these modules, the first sixteen test points can be switched from general purpose analog MPX points to digital I/O points when performing power-on testing. These points can source up to 2 ma and sink up to 24 ma. Basic TR-6 Digital I/O Bits: 8 Direction: Output w/readback Logic Family: 5V TTL/LS/HC-MOS Outputs: Open-collector w/pull-up Distribution: Back panel connector only Sink/Source: Sink 100 ma. Source determined by pull-up resistor Pull-ups: 10K socketed pull-up to +5V or +12V CheckSum Model TR-4/6 Manual Page 3-9

34 Undedicated Switching The Model TR-6 provides four undedicated relays, available at the back panel, that can be used for various testing needs such as switching power or other signals to the UUT. Typically, all of the signals from the Model TR-6 back panel connector are available inside the test fixture. When a test fixture is built for a particular UUT, other TR-6 signals and UUT test points can be connected to the undedicated relay connections for use during the power-up tests. In addition, an accessory 16-pin ribbon cable header on each Model TR-6-1 MPX Module provides four relays for custom use. Undedicated Switches: 4 SPDT relays hardwired to back panel (12 connections) Contact Rating: 250V, 1A, 30 VA resistive switched Isolation: 250V RMS Test Point Switching The Model TR-6 provides 16 relay-switched test points at its back panel. These test points can be expanded in 50-point increments by adding Model TR-6-1 Relay Modules (up to 6 TR-6-1 modules can be configured into a system). The relay test points are used for UUT connections that exceed ± 12 volts with respect to the computer chassis when power is applied to the UUT. The Model TR-6 can make DMM and Counter/Timer measurements at these points. In addition, unguarded 2-wire Model TR-4 MDA measurements (e.g. resistance, capacitance and inductance) can be made through these points. TR-6 Test Point Matrix: 16 relay-switched test points. Each TR-6 relay test point may be specified as a high or low for DMM measurement. Relay Expansion: The matrix may be expanded in 50-point increments with the Model TR-6-1 Relay Expansion Module. Each TR-6-1 module uses one full-length/full-height PC slot. Model TR-4 Test Points: 2-wire measurements from the Model TR-4 can be made through the Model TR-6 matrix. TR-6 source and measurement capability (except high-voltage & resistance measurement) is available from all TR-4 test points. Multiple sources can be active at TR-4 test points while making measurements. CheckSum Model TR-4/6 Manual Page 3-10

35 Fixture Interface Module The Model TR-6-2 Fixture Interface Module is designed to be used inside or near the UUT fixture to help support functional test operations. Connecting to the Model TR-6, it provides a number of special capabilities with wire-wrap terminals for connection to the UUT and test point electronics. The basic module contains fundamental capabilities, and by setting jumpers and adding components as necessary, you can perform a number of specialized functions. Under automated control of the Model TR-6, it provides power relays that can be used to switch power supplies or other signals to the UUT, an interface to the counter/timer that allows you to redrive or frequency-divide low-level UUT oscillator signals, dual instrumentation amplifiers that can buffer and differentially amplify low level signals for the DMM, two shunt locations for current monitoring and a bread-board area for custom circuitry. The Fixture Interface includes stand-offs for easy mounting inside the fixture or on any flat surface. The 50-pin ribbon cable from the Model TR-6 back panel can be directly plugged into the Fixture interface, or when used inside a Model TR-3 vacuum test head, the special Model TR-6-3-THC plugs directly from the Fixture Interface to the inside of the fixture wiring block connected to the Model TR-6. The basic Fixture Interface contains two power relays, connectors and interface circuits. You can install your own components to tailor it to your application or purchase kits from CheckSum to populate it as necessary. The Model TR-6-RLY is an additional power relay (up to 8 can be installed), the Model TR-6-CT is the counter/timer interface, the Model TR-6-2-DMM is the DMM signal conditioner interface parts, and the Model TR-6-2-SWO allows change-over of test points from one source to another (or isolation of the test points to eliminate loading). Mechanical Size: 8" x 6.9" x 3"H (with relays installed). Mounting: 8-3/4" x #6 screws (not included) Relay Switching Provisions for up to 8 DPDT (2 form-c) relays Contact rating 10A, 250VAC, 240VA Remotely controlled by Model TR-6 Counter/Timer Interface Inputs: 2 via wire-wrap or SMA connectors Frequency divider ratios: 2, 4, 8, 16 Sensitivity: 100 mv CheckSum Model TR-4/6 Manual Page 3-11

36 Frequency response: 50 MHz DMM Signal Conditioner Interface Dual 2-input buffer amplifiers Amplification ratios: 1 to 1000 Max input voltage: ± 6 volts, differential Switch-Over Module The Model TR-6-2-SWO modules install in the Model TR-6 Fixture Interface Module allowing test points (close to the UUT) to be switched from one source to another (e.g. digital to analog) or to isolate pins to reduce capacitive loading. Each switch-over module installs in 2-power relay positions (for a maximum of 4 switch-over modules with no power relays installed). Provides 17 ganged test point switch-overs per module. External Verification The Model TR-6 can be tested and calibrated against external standards to confirm proper operation and to provide full accuracy. This process uses an external multifunction calibrator and DMM and should be run semi-annually for best performance. Automated software is included for this purpose. See Chapter 10 of this manual for details of this process. CheckSum Model TR-4/6 Manual Page 3-12