Download Solenoid Circuit Board Manual - Actuation Test Equipment Company

ATE-CFM56-3 Manual
98-4-5
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Actuation Test Equipment
ATE-100 TorqueMotor Module Manual
Actuation Test Equipment
3393 Eddie Road
Winnebago, IL 61088-8736
Ph# 815.335.1143
Email: [email protected]
February 18, 2015
Rev 1.
ATE-CFM56-3 Manual
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TABLE OF CONTENTES
Topic
Calibration Cycle - 3
Overview of Calibration Procedures -3
Calibration Tools – 4
Controls and Indicators – 6
Datel Meter indicating TM Current - 6
CW SetPoint Voltage – 6
TM mA SetPoint Pot – 6
CCW SetPoint Voltage - 6
mA Span Gain – 6
Coil Selector Switch – 6
Resistance Test Select - 6
TorqueMotor PC Board Power Supply - 6
Normal Operation – 6
TorqueMotor Current Meter Reading - 7
Coil Resistance Test - 7
Insulation Resistance test – 7
Calibration Procedure – 7
TorqueMotor Current Meter Calibration - 8
Figures
Cover Picture – ATE-100 19” Rack mount -1
Fig 1 – ATE-100 Signal Breakout block - 4
Fig 2 – ATE-100 TMI Module Faceplate – 5
Fig 3 – TorqueMotor PCBoard Schematic 9
Fig 4 – PC Board Silkscreen Artwork – 10
Fig 5 – TorqueMotor PC Board Component side Top View – 10
Table 1 – Parts list from PCB Schematic Capture Tool
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Calibration Cycle
Each time the test box is calibrated, note and record the change in the
electrical performance of the circuits. This data will allow determination of
appropriate calibration cycles.
Overview of Calibration Procedures
Start by measuring and recording Ohms from power cord ground prong to the test
kit chassis, and then plug it in and measure the +30, +25, +15 and +5 volt power
supplies on all of the PC Boards.
Measure and record torquemotor output current range, AC noise component and
then record AC RMS and AC Pk meter calibration values at 5 test points.
Set Ma Setpoint Calibrated Dial to 0, 2.5, 5.0, 7.5 & 10. At each test point record
External NIST traceable AC RMS meter and Datel Meter and measure AC RMS
component of TorqueMotor current with External NIST meter and record.
Measure and record Coil Resistance test 1mA current output.
Measure and record the 20M Ohm Insulation Resistance test threshold.
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Calibration tools
 Two resistor sets measured at 19.5M and 20M Ohms. Use 1/4W 1% metal
film resistors. Connect them from the connector pin to ground as a go/no-go
determination of the Insulation Resistance test calibration. Adjust Resistance
Threshold trimpot to get Pass LED on at 20M Ohms and Fail LED on at
19.5M Ohms.
 A Small “tweaker” screwdriver to adjust 25 turn trimmer pots.
 A multimeter capable of measuring 1mA, 250VDC and 3 to 8VAC.
 An optional connector breakout block with BNC connectors for all Input and
Output signals.
Figure 1 ATE-100 Signal Breakout
All calibration test points can be accessed via this test block
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TorqueMotor Module
Datel Meter
CW Setpoint Voltage
TM mA SetPoint Pot
Ma Span Gain
Coil Selector Switch
Resistance Test Select
Frequency Response InPut Jack
FR Input Gain
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Controls and Indicators
Datel Meter
Datel DMS-40PC-1-RS panel meters are used in the ATE-CFM56 test box.
The red LED display has been selected for the final configuration to improve
visibility. The red LED display has increased viewing angle and can be seen from a
greater distance.
Meter Calibration Trimmer
Fine calibration of mA uses an internal trimpot on the back of the Datel Meter.
A small “Tweaker” screwdriver is used to make this adjustment. Access to the pot is
gained by a slit between the conductors of the ribbon cable as shown below.
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Coarse calibration is accomplished by hand-selecting the 1-Ohm current sense
resistor to find one that measures higher than 1-Ohm, and then trimming it down by
soldering parallel resistors across it to get the sense voltage calibration at 1mA =
1mV exactly.
Coil Select
The Coil Select switch connects the output of the Torque Motor module to
either the A or B coils of the Torque Motor.
Resistance Test Select
This switch invokes the two resistance test functions of the test kit. The InsRes test
is a pass/fail test of the insulation resistance of the selected torque motor coil. The
CoilRes test measures the selected torque motor coil resistance in Ohms.
Torque Motor Driver Board Supply Power
Power input to this board is110 VAC. On-board regulators provide the +15 volt and
+5 volt power required for the circuits on this board.
Normal Operation
Normal operation is output current between +110 mA flowing through either coil A
or coil B of the torque motor.
Coil Resistance Test
Resistance Tests
Insulation and Coil Resistance test selector switches on the front panel of each test
panel provide convenient, calibrated measurements for DC Coil resistance and
Insulation Resistance of the signal conductors and coils.
The Coil Resistance test applies a 1mA current source to the coil and then measures
the voltage drop across the coil with 1mA flowing through it. This voltage drop is
displayed on the digital meter: 1mV @ 1 mA = 1 Ohm.
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The Insulation Resistance test applies a 100 Volt source to the selected conductor.
A 1Meg series resistor provides measurement and limits current to 100uA max with
a direct short across the output. The voltage drop across this resistance is compared
with a reference voltage to toggle the output LEDS; red if the resistance is less than
19.5M Ohms and Green if greater than 20M Ohms.
Calibration Procedure
The power supply calibration consists of checking the + 25 volt input supplies, the
+15 volt and + 5 volt regulators. If the LM7815, LM7915 and LM7805 voltage
regulators are working properly, no adjustment is required. If there is a problem, it
will probably be either a short in the circuit that is exceeding the current capability
of the regulator, or the regulator has failed.
During calibration, even if measured values are within limits, record the voltage
outputs from all three regulators so that long term trending of circuit performance
can be noted.
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Figure 2 TorqueMotor PC Board Schematic
page 9 of 13
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Figure 3 TorqueMotor PC Board Silkscreen Artwork
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Figure 4 Electrical speed Trim TorqueMotor PC Board Component Side
ATE-CFM56-3 Manual
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Item Quan tity
Reference
2
2 A1,A2
3
1 A3
4
1 A4
5
1 BR1
6
4 C1,C31,C33,C36
7
2 C2,C15
8
18 CFr1,Cm1,CFr2,C3,C4,C6,
8.1
C7,C9,C10,C11,C12,C13,
8.2
C14,C16,C17,C32,C34,C37
9
2 CFr3,C5
10
5 Rm1,Rm2,Rm3,Rm4,C8
11
2 C30,C35
12
6 D1,D2,D3,D4,D5,D6
13
1 F1
14
1 FR In
15
1 GND1
16
1 HS1
17
3 HS2,HS3,HS4
18
2 Ry2,L9
19
1 L10
20
1 L10b
21
1 L11
22
2 MOV1,MOV2
23
1 MU2
24
2 P1,P3
25
2 P4,P6
26
1 P5
27
1 P7
28
1 P8
29
1 P9
30
1 PL2
31
1 Q6
32
4 Q9,Q10,Q10b,Q11
33
1 R1
34
2 R2,R20
35
1 R3
36
2 R4,R5
37
4 R6,R8,R10,R13
38
4 R7,R9,R11,R14
39
1 R12
40
1 R15
41
1 R21
42
3 R22,R24,R25
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Part
LM124
OPA541AP
LM301A
BRIDGE
10uF
1uF
.1uF
33pF
tbd
1kuF 50V
1N4148
.5A
1V=10mA
GND/SHLD
HS
HS1
1mA/100V
Norm/Test
Mode
ChA/ChB
130V
DMSBCD
12LONG
DB9F
WGCBUS
Bus
Spare
26LONG
Umb
LM299
2N3904
43.2k
7.5k
5 Ohm
1.5k
4.53k
365 Ohm
1 Ohm
10k
75k
90.9k
ATE-CFM56-3 Manual
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
4
1
2
1
1
1
1
1
1
2
3
1
1
1
1
1
1
2
Rfr3,Rfr4,R23,R26
Rfr1
Rfr2,Rfr5
Ry1
Ry3
Ry4
S2
S3
SW1
T1,T2
VR1,VR2,VRFr
VR3
VR4
VREG1
VREG2
VREG3
VRm1
com,hot
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49.9k
1k
100k
MODE SEL
Nrm/Tst
Pri/Sec
100V/1mA
TMCoil
DPDT
7.5VA/12.5VA
100K
10K
20K
LM7805
LM7815
LM7915
1K
ts1