C&I Electric Unit Test Procedure Revision A August 22, 2000
Table of Contents 1. 2. 3. 4. 5. Equipment Requirements PCA Sub-Assembly Power Supply Function Test PCA Sub-Assembly RF Communications Test Final Assembly Test Shipping Preparation Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
1. Equipment Requirements DVM (Digital voltmeter) with ohm and amp functions. (Bel MERIT, DX451) Dual Channel Oscilloscope, 100 MHz, 1GBs (Tektronix, TDS 220) Variable/Isolation AC Transformer (VIT), 0-150 Vac, 4 Amp (Global Specialties, 1504) PC with Windows 95 Operating System NCTT, Test software, Version 2.2.0 or later Field Service Unit with Version 2 Communications Chip (Siliconians) NCI installed Unit Under Test (UUT), in this case the C&I Electric Unit, Fab. Rev. 5.3 or higher, Firmware Ver.
2. PCA Sub-Assembly Power Supply and Battery Charger Function Test The following test in this section is to be performed before the PCA is installed into the Relay Housing. 2.1. Visual Inspection 2.1.1 Verify that the following components are installed with proper orientation / polarity, per assembly drawings: IC’s, Transistors, Diodes, Capacitors and Transformer. 2.1.2 Check for solder bridges/solder splash across traces or other conductors. Pass____Fail___ 2.2. Continuity Tests 2.2.
2.3. Power Supply Test 2.3.1. Connect 220 V variac (with isolation transformer and built-in fuse) to the input connector of power supply. Then, slowly bring up the voltage from 0 –85V while monitoring the line current. The line current at 85V should be < 15 mA Pass____Fail___ 2.3.2. Wait few seconds and then verify all LEDs are turned on. Pass____Fail___ 2.3.3. Measure the DC voltage between pins 3 and 21 of NCI connector (J7). Specification: 5.5 – 5.7V DC. Pass____Fail___ 2.3.4.
2.4. Battery Charger Tests 2.4.1. Connect battery charger module to C&I main board connector (JP2) and verify that the voltage across BAT + and BAT- on the charger board is set to 6.9 Vdc with 680 Ohm resistor connected across battery leads. Otherwise, adjust R7 Pot to set battery voltage to 6.9Vdc. Pass__Fail___ 2.4.2. Connect battery leads to the battery terminals and verify that voltage across battery terminals has reached to 6.9Vdc (fully charged). Pass__Fail___ 2.4.3.
3. PCA Sub-Assembly RF Communications Test 3.1. System Hardware Set-up: 3.1.1. Firmware Installation: Remove AC line voltage from PCA power leads. Disconnect battery lead from Charger Assembly. Verify installation of the EPROM with appropriate firmware reversion. 3.1.2. NCI Installation: Install the NCI with version 2 communications IC (Siliconians) onto the PCA with appropriate antenna, 900 MHz, and 50 Ohms impedance. 3.1.3.
3.2. NCTT Setting: Using the PC, start the NCTT program. Connect the FSU (Field Service Unit) with version 2 communications IC (Siliconians) to the PC. Select “Setting” ! “Option”: Serial Port: Wakeup Interval Transmit Power Repeat Interval NCI Interaction Conversion Factor = = = = = = Select appropriate Serial Port 1.25 Sec 28 dBm 3 Sec (Min.); Unchecked “Random” Checked “Automatic” 0.00001 FIGURE 1 Select “O.K.
3.3. C&I Electric Communications and Functional Test 3.3.1. General device setup in NCTT: For “DEVICE”, select “Electric IMU” and “Device ID” select “7” For “TRANSMIT”, select “CHANNEL”= 0 (Default for untested Relay PCA) The following Transmit options are “unchecked”: “Auto Repeat” “Scan” “Wakeup/IMU” (The untested Relay UUT Communication Channel defaults initially to Channel 0; if unable to establish a communications link between the FSU and the Relay UUT, try to scan all channels for the UUT.
3.3.1. [Query Serial Number] Select Query Serial Numbers and select “Transmit!” Observer for the “Incoming Message”, make sure the FSU (Field Service Unit) are communicating with the UUT, and reporting the correct serial number for attached Meter (Either Landis & Gyr, Vectron or applicable Device) FIGURE 3 METER S/N REPORTED: ______________________ C&I DEVICE S/N REPORTED: ______________________ Pass__Fail___ Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V.
3.3.2. [Set Serial Number] Set “Electric USN” = Type in the C&I Serial Number then press “Transmit” Make sure to obtain a “Acknowledgement Message “ reply from Incoming Data Pass__Fail___ FIGURE 4 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
3.3.3. [Set Communication Parameters] RF CHANNEL LCD UPDATE RATE BLINK RATE = = = INITIAL CHANNEL 1 1 Press “TRANMIT” Make sure to obtain a “Acknowledgement Message “ reply from Incoming Data Pass__Fail___ FIGURE 5 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
3.3.4. [Query Status] Select “Query Status for Message Type” then press “Transmit” Make sure to obtain a reply from Incoming Data Pass__Fail___ FIGURE 6 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
4. Final Assembly Test The following test is to be performed after the PCA Assembly has been tested and install into appropriate Relay housing unit. 4.1. General Test Repeat step 3.3.2. and step 3.3.3., if necessary. 4.1.1. [Set Clock] Select “Set Clock” message, enter the applicable data then press “Transmit” Observe “Acknowledged Message “ reply in Incoming Data (See Figure 7) Pass__Fail__ FIGURE 7 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V.
4.1.2. [Query Clock] Select “Query Clock” message, enter the appropriate Relay Serial Number, and press “Transmit” Observe “Acknowledged Message” reply in the Incoming Data fields (See Figure 8) Verify Calendar and Clock settings. Pass__Fail__ FIGURE 8 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
4.2. Alarms Test: 4.2.1. [Set Alarm Option] Electric USN Set Alarm Active Mask Set Alarm Priority Mask Alarm Timer Alarm Channel = = = = = UUT Serial Number FFFFFFFF (8) FFFFFFFF (8) 1 (Optional) INITIAL CHANNEL (Same as Communications Channel) Pass__Fail___ FIGURE 9 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
4.2.2. Tamper Alarm Function Test: Open the C&I UUT cover (Will release the Tamper Switch) Verify the Tamper Alarm message is sent Pass__Fail___ FIGURE 10 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
4.2.3. Power Failure Alarm Function Test: Disconnect the ac power to the C&I UUT; verify the Power Failure Alarm Message is sent Pass__Fail___ FIGURE 11 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
4.2.4. Power Restore Alarm Function Test Re-connect the ac power to the C&I UUT; verify the Power Failure Restore Status Report Pass__Fail___ FIGURE 12 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
4.2.5. Disabling Alarm Transmit Function Test Repeat step 4.2.1 and set “Alarm Active Mask” and “Alarm priority Mask” to 0: Electric USN Set Alarm Active Mask Set Alarm Priority Mask Alarm Timer Alarm Channel = = = = = UUT Serial Number 00000000 (8) 00000000 (8) 1 (Optional) INITIAL CHANNEL (Same as Communications Channel) 4.2.5.1. Activate “Tamper” switch; observe for none alarm send message transmits. 4.2.5.2. Disconnect AC power; observe for none alarm send message transmits. 4.2.5.3.
4.3. Actuators Test: 4.3.5.
4.3.6.
4.4. Battery Power Sustain Test: 4.4.5. 4.4.6. Disconnect the ac power to the C&I UUT [Query Serial Number] Verify to obtain the correct Serial Number report for the C&I UUT. Pass__Fail___ FIGURE 15 Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
5. Shipping Preparation: • IMPORTANT!: Make sure to disconnect the hook-up wire from the Battery charger to the Positive (+) terminal of the battery! Battery Disconnect Check: Initial_____ • Mechanical Inspection: Inspect all harware, screw and nut, wires and cables for propper fitting. • Cosmetic Inspection: Inspect for cosmetic defective. Document Type: Test Procedure Equipment Name: Innovatec C and I Electric Author: Dithien V. Ho, RF Design Engineer.
