Advanced Systems Tester 900AST Series Calibratin Verificatin Prcedure Instructins February 2006
Table f Cntents Intrductin...3 Test Instruments Required...3 Test Cmpnents Required...3 Test Prcedure...3 Self-Calibratin...3 DC Vlts...3 AC Vlts...4 Ohms...4 Capitance...5 ID Tne...5 TDR...6 Precisin Resistance Measurements...7 Special Resistance / Resistive Balance...9 Cntact Resistance...9 Appendix A...10 Appendix B...11 Appendix C...15
Intrductin This dcument is a prcedure t verify the calibratin f the 3M Advanced Systems Tester 900AST. An internal sftware calibratin functin is prvided in the 900AST tester fr self-calibratin f internal circuits and test leads. This shuld be run n a peridic basis, r after lead replacement. T ensure the maximum accuracy this internal self calibratin shuld be run using the same adapters at the ends f the test leads as thse that will be used during measurements. The prcedure cntained in this dcument is prvided nly as an assurance t the custmer that the 900AST tester is functining within its specified precisin limits. If any f the results f these tests fail t fall within the limits given, the instrument shuld be returned t 3M fr service. Befre equipment is sent in fr repair, upgrade, and/r calibratin, yu must first get a Return Material Authrizatin (RMA) number frm the 3M Repair & Service Center. Please cntact yur 3M Repair & Service Center Custmer Service Representative, tll-free, by dialing (800) 426-8688 and pressing ptin #2, fr test equipment upgrades, calibratin, r warranty service. Test Instruments Required The fllwing test instruments r their equivalent are required t run the 900AST tester functinal verificatin prcedure. Agilent 34401A 6-1/2 Digit Multimeter () r equivalent Agilent 11059A Kelvin Prbe Set r equivalent Agilent 33220A 20 MHz Functin Generatr / Arbitrary Wavefrm Generatr r equivalent Tektrnix 1502C Metallic TDR Cable Tester r equivalent Tektrnix TDS 220 tw channel scillscpe r equivalent RFL Industries Mdel 828 AC/DC V-A Surce r equivalent Test Cmpnents Required The fllwing cmpnents are required fr this 900AST tester Calibratin Verificatin Prcedure. Resistr Netwrk fr Verifying RFL/Cntact Resistance/Special Resistance, see Appendix A. Capacitr film Mkt 1.0 μf 250VDC 1% radial lead Capacitr Panasnic ECG 0.01 μf (10 nf) 100V PPS film ECHS radial lead (Digikey P/N PS1103J-ND) Precisin Metal Film 1% tlerance +/-50ppm/ C 0.6W axial lead Resistrs, ne each: 135, 10.0K and 1.00M Ohm. 3 Optinal: Precisin Metal Film 1% tlerance +/-50ppm/ C 0.6W axial lead Resistrs, ne each: 1.00K, 100K, 10.0M and 115M Ohm. 20 feet RG62A/U 93 Ohm cax with Male BNC n ne end. Other end is pen. One duble female BNC cupler. Test Prcedure Self Calibratin Run the internal self-calibratin. Nte: T ensure the maximum accuracy f the 900AST tester the internal self calibratin must be run using the same adapters at the ends f the test leads as thse that will be used during measurements. With the unit n, press the tl key (4). Cursr up as necessary t highlight Self Calibrate and press the Enter key. Shrt all 5 leads tgether. Press Enter. Wait fr Calibratin t cmplete (Apprximately 2 minutes). DC Vlts Self Calibratin Cmplete? Verify tw DC vltage measurements: Select Vlts functin (blue key 1) Ensure DC Vlts is selected. Set the RFL Mdel 828 surce fr 2.0 VDC. With the surce de-energized, cnnect the red and black leads f the 900AST tester and the (in parallel) t the surce. Select OPERATE n the surce and verify the DC vltage n the 900AST tester with that measured with the De-energize the surce Change the surce t 48 VDC. Select OPERATE n the surce and verify the DC vltage n the 900AST test set with that measured with the De-energize the surce. Change the surce t 120 VDC (1K Vlts, scale factr 0.120). Select OPERATE n the surce and verify the DC vltage n the 900AST unit with that measured with the De-energize the surce. Change the surce t 250 VDC (1K Vlts, scale factr 0.250). Select OPERATE n the surce and verify the DC vltage n the 900AST unit with that measured with the De-energize the surce.
AC Vlts Input [VDC] [VDC] [VDC] 2.0 1.5 2.5 48.0 47.0 49.0 120.0 116.4 123.6 250.0 242.5 257.5 Verify tw AC vltage measurements: Select Vlts functin (blue key 1) Ensure AC vlts is selected. Set the RFL Mdel 828 surce fr 20.0 Vrms 60 Hz VDC. With the surce de-energized, cnnect the red and black leads f the 3M Advanced Systems Tester 900AST and the (in parallel) t the surce. Select OPERATE n the surce and verify the AC vltage n the 900AST tester with that measured with the. Repeat measurement fr 400 Hz. Set the surce t 200.0 Vrms 60 Hz. Select OPERATE n the surce and verify the AC vltage n the 900AST tester with that measured with the. Repeat measurement fr 400 Hz. De-energize the surce. Ohms Input [Vrms] [Vrms] 20.0 Vrms 60 Hz +/- 6 Hz 19.3 20.7 200 Vrms 60 Hz +/- 6 Hz 194 206 20.0 Vrms 400 Hz +/- 40 Hz 19.3 20.7 200 Vrms 400 Hz +/- 40 Hz 194 206 Fr resistance verificatin, the readings f the 900AST test set fr three resistrs are cmpared with thse measured with the. Using the measure and recrd the actual value f a 135, 10K and 1M hm metal film resistr. Calculate the 900AST unit's tlerance n these resistrs using the table belw: Apprximate Resistance, R Calculate, R Calculate 135 x 0.99-5 = x 1.01 + 5 = 10K x 0.99 = x 1.01 = 1M x 0.97 = x 1.03 = Select Ohms (Blue key 3) n the 900AST tester. Verify that the 900AST test set's measured value f each resistr is within the calculated range determined frm the value measured with the. Apprximate Resistance 135 10K 1M
Additinal accuracy ranges can be verified, but are nt necessary as the same hardware is used fr all resistance measurements. OPTIONAL: Using the measure and recrd the actual value f a 1K, 100K, 10M and 150M hm metal film resistr. Calculate the 3M Advanced Systems Tester 900AST's tlerance n these resistrs using the table belw: Optinal Apprximate Resistance, R Calculate, R Calculate 1K x 0.99-5 = x 1.01 + 5 = 100K x 0.97 = x 1.03 = 10M x 0.95 = x 1.05 = 150M x 0.90 = x 1.10 = Select Ohms (Blue key 3) n the 900AST tester. Verify that the 900AST tester measured value f each resistr is within 1% +/- 5 hms f that measured with the. Capacitance Optinal Apprximate Resistance 1K 100K 10M 150M, R Fr capacitance verificatin tw precisin (2% r better) capacitrs are used t verify the readings f the 900AST tester. Select Capacitance functin (blue key 5) n the 900AST tester. Verify that the measured value f each capacitr is within 10% f its value. ID Tne Capacitance Lw Limit High Limit 10 nf 9 nf 11 nf 1 μf 0.9 μf 1.1 μf Fr ID Tne the 900AST tester ID utputs a nminal 8 Vp-p square wave under n lad with apprximately 50% duty cycle, at the selected frequency in tw bursts, each nminal 80 ms lng, spaced abut 80 ms apart. This dual burst is repeated apprximately every 560 ms. Nte: Because the ID tne is nt cntinuus, a frequency cunter cannt be used. On the scillscpe set hrizntal scale t 250 μs/div. sweep. On the CH1 menu select Cupling DC, BW Limit Off, Vlts/Div Carse. Select 2.00 V/div. On the MEASURE menu select CH1 Freq. On the Trigger menu select Edge Vide, slpe Rising, Surce CH1, Mde Single, Cupling DC. Cnnect the red and black leads f the 900AST tester t Channel 1. Nte that since the 900AST tester is islated either lead can be cnnected t grund. Reversing the leads will affect the DC ffset, but nt the frequency reading. 5
TDR Select the ID Tne functin (blue key 6) and verify that the selected frequency is 577 Hz. Press Enter t start the ID tne. Verify that the square wave frequency is 577 Hz +/- 1 Hz. In rder t btain a gd frequency measurement several samples may need t be taken by pressing the RUN/STOP buttn until a square wave is captured. ID Tne Lw Limit [Hz] Frequency [Hz] High Limit [Hz] 577 Hz 576 578 In rder t measure the distance t a fault by lcating the cursr at the start f the reflected pulse, the start f the rising edge f the start pulse must be at 0.0 inches. If it is nt, then the prcedure in Appendix B shuld be used t re-calibrate the TDR start pulse. Plug the supplied six ft caxial test lead in the red/black jacks. Leave the BNC end discnnected. Select the TDR functin (blue key 9) and enter TDR setup. Select the wire type as caxial. Select the Gauge as RG-8. Select First Length as Minimum. Start the TDR. If the base f the pen circuit is at 0.0 (left edge f the display), n adjustment is required. The image belw shws a TDR that requires n adjustment since the base f the pulse is a 0.0. If the base f the pen circuit is nt at 0.0 then re-calibrate its lcatin using the prcedure in Appendix B. Since the Vp f a wire in a cable bundle is specific t that cable, the verificatin f TDR is dne with a twenty ft lng 93 Ohm caxial cable whse Vp has been determined by the Tektrnix 1502C Metallic TDR Cable Tester. Determine Vp f 20 ft caxial cable: Turn n the Tektrnix 1502C Metallic TDR Cable Tester, set the dist/div t 5.0 feet. As a preliminary value, set the Vp t 0.84. Adjust the <> psitin cntrl until the cursr is at the start f the rising prtin f the start pulse. Zer the meter by selecting hriz and pressing the stre buttn. Cnnect the 20 ft caxial cable t the Tektrnix 1502C Metallic TDR Cable Tester. Mve the cursr t exactly 20 feet and adjust the Vp until the cursr is at the start f the rising prtin f the reflected TDR pulse. Remve the cable and verify that the start f the rising prtin f the start pulse is still at 0.0 feet. If nt, repeat the abve. Recrd the Vp. Measure the length f the cable with the 3M Advanced Systems Tester 900AST with 3ns Pulse: Plug the supplied six ft caxial cable int the 900AST red-black input. Plug the BNC f the 20 caxial cable int the six ft caxial cable. 6
Turn n the 3M Advanced Systems Tester 900AST, select the TDR (blue key 9) and g int setup. Select caxial cable, and set the Vp t that previusly measured by the 1502C and press Enter. Select Single Trace and press Enter. Select the 384 range. This will autmatically use a 3ns pulse. Mve the cursr t the start f the rising prtin f the reflected pulse. Recrd this distance reading. 3ns TDR Vp f 20 cable (~0.84) Lw Limit [inches] High Limit [inches] Test lead + 20 cable 235 245 Measure the length f the cable with the 900AST test set using a 5ns Pulse: Cntinuing frm the previus, 3ns measurement, press the left-right arrw key until Pulse is displayed at the bttm f the screen. Using the up-arrw key change the pulse width t 5ns. Mve the cursr t the start f the rising prtin f the reflected pulse. Recrd this distance reading. Mve the curser t 0.0 in. Verify that this is the start f the rising edge f the pulse. 5ns TDR Vp f 20 cable (~0.84) Lw Limit [inches] High Limit [inches] Test lead + 20 cable, 5ns Pulse 235 245 With test lead nly, start f rising edge f 5ns pulse is at 0.0 inches Precisin Resistance Measurements Passed The same 900AST tester internal circuits are used fr Resistive Fault Lcate (RFL), Special Resistance (als called Resistive Balance), and Cntact Resistance, therefre it is nt necessary t verify bth RFL and Resistive Balance. Nte: T achieve the accuracy specificatin, the lead adapters used during 900AST tester internal self calibratin must be the same as used during these tests. Using the Agilent 34401A 6-1/2 Digit Multimeter in 4 wire resistance mde, with Agilent 11059A Kelvin Prbe Set measure and recrd the values f the resistances in the table belw f the Resistr Netwrk fr Verifying RFL/Cntact Resistance/Special Resistance (See appendix A). B D Ten 1.00 Ohm resistrs in parallel t make ~ 0.100 Ohms A Tw 1.00 Ohm resistrs in parallel t make ~ 0.500 Ohms 1K Ohm C 7
Parameter Measurement Pints Apprximate RTS (Resistance t Strap) B t C 0.600 RTF (Resistance t Fault) B t D 0.100 Rf (Fault Resistance) A t D 1K Resistive Fault Lcate (RFL) Verify that the RFL values f the Resistr Netwrk fr Verifying RFL/Cntact Resistance/Special Resistance fall within the specified limits. Frm the resistance values abve use the table belw t determine the acceptable RFL lwer and upper limits. Parameter Apprximate Tlerance: Lwer Limit Tlerance: RTS (B-C) 0.600-0.010 = - 0.010 = RTF (B-D) 0.100-0.010 = - 0.010 = Rf (A-D) 1.00K - 15 = - 15 = Make the RFL measurement and cmpare the results with these limits. Cnnect the black lead t the pen end (pint A) f the 1K hm resistr. Cnnect the red and blue test leads t the pen end (pint B) f the 0.100 hm resistr. Cnnect the green and yellw test leads t the pen end (pint C) f the 0.500 hm resistr. Select RFL (blue key 7) n the 900AST tester and press Enter. Wait fr the measurement t cmplete. Ensure that hms (nt distance) is selected. Verify that the Resistance t Strap (RTS) value (upper reading) is that f the measured B t C value +/- 0.010 hms. Verify that the Resistance t Fault (RTF) value (left center reading) is that f the measured B t D value +/- 0.010 hms. Verify that the Fault Resistance (Rf) value (lwer left reading) is that f the measured A t D value +/- 15 hms. Red & Blue Leads B Ten 1.00 Ohm resistrs in parallel t make ~ 0.100 Ohms RFL VERIFICATION Measurement Pint RTS (B-C) RTF (B-D) Rf (A-D) D A Tw 1.00 Ohm resistrs in parallel t make ~ 0.500 Ohms 1K Ohm Black Lead Green & Yellw Leads C Upper Limit 8
Special Resistance / Resistive Balance This functin is verified using the previus RFL test. Cntact Resistance Measure the precise value f the 0.500 hm resistr in the resistr netwrk fr verifying RFL/Cntact Resistance/ Special Resistance. Using the values previusly measured with the, calculate the acceptable lwer and upper limits. The table belw is prvided t assist in this calculatin. Measurement Pint Apprximate Tlerance: Lwer Limit Tlerance: B t D 0.100-0.010 = - 0.010 = C t D 0.500-0.010 = - 0.010 = Turn n the 3M Advanced Systems Tester 900AST, select the hms functin (blue key 3). Press the left arrw t select Cntact Resistance. Cnnect the red and the blue leads t the pen end f the 0.100 hm resistr (pint B) n the resistr netwrk. Cnnect the green and the yellw leads t the cmmn center (pint D) n the resistr netwrk. Press Enter and wait fr the measurement t cmplete. Cnnect the red and the blue leads t the pen end f the 0.500 hm resistr (pint C) n the resistr netwrk. Press Enter and wait fr the measurement t cmplete. Measurement Pint B t D C t D A Upper Limit Green & Yellw Red & Blue Leads Red & Blue Leads Leads B t D D C t D B C Tw 1.00 Ohm resistrs Ten 1.00 Ohm resistrs in parallel t make in parallel t make ~ 0.500 Ohms ~ 0.100 Ohms 1K Ohm CONTACT RESISTANCE VERIFICATION 9
APPENDIX Appendix A: Resistr Netwrk fr Verifying RFL/Cntact Resistance/Special Resistance This resistr netwrk cnsists f three sets f resistrs wired and sldered tgether in a T netwrk. Parts required: Twelve 1.00 hm 1% 0.6W +/-50ppm/C axial leaded metallic film resistrs (Digikey P/N MRS25F-1-ND) One 1.00K hm 1% +/-50ppm/C axial leaded metallic film resistr (Digikey P/N PPC-1.00K-ND) Assembly Instructins: Parallel ten 1.00 hm 1% metallic film resistrs t create the precisin resistance left side f the tp f the T. This resistance is apprximately 0.1 hms. Parallel anther tw 1.00 hm metallic film resistrs t create the precisin resistance right side f the tp f the T. This resistance is apprximately 0.5 hms. The stem f the T cnsists f a single 1K 1% metallic film resistr. B Ten 1.00 Ohm resistrs in parallel t make ~ 0.100 Ohms 1K Ohm D A Tw 1.00 Ohm resistrs in parallel t make ~ 0.500 Ohms C 10
Appendix B: Zering the 3M Advanced Systems Tester 900AST TDR 900AST units manufactured with Versin 2.0 sftware and later have the capability f adjusting the TDR launch timing s that the start f the launch pulse is at 0.0 inches. This prcess is perfrmed during the manufacturing f the unit. If necessary it can be perfrmed in the field as n external test equipment is required. Please use the fllwing prcedure t verify that the TDR is crrectly zered t the end f the caxial test leads. 1. Insert a caxial test lead in the Red/Black jacks. Leave the BNC end discnnected. 2. G t TOOLBOX -> MAINTENANCE, enter the sequence 9844185 using the keypad, and then press the [Enter] key. The unit will display Clear All fr a few secnds and then rebt. This is necessary t refrmat the system memry t prvide a lcatin fr the new TDR Launch Delay variable. Nte: Unit may require self-calibratin after perfrming this step. 3. G t TOOLBOX -> MAINTENANCE, enter the sequence 5594 using the keypad, and then press the [Enter] key. Yu will see a screen like this: If yu d NOT see a 5 next t the lwer bx, use the blue 5 key t enter a 5 in the lwer bx and press the [Enter] key. This ensures that yu are starting frm the neutral (nn-shifted) psitin initially. Nte: 5 is the zer shift value. s less than 5 shift t the right and values greater than 5 shift t the left. Yu can always return t 5 t get the initial zer shift trace. Press the [Return} key t exit MAINTENANCE and again t exit the TOOLBOX. 4. Start the TDR functin and enter TDR setup. Select the wire type as Caxial. Select the Gauge as RG-8. Select First Length as Minimum. 11
5. Start the TDR. Put the cursr at the base f the pen. If the base f the pen is nt visible, skip t step 9 belw. If the base f the pen circuit is at apprximately 0, n adjustment is required. The image belw shws a TDR that requires n adjustment since the base f the pulse is a 0. 6. If the base f the pen circuit is shifted left r right frm 0, yu can use a Maintenance cde t shift the trace int psitin. First, determine the apprximate amunt that the trace is shifted. 7. If the trace is shifted right n the screen, put the cursr n base f the pen as shwn. In this case, the base is at 14. The trace must be shifted by 14 t the left t get the base at 0. 8. G t TOOLBOX -> MAINTENANCE, enter the sequence 5594 using the keypad, and then press the [Enter] key. Yu will see a screen like this: 9. Refer t the Table belw fr the delay factr t use t shift the trace. In this case, select delay factr 8 t shift the pulse left by 13.2. Enter 8 using the blue key 8 and then press [Enter] t accept. Press the [Return] key t exit. The adjustment factr is saved in system memry. Run the TDR functin again t verify that the base f the pulse is lcated at r near 0. 12
10. If the trace is nt visible n the screen because the pulse is shifted t far left (as in the image belw), the pulse must first be shifted as far right as pssible t make the pulse base viewable. 11. First, g t TOOLBOX -> MAINTENANCE, enter the sequence 5594 using the keypad, and then press the [Enter] key. Yu will see a screen like this: 12. Enter 0 using the 0 blue key. Press [Enter] t accept and then the [Return] key t exit. Press the TDR blue key t restart the TDR. The pulse will have shifted as far right (22 ) as pssible. Psitin the cursr n the base f the pulse. In this case the cursr is at 14 n the right-shifted pulse. 13
13. At this pint yu can determine that the pulse needed t shift 22 14 = 8 t the right. Use the Table belw t determine the delay factr fr an 8 right shift. G t TOOLBOX -> MAINTENANCE, enter the sequence 5594 using the keypad, and then press the [Enter] key. Use the blue 3 key t enter a 3 and press the [Enter] key t accept. Press [Return] t exit MAINTENANCE. The shift value is nw saved in memry. Shift Directin Shift Amunt Delay Factr Right 22 0 Right 17.6 1 Right 13.2 2 Right 8.8 3 Right 4.4 4 Nne 0 5 Left 4.4 6 Left 8.8 7 Left 13.2 8 Left 17.6 9 Left 22 10 14. Enter TDR mde and verify that the pulse is similar t the image belw t verify that the prcedure has been successfully cmpleted. 14
Appendix C: 3M Advanced Systems Tester 900AST Electrical Specificatins Functins Range Reslutin Accuracy Vltage (DC) 0 t 99.9 V 0.1 V 1% f reading ± 0.5 V 100 t 300 V 1 V 3% f reading Vltage (AC) 0 t 99.9 V 0.1 V 1% f reading ± 0.5 V 100 t 250 V 1 V 3% f reading Ohms (resistance) N freign vltage * 0 t 9999 hms 1 hm 1% f reading ± 5 hm With freign vltage present 0 t 9999 hms 1 hm 1% f reading ± 50 hms 10 k t 99.9 k hms 0.1 k hm 1% f reading 100 k t 999 k hms 1 k hm 3% f reading 1 M t 9.9 M hms 10 k hm 3% f reading 10 M t 99 M hms 0.1 M hm 5% f reading 100 M t 990 M hms 1 M hm 10% f reading Cntact Resistance * 0 t 5 hms 0.001 hm 0.1% f reading +/- 0.01 hm Special Resistance * 0 t 25 hms 0.01 hm 1% f lp resistance ± 0.01 hm Capacitance) 10nF t 9.9uF 1nF 10% f reading ID Tne RFL * 200 t 1000 Hz, fixed level, interrupted Fault range 0 t 500 K hms 1Hz +1Hz Resistance t Fault 0 t 15 hm 0.001 hm 0.1% f RTS +/- 0.01 hm TDR ** Pulse width 3ns, 5ns, 34ns Fixed values Ranges (nminal, specified fr twisted pair with Vp f 0.68) 192, 384, 624, 1320, 2640, 3840, 5760, 15360 Velcity f Prpagatin 0.10 t 0.99 0.01 Mdes 2% f range Single, Dual, Differential, Crsstalk, Memry, Peak * Measurement applies current-limited (<1mA) 80V stimulus ** Measurement applies pulse amplitude f apprximately 60Vpeak 15
3M is a trademark f 3M Cmpany. Other trademarks used herein are the prperties f their respective wners. Imprtant Ntice All statements, technical infrmatin, and recmmendatins related t 3M s prducts are based n infrmatin believed t be reliable, but the accuracy r cmpleteness is nt guaranteed. Befre using this prduct, yu must evaluate it and determine if it is suitable fr yur intended applicatin. Yu assume all risks and liability assciated with such use. Any statements related t the prduct which are nt cntained in 3M s current publicatins, r any cntrary statements cntained n yur purchase rder shall have n frce r effect unless expressly agreed upn, in writing, by an authrized fficer f 3M. Warranty; Limited Remedy; Limited Liability. This prduct will be free frm defects in material and manufacture fr a perid f ne (1) year frm the time f purchase. 3M MAKES NO OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. If this prduct is defective within the warranty perid stated abve, yur exclusive remedy shall be, at 3M s ptin, t replace r repair the 3M prduct r refund the purchase price f the 3M prduct. Except where prhibited by law, 3M will nt be liable fr any indirect, special, incidental r cnsequential lss r damage arising frm this 3M prduct, regardless f the legal thery asserted. Aerspace and Aircraft Maintenance Divisin Transprtatin Business 3M Center, Building 220-9W-14 St. Paul, MN 55144-1000 Recycled paper 1-800-364-3577 r 651-737-6501 40% Pre-cnsumer waste paper www.3m.cm/aerspace 10% Pst-cnsumer waste paper Lith in USA 3M 2006