Itron 925 Operational Instruction

C&I Electric

Unit Test Procedure

Revision A

August 22, 2000

Table of Contents

1. Equipment Requirements

2. PCA Sub-Assembly Power Supply Function Test

3. PCA Sub-Assembly RF Communications Test

4. Final Assembly Test

5. Shipping Preparation

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 2 of 24

1. Equipment Requirements

DVM (Digital vo ltmeter) w ith ohm and a m p fu nctio ns.
(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 Com m unications Ch ip (Silicon ians ) NCI installed
Unit Under Test (UUT), in this case the C&I Electric Unit, Fab. Rev. 5.3 or higher, Firmware Ver. 23 or
higher (CnI_V23.HEX, CS = 1c59)
(Innovatec, Relay, Rev. 5.3 or later)

Note: The information in parenth eses is a suggested test equipment Manufacturer and Model.
Equivalents may be substituted.

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 3 of 24

2. PCA S ub-Assem bly Power Supply and Battery Charg er Function Test

The f ollowing test in this section is t o be perfor med before the P CA is in stalled into t he Relay Hous ing.

2.1. Visual Inspection

2.1.1 Verify th at t he followin g components are installed w ith pr o per orientat io n / polarity, per as sembly
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

2.2.1 Perform continuity test using DVM between metal tabs of U1, D2 and their heatsinks.

It should be open circuit or > 10 Meg Ohms for U1 and > 2 Meg Ohms for D2.

Pass____Fail___

2.2.2 Perf o rm con tin uity tes t b etween inp ut AC line con nectors (J3 to J 4 ) an d line to groun d (J3-H to
J1-G and J4-N to J1-G). Should be open circuit or >2 Meg Ohms.

Pass____Fail___

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 4 of 24

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 u p the voltage fr om 0 –85V wh ile monitoring the line current.
The line current at 85V should be < 15 mA

2.3.2. Wait few seconds and then verify all LEDs are turned on.

2.3.3. Measure the DC voltage between pins 3 and 21 of NCI connector (J7).

Specification: 5.5 – 5.7V DC.

2.3.4. Measure DC voltage between pins 15 and 21 of N CI connector (J7).

Specification: 5.0 to 5.1 Vdc

2.3.5. Measure DC voltage between pins 17 and 21 of N CI connector (J7).

Specification: 3.5 to 3.7 Vdc

2.3.6. Measure DC voltage between pins 2 and 5 of Molex connector (JP2).

Specification: 12 to 14 Vdc

Pass____Fail___

Pass____Fail___

Pass____Fail___

Pass____Fail___

Pass____Fail___

Pass____Fail___

2.3.7. Disconnect AC Power to UUT and install NCI unit onto the main board. Then, bring the voltage
slowly up to 85 Vac and repeat the above steps 4.2- 4.6.

Pass____Fail___

2.3.8. Bring u p the AC line voltage slowly from 85 to 265 Vac and rep eat the above steps with NCI
insta lled (f ull- lo ad).

Pass____Fail___

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 5 of 24

2.4. Battery Charger Tests

2.4.1. Connect battery charger module to C&I main board connector (JP2) and ver ify that the voltag e
across BAT + and BAT- on the charger board is set to 6.9 Vdc with 680 Ohm resistor c on n ected
across battery leads. Otherwise, adjust R7 P o t to set battery vo ltage to 6.9Vd c.

2.4.2 . Connect b attery leads to the b att er y termin als an d verify that v oltage across battery ter minals

has reached to 6.9Vdc (fully charged).

2.4.3. Disconnect AC power to C&I main board and verify th at the LEDs stays on (good indication that

UUT is powered by battery only).

2.4.4. Remove battery charger module from C&I board with battery leads disconnected from battery
terminals . Then con nect a d c pow er supply t o batter y lead s and slowly increase th e vo ltage fro m
0-6.5 Vdc while monitoring battery status pin (JP1-4). Verify that battery status pin goes high at

5.25 Vdc

2.4.5. Then, lower the dc Power supplies voltage slowly and verify that battery status pin (JP1-4) goes
low at 5.0Vdc.

Pass__Fail___

Pass__Fail___

Pass__Fail___

Pass__Fail___

Pass__Fail___

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 6 of 24

3. PCA S ub-Assem bly RF Communi cations Test

3.1. System Hardware Set-up:

3.1.1. Firmware Installation:
Remo ve AC line v o ltage fro m PCA p ower leads.

Disconnect battery lead from Charger Assembly.
Verify in s tallation of the EP ROM with appropriate firmw are rev er s ion.

3.1.2. NCI Ins t a l la t i o n :
In stall the NC I with version 2 c o m m unic ation s IC (Silicon ians) onto t he PCA with appropriate

antenna, 900 MHz, and 50 Ohms impedance.

3.1.3. Electric Meter RS-232 Communicat ion c on n ection:
In stall the Electric Meter to connecto r J7 as follow :

J7, Pin 12 = Tr an s m it (Pin 2 of the DB9 M eter commun ications cable)
J7, Pin 11 = Receive (Pin 3 of the DB9 M eter co m m unications cable)
J7, Pin 10 = Ground (Pin 5 of the DB9 Meter communications cable)

Power up t he electric meter.

3.1.4. Power on test:
Apply 120V AC line voltage to the PCA power leads, observe for the Status Indicator LEDs, make

sure the Green and Yellow LEDs are illuminated.
Reconnect battery lead to Charger Assembly.

Pass__Fail___

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 7 of 24

3.2. NCTT Setting:

Using the PC, star t the NCTT program.
Connect the FS U (Field Service Unit) with v ersion 2 commu nications IC (S ilico nians) to the PC.
Select “Setting” ! “Option”:
Serial Port: = Select appropriate Serial Port

Wakeup Interval = 1.25 Sec
Transmit Power = 28 dBm
Repeat Interval = 3 Sec (Min.); Unchecked “Random”
NCI Int e r a ct i o n = Che ck e d “Aut o m at i c”
Conversion Factor = 0.00001

FIGURE 1

Select “O.K.”, then setting NCTT for C&I Electric Communications:

Document Type: Test Procedure
Equipment Name: Innovatec C and I Electric
Author: Dithien V. Ho, RF Design Engineer.

Page 8 of 24