SHIMPO 921A User Manual
Contents
1 INTRODUCTION ................................................................................. 1.1
2 SETUP AND INTERCONNECTION .................................................... 2.1
2.1 Hardware ..................................................................................... 2.1
2.2 PC Connection............................................................................. 2.1
2.3 Software....................................................................................... 2.1
2.4 Precision Drive Mechanism Setup/Connection ............................ 2.3
2.5 Electrical Resistance Connection (Optional)................................ 2.4
2.6 Generic Nest Assembly Connection (Optional) ........................... 2.4
2.7 User Nests ................................................................................... 2.4
2.8 Force Transducer Tips ................................................................. 2.4
2.8.1 Interchangeable Force Transducer Tips ......................... 2.4
2.8.2 75 g, 360 g and 750 g Transducer Tips .......................... 2.7
2.9 Changing Force Transducer Assemblies ..................................... 2.7
3 CONFIGURATION ............................................................................... 3.1
3.1 Turn-On ....................................................................................... 3.1
3.2 Self-Test ...................................................................................... 3.1
4 OPERATION........................................................................................ 4.1
4.1 Calibration Mode .......................................................................... 4.1
5 SERVICE & ADJUSTMENTS .............................................................. 5.1
5.1 Service Mode ............................................................................... 5.1
5.1.1 Force Calibration ............................................................. 5.1
5.1.2 Resistance Offset (Resistance Option Only)................... 5.2
5.1.3 Lamp Test ....................................................................... 5.2
5.1.4 Resistance CCA Code/Switch Installed
(Resistance Option Only) ................................................ 5.2
5.1.5 Pressure Code ................................................................ 5.2
5.1.6 Displacement Verification ............................................... 5.3
6 TROUBLESHOOTING ........................................................................ 6.1
Appendix A Restrictions and DF Warning / Problem / Failure Message
Descriptions
Appendix B Force Transducer CCA Calibration
Appendix C Resistance Adjustment / Verification
Appendix D Displacement Verification Procedure
ii
SECTION 1
INTRODUCTION
The Model 921A Displacement - Force (DF) Test Station operation is similar
to the highly acclaimed Models 951A and 961A Test Stations. The high
accuracy and many of the features of the 951A and 961A have been
incorporated in the 921A. Testing on the 921A is performed using remote
test fixtures similar to the 961A. The remote operation permits testing a wide
variety of components/devices and also allows the 921A to operate as part of
a fully automated test line. Keyboards, springs, switches and other
components requiring measurement of displacement, force, or resistance
(one channel optional) can be tested manually, individually or with automatic
feed. The 921A is also ideally suited for engineering investigation and new
product development. Table 1-1 lists the specifications of the 921A.
When interfaced with a personal computer (PC), the resulting test data can
be viewed, analyzed, and printed. The 921A stores test criteria for one test
configuration. To assure simplicity of operation and efficient, effective, errorfree use by anyone, the test station displays operator prompts and provides a
minimum of operator controls: a MODE switch and a TEST switch.
Three operating modes are featured: 1) Local - a pass/fail indication is
provided during standalone operation, test results are not stored; 2) PC - a
PC interfaces with the test station and is used to configure device test criteria
and view stored test results; and 3) Engineering - test data is logged for
every 0.0001 inch of travel and is available for viewing at the PC.
The 921A features a precision lead-screw drive mechanism used to trip the
device under test which serves to guarantee repeatability of results.
Prior to testing, the operator must perform a calibration cycle (refer to section
4.1). Testing cannot be initiated until a calibration cycle has been performed.
1.1
TABLE 1-1
MODEL 921A DISPLACEMENT - FORCE TEST STATION
SPECIFICATIONS
Power Requirements 115/220 V ac, 50/60 Hz, 230 VA
Test Cycle Time 6 to 10 seconds typ
Resistance Test Current 10 mA standard*
Resistance Measurement One (Optional)
Channels
Displacement*
Range: 6.25 to 62.51 mm (0.246 to 2.461 inches)
standard*
Resolution: 0.00254 mm (0.0001 inch)
programmable
Abs Accuracy†: ±0.00762 mm (±0.0003 inch) max
±0.00254 mm (±0.0001 inch) typ
±0.00762 mm (±0.0003 inch) max
±0.00254 mm (±0.0001 inch) typ
Force*
Range: 0 to 3.6 kg (0 to 8 lb)
Resolution: 1 g (0.035 oz)
Abs Accuracy: ±0.25% of fsc max, ±0.2% of fsc typ
Repeatability: ±0.1% of fsc max, ±0.05% of fsc typ
Resistance* (Optional)
Range: 0 to 4 5
Resolution: 1 m5
Abs Accuracy: ±0.25% of fsc max, ±0.1% of fsc typ
Repeatability: ±0.1% of fsc max, ±0.05% of fsc typ
* Other ranges available.
† Related to free position.
standard*
standard*
1.2
The test sequence is initiated by pressing the TEST switch or externally by the
PC. During the test sequence, sensor data is logged in 921A memory. Test
data is then analyzed, parameters are calculated, and the results are
compared with the configuration criteria to determine a pass or fail status. The
PASS or FAIL indicator then illuminates. Upon completion of the test
sequence, the 921A is ready to test the next device.
The 921A stores test criteria for one device configuration and up to 32 test
results (PC operating mode) in non-volatile memory so that once loaded the
station will retain the test criteria even upon power-down. Device
configurations are identified by device part numbers. The operator's display
indicates which device is currently being tested by displaying the part number
of the device in the left-hand corner of the display.
For a complete description of operating modes, configuration parameters, test
results, test algorithms and the details for creating configurations and viewing
results, refer to the DFR Operations Software Manual.
1.3
F G
HI
FRONT PANEL
K
J
2-204-3
C
E
BACK PANEL
Figure 1.1 921A Controls and Indicators
D
A
B
2-204-4
1.4
TABLE 1-2
CONTROLS AND INDICATORS
(Refer to Figure 1.1)
A - Back Panel Connector J1 — the serial communication channel
connector used to connect the 921A to a PC using the supplied serial
cable (Figure 1.4 or 1.5).
B - SERVICE/RUN Select Switch — active only when power is first
applied to the 921A. This switch is placed in the RUN position for
normal operation. When the switch is placed in the SERVICE
position, the 921A is in the Service Mode where internal
instrumentation circuits can be adjusted
and various system functions checked.
C - Power Switch / Back Panel Input Power
Module
—
consists of the following:
1) Input power voltage selection permits selecting 110-120 V ac or
220-240 V ac operation by positioning
the slideout voltage selector as
Slideout Panel
indicated in section 2.1.
2) The slideout voltage selector panel contains two fuses. Remove
the slideout panel to access the fuses.
3) Contains the male connector for the power
cord.
4) Contains the power On/Off switch.
D - Precision Drive Mechanism — includes the
motor, lead screw, and precision guide and sensor
used to apply the force to the device under test.
The connector on the corrugated cable of this
assembly is connected to the rear (D) of the 921A
electronics unit.
Precision Drive Mechanism
(Cover Removed)
Force Sensor
1.5
TABLE 1-2
CONTROLS AND INDICATORS (Cont.)
E - Back Panel Resistance Connector J2 (optional) — the electrical
resistance connector used with the resistance cable PN 921-112 to
connect 921A to generic or user nests.
F - TEST STATUS PASS Indicator — illuminates green after a test
cycle in which the device being tested passes all of the specified
parameters (within tolerance).
G - TEST Switch / READY Indicator — has two functions:
1) The READY indicator illuminates when the 921A is ready for
another device test sequence. The indicator extinguishes when a
test sequence is initiated or if the 921A is not ready to accept a
device for test.
2) The TEST switch is a pushbutton switch which, when illuminated,
is pressed to initiate a test sequence. This switch is also used to
initiate a calibration cycle when the 921A is in Calibration Mode.
NOTE: The READY indicator does not indicate when to press the TEST
switch. Its function is only to indicate that the 921A is ready for
another test cycle.
H - TEST STATUS FAIL Indicator — illuminates red after a test
sequence in which a device fails one or more of the specified test
parameters (out of tolerance).
I -MODE Switch / CAL Indicator — has two functions:
1) The MODE switch is used to initiate a calibration cycle.
2) The CAL indicator illuminates green when the 921A is in the
Calibration Mode.
1.6
TABLE 1-6
CONTROLS AND INDICATORS (Cont.)
J - POWER Indicator — illuminates green when the 921A is turned on
with power applied.
K - SYSTEM STATUS Operator's Display — contains two 40-
character lines which supply information about 921A operation, such
as the part number and version of the device configuration being
tested. This display also prompts the operator concerning necessary
actions, such as "Install Device and Press Ready," etc.
1.7
Figure 1.2 Resistance Cable 15-Pin M/F Sub D (Optional)
2-204-5
PN 921-112
2-204-8
Figure 1.3 Precision Drive Mechanism Showing Corrugated Cable
and 37-Pin Connector
2-204-7
Figure 1.4 25-Pin M/F Sub D Serial Cable
PN 905-390-101
1.8
2-204-6
Figure 1.5 25 Pin M/ 9-Pin Female Serial Cable
PN 905-390-102
2-204-9
Figure 1.6 Two-Clip Generic Nest Assy
PN 921-140-101
2-204-10
Figure 1.7 Four-Clip Generic Nest Assy
PN 921-140-102
1.9
SECTION 2
SETUP AND INTERCONNECTION
2.1 HARDWARE
The power entry module (C-Figure 1.1)
must be set for the user's facility power.
The 921A is normally supplied configured
for 110-120 V ac, 60 Hz. To reconfigure
the 921A for 220-240 V ac, 50-60 Hz
rotate the slideout voltage selector and
position it accordingly. Plug the power
cord into the 921A power entry module
and into a properly grounded outlet.
2.2 PC CONNECTION
The 921A must be connected to a PC to upload configuration data to the
station or download test data to the PC. Connect a PC with an open
communication channel to the 921A using the serial communication cable
supplied with the unit (see Figure 1.4 or 1.5) between the PC Serial COM port
connector and 921A connector J1 (A-Figure 1.1). Tighten the connector
securing screws to ensure a secure connection. If the cable supplied with the
921A is not long enough, a generic 1:1 25-pin
D-type extension cable can be used with the
cable supplied.
110-120V 220-240V
2.3 SOFTWARE
Refer to DFR Operations Software Manual.
Typical Test Fixture
Setup
2.1
Set up unit for facility power (115 or 220 Vac) prior
to connecting to facility power (see paragraph 2.1).
110 - 120 VAC OR
220 - 240 VAC
WARNING
15-PIN MALE
DF TEST STATION
25-PIN MALE
SERIAL COM
CHANNEL
PC
MODEL 921A
SERIAL CABLE
25-PIN FEMALE
(9-PIN OPTIONAL)
J1
J2
RESISTANCE CABLE
15-PIN FEMALE
GENERIC NEST
PN 921-140-
(OR USER NEST)
PRECISION DRIVE
MECHANISM
Figure 2.1 921A DF Test Station Interconnect
2.2
2.4 PRECISION DRIVE MECHANISM SETUP/CONNECTION
A suitable test fixture or vice should be used to hold the device for test. The
drive mechanism force sensor must be centered over the device button,
dome, etc., to which force is to be applied. The sensor must not be in contact
with the device for test (allow at least a 1/16-inch gap). If the optional
platform was purchased, the height of the force sensor above the device for
test can be easily adjusted by loosening the knobs and raising and lowering
the Precision Drive Mechanism to the desired position, and tightening the
knobs.
WARNING
Support the Precision Drive Mechanism when loosening
the knobs or the mechanism will slip on the post,
possibly damaging the force transducer and/or the
device under test.
The Precision Drive Mechanism cable connector connects to the rear of the
921A electronic unit using the two screws provided. Refer to Figure 2.2.
Carefully remove the two screws, at the sides of the opening in the rear
panel. Carefully mate the cable connector with the connector recessed in the
rear panel opening. Secure with the two screws removed above.
2 Screws
2-204-12 2-204-11
Figure 2.2a Figure 2.2b
2.3
2.5 ELECTRICAL RESISTANCE CONNECTION (OPTIONAL)
The 5-foot 15-pin Subminiature "D" Male/Female connector cable supplied
with the resistance option is used to connect either the supplied generic nest
assembly or the user's nest to the 921A (refer to Figure 1.2).
2.6 GENERIC NEST ASSEMBLY CONNECTION (OPTIONAL)
Two types of Generic Nest Assemblies are available: a two-clip version and a
four-clip version. The type must be specified when ordering.
PN 921-140-101 Two-Clip Version
Resistance channel source and sense plus (red clip) are connected
together and channel source and sense minus (black clip) are connected together. This nest does not allow 4-wire resistance measurement.
PN 921-140-102 Four-Clip Version
Resistance channel source (I+) and sense (S+) plus are separated and
supplied with red clips. Resistance channel source (I-) and sense (S-)
minus are separated and supplied with black clips. This nest allows
performing 4-wire (Kelvin) resistance measurements with the 4 5
resistance options.
2.7 USER NESTS
Table 2-1 shows the wiring of the 15-pin connector J2 on the rear of the unit.
This information is provided for users who wish to wire their own nests.
2.8 FORCE TRANSDUCER TIPS
2.8.1 Interchangeable Force Transducer Tips (2.0 kg, 3.6 kg and 50 lb
Transducers)
2.4
Table 2-1
J2 Connector Wiring
PIN SIGNAL
1 INSTALL
2 CH1 SENSE +
3 CH1 SENSE 4
5
6
7
8 CH1 SRC+
9 CHASSIS GROUND
10
11
12
13
14 SIGNAL GND
15 CH1 SRC -
Notes: 1. Pin 9, chassis ground is provided for shield termination. If user-
designed nests have wire lengths in excess of 8 inches, those
wires should be shielded. If the user nest is to be used in an
electrically noisy environment, the wiring should be metal en-
closed with the metal enclosure chassis grounded.
2. Pin 1, INSTALL signal provides a device installed interlock for
testing. The test cycle will not initiate unless the Install signal is
grounded (connected to Pin 14). The user-designed nest can
incorporate a switch which is actuated when a device is in-
stalled in the nest, thereby grounding the Install signal. The
user's nest design can defeat the interlock by jumpering Pin 1 to
Pin 14 if the interlock function is not required.
3. Pin 3, CH1 SENSE - applies only to the 4 5resistance options.
2.5
WARNING
Care must be taken whenever handling the force
transducer. These transducers are easily damaged. The 2.0 kg, 3.6 kg and 50 lb transducers
are supplied with protective stops for overload
under compression. However, tension or rotational forces applied in excess of 150% of fullscale rating will permanently damage the transducer.
The 2.0 kg, 3.6 kg and 50 lb force transducers are supplied with two tips
(small and large, refer to Figure 2.3). To change tips on the force transducer,
use the allen wrench provided and carefully loosen the set screw holding the
tip (refer to Figure 2.4).
2-204-13
Figure 2.3 Typical Tips
Install the desired tip until it seats (bottoms out) in the transducer opening,
and carefully tighten the set screw with the allen wrench.
2-204-14
Figure 2.4 3.6 kg / 2.0 kg / 50 lb Tip Setscrew Location
2.6
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