IAEA-TECDOC-426
TROUBLESHOOTING NUCLEAR INSTRUMENTS
A TECHNICAL DOCUMENT ISSUED BY THE
INTERNATIONAL ATOMIC ENERGY AGENCY, VIENNA, 1987
IAEA-TECDOC-426
Printed by the IAEA in Vienna June 1987
PLEASE BE AWARE THAT
ALL OF THE MISSING PAGES IN THIS DOCUMENT
WERE ORIGINALLY BLANK
IN IS Clearinghouse
International Atomic Energy Agency Wagramerstrasse 5
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A-1400 Vienna, Austria
Orders should be accompanied by prepayment of Austrian Schillings 100,- in the form of a cheque or in the form of IAEA microfiche service coupons which may be ordered separately from the INIS Clearinghouse.
FOREWORD
The servicing and repair of nuclear instruments is a d i f f i c u l t task.. The c o m m e r c i a l manufacturers of nuclear e q u i p m e n t can assure reliable service only in the most advanced countries that have many i n s t r u m e n t s installed. In developing countries, as a rule, good service l a b o r a t o r i e s organized by the m a n u f a c t u r e r s do not exist.
The nuclear research l a b o r a t o r i e s must rely upon their own resources to keep the instruments in operation.
The I n t e r n a t i o n a l A t o m i c Energy Agency is trying to assist the d e v e l o p i n g c o u n t r i e s by providing different types of service in t h i s f i e l d . This includes help in the e s t a b l i s h m e n t of s u i t a b l e e l e c t r o n i c s laboratories, advice and assistance in the topic of p r e v e n t i v e m a i n t e n a n c e , and training. Obviously, a necessary p r e r e q u i s i t e for s t a f f responsible for servicing of nuclear i n s t r u m e n t s , is the u n d e r s t a n d i n g of nuclear e l e c t r o n i c s . In i n t e r r e g i o n a l , regional, and national courses, the IAEA is training nuclear electronics s t a f f , b o t h in basic and in advanced aspects.
The present book is devoted to such persons who have either received IAEA training, or have studied nuclear electronics by themselves at home.
In p r e p a r i n g a book on troubleshooting of nuclear i n s t r u m e n t s , one is faced w i t h a number of problems:
(i) The t e c h n i c a l level of the book must be properly d e f i n e d ; it should not be too elementary, but should avoid the most advanced aspects. The present p u b l i c a t i o n is meant for young electronics engineers who will specialize in nuclear e l e c t r o n i c s , for senior technicians, or for the scientists (physicists, chemists) who are forced to maintain and repair their instruments themselves.
(ii) Nuclear instrumentation is facing a period of rapid d e v e l o p m e n t . New instruments are appearing on the market each week. It would be impossible to analyze all the electronic circuits in these modern instruments. Therefore, the book must mainly focus on some general features and use some specific c i r c u i t s to illustrate the troubleshooting and repair procedures that will hopefully be a p p l i c a b l e to many different types of instruments.
(iii) The present effort to p r e p a r e a set of recommendations and tips on troubleshooting cannot replace a good service manual. However, good service manuals are an exception; as a rule, service manuals are not available, or are bad.
Therefore, it is believed that the book will give valuable orientation for troubleshooting to the persons who are facing a malfunctioning instrument, and have no proper service manuals available.
The book is the product of several scientists and engineers who are closely associated with nuclear instrumentation, and with the IAEA activities in the field. Everybody contributed to all
P r e a m p l i f i e r s , A m p l i f i e r s S e a l e r s , T i m e r s , R a t e m e t e r s M u l t i c h a n n e l Analyzers
D e d i c a t e d Instruments
Tools, I n s t r u m e n t s , Accessories, C o m p o n e n t s , Skills
I n t e r f a c e s Power S u p p l i e s
P r e v e n t i v e M a i n t e n a n c e T r o u b l e s h o o t i n g in Systems R a d i a t i o n D e t e c t o r s
Overal1 e d i t i n g
M a n f r e d i (Italy)
Sousa Lopes (Portugal) Pahor (Yugosalia)
A m b r o (Hungary) F
J J P
0. M u t z (IAEA)
S. H o l l e n t h o n e r (IAEA) H. K a u f m a n n (IAEA) P. V u i s t e r (IAEA),
J. Sousa Lopes (Portugal) P. V u i s t e r (IAEA)
J. Dolnicar (IAEA) K.D. Mueller (FRG)
The o r g a n i z a t i o n of the m e e t i n g where the f i r s t d r a f t of the p u b l i c a t i o n was p r e p a r e d , and the s u b s e q u e n t i m p r o v e m e n t of the t e x t s were in the hands of Mr. L. K o f i (Ghana) and Miss L.
K i n g s t o n (IAEA).
S t u d y i n g the book, it can be n o t e d t h a t there are d i f f e r e n t a p p r o a c h e s and d i f f e r e n t s t y l e s used in i n d i v i d u a l sections. This is in p a r t the consequence of the f a c t t h a t each c h a p t e r was d r a f t e d b y a d i f f e r e n t p e r s o n , b u t i t also r e f l e c t s t h e o b s e r v a t i o n t h a t v a r i o u s p a r t s o f n u c l e a r e l e c t r o n i c s r e q u i r e d i f f e r e n t ways o f p r e s e n t a t i o n . For t h i s reason, no p a r t i c u l a r e f f o r t was taken to p r e s e n t all the c h a p t e r s of the book in a uniform s t y l e .
All the persons who c o n t r i b u t e d to the first e d i t i o n of the t r o u b l e s h o o t i n g m a n u a l a r e w e l l aware t h a t t h e book needs f u r t h e r i m p r o v e m e n t . In the jargon of the e l e c t r o n i c s e x p e r t s , we r e q u e s t the users of the book for "a f a s t , p o s i t i v e f e e d b a c k " t h a t w i l l enable us to i m p r o v e the t e x t and make it more r e a d a b l e and u n d e r s t a n d a b l e for the e n g i n e e r s , scientists and t e c h n i c i a n s to w h o m it is i n t e n d e d .
The t r o u b l e s h o o t i n g and repair of i n s t r u m e n t s is i l l u s t r a t e d by some real examples. The c i r c u i t diagrams and service manuals of ORTEC, C A N B E R R A and N A R D E A U X instruments were selected for this purpose. O b v i o u s l y the choice of these i n s t r u m e n t s was made only for t r a i n i n g purposes and has no r e l e v a n c e to the Agency's p r e f e r e n c e s for p a r t i c u l a r b r a n d s of nuclear i n s t r u m e n t s .
EDITORIAL NOTE
In preparing this material for the press, staff of the International Atomic Energy Agency have mounted and paginated the original manuscripts and given some attention to presentation.
The views expressed do not necessarily reflect those of the governments of the Member States or organizations under whose auspices the manuscripts were produced.
The use in this book of particular designations of countries or territories does not imply any judgement by the publisher, the IAEA, as to the legal status of such countries or territories, of
their authorities and institutions or of the delimitation of their boundaries.
The mention of specific companies or of their products or brand names does not imply any endorsement or recommendation on the part of the IAEA.
CONTENTS
CHAPTER 1. INTRODUCTION ... 9
CHAPTER 2. ORGANIZATION OF THE LABORATORY ... 13
CHAPTER 3. TOOLS, INSTRUMENTS, ACCESSORIES, COMPONENTS, SKILLS .... 21
CHAPTER 4. TROUBLESHOOTING IN SYSTEMS ... 69
CHAPTER 5. POWER SUPPLIES ... 79
CHAPTER 6. PREAMPLIFIERS, AMPLIFIERS ... 105
CHAPTER 7. DISCRIMINATORS, SINGLE CHANNEL ANALYZERS, TIMING CIRCUITS ... 145
CHAPTERS. SCALERS, TIMERS, RATEMETERS ... 155
CHAPTER 9. MULTICHANNEL ANALYZERS ... 173
CHAPTER 10. INTERFACES ... 211
CHAPTER 11. DEDICATED INSTRUMENTS ... 241
CHAPTER 12. RADIATION DETECTORS ... 279
INTRODUCTION
-1- C h a p t e r 1
l INTRODUCTION
N u c l e a r i n s t r u m e n t a t i o n can be found in many d i f f e r e n t i n s t i t u t i o n s ; t h e r e are nuclear research c e n t r e s , u n i v e r s i t i e s , and h o s p i t a l s w i t h t h e i r n u c l e a r m e d i c i n e d i a g n o s t i c o r t h e r a p y units.
In i n d u s t r y , r a d i a t i o n and a s s o c i a t e d n u c l e a r i n s t r u m e n t s are a p p l i e d in p r o d u c t s and in process c o n t r o l . As a rule, nuclear i n s t r u m e n t s are r a t h e r s o p h i s t i c a t e d and d e l i c a t e i n s t r u m e n t s . If t h e y d e v e l o p f a u l t s , as any i n s t r u m e n t s sooner or l a t e r do, t h e y are not easy to r e p a i r . C o n s i d e r a b l e s p e c i a l i z e d k n o w l e d g e , e x t e n s i v e e x p e r i e n c e , and s u i t a b l e e q u i p m e n t is needed for t h e i r r e p a i r and s e r v i c i n g .
For a p r i c e , the m a n u f a c t u r e r s of nuclear i n s t r u m e n t s offer the r e q u i r e d service for t h e i r i n s t r u m e n t s . If s u f f i c i e n t funds are a v a i l a b l e , a service c o n t r a c t can be e s t a b l i s h e d , and the m a n u f a c t u r e r , or his s e r v i c e l a b o r a t o r y , will take care of the i n s t a l l e d i n s t r u m e n t a t i o n . This is sound p r a c t i c e for a l a b o r a t o r y in an a d v a n c e d c o u n t r y w h e r e the m a n u f a c t u r e r ' s s e r v i c e person is a v a i l a b l e on c a l l , and where the r a t h e r s t i f f p r i c e s of the service c o n t r a c t s can be a c c o m m o d a t e d in the l a b o r a t o r y b u d g e t . In d e v e l o p i n g c o u n t r i e s , b o t h c o m m o d i t i e s (available s e r v i c e a n d s u f f i c i e n t h a r d c u r r e n c y ) are an e x c e p t i o n r a t h e r than a rule. The m a n a g e m e n t of d e v e l o p i n g l a b o r a t o r i e s must find an a l t e r n a t i v e s o l u t i o n .
C r e a t i n g a m a i n t e n a n c e and service laboratory in an i n s t i t u t i o n in a d e v e l o p i n g c o u n t r y is not easy. Following r e a s o n a b l e a d v i c e , like some g i v e n in the p r e s e n t p u b l i c a t i o n , can h e l p in the s e l e c t i o n of s u i t a b l e t e s t i n g i n s t r u m e n t s , tools and c o m p o n e n t s . H o w e v e r , the training of the s t a f f who must have all the r e q u i r e d skills, k n o w l e d g e and e x p e r i e n c e , is a long and d i f f i c u l t p r o c e d u r e .
It is very d i f f i c u l t to teach troubleshooting and repair of any i n s t r u m e n t . In f a c t , the a c q u i s i t i o n of the necessary e x p e r i e n c e for repair of e l e c t r o n i c and e l e c t r o m e c h a n i c a l i n s t r u m e n t s is a t y p i c a l case where on-the-job t r a i n i n g is most e f f e c t i v e . As a r u l e , one should not take the m e t h o d s that the m a n u f a c t u r e r s a p p l y t o train t h e i r f i e l d e n g i n e e r s ; their t r a i n i n g is l i m i t e d to a c e r t a i n line of p r o d u c t s , or even a single i n s t r u m e n t , a n d f o r this they h a v e d e v e l o p e d e f f i c i e n t a p p r o a c h e s to convey the r e q u i r e d skills in a short time. The s t a f f of a service l a b o r a t o r y in a d e v e l o p i n g c o u n t r y cannot be trained in t h i s m a n n e r on all p o s s i b l e t y p e s of e q u i p m e n t , w h i c h t h e r e m i g h t be only one i n s t a l l e d in the c o u n t r y . Their a p p r o a c h to the servicing and r e p a i r must be more general, and is more demanding.
In the nuclear f i e l d , the s t a f f responsible for i n s t r u m e n t a t i o n m a i n t e n a n c e and s e r v i c i n g face a number of a d d i t i o n a l p r o b l e m s .
(i) N u c l e a r e l e c t r o n i c s is not t a u g h t regularly at the u n i v e r s i t i e s or t e c h n i c a l schools in d e v e l o p i n g countries.
(ii) L i t e r a t u r e on nuclear i n s t r u m e n t a t i o n , and p a r t i c u l a r l y on servicing of such d e v i c e s , is scarce or non-existing.
(9)
(iii) M a n u f a c t u r e r s ' information on their p r o d u c t s and servicing is generally either b a d , i n c o m p l e t e or not available.
(iv) There are very few e x p e r t s who are familiar with the repair of nuclear instruments.
(v) A t a l e n t e d person who received p r o p e r training in servicing of nuclear instruments can easily find a well-paid job in p r i v a t e e n t e r p r i s e , and would thus be lost for the nuclear
laboratories.
A c c o r d i n g l y , it is not easy to create a team and a laboratory for nuclear i n s t r u m e n t a t i o n service. In an average l a b o r a t o r y , the m a i n t e n a n c e and servicing a b i l i t i e s are hardly t r a n s f e r r e d to the junior s t a f f . It takes much t i m e to a c q u i r e the necessary skills for i n s t r u m e n t a t i o n r e p a i r , and it is d i f f i c u l t to share the e x p e r i e n c e w i t h i n a group.
In many d e v e l o p i n g c o u n t r i e s , there is no a l t e r n a t i v e to the d e c i s i o n to c r e a t e and s u p p o r t a m a i n t e n a n c e and repair service.
Depending on the size of the c o u n t r y , and on the a m o u n t of nuclear i n s t r u m e n t a t i o n in the c o u n t r y , it m i g h t be s u f f i c i e n t to e s t a b l i s h one c e n t r a l l a b o r a t o r y , or it m i g h t be necessary to plan for more of t h e m , s t r a t e g i c a l l y l o c a t e d in d i f f e r e n t p a r t s of the c o u n t r y . This l a b o r a t o r y , or l a b o r a t o r i e s , should be s u i t a b l y s t a f f e d and e q u i p p e d , a n d should m a i n t a i n :
- a d o c u m e n t a t i o n library w i t h d a t a books, copies of all m a n u a l s , c a t a l o g u e s of e q u i p m e n t s u p p l i e s , and a selection of e l e c t r o n i c s t e x t b o o k s ;
- a stock of components and spare p a r t s ; - if p o s s i b l e , a stock of s p a r e i n s t r u m e n t s ; - m a i n t e n a n c e kits.
It is o b v i o u s l y not easy to create and s t a f f such a laboratory in a d e v e l o p i n g c o u n t r y . The p r e s e n t p u b l i c a t i o n should p r o v i d e some h e l p in this d i f f i c u l t task.
Chapter 2
ORGANIZATION OF THE LABORATORY
2 ORGANIZATION OF THE LABORATORY 2. 1 G E N E R A L R E M A R K S
The c o n t e n t s of this chapter are limited to some general observations and conclusions on the organization and o p e r a t i o n of an electronics laboratory that serves nuclear i n t r u m e n t a t ion and r e l a t e d e q u i p m e n t . The same r e c o m m e n d a t i o n a p p l i e s as well for all d o n a t e d i n s t r u m e n t s . It should be noted t h a t there are several IAEA publications dealing with the topic (IAEA TECDOC-309, Nuclear E l e c t r o n i c s L a b o r a t o r y M a n u a l , and TECDOC-363, S e l e c t e d Topics in N u c l e a r Electronics).
The o p t i m a l set-up of a service laboratory d e p e n d s , to a large e x t e n t , on the social, economic and policy s i t u a t i o n in the country. As an e x a m p l e , consider the specific r e g u l a t i o n s in a country, referring to the financing and control of material s u p p o r t to the l a b o r a t o r i e s . T h e r e f o r e , it is d i f f i c u l t to present a d e t a i l e d assessment of the best a p p r o a c h for e s t a b l i s h i n g and operating such a l a b o r a t o r y . Below, only some points t h a t seem to a p p l y to all c o u n t r i e s and s i t u a t i o n s are s u m m a r i z e d .
2.2 PHYSICAL E N V I R O N M E N T
A summary of the main items of recommended f a c i l i t i e s r e q u i r e d for a service laboratory is given here. Only a reminder on the essential f e a t u r e s to be c o n s i d e r e d when a l a b o r a t o r y is created are p r e s e n t e d . F u r t h e r d e t a i l s are given in the following chapters.
1. The laboratory should have a m i n i m a l u s e f u l square m e t e r s for each employee. If Engineering (CAE) f a c i l i t i e s are e n v i s a g e d , an c o m p u t e r room and a room for work stations available.
area of 10-12 C o m p u t e r A i d e d a i r - c o n d i t i o n e d should be m a d e
2.
3.
For countries in a i r - c o n d i t i o n e d , e q u i p p e d to have
t r o p i c a l regions, the laboratory should be At least a part of the l a b o r a t o r y should be a dry a r e a , i.e a room w i t h r e d u c e d h u m i d i t y . An a d e q u a t e
has to be available.
storage room, for special kept for emergency return
packing material that s h i p m e n t , s h o u l d be
4.
5.
6.
The e l e c t r o n i c s l a b o r a t o r y should have a g o o d , reliable mains s u p p l y , properly arranged e l e c t r i c a l power d i s t r i b u t i o n , a n d , p r e f e r a b l y , a good dedicated grounding system.
The l a b o r a t o r y should have good o v e r a l l precise work on electronics instruments places should have a d d i t i o n a l lights.
illumination. For individual working
Depending add it ional e l e c t r o n i c
on the size of the l a b o r a t o r y , and its a c t i v i t i e s , room space w i t h reduced h u m i d i t y for storage of c o m p o n e n t s , as well as the proper i n s t r u m e n t s and
C h a p t e r 2 -2-
l a b o r a t o r i e s for p r o d u c t i o n of p r i n t e d c i r c u i t s , should be a r r a n g e d .
2.3 A D M I N I S T R A T I O N OF A N U C L E A R I N S T R U M E N T A T I O N L A B O R A T O R Y 2.3.1 S t a f f
The p r o p e r s t a f f i n g of the m a i n t e n a n c e and s e r v i c e of a n u c l e a r e l e c t r o n i c s l a b o r a t o r y i s o b v i o u s l y t h e m o s t i m p o r t a n t p a r t of good m a n a g e m e n t . At the s t a r t of s u c h a l a b o r a t o r y , it is a d v i s a b l e to m a k e a c o m p l e t e i n v e n t o r y of all the i n s t r u m e n t s in the i n s t i t u t e or i n s t i t u t i o n s t h a t are e x p e c t e d to be s e r v e d by the l a b o r a t o r y . A c c o r d i n g to the v o l u m e and c o m p l e x i t y of the i n s t r u m e n t a t i o n , the r e q u i r e d skills s h o u l d be d e t e r m i n e d , and on t h i s b a s i s , t h e persons w i t h s u i t a b l e p r o f e s s i o n a l p r o f i l e s r e c r u i t e d .
It is h i g h l y a d v i s a b l e to r e c r u i t for the l a b o r a t o r y such s t a f f m e m b e r s who can c o v e r a w i d e s p e c t r u m of i n s t r u m e n t s . N e v e r t h e l e s s , i t will b e n e c e s s a r y , w i t h t h e i n c r e a s i n g d e m a n d s p l a c e d on the work of the l a b o r a t o r y , to s p e c i a l i z e some of the s t a f f m e m b e r s i n p a r t i c u l a r a s p e c t s o f n u c l e a r i n s t r u m e n t a t i o n . Some of the t o p i c s of such e x p e r t i s e are: r a d i a t i o n d e t e c t o r s , a n a l o g e l e c t r o n i c s , d i g i t a l e l e c t r o n i c s , i n t e r f a c i n g , c o m p u t e r s a n d e l e c t r o m e c h a n i c a l a p p a r a t u s . N o t e : the recent t r e n d s in e l e c t r o n i c s t e n d t o o v e r - e m p h a s i z e d i g i t a l e l e c t r o n i c s a n d c o m p u t e r s o f t w a r e d e v e l o p m e n t . P a r t i c u l a r l y in the nuclear f i e l d , t h e r e is a c r i t i c a l need for p e r s o n s w i t h k n o w l e d g e and e x p e r i e n c e in h i g h q u a l i t y a n a l o g e l e c t r o n i c s , a n d t h i s s h o u l d n o t b e n e g l e c t e d . F u r t h e r m o r e , it s h o u l d be k e p t in m i n d t h a t many i n s t r u m e n t s in the n u c l e a r l a b o r a t o r i e s a r e n o t s t r i c t l y n u c l e a r . E l e c t r o n i c b a l a n c e s , s a m p l e c h a n g e r s , o p t i c a l s p e c t r o m e t e r s , d i f f r a c t orne t ers, and p h - m e t e r s are r e s e a r c h tools t h a t also need m a i n t e n a n c e and s e r v i c e , and the e l e c t r o n i c s l a b o r a t o r y s h o u l d be in a p o s i t i o n to o f f e r i t.
The m a n a g e m e n t of the l a b o r a t o r y should design a s u i t a b l e scheme to e v a l u a t e and p r o m o t e the a c t i v i t i e s of the s t a f f . S p e c i a l a t t e n t i o n should be given to the fact t h a t c o n t i n u o u s t r a i n i n g of the s t a f f is r e q u i r e d to keep up w i t h the e x t r e m e l y f a s t p r o g r e s s in the world of e l e c t r o n i c s and c o m p u t e r science. The IAEA is d e v e l o p i n g a c o m p u t e r - b a s e d m a n a g e m e n t scheme for p r e v e n t i v e maintenance; such a system can be developed locally, not n e c e s s a r i l y c o m p u t e r - s u p p o r t e d , and can also i n c l u d e r e p a i r and s e r v i c i n g a s p e c t s .
2.4 I N S T R U M E N T A T I O N AND E L E C T R O N I C S C O M P O N E N T S
C h a p t e r 3 p r o v i d e s d e t a i l e d information on the type and amount of t e s t i n g i n s t r u m e n t s and tools r e q u i r e d for normal operation of a service l a b o r a t o r y , at d i f f e r e n t levels.
It s h o u l d be emphasized that the t e s t i n g instruments in a laboratory should be regularly checked and c a l i b r a t e d for proper o p e r a t i o n ; such c o n t r o l s should include c o n n e c t o r s and cables.
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F u r t h e r m o r e , a c e r t i f i e d r e c a l i b r a t ion of i n s t r u m e n t s used as m e a s u r e m e n t s t a n d a r d , at a n a t i o n a l i n s t i t u t i o n , s h o u l d be p l a n n e d . The a c q u i s i t i o n of any i n s t r u m e n t , p r e f e r a b l y w i t h two sets of o p e r a t o r a n d s e r v i c e m a n u a l s even a t a d d i t i o n a l e x p e n s e , should b e a c c o m p a n i e d w i t h t h e p r o v i s i o n t o o r d e r some s p a r e p a r t s a n d c o m p o n e n t s . One set of o p e r a t o r and service m a n u a l s s h o u l d stay at the l o c a t i o n of each i n s t r u m e n t w h i l e the other set s h o u l d be k e p t in the t e c h n i c a l library of the s e r v i c e l a b o r a t o r y .
A good rule can be t h a t 1 1/2 % of the v a l u e of the i n s t r u m e n t s s h o u l d be i n v e s t e d in spare p a r t s , at the t i m e when the p u r c h a s e is m a d e . In the f o l l o w i n g y e a r s , each i n s t r u m e n t w i l l need b e t w e e n 1 and 3 % for r e p l a c e m e n t p a r t s , d e p e n d i n g on the c o m p l e x i t y a n d d e s i g n o f t h e i n s t r u m e n t .
Each l a b o r a t o r y should have a basic s u p p l y of e l e c t r o n i c c o m p o n e n t s . A l i s t is p r e s e n t e d in C h a p t e r 3, S e c t i o n 3.4; t h i s is c o n s i d e r e d to be a m i n i m a l set of c o m p o n e n t s t h a t h a v e to be on stock in the l a b o r a t o r y and need to be u p d a t e d r e g u l a r l y .
It is c o n s i d e r e d a b s o l u t e l y m a n d a t o r y t h a t a n u c l e a r e l e c t r o n i c s l a b o r a t o r y h a v e access to some local and f o r e i g n p e t t y c a s h , f o r r a p i d a n d u n b u r e a u c r a t i c a c q u i s i t i o n o f p a r t s a n d c o m p o n e n t s t h a t are or are not a v a i l a b l e on the home m a r k e t . This is e s s e n t i a l for r a p i d t u r n - a r o u n d of r e p a i r s ; it is not t o l e r a b l e t h a t t h e s t a f f m u s t wait m o n t h s f o r t h e a p p r o p r i a t e a p p r o v a l t o b u y a m i n o r e l e c t r o n i c p a r t , and the e x p e r i m e n t e r c a n n o t use his ins t r u m e n t.
It s h o u l d be p o i n t e d out here t h a t t h e r e is a tendency more and more o f t e n in m o d e r n e l e c t r o n i c i n s t r u m e n t a t i o n to make use of h y b r i d a n a l o g , c u s t o m i z e d d i g i t a l c i r c u i t s , EPROMs, PALs a n d o t h e r p r o g r a m m a b l e c h i p s , t o a c h i e v e h i g h e r p a c k i n g d e n s i t i e s , b e t t e r o v e r a l l p e r f o r m a n c e , and to reduce p r o d u c t i o n cost. It will not be p o s s i b l e , even in a very w e l l - e q u i p p e d l a b o r a t o r y , to have all t h e s e s p e c i a l spare p a r t s a v a i l a b l e in a stockroom. F o r t u n a t e l y , the f a i l u r e r a t e of such c o m p o n e n t s is low. These s p a r e p a r t s h a v e to be o r d e r e d from the m a n u f a c t u r e r of the instrument or its r e p r e s e n t a t i v e and are not a v a i l a b l e from the s e m i c o n d u c t o r m a n u f a c t u r e r .
Even so, one has to realize the f a c t that the on-site s e r v i c e of h i g h l y s o p h i s t i c a t e d nuclear i n s t r u m e n t a t i o n may o f t e n have to l i m i t i t s e l f to the board level just by swapping b o a r d s . Board test e q u i p m e n t , w h i c h is r e q u i r e d to enable repair on the chip level, will only be a f f o r d a b l e to the instrument manufacturer in some s t r a t e g i c a l l y located service centers worldwide.
One may c o m p l a i n about this s i t u a t i o n , but it also offers a c o n s i d e r a b l e a d v a n t a g e by reducing the number of b o a r d s in a t y p i c a l n u c l e a r i n s t r u m e n t , a n d c o n s e q u e n t l y , t h e f a i l u r e rate.
Many m a n u f a c t u r e r s are now able to use a functionally p a r t i t i o n e d a p p r o a c h to break down a d e s i g n to the board l e v e l , which allows them to p r o v i d e d i a g n o s t i c r o u t i n e s and f a c i l i t i e s to the c u s t o m e r for easy f a u l t l o c a t i o n to the board level.
C h a p t e r 2 -it-
Special e m p h a s i s should t h e r e f o r e be g i v e n to this fact when o r d e r i n g e q u i p m e n t if such d i a g n o s t i c facilities are available. In such a c a s e , r e t u r n of an i n s t r u m e n t to the m a n u f a c t u r e r may never be necessary and the p o s s i b i l i t y of s h i p p i n g d a m a g e s w h e n r e t u r n i n g a b o a r d to the m a n u f a c t u r e r l a r g e l y v a n i s h e s .
Of s p e c i f i c i m p o r t a n c e for a service l a b o r a t o r y is the a v a i l a b i l i t y of s u i t a b l e e x t e n s i o n b o a r d s and c a b l e s . If they c a n n o t b e p u r c h a s e d , t h e y m u s t b e p r o d u c e d i n t h e l a b o r a t o r y .
A n o t h e r e s s e n t i a l a c t i v i t y of a p r o p e r l y organized l a b o r a t o r y , is the g o o d o r g a n i z a t i o n of the t e c h n i c a l l i b r a r y . This s h o u l d i n c l u d e :
- O r i g i n a l s of all the o p e r a t o r m a n u a l s
- Originals of all available service manuals, circuit digrams, p a r t s l i s t s , a n d t r o u b l e s h o o t i n g i n f o r m a t i o n ;
- A set of d a t a books on e l e c t r o n i c c o m p o n e n t s ; as a m i n i m u m , it is r e c o m m e n d e d to have a set of U.A.T.A. Books (D.A.T.A., Inc. P.O. Box 26875, San D i e g o , C a l i f o r n i a 92126, USA), p o s s i b l y c o m p l e m e n t e d w i t h some p u b l i c a t i o n s of i n d i v i d u a l p r o d u c e r s o f e l e c t r o n i c c o m p o n e n t s ;
- a p p l i c a t i o n n o t e s r e f e r r i n g to n u c l e a r e l e c t r o n i c s from i n s t r u m e n t m a n u f a c t u r e r s ;
- c a t a l o g u e s .
2 .5 O R G A N I Z A T I O N OF THE WORK IN AN E L E C T R O N I C S L A B O R A T O R Y
F r e q u e n t l y , a n u c l e a r e l e c t r o n i c s l a b o r a t o r y c o m b i n e s its a c t i v i t i e s in s e r v i c e w i t h some d e v e l o p m e n t work in order to g i v e its s t a f f a c h a n c e to keep up w i t h the r a p i d d e v e l o p m e n t in n u c l e a r e l e c t r o n i c s . In such cases, the b a s i c r u l e should be:
| The r e p a i r and s e r v i c i n g of i n s t r u m e n t s has p r i o r i t y to any |
| o t h e r a c t i v i t y o f t h e l a b o r a t o r y . | I_______________________________________________________________I
The e l e c t r o n i c s l a b o r a t o r y should be i n v o l v e d in a research i n s t r u m e n t from the m o m e n t of its d e l i v e r y . A s t a f f member should assist in the u n p a c k i n g , i n s t a l l a t i o n , and i n i t i a l t e s t i n g of every newly a c q u i r e d instrument. For those instruments that cannot be r e p a i r e d l o c a l l y , and w h e r e t h e r e is a p o s s i b i l i t y for t h e m to be sent for r e p a i r , s p e c i a l s h i p m e n t m a t e r i a l should be s t o r e d .
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In l a b o r a t o r i e s and i n s t i t u t e s in d e v e l o p i n g c o u n t r i e s , we f r e q u e n t l y o b s e r v e t h e "wooden b o x e f f e c t " : t h e d e l i v e r e d e q u i p m e n t is k e p t in b o x e s , s o m e t i m e s for y e a r s . This is not t o l e r a b l e , and the e l e c t r o n i c s l a b o r a t o r y can c o n t r i b u t e to the a c t i o n : upon d e l i v e r y , each i n s t r u m e n t should be
i m m e d i a t e l y u n p a c k e d , i n s p e c t e d f o r p o s s i b l e d a m a g e (and a l l c l a i m s s h o u l d be s u b m i t t e d as soon as p o s s i b l e , o t h e r w i s e the w a r r a n t y m i g h t b e lost), i n s t a l l e d a n d t e s t e d . A d o c u m e n t should b e p r e p a r e d s p e c i f y i n g t h e m e a s u r e d p r o p e r t i e s o f t h e
i n s t r u m e n t ; l a t e r , t h i s w i l l p e r m i t a c o m p a r i s o n o n t h e i n s t r u m e n t ' s p e r f o r m a n c e .
For e v e r y i n s t r u m e n t , a logbook and r e p a i r list should be o p e n e d , at the t i m e of its a r r i v a l . All s u b s e q u e n t a c t i o n s , be it for p r e v e n t i v e m a i n t e n a n c e or r e p a i r of the i n s t r u m e n t , s h o u l d be r e g i s t e r e d in t h i s book. The h e a d of the w o r k s h o p s h o u l d set a good e x a m p l e on the u t i l i z a t i o n of the l o g b o o k s , o t h e r w i s e it w i l l not be used by the personnel. It is h i g h l y r e c o m m e n d e d to start w e e k l y r e p a i r case d i s c u s s i o n s and to use the logbook d u r i n g t h i s
session.
It is a d v i s a b l e for the r e p a i r of an i n s t r u m e n t to be o r g a n i z e d in the f o l l o w i n g w a y : a copy of the c i r c u i t d i a g r a m s h o u l d be m a d e , and the values o b t a i n e d in m e a s u r i n g the q u a n t i t i e s , such as DC v o l t a g e and signal s h a p e , s h o u l d be registered. Such an " u p d a t e d " diagram should be stored in the logbook. If no d i a g r a m s are a v a i l a b l e , a c a r e f u l record s h o u l d be m a i n t a i n e d of the m e a s u r e d v a l u e s at s e l e c t e d p o i n t s of the c i r c u i t .
The s t a f f of nuclear e l e c t r o n i c s l a b o r a t o r i e s should learn from t h e i r m i s t a k e s . T h e s t a f f m e m b e r o f t h e e l e c t r o n i c s l a b o r a t o r y who is e x p e c t e d to r e p a i r a f a u l t y i n s t r u m e n t s h o u l d make i n q u i r i e s on how the fault has developed. This m i g h t require a n a d e q u a t e a p p r o a c h , some c a r e f u l , n o t i n q u i s i t o r y i n v e s t i g a t i o n , and should p r e f e r a b l y be m a d e by a senior person. The f i n d i n g s should be r e c o r d e d in the logbook.
P r e v e n t i v e m a i n t e n a n c e is d e s c r i b e d in C h a p t e r 13.
Chapter 3
TOOLS, INSTRUMENTS, ACCESSORIES,
COMPONENTS, SKILLS
3 TOOLS, INSTRUMENTS. ACCESSORIES, COMPONENTS. SKILLS
Tools are n e e d e d for p r o p e r m a i n t e n a n c e of i n s t r u m e n t s . The number of t o o l s , however, is very l a r g e , even if only a c e r t a i n c a t e g o r y of s e r v i c e work, let us say t r o u b l e s h o o t i n g , of nuclear i n s t r u m e n t s has to be p e r f o r m e d . The f o l l o w i n g c o m p i l a t i o n of t o o l s shall g i v e an i d e a of what is n e e d e d at a work bench or in the l a b o r a t o r y . The d i s c u s s i o n s on the a p p r o p r i a t e tools and i n s t r u m e n t s will d i s t i n g u i s h b e t w e e n d i f f e r e n t levels o f t r o u b l e s h o o t i n g . A c c o r d i n g l y , the f o l l o w i n g l i s t of tools w i l l be d i v i d e d into t h r e e g r o u p s .
Group A:
G r o u p B
necessary as a m i n i m u m to solve simpler t r o u b l e s h o o t i n g and m a i n t e n a n c e tasks, e.g. c l e a n i n g , r e p l a c i n g of s i m p l e c o m p o n e n t s , yes or no t e s t s .
for a d v a n c e d r e p a i r w o r k , e.g. in r e p l a c e m e n t or repair of more c o m p l e x m u l t i p l e step s w i t c h e s , h y b r i d
m o v i n g coil i n s t r u m e n t s , e t c .
a d d i t i o n t o A , c o m p o n e n t s like c i r c u i t s
G r o u p C: for s o p h i s t i c a t e d r e p a i r work, e . g - v e r i f i c a t i o n o f m a n u f a c t u r e r s p é c i f i c a t i o n , and new d e v e l o p m e n t s (or p r o t o t y p e s ) .
c o n n e c t o r s
c a l i b r a t i o n , m o d i f i c a t i o n
In the following l i s t , you will also find a Group F: s p e c i a l l y for field service. This group will strongly overlap the other g r o u p s of tools but is m e a n t for t r o u b l e s h o o t i n g and m a i n t e n a n c e away from the work b e n c h . For t h i s p u r p o s e , p r e - p a c k e d tool b a g s are a v a i l a b l e but m o s t l y they do not f u l l y s a t i s f y the needs.
E i t h e r some items are m i s s i n g or some of them will never be used.
T h e r e f o r e , it seems b e t t e r to put tools used at the work bench into a bag for f i e l d s e r v i c e .
C h a p t e r 3 -2-
3. 1 LIST OF TOOLS (MATERIALS)
3.1.1 Room ABC 3.1.2 Work Benches ABC 3.1.3 Chairs ABC 3.1.4 Bench lights ABC 3.1.5 Trolley table ABC 3.1.6 Shelf ABC 3.1.7 C u p b o a r d ABC 3.1.8 Storage cabinet ABC 3.1.y Storage boxes ABC 3.1.10 C a b i n e t ABC 3.1.11 S c r e w d r i v e r s ABC F 3.1.12 Allen keys BC F 3.1.13 Pliers ABC F 3.1.14 Diagonal c u t t i n g nippers ABC F 3.1.15 Jewellers snips ABC F 3.1.16 Knives ABC F 3.1.17 Spanners ABC F 3.1.18 Soldering units ABC F 3.1.19 Tin (different types) ABC F 3.1.20 Desoldering units ABC F 3.1.21 Desoldering tapes (different types) ABC F 3.1.22 Calipers BC 3.1.23 Steel ruler BC 3.1.24 Measuring tapes ABC F 3.1.25 Punches ABC F 3.1.26 Hammer ABC F 3.1.27 Drills ABC F 3.1.28 Trepanning c u t t e r s BC F 3.1.29 Correcut drills C 3.1.30 D r i l l s for p r i n t e d circuit boards C 3.1.31 Hand drilling machines ABC F 3.1.32 El. drilling machine (with stand) BC 3.1.33 Stand-alone drilling machine C 3.1.34 Dental drills C 3.1.35 Dental drilling machine C 3.1.36 Thread taps C 3.1.37 Die nuts (threading dies) C 3.1.38 Files ABC F 3.1.39 Vices BC 3.1.40 Clamps C F 3.1.41 Tweezers ABC F 3.1.42 Inspection mirrors ABC F 3.1.43 Magnifier mirrors, lenses BC F 3.1.44 Brushes (cleaning) ABC F 3.1.45 Sprays (liquids for d i f f e r e n t purposes) ABC F
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3.1 List of tools (materials) (cont'd.)
3.1.46 Tapes ABC F 3.1.47 Saws ABC F 3.1.48 Saws (special) C 3.1.49 Tool bags F 3.1.50 Tool kits F 3.1.51 Storage boxes BC F 3.1.52 Cable crimping tools BC F 3.1.53 W r a p p i n g tools C 3.1.54 Blower and vacuum cleaner ABC F 3.1.55 Screw punches C 3.1.56 Tools for surface mounted devices C (F) 3.1.57 Glue (instant action type like ABC F
L o c t i t e or similar)
3.1.58 W i n d i n g machine (small size with turn c o u n t e r )
D e t a i l e d descriptions of the most important tools are p r e s e n t e d in the following pages.
C h a p t e r 3 -4-
3.1.1 R o o m
For c o n s t r u c t i o n , the f o l l o w i n g should be c o n s i d e r e d : a. Size - big enough not only for the work b e n c h but also
to allow space for t o o l s , t e s t i n s t r u m e n t s , spare p a r t s , c o m p o n e n t s , d o c u m e n t a t i o n , f a u l t y i n s t r u m e n t s (up to rack-size and d e t e c t o r w i t h c r y s t a l a s s e m b l i e s ) , r e p a i r e d i n s t r u m e n t s t r o l l e y s . . . A s e p a r a t e s t o r e r o o m , d i r t y room . . . B s e p a r a t e clean r o o m , d o c u m e n t a t i o n room . . . C b. L i g h t i n g s y s t e m - p r e f e r a b l y d a y l i g h t w i t h b l i n d s (for
screenwork) a n d d a y l i g h t f l u o r e s c e n t l a m p c. Floor - s u r f a c e w i t h o u t cracks or chinks
d. Ma t er ia1 - sealed and p a i n t e d c o n c r e t e , P V C , stone (terrazzo) . . . A P V C a n t i s t a t i c . . . B , C e. C oIpu r - g r e e n , g r e y , uni
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3.1.2 Work Benches
work b e n c h w i t h a d d i t i o n a l shelf of
beech m a t e r i a l . . . ABC
solid c o n s t r u c t i o n (permissible load 100 kg m i n ) , n o n - i n f l a m m a b l e s u r f a c e , p r e f e r a b l y w i t h d r a w e r s a n d a d d i t i o n a l shelves . . . .
w i t h a n t i s t a t i c bench m a t s B,C
3.1.3 Chairs
two for each working place w i t h and w i t h o u t b a c k p l a t e ; at least one w i t h a d j u s t a b l e h e i g h t a n d rolls . . . .
3.1.4 B e n c h L i g h t s
A.B.C
a d j u s t a b l e in all d i r e c t i o n s , arm l e n g t h m i n 8 0 c m . . . A f l u o r e s c e n t l i g h t s a n d lenses . . . B halogen lamp (spot l i g h t ) . . . C
3.1.5 Trolley Table
rain, size 6Ü x 70 cm, m i n . load c a p a c i t y 60 kg, should have the same h e i g h t as
t h e working table . . . A,B,C
C h a p t e r 3 -6-
3.1.6 S h e l f
p r e f e r a b l y a m o d u l a r system w i t h p i l l a r s a d e q u a t e t o t h e room h e i g h t ; p r e c a u t i o n : shelf m u s t be a n c h o r e d to the wall at a
r e a s o n a b l e h e i g h t . . . A.B.C
3.1.7 C u p b o a r d
s o l i d , p r e f e r a b l y m e t a l , l o c k a b l e w i t h
d r a w e r s a n d a d j u s t a b l e s h e l v e s . . . A . B . C
3.1.8 S t o r a g e C a b i n e t
me t al f rame d r a w e r s w i t h an t a n t w i t h d r a w a l
w i t h p l a s t i c d r a w e r s , edge t o a v o i d i n a d v e r -
A.B.C
3.1.9 S t o r a g e Boxes
d i f f e r e n t s i z e s , p l a s t i c , m a i n l y for spare p a r t s . .
s t o c k a b l e ,
A.B.C
3.1.10 C a b i n e t
w i t h d r a w e r s , s h e l v e s s u i t a b l e f o r
files, d o c u m e n t s and manuals, lockable . A.B.C
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3 . 1 . 1 1 S C R E W D R I V E R S H i n t s f o r s e l e c t i o n :
a. The shank s h o u l d be m a d e of a s p e c i a l alloy (chromium, e t c . ) b e t t e r t h a n n i c k e l - p l a t e d . Layer shanks are not so handy but m o r e u n i v e r s a l . F o r b i g g e r sizes, i t s p r o f i l e s h o u l d b e h e x a g o n a l t o g i v e a d d i t i o n a l t o r q u e w i t h a spanner.
b. The tip s h o u l d be s p e c i a l l y h a r d e n e d ; the two p l a n e s of the b l a d e h a v e to be p a r a l l e l in the slot of the screw.
c. The h a n d l e should be of s p e c i a l p l a s t i c , p r e f e r a b l y hammer h i t - p r o o f . H i t s on the end of the h a n d l e are only allowed if the shank goes f u l l y t h r o u g h the h a n d l e ( p r e c a u t i o n : no i s o l a t i o n ! ) .
l e n g t h (mm) 60-100 (shank), 100-120 (shank),
bit p r o f i l e (mm) 0.4x2.5
0.6x4
ABC F BC (F)
125 (shank), 170 (shank),
0.8x5.5 1 .6x8
ABC F BC (F)
170 200
(shank) (shank)
1.6x10 2 x!2
BC F BC (F)
25 (shank), 1 x 6 BC F
00
60 (shank), 80 (shank), 150 (shank),
PZD 0 PZD 1 PZD 3
BC F ABC F ABC F
100 (shank), 0.9x 5 C F
o o
100 (shank), PZD 1-2 C F
C h a p t e r 3 -8-
w a t c h m a k e r s s c r e w d r i v e r s , set of 0.25x0.8 up to 0.6x3.8 mm
set of 2 P h i l i p s 0,1 mm and 3 Hex 1.5-2.5 mm
BC
C (F)
8554
(mains t e s t e r s c r e w d r i v e r ABC F
s p l i t b l a d e h o l d i n g s c r e w d r i v e r
200 mm l o n g , 4 mm b l a d e BC
If s p e c i a l h e a d s ( o t h e r t h a n e.g. P o z i d r i v e ) a r e n e e d e d , t h e n use d i f f e r e n t b i t s in a h o l d e r ; a s p r i n g c o l l a r or a m a g n e t h o l d s t ne bit in a h e x a g o n s o c k e t .
100 mm l o n g , 1/4 inch socket C (F)
0286
E x a m p l e of d i f f e r e n t sizes of P o z i d r i v e b i t s :
"Wer» No 655 H'1. Sirewurivers lor Pozidnv/Supadnv slots C form Extra hard quality HRC 64-65 Specially intended for tightening sheet metal screws
Ortg. No. 855/1 H=V."0 Ret .. . .. .. .. . .. ... 5014 Pozidnv slots No Length mm Std pack Price each SEK Orijj. No.855/1H=V."0
Rfl. ... ... 5014 Pozidnv slots No Length mm Std pack Price each SEK
0052 0 25 10 525
0284 3-25 25 10 525
0102 1 25 10 5 2 5
0300 3-32 32 10 1200
020) 2-25 25 10 525
0409 4 32 10 1450
0250 2-50 50 10 8 7 5
oo
5014-5015 Bits for Pozidnv slots
Fitting in universal holders i BOO/I -
! 855/1 ' 840/1 -
O 867/1 -
d i f f e r e n t t y p e s o f b i t s
(28)
3.1.12 Allen Keys
keys are r e m o v e a b l e from the holder metric set 1.5-6mm, hex
inch set 1/16-1/4, hex
f o r m u l t i t u r n d i a l s o f p r e c i s i o n p o t s , a d d i t i o n a l special sizes should be o r d e r e d
BC BC
(F) (F)
3 . 1 . 1 3 P l i e r s
flat-nose p l i e r , l e n g t h 170 mm ABC
snipe-nose p l i e r , l e n g t h 1 2 0 m m C (F)
h a l f - r o u n d - n o s e p l i e r ,
l e n g t h 140 mm ABC (F)
c o m b i n a t i o n p l i e r , l e n g t h 160 mm ABC F
w a t e r p u m p p l i e r , l e n g t h 130-170 m m C (F)
wire strip plier, l e n g t h 130 mm BC F
-11-
C h a p t e r 3SKILLS ; G e n e r a l i n s t r u c t i o n s on s o l d e r i n g
S o l d e r i n g (and d e s o l d e r i n g ) is one of the m a i n tasks in e l e c t r o n i c t r o u b l e s h o o t i n g work. To solve t h e s e tasks p r o p e r l y , one has to c o n s i d e r several p o i n t s :
1. The p h y s i c a l d i m e n s i o n s of the s o l d e r i n g p o i n t .
The range is from tiny h y b r i d c i r c u i t s , w a t c h e s , d o u b l e or m u l t i - l a y e r b o a r d s (e.g. pocket c a l c u l a t o r ) up to big area s o l d e r i n g e.g. for s h i e l d g r o u n d i n g .
2. M a t e r i a l on w h i c h s o l d e r i n g m u s t be done.
N o r m a l l y , t h e r e w i l l b e a p r i n t e d c i r c u i t board covered w i t h s p e c i a l p r o t e c t i o n v a r n i s h o r t i n , s i l v e r , g o l d , e t c . , b u t also o n s t a n d - o f f s , l e a d s , p l a t e s , c a b l e s , e t c .
Let us as sume t h e r e a r e b i g a d d i t i o n t o t h e c o n d i t i o n s h a v e THE S O L D E R I N G
all m a t e r i a l is t i n - s o l d e r a b l e ; n e v e r t h e l e s s , d i f f e r e n c e s , e.g. for iron and g o l d . In d i f f e r e n t heat t r a n s f e r also d i f f e r e n t s u r f a c e to be c o n s i d e r e d . IT IS E S S E N T I A L T H A T FOR PERIOD THE TWO M A T E R I A L S R E M A I N C L E A N (NO O R G A N I C M A T E R I A L OR CORROSION).
3. M a t e r i a l used as s o l d e r .
The m a t e r i a l normally called "tin" is in r e a l i t y w h i c h is m o s t l y c o m p o s e d of o t h e r e l e m e n t s like Pb, Bi . Cu , and Sb .
an Cd
alloy A g ,
T A B L E 3 . 1 ; Some common t y p e s of s o l d e r and t h e i r c o m p o s i t i o n
S t a n d a r d Alloy TLC LMP SN63 60/40 S A V B I T 6 50/5U S A V B I T 1
96S
40/60 95A 30/70 2U/80 HMP
Mel t ing Point C
145 179 183 188 190 212 215 221 234 243 255 275 301
S p e c i f i c a t (A)=QQ=S-5 (B)=BS 219 (B)T, (G) (B)62S (A)SN63 (B)DP,(G) (G)
( B ) F , ( G ) (G)
(A)Sn96 , (B (B)G,(G) (B)95A,(G) (B)J(G) (B)V(G) (B)5S
ions
7 1 E , (G)=DIN1707
L - S n P b C d l 8 L - S n P b A G l ,8 L-Sn63PbBi03 L-Sn60Pb L-Sn60PbCu2 L-Sn50Pb L-Sn50PbCu )96S , (G)L-SnAg5
L-PbSn40 L-SnSb5 L - P b 7 0 S n L-Pb80Sn
U s e d for
s o l d e r of g a l v . g o l d
s o l d e r of g a l v . s i l v e r
p r i n t e d boards e l e c t r o n i c
s t o p s d i s i n t e g r a - t i o n of cu
e l e c t r o n i c
stops d i s i n t e g r a - tion of Cu
w i t h o u t lead c o m m o n e l e c t r i c w i t h o u t lead E -Mo t or s l a m p s
h i g h t e m p , s o l d e r
(31)
U i t f e r e n t a m o u n t of these e l e m e n t s r e s u l t in a l l o y s w i t h d i f f e r e n t c h a r a c t e r i s t i c s like m e l t i n g p o i n t , c o n d u c t i v i t y , a g r e s s i v i t y t o o t h e r m a t e r i a l s (copper), m e c h a n i c a l s t r e n g t h , e t c .
Ok Zll
3 7 0 - 315- 260 -
3
D
5 11,9-
i—3
01 g? . Q. *J
EO)
(
"N
%^
V l\ paste
v ,
^^^
solide
^*^
) 10 20 30 1,0 50 60 Ti'nn Sn - Pb [%}
^*~
Liquid
^^^*
- ^ p a s t e
l
"l 70 80 90 100 63
E u f e c h c point
This d i a g r a m shows a s o l d e r w i r e c o m p o s i - t i o n of t i n - l e a d . There is a p a s t e - r e g i o n a b o v e and b e l o w the 63% tin c o n c e n t r a t i o n .
F l u x is n e c e s s a r y to allow N o r m a l l y t h e f l u x o u g h t t o b e c o p p e r .
s o l d e r i n g or to make it e a s i e r , i n a g r e s s i v e , e s p e c i a l l y a g a i n s t
D u r i n g t h e s o l d e r i n g p r o c e d u r e , some i m p o r t a n t c o n s i d e r a t i o n s m u s t b e f o l l o w e d . A f t e r s w i t c h - o n o f m a i n s , t h e s o l d e r i n g iron s h o u l d h e a t up f a s t and s h o u l d r e m a i n at a c o n s t a n t t e m p e r a t u r e . D u r i n g t h e s o l d e r i n g p e r i o d , i t s h o u l d warm u p fast t h e m a t e r i a l o f t h e s o l d e r i n g p o i n t t o a t e m p e r a t u r e close t o t h e l i q u i d r e g i o n o f t h e s o l d e r . A d e q u a t e s o l d e r h a s t o b e a p p l i e d . D u r i n g t h e m e l t i n g t i - n e , t h e h e a t c a p a c i t y o f t h e solder t i p h a s t o b e s u f f i c i e n t n o t to d r o p t h e t e m p e r a t u r e b e y o n d t h e l i q u i d region o f t h e s o l d e r .
Why not take a soldering iron with a t e m p e r a t u r e far above the m e l t i n g region? The f o l l o w i b g observations speak against such a p r o c e d u r e .
-13- Chapter 3
1. S e n s i t i v e c o m p o n e n t s , c a b l e s , c o n n e c t o r s , p r i n t e d c i r c u i t s , etc. will be d e s t r o y e d if they are e x p o s e d too long to h i g h e r t e m p e r a t u r e s .
2. The t e m p e r a t u r e of the solder should drop into the solid s t a t e v e r y f a s t because m o v e m e n t of the p a r t s in liquid or p a s t e c o n d i t i o n will cause a bad c o n t a c t (cold solder point).
C o n s i d e r i n g the previous, a d e q u a t e soldering tools have to be s e l e c t e d .
(33)
3.1.18 Soldering irons and b i t s
Multitip 230 8 Wdtt
Wattage 8 W
Heating up time ca 90 s Bit temperature 290 °C Weight without lead 26 g with rubber rest
Voltages 6 V, 110 V, 130 V, 220 V, 240 V Order nos.
230 LN/8 W Iron with nickel-plated copper bit 230 LD/8 W Iron with ERSADUR long-life bit
BC
Multitip 230'15 Wall
Wattage 15 W
Heating up time ca 60 s Bit temperature 350 °C Weight without lead 28 g with rubber rest
Voltages 6 V, 12 V, 24 V 42 V, 48 V 110 V, 130V, 220V, 240V
Order nos.
230 LN/15 W Iron with nickel-plated copper bit 230 LD/15 Wlron with ERSADUR long-life bit
BC
Multitip 230/25 Walt
Wattage 25 W
Heating up time ca 60 s Bit temperature 450 °C 9a Weight without lead 34 g
with rubber rest
Voltages 6 V 12 V 24 V, 42 V, 48 V, 110 V, 130V, 220V, 240V
Order nos.
230 LN/25 Wlron with nickel-plated copper bit 230 LD/25 Wlron with ERSADUR long-life bit
B i t s (surface like "Ersadur" t y p e is r e c o m m e n d e d for all)
ABC F
BC F ABC F
bits / pannes
«t^a
—G5B
—G=a
^' '
Multitip 230/8 W vernickelt
nickel-plated nickelée
132LN 132BN 132KN 132SN
ERSADUR
132LD 132BD 132KD 132 SD
Multitip 230/1 5 W vernickelt
nickel-plated nickelée
162LN 162BN 162KN 162SN
ERSADUR
162LD 162BD 162 KO 162 SD
Multitip 230/25 W vernickelt
nickel-plated nickelée
172LN 172BN 172KN 172SN
ERSADUR
172LD 172BD 172 KD 172 SD
C o r d l e s s i n d u s t r i a l s o l d e r i n g iron:
T h e c o r d l e s s i n d u s t r i a l s o l d e r i n g iron is p o w e r e d by l o n g - l i f e n i c k e l c a d m i u m b a t t e r i e s , w h i c h a r e easily r e p l a c e a b l e , g i v i n g t i p p e r f o r m a n c e e q u i v a l e n t to up to 50 w a t t s w i t h over 370°C (700°F) tip t e m p e r a t u r e .
C (F) S o l d e r i n g irons w i t h b u t h a n g a s f i r i n g w i t h h e a t r e g u l a t i o n a n d d i f f e r e n t t i p s a r e s u i t a b l e , e s p e c i a l l y f o r h i g h e r h e a t t r a n s f e r ( g r o u n d i n g ) in the f i e l d s e r v i c e . F
-15- C h a p t e r 3
3.1.18 Soldering iron (cont'd.)
030 KK/30 W Iron with copper bit 030 KK/40 W
030 KD/30 W Iron with ERSADUR long-life bit 030 KD/40 W
Wattage 30 W or 40 W Heating up time approx. 2 mm Bit temperature 380 °C, 420 °C Weight without lead: 95 g with plastic rest
Voltages 6 V, 12 V. 24 V, 42 V, 48 V, 110. 120 V, 125. 135V, 220V, 225.. 235V. 240 ..250V
ABC F
Lotspitzen / bits / pannes Kupfer / copper / cuivre ERSADUR
__
032 KK 032 KD
/ ==
032 JK 032 JO
' '
032 BK 032 BD
" ' ———
032 CK 032 CO
c^«
032 NK 032 NO
Wattage SOW Heating up time- 3 mm Bit temperature. 410 °C Weight without lead. 220 g
Voltages: 12V,24V,42V,48V, 110. .120V, 125 ..135 V, 220 V, 225...235 V, 240...250 V
Order nos
080 JK Iron with copper bit
080 JD Iron with ERSADUR long-life bit ABC
bits / pannes
, __ y —
cr^^
/————
^BB™
———————
ERS Kupfer copper cuivre 052 JK 052 KK 052 NK
052 CK
A 50
ERSAOUR
052 JO ACO vn
052 NO 052 DO 052 BO 052 CD
ERS Kupfer copper cuivre 082 JK 082 KK 062 FK
A 80
ERSADUR
082 JD 082 KD
H o l d e r s
A B C
ABC
(35)
3 . 1 . 1 8 S o l d e r i n g ( d e s o l d e r i n g s t a t i o n )
Lotspitzen / bits / pannes
ERSADUR
' J
602 CD
^ ' ' 602 ED
~«a
602 BD
This electronic t e m p e r a t u r e regulated soldering and d e s o l d e r i n g s t a t i o n is e s p e c i a l l y d e s i g n e d for i n d u s t r i a l u s e , l a b o r a t o r i e s and r e p a i r works. The m o d u l a r s y s t e m p e r m i t s a large f i e l d of a p p l i c a t i o n s . The single e l e m e n t s can be used in i n d i v i d u a l combinations.
B e c a u s e of a b u i l t - i n v a c u u m p u m p the e f f i c i e n t s t a t i o n is i n d e p e n d e n t of an air p r e s s u r e connection. In a d d i t i o n , the basic s t a t i o n c o n t a i n s a power s u p p l y of 220V/24V which f i t s all 24V soldering irons and desoldering irons up to 80W r a t i n g .
A n e l e c t r o n i c control unit p e r m i t s c o n t i n u o u s v a r i a t i o n o f t h e s o l d e r i n g bit t e m p e r a t u r e b e t w e e n 150 and 400 d e g r e e s C. By m e a n s of a t h e r m o c o u p l e sensor l o c a t e d in the s o l d e r i n g iron next to the
-17- C h a p t e r 3
b i t , t h e e l e c t r o n i c c o n t r o l c o m p a r e s it to the n o m i n a l i n t e g r a t e d zero v o l t a g e swit t e m p e r a t u r e is elee t r o n i c a l 1 is i n d i c a t e d by a p i l o t 1 d i f f e r e n c e o r h e a t r e q u i r c o n t r o l s t h e h e a t i n g ener o p e r a t i o n a l s t a t e (idling d e s o l d e r i n g b i t i s c o n n e c t e d i n t e g r a t e d h i g h O h m r e s i s t o r
m e a s u r e s t h e a c t u a l t e m p e r a t u r e a n d t e m p e r a t u r e s e t t i n g . By means of an ch w i t h full-wave logic and T r i a c , the y c o n t r o l l e d and the o p e r a t i o n a l s t a t e i g h t . D e p e n d i n g o n t h e t e m p e r a t u r e e m e n t , t h e s e n s i t i v e e l e c t r o n i c u n i t gy i n p u t in a c c o r d a n c e w i t h the or load). The s o l d e r i n g bit and to the l e v e l - p o t e n t i a l t e r m i n a l via an
The s m a l l s o l d e r i n g iron is v e r y e f f i c i e n t t h a n k s to its c e r a m i c h e a t i n g e l e m e n t , w h i c h h a s a p r o n o u n c e d p o s i t i v e t e m p e r a t u r e c o e f f i c i e n t (PTC) and 80 W a t t s r a t i n g (at 350 d e g r e e s C).
The d e s o l d e r i n g s y s t e m c o n s i s t s of the iron on w h i c h a d e s o l d e r i n g h e a d i s m o u n t e d . T h e t r a n s p a r e n t solder c h a m b e r c a n b e e m p t i e d s i m p l y a n d q u i c k l y . T h e n e c e s s a r y v a c u u m i m p u l s e f o r d e s o l d e r i n g is r e l e a s e d by a f o o t s w i t c h .
T h e f o l l o w i n g p i c t u r e g i v e s a n o v e r v i e w o f a n e x t e n d a b l e s o l d e r - d e s o l de r s t a t i o n of one of the l e a d i n g m a n u f a c t u r e r s .
Netzspannung
Grundgerat station No. 003
f Lötkolben 2 4 V b t s S O W unregulated iron 24V up 10 30 W
l im Griff geregeller
( Lotkotben 24 V bis 8Û W
1 regulated in the handle
1 2 -i V up to 80 W
elektronische Regetemheit electrons control unit No. TCS-flOO
elektronische Regetemheit mit Digitalanzeige electronic control unit with digital d'spiay No. TCS-D 800
ungeregelter Lolkolben 24 V bis 80 W unregulated iron 24 V up to 80 W
im Griff geregelter Lotkolben 24 V, bis 80 W regulated in the handle 24 V. up to 80 W
eteklronische Regeteinheit electronic control unit No TCS800
elektronische Regeteinheil mrt Ognalanze.ge electronic control unit with digital display No. TCSO800
(37)
3.1.19 Tin
As shown on page 11, T a b l e 3.1, one s h o u l d also select for a s p e c i a l p u r p o s e t h e a d e q u a t e solder.
In real l i f e , h o w e v e r , one to t h r e e t y p e s of tin alloys w i l l b e e n o u g n .
60/40 w i t h low m e l t i n g region BC S a v b i t b p r o t e c t s c o p p e r ABC F S a v b i t 1 p r o t e c t s c o p p e r , h i g h e r m e l t i n g r e g i o n B C
Tin of m u l t i - c o n t y p e w i t h n o n - c o r r o s i v e flux like rosin s h o u l d be s e l e c t e d . The q u a n t i t y is n o r m a l l y 100g, 250g, 500g per u n i t . A h a n d y d i m e n s i o n g i v e s the 250g spool.
The d i a m e t e r of the solder w i r e tiny c i r c u i t - w o r k , a small spool of wire is r e c o m m e n d e d to have on s t o c k .
s h o u l d be a b o u t Imra; only for a b o u t 0.3mm d i a m e t e r s o l d e r
C (F)
-19- C h a p t e r 3
3.1.20 ü e s o l d e r i n g Tools
BC (F)
The d e s o l d e r i n g bit can be inserted in soldering irons or soldering s t a t i o n s . In any case the a p p l i e d t e m p e r a t u r e should not be too h i g h and not too long, o t h e r w i s e the PC board w i l l be d e s t r o y e d .
case one .
This is d a n g e r o u s e s p e c i a l l y on m u l É i - l a y e r b o a r d s ; in t h i s it is b e t t e r to cut the leads of the 1C and r e m o v e t h e m one by
Tin s u c t i o n d e v i c e s
6750/SP
6750/XS
one-hand o p e r a t i o n w i t h e x c h a n g e a b l e t e f l o n t i p l e n g t h 210, 190 mm
ABC F
D e s o l d e r i n g t a p e s
l e n g t h 1.6m
w i d t h 1.5, 2, 2.5
ABC F
D e s o l d e r i n g c i r c u i t b o a r d s , i n c l u d e d . T h e
t a p e s are A min ima1 d e s o l d e r i n g
used for a b s o r b i n g excess solder on q u a n t i t y of m i l d and n e u t r a l f l u x is
t a p e is h i g h l y - a b s o r b a n t .
3.2 LIST OF ACCESSORIES
3.2.1 S t r i p s w i t h banana p l u g s (0.5, 1, 1.5m) ABC F 3.2.2 Alligator clips ABC F 3.2.3 Test c l i p s (for strips) ABC F 3.2.4 Test clip for IC-tests BC F 3.2.5 Cable reeling u n i t s ABC F 3.2.6 Oscilloscope p r o b e s (1:10, 1:1) ABC F 3.2.7 Oscilloscope c u r r e n t p r o b e BC 3.2.8 Oscilloscope HV p r o b e BC 3.2.9 HV p r o b e for m u l t i m e t e r ABC F 3.2.10 Shielded black box BC
BC (F) 10,20 dB) BC (F)
ABC F ABC F ABC F ABC F ABC F ABC F ABC F ABC F 3.2.21 BNC 50-Ohm cables (0.3, 0.5, 1, 2, 4m length) ABC F 3.2.22 SHV - 5kV - cables (2, 4m) ABC F 3
3 3 3 3 3 3 3 3 3
.2 .2 .2 .2 .2 .2 .2 .2 .2 .2
. 11 . 12 . 13 . 14 . 15 .16 .17 .18 .19 .20
BNC BNC BNC BNC BNC MHV MHV SHV SHV
5u-0hm 50-Ohm T-type I-type I-type T-type 1-type T-type I-type
t e r m i n a t o r (male) plug a t t e n u a t o r (1,3,6,10,10 male
female
female female SHV-MHV-adaptor
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3.2.6 O s c i l l o s c o p e P r o b e s
M o d u l a r s w i t c h a b l e p r o b e w i t h x l a n d x l O a t t é n u a t i o n
AH. 10:1 B a n d w i d t h : DC-250 MHZ rise t i m e : 1,4 nsec i n p u t r e s i s t a n c e :
10 M o h m
A H . 1 : 1 B a n d w i d t h : DC-10 M H Z r i s e t i m e : 35 nsec i n p u t r e s i s t a n c e :
1 M o h m
M o d u l a r p r o b e s allow easy r e p a i r of broken p a r t s ;
a n y m o d u l e c a n b e s i m p l y r e p l a c e d . A B C
3.2.7 O s c i l l o s c o p e Current P r o b e
1I10B
S e n s i t i v i t y A c c u r a c y : B a n d w i d t h : rise t irae:
I max. dc : I m a x . ac :
I m V / m A
± 3%
I k H z to 40 MHz
8 nsec 0.5A
15A
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3.2.10 Shielded Black Box
68 "-22 35
For c o m p a c t p a c k a g i n g of m a t c h i n g n e t w o r k s .
F e a t u r e s s h i e l d e d h o u s i n g of d i e cast a l u m i n u m .
I n c l u d e s c o v e r and four self t r a p p i n g sc rews.
B C
3 . 2 . 1 1 BNC 50-Ohm T e r m i n a t o r P l u g
1%, 0.5 w a t t s , + 100 C max g o l d - p l a t e d center c o n t a c t
BC (F)
3.2.12 BNC 50-Ohm A t t e n u a t o r
Impedance : f-range : A c c u r a c y : Max Power :
50-Ohm DC-1 GHz
^0.2 dB 1 W a t t
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3.3 I N S T R U M E N T S
S e l e c t i o n o f i n s t r u m e n t s f o r t r o u b l e s h o o t i n g a n d d e v e l o p m e n t may be t r o u b l e s o m e b e c a u s e n o w a d a y s a large a m o u n t of d i f f e r e n t t y p e s , e v e n f o r s i m i l a r p u r p o s e s , a r e a v a i l a b l e o n t h e m a r k e t .
E v e n e x p e r t s are only f a m i l i a r w i t h a few t y p e s of i n s t r u m e n t s a n d t h e s e a r e m o s t l y i n s t r u m e n t s t h e y a r e d e a l i n g w i t h . T h e p r o b l e m is to o r d e r the b e s t for a c e r t a i n p u r p o s e . To o r d e r the i n s t r u m e n t s at the lowest p o s s i b l e cost is not n e c e s s a r i l y the b e s t s o l u t i o n . Some a d d i t i o n a l f a c t o r s h a v e t o b e c o n s i d e r e d :
1. for w h i c h p u r p o s e the i n s t r u m e n t s are n e e d e d , i.e. w h i c h f i e l d o f t r o u b l e s h o o t i n g ( d e v e l o p m e n t ) s h o u l d b e c o v e r e d ?
2. W i l l the i n s t r u m e n t be u p g r a d e d for a d d i t i o n a l p u r p o s e s in the f u t u r e ?
3. Is the m a n u f a c t u r e r r e p r e s e n t e d on the l o c a l m a r k e t ?
4. Is the i n s t r u m e n t s u p p l i e d w i t h all t e c h n i c a l i n f o r m a t i o n and s e r v i c e m a n u a l s ?
5. How is the s i t u a t i o n in s e r v i c i n g the i n s t r u m e n t (local s e r v i c e s t a t i o n , s h i p m e n t , c u s t o m d i f f i c u l t i e s , etc.)?
6 . C a n t h e i n s t r u m e n t b e o r d e r e d t o g e t h e r w i t h spare p a r t s , a c c e s s o r i e s , o p t i o n s , s e r v i c e k i t s , e t c . ?
7. Who is the user of the i n s t r u m e n t (level of e x p e r i e n c e and k n o w l e d g e ) ?
8. W h e r e w i l l the i n s t r u m e n t be used ( e n v i r o n m e n t a l s i t u a t i o n ) ? These e i g h t p o i n t s m a y b e e x t e n d e d a c c o r d i n g t o special s i t u a t i o n s . The i n s t r u m e n t s l i s t e d in the f o l l o w i n g pages are used i n d i f f e r e n t n u c l e a r e l e c t r o n i c s l a b o r a t o r i e s t h a t h a v e r e c e i v e d a s s i s t a n c e from the IAEA. Considerable experience of e x p e r t s is i n c o r p o r a t e d i n t o t h i s s e l e c t i o n . N e v e r t h e l e s s , only p o i n t 1 and 2, m e n t i o n e d a b o v e , will be c o v e r e d . For a final o r d e r i n g d e c i s i o n , a l l o t h e r p o i n t s s h o u l d b e c o n s i d e r e d .
The f o l l o w i n g l i s t e d i n s t r u m e n t s are to be u n d e r s t o o d as e x a m p l e s only. This list also should be u p g r a d e d p e r i o d i c a l l y - o l d - f a s h i o n e d e q u i p m e n t should b e r e p l a c e d .
(43)
List of i n s t r u m e n t s
F o r a n a l o g t r o u b l e s h o o t i n g a n d d e v e l o p m e n t :
3.3.1 A V O - m e t e r ABC F 3.3.2 D i g i t a l m u l t i m e t e r
3.3.2a h a n d h e l d , 4 1/2 d i g i t ABC F 3 . 3 . 2 b b e n c h m o d e l , 4 1 / 2 d i g i t B C 3.3.2c b e n c h m o d e l , 6 1/2 d i g i t C 3.3.3 C a p a c i t y - I n d u e t i v i t y m e t e r ABC F 3.3.4 T r a n s i s t o r t e s t e r ABC F 3.3.5 I n s u l a t i o n t e s t e r BC 3.3.6 O s c i l l o s c o p e s
3.3.6a p o r t a b l e (up to 20 M H z ) A F 3.3.6b b e n c h t y p e (up to 40 M H z ) A
3.3.6e b e n c h t y p e (up to 100 M H z ) BC 3.3.6d s t o r a g e t y p e C 3.3.7 P u l s e g e n e r a t o r s
3 . 3 . 8 a d o u b l e p u l s e g e n e r a t o r BC F 3.3.8b p r e c i s i o n p u l s e g e n e r a t o r C 3.3.8c s l i d i n g p u l s e g e n e r a t o r C 3.3.8 D C - p o w e r s u p p l i e s BC 3.3.9 T r a n s i s t o r c u r v e t r a c e r C 3.3.10 D C - c u r r e n t m e t e r ( c u r r e n t p r o b e ) B C 3 . 3 . 1 1 N o i s e (RMS) m e t e r BC 3 . 3 . 1 2 C o m p l e t e e q u i p m e n t for - s p e c t r o s c o p y C
F o r d i g i t a l t r o u b l e s h o o t i n g a n d d e v e l o p m e n t :
3 . 3 . 1 3 L o g i c t e s t e r p r o b e A B C F 3.3.14 S i g n a l i n j e c t o r BC 3.3.15 D i g i t a l c i r c u i t t e s t e r ( t r o u b l e s h o o t e r k i t ) B C F 3.3.16 B r e a k - o u t b o x B C F 3.3.17 IC-tester BC 3.3.18 L o g i c analyzer C 3.3.19 Prom p r o g r a m m e r C 3.3.20 I n - c i r c u i t e m u l a t o r (with t e r m i n a l or PC) C 3.3.21 D e v e l o p m e n t s y s t e m (with p r i n t e r ) C 3.3.22 E x p e r i m e n t a l c o m p u t e r board (single board
c o m p u t e r ) C
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3.3.1 A V O - M e t e r
A n a l o g i n s t r u m e n t w i t h f a s t o v e r l o a d p r o t e c t i o n
i n t e r n a l b a t t e r y (1.5V) f o r r e s i s t a n c e m e a s u r e m e n t s
s i m i l a r t y p e s f o r h i g h e r c u r r e n t ranges are also a v a i l a b l e
S p e c i f i c a t i o n s : Vdc Ü. IV A d c l O u A Vac 10V R l
5 Ü U U V +_ 1.5% ( 10k - 500M ) 1A( IDA) +_ 1.5% ( 10k - 0.24 ) 1000V +_ 2.5% (200k - 20M )
5M + 1.5% (with i n t e r n a l 1 . 5 V b a t t e r y )
These kind of i n s t r u m e n t s h a v e b e e n used for m a n y y e a r s and m i g h t seem o l d - f a s h i o n e d nowadays, b u t n e v e r t h e l e s s t h e y a r e o f t e n n e e d e d where t r e n d s are to be a n a l y z e d or m e a s u r e m e n t s u n d e r
f l o a t i n g c o n d i t i o n s are to be taken.
ABC F
(45)
