TR-2000 Final Test Procedure

System Information
Serial Number(s) _________________________________________________________

Ametek SO Number: _____________________ Customer PO Number: ________________________

Model Number: ___________________________________________________________________________

Equipment Required
Associated Research Model 3565D Hi-Pot tester or equivalent
Wavetek Model 4800A calibration source
TR2000 ATE( For automated testing only ).

I. TR-2000 Hardware Setup Instructions

Acquisition Board Configuration Switches

Set-up the acquisition board configuration switches as shown below. Reference the System Drawings for
number of channels and options to be enabled.

Bank 1 – left Table #1

Switch Default setting Function Off On
1 On Reserved Normal
2 On System frequency 50Hz. 60Hz.
3 See table No. of inputs - 1 See Table #2
4 See table No. of inputs - 2 Below
5 Off Cross triggering Disabled Enabled
6 Per cust. Spec GPS Receiver Yes No
7 Off GPS Time Code Port Master Slave
8 Off (Undefined)

Table #2
Switch 3 Switch 4 Inputs (A/D)
Off Off 8/16
Off On 16/32
On Off 24/48
On On 32/64

Bank 2 - right Table #3

Switch Default setting Function Off On
1 Off External time code – Com 2 Disabled Enabled
2 On Baud rate on COM1 - 1 See Table #4
3 On Baud rate on COM1 - 2 Below
4 Off External printer No Yes
5 Off Modem No Yes
6 Off Synchrophasor on Com 2 No Yes
7 Off (Undefined) 0 1
8 Off (Undefined) 0 1

Table #4
Digitally signed

1082-697 Shawn
by Shawn Rowan
DN: cn=Shawn
Rowan, o=API,
ou=Rochester,
c=US

Rev.E Signature
Not Verified
Rowan Date:
2005.03.11
08:15:39 -05'00'

Power Instruments
Page 1 of 9 APPROVED
 Switch 2 Switch 3 Baud rate
Off Off 9600
Off On 19,200
On Off 38,400
On On 57,600

Digital Input Board Resistor Table

If necessary, the Digital Inputs can be changed to accept a different voltage level. Reference the Input
Module schematic for resistor locations and change the value of Rx51 to match the Digital input voltage.

Input VDC
Rx51 Description AMETEK Part No.
(Nominal)
12 V 3.6K Carbon Composition 4716-130
Resistor (1W)
24 V 6.8K Carbon Composition 4716-140
Resistor (1W)
48 V 15K Carbon Composition 4716-152
Resistor (1W)
125V 39K Carbon Composition 4716-164
Resistor (1W)
250 V 82K Carbon Composition 4721-180
Resistor (2W)

Input Board Jumper Locations

Set the Input Board configuration jumpers per the table below.

Board Status Output

Channels Acquisition Status Relay EEPROM
# #1
1 1-8 J1 J171 J5, J6, J7 J170 (1-2)
2 9-16 J2 J172 J6, J7 J170 (2-3)
3 17-24 J3 J173 J5, J7 J170 (2-3)
4 18-32 J4 J174 J7 J170 (2-3)

Input Board Analog Input Range Selection Table

Set the Input Board range selection jumpers per the table below. The jumpers are located at the back and
center right of the board. The channels are ordered from right to left and the odd numbers are at the rear
and the evens at the front.

Input Range Jumper (Jx01) Resistor Selected

0-2 Vpk (Current) None None
0-300 Vpk (Voltage) A Rx06
0-12 Vpk (Transducer) B Rx07
TBD C Rx08

II. Standard Network Card Setup Instructions ( if supplied )

1. Place network card in setup fixture. The network card cannot be configured using ________
the TR2000 SBC so use the 486 SBC for this step.

2. Run the set-up utility which is included with the Ethernet card. Set the following ________
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 information for the Ethernet option: Address=$360H, interrupt=IRQ11, and
remote boot disabled. If the Ethernet card is plug and play, disable this feature.
After card is setup install it in TR2000.

III. Fiber Optic Network Card Setup Instructions ( if supplied )

1. Place network card in setup fixture. The network card cannot be configured using ________
the TR2000 SBC so use the 486 SBC for this step.

2. Run the set-up utility which is included with the Ethernet card. Set the following ________
information for the Ethernet option: Address=$360H, interrupt=IRQ11, and
remote boot disabled. If the Ethernet card is plug and play, disable this feature.
After card is setup install it in TR2000.
Setup as follows:
Boot from TR100+ setup disk
Run Autoset8.exe from setup supplied with network card
Select ‘Configure New Adapter’
Select ‘Configure New Adapter Manually’
Novell Configuration – None
I/O Address – 0x360
IRQ – 11
Physical Media – Fiber
Adapter Architecture – I/O Port
Boot Prom – No Boot Prom
Save Configuration, Ignore write protect error
Run Diagnostics, all should pass
Power down. Then back up. Ensure card has saved settings
Run Diagnostics
Install in TR2000

IV. Modem Card Setup Instructions ( if supplied )

1. Using switches, jumpers, or software set modem to COM3, IRQ5 and install in ________
TR2000.

V. SBC Setup Instructions

1. Connect a monitor, floppy drive, and keyboard to TR2000. ________

2. Setup SBC hardware and BIOS per appendix A. Ensure all voltages displayed in ________
Chipset Features Setup are within specifications displayed in appendix.

3. Boot the machine using the TR-2000 System Set-up Boot Disk. Once at the A:> ________
prompt, type “setup” and follow the instructions on the screen.

4. When this is complete switch off the TR-2000, remove the floppy drive then switch ________
it on again. The BIOS setup program may be run again to disable the floppy disk
options (see above).

5. The display will show the SBC board initializing then running the TR-2000 ________
program. A number of status messages are displayed to indicate the progress of
the initialization.

7. When the initialization is complete, a debug menu should be displayed. This ________
indicates that the system programs have been loaded properly. If this menu does
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 not appear, recheck each step of this setup procedure.

8. Once the system has booted up, connect to the front port of the TR-2000 and ________
enter the CLI through terminal mode, to verify that the recorder firmware is
functioning properly.

9. Enter the command “systemreset” via CLI. Ensure system watch dog times out ________
and unit reboots within a minute or two.
VI. Initial Checks and Burn In

1. Ensure all aspects of the system drawings match the system as supplied. ________

2. With prime power disconnected, turn on the TR2000 power switch. Hi-Pot the ________
following points per the setup shown below.

Points All channel inputs to chassis ground

All status relay outputs to chassis ground
Trip 1ma
Voltage 3110VDC
Rise Time 3 Seconds
Dwell Time 1 Second

3. Reset the output voltage of the HI-Pot tester to 2333VDC. Hi-Pot the unit between ________
the prime power input terminals and ground using the above trip and time settings.

4. Turn off TR2000 power switch, Reconnect prime power to the unit and turn on the ________
power switch. Verify that the Power LED illuminates on the TR-2000 front panel.

5. Apply approximately 90% full scale to each analog input. Reference chart below. ________
Using either Display Station32 verify that each analog channel has a clean,
undistorted sinewave and a quality factor > 98%.

Channels Full Scale 90% FS

Voltage 212.13 190
Current 1.4142 1.27
Transducer 12 9

6. Using the CLI command “system formatdisk” format the hard drive and verify there ________
are no errors. DO NOT perform a quick format.

7. Heat run the system for 12 hours at 122 degrees Fahrenheit in the armed state. ________

8. If GPS is installed perform the following: enter Recorder Configuration. Click the ________
Configure System Time button. Ensure the letter ‘X’ ( for loss of sync. ) is
displayed after the time. Connect GPS Test cable to GPS input on rear of TR2000
chassis. Ensure the ‘X’ changes to a ‘G’ ( for locked ) within a couple of minutes.
Also ensure recorder time changes to reflect GPS time.

9. If Irig B is installed perform the following. Using computer and DS32 connect to ________
recorder. Enter configuration. Select Peripherals tab. Select IRIG-B time
synchronization. Press OK, and Setup to send configuration to TR2000 recorder.

Re-enter Recorder Configuration. Click the Set Time button. Ensure the letter ‘X’ (
for loss of sync. ) is displayed after the time. Connect IRIG-B signal to IRIG-B
input on rear of TR2000 chassis. Ensure the ‘X’ changes to an ‘L’ ( for locked )
within a couple of minutes. Also ensure recorder time changes to reflect IRIG-B
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 time.

10. If channel information is specified in system drawings set them now. Leave at ________
defaults if not specified.

VII. Calibration and Verification ( Perform either ATE or Manual )

ATE
1. Connect unit to ATE and initiate system test. ________

Manual
1. Using either Display station32 or CLI connect to recorder through the local port. ________
Initialize event parameters as follows:
Set sample rate to 96 samples per cycle.
Set the transient pre-fault time to 2 cycles
Set the transient post fault time to 8 cycles
Set the transient safety window to 0 cycles
Set the maximum record size to 1 seconds
Set to stop recording on memory full.
Set analog nominal values and units to defaults below.
Channels Nominal Value Full Scale Units
Voltage 100 212.13 V
Current 0.70 1.414 A
Transducer 5 12 Vdc

2. Run Calibration Software. Connect shorting bars to each input board and set the ________
offset correction for each board.

3. For Voltage Channels ________

Apply 75% Peak Full scale (225VDC) to the channel(s) being calibrated and use
the calibration software to correct the gain.

For Current Channels

Apply 75% Peak Full Scale (1.5VDC) to the channel(s) being calibrated and use
the calibration software to correct the gain.

For Transducer Channels

Apply 75% Peak Full Scale (7.5VDC) to the channel(s) being calibrated and use
the calibration software to correct the gain.

4. Cycle power to unit. Ensure offset and gain values were stored in E2 properly. ________

5. Hook up all voltage inputs in parallel and apply 5%, 25%, 50%, 75%, and 99% full ________
scale. Ensure all readings are within +/-0.1% full scale. Reference table below.

Input Reading
10.606Vrms 10.39-10.82Vrms
53.032Vrms 52.82-53.24Vrms
106.065Vrms 105.86-106.28Vrms
159.097Vrms 158.89-159.31Vrms
210.008Vrms 209.80-210.22Vrms

6. Hook up all current inputs in parallel and apply 5%, 25%, 50%, 75%, and 99% full ________
scale. Ensure all readings are within +/-0.1% full scale. Reference table below.
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 Input Reading
0.0707Vrms 0.0693-0.0721Vrms
0.3536Vrms 0.3521-0.3550Vrms
0.7071Vrms 0.7056-0.7085Vrms
1.0607Vrms 1.0592-1.0621Vrms
1.4001Vrms 1.3986-1.4015Vrms

7. Hook up all Transducer inputs in parallel and apply test voltages. Ensure all ________
readings are within +/-0.1% full scale. Reference table below.

Input Reading
(-11.0000)Vdc (-11.0120)-(-10.9880)Vdc
(-6.0000)Vdc (-6.0120)-(-5.9880)Vdc
0.0000Vdc (-0.0120)-0.120Vdc
6.0000Vrms 5.9880-6.0120Vdc
11.0000Vrms 10.9880-11.0120Vdc

8. Using Display Station set all digital channel information and triggering sections of ________
the configuration to Normally Open, 1ms debounce, and edge triggered.

9. Alarm each digital input one at a time. Ensure each triggered an event. ________

10. Using the CLI and srelay/crelay commands, activate each output relay one at a ________
time. Ensure corresponding relay closes and opens while all other relays are
unaffected.

11. Ensure power relay closes on power up and opens on power down. ________

12. If system is configured with a modem use Display Station to call unit and verify ________
modem operation.

13. If system is configured with a network card use Display Station to connect to ________
recorder over an Ethernet link and verify network operation.

VIII. Cabinet Systems, Perform Following Steps For Units Supplied In Cabinets

1. With prime power disconnected turn on main DC power, main Ac power, and all ________
light fixtures. Hi-Pot all customer connections including power, analog input
terminal blocks, digital input terminal blocks, and status relay terminal blocks with
the settings below.
Trip 1ma
Voltage 3110VDC
Rise Time 3 Seconds
Dwell Time 1 Second

2. Install MFR in cabinet. ________

3. Using Display Station apply a DC voltage to each analog input one at a time. ________
Ensure cabinet wiring is in correct sequence and correct polarity.

4. Alarm each digital input one at a time. Ensure each channel alarms in correct ________
sequence. Ensure only the channel being alarmed is affected.

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 Appendix A
SBC Setup Instructions

AAEON SBC-597, BIOS Award Revision 1.4 For Ametek ( 03/17/2004 )

SBC Jumpers

The jumper settings for the Tillamook CPU (266MHz type G) are as follows :-

SW1-1 on
SW1-2 on
SW1-3 on
SW1-4 off
SW1-5 off Core voltage = 1.9V
SW1-6 off

SW2-1 on
SW2-2 off
SW2-3 on Clock multiplier = x4
SW2-4 off
SW2-5 on
SW2-6 on CPU = 66.8MHz PCI bus = 33.4MHz
JP7 1-2

N.B. Care must be taken when making these settings as an error may damage the CPU

JP1 1-2 DOC page = $D000

JP5 1-2, 4-5, 7-8, 10-11
JP6 1-2 Com2 = RS232

BIOS Setup

Standard CMOS Setup Menu

1. Set the current time and date.
2. Set Primary Master Type to ‘Auto’ and Mode to ‘LBA’. If the disk parameters are known the type may be
set to ‘User’ and the individual parameters entered. Set all other drives to ‘None’.
1. Set Error Halt for ‘No errors’.
2. For configuration, set Drive A to ‘1.44M, 3.5 in’. This may be changed to ‘None’ after the configuration is
complete.
3. Set LCD&CRT to CRT

BIOS Features Setup

Virus Warning : Disabled
CPU Internal Cache : Enabled
External Cache : Enabled
Quick Power On Self Test : Disabled
Boot From LAN First : Disabled
Boot Sequence : A, C, SCSI
Swap Floppy Drive : Disabled
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 Boot Up Floppy Seek : Enabled
Boot Up NumLock Status : On
Boot Up System Speed : High
Gate A20 Option : Fast
Typematic Rate Setting : Disabled
Typematic Rate ( Chars/Sec ) :6
Typematic Delay ( Msec ) : 250
Security option : Setup
OS Select For DRAM > 64MB : non-OS2
Report No FDD For Win 95 : NO
Video BIOS Shadow : Disabled
C8000-CBFFF Shadow : Disabled
CC000-CFFFF Shadow : Disabled
D0000-D3FFF Shadow : Disabled
D4000-D7FFF Shadow : Disabled
D8000-DBFFF Shadow : Disabled
DC000-DFFFF Shadow : Disabled
Cyrix ^x86/MII CPUID : Enabled

Chipset Features Setup

Auto Configuration : Enabled

AT Bus Clock : CLK2/4

L2 Tag RAM Size :8
DRAM Timing : Slow
SDRAM CAS Latency :3
Pipelined function : Enabled
DRAM Data Integrity Mode : Disabled
Memory Hole at 15M-16M : Disabled
Host Read DRAM Command Mode: Bypass
ISA Line Buffer : Disabled
Passive Release : Disabled
Delay Transaction : Disabled
Primary Frame Buffer : All
VGA Frame Buffer : Disabled
Data Merge : Disabled
IO Recovery : 0us
Verify +5V, 12V, and –12V voltages. Adjust power supply as required.

5V: 4.80 – 5.10VDC

12V: 11.0 – 13.0VDC
-12V: (-13) – (-11)VDC

Power Management Setup

Power Management : User Define
PM Control by APM : Yes
MODEM Use IRQ :3
Video Off Option : Susp, Stby -> OFF
Video Off Method : DPMS Support

HDD Power Down : Disable

Doze Mode : Disable
Standby Mode : Disable
Suspend Mode : Disable

Primary HDD : Disabled

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 Floppy : Disabled
Com Ports : Enabled
Keyboard : Enabled
LPT Port : Disabled

PNP/PCI Configuration
Resources Controlled By : Manual
Reset Configuration Data : Disabled

IRQ-3 assigned to : Legacy ISA

IRQ-4 assigned to : Legacy ISA
IRQ-5 assigned to : Legacy ISA
IRQ-7 assigned to : Legacy ISA
IRQ-9 assigned to : Legacy ISA
IRQ-10 assigned to : PCI/ISA PnP
IRQ-11 assigned to : Legacy ISA
IRQ-12 assigned to : PCI/ISA PnP
IRQ-14 assigned to : PCI/ISA PnP
IRQ-15 assigned to : PCI/ISA PnP
DMA-0 assigned to : Legacy ISA
DMA-1 assigned to : Legacy ISA
DMA-2 assigned to : Legacy ISA
DMA-3 assigned to : Legacy ISA
DMA-4 assigned to : Legacy ISA
DMA-5 assigned to : Legacy ISA
DMA-6 assigned to : Legacy ISA
DMA-7 assigned to : Legacy ISA

PCI IDE 2nd Channel : Enabled

PCI IRQ Actived : Level

Integrated Peripherals
On-chip Primary IDE : Enabled
Master PIO : Auto
Slave PIO : Auto
Master Ultra DMA : Auto
Slave Ultra DMA : Disabled
On-chip Secondary IDE : Disabled

IDE HDD Block Mode : Disabled

On-Chip USB Controller : Disabled

Init Display First : Onboard

Onboard FDC Controller : Enabled

Onboard UART 1 : 3F8/IRQ4
Onboard UART 2 : 2F8/IRQ3
OnBoard Parallel Port : 378/IRQ7
Parallel Port Mode : SPP

Onboard IrDA Port : Disable

Select “SAVE & EXIT SETUP” to exit the BIOS and save the parameter updates.

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