LCB Checkout Procedure
Brief Version for Production

17 Jul 14	ecm	fork from LCBCheckout.rtf (old full version)
24 Jul 14	ecm	Rev 2: add current limit test, outline for in-backplane serial and overcurrent tests

Equipment

	Backplane test connector with Logic 3.3V and VBatt power inputs.
	Instrument Power output cable

	Logic power supply: 3.3V @ 500mA
HV power supply: 0-30V @ 3A adjustable
	DVM ammeter with mA and A ranges
	DVM voltmeter
	Power Resistor Decade with 3A/50W capability

Procedure: Basic Switch Function

1)   Visual Inspection
	double-check configuration: jumpers and IC's (especially JMP2)

2)   Program PIC with On-Off cycle program.  This program will, at one-second intervals, start from the Off state, Enable the switch section, turn On the switch section, turn Off the switch section, Disable the switch section, and repeat.

3)   Set Relay

	a) connect VBatt leads to HV power supply via DVM ammeter
	b) connect Logic 3.3V leads to Logic power supply
c) advance HV Supply to 15V
d) switch on Logic supply; relay should audibly click

4)   Configure for Board voltage (if board is not a Batt voltage board)

	a) turn HV supply to zero output
	b) disconnect +VBatt lead from DVM ammeter
c) connect test clip lead to DVM ammeter
d) connect test clip to D7 cathode lead
e) turn HV supply up to board nominal voltage (3.3, 5, 12, or 24)
	
5)   Check Off/Enable/On no-load current

a)	Set DVM ammeter to mA range
b)	Switch will be cycling through Off, Enabled, and On states at 1-second intervals.
c)	Off state Hi limit is 0.05mA, Lo limit 0.01 mA
d)	Enabled state Hi limit is 0.15mA, Lo limit 0.07 mA
e)	On state Hi limit is 0.33 mA, Lo limit 0.15 mA
f)	Set DVM ammeter back to A range

6)   Check On state voltage drops (on resistance)

a)	Connect Instrument Power cable to resistor decade; set decade to draw 1.0 A (i.e. set Ohms = Board Voltage)
b)	Connect Instrument Power cable to board, verify the load draws 1.0A when switch is in On state.  (May need to increase HV supply slightly.)
c)	Check high side voltage drop with DVM voltmeter probes between D7 cathode and TP5.  Hi limit 60 mV; Lo limit 40 mV.
d)	Check low side voltage drop with DVM voltmeter between D7 anode and TP6.  Hi limit 15 mV, Lo limit 7 mV.

7)	Check current limit function 

a)	Set decade to draw 3.0 A (Ohms = Board Voltage/3)
b)	Briefly connect to board, check current on ammeter during on state.  (Note: switch transistor will get hot, limit this test to a few on cycles
c)	Hi limit 2.8 A, Lo limit 2.5 A

7)	Install shunt on JMP1 and verify LED function.

8)	Wrap up of Basic Switch Function.

a)	Turn down HV supply and switch off.
b)	Switch off Logic supply
c)	Disconnect HV test clip (if used) from D7

Procedure: Advanced (Circuit Breaker, Telemetry) and Serial I/O Function
[Draft – this is an outline of final full procedure]

9)	Switch function and telemetry

a)	Plug board into Power Backplane and apply power
b)	Verify communication between Vehicle CPU and board
c)	Verify basic switch-on/switch-off function
d)	Connect 1A load (decade box) and verify current reading from board
e)	Verify voltage reading from board.

10)	Circuit Breaker function

a)	Switch board on
b)	Connect 3A load (standard board) or 6A load (5A board)
c)	Verify switch turns off within 50-70 msec

11)	Serial I/O function

a)	RS-232 board: install RS-232 loopback connector (loops J2 pin 1 to pin 2)
b)	485 board: half duplex, no loopback needed
c)	Send character string and verify echo