Electronic Systems Maintenance Handbook, Second Edition (Electronics Handbook Series) PDF
Preview Electronic Systems Maintenance Handbook, Second Edition (Electronics Handbook Series)
ELECTRONIC SYSTEMS MAINTENANCE H A N D B O O K S e c o n d E d i t i o n ELECTRONICS HANDBOOK SERIES Series Editor: Jerry C. Whitaker Technical Press Morgan Hill, California P U B L I S H E D T I T L E S AC POWER SYSTEMS HANDBOOK, SECOND EDITION Jerry C. Whitaker THE COMMUNICATIONS FACILITY DESIGN HANDBOOK Jerry C. Whitaker THE ELECTRONIC PACKAGING HANDBOOK Glenn R. Blackwell POWER VACUUM TUBES HANDBOOK, SECOND EDITION Jerry C. Whitaker THERMAL DESIGN OF ELECTRONIC EQUIPMENT Ralph Remsburg THE RESOURCE HANDBOOK OF ELECTRONICS Jerry C. Whitaker MICROELECTRONICS Jerry C. Whitaker SEMICONDUCTOR DEVICES AND CIRCUITS Jerry C. Whitaker SIGNAL MEASUREMENT, ANALYSIS, AND TESTING Jerry C. Whitaker ELECTRONIC SYSTEMS MAINTENANCE HANDBOOK, SECOND EDITION Jerry C. Whitaker DESIGN FOR RELIABILITY Dana Crowe and Alec Feinberg F O R T H C O M I N G T I T L E S THE RF TRANSMISSION SYSTEMS HANDBOOK Jerry C. Whitaker ELECTRONIC SYSTEMS MAINTENANCE H A N D B O O K S e c o n d E d i t i o n Edited by Jerry C. Whitaker CRC PR ESS Boca Raton London New York Washington, D.C. Library of Congress Cataloging-in-Publication Data Electronic systems maintenance handbook / Jerry C. Whitaker, editor-in-chief.—2nd ed. p. cm. — (The Electronics handbook series) Rev. ed. of: Maintaining electronic systems. c1991. Includes bibliographical references and index. ISBN 0-8493-8354-4 (alk. paper) 1. Electronic systems—Maintenance and repair—Handbooks, manuals, etc. 2. Electronic systems—Reliability—Handbooks, manuals, etc. I. Whitaker, Jerry C. II. Maintaining electronic systems. III. Series. TK7870 .E212 2001 621.381'028'8—dc21 2001043885 CIP This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the authors and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher. All rights reserved. Authorization to photocopy items for internal or personal use, or the personal or internal use of specific clients, may be granted by CRC Press LLC, provided that $1.50 per page photocopied is paid directly to Copyright clearance Center, 222 Rosewood Drive, Danvers, MA 01923 USA The fee code for users of the Transactional Reporting Service is ISBN 0-8493-8354-4/02/$0.00+$1.50. The fee is subject to change without notice. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. The consent of CRC Press LLC does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from CRC Press LLC for such copying. Direct all inquiries to CRC Press LLC, 2000 N.W. Corporate Blvd., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. Visit the CRC Press Web site at www.crcpress.com © 2002 by CRC Press LLC No claim to original U.S. Government works International Standard Book Number 0-8493-8354-4 Library of Congress Card Number 2001043885 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper © 2002 by CRC Press LLC Preface Technology is a moving target. Continuing advancements in hardware and software provide new features and increased performance for consumer, commercial, and industrial customers. Those same advance- ments, however, place new demands on the engineering and maintenance departments of the facility. Today—more than ever—the reliability of a system can have a direct and immediate impact on the profitability of an operation. The days of troubleshooting a piece of gear armed only with a scope, multimeter, and general idea of how the hardware works are gone forever. Today, unless you have a detailed maintenance manual and the right test equipment, you are out of luck. The test bench of the 1980s—stocked with a VTVM, oscilloscope, signal generator, and signal analyzer—is a relic of the past. The work bench of today resembles more a small computer repair center than anything else. It is true that some equipment problems can still be located with little more than a digital multimeter (DMM) and oscilloscope, given enough time and effort. But time costs money. Few technical managers are willing to make the trade. With current technology equipment, the proper test equipment is a must. Two of the most important pieces of equipment for a maintenance technician servicing modern products are good lighting and a whopping big magnifier! While that is certainly an exaggeration, it points up a significant problem in equipment maintenance today: there are many tiny components, most of them jammed into a small amount of circuit board real estate. Tight component packaging makes printed wiring boards (PWBs) difficult to repair, at best. When complex and inter-related circuitry is added to the servicing equation, repair down to the component level may be virtually impossible. The equipment is just too complex, electrically and mechanically. The sophistication of hardware today has ushered in a new era in equipment maintenance—that of repair by replacement. Some equipment manufacturers have built sophisticated test and diagnostic routines into their prod- ucts. This trend is welcomed, and will likely accelerate as the maintainability of products becomes an important selling point. Still, however, specialized test equipment is often necessary to trace a problem to the board level. Analytical Approach to Maintenance Because of the requirement for maximum uptime and top performance, a comprehensive preventive maintenance (CPM) program should be considered for any facility. Priority-based considerations of reliability and economics are applied to identify the applicable and appropriate preventive maintenance tasks to be performed. CPM involves a realistic assessment of the vulnerable sections or components within the system, and a cause-and-effect analysis of the consequences of component failure. Basic to this analysis is the importance of keeping the system up and running at all times. Obvious applications of CPM include the stocking of critical spare parts used in stages of the equipment exposed to high temperatures and/or high voltages, or the installation of standby power/transient overvoltage protection © 2002 by CRC Press LLC equipment at the AC input point of critical equipment. Usually, the sections of a system most vulnerable to failure are those exposed to the outside world. The primary goals of any CPM program are to prevent equipment deterioration and/or failure, and to detect impending failures. There are, logically, three broad categories into which preventive mainte- nance work can be classified: • Time-directed: Tasks performed based upon a timetable established by the system manufacturer or user. • Condition-directed: Maintenance functions undertaken because of feedback from the equipment itself (such as declining power output or frequency drift). • Failure-directed: Maintenance performed first to return the system to operation, and second to prevent future failures through the addition of protection devices or component upgrades recom- mended by the manufacturer. Regardless of whether such work is described as CPM or just plain common sense, the result is the same. Preventive maintenance is a requirement for reliability. Training of Maintenance Personnel The increasingly complex hardware used in industry today requires competent technical personnel to keep it running. The need for well-trained engineers has never been greater. Proper maintenance proce- dures are vital to top performance. A comprehensive training program can prevent equipment failures that impact productivity, worker morale, and income. Good maintenance is good business. Maintenance personnel today must think in a “systems mode” to troubleshoot much of the hardware now in the field. New technologies and changing economic conditions have reshaped the way maintenance professionals view their jobs. As technology drives equipment design forward, maintenance difficulties will continue to increase. Such problems can be met only through improved test equipment and increased technician training. The goal of every maintenance engineer is to ensure top quality performance from each piece of hardware. These objectives do not just happen. They are the result of a carefully planned maintenance effort. It is easy to get into a rut and conclude that the old ways, tried and true, are best. Change for the sake of change does not make sense, but the electronics industry has gone through a revolution within the past 10 years. Every facility should re-evaluate its inventory of tools, supplies, and procedures. Technology has altered the way electronic products are designed and constructed. The service bench needs to keep up as well. That is the goal of this book. Jerry C. Whitaker Editor-in-Chief © 2002 by CRC Press LLC Editor-in-Chief Jerry C. Whitaker is Technical Director of the Advanced Television Systems Committee, Washington D.C. He previously operated the consulting firm Technical Press. Mr. Whitaker has been involved in various aspects of the communications industry for more than 25 years. He is a Fellow of the Society of Broadcast Engineers and an SBE-certified Professional Broadcast Engineer. He is also a member and Fellow of the Society of Motion Picture and Television Engineers, and a member of the Institute of Electrical and Electronics Engineers. Mr. Whitaker has written and lectured extensively on the topic of electronic systems installation and maintenance. Mr. Whitaker is the former editorial director and associate publisher of Broadcast Engineering and Video Systems magazines. He is also a former radio station chief engineer and TV news producer. Mr. Whitaker is the author of a number of books, including: • The Resource Handbook of Electronics, CRC Press, 2000. • The Communications Facility Design Handbook, CRC Press, 2000. • Power Vacuum Tubes Handbook, 2nd ed., CRC Press, 1999. • AC Power Systems, 2nd ed., CRC Press, 1998. • DTV Handbook, 3rd ed., McGraw-Hill, 2000. • Editor-in-Chief, NAB Engineering Handbook, 9th ed., National Association of Broadcasters, 1999. • Editor-in-Chief, The Electronics Handbook, CRC Press, 1996. • Co-author, Communications Receivers: Principles and Design, 3rd ed., McGraw-Hill, 2000. • Electronic Display Engineering, McGraw-Hill, 2000. • Co-editor, Standard Handbook of Video and Television Engineering, 3rd ed., McGraw-Hill, 2000. • Co-editor, Information Age Dictionary, Intertec/Bellcore, 1992. • Radio Frequency Transmission Systems: Design and Operation, McGraw-Hill, 1990. Mr. Whitaker has twice received a Jesse H. Neal Award Certificate of Merit from the Association of Business Publishers for editorial excellence. He also has been recognized as Educator of the Year by the Society of Broadcast Engineers. He resides in Morgan Hill, California. © 2002 by CRC Press LLC Contributors Samuel O. Agbo Ravindranath Kollipara California Polytechnic University LSI Logic Corporation San Luis Obispo, California Milpitas, Calfornia Bashir Al-Hashimi Edward McConnell Staffordshire University National Instruments Stafford, England Austin, Texas David F. Besch Michael Pecht University of the Pacific University of Maryland Stockton, California College Park, Maryland Glenn R. Blackwell John W. Pierre Purdue University University of Wyoming West Lafayette, Indiana Laramie, Wyoming Iuliana Bordelon Richard Rudman University of Maryland KFWB Radio College Park, Maryland Los Angeles, Calfornia Gene DeSantis Jerry E. Sergent DeSantis Associates BBS PowerMod, Incorporated Little Falls, New Jersey Victor, New York James E. Goldman Carol Smidts Purdue University University of Maryland West Lafayette, Indiana College Park, Maryland Jerry C. Hamann Zbigniew J. Staszak University of Wyoming Technical University of Gdansk Laramie, Wyoming Gdansk, Poland Dave Jernigan Vijai Tripathi National Instruments Oregon State University Austin, Texas Corvallis, Oregon Hagbae Kim Jerry C. Whitaker NASA Langely Research Center ATSC Hampton, Virginia Morgan Hill, California © 2002 by CRC Press LLC Allan White Tsong-Ho Wu NASA Langely Research Center Bellcore Hampton, Virginia Redbank, New Jersey Don White Rodger E. Ziemer emf-emf control, Inc. University of Colorado Gainesville, Virginia Colorado Springs, Colorado © 2002 by CRC Press LLC Contents 1 Probability and Statistics Allan White and Hagbae Kim 2 Electronic Hardware Reliability Michael Pecht and Iuliana Bordelon 3 Software Reliability Carol Smidts 4 Thermal Properties David F. Besch 5 Heat Management Zbigniew J. Staszak 6 Shielding and EMI Considerations Don White 7 Resistors and Resistive Materials Jerry C. Whitaker 8 Capacitance and Capacitors Jerry C. Whitaker 9 Inductors and Magnetic Properties Jerry C. Whitaker 10 Printed Wiring Boards Ravindranath Kollipara and Vijai Tripathi © 2002 by CRC Press LLC
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