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The Cassini 16 Infrastructure's Testhead uses Y00099C1 RIFL Hubs (Front/Rear) to distribute power and control to the TIMs. These instructions detail how to remove the Top Plate and replace the Top Board. Contact Support ([email protected]) for specific instructions for diagnosing or replacing malfunctioning items.


Tools Needed:
#1 Philips (All Panels)

Electrical Shock Hazards

IMPORTANT Switch the "TIM Front" & "TIM Rear" (RevA) or "Head" (RevB) side breakers to OFF before opening the Testhead service panel.

There are NO electrical shock hazards from any of the exposed electrical connections on the test head or on any surface of the system. The system uses 48 volts or less and shock hazards are typically designated as to 50 volts or higher. No high-voltage cables or connections are exposed at any time during operations or when moving the system. Fixtures and Tester Instrument Modules (TIMs) can be safely removed "hot" without disconnecting power without damaging the equipment or exposing live connections to the operator. The system is equipped with an Emergency Off (EMO) button that instantly disables all 48 volt connections.

The System Controller MUST ALWAYS be properly powered down BEFORE switching off any breakers. The "Main Breaker" is used to disconnect all electrical connections and can be switched "Off" before performing any infrastructure maintenance that requires tools to remove protective metal covers. The side breakers labeled "TIM Front", "TIM Rear", "Head" or "Mainframe" can be switched "Off" before opening specific service panels.

Testhead Top Removal
  1. IMPORTANT Switch the "TIM Front" & "TIM Rear" (RevA) or "Head" (RevB) side breakers to OFF before opening the Testhead service panel.
  2. Diagram A shows the 16 screw locations needed to remove the access panels for either the Testhead or Front panel, 3 on the back, 12 on the top, and 3 on the front. Remove ALL TIMs and rotate the top of the Testhead away (as pictured).
    Diagram A
  3. With the side cover removed, you can access the connectors on the top boards. Unplug 2 power harnesses, one from the front and one from the back, and unplug 2 flat ribbon cables, one from the front and one from the back. Note that you do not need to remove the harness that goes to the center block.
  4. Now, with the testhead straight up, begin removing screws from the top of the Testhead. There are 8 ea. 4-40 screws that hold the top plate to the lower assembly (also called the 'canoe'). There are 8 ea. 6-32 screws that hold the linear bearings inside the canoe. And there are 8 ea. 8-32 screws that also need to come out. With all the screws removed, you should be able to lift the top plate straight up.
    Diagram B
  5. Turn the top plate upside down, identify the damaged board (either Front or Rear) and remove the 3 screws holding the board in place. Now, remove the bad board.

    Y00099C1 Hub, 16 Slot Testhead top x8

To install, reverse the process as follows:
  1. Screw the new board to the top plate with the 3 screws.

    Note: As you prepare to set the top plate back on the canoes, note that the linear bearings need to align with the holes. They should not have moved but, if they have, you may have to adjust them as shown in Diagram B (above). Also note that there are 2 alignment "Joist Pins" that need to go through holes in the top plate. When you set the top plate on the canoes, you will need to make sure these pins go through the top plate's holes.
  2. Now carefully set the top plate back onto the canoes, keeping in mind the notes above.
  3. Install the 6-32 screws into the linear bearings first. These screws must be started by hand. If you are using a power driver, start the screws by hand, then you can power them down. Next, install the rest of the screws in the top cover.
  4. Plug in the power harnesses and flat ribbon cables to the boards. Carefully re-install the side panel using care to not damage the RIFL Hub.
  5. Plug the TIMs back in. Switch the "TIM Front" & "TIM Rear" (RevA) or "Head" (RevB) side breakers to ON or Power ON the tester and confirm that all the TIMs are now working by following the Diagnostic procedure.

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