Description of Internal Connections in the ID-2500 Ion Mill Power Supply ---------------------------------------- Original Rev. 5-July-2021 Current Rev. 16-July-2021 J1 Control Signal Connector on the 5 Power Supply Boards: --------------------------------------------------------- This is the 18 pin connector on the power supply boards that is closest to the front panel. Pin #1 of this connector is the closest pin to the front panel. Pin Function --- -------------------------------------------------- 1 This pin is the analog control signal input to the power supply module that controls the output level of the module - be it a voltage or current output. The range of this control signal is from 0.0 V ---> zero output from the module, up to +5.0 V ---> full scale output from the module. 2 This pin is an On/Off control signal input to the power supply module. < 1 V ---> Run and > 2.5 V ---> Off / No Output. 3 Power Return Ground - somewhat noisy. This is one of three ground pins all three of which become a common ground near the Logic Card. 4 Run to the following not installed parts: R16 that connects to Vcc +15V, R17 that connects to pin 3 Gnd, and to a layout pattern for Q2. The backplane makes no connection to pin #4 at any power supply slot locaton. 5 No Connection - Key Pin 6 Bulk -24 V power - typically runs about -29 Volts. 7 Signal Ground, Quiet Ground, No Current This is one of three ground pins all three of which become a common ground near the Logic Card. 8 Bulk +24 V power - typically runs about +28 Volts. 9 Noisy Ground for Heat-Sinks and Transformer Frames. This is one of three ground pins all three of which become a common ground near the Logic Card. 10 Monitor Output driven by U1-8. On the Discharge, Beam, and Accelerator boards this pin is their Current Monitor output that runs to the Front Panel for display and for the Discharge, Beam, and Neutralizer boards it also connects to the Logic Card. +5 V ---> full scale output current. On the Neutralizer board this monitor signal measures the Neutralizer Emission Current. This pin is not driven on the Cathode board. 11 No Connection - Key Pin 12 Same function as pin 10 but driven by U1-7 and this copy of the current monitor signal runs to the back panel DB-25 connector. 13 No Connection - Key Pin 14 Monitor Outpur driven by U4-1. On the Cathode and Neutralizer boards this monitor signal is a measure of their output Current. On the Discharge, Beam, and Accelerator boards this monitor signal is a measure of their output Voltage. So this monitor signal is always a measure of the feedback control parameter used by the supply. This monitor signal runs to the Front Panel for display and for the Cathode and Neutralizer boards it also connects to the Logic card. +5 V ---> full scale output. 15 Same function as pin 14 but driven by U1-8 and this copy of this monitor signal runs to the back panel DB-25 connector. 16 Status Output signal. Low ---> Running OK High ---> Off or else the main switch emitter current is too high. This is an open collector output. For the Discharge, Beam, and Accelerator boards this signal runs to the Logic card. This Status Output is not used on the Cathode and Neutralizer boards. 17 No Connection - Key Pin 18 No Connection - Key Pin Backplane Connections to the 5 Power Supply Boards: --------------------------------------------------- This section covers just the backplane connections to the J1 Control Connector on the 5 power supply boards. The following pins are bussed in parallel to all 5 power supply boards and to the unused power supply slot between the Accelerator and Neutralizer boards. Pin Function --- -------------------------------------------- 3 Power Return Ground 6 Bulk -24 V power 7 Signal Ground - Quiet Ground 8 Bulk +24 V power 9 Heat-Sink and Transformer Frame Noisy Ground The following pins have individual connections at the 5 power supply boards Front Back P.S. Logic Card Panel Panel Pin Connector & Pin 50 Pin DB-25 Function --- ------------------ ------ ----- -------- Beam Supply: 1 conn 2 pin 17 U34-1 48 -- control 2 conn 2 pin 6 -- -- On-Off 10 conn 2 pin 19 16 -- current 12 --- -- 5 current 14 --- 14 -- voltage 15 --- -- 6 voltage 16 conn 1 pin 9 -- -- status Discharge Supply: 1 conn 2 pin 10 U32-7 -- -- control 2 conn 2 pin 5 -- -- On-Off 10 conn 2 pin 23 18 -- current 12 --- -- 3 current 14 --- 22 -- voltage 15 --- -- 4 voltage 16 conn 2 pin 24 -- -- status Cathode Supply: 1 conn 2 pin 11 U32-8 -- -- control 2 conn 2 pin 4 -- -- On-Off 10 --- -- -- not used 12 --- -- -- not used 14 conn 2 pin 25 21 -- fil amps 15 --- -- 2 fil amps 16 --- -- -- status Accelerator Supply: 1 conn 2 pin 12 U32-14 -- -- control 2 conn 2 pin 6 -- -- On-Off 10 --- 24 -- current 12 --- -- 14 current 14 --- 19 -- voltage 15 --- -- 1 voltage 16 conn 1 pin 10 -- -- status Neutralizer Supply: 1 conn 2 pin 9 U32-1 -- -- control 2 conn 2 pin 3 -- -- On-Off 10 conn 2 pin 13 17 -- emission 12 --- -- 16 emission 14 conn 2 pin 21 23 -- fil amps 15 --- -- 15 fil amps 16 --- -- -- status Support Board Backplane Connector: ---------------------------------- The Support Board has a 7 pin connector that plugs into the backplane with the following signals. Pin Function and Connections --- -------------------------------------------------- 1 Ground 2 Bulk +24 V power - typically runs about +28 Volts. 3 Reference Voltage from the Logic Card conn 2 pin 20 that is also connected to the Front Panel via pin 36 in the 50 pin Front Panel connector. This is a reference for the differential amp and the two comparators on the Support board. 4 This is a signal from the Support board that goes Low when the Support board detects either an under-volt or and over-volt condition on the +150 V bus. From the Support board this signal runs across the backplane to conn 1 pin 16 of the Logic card. 5 This is a signal that comes from conn 2 pin 14 of the Logic card and connects to the gate of the FET on the Suupport board that turn on the power relay for the +150 V bus. When this signal is High, the FET turn On, the relay closes, and the +150 V bus is energized. 6 Bulk -24 V power - typically runs about -29 Volts. 7 No Connection Support Board Cable Connector: ------------------------------ The Support Board has a 7 pin Cable connector. The wires from this connector run to components that are mounted to the left side wall of the ID-2500 power supply. This Cable connector carries the following signals. Pin Function and Connections --- -------------------------------------------------- 1 Bulk +24 V power from the Support board that is connected to one side of the coil on the power relay that energizes the 150 V bus. 2 FET Drain that energizes the coil on the power relay for the 150 V bus. 3 ?? 4 Sense lead from the positive side of the 150 V bus connected to one input of the differential amp on the Support board. 5 Sense lead from the negative side of the 150 V bus connected to the other input of the differential amp on the Support board. 6 Sense lead from the positive side of the 150 V bus connected to one input of the differential amp and to one side of the SCR Trigger pulse transformer on the Support board. 7 Trigger signal from the pot pulse transformer on the Support board that is connected to the Gate on the power SCR that turns on the full power of the 150 V bus. The return to the other side of the pulse transformer secondary is via pin #6 of this connector. Front Panel 50 Pin Connector: ------------------------------ The Front Panel is connected to the rest of the ID-2500 power supply via a 50 pin flat cable that plugs into the backplane. This is a list of the connections carried on this flat cable, what they connect to in the rest of the ID-2500, and where known their Front Panel function. Pin Function and Connections --- -------------------------------------------------- 1,2 Bulk +24 V power runs to Logic Card conn 1 pin 8 3,4 Bulk -24 V power runs to Logic Card conn 1 pin 6 5,6 No Connection 7,8 Ground runs to Logic Card conn 1 pin 3 9,10 No Connection 11,12 Ground runs to Logic Card conn 1 pin 5 13 Source On/Off Switch runs to Logic Card conn 1 pin 13 14 Beam Voltage Monitor Signal to R17 and then to the Beam Monitor Selector Switch 15 Source On/Off Switch runs to Rear Panel DB-25 pin 25 16 Beam Voltage Monitor Signal to R16 and then to the Beam Monitor Selector Switch 17 Neutralizer Emission Monitor Signal to R26 and then to a 4066 mux U14-11 18 Discharge Current Monitor Signal to R19 and then to a 4066 mux U13-11 19 Accelerator Voltage Monitor Signal to R25 and then to a 4066 mux U14-8 20 run to pin 10 of the control connector at the unused power supply slot, i.e. a monitor signal from the unused slot, connects via R20 to mux 4066 U13-4 21 Cathode Filament Current Monitor Signal to R24 and then to a 4066 mux U13-8 22 Discharge Voltage Monitor Signal to R21 and then to a 4066 mux U13-1 23 Neutralizer Filament Current Monitor Signal to R23 and then to a 4066 mux U14-1 24 Accelerator Current Monitor Signal to R22 and then to a 4066 mux U14-4 25 Auto Manual Switch runs to Rear Panel DB-25 pin 10 26 Neutralizer 10-turn pot wiper runs to Logic conn 2 pin 15 27 Auto Manual Switch runs to Logic conn 1 pin 14 28 Cathode 10-turn pot wiper runs to Logic conn 2 pin 8 29 FP Emission LED runs to Logic conn 2 pin 1 30 Discharge 10-turn pot wiper runs to Logic conn 2 pin 16 31 FP Beam LED runs to Logic conn 1 pin 25 32 Accelerator 10-turn pot wiper runs to Logic conn 2 pin 7 33,34 Ground (clean) CCW end of all 10-turn pots runs to Logic conn 1 pin 7 35 FP Accelerator LED runs to Logic conn 1 pin 24 36 CW end of all 10-turn pots Reference Voltage from Logic runs to Support Card pin 3 and Logic conn 2 pin 20 37 FP Discharge LED runs to Logic conn 1 pin 23 38 Right Local-Remote Switch runs to Logic conn 1 pin 15 39 FP Neutralizer LED runs to Logic conn 1 pin 22 40 Right Local-Remote Switch runs to Logic conn 1 pin 11 41 FP Cathode LED runs to Logic conn 1 pin 21 42 Right Local-Remote Switch runs to Rear Panel DB-25 pin 9 43 FP Source Power LED runs to Logic conn 1 pin 20 44 Right Local-Remote Switch runs to Rear Panel DB-25 pin 8 45 FP Ext Interlock LED runs to Logic conn 2 pin 2 46 Beam Current 10-turn pot wiper & Left Local-Remote Switch runs to Logic conn 2 pin 18 47 No Connection 48 Beam Voltage 10-turn pot wiper & Left Local-Remote Switch 49 No Connection 50 Left Local-Remote Switch runs to Rear Panel DB-25 pin 7 Scaling Resistors Used on the Front Panel Digital Monitor Displays: ------------------------------------------------------------------- R16 301k Beam I ratio 0.249 with R18 R17 232k Beam V ratio 0.301 with R18 R18 100k with C10 input to the Beam Monitor Display R19 1.58 Meg Discharge I ratio 0.060 with R30 R20 Not Installed R21 562k Discharge V ratio 0.151 with R30 R22 2,43 Meg Accelerator I ratio 0.040 with R30 R23 523k Neut Fil I ratio 0.161 with R30 R24 523k Cathode Fil I ratio 0.161 with R30 R25 887k Accelerator V ratio 0.101 with R30 R26 402k Neut Emission I ratio 0.199 with R30 R30 100k with C17 input to the Right-Hand Monitor Display Miscellaneous Backplane Connections: ------------------------------------ Back Panel DB-25 pin 24 is connected via the backplane to Logic Card conn 1 pin 18 The Back Cover Interlock Microswitch is connected via the backplane to: Logic Card conn 1 pin 12 and to Back Panel DB-25 pin 17 Logic Card Component List: -------------------------- The Logic Card has an array of about 40 sites for DIPs. To begin an understanding of the Logic Card list the components that are used on it. 7815 and 7915 1 each TL 084 CN TI 5x LM 324 N Ray 1x LM 329 BZ 1x CD 4001 BCN NS 5x CD 4011 BCN NS 1x MC 14012 B Mot 1x MC 14025 B Mot 1x CD 4027 BCN NS 7x MC 14066 B Mot 2x HCF 4069 UBE SSS 1x MC 14070 B Mot 1x ULN 2002 A SSS 1x Resistor Network 314B103 AB 7x Resistor Network 314B102 AB 2x Resistor Network 314B681 AB 1x SiVN10K MOSFET 2x J113 Junction FET 2x 2N3904 and 2N3906 1 each Al Electrolytic 1 uF 50V 7x 10 uF 16 V 3x 10 uF 35 V 2x 25 pin conn 2x 7 pin conn mech only 1x Front Panel Component List: --------------------------- To begin an understanding of the Front Panel list some of the components that are used on it. MAN4710A and MAN4705A 7 segment & +-1 displays 6x & 2x attempting to replace with HP Broadcom HDSP-311E ICL 7107 CPL panel meter 3 1/2 digit ADCs 2x ICL 8069 DCSQ 1x voltage reference MC 14049 UB 2x MC 14066 B 2x 4078 B 1x 7805 2x 7905 1x 7815 1x Aluminum Electrolytic: 10 uF 16 V 10 uF 35 V All 10-Turn pots are 10k Ohm All switches are DPDT except Disch, Cath, Neut are SPST attempting to replace supply board backplane connectors with Molex series KK254 4455 parts: 38001336 & 0038001337