Electronic Systems Maintenance Handbook, Second Edition (Electronics Handbook Series)

598 Pages·2001·51.31 MB·English

by  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
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
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© 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