RRCIU SIR Section J.10 RRCIU Production Acceptance Test Report.pdf

Attachment J.10

RRCIU Production Acceptance Test Report

4.3.1.1 Manual Test Procedures.-

OBJECTIVE: The procedures are for production unit testing of the Remote Radio Control Interface Unit

(RRCIU). These particular procedures are for using the manual test procedures discussed in specification

FAA-E-2663a dated November 19, 1999.

The contractor must test each printed-circuit board to verify correct components, component installation, component operation, and printed-circuit conductive pattern.

Tools & Equipment Required:

#2 Philips-head screwdriver, AC/DC Voltmeter/Ohmmeter, 120 Vac power supply, four jumper wires (12 inches long with spade lugs on both ends).

Location: _____________________________________________________________________

Voltmeter Model:________________________________________________________________

Voltmeter Serial Number: ________________________________________________________

Voltmeter Last Calibration:________________________________________________________

Voltmeter Next Calibration:________________________________________________________

Notes:

Locate the test jumper J1 and review the locations of G/G, A/G, LO, HI, OFF, MED, FL0(flasher off), and FL1(flasher on).

Care must be taken when measuring the voltages as some are nominally 24 Vdc while others are 120 Vac. The point of reference for DC measurements is TB3-1 while the reference for the 120 Vac measurements is TB2-2 or TB2-11 (tester's choice). TB2 pins 8/9 are dry contacts and must be measured with an ohmmeter.

All steps must be completed sequentially. If an individual test (G/G Mode, A/G Mode, Memory) must be stopped before completion, then that test must be restarted from step 1.

Momentary. - This term will be used to describe input signal simulation from the G/G controller.

The duration of the connection is not critical but will be greater than ½ second and less than 2 seconds.

Line voltage. - This term describes the AC input voltage as measured between TB2 pin 2 and 1, and is nominally 120 Vac. Line voltage measurements at pins 3 through 6 of TB2 means the AC line voltage measured between those pins and TB2 pin 2. The no load voltage corresponding to zero volts may vary between 0 and 10 Vac depending upon the meter used.

AC voltage. - AC voltage measurements are RMS voltages.

4.3.1.1.2 Manual TEST SET-UP

1. Attach the 120 Vac source to TB2-11(NEUTRAL) and TB2-12(LINE/120).

2. The 120 Vac source ground should be attached to the RRCIU ground lug.

3. Remove all jumper wires on TB2.

4. Turn 120 Vac power on.

5. Make sure RRCIU outputs are off by executing the following procedure:

a. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

b. Turn flashers off by momentarily placing test jumper J1 on FL0.

c. Turn intensity off by momentarily placing test jumper J1 on OFF.

NOTE: Be careful not to make any additional connections with the jumper, because the relays will not be in the correct state (i.e. MED or HI instead of OFF). If an incorrect connection is made, the test should be restarted from the beginning.

G/G Mode

1. Place RRCIU in G/G mode (with lights and flashers off) by momentarily placing the test jumper J1 on G/G, then OFF, then FL0.

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It should be an open circuit. Connect one lead of voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 0 Vac Vac

TB2 4 MALSMED 0 Vac Vac

TB2 5 MALSHI 0 Vac Vac

TB2 7 FL 0 Vac Vac

2. Place RRCIU in low intensity mode with flashers off by momentarily placing test jumper J1 on LO.

Connect one lead of the voltmeter to TB2-2 (Neutral) for 120 Vac, and verify the following conditions.

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 0 Vac Vac

3 Place RRCIU in medium intensity mode with flashers off by momentarily placing test jumper

J1 on MED.

Connect one lead of the voltmeter to TB2-2 (Neutral) for 120 Vac, and verify the following conditions.

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

4 Place RRCIU in high intensity mode with flashers off by momentarily placing test jumper J1 to

HI.

Connect one lead of the voltmeter to TB2-2 (Neutral) for 120 Vac, and verify the following conditions.

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

TB2 5 MALSHI 120 Vac Vac

5. Place RRCIU in high intensity mode with flashers on by momentarily placing test jumper J1 on FL1.

Connect one lead of the voltmeter to TB2-2 (Neutral) for 120 Vac, and verify the following conditions.

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

TB2 7 FL 120 Vac Vac

6. Place RRCIU in high intensity mode with flashers off by momentarily placing test jumper J1 on FL0.

Connect one lead of voltmeter to TB2-2 (Neutral) for 120 Vac, and verify the following conditions.

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

7. Turn RRCIU outputs off by momentarily placing the test jumper on OFF.

Connect one lead of the voltmeter to TB2-2 (Neutral) for 120 Vac, and verify the following conditions.

TB2 3 MALSLO 0 Vac Vac

TB2 4 MALSMED 0 Vac Vac

RMS CONTACT CHECKOUT

1. Place RRCIU in G/G mode by momentarily placing test jumper J1 on G/G. Check for contact open (no continuity, infinity)

Measure the continuity between TB2-8 and TB2-9 and record. Ohms (open)

2. Place RRCIU in A/G mode by momentarily placing test jumper J1 on A/G. Check for contact closure (continuity, less than 100 ohms)

Measure the continuity between TB2-8 and TB2-9 and record. Ohms (close)

A/G MODE

1. Place RRCIU in A/G mode by momentarily placing test jumper J1 on A/G.

Verify the system is in A/G mode by measuring the resistance between TB2-8 and TB2-9. It should be less than 100 ohms. Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 0 Vac Vac

TB2 4 MALSMED 0 Vac Vac

2. Turn 120 Vac power off. Place RRCIU in low intensity with flashers on by connecting a wire between TB2-1 and TB1-10. Turn 120 Vac power on.

Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 0 Vac Vac

3. Turn 120 Vac power off. Place RRCIU in medium intensity with flashers on by connecting a jumper wire between TB1-11 and TB1-10. Turn 120 Vac power on.

Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

4. Turn 120 Vac power off. Place RRCIU in high intensity with flashers on by connecting a wire between TB1-12 and TB1-11. Turn 120 Vac power on.

Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

5. Turn 120 Vac power off. Turn RRCIU outputs off by removing all jumper wires. Turn 120 Vac power on.

Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 0 Vac Vac

TB2 4 MALSMED 0 Vac Vac

MEMORY TEST

The purpose of this test is to determine if the RRCIU returns to the previous G/G mode state after being in A/G mode.

1. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

2. Turn the RRCIU outputs off by momentarily placing the test jumper J1 on OFF.

3. Turn the flashers off by momentarily placing the test jumper J1 on FL0.

4. Place the RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

5. Turn 120 Vac power off. Place RRCIU in low intensity with flashers on by connecting a wire between TB2-1 and TB1-10. Turn 120 Vac power on.

6. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It should be an open circuit. Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB2 3 MALSLO 0 Vac Vac

TB2 4 MALSMED 0 Vac Vac

7. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

8. Place RRCIU in low intensity by momentarily placing the test jumper J1 on LO.

9. Turn flashers Off by momentarily placing the test jumper J1 on FL0.

10. Place RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

11. Turn 120 Vac power off. Place RRCIU in medium intensity with flashers on by connecting a jumper wire between TB1-10 and TB1-11. Turn 120 Vac power on.

12. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It should be an open circuit. Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 0 Vac Vac

13. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

14. Place RRCIU in low intensity by momentarily placing the test jumper J1 on LO.

15. Turn flashers On by momentarily placing the test jumper J1 on FL1.

16. Place RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

17. Turn 120 Vac power off. Place RRCIU in high intensity with flashers on by connecting a jumper wire between TB1-12 and TB1-11. Turn 120 Vac power on.

18. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It should be an open circuit. Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 0 Vac Vac

19. Turn 120 Vac power off. Remove the three jumper wires. Turn 120 Vac power on.

20. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

21. Place RRCIU in medium intensity by momentarily placing the test jumper J1 on MED.

22. Turn flashers Off by momentarily placing the test jumper J1 on FL0.

23. Place RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

24. Turn 120 Vac power off. Place RRCIU in high intensity with flashers on by connecting a wire between TB2-1 and TB1-10, TB1-10 and TB1-11, and TB1-11 and TB1-12. Turn 120 Vac power on.

25. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

26. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

27. Place RRCIU in medium intensity by momentarily placing the test jumper J1 on MED.

28. Turn flashers On by momentarily placing the test jumper J1 on FL1.

29. Place RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

30. Turn 120 Vac power off. Place RRCIU in medium intensity with flashers on by removing the wire between TB1-11 and TB1-12. Turn 120 Vac power on.

31. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It should be an open circuit. Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

32. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

33. Place RRCIU in high intensity by momentarily placing the test jumper J1 on HI.

34. Turn flashers Off by momentarily placing the test jumper J1 on FL0.

35. Place RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

36. Turn 120 Vac power off. Place RRCIU in low intensity with flashers on by removing the wire between TB1-10 and TB1-11. Turn 120 Vac power on.

37. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It verify the following conditions:

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

38. Place RRCIU in G/G mode by momentarily placing the test jumper J1 on G/G.

39. Place RRCIU in high intensity by momentarily placing the test jumper J1 on HI.

40. Turn flashers On by momentarily placing the test jumper J1 on FL1.

41. Place RRCIU in A/G mode by momentarily placing the test jumper J1 on A/G.

42. Turn 120 Vac power off. Place RRCIU in medium intensity with flashers on by connecting a wire between TB1-10 and TB1-11. Turn 120 Vac power on.

43. Return to G/G mode by momentarily placing the test jumper J1 on G/G and make the following measurements:

Verify the system is in G/G mode by measuring the resistance between TB2-8 and TB2-9. It should be an open circuit. Connect one lead of the voltmeter to TB2-2 (neutral) for 120 Vac, and verify the following conditions:

TB Pin Signal Name Expected Value Measured Voltage

TB2 3 MALSLO 120 Vac Vac

TB2 4 MALSMED 120 Vac Vac

44. Turn 120 Vac power off. Remove all jumper wires. Disconnect 120 Vac power from the unit.

This completes the test.

Tester_____________________________________ Date:____________________

Quality Assurance____________________________ Date:___________________

FAA Representative:__________________________ Date: ___________________