Attachment 3 ASIS2_FAT_Procedures.doc

Factory Acceptance Test

Procedures for the

ASR9 Serial Interface System (ASIS)

Phase 2

January 18, 2008 Revision C Prepared by the

Federal Aviation Administration

National Airways Systems

Engineering Division, AJW-146 Contact: Paul Seyler (609)485-4762 or paul.seyler@faa.gov

Asis2_fat_revc.doc

Table of Contents

SUMMARY:

A) GFE ASIS Test Equipment

1) Test Fixture

B) GFE EQUIPMENT DETAILED DESCRIPTION

1) Test Fixture

C) TEST SUMMARY

1) ASIS Final Acceptance Test # 1

D) Procedures.

1) Assembly of the Government Furnished Equipment (GFE).

2) Testing the ASIS Assemblies

Acceptance Test Procedure for the

ASIS Assemblies PRIVATE

SUMMARY:

All of the deliverables shall be tested at the factory; i.e., factory acceptance tested prior to their delivery to the Government (FAA/AJW-146). The customer (AJW-146) reserves the right to witness those factory acceptance tests. The contractor/supplier shall provide at least one week’s prior notice to AJW-146 before testing begins.

Apart from the acceptance test criteria detailed herein, the FAA reserves the right to reject any ASIS Assembly for any of the following reasons:

a) Manufacture / assembly deviates from the ASIS manufacturing specification or the PCB manufacture does not meet requirements of the ASIS manufacturing specification.

b) Incorrect tolerances for card dimensions as defined in the ASIS manufacturing specification.

c) Parts used were not defined in the ASIS manufacturing specification or not approved (in writing) by the FAA.

d) Sloppy workmanship not in keeping with IPC standards and common industry practice, i.e., cold solder joints, cards not cleaned, trimmed improperly, parts not correctly aligned on the cards, serial # not correctly marked with legible and indelible ink, metal parts not deburred, screws not tight, etc.

e) Connectors, switches, or other parts found to be faulty.

The hardware and executable software which contains the diagnostics and test scenarios will be made available to the selected contractor as GFE (Government Furnished Equipment).

The ASIS Factory Acceptance Test Procedure , this document, will be supplied to the selected contractor as GFE.

A) GFE ASIS Test Equipment

The following equipment will be supplied by the FAA/AJW-146:

1) Test Fixture

Comprises a card chassis into which the ASIS PCB will be inserted. It also includes a known working ASIS PCB, and an ASIS Adapter Box Assembly with associated ribbon cables.

B) GFE EQUIPMENT DETAILED DESCRIPTION

1) Test Fixture

Figure 2

a) Card chassis which will accept an ASIS PCB and an ASIS Adapter Box assembly.

b) One known working ASIS card which is already plugged into the card chassis.

c) One known working ASIS Adapter Box Assembly with associated ribbon cables which are plugged into the backplane of the card chassis at connectors P7, P8, and P9.

C) TEST SUMMARY

The following scenario comprises a typical factory acceptance testing session requiring approximately five (5) minutes per system assuming they pass:

1) ASIS Final Acceptance Test # 1 1) The power ON boot will test the entire RAM. The Entire FLASH memory will be ERASED. Test software will be downloaded into the FLASH memory on the ASIS PCB using a PC (not supplied).

2) Software parameters will be downloaded into the ASIS PCB using a PC (not supplied).

3) The ASIS PCB is RESET to perform built-in diagnostics.

4) The switch box (SW2) will test each data port by selecting positions A,B,D,E,F,G on the switch box.

5) The ETHERNET controller will be tested through an external loop back test.

6) Any failures shall be corrected/repaired by the contractor/supplier. Those repaired items shall then be resubmitted for factory acceptance testing.

D) Procedures.

This procedure will verify the operation of the GFE ASIS test system (Test Fixture) independent of the manufactured ASIS assemblies. A functional ASIS assembly was included in the ASIS Test System for this purpose. Once this procedure is completed, the contractor/manufacturer will have verified that the ASIS test system (hardware and software) is complete and functional.

The test procedures described below are essentially the same as those used to test the manufactured ASIS systems. First the ASIS test system will be verified. Then, manufactured assemblies will be tested. Figure 1-1 and Table 1-1 on the next two pages are reference diagrams for the procedures.

Figure 1-1. ASIS II Controls and Indicators Locator Diagram

Table 1-1. ASIS-Phase II, Description of Controls and Indicators

Fig. 1-1

Find No.

Ref

Des

Processor Bypass

Maintenance Terminal port used for control and monitoring of the ASIS card.

Jumper – Pins 1-2 With jumper installed, bootloader is enabled upon a system RESET. Test Points.

Button switch Pressing pushbutton resets ASIS II.

LED flashes while data is received by card.

Jumper – Pins 1-2

Jumper – Pins 2-3 With jumper installed, external clocking is available for high speed auxillary port.

Installed for Ethernet mode.

Jumper – Pins 1-2

Jumper – Pins 2-3 With jumper installed, ethernet port is available.

With jumper installed, high speed auxillary port is available. Must be installed for transmission on aux port.

Pos 01-06 Open

Pos 01-06 Closed

Data polarity is NORMAL for the respective adapter box jack.

Data polarity is NORMAL for the respective adapter box jack.

1) Assembly of the Government Furnished Equipment (GFE).

a) Make sure all power is off on the Test Fixture. Connect power cord to Test Fixture and to an appropriate power outlet (120 VAC).

b) Assemble one PC system (not supplied), i.e., computer, monitor, keyboard, mouse, power cords, etc. Connect tester Comm port cable to PC serial port. Run Terminal program on PC (Hyperterminal, Procomm). The terminal should be setup as follows:

Baud:9600

Start bits: 1

Stop Bits: 1

Parity: None

File transfer mode: XMODEM

Terminal Type: ANSI

Connection: direct to COM1 or available port. Attach tester serial port cable to terminal port on PC.

c) Refer to Figure 1-1 and Table 1-1. Configure the card to be tested as follows:

JP3: Installed

JP7: jumper 2-3

JP8: jumper 1-2

SW2: 1-6 OPEN

SW3: 1-3 OPEN, 4-6 CLOSED

Insert card to be tested in tester slot A02. (make sure POWER , tester SW1, is OFF)

d) Power ON tester (SW1).

e) Connect a jumper (jumper pins 1,2) or BOOT SWITCH (in LOAD position) on ASIS PCB, J1.

f) Press the RESET switch (SW1) on the ASIS card.

g) Observe the PC terminal. The following is displayed (assuming blank FLASH memory):

The RISC REVISION should display: 4 ( any other number is an outdated 68360 processor)

The RAM TEST should display: PASSED

Ignore the PARAMETER and SOFTWARE CRC test results. Blank FLASH memory results are shown.

************ ASIS BOOT VERSION 2.2 **** 02/24/2003

68360 RISC REVISION: 4

RAM TEST PASSED

PARAMETER CRC TEST: FAILED, CRC: FFFF, computed CRC: 0, Size=-1

SOFTWARE CRC TEST: FAILED, CRC: FFFF, computed CRC: 0, Size=-1

BOOT LOADER MODE

Press Cntrl-X to start software download to Flash using XMODEM

Press Cntrl-P to start parameter download to Flash using XMODEM

Press Cntrl-U to start parameter upload to Terminal using XMODEM

Press Cntrl-C to start software upload to Terminal using XMODEM

Press Cntrl-E to ERASE entire FLASH memory

Remove Jumper and press any other key to resume RUN mode.

h) Press Ctrl-E keys on the PC terminal keyboard. Respond to the prompt with a “y”. The flash memory will then erase ( approx. 5-10 seconds). The message “Flash erase completed.” indicates a successful erasure. “If erase fails, the message “Flash erase failed.” will be displayed. After the erase has completed, press the RESET switch (SW1) on the ASIS card.

i) Press Ctrl -X keys on the PC terminal keyboard after the BOOT self tests are completed.

j) Initiate a file transfer (Send File from PC) of the file “u.dwn”. (approx. 2 min). If using “Hyperterminal” : Select “Transfer -> Send File”. Select the file “u.dwn”.

k) After the transfer is completed, press the RESET switch (SW1) on the ASIS card. Observe that the SOFTWARE CRC TEST has PASSED. If not the software load has failed.

CRC= B77E SIZE= 84464

l) Press Ctrl- P keys on the PC terminal keyboard.

m) Initiate a file transfer of the file “params.bin” (approx. 10 sec). If using “Hyperterminal” : Select “Transfer -> Send File”. Select the file “params.bin”.

n) After the transfer is completed, press the RESET switch (SW1) on the ASIS card. Observe that the PARAMETER CRC TEST has PASSED. If not the parameter load has failed.

CRC= 41D0 SIZE= 1776

o) Remove BOOT JUMPER from J1.

p) Select position “A” (B,D,E,F,G used later) on the tester switch box (SW2).

q) Press the RESET switch (SW1) on the ASIS PCB.

r) Observe the boot test results are as follows :

************ ASIS BOOT VERSION 2.2 **** 02/24/2003

68360 RISC REVISION: 4

RAM TEST PASSED

PARAMETER CRC TEST: PASSED, CRC: 41D0, computed CRC: 41D0, Size=1776

SOFTWARE CRC TEST: PASSED, CRC: B77E, computed CRC: B77E, Size=84464

RUN MODE

s) Wait for the ASIS card RED and GREEN LEDs to turn OFF ( approx. 5 seconds). If the LEDs do not turn OFF, there is a card fault.

t) Press the Ctrl-Z keys on the PC terminal keyboard. The software main menu should now be displayed.

u) Enter option 8 on the main menu. Press 8 followed by the <Enter> key. This clears the performance counters.

v) Enter menu option 12 on the main menu. The display should only have non-zero values in the “idle” fields (BOLD, see below). If there are non-zero values in the other fields, the card has failed this test. Make sure the previous step (clear the performance counters) was completed .

TYPICAL SCREEN DISPLAY:

CH1 CH2 CH3 CH4

MSG 0 0 0 0

IDLE 2515 2599 2668 2737

NO DATA 0 0 0 0

SYNC 0 0 0 0

PARITY 0 0 0 0

BUSY 0 0 0 0

4 FIELD 0 0 0 0

7 FIELD 0 0 0 0

10 FIELD 0 0 0 0

32 FIELD 0 0 0 0

? LENGTH 0 0 0 0

DCD LOSS 0 0 0 0

---- General Performance ---- ---- Spare Channels ----

Sector Error 0 DCD LOSS 5 0

WX Error 0 DCD LOSS 6 0

w) Repeat steps “p” through “u” for each remaining position (B,D,E,F,G) on the Tester switch box (SW2).

x) Press the RESET switch (SW1) on the ASIS PCB.

y) After the boot has completed, Enter “Ctrl-Z” to acces main menu.

z) Select menu item 7 ( press “7” <Enter>)

aa) Observe the ETHERNET UDP RX count and compare it to ETHERNET TX count. To pass this Ethernet loopback test the counts should be matching or within 1-2 counts.

TYPICAL SCREEN DISPLAY:

Data Performance Counts

Ch 1 Sync 0 Overflow 1 0 Beacon 0

Radar 0

Ch 2 Sync 0 Overflow 2 0 Status 0

Sector 0

Ch 3 Sync 0 Overflow 3 0 SRTQC 0

Weather 0

Ch 4 Sync 0 Overflow 4 0 CPC/SITE ID 0

MsgLen Err 0 Invalid ID 0 Ch1 Msg 0

MsgLen = 0 ID in HEX 0000 Ch2 Msg 0

Msg ID = 0000 Ch3 Msg 0

Ch4 Msg 0

Ethernet UDP RX 19

Ethernet ICMP RX 0 BFTL Edits 0

Ethernet TX 20 FRAG = 3/A 0

The test is now complete. The ASIS PCB assembly has now been thoroughly tested with the ASIS tester. This procedure is an “integrity verification” of the ASIS test system furnished by AOS-270. Accordingly; once completed, the functional operation of the FAA ASIS test system, including both the hardware and the software, has been verified.

4) Testing the ASIS Assemblies

a) Now that the test system has been verified with a known good ASIS card, it may be swapped with manufactured items. When swapping ASIS it is necessary to power off the Test Fixture, but not the PC terminal.

b) When an ASIS card has successfully completed this test, be sure to fill out the sign-off sheet which is included at the end of this document. Copies may be made if necessary. A copy of the completed sign-off sheet is to be included with the deliverables.

c) Complete steps 1)c-aa for each card.

ASIS PCB Assembly Acceptance Test Procedure

Quality Control Signature Authority

(Sign-off Sheet)

Name: (Please Type or Print)

Signature: Initials: .

S/N Final

Acceptance Test Initial/Date

S/N Final

Acceptance Test Initial/Date