Attachment_4_-_Test_Procedures.pdf

ASOS Acceptance Test Equipment List

Equipment

Laptop or Desktop Computer

Minimum requirements: i5, 8GB Ram, Windows 10, Display, Keyboard, Mouse

National Instruments TestStand License: TestStand 2014

Agilent 34401A Multimeter (or Equivalent)

Agilent E4418B EPM Series PowerMeter

Agilent E9304AE-Series Avg Power Sensor

Oscilliscope

Power Supply (12V)

Cal Amp Viper SC 400 IP Radio

30 dB coupler (N Connections)

3 - 30dB attenuators (N Connections)

SMA Female to N Male Adapter

SMA Female to N Female Adapter

Solder Cup D-Sub Connector, DB9 Male

DB9 Female to RJ45 Adapter https://www.newegg.com/Product/Product.aspx?Item=N82E16812120923

DB9 Male RS-422 Loopback Tester http://www.pacificcable.com/Picture_Page.asp?DataName=NPort2

DB9 Male RS-422 Loopback Tester http://www.pacificcable.com/Picture_Page.asp?DataName=NPort1 http://www.pacificcable.com/Picture_Page.asp?DataName=NPort2

Cables

Probes for the Multimeter

2 Ethernet Cables (One for test, one for IP Radio)

USB to Ethernet adapter (for test Ethernet cable)

N Male to TNC Male RF Cable

SMA Male to SMA Male RF cable

Audio Extension Cable- 3.5mm male to female

Serial RS232 cable Male to Female

IEEE-448 GPIO Cable

National Instruments GPIB-USB-HS Cable

Power Cord with a switch:

NOAA ASOS, Factory Acceptance Test, ACU Connection Procedures

1 PURPOSE

This document defines the necessary setup and required connections to execute the ASOS SLEP Factory Acceptance Test for the ACU assembly.

2 Equipment, Documents, and Set-up Required

2.1 Required Equipment

2.1.1 See Document: ASOS-SLEP-AMTI-DL-000078-20180221 (FAT Required Equipment List)

2.2 Computer, National Instruments Teststand deployment Setup

The computer must be equipped with a i7 processor, 8 GB ram (min), running Windows 7 or newer. The following software applications and licenses are required.

1.ASOS SLEP Factory Acceptance Test, CLIN 003 REV E, software application (S100-32009)

2.National Instruments, TestStand Deployment License

NOTE: Setup of the Test Computer may require assistance of the customers IT department.

2.3 Test Equipment and Hardware Setup

Refer to the Appendix at the end of this document for general guidance on setting up the equipment.

Reference the following NOAA supplied documents for the latest revision and additional detail.

1.ASOS-SLEP-AMTI-DL-000075-20180214, Interconnect Diag. AC Power, ASOS FAT

2.ASOS-SLEP-AMTI-DL-000076-20180214, Interconnect Diag. DC Power, ASOS FAT

3.ASOS-SLEP-AMTI-DL-000077-20180214, Interconnect Diag. Signal, ASOS FAT

2.4 Hardware Connections

1. Setup the benchtop DMM, connect the GPIB cable to the DMM.

2. Setup the benchtop RF Power Meter, connect the GPIB cable from the DMM to the RF Power Meter.

3. Connect the GPIB-USB-HS adaptor to the GPIB cable at either cable connector and connect the USB cable from the adaptor to the test computer USB bus.

4. Connect the USB to Ethernet adaptor to the test computer USB bus. Connect the USB to UUT cable to the USB to Ethernet adaptor.

5. Assemble the RF Directional Coupler ASSY., attach two -30dB attenuators inline at the -30-coupled port. Attach a -30db attenuator at the output port.

6. Setup the Test IP Radio; connect the N-Male RA to TNC RA cable (PE3C1271-12) to the -30db port of the RF Directional Coupler ASSY. Connect the TNC RA end to the Test IP Radio RF port. Connect the 12VDC Power Supply (GCS250PS12-C) output to the Test IP Radio. Connect the Test IP Radio Ethernet port to the test computer Ethernet port

7. Connect the N-Male RA to N-Male cable (PE33321-60) to the input port of the RF Directional Coupler

ASSY.

8. Connect the RF Power Meter, power head to the RF Directional Coupler ASSY output port -30db attenuator.

9. Setup the benchtop Oscilloscope (TBS1032B). This equipment is not connected to the GPIB bus.

3 Acceptance Test User Guide

3.1 Pre-Test Setup

Connect the ACU “Unit Under Test” (UUT) to the Main AC Power cable (Appendix D) at the A8 Distribution Rail to the terminals listed below. Ensure that all UUT equipment (serial servers, modems) power switches are in the “OFF” position. Ensure that the A8CB-1 and UUT Main AC Power cable switch is in the “OFF” position.

3.1.1 Electrical Connections

1. A8ACTB1-A (AC LINE)

2. A8ACTB2-A (AC NEUTRAL)

3. A8ACTB3-A (GND)

3.2 Startup

Bootup the test computer.

3.3 ACU Test Sequence, TestStand

On the test computer desktop select the “ACU Factory Acceptance Test” icon to open the ACU test environment in the TestStand application. With the TestStand application open set the following parameters to execute the ACU cabinet test.

1. At the bottom left corner of the User Interface Screen, select “Test UUT” this opens the UUT Information screen.

2. UUT Information Screen: In the UUT information window, enter the Serial Number of the unit to be tested then select ‘OK’.

3. RMA Dialog Window: The RMA dialog window gives the user options for configuring the UUT test sequence. The user can select which test or groups of tests to run from the ‘Test Group’ drop-down menu at the bottom left of the RMA window, manually select test at the main RMA window, or using the radio buttons at the bottom center of the RMA window, select or deselect all tests. The default configure for test is ‘Manual’ mode, no test sequences are selected. The UUT test sequence are organized into three main groups;

i. Power-Up Test

ii. Network Setup

iii. Functional Test

The Power-Up test is the first test to be executed. This test also sets all cabinet equipment to the correct power settings for all successive test. By-passing the Power-Up test requires that all equipment be manually set to the correct power settings as required to execute individual test sequences. When testing a UUT for the first time, the next most important step is the Network Setup. This procedure must be carried out to configure required devices, and establish the network communication links to all cabinet equipment and cannot be bypassed in most cases.

4 Test Sequence Procedures

All operator instructions for the Factory Acceptance Test are embedded within the “ASOS SLEP Factory Acceptance Test”, in the form of pop-up windows. Most of these instructions are interactive, requiring operator input to move to the next test. This test architecture reduces the required supporting instruction, and operator learning curve to execute the Factory Acceptance Test. Note: In the event that this procedure document conflicts with the actual “Factory Acceptance Test” the Factory Acceptance Test must take precedence.

4.1 Power Up Test

1. Following the on-screen prompts, run the ‘AC Shorts’ test on the terminal block as prompted.

2. Following the on-screen prompts, run the ‘DC Shorts’ test on the terminal block as prompted.

3. Ensure that A8CB-1and the UUT Main AC Power cable switch are in the “OFF” position and connect the P1-A1A6J1and P2-A1A6J2 connectors to J1 and J2 at the bottom of the Sub-Rack (S100-43009).

Connect the UUT Main AC Power cable to an AC power source. Move the UUT Main AC Power cable switch to the “ON” Position.

4. Move the A8CB-1 switch to the “ON” position.

5. Following the on-screen prompts, the operator will then run the DC Voltage checks on the A8 Power Distribution Rail, and all power supplies as prompted by the FAT.

6. The Test will then Prompt the Operator to turn on all Serial Servers and modems.

7. The test will then prompt the user to connect the Molex connectors (A9FOMJ1) into the Test interface module (S100-xxxxx-xx). Follow the test prompts to proceed with the test.

8. The test will then prompt the user to connect the DB9 Female Connector (A9BDF) into the Test interface module (B0001-0846). Follow the test prompts to proceed with the test.

9. At the “5V Pressure Sensor” Tests, the test will prompt the user to connect the three DB9 male connectors (A5A1P2, A5A2P2, A5A3P2) into the Test interface module (B0001-0846). These connectors will require gender converters to connect to the box. Follow the test prompts to proceed with the test.

4.2 Network Setup Test

1. Following the on-screen prompts, the operator will disconnect the Ethernet cables form the MOXA Ethernet Switch.

2. The operator will be prompted to connect the test Ethernet Cable to all devices that need to be configured consecutively. Follow the on-screen prompts to complete the equipment configuration. The devices that need to be configured are;

i. Ethernet Switch

ii. Serial Servers

iii. IP Radio

iv. Data Logger (LabJack)

4.3 Network Connectivity Test

1. The Operator will be prompted to connect the device Ethernet cables back into their associated port on the MOXA Ethernet switch.

2. The operator will be prompted to connect the Test Ethernet cable to Port-8 of the MOXA Ethernet switch to establish communications with all required devices

3. Follow the on-screen prompt start the connectivity test, each device connected to the Ethernet switch will undergo a ping test to verify connectivity.

4.4 Audio Signal and Power Monitor Test

1. Following the on-screen prompts, connect the DB37 receptacle of the Test interface module (B0001- 0846) to the mating end of the Audio & Analog Signal Monitor module (A4A3) output cable (P4-A4A3).

Follow the test prompts to proceed with the test.

4.5 LabJack Test

1. No connections or operator interaction are required. The test will run automatically without any prompts.

4.6 IP Radio Test

1. Connect the Test RF Cable with the N Male adapter into the RF cable on the ACU (A1A4A4- ANT) as prompted by the test. Follow the test prompts to proceed with the test.

4.7 Serial Server Test

4.7.1 Serial Server 1

1. Following the test prompts, connect the 8 Ethernet Cables (A1A5A1-1 to A1A5A1-6) into the Loopback interface module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

4.7.2 Serial Server 2

1. Following the test prompts, connect the 8 Ethernet Cables (A1A5A2-1, A1A5A2-2, A1A5A2-4 to A1A5A2-8 ) Cables into the Loopback interface module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

4.7.3 Serial Server 3

1. Following the test prompts, connect the 8 Ethernet Cables (A1A1A4-1 to A1A1A4-8) Cables into the Loopback interface module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

5 Modem Loopback Test

5.1.1 Following the test prompts, connect the Line connections from the three modems (A1A1A1, A1A1A2, and A1A1A3) into the RJ11 Loopback Test Interface module B0001-0848). Follow the test prompts to proceed with the test.

5.1.2 Following the test prompts, connect the Line cable for Data Modem A1A1A2 to the (B0001- 0848) RJ11 Loopback interface module. Follow the test prompts to proceed with the test.

5.1.3 Following the test prompts, connect the Line cable for Data Modem A1A1A3 to the (B0001- 0848) Loopback interface module. Follow the test prompts to proceed with the test.

6 GTA Radio Loopback Test

1. Following the test prompts, connect the GTA Radio Test Cable (S100-45XXX) to the Test Interface module (B0001-0846). Connect the A7P3 (GTA Radio) Connector to the receptacle on the GTA Radio Test Cable (S100-45XXX). Follow the test prompts to proceed with the test.

7 Audio Test

1. Following the test prompts, connect the Audio extension cable into the test computer as indicated.

Then connect the other end of the cable to the A13A1-Speaker cable on the Embedded Controller.

2. Following the test prompts, connect the (A9J9, A9P10) to the (B0001-0848) RJ11 Loopback interface module as prompted. Follow the test prompts to proceed with the test.

8 Post Test

After completion of the UUT test perform the following Post Test procedures.

1. After the UUT test sequence is complete, select ‘OK’. This saves the UUT test record to the C:\Reports folder under the UUT serial number.

2. At the UUT information prompt, enter the next UUT Serial Number to continue testing or select ‘STOP’ to conclude the testing.

3. Navigate to the C:\Reports folder to view the UUT test record.

4. If testing is complete, shutdown the UUT as follows;

i. Shutdown Embedded Controller.

ii. Turn ‘OFF’ all Serial Servers and modems.

iii. Move the A8CB-1 switch to the “OFF” position.

iv. Turn ‘OFF’ UUT Main AC Power cable switch.

v. Disconnect the UUT Main AC Power cable from the A8 Distribution Rail.

NOAA ASOS, Factory Acceptance Test for DCP Production

This document defines the necessary equipment, and required connections to execute the ASOS SLEP Factory Acceptance Test (FAT) for the DCP assembly.

2 Equipment, Documents, and Set-up Required

2.1 Required Equipment

Refer to the Appendix at the end of this document for general guidance. Reference the following NOAA supplied document for the latest revision and additional detail.

See Document: ASOS-SLEP-AMTI-DL-000078-20180221 Factory Acceptance Test Equipment List.

2.2 Computer, National Instruments Teststand deployment Setup

The computer must be equipped with a i7 processor, 8 GB ram (min), running Windows 7 or newer. The following software applications and licenses are required.

1. ASOS SLEP Factory Acceptance Test, REV (TBD) , software application (S100-32009)

2. National Instruments, TestStand Deployment License

NOTE: Setup of the Test Computer may require assistance from IT department

2.3 Test Equipment and Hardware Setup

Refer to the Appendix at the end of this document for general guidance on setting up the equipment.

Reference the following NOAA supplied documents for the latest revision and additional detail.

1. ASOS-SLEP-AMTI-DL-000075-20180214, Interconnect Diag. AC Power, ASOS FAT

2. ASOS-SLEP-AMTI-DL-000076-20180214, Interconnect Diag. DC Power, ASOS FAT

3. ASOS-SLEP-AMTI-DL-000077-20180214, Interconnect Diag. Signal, ASOS FAT

2.4 Hardware Connections

1. Setup the benchtop DMM, connect the GPIB cable to the DMM.

2. Setup the benchtop RF Power Meter, connect the GPIB cable from the DMM to the RF Power Meter.

3. Connect the GPIB-USB-HS adaptor to the GPIB cable at either cable connector and connect the USB cable from the adaptor to the test computer USB bus.

4. Connect the USB to Ethernet adaptor to the test computer USB bus. Connect the USB to UUT cable to the USB to Ethernet adaptor.

6. Setup the Test IP Radio; connect the N-Male RA to TNC RA cable (PE3C1271-12) to the -30db port of the RF Directional Coupler ASSY. Connect the TNC RA end to the Test IP Radio RF port. Connect the 12VDC Power Supply (GCS250PS12-C) output to the Test IP Radio. Connect the Test IP Radio Ethernet port to the test computer Ethernet port.

7. Connect the N-Male RA to N-Male cable (PE33321-60) to the input port of the RF Directional Coupler

ASSY.

8. Connect the RF Power Meter, power head to the RF Directional Coupler ASSY output port -30db attenuator.

9. Setup the benchtop Oscilloscope (TBS1032B). This equipment is not connected to the GPIB bus.

3 Acceptance Test User Guide

3.1 Pre-Test Setup

Connect the DCP “Unit Under Test” (UUT) to the Main AC Power cable (Appendix D) at the A1A3, A17 and A18 Distribution Rails at the terminals listed below. Ensure that all UUT equipment (serial servers, modems) power switches are in the “OFF” position. Ensure that the A1A1CB-1 and UUT Main AC Power cable switch is in the “OFF” position.

3.1.1 Electrical Connections

1. A3A17TB2-C (AC LINE)

2. A3A18TB1-C (AC NEUTRAL)

3. A3A17TB2-GND (GND)

3.2 Startup

Bootup the test computer.

3.3 DCP Test Sequence, TestStand

On the test computer desktop select the “DCP Factory Acceptance Test” icon to open the DCP test environment in the TestStand application. With the TestStand application open set the following parameters to execute the DCP cabinet test.

1. At the bottom left corner of the User Interface Screen, select “Test UUT” this opens the UUT Information screen.

2. UUT Information Screen: In the UUT information window, enter the Serial Number of the unit to be tested then select ‘OK’.

3. RMA Dialog Window: The RMA dialog window gives the user options for configuring the UUT test sequence. The user can select which test or groups of tests to run from the ‘Test Group’ drop-down menu at the bottom left of the RMA window, manually select test at the main RMA window, or using the radio buttons at the bottom center of the RMA window, select or deselect all tests. The default configuration for test is ‘Manual’ mode, no test sequences are selected. The UUT test sequence are organized into three main groups;

i. Power-Up Test

ii. Network Setup

iii. Functional Test

The Power-Up test is the first test to be executed. This test also sets all cabinet equipment to the correct power settings for all successive test. By-passing the Power-Up test requires that all equipment be manually set to the correct power settings required to execute individual test sequences. When testing a UUT for the first time, the next most important step is the Network Setup. This procedure must be carried out to configure required devices, and establish the network communication links to all cabinet equipment and cannot be bypassed.

4 Test Sequence Procedures

All operator instructions for the Factory Acceptance Test are embedded within the test application, appearing in the form of pop-up windows. Some of these instructions are interactive, requiring operator input to move to the next test. This test architecture reduces the required supporting instruction, and operator learning curve to execute the Factory Acceptance Test. Note: In the event that this procedure document conflicts with the actual “Factory Acceptance Test” the Factory Acceptance Test must take precedence.

4.1 Power Up Test

1. Following the on-screen prompts, run the ‘AC Shorts’ test on the terminal block as prompted.

2. Following the on-screen prompts, run the ‘DC Shorts’ test on the terminal block as prompted.

3. Ensure that A1A1CB-1 and the UUT Main AC Power cable switch are in the “OFF” position. Connect the UUT Main AC Power cable to an AC power source. Move the UUT Main AC Power cable switch to the “ON” Position.

4. Move the A1A1CB-1 switch to the “ON” position.

5. Following the on-screen prompts, probe all Bus bars, breakers and terminal blocks.

6. Following the on-screen prompts, set enclosure thermostats to the maximum setting and measure the heater bar temperature using a Fluke 561 Inferred Thermometer until the heater temperature reaches 150 °F. Select the Pass or Fail button on the test as required. After completing the test, reset the thermostat 1 to 32°F and thermostat 2 to 37°F.

7. Following the on-screen prompts, Verify and set as required the 5V, and 12V power supplies at the A4A1 rail of the Side Plate ASSY by monitoring the output voltage using the DMM. Set the output voltage by adjusting the potentiometer at the front of the power supplies to meet the required output.

8. Follow the prompts to turn on all necessary equipment (UPS, ACU, Serial Servers, and Modems) and verify power up by monitoring the unit LED’s. At the prompt, monitor the UPS output voltage with the cabinet batteries engaged. Follow the test prompts to proceed with the test.

9. Before the “5V Pressure Sensor” Tests, the test application will prompt the user to connect the three DB9 male connectors (A1A6A1P1, A1A6A2P1, A1A6A3P1) at the back plate into the Test Interface Module (B0001-0846). These connectors will require a gender converter to connect to the Test interface module. Follow the test prompts to proceed with the test.

10. Following the on-screen prompts, connect the DB9 Female Connector (A3A12P1) on top of the faraday box into the Test interface module (B0001-0846). Follow the test prompts to proceed with the test.

11. Following the on-screen prompts, connect the 12 Molex connectors (A3A1TB to A3A12TB) to the Test Interface Module (B0001-0846). Follow the test prompts to proceed with the test.

12. Following the on-screen prompts, connect the Molex connector (A3A16J1). Follow the test prompts to proceed with the test.

4.2 Network Setup Test

1. Following the on-screen prompts, the operator will disconnect the Ethernet cables form the MOXA Ethernet Switch (A4A3A2).

2. Following the on-screen prompts, the operator will be directed to connect the test Ethernet cable to the devices that need to be configured consecutively. Follow the on-screen prompts to complete the equipment configuration. The devices that need to be configured are;

i i. Ethernet Switch ii ii. Serial Servers iii iii. IP Radio iv iv. LabJack Module v v. Uninterruptable Power Supply (UPS) vi vi. Power Distribution Unit (PDU)

4.3 Network Connectivity

1. Following the on-screen prompts, connect the Ethernet cables back into their associated port on the MOXA Ethernet switch (A4A3A2).

2. Following the on-screen prompts, the operator will be prompted to connect the Test Ethernet cable to Port-8 of the MOXA Ethernet switch to establish communications with all required devices.

3. Follow the on-screen prompt start the connectivity test, each device connected to the Ethernet switch will undergo a ping test to verify connectivity.

4.4 Audio Signal and Power Monitor Test

1. Following the on-screen prompts, connect the DB37 receptacle of the Test Interface Module (B0001- 0846) to the mating end of the Audio & Analog Signal Monitor module (A4A3) output cable (P4-A4A3).

Follow the test prompts to proceed with the test.

4.5 LabJack Test

1. No connections or operator interaction are required. The test will run automatically without any prompts.

4.6 IP Radio Test

1. No connections or operator interaction are required. The test will run automatically without any prompts.

4.7 Serial Server Test

4.7.1 Server 1

1. Following the on-screen prompts, connect the 8 Ethernet Cables (A1A3A2A1-1 to A1A3A2A1-8) Cables to the Loopback Interface Module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

4.7.2 Server 2

1. Following the on-screen prompts, connect the 8 Ethernet Cables (A1A3A2A2-1 to A1A3A2A2-8) Cables into the Loopback Interface Module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

5 Post Test

After completion of the UUT test perform the following Post Test procedures

1. After the UUT test sequence is complete, select ‘OK’. This saves the UUT test record to the C:\Reports folder under the UUT serial number.

2. At the UUT information prompt, enter the next UUT Serial Number to continue testing or select ‘STOP’ to conclude the testing.

3. Navigate to the C:\Reports folder on the Test Computer to view the UUT test record.

4. If testing is complete, shutdown the UUT as follows;

i. Shutdown Embedded Controller.

ii. Turn ‘OFF’ all Serial Servers and modems.

iii. Move the A1A1CB-1 switch to the “OFF” position.

v. Disconnect the UUT Main AC Power cable from the A3A17 and A3A18 Distribution Rails.

NOAA ASOS, Factory Acceptance Test for SCA Production

This document defines the necessary setup and required connections to execute the ASOS SLEP Factory Acceptance Test (FAT) for the SCA assembly.

2 Equipment, Documents, and Set-up Required

2.1 Required Equipment

See Document: ASOS-SLEP-AMTI-DL-000078-20180221 (FAT Required Equipment List)

2.2 Computer, National Instruments Teststand deployment Setup:

The computer must be equipped with a i7 processor, 8 GB ram (min), running Windows 7 or newer. The following software applications and licenses are required.

1. ASOS SLEP Factory Acceptance Test, REV (TBD), software application (S100-32009)

2. National Instruments, TestStand Deployment License

NOTE: Setup of the Test Computer may require assistance from your IT department.

2.3 Test Equipment and Hardware Setup

Refer to Appendix A through C at the end of this document for general guidance on setting up the equipment. Reference the following NOAA supplied documents for the latest revision and additional detail.

1. ASOS-SLEP-AMTI-DL-000075-20180214, Interconnect Diag. AC Power, ASOS FAT

2. ASOS-SLEP-AMTI-DL-000076-20180214, Interconnect Diag. DC Power, ASOS FAT

3. ASOS-SLEP-AMTI-DL-000077-20180214, Interconnect Diag. Signal, ASOS FAT

2.4 Hardware Connections

1. Setup the benchtop DMM, connect the GPIB cable to the DMM.

2. Setup the benchtop RF Power Meter, connect the GPIB cable from the DMM to the RF Power Meter.

3. Connect the GPIB-USB-HS adaptor to the GPIB cable at either cable connector and connect the USB cable from the adaptor to the test computer USB bus.

4. Connect the USB to Ethernet adaptor to the test computer USB bus. Connect the USB to UUT cable to the USB to Ethernet adaptor.

6. Setup the Test IP Radio; connect the N-Male RA to TNC RA cable (PE3C1271-12) to the -30db port of the RF Directional Coupler ASSY. Connect the TNC RA end to the Test IP Radio RF port. Connect the 12VDC Power Supply (GCS250PS12-C) output to the Test IP Radio. Connect the Test IP Radio Ethernet port to the test computer Ethernet port.

7. Connect the N-Male RA to N-Male cable (PE33321-60) to the input port of the RF Directional Coupler

ASSY.

8. Connect the RF Power Meter, power head to the RF Directional Coupler ASSY output port -30db attenuator.

9. Setup the benchtop Oscilloscope (TBS1032B). This equipment is not connected to the GPIB bus.

3 Factory Acceptance Test User Guide

3.1 Pre-Test Setup

Connect the Unit Under Test (UUT) Main AC Power cable (Appendix D) to the A1A3, A17 and A18 Distribution Rails at the terminals listed below. Ensure that all UUT equipment (serial servers, modems) power switches are in the “OFF” position. Ensure that the A1A1CB-1 and UUT Main AC Power cable switch is in the “OFF” position.

3.1.1 Electrical Connections

1. A3A17TB2-C (AC LINE)

2. A3A18TB1-C (AC NEUTRAL)

3. A3A17TB2-GND (GND)

3.2 Startup

Boot-up the test computer.

3.3 SCA Test Sequence, TestStand

On the test computer desktop select the “SCA Factory Acceptance Test” icon to open the SCA test environment in the TestStand application. With the TestStand application open set the following parameters to execute the SCA cabinet test.

1. At the bottom left corner of the User Interface Screen, select “Test UUT” this opens the UUT Information screen.

2. UUT Information Screen: In the UUT information window, enter the Serial Number of the unit to be tested then select ‘OK’.

3. RMA Dialog Window: The RMA dialog window gives the user options for configuring the UUT test sequence. The user can select which test or groups of tests to run from the ‘Test Group’ drop-down menu at the bottom left of the RMA window, manually select test at the main RMA window, or using the radio buttons at the bottom center of the RMA window, select or deselect all tests. The default configure for test is ‘Manual’ mode, no test sequences are selected.

i. Power-Up Test

ii. Network Setup

iii. Functional Test

The Power-Up test is the first test to be executed. This test also sets all cabinet equipment to the correct power settings for all successive test. By-passing the Power-Up test requires that all equipment be manually set to the correct power settings required to execute individual test sequences. When testing a UUT for the first time, the next most important step is the Network Setup. This procedure must be carried out to configure required devices, and establish the network communication links to all cabinet equipment and cannot be bypassed.

4 Test Sequence Procedures

All operator instructions for the Factory Acceptance Test are embedded within the test application appearing in the form of pop-up windows. Some of these instructions are interactive, requiring operator input to move to the next test. This test architecture reduces the required supporting instruction, and operator learning curve to execute the Factory Acceptance Test. Note: In the event that this procedure document conflicts with the actual “Factory Acceptance Test” the Factory Acceptance Test must take precedence.

4.1 Power Up Test

1. Following the on-screen prompts, run the ‘AC Shorts’ test on the terminal block as prompted.

2. Following the on-screen prompts, run the ‘DC Shorts’ test on the terminal block as prompted.

3. Ensure that A1A1CB-1 and the UUT Main AC Power cable switch are in the “OFF” position. Connect the UUT Main AC Power cable to an AC power source. Move the UUT Main AC Power cable switch to the “ON” Position.

4. Move the A1A1CB-1 switch to the “ON” position

5. Following the on-screen prompts, probe all Bus bars, breakers and terminal blocks.

6. Following the on-screen prompts, set enclosure thermostats to the maximum setting and measure the heater bar temperature using a Fluke 561 Inferred Thermometer until the heater temperature reaches 150 °F. Select the Pass or Fail button on the test as required. After completing the test, reset the thermostat 1 to 32°F and thermostat 2 to 37°F.

7. Following the on-screen prompts, Verify and set as required the 5V, and 12V power supplies at the A4A1 rail of the Side Plate ASSY by monitoring the output voltage using the DMM. Set the output voltage by adjusting the potentiometer at the front of the power supplies to meet the required output.

8. Follow the prompts to turn on all necessary equipment (UPS, ACU, Serial Servers, and Modems) and verify power up by monitoring the unit LED’s. At the prompt, monitor the UPS output voltage with the cabinet batteries engaged. Follow the test prompts to proceed with the test.

9. Before the “5V Pressure Sensor” Tests, the test application will prompt the user to connect the three DB9 male connectors (A1A6A1P1, A1A6A2P1, A1A6A3P1) at the A1A6 Sensor Shelf into the Test interface module (B0001-0846). These connectors will require gender converters to connect to the box.

Follow the test prompts to proceed with the test.

10. The test will then prompt the user to connect the DB9 Female Connector (A3A12P1) on top of the faraday box into the Test interface box (B0001-0846). Follow the test prompts to proceed with the test.

11. Following the on-screen prompts, connect the 12 Molex connectors (A3A1TB to A3A12TB) into the Test interface module (B0001-0846). Follow the test prompts to proceed with the test.

12. Following the on-screen prompts, connect the Molex connector the Molex connector (A3A15J1) to the Test interface module (B0001-0846). Follow the test prompts to proceed with the test.

4.2 Network Setup Test

1. Following the on-screen prompts, the operator will disconnect the Ethernet cables form the MOXA Ethernet Switch (A4A3A2).

2. Following the on-screen prompts, the operator will be directed to connect the test Ethernet cable to the devices that need to be configured consecutively. Follow the on-screen prompts to complete the equipment configuration. The devices that need to be configured are;

i. Ethernet Switch

ii. Serial Servers

iii. IP Radio

iv. LabJack Module

v. Uninterruptable Power Supply (UPS

vi. Power Distribution Unit (PDU)

vii. Embedded Controller

4.3 Network Connectivity

1. Following the on-screen prompts, connect the Ethernet cables back into their associated port on the MOXA Ethernet switch (A4A3A2).

2. Following the on-screen prompts, the operator will be prompted to connect the Test Ethernet cable to Port-8 of the MOXA Ethernet switch to establish communications with all required devices

3. Follow the on-screen prompt start the connectivity test, each device connected to the Ethernet switch will undergo a ping test to verify connectivity.

4.4 Audio Signal and Power Monitor Test

1. Following the on-screen prompts, connect the DB37 receptacle of the Test interface module (B0001- 0846) to the mating end of the Audio & Analog Signal Monitor module (A4A3). Follow the test prompts to proceed with the test.

4.5 LabJack Test

1. No connections or operator interaction are required. The test will run automatically without any prompts.

4.6 Serial Server Test

4.6.1 Server 1

1. Following the on-screen prompts, connect the 8 Ethernet Cables (A1A3A2A1-1 to A1A3A2A1-8) Cables to the Loopback interface module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

4.6.2 Server 2

1. Following the on-screen prompts, connect the 8 Ethernet Cables (A1A3A2A2-1 to A1A3A2A2-8) Cables into the Loopback interface module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

4.6.3 Server 3

1. Following the on-screen prompts, connect the 8 Ethernet Cables (A1A3A7-1 to A1A3A7-8) Cables into the Loopback interface module (B0001-0847) as prompted by the test. Follow the test prompts to proceed with the test.

4.7 Modem Loopback Test

4.7.1 Following the test prompts, connect the Line cable for Voice Modem A1A3A3A1 to the (B0001- 0848) RJ11 Loopback interface module. Follow the test prompts to proceed with the test.

4.7.2 Following the test prompts, connect the Line cable for Data Modem A1A3A3A2 to the (B0001- 0848) RJ11 Loopback interface module. Follow the test prompts to proceed with the test.

4.7.3 Following the test prompts, connect the Line cable for Data Modem A1A3A3A3 to the (B0001- 0848) RJ11 Loopback interface module. Follow the test prompts to proceed with the test.

5 Post Test

After completion of the UUT test perform the following Post Test procedures.

1. After the UUT test sequence is complete, select ‘OK’. This saves the UUT test record to the C:\Reports folder under the UUT serial number.

2. At the UUT information prompt, enter the next UUT Serial Number to continue testing or select ‘STOP’ to conclude the testing.

3. Navigate to the C:\Reports folder to view the UUT test record.

4. If testing is complete, shutdown the UUT as follows;

i. Shutdown Embedded Controller.

ii. Turn ‘OFF’ all Serial Servers and modems.

iii. Move the A1A1CB-1 switch to the “OFF” position.

v. Disconnect the UUT Main AC Power cable from the A3A17 and A3A18 Distribution Rails.