OC-ALC-TPSD-ITAPRS-001.pdf

OC-ALC-TPSD-ITAPRS-001

PRODUCT REQUIREMENTS

SPECIFICATION

INTERFACE TEST ADAPTER

FOR:

76 SMXG Oklahoma City Air Logistics Complex (OC-ALC) Tinker AFB Oklahoma

20 January 2016

PREPARED BY:

556 SMXS/MXDPBA

76 SMXG

TINKER AFB 73145

DISTRIBUTION A. Approved for public release: distribution unlimited Case: 72ABW-2016-0006

TABLE OF CONTENTS

1. PRODUCT REQUIREMENTS SPECIFICATION

1.1 OVERVIEW OF THE PRODUCT REQUIREMENTS SPECIFICATION FOR ITA

1.2 APPLICABLE DOCUMENTS

2. REQUIREMENTS

2.1 GENERAL

2.2 ITA HARDWARE

2.2.1 ITA HARDWARE DESIGN

2.2.2 TPS HARDWARE COMPONENTS

2.2.3 INTERFACE TEST ADAPTER

2.2.4 CONNECTORS

2.2.5 CABLES

2.2.6 HOLDING FIXTURES

2.2.7 EXTENDER CARDS

2.2.8 FINISH

2.2.9 GROUNDING

2.2.10 ELECTROMAGNETIC INTERFERENCE

2.2.11 SAFETY

2.2.12 ELECTRICAL COMPLEXITY

2.2.13 ELECTRICAL CONTINUITY

2.2.14 INSULATION RESISTANCE

2.2.15 SELF-TEST PROVISIONS

2.2.16 WEIGHT

2.2.17 ACCESSIBILITY

2.2.18 RELIABILITY

2.2.19 MAINTAINABILITY

2.2.20 MEAN TIME TO REPAIR

2.2.21 ENVIRONMENTAL CONDITIONS

2.2.22 DISSIMILAR METALS

2.2.23 CARD GUIDES

2.2.24 CIRCUIT CARD ASSEMBLIES

2.3 MARKING

3.1 PACKING AND PACKAGING

List of Acronyms

1. PRODUCT REQUIREMENTS SPECIFICATION

1.1 OVERVIEW OF THE PRODUCT REQUIREMENTS SPECIFICATION FOR ITA

This document defines the Product Requirements Specification for the Interface Test Adapter (ITA) for use on the Automated Test Equipment (ATE).The ITA specification includes hardware design criteria, test requirements, and delivery guidelines. The ITA hardware provides an interface between the ATE and the Unit Under Test (UUT). The UUT may be either a Line Replaceable Unit (LRU) or Shop Replaceable Unit (SRU). The terms ITA Hardware and TPS Hardware (Test Program Set Hardware) may be used interchangeably throughout this document, but mean the same thing.

1.2 APPLICABLE DOCUMENTS

The following documents form a part of this specification to the extent specified herein.

If a document is referenced within this specification without indicating specific paragraphs as being applicable, then the document is applicable in its entirety. The applicable documents:

MIL-STD-130N Identification Marking of U.S. Military Property

MIL-DTL-14072E Finishes for Ground Based Electronic Equipment

FED-STD-595C

MIL-HDBK-454B

Colors Used in Government Procurement

General Guidelines for Electrical Equipment

29CFR1910 Federal Code, Title 29, Section 12, Part 1910 (1985)

Occupational Safety and Health Administration (OSHA) Regulations

MIL-HDBK-217F

MIL-STD-31000A

ASME Y14.44

MIL-STD-1472G

MIL-STD-889B

IEEE-STD-287

Reliability Prediction of Electronic Equipment

Department of Defense Standard Practice Technical Data(Packages)

Reference Designations for Electrical and Electronics Parts and Equipment

Human Engineering

Dissimilar Metals

IEEE Standard for Precision Coaxial Connectors

2. REQUIREMENTS

2.1 GENERAL

This section identifies the performance requirements which must be met for an acceptable design, fabrication, and delivery of ITA hardware.

2.2 ITA HARDWARE

The following paragraphs identify specific hardware requirements for the ITA.

2.2.1 ITA HARDWARE DESIGN

The ITA hardware design shall meet all the requirements in this specification. In the event of a conflict between the Government furnished design and this specification, the Government furnished design shall take precedence.

2.2.2 TPS HARDWARE COMPONENTS

The TPS hardware shall provide all interfaces between the UUT and ATE required for accomplishing testing of the UUT and for self-testing the ITA.

The TPS hardware includes Interface Test Adapter Enclosure(s), connectors, wiring, circuitry, cabling, card guides, holding fixture, cooling fixture, extender cards, wrap-around self- test circuit cards and cabling.

2.2.3 INTERFACE TEST ADAPTER

2.2.3.1 The ITA shall be the mating device between the ATE and the UUT.

2.2.3.2 The ITA shall be designed to connect to the ATE. ITAs may require additional connections to an ATE Augmentation rack(s) located next to the ATE. ITAs may also require additional connections to an RF rack located next to the ATE. An ITA that requires an additional connection to an RF rack will utilize the correct series of connector interfaces to connect to the RF rack.

2.2.3.3 The ITA shall be provided with a removable metal cover to protect the ATE contact pins during storage and shipping.

2.2.3.4 ITA design shall include strain relief to prevent damage during normal operation and storage.

2.2.3.5 ITA design shall include wiring maintenance loops that allow enough wire length to replace each pin a minimum of two (2) times.

2.2.3.6 ITA wiring shall be neatly routed within the ITA utilizing cable ties and non-adhesive hold downs.

2.2.3.7 The ITA terminal blocks and connectors used to provide connection to external cables shall be designed with a 20% expansion capability.

2.2.3.8 The ITA shall use terminal blocks when splicing 4 or more connections together on a single wire run.

2.2.3.9 The ITA shall have its internal wiring scheme such that the wiring shall not be damaged during normal maintenance.

2.2.3.10 The ITA handles shall be designed in accordance with MIL-STD- 1472G paragraph 5.8.6.5.3.a thru 5.8.6.5.3.c

2.2.3.11 Vents shall be installed on the ITA when there is heat generating components within the ITA. Fans or forced air cooling shall be installed on the ITA when vents alone cannot compensate for the heat generating components. The Contractor shall produce a thermal analysis when proposing vents, fans, or forced air cooling to the ITA in accordance with

MIL-HDBK-454B.

2.2.3.12 The ITA enclosure panels shall have a metal thickness of 125 thousandths of an inch.

2.2.3.13 The ITA shall use self- locking fasteners when mounting assemblies within the ITA.

2.2.4 CONNECTORS

2.2.4.1 Connectors utilized during tear down or installation of TPS hardware on the ATE shall be connected and disconnected by hand and shall not require special tools (unless specified by the TPS design).

2.2.4.2 ITA connectors shall be clearly labeled with their associated connector identification numbers and follow MIL-STD-1472G paragraph 5.9.15.3.1.

2.2.4.3 External connectors shall include protective covers that are attached to the ITA, holding fixture, or cable via a cord.

2.2.4.4 The external connectors and connector covers shall be metal whenever available.

2.2.4.5 Connectors shall be spaced far enough apart so that they can be grasped firmly for connecting and disconnecting.

2.2.4.6 Connector placement shall not require connecting or disconnecting any adjacent connector during coupling or decoupling actions.

2.2.4.7 The mating connector-engaging mechanism shall lock or tighten in its fully closed position.

2.2.4.8 Identical ITA connectors shall be keyed differently.

2.2.4.9 All RF connectors of the ITA hardware shall be of “Instrument Grade” also known as “General Precision Connector” (GPC) per IEEE-STD-287.

2.2.4.10 Connector savers shall be used to protect the RF connectors of the ITA hardware.

2.2.5 CABLES

2.2.5.1 Cables shall be protected with flexible, rugged sheathing.

2.2.5.2 Cables shall include strain relief designs with back shells to protect against damage caused by normal use or storage.

2.2.5.3 Cable connectors will be free of potting compound unless the cable is

COTS.

2.2.5.4 Cables shall be designed for rapid replacement of individual pins.

2.2.5.5 Cables will not use cable ties on wire bundles within a protective covering.

2.2.5.6 Cables shall have assemblies constructed such that a maximum of one inch of wire shall be exposed between the cable shield and the connector.

2.2.5.7 External cables shall not use ribbon cable.

2.2.5.8 Cable Spare Wires:

2.2.5.8.1 Cables shall have 10% spare wires of each wire type with a minimum of 1 of each type. Max of 5 for each type.

2.2.5.8.2 Cable spare wires shall not have contacts on them.

2.2.5.8.3 Cable wire spares shall be folded back in the backshell with heat shrink over end.

2.2.5.8.4 Cable spare wires shall be documented in the ITA schematics and wire lists labeled as spare with any applicable designation of wire type. The parts list shall reflect the quantity increase for spares wires as well.

2.2.5.9 Cables shall have individual wires of length and flexibility such as to prevent damage when being bent during use, repair, and storage.

2.2.6 HOLDING FIXTURES

2.2.6.1 The holding fixture shall be used to provide electrical contact between the UUT and ITA

2.2.6.2 The holding fixture shall provide physical support required to secure the UUT during test.

2.2.6.3 Holding fixture air hoses shall be designed to quickly connect and disconnect to/from the holding fixture without any special tools.

2.2.6.4 Holding fixture air hoses shall have 2 inch inner diameter fittings and the fixture shall have 2 inch outer diameter fittings allowing the two to mate.

2.2.6.5 Holding fixtures and hoses shall be designed to accommodate 39CFM to 92CFM of air flow unless otherwise specified in the ITA design.

2.2.7 EXTENDER CARDS

2.2.7.1 Extender cards shall allow Shop Replaceable Units (SRUs) to operate normally while extended out of the LRU.

2.2.7.2 Extender cards shall be designed to allow a minimum of two (SRUs) to be extended from the LRU during testing.

2.2.7.3 The extender cards shall include card guides to hold the SRUs in place.

2.2.7.4 The extender cards shall provide probe points below the SRU connector to allow probing of all extended trace points without damaging the extender card or SRU under normal operation and use.

2.2.7.5 A Fault insertion Device (FID) shall be designed to meet all requirement of an extender card with the addition of providing an integral method to electrically connect and isolate each signal path.

2.2.8 FINISH

The ITA shall be finished in powder coat P/N: RFB607R8, DuPont Axalta Coating Systems, Alesta, Supreme Black.

2.2.9 GROUNDING

2.2.9.1 All external metal chassis surfaces shall be connected to chassis ground via a separate 12 AWG wire and lug. Screw threads are not considered a conductive path.

2.2.9.2 Ground loops shall be eliminated. The design of the ground systems shall protect personnel from electrical hazards, provide the necessary shielding for signal circuits and minimize Electromagnetic Interference (EMI).

2.2.9.3 Primary AC power return (Neutral) shall remain isolated from all signal and chassis grounds unless otherwise specified in the ITA design.

2.2.10 ELECTROMAGNETIC INTERFERENCE

The TPS hardware shall achieve an electromagnetic compatibility level such that operation does not interfere with normal operation of the UUT, other TPSs, or similar equipment in the area of intended usage.

2.2.11 SAFETY

2.2.11.1 The ITA shall have precautionary markings notifying personnel of hazardous conditions in accordance with MIL-STD-1472G paragraphs 5.7.2.1.1, 5.7.2.1.2, 5.7.2.2, 5.7.2.3.

2.2.11.2 ITAs utilizing voltages above 30 VDC shall be marked on the outside of the ITA with high voltage warning labels that follow government furnished design.

2.2.11.3 The ITA shall utilize the ATE safety interlock to disconnect power supplies when the ITA is removed from the Interface Connector Assembly (ICA) of the ATE.

2.2.12 ELECTRICAL COMPLEXITY

2.2.12.1 All electrical incompatibilities between the UUT and the ATE shall be resolved by the use of passive circuitry within the ITA.

2.2.12.2 Active circuits and circuitry requiring alignments or adjustments shall only be used as a last resort.

2.2.13 ELECTRICAL CONTINUITY

The resistance of each point-to-point path of the ITA shall be less than or equal to 500 milliohms.

2.2.14 INSULATION RESISTANCE

The ITA circuitry shall have insulation resistance of more than 100 megohms when subjected to 500 plus or minus 50 volts direct current (Vdc) for a period of 50 to 70 seconds, measured between all mutually insulated circuit paths and between all mutually insulated circuit paths and the ITA enclosure.

2.2.15 SELF-TEST PROVISIONS

2.2.15.1 The ITA shall include a government designed wrap-around self-test provisions so that each electrical path through the ITA can be verified by tests.

2.2.15.2 For SRU type ITAs, a wrap-around circuit card will be fabricated to meet the self-test provisions.

2.2.15.2.1 The wrap-around circuit card will optimize connector location and orientation to facilitate self-testing by matching the connector locations of the UUT.

2.2.16 WEIGHT

2.2.16.1 The ITA shall not exceed the manufacturers’ established weight limits of the ATE Interface Connector Assembly (ICA).

2.2.16.2 The ITA shall include two person lift warnings if the ITA weighs more than 40 pounds.

2.2.17 ACCESSIBILITY

2.2.17.1 The ITA design shall provide easy access to

repairable/replaceable components, wires, cables, and assemblies by use of hinged maintenance access door(s).

2.2.17.1.1 The ITA access doors shall have arms to secure them in the open position and can easily be lowered again.

2.2.17.1.2 The ITA shall have quick disconnect tool less, captive, thumb screws to secure the access doors.

2.2.17.2 The ITA access shall be such that, with the ITA connected to the ATE, ITA mounted SRUs are accessible for circuit probing.

2.2.17.3 The ITA access shall be such that, with the ITA connected to the ATE and with all cabling and UUTs mounted on ITA, probing of the internal ITA wiring/CCAs will be possible when access doors are open.

2.2.17.4 The ITA fasteners normally removed or installed during service repair/replacement of the ITA shall be ¼ inch in diameter or larger.

2.2.18 RELIABILITY

TPS hardware elements shall be designed with a Mean Time Between Failure (MTBF) of no less than 1,000 hours. MIL-HDBK-217F shall be used as guidance in calculating MTBF.

2.2.19 MAINTAINABILITY

The following basic maintainability principles shall apply as goals during the design of the TPS hardware:

a) Design to utilize easily removable circuit cards and assemblies.

b) Design for rapid and positive identification of defective parts.

c) Design for use of standard tools.

d) Design for personnel safety.

e) Design with standard replacement parts.

2.2.20 MEAN TIME TO REPAIR

The ITA mean time to repair shall be less than one (1) hour.

2.2.21 ENVIRONMENTAL CONDITIONS

2.2.21.1 The TPS hardware shall be designed so that it shall not suffer damage, deterioration, or degradation of performance when used and stored in a depot shop environment.

2.2.21.2 The ITA shall have protective components affixed to the bottom of the ITA that allow the ITA to slide easily on the storage racks while also preventing damage to the ITA.

2.2.22 DISSIMILAR METALS

2.2.22.1 The ITA shall be constructed in accordance with MIL-STD-889.

The ITA shall resist corrosion.

2.2.23 CARD GUIDES

2.2.23.1 UUTs with card edge connectors shall utilize card guides affixed to the ITA to support the UUT during testing.

2.2.23.2 Card guides shall be designed to allow diagnostic probing to be conducted in a safe and accessible manner.

2.2.23.3 An ESD safe non-metal or ESD safe coated metal material shall be used at the point the card guides come into contact with the UUT. No 3D printed card guides.

2.2.23.4 Card ejectors shall be implemented to facilitate safe removal of the UUT from the mating connector.

2.2.23.5 Card ejectors shall not interfere with UUT insertion.

2.2.24 CIRCUIT CARD ASSEMBLIES

The design requirements for Circuit Card Assemblies (CCAs) within the ITA are as follows:

2.2.24.1 Printed wiring boards shall be utilized for all CCAs.

2.2.24.2 CCAs shall use connectors for connection to the UUT to facilitate CCA replacement and repair.

2.2.24.3 Components shall be mounted on CCAs, unless the mounting of a component would jeopardize the engineering integrity of the design (i.e., transformers, power loads).

2.2.24.4 Each component mounted on the CCA(s) shall have the location of that component labeled on the CCA with a unique identifier, as shown in ASME Y14.44 paragraph 2.

2.3 MARKING

2.3.1 Unless otherwise stated reference designations shall be in accordance with

ASME Y14.44.

2.3.2 Unless otherwise stated Marking and identification of TPS hardware shall be in accordance with MIL-STD-130N.

2.3.3 The ITA shall be marked with the “partial CPIN” on the same panel that the UUT is mounted to. The marking shall be at least 1 inch high.

2.3.4 Electrostatic Discharge Sensitive items shall be marked in accordance with MIL-STD-130N paragraph 5.9.

2.3.5 ITA Identification Plate

2.3.5.1 A non-adhesive metal identification plate shall be fastened to each ITA enclosure with fastener devices.

2.3.5.2 Characters shall be metal etched with a minimum height of 0.12 inches.

2.3.5.3 At a minimum, the identification plate shall include the following government supplied information:

a. Weapon system identification

b. ITA Nomenclature

c. Government Entity (CAGE) Code

d. ITA Part or Identifying Number

e. ITA Serial Number

f. ITA Weight

2.3.5.4 The identification plate shall match the following

2.3.6 ITA Item Unique Identification

2.3.6.1 Items shall be marked with an Item Unique Identification (IUID) plate in accordance with MIL-STD-130N. The item shall be marked using Construct #2. The three data identifiers shall be included on the label as linear bar codes and free text. Plates shall be mounted by fastener devices.

Plates must not be mounted by an adhesive. Metal etch characters shall be a minimum of 0.12 inches high.

2.3.7 Cable identification labels shall include the proper configuration data listed via Human Readable Information MIL-STD-130N paragraph 4.3 and:

a. Use non-metallic identification bands.

b. Use ‘W’ reference designator

c. Cable connectors shall use the ‘P’ reference designator.

d. Use “mates with connector” nomenclature.

e. Part number

f. CAGE code: 98748

g. Serial number

2.3.8 Connector identification labels shall include the proper configuration data listed via Human Readable Information MIL-STD-130N paragraph 4.3 and:

a. All connectors shall be identified and clearly labeled by sequentially numbered designators.

b. “J” designation shall identify stationary (most fixed) connector jacks.

c. “P” shall identify movable (least fixed) connector plugs.

2.3.9 Product marking

Purchased parts which are marked by the manufacturer shall not be renumbered.

2.3.10 Non-available identification information

If the ITA information is not available at the time of marking, a blank shall be provided for marking to be added when the information is made available.

2.3.11 ITA

Serial numbers shall be a maximum of three (3) numeric characters and will start with 001 and continue in ascending order.

3.1 PACKING AND PACKAGING

Preservation methods, packing designs, and packaging shall be adequate to ensure protection against natural and induced environments. Packaging insulation shall be adequate to prevent ITA and associated ITA cabling from being damaged due to accidental drop or sudden movement during shipment.

List of Acronyms

AFIL Acceptance Fault Insertion List ALC Air Logistics Center AT Acceptance Test ATP Acceptance Test Procedure ATE Automatic Test Equipment ATS Automatic Test System BFIL Blind Fault Insertion List BIT Built-In Test CAGE Commercial and Government Entity COTS Commercial Off-The-Shelf CPIN Computer Program Identification Number DR Design Review EMI Electromagnetic Interference ESD Electrostatic Sensitive Device RF Radio Frequency GFE Government Furnished Equipment IATE Intermediate Automatic Test Equipment ICA Interface Connector Assembly IFIL Integration Fault Insertion List I-Level Intermediate Level ITA Interface Test Adapter LRU Line Replaceable Unit MTBF Mean-Time-Between-Failure MTTR Mean-Time-To-Repair NSN National Stock Number OSHA Occupational Safety and Health Administration PIN Part or Identifying Number RFI Ready-For-Issue SPG Single Point Ground SRU Shop Replaceable Unit STTO Safe-To-Turn-On TAR Test Accuracy Ratio TP Test Program TPS Test Program Set TRR Test Readiness Review UUT Unit Under Test VDATS Versatile Depot Automatic Test System VCRI Verification Cross Reference Index