Attachment_15_MTS8E_TSUM.pdf

03-1449-TSUM

MTS8E TEST STATION USER’S MANUAL

For The

AIR LAUNCHED CRUISE MISSILE (ALCM)

GUIDED MISSILE FLIGHT CONTROLLER

In Support of the

AGING & SURVEILLANCE PROGRAM

(AGM-86)

FA8222-12-D-0001-SD01

(CDRL Sequence A032)

Prepared by:

Aerospace Engineering Spectrum LTD

1307 West 2550 South Ogden, UT 844401-3239

Submitted to:

AFNWC/NCM

Attn: Ms Stasha Hicks 7330 Sentry Blvd

Tinker Air Force Base, OK 73145-8901

Date Submitted:

16 February 2015

Revision History

Revision Date Summary of Changes

0 02/16/2015 Baseline

[MTS8E TSUM for ALCM GMFC A&S Testing-Baseline.docx]

File located at: \\Droboshare\Drobo\Projects\03-1449 Tinker AFB ALCM A&S Cycle 5\Test Station Users Manual

Table of Contents

Section Page

1 SAFETY SUMMARY

1.1 General WARNINGS

2 ANCILLARY TEST AND HANDLING EQUIPMENT

2.1 Ancillary Test Equipment

2.2 Ancillary Handling Fixtures and Test Fixtures

2.3 Consumables

3 MAJOR EQUIPMENT ITEMS

4 TEST STATION DESCRIPTION

4.1 Hardware

Digital Multi-Meter

Power Distribution Unit and Remote EMO Panel

Oscilloscope

LCR Meter

Waveform Generators

Synchro/Resolver Simulator

Power Supplies

4.2 Interface Test Adapters

4.3 Software

4.3.1 ALCM GMFC A&S Test Executive

4.3.2 MTS8E Test Station Self Test Routine

4.3.3 GMFC Functional Test

4.3.4 GFMC A&S Unique Test

4.3.5 GMFC SRU A&S Tests

5 CALIBRATION & ALIGNMENT

5.1 MTS8E Test Station

5.2 Ancillary Equipment

5.3 MTS8E Calibrated Component Procedures

5.3.1 HP 3458A Digital Multimeter

5.3.1.1 DMM AutoCal

5.3.1.2 Removal

5.3.1.3 Installation

5.3.2 HP4263 LCR Meter

5.3.2.1 Removal

5.3.2.2 Installation

5.3.3 TDS 2004 Oscilloscope

5.3.3.1 Scope Functional Check

5.3.3.2 Scope Self Calibration

5.3.3.3 Removal

5.3.3.4 Installation

6 GMFC A&S TEST PROCEDURES

6.1 MTS8E Test Station Power Up Procedure

6.2 MTS8E Test Station Self Test Procedure

6.3 ALCM A&S Test Selection

6.3.1 GMFC A&S Unique Tests

6.3.1.1 GMFC ITA #2 Self Test Procedure

6.3.1.2 GMFC A&S Unique Test Procedure

6.3.2 GMFC Functional Tests

6.3.2.1 GMFC ITA #1 Self Test

6.3.2.2 GMFC Functional Test Procedure

6.3.3 GMFC SRU Tests

6.3.3.1 GMFC SRU ITA Self-Test Procedure

6.3.3.2 A1 EMI Filter Test Procedure

6.3.3.3 A2 thru A9 CCA Tests

6.3.4 GMFC Environmental Test Procedure

7 FAILURE REPORTING PROCEDURE

8 MTS8E DATA ARCHIVES

9 TEST DATA ARCHIVES

10 A&S TEST FLOWS

11 ALCM MTS8E TEST STATION A&S TEST COMPLEX DRAWING TREE

12 TROUBLESHOOTING

12.1 MTS8E Test Station

12.1.1 Test Station

12.1.2 (Next Test Station Issue TBD)

List of Tables

Table Page

Table 2-1. Handling Fixtures and Test Fixtures

Table 2-2. Consumables

Table 5-1. Test Station Calibration Information

Table 5-2. 3458A Calibration Information

Table 5-3. 4338B Calibration Information

Table 6-1. Test Environments for GMFC Orientations 1, 2 and 3

List of Figures

Figure Page

Figure 2-1. Guided Missile Flight Controller Vibration Fixture

Figure 4-1. MTS8E Test Station

Figure 4-2. Agilent 3458A DMM

Figure 4-3. PDU Enable and Emergency Stop Switch

Figure 4-4. Tektronix RM 2000B Oscilloscope

Figure 4-5. HP 4263B LCR Meter

Figure 4-6. Agilent 33500B Waveform Generators

Figure 4-7. North Atlantic Industries SRS 533A Synchro/Resolver

Figure 4-8. MTS8E ITA Interface

Figure 4-9. Agilent Modular DC Power Supplies, 66000A/66103A

Figure 4-10. Chroma 6404 AC Power Supply

Figure 4-11. MTS8E Self-Test ITA, 03-1449-0500

Figure 4-12. GMFC ITA #1, Load Box, & Cables W1-W4, 03-1449-0200, -0220 thru -0250 . 19

Figure 4-13. GMFC ITA #2, 03-1449-0300

Figure 4-14. GMFC SRU ITA #3, 03-1449-0400, W5 Cable, -0260

Figure 4-15. ALCM GMFC A&S Tests

Figure 4-16. MTS8E Test Station Self Test

Figure 4-17. Operator Notebook Entry Screen

Figure 4-18. A&S Test Monitor Screen

Figure 4-19. GMFC Functional Test

Figure 4-20. GMFC Functional Test Operator Notebook Entry Screen

Figure 4-21. GMFC Test Sep

Figure 4-22. GMFC A&S Unique Test Selection

Figure 4-23. GMFC SRU A&S Unique Tests

Figure 5-1. HP 3458A Digital Multimeter IO Connection

Figure 5-2. HP 4263 LCR Meter Interface Connections

Figure 5-3. TEK TDS 2004C Scope Front Panel

Figure 5-4. TDS 2004 Oscilloscope Connections

Figure 6-1. Facility Air Supply Connection

Figure 6-2. Air Isolation and Armature Support Controls

Figure 6-3. Orientation 1 - GMFC Adapter Mounted to L Fixture

Figure 6-4. Orientation 1 - Accelerometer Placement

Figure 6-5. Accelerometer Cable Routing

Figure 6-6. GMFC Orientation 1

Figure 6-7. Chamber Access Hole

Figure 6-8. Orientation 1 - Cable Connections

Figure 6-9. Close Chamber Door

Figure 6-10. Accelerometer Breakout Box

Figure 6-11. Chamber Touch Screen

Figure 6-12. Shaker Controller Main Power Switch

Figure 6-13. Controller Desktop

Figure 6-14. Mode Key Switch

Figure 6-15. Orientation 2 - GMFC Adapter Mounted to L Fixture

Figure 6-16. Orientation 2 - Accelerometer Placement

Figure 6-17. GMFC Orientation 2

Figure 6-18. Orientation 2 - Cable Connections

Figure 10-1. GMFC A&S Unique Test Flow

Figure 10-2. GMFC Functional Test Flow

Figure 10-3. GMFC SRU A&S Unique Test Flow

Figure 10-4. GMFC Environmental Test Flow

Figure 10-5. GMFC A&S Test Top Level Flow Diagram

1 Safety Summary

1.1 General WARNINGS

DO NOT operate the MTS8E in an explosive atmosphere or in the presence of flammable gases or fumes.

DO NOT remove covers and/or shields with power applied.

DO NOT operate damaged equipment.

DO NOT attempt internal service or adjustments alone.

DO NOT substitute parts or modify equipment without cognizant engineering and safety office approval.

Operators should not wear jewelry that could complete a circuit path.

Personnel with heart ailments or devices such as pacemakers should not operate this test station.

Safety devices on the MTS8E and the associated A&S environmental test chambers and equipment include both software and hardware interlocks to prevent operators from contacting high voltage. The safety interlocks MUST NOT be defeated. Any deviation to this requirement could cause harmful or fatal shock.

2 Ancillary Test and Handling Equipment

2.1 Ancillary Test Equipment

In order to develop the ALCM Guided Missile Flight Controller (GMFC) A&S tests various test components were either developed or acquired. Those components are identified in the following paragraphs.

ALCM GMFCs

Part number 232-11270-21, serial numbers 0945, 1292, 1456, and 2086

These four GMFCs were delivered as Government Furnished Equipment and were subsequently identified as the 4 units to be set aside for use as part of an age sensitivity item analysis (ASIA).

They are not considered serviceable assets for future return to the operational inventory, but will be used as dedicated A&S Program lab test assets.

Accelerometer, Endevco Model 6251-10

This accelerometer is used during Guided Missile testing to control and monitor vibration and is designed specifically for vibration measurement on small structures and objects. The accelerometer has a temperature operating range of –67 F0 to 257 F0. This accelerometer is also used in the A&S test for both ALCM Warhead Arming Devices and Rotary Switches in conjunction with the MTS-8 Test Station.

2.2 Ancillary Handling Fixtures and Test Fixtures

Table 2-1. Handling Fixtures and Test Fixtures

Figure Nomenclature Part Number Manufacturer Quantity

2-1 Guided Missile Flight Controller Vibration Fixture 03-1249-0250 E-Spectrum 1

Figure 2-1. Guided Missile Flight Controller Vibration Fixture

2.3 Consumables

Table 2-2. Consumables

# Nomenclature Purpose Manf. Vendor Part Number

Insulating Washer for Endevco Accelerometer (Small – Top Washer)

Isolate accelerometer from metal surface Thermotron 1239911

Insulating Washer for Endevco Accelerometer (Large – Bottom Washer)

Isolate accelerometer from metal surface Thermotron 1239929

3 Major Equipment Items Various test and storage chambers have been acquired to meet the environmental requirements of both the test configurations and the storage configurations. These major equipment items are identified in the following paragraphs. All of this equipment is maintained as Government Furnished Equipment under an asset storage contract. All of this equipment was purchased for cruise missile test program purposes and use prior to the development of the GMFC A&S test program, but has capacity to be used for the GMFC also.

Cincinnati Sub-Zero ZP-Series Temperature/Humidity Controlled Chamber. The Cincinnati Sub-Zero ZP temperature/humidity chamber (Model Number ZPHS-32-2-2-H/AC) is integral to the overall A&S program. Dedicated test assets are stored in the chamber under temperature and humidity conditions representative of “field conditions” as directed by the Program Management Plan. This chamber was purchased in late CY 2004.

Thermotron AGREE style Temperature Chamber/Vibration Table. This combination system (Chamber Model Number F-12-CHV-5-5 and Shaker Model Number DS-2000-911-12M) allows simultaneous application of vibration and thermal environments while the Warhead Arming Device (WAD), Rotary Switch, or Guided Missile Flight Controller (GMFC) is subjected to tests. The MTS-8 is used for signal stimulus application and data acquisition and analysis for both the warhead arming device and rotary switch tests, while the MTS-8E provides the same capability for the GMFC tests.

4 Test Station Description

4.1 Hardware

MTS8E Test Station. The MTS8E is an analog/digital automatic test station that provides a wide range of test capability. The original specifications for the MTS8E included sufficient capacity to meet the Aging & Surveillance electrical stimulus application and data acquisition test requirements for the ALCM Guided Missile Flight Controller and its 8 Shop Replaceable Units (SRUs). Further, all of the electrical production/acceptance test requirements for the GMFC can be met with the MTS8E.

A complete set of engineering drawings has been created to provide long-term supportability.

Section 10 of this document includes a drawing tree for the entire ALCM A&S Test Complex.

The following figure depicts the MTS8E and in its current configuration.

Figure 4-1. MTS8E Test Station

Station Controller. The test station controller is a National Instrument PXi based plug in unit that is resident in the PXi chassis within the test station instrument rack. It includes a 2.5 GHz Intel dual-core i5-2510E processor, with 2 GB dual channel DDR3 RAM memory operating at 1333 MHZ. The controller includes a 250 GB hard drive, 2 Ethernet ports, 6 hi-speed USB ports, a serial port (RS232) and a parallel port.

Station Video Monitor. A 22-inch LCD-backlit eco-friendly widescreen desktop monitor is mounted on an Ergotron style view adjustable height combination arm. The Ergo-Arm also has integrated trays for mounting the key board and mouse. These devices interface with the monitor via USB interconnects.

Instrument Rack. The rack contains common COTS instrumentation as well as some custom hardware. A National Instrument PXIe-1065 Chassis provides 9 PXI slots, 4 hybrid slots, 3 PXI Express slots, 1 PXI Express system timing slot which is sufficient capacity to meet the test requirements and data acquisition needs for the GMFC and provides some limited measure of expandability. The following paragraphs describe the various Tester Replaceable Units within the instrument rack and are presented in sequential order from the top of the instrument rack down to the bottom.

Digital Multi-Meter As shown in the following figure, this is a standard commercial off the shelf Agilent 3458A Digital Multi-Meter.

Figure 4-2. Agilent 3458A DMM

Power Distribution Unit and Remote EMO Panel The power distribution unit is a standard Eaton designed chassis, Part number TPC 115-10-D- LT, that implements a ground fault interrupt, provides emergency shut off capabilities for all AC power within the MTS8E, and filters the input power to the test station. All instruments in the MTS8E receive their input power from the PDU. The PDU is mounted inside the MTS8E and the Remote EMO feature provides a test station front panel means of performing emergency test station shut down. The following figure shows a view of the front panel view of the Enable and Emergency stop switches for the unit.

Figure 4-3. PDU Enable and Emergency Stop Switch Oscilloscope The scope is a standard commercial off the shelf TEK RM 2000B Oscilloscope.

Figure 4-4. Tektronix RM 2000B Oscilloscope

LCR Meter This is a standard commercial off the shelf HP 4263B LCR Meter. An HP Clip Lead Adapter, 160890, has been modified for use in circuit. The adapter mounts to the front of the LCR Meter in a normal fashion, however the alligator clips have been removed and the leads have been terminated with interface pins for this application.

Figure 4-5. HP 4263B LCR Meter

Waveform Generators The two Waveform Generators are mounted side-by-side in the instrument rack and are Agilent 33500B devices.

Figure 4-6. Agilent 33500B Waveform Generators

Synchro/Resolver Simulator The North Atlantic Industries SRS 5330A is the COTS instrument used in the MTS8E.

Figure 4-7. North Atlantic Industries SRS 533A Synchro/Resolver

ITA Interface A Virginia Panel interface has been custom designed to meet all of the I/O for the test requirements for the GFMC and its SRUs. Various Virginia panel based Interface Test Adapters (ITAs) have been designed to electrically interface the MTS8E stimulus and measurement instruments with the unit under test. The ITA interface at the MTS8E is shown in the following figure.

Figure 4-8. MTS8E ITA Interface

Power Supplies Three DC power supplies and a single AC power supply have been incorporated to satisfy the various test requirements. Three Agilent 66103A dc power supplies which provide 0-35V @4.5A are housed in a 66000A Modular Power Supply Mainframe while the Chroma 6404 AC power supply (0-300 VAC from 45 to 1KHz) is a typical rack mount unit that operates in the 400 Hz range required for military applications.

Figure 4-9. Agilent Modular DC Power Supplies, 66000A/66103A

Figure 4-10. Chroma 6404 AC Power Supply

4.2 Interface Test Adapters.

Various interface test adapters (ITAs) have been designed and developed in support of the ALCM GMFC A&S Program. The ITAs include the ITA box itself and in some cases integrated pigtail cable legs, interface disconnect cables for the UUT, and/or a Load Box when appropriate (see Table 4-1). The ITAs are described in the paragraphs following Table 1.

Table 4-1 Interface Test Adapters

MTS8E Self-Test ITA. A self-test ITA, P/N 03-1449-0500, is provided to allow for a comprehensive internal test of the MTS8E. During the self-test, each instrument with a built-in-test (BIT) is commanded to perform that BIT. The results are displayed on the PC controller.

The switching matrix in the test station is functioned to verify that all relays and circuit paths are intact and operational via continuity and isolation testing.

Figure 4-11 shows a rear view of the MTS8E Self-Test ITA with the Virginia panel interface exposed.

Nomenclature P/N Figure Remarks MTS8E Self-Test ITA 03-1449-0500 4-11 Used for test station self test GMFC ITA #1 03-1449-0200 4-12 Used for Functional Test on GMFC

W1 Cable 03-1449-0230 4-12 Used in conjunction with ITA #1 W2 Cable 03-1449-0240 4-12 Used in conjunction with ITA #1 W3 Cable 03-1449-0250 4-12 Used in conjunction with ITA #1 W4 Cable 03-1449-0260 4-12 Used in conjunction with ITA #1

GMFC Load Box 03-1449-0220 4-12 Used in conjunction with ITA #1 GMFC ITA #2 03-1449-0300 4-13 Used for A&S Unique Test on GMFC GMFC SRU ITA #3 03-1449-0400 4-14 Used for A&S Unique Tests on GMFC SRUs

W5 Cable 03-1449-0420 4-14 Used in conjunction with ITA #3 for CCA SRUs

Figure 4-11. MTS8E Self-Test ITA, 03-1449-0500

Guided Missile Flight Controller ITA#1. GMFC ITA #1, PN 03-1449-0200, includes a Virginia panel interface mounted at the rear of the ITA along with three front mounted interface connectors. Cables W1 thru W3 (P/Ns 03-1449-0230 thru -0250) provide the interface required at MTS8E to meet all GMFC functional test requirements. A Load Box, P/N 03-1449-0220, is used during GMFC testing to provide simulated in-circuit loading while cable W4, P/N 03-1449- 0260, is included to complete the interface between the load and the GMFC. This ITA is used to conduct functional tests on the GMFC. The following figure depicts the ITA and Load Box with the various interface cables connected.

Figure 4-12. GMFC ITA #1, Load Box, & Cables W1-W4, 03-1449-0200, -0220 thru -0250

Guided Missile Flight Controller ITA#2. GMFC ITA #2, PN 03-1449-0300, includes a Virginia panel interface mounted at the rear of the ITA along with a three legged pigtail cable secured to the front panel of the ITA. The pigtail cable legs mate to the GMFC and provide the interface required at MTS8E to meet all GMFC A&S Unique test requirements. This ITA is used to conduct A&S Unique tests on the GMFC. The following figure depicts the ITA.

Figure 4-13. GMFC ITA #2, 03-1449-0300

GMFC Shop Replaceable Unit ITA#3. GMFC SRU ITA #3, PN 03-1449-0400, includes a Virginia panel interface mounted at the rear of the ITA along with a 2 legged pigtail cable and a single front mounted interface connector. The pig tail cable legs mate with the EMI Filter for A&S Unique tests while Cable W5, P/N 03-1449-0260, provides the interface required at MTS8E to meet all GMFC Circuit Card Assembly A&S Unique test requirements using ITA #3.

The following figure depicts the ITA and W5 Cable with an SRU attached to the W5 Cable.

Figure 4-14. GMFC SRU ITA #3, 03-1449-0400, W5 Cable, -0260

4.3 Software

The executable GMFC A&S Program software was developed using LabView. A single executable program contains all of the sub-routines required to self-test the test station, self-test the GMFC and GMFC SRU ITAs, test the GMFC and GMFC SRUs, acquire the data and archive the results. Two separate documents contain a detailed description of the software and its functionality. Those documents include the Software Program Specification, document number 03-1449-SPS-MTS8E, and the Software Users Manual, document number 03-1449-

SUM-MTS8E.

4.3.1 ALCM GMFC A&S Test Executive

This is the top-level program that is launched from the Windows desktop. The program handles all initialization functions and then displays a date and time verification screen. The operator has the option to exit to Windows to correct any discrepancies in the date or time or enter the GMFC A&S test sequence. Upon entry into the test sequence four selectable test routines are displayed as selectable buttons shown in Figure 4-15.

Figure 4-15. ALCM GMFC A&S Tests

The following paragraphs describe the sub-routines available on the various display screens within these four test routines.

4.3.2 MTS8E Test Station Self Test Routine

Upon selecting the MTS8E Test Station Self Test button, the following screen is displayed.

Figure 4-16. MTS8E Test Station Self Test

From the test screen shown in Figure 4-16, the operator can select to exit the test mode to return to the ALCM A&S Test Selection panel or either of 2 test routines, namely Test Station Self test and DMM AutoCal. The following paragraphs describe the functionality of the 2 test routines.

4.3.2.1 Test Station Self Test

1) Test Station Self Test selection opens the Operator Notebook Entry panel (Figure 4-17) where the operator name is entered and a click outside the entry field activates the CONTINUE button.

Figure 4-17. Operator Notebook Entry Screen

2) The operator has the option of selecting the Clear button to clear the data field or the Cancel button to return to the MTS8E Test Station Self Test screen. Selecting the CONTINUE button launches the A&S Test Monitor screen.

NOTE

The test monitor screen (as shown in Figure 4-18) is often referred to throughout these procedures. It provides the operator with INSTRUCTIONS/STATUS updates, displays test results as the test is executed, a means to STOP and EXIT, a PRINT DATA function, and the opportunity to CONTINUE when displayed instructions are completed. Upon exiting the A&S Test Monitor screen all test results and associated header information from the Operator Notebook Entry screen are archived to the MTS8E hard drive.

Figure 4-18. A&S Test Monitor Screen

3) The operator is prompted to perform various maintenance actions during the test. Appropriate pictures of the operations to be performed are included in the Instructions/Status window on the A&S Test Monitor screen. When instructions are completed and the operator selects the Continue button, the software returns to test in progress.

4) The operator can select the Stop button anytime during a test which will change the Stop button to an Exit button and then require the operator to Print Data and/or Exit to the MTS8E Test Station Self Test screen.

5) At the end of the test, the Print Data button is activated and the Stop button changes to an Exit button. The operator can then select Print Data and/or Exit to the MTS8E Test Station Self Test screen.

4.3.2.2 DMM AutoCal

DMM AutoCal selection launches the DMM AutoCal screen. A pop-up screen advises the operator that the AutoCal takes 15 minutes to complete and offers the opportunity for the operator to continue or exit. If continued, the AutoCal screen displays the time remaining for Cal completion, and the program cannot be aborted. Upon completion the program returns to the MTS8E Test Station Self Test.

4.3.3 GMFC Functional Test

1) From the ALCM A&S Test Selection screen, Figure 4-15, the operator can select the GMFC Functional Test which will enter the test routine by displaying the screen display shown in Figure 4-19.

Figure 4-19. GMFC Functional Test

2) The operator can select the Exit button to return to the ALCM A&S Test Selection screen or any one of 5 test routines, namely, DMM AutoCal, ITA Self Test, GMFC Functional Test, GMFC Environmental Test, and GMFC Test Step. A selection of the DMM AutoCal enters the routine described in section 4.3.2.2. The remaining test routines are described below.

4.3.3.1 ITA Self Test

ITA Self Test selection opens the Operator Notebook Entry panel (see Figure 4-17) where the operator enters the associated GMFC serial number or the words “self-test” and clicks outside the entry field to activate the CONTINUE button. Selecting the CONTINUE button launches the A&S Test Monitor screen (see Figure 4-18). Refer to section 4.3.2 for details on operator options and actions within the self test routine.

4.3.3.2 GMFC Functional Test

1) From the GMFC Functional Test menu a selection of the GMFC Functional Test launches the OPERATOR NOTEBOOK ENTRY screen as displayed in Figure 4-20.

Figure 4-20. GMFC Functional Test Operator Notebook Entry Screen

2) The operator has the opportunity to Cancel and return to the GMFC Functional Test screen, select a Clear option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen (see Figure 4-18). Operator instructions are provided on the Test Monitor screen to complete the test, stop the test, print the test data and exit the test.

4.3.3.3 GMFC A&S Environmental Test

1) From the GMFC Functional Test menu a selection of the GMFC A&S Environmental Test launches the OPERATOR NOTEBOOK ENTRY screen as displayed in Figure 4-20.

2) The operator has the opportunity to Cancel and return to the GMFC Functional Test screen, select a Clear option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen (see Figure 4-18). Operator instructions are provided on the Test Monitor screen to complete the test, stop the test, print the test data and exit the test.

4.3.3.4 GFMC Test Step

1) During troubleshooting efforts, the operator may want to perform an individual test rather than an end-to-end test to expedite the process. By selecting the GMFC Test Step routine, the operator is given the ability to run the minimal number of steps required to augment the troubleshooting effort. Once selected, the Test Step Entry screen is displayed as shown in Figure 4-21.

Figure 4-21. GMFC Test Sep

2) The operator enters the applicable test step to execute and the test routine automatically enters the A&S Test Monitor screen. Operator instructions are provided on the Test Monitor screen to complete the test, stop the test, print the test data and exit the test. Exiting the test returns the program to the GMFC Functional Test screen.

4.3.4 GFMC A&S Unique Test

1) From the ALCM A&S Test Selection menu, Figure 4-15, a selection of the GMFC A&S Unique Test launches the GMFC A&S Unique Tests selection screen as displayed in Figure 4- 22.

Figure 4-22. GMFC A&S Unique Test Selection

2) The operator can select the Exit button to return to the ALCM A&S Test selection screen, DMM AutoCal, ITA Self Test, or GMFC A&S Unique Tests. A selection of the DMM AutoCal enters the routine described in section 4.3.2.2 while the ITA Self Test follows the test described in section 4.3.3.1. Selection of the GMFC A&S Unique Tests enters the routine described in section 4.3.4.1.

4.3.4.1 GMFC A&S Unique Test

1) From the GMFC A&S Unique Test menu a selection of the GMFC A&S Unique Test launches the OPERATOR NOTEBOOK ENTRY screen as displayed in Figure 4-20.

2) The operator has the opportunity to Cancel and return to the GMFC A&S Unique Test screen, select a Clear option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen (see Figure 4-18). Operator instructions are provided on the Test Monitor screen to complete the test, stop the test, print the test data and exit the test.

4.3.5 GMFC SRU A&S Tests

1) From the ALCM A&S Tests Selection menu, Figure 4-15, the operator selects the GMFC SRU Tests button to launch the GMFC SRU A&S Tests selection screen as displayed in Figure 4-22.

Figure 4-23. GMFC SRU A&S Unique Tests

2) The operator can select the Exit button to return to the ALCM A&S Test Selection screen or any one of 11 test routines, namely, DMM AutoCal, ITA J1 Self Test, ITA J2 & J3 Self Test, and any of the A1 thru A9 SRUs. A selection of the DMM AutoCal enters the routine described in section 4.3.2.2. The remaining test routines are described below.

4.3.5.1 ITA J1 Self Test or ITA J2&J3 Self Test

A selection of either self test button opens the Operator Notebook Entry panel (see Figure 4-17) where the operator enters his name and clicks outside the entry field to activate the CONTINUE button. Selecting the CONTINUE button launches the A&S Test Monitor screen (see Figure 4- 18). Refer to section 4.3.2 for details on operator options and actions within the self test routine.

4.3.5.2 A1 thru A9 SRU Tests

A selection of one of the A1 thru A9 SRU tests launches the OPERATOR NOTEBOOK ENTRY screen, as displayed in Figure 4-20, where the operator enters appropriate data in the fields provided. After all data entry has been completed the operator clicks outside the data field areas to activate the CONTINUE button. Selecting Continue launches the A&S Test Monitor screen (see Figure 4-18). Operator instructions are provided on the Test Monitor screen to complete the test, stop the test, print the test data and exit the test.

5 Calibration & Alignment

5.1 MTS8E Test Station

Presently, three Tester Replaceable Units (TRUs) from the test station require periodic calibration.

Model Number Description

Recommended Calibration

Interval

HP 3458A 8.5-Digit Digital Multimeter 12 months

HP 4263 LCR Meter 12 months

TDS 4004C Oscilloscope 12 months

Table 5-1. Test Station Calibration Information

Calibration requirements for each TRU are individually discussed below. Each OEM recommends a 12-month calibration cycle. Due to the complexity of the calibration requirements and the need for special standards traceable to NIST, it is recommended that the instruments be shipped to the OEM or a certified PMEL lab annually for calibration.

HP 3458A Digital Multi-meter. The following table was copied from Agilent/Keysight’s web site to reflect recommended calibration frequency and their dated cost information.

Model Number Price* Description (As of: January 5, 2015)

Recommended Calibration

Interval

3458A 8.5-Digit Digital Multimeter 12 months

US$ 2795.00 Standard repair

US$ 609.00 Agilent Commercial Calibration

US$ 912.00 Z540 Compliant Calibration.

Table 5-2. 3458A Calibration Information

HP 4263 LCR Meter. The following table was copied from Agilent/Keysight’s web site to reflect recommended calibration frequency and their dated cost information.

Model Number Price* Description (As of: January 5, 2015)

Recommended Calibration

Interval

4263 LCR Meter 12 months

US$ 1952.00 Standard repair

US$ 328.00 Agilent Commercial Calibration

US$ 521.00 Z540 Compliant Calibration.

Table 5-3. 4338B Calibration Information

TEK TDS 2004C Oscilloscope. The following table was copied from the Tektronix web site to reflect recommended calibration frequency and their dated cost information.

Model Number Price* Description (As of: January 5, 2015)

Recommended Calibration

Interval

TDS2004C Oscilloscope 12 months

US$ 835.00 Standard repair

US$ 200.00 Agilent Commercial Calibration

US$ 300.00 Z540 Compliant Calibration.

5.2 Ancillary Equipment

All Calibration / Programmed Maintenance Inspection (PMI) Requirements for the ancillary equipment are contained in the MTS8 Users Manual and will not be duplicated here.

5.3 MTS8E Calibrated Component Procedures

5.3.1 HP 3458A Digital Multimeter

5.3.1.1 DMM AutoCal

During the course of testing the operator may wish to perform a built in AutoCal on the DMM for maximum accuracy and/or to assure the DMM is functioning properly. The DMM AutoCal option is provided during all ALCM A&S test sequences as an operator selectable function that is completed under automatic control of the test station. This test should be completed before any test cycle and at 30 day intervals during extended test flows.

5.3.1.2 Removal

a. Turn off the MTS8E test set.

b. Disconnect the Input, Sense, Current (I), ground, GPIB connectors, and power cord.

c. Remove four face plate screws.

d. Remove the Multimeter from the test fixture and package for shipment.

e. Contact Rothe Development (648-3131, Jose X19) for pickup.

5.3.1.3 Installation

a. Install the Multimeter into the test fixture.

b. Install four face plate screws.

c. Connect the Input, Sense, Current (I), ground, GPIB connectors, and power cord (see figure below).

d. Select “Rear Terminals” button in upper right corner of front panel.

Figure 5-1. HP 3458A Digital Multimeter IO Connection

5.3.2 HP4263 LCR Meter

5.3.2.1 Removal

a. Turn off the MTS8E test set.

b. Rotate the 2 level arms (see Figure 5-2) counterclockwise to release the coaxial connections of the Alligator Clip Assembly from the LCR Meter interface connectors.

c. Position the Alligator Clip Assembly out of the way for LCR Meter removal.

d. Disconnect the GPIB connectors and power cord from the rear of the meter.

e. Remove four face plate screws.

f. Remove the meter from the test fixture and package for shipment.

g. Contact Rothe Development (648-3131, Jose X19) for pickup.

5.3.2.2 Installation

a. Install the meter into the test fixture.

b. Install four face plate screws.

c. Align the Alligator Clip Assembly so that the 2 coaxial connectors controlled by the Lever Arms (see Figure 5-2) will mate with the “LCUR and HCUR connectors on the meter.

d. Connect the Alligatror Clip by gently pressing the connectors together and using the Lever Arms to make the final connection with the coax connectors on the meter.

e. Connect the GPIB connector and power cord.

Figure 5-2. HP 4263 LCR Meter Interface Connections

HP16089D

Alligator Clip

Assy

Fr ont View

Lever Arms

GPIB

VAC

Rear View

5.3.3 TDS 2004 Oscilloscope

5.3.3.1 Scope Functional Check

NOTE

If there is uncertainty in the functional performance of the scope complete the following steps. See Figure 5-3 for reference during the following test sequence.

Fr ont View

AutoSet

1 3 42

Default Setup

PROBE COMP

Terminals

Figure 5-3. TEK TDS 2004C Scope Front Panel

a. Turn off the scope.

b. Disconnect the scope input line BNC connectors at CH1 thru CH4.

c. Turn on the oscilloscope.

d. Push the “Default Setup” button. (The default Probe option attenuation setting is 10X).

e. Connect the TPP0101/TP0201 probe to channel 1 on the oscilloscope. To do this, align the slot in the probe connector with the key on the CH 1 BNC, push to connect, and twist to the right to lock the probe in place.

f. Connect the probe tip and reference lead to the PROBE COMP terminals.

g. Press the channel select Menu “1” button (yellow).

h. Press the “Auto Set” button.

i. After a short pause a signal trace will be presented on the scope display. Verify that the signal is a 5.0 V peak-to-peak square wave at 1 kHz. (Note: The documentation on the scope does not provide limits for this functional test, however when new and calibrated as received, the signal was 5.12 V p-p signal at 1.0 kHz.)

j. Press the channel select Menu “1” button 2 times to remove the trace from the scope.

k. Disconnect the TPP0101/TP0201 probe from channel 1 on the oscilloscope.

l. Connect the TPP0101/TP0201 probe to channel 2 on the oscilloscope.

m. Press the channel select Menu “2” button (blue).

n. Press the “Auto Set” button.

o. After a short pause a signal trace will be presented on the scope display. Verify that the signal is a 5.0 V peak-to-peak square wave at 1 kHz. (Note: The documentation on the scope does not provide limits for this functional test, however when new and calibrated as received, the signal was 5.12 V p-p signal at 1.0 kHz.)

p. Press the channel select Menu “2” button 2 times to remove the trace from the scope.

q. Disconnect the TPP0101/TP0201 probe from channel 2 on the oscilloscope.

r. Connect the TPP0101/TP0201 probe to channel 3 on the oscilloscope.

s. Press the channel select Menu “3” button (pink).

t. Press the “Auto Set” button.

u. After a short pause a signal trace will be presented on the scope display. Verify that the signal is a 5.0 V peak-to-peak square wave at 1 kHz. (Note: The documentation on the scope does not provide limits for this functional test, however when new and calibrated as received, the signal was 5.12 V p-p signal at 1.0 kHz.)

v. Press the channel select Menu “3” button 2 times to remove the trace from the scope.

w. Disconnect the TPP0101/TP0201 probe from channel 3 on the oscilloscope.

x. Connect the TPP0101/TP0201 probe to channel 4 on the oscilloscope.

y. Press the channel select Menu “4” button (green).

z. Press the “Auto Set” button.

aa. After a short pause a signal trace will be presented on the scope display. Verify that the signal is a 5.0 V peak-to-peak square wave at 1 kHz. (Note: The documentation on the scope does not provide limits for this functional test, however when new and calibrated as received, the signal was 5.12 V p-p signal at 1.0 kHz.)

bb. Disconnect the TPP0101/TP0201 probe from channel 4 and the comp terminals on the oscilloscope. Stow the probe.

cc. Turn off the scope.

dd. Connect the scope input line BNC connectors at CH1 thru CH4.

ee. Turn on the oscilloscope.

5.3.3.2 Scope Self Calibration

The self calibration routine optimizes the oscilloscope signal path for maximum measurement accuracy. The routine can be run at any time but should always be completed if the ambient temperature changes by 5 °C (9 °F) or more. The routine takes about two minutes.

For accurate calibration, power on the oscilloscope and wait twenty minutes to ensure it is warmed up.

a. To compensate the signal path, disconnect any probes or cables from the input connectors

b. Access the Utility ► Do Self Cal option, and follow the directions on the screen.

5.3.3.3 Removal

a. Turn off the MTS8E test set.

b. Disconnect the USB connector and power cord from the rear of the scope (Figure 5-3).

c. Disconnect the five coax cables from the Ch 1 – Ch 4 and the External Trigger inputs on the front of the scope and position them out of the way for oscilloscope removal.

d. Remove four face plate screws.

e. Remove the oscilloscope from the test fixture and package for shipment.

f. Contact Rothe Development (648-3131, Jose X19) for pickup.

5.3.3.4 Installation

g. Install the oscilloscope into the test fixture.

h. Install four face plate screws.

i. At the front of the scope, connect the five coax cables to Ch 1 – Ch 4 and External Trigger inputs (Figure 5-3).

j. At the rear of the scope, connect the USB connector and power cord.

Figure 5-4. TDS 2004 Oscilloscope Connections

CH 1 CH 2 CH 3 CH 4

Trig

Input

Fr ont View

USB 2.0

VAC

Rear View

6 GMFC A&S Test Procedures The test flow for the GMFC and the GMFC SRUs are included in Section 10 of this manual.

During the operation of the MTS8E the operator has many opportunities to deviate from the normal test sequence. Screen prompts at the control PC provide the operator sufficient guidance in the event of an abnormal test condition so that testing could either be completed or the test sequence can be properly terminated. The procedures outlined here provide the normal sequence of events given that there are no failures or abnormalities during a test sequence.

Prior to use, a self-test of MTS8E Test Station must be successfully completed. The Self-Test is a selectable feature within each component test function. Section 6.2 details the procedures for completing the self-test.

6.1 MTS8E Test Station Power Up Procedure

CAUTION

Do not conduct A&S tests using instruments that are outside of their calibration interval. See table 5-1 for a complete list of instruments and equipment requiring calibration.

a. Verify that the following instruments are within their current calibration interval.

o HP 3458A Digital Multi-meter o TEK TDS 2004C Oscilloscope o HP 6263 LCR Meter

b. At the Emergency Shut Down Panel on the MTS8E, turn on the ENABLE key clockwise to the On position, and then rotate the Enable key to the Start position. If necessary, press and release the EMERGENCY STOP switch and repeat this step.

c. Turn on the remaining MTS8E components by selecting the ON switch located on the front, upper right corner of the station under a protective clear plastic cover.

The Scope Self Calibration routine, paragraph

5.3.3.2 should be run every 30 days. If the scope is suspect, refer to paragraph 5.3.3.1 for functional testing.

d. Verify all MTS8E COTS Instruments are powered on.

e. Turn on the test station Monitor.

On boot up, the embedded controller in the MTS8E will proceed to a login screen that requires a password entry only, as there is only one user

(MTS8E).

f. When prompted, enter the password as “password”.

g. Double click the “ALCM A&S.Exe” icon located on the Desktop to begin the executable ALCM Aging & Surveillance Test Program.

h. Verify the date and time as prompted by the Date and Time Screen. Correct as necessary and then select the OK button.

i. From the ALCM A&S Test Selection screen, select the desired test and proceed to the appropriate section as indicated below:

• MTS8E Test Station Self Test Section 6.2

• GMFC A&S Unique Tests Section 6.3.1

• GMFC Functional Tests Section 6.3.2

• GMFC SRU A&S Tests

• GMFC Environmental Tests

6.2 MTS8E Test Station Self Test Procedure

The DMM is used to perform critical measurements during all GMFC A&S test procedures. An AutoCal must be conducted every 30 days and can be run from MTS8E Test Station Self Test screen or from any of the other major test select screens (i.e., GMFC A&S Unique Tests, GMFC Functional Tests, or GMFC SRU A&S Tests).

a. Select the DMM AutoCal button. The AutoCal takes approximately 15 minutes to complete. Select “OK” to continue AutoCal or “Cancel” to return to the applicable A&S Test screen.

NOTE

The MTS8E A&S Test Set self test must be run prior to GMFC or GMFC SRU testing and can be completed.

b. Select the Test Station Self Test button.

c. At the OPERATOR NOTEBOOK ENTRY PANEL, the operator is prompted to enter the UUT serial number associated with the current test. This can be a valid serial number, or the words “NONE” or “Self Test”. Click in the gray area outside the serial number window and the “Continue” button will become active.

d. Select the CONTINUE button to enter the Self Test Selection screen.

At the Self Test Selection screen the operator has the option of running the complete self-test or individual test step. The latter capability is provided as a troubleshooting aid. The Single Test Step button is not activated until a test step number is entered. The complete self-test must be completed prior to A&S testing.

e. Select the Complete Self Test button.

f. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as installing the self-test Interface Test Adapter. Select the CONTINUE button to proceed with the test after completing operator instructions. Test results are displayed as the test proceeds. A STOP button is provided as a means of terminating the test at the discretion of the operator.

g. At the end of the self-test, the operator can review the test results, select the PRINT DATA button or select the EXIT button to return to the applicable A&S Test screen.

h. Proceed to the appropriate section as indicated below:

• GMFC A&S Unique Tests Section 6.3.1

• GMFC Functional Tests Section 6.3.2

• GMFC SRU A&S Tests Section 6.3.3

• GMFC Environmental Tests Section 6.3.4

6.3 ALCM A&S Test Selection

6.3.1 GMFC A&S Unique Tests

NOTE

Follow Power Up procedures in Section 6.1 to turn on MTS8E Test Station.

The MTS8E Self Test Procedure in Section 6.2 must be completed prior to running GMFC tests.

GMFC ITA #2 is used during the A&S GMFC Unique Test sequence. Therefore, the Self Test Procedure must be conducted on the ITA prior to use.

6.3.1.1 GMFC ITA #2 Self Test Procedure

a. At the ALCM A&S Test Selection screen select the” GMFC A&S Unique Tests” button.

b. At the GMFC A&S Unique Tests screen, select the “GMFC ITA#2 Self Test” button.

c. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as installing the GMFC Interface Test Adapter and connecting and disconnecting interface cables at the surface mounted self test connectors on the ITA. Select the CONTINUE button to proceed with the test after completing operator instructions. Test results are displayed as the test proceeds. A STOP button is provided as a means of terminating the test at the discretion of the operator.

d. At the end of the test, the operator can review the test results, select the PRINT DATA button or select the EXIT button to return to the A&S Test Selection screen.

6.3.1.2 GMFC A&S Unique Test Procedure

• Additional GMFCs can be tested by looping through this procedure.

• Failures and/or other anomalous conditions must be reported in accordance with the guidance in the section of this manual labeled Failure Reporting Procedure.

• The data from each test is automatically archived on the hard drive of the PC controller. The Data Archives section of this manual discusses the file directory structure and the process to review previous data results on tests run on the MTS8E.

• This test is performed with the SAF plug removed.

a. From the ALCM A&S Test Selection screen, select the GMFC A&S Unique Tests button to begin the test.

b. Complete the GMFC ITA #2 Self Test if not yet completed (see 6.3.1.1).

c. At the GMFC A&S Tests screen, select the GMFC A&S Unique Tests button

d. At the OPERATOR NOTEBOOK ENTRY screen, the operator must either enter data or select from drop down menus to fill the data fields displayed. CANCEL and CLEAR ALL buttons provide the operator flexibility during the test sequence. Once all data has been entered, the operator can select the CONTINUE button.

e. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as connecting and disconnecting interface cables between the ITA and the GMFC. Select the CONTINUE button to proceed with the test after completing operator instructions. Test results are displayed as the test proceeds. A STOP button is provided as a means of terminating the test at the discretion of the operator.

f. At the end of the test, the operator can review the test results, select the PRINT DATA

6.3.2 GMFC Functional Tests

The GMFC Functional test sequence normally includes a self test of the GMFC ITA #1, a Functional Test of the GMFC, and the Environmental Test of the GMFC. After these sequences are completed the GMFC is disassembled for GMFC SRU Test IAW section 6.3.3. After all SRU test have been completed the GMFC is reassembled and it is subjected to bond tests as well as a repeat of the GMFC Functional test prior to return to the depot facility for repair or use as deemed appropriate.

6.3.2.1 GMFC ITA #1 Self Test

a. At the ALCM A&S Test Selection screen select the” GMFC Functional Tests” button.

b. At the GFMC Functional Test screen, select the “ITA #1 Self Test” button.

c. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as installing the GMFC Interface Test Adapter and connecting and disconnecting interface cables at the load box and the load box surface mounted self test connectors. Select the CONTINUE button to proceed with the test after completing operator instructions. Test results are displayed as the test proceeds. A STOP button is provided as a means of terminating the test at the discretion of the operator.

d. At the end of the test, the operator can review the test results, select the PRINT DATA

6.3.2.2 GMFC Functional Test Procedure

Additional GMFCs can be tested by looping through this procedure.

Failures and/or other anomalous conditions must be reported in accordance with the guidance in the section of this manual labeled Failure Reporting Procedure.

The data from each test is automatically archived on the test station controller. The Data Archives section of this manual discusses the file directory structure and the process to review previous data results on tests run on the MTS8E.

a. From the ALCM A&S Test Selection screen, select the GMFC Functional Tests button to

b. Complete the GMFC ITA #1 Self Test if not yet completed (see 6.3.2.1).

c. Select the GMFC Functional Test button to begin the test.

d. At the OPERATOR NOTEBOOK ENTRY screen, the operator must either enter data or select from drop down menus to fill the data fields displayed. CANCEL and CLEAR ALL buttons provide the operator flexibility during the test sequence. Once all data has been entered, the operator can select the CONTINUE button.

e. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as connecting and disconnecting interface cables between the ITA and the GMFC. Select the CONTINUE button to proceed with the test after completing operator instructions. Test results are displayed as the test proceeds. A STOP button is provided as a means of terminating the test at the discretion of the operator.

f. At the end of the test, the operator can review the test results, select the PRINT DATA button or select the EXIT button to return to the A&S Test Selection screen.

6.3.3 GMFC SRU Tests

The GMFC SRU test sequence includes 2 self tests (one for EMI Filter testing and one for CCA testing), as well as the DMM AutoCal sequence and 8 options to select either the EMI Filter test or one of the seven various CCA tests.

Follow Power Up procedures in Section 6.1 to turn on MTS8E Test Station.

The MTS8E Self Test Procedure in Section

6.2 must be completed prior to running GMFC SRU tests.

The GMFC SRU ITA Self Test must be completed daily prior to SRU testing.

6.3.3.1 GMFC SRU ITA Self-Test Procedure

Two self tests are selectable from the GMFC SRU A&S TESTS screen. They include the ITA J1 Self Test for CCA tests and the ITA J2&J3 Self Test for the EMI Filter test.

The applicable GMFC SRU ITA Self Test procedure must be successfully completed prior to testing the EMI Filters or the CCA SRUs.

a. Select either the “ITA J1 Self Test” or the “ITA J2 & J3 Self Test” button.

b. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as installing the GMFC SRU ITA and connecting and disconnecting interface cables between the ITA and the self test connectors. Select the CONTINUE button to proceed with the test after completing operator instructions.

Test results are displayed as the test proceeds. A STOP button is provided as a means of terminating the test at the discretion of the operator.

c. At the end of the test, the operator can review the test results, select the PRINT DATA button or select the EXIT button to return to the A&S Test Selection screen.

6.3.3.2 A1 EMI Filter Test Procedure

The GMFC SRU Self Test Procedure, 6.3.3.1, for ITA J2 & J3 must be completed prior to EMI Filter testing.

Additional EMI Filters can be tested by looping through this procedure.

Failures and/or other anomalous conditions must be reported in accordance with the guidance in the section of this manual labeled Failure Reporting Procedure.

The data from each test is automatically archived on the hard drive of the test station controller. The Data Archives section of this manual discusses the file directory structure and the process to review previous data results on tests run on the MTS8E.

a. From the ALCM A&S Test Selection screen, select the GMFC SRU A&S Tests button.

b. Verify that the ITA self test has been completed in accordance with 6.3.3.1 (ITA J2 & J3 Self Test).

c. At the GMFC SRU A&S Tests screen, select the A1 EMI Filter test button to begin the test.

d. At the OPERATOR NOTEBOOK ENTRY screen, the operator must either enter data or select from drop down menus to fill the data fields displayed. CANCEL and CLEAR ALL buttons provide the operator flexibility during the test sequence.

Once all data has been entered, the operator can select the CONTINUE button.

e. At the A&S Test Monitor screen, operator instructions are found in the INSTRUCTIONS/STATUS display window. These instructions include such things as connecting and disconnecting interface cables between the ITA and the EMI Filter. Select the CONTINUE button to proceed with the test after completing operator instructions. Test results are displayed as the test proceeds.