Attachment_5_MTS-8_Test_Station_Users_Manual.pdf

This document is provided for informational purposes only.

03-1249-TSUM (Month Day, 2009)

MTS-8 TEST STATION USER’S MANUAL

For The

AIR LAUNCHED CRUISE MISSILE (ALCM)

In Support of the

AGING & SURVEILLANCE PROGRAM

(AGM-86)

Prepared for:

498th MSUG

7339 Sentry Blvd

Tinker AFB, OK 73145

Revision History

Revision Date Summary of Changes

Basic TBD

Table of Contents Section Page

1 SAFETY SUMMARY

1.1 General WARNINGS

1.2 High Potential Test 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

4.2 Interface Test Adapters

4.3 Instrumentation Rack

4.3.1 Digital Multi-Meter

4.3.2 Oscilloscope

4.3.3 Milliohmmeter

4.3.4 Impact Sensor Accelerometer Signal Conditioner

4.3.5 HYPOT

4.3.6 AC Power Distribution Box

4.3.7 Power Supplies

4.4 Software

4.4.1 A&S Test Executive

4.4.2 Warhead Arming Device Routines

4.4.3 Impact Sensor Routines

4.4.4 Rotary Switch Routines

5 CALIBRATION & ALIGNMENT

5.1 MTS-8 Test Station

5.2 Ancillary Equipment

5.3 A&S Complex Calibrated Component Replacement Procedures

5.3.1 Model 979 HE Mass Spectrometer Leak Detector

5.3.2 Tension Compression Stand

5.3.2.1 Advanced Force Gauge AFG 500N

5.3.2.1.1 Removal

5.3.2.1.2 Installation

5.3.2.2 TC2 Height Scale (Not Used)

5.3.2.2.1 Removal

5.3.2.2.2 Installation

5.3.3 Accelerometers and Simulator

5.3.4 Electronic Test Equipment

5.3.4.1 HP 3458A Digital Multimeter

5.3.4.1.1 Removal

5.3.4.1.2 Installation

5.3.4.2 TDS 420 Oscilloscope

5.3.4.2.1 Removal

5.3.4.2.2 Installation

5.3.4.2.3 Verify Internal Diagnostics Pass

5.3.4.3 7550DT Dielectric Analyzer (Hypot Tester)

5.3.4.3.1 Removal

5.3.4.3.2 Installation

6 ALCM A&S TEST PROCEDURES

6.1 MTS-8 Test Station & Station Controller Power Up Procedure

6.2 MTS-8 Test Station & Station Controller Self Test Procedure

6.3 ALCM A&S Test Selection

6.3.1 Warhead Arming Device

6.3.1.1 WAD ITA #1 Self Test Procedure

6.3.1.2 WAD ITA #2 Self-Test Procedure

6.3.1.3 WAD A&S Unique Test Procedure

6.3.1.4 WAD Helium Leak Check Procedure

6.3.1.4.1 WAD Helium Leak Test Stand Setup

6.3.1.4.2 WAD Helium Leak Test

6.3.1.4.3 WAD Helium (He) Leak Sniff Test

6.3.1.4.4 WAD Helium Leak Post-Test

6.3.1.4.5 WAD Helium Leak Test Stand Shutdown

6.3.1.5 WAD Basic Functional Test Procedure

6.3.1.6 WAD Environmental Test Procedure

6.3.1.7 WAD Extended Functional Test Procedure

6.3.2 Impact Sensor

6.3.2.1 Impact Sensor Static Test ITA #1 Self-Test Procedure

6.3.2.2 Impact Sensor Static Test Procedure

6.3.2.3 Impact Test Alignment Check

6.3.2.4 Impact Sensor Dynamic Test ITA #2 Self-Test Procedure

6.3.2.5 Impact Sensor Dynamic Test Procedure

6.3.2.6 Shock Machine Shutdown Procedure

6.3.3 Rotary Switch

6.3.3.1 RS ITA #1 Self-Test Procedure

6.3.3.2 RS ITA #2 Self-Test Procedure

6.3.3.3 Rotary Switch ITA #3 Self-Test Procedure

6.3.3.4 RS A&S Unique Test Procedure

6.3.3.5 RS Helium Leak Check Procedure

6.3.3.5.1 RS Helium Leak Test Stand Setup

6.3.3.5.2 RS Helium Leak Test

6.3.3.5.3 RS Helium (He) Leak Sniff Test

6.3.3.5.4 RS Helium Leak Post-Test

6.3.3.5.5 RS Helium Leak Test Stand Shutdown

6.3.3.6 RS Basic Functional Test Procedure

6.3.3.7 RS Environmental Test Procedure

6.3.3.8 RS Extended Functional Test Procedure

7 FAILURE REPORTING PROCEDURE

8 MTS-8 DATA ARCHIVES (STATIC TEST EXAMPLE)

9 TEST DATA ARCHIVES

10 A&S TEST FLOWS

11 ALCM A&S TEST COMPLEX DRAWING TREE

12 SHOCK MACHINE OPTICAL READER ALIGNMENT PROCEDURE

13 TROUBLESHOOTING

13.1 Controller

13.1.1 Monitor

13.2 MTS-8 Test Station

List of Tables Table Page

Table 2-1. Handling Equipment

Table 2-2. Consumables

Table 4-1. Test Program Support Files

Table 5-1. Test Station Calibration Information

Table 5-2. 3458A Calibration Information

Table 5-3. 4338B Calibration Information

Table 5-4. 4263B Calibration Information

Table 5-5. Ancillary Equipment Calibration and PMI Requirements

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

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

List of Figures Figure Page

Figure 2-1. Warhead Arming Device Vibration Fixture

Figure 2-2. Rotary Switch Vibration Fixture

Figure 2-3. Rotary Switch Timing Test Fixture

Figure 2-4. Rotary Switch Force Displacement Test Fixture

Figure 2-5. Shock Test Machine Holding Fixture

Figure 2-6. Furnace

Figure 4-1. MTS-8 Test Station and Station Control PC

Figure 4-2. Controller (Rear View) and ALCM A&S Test Complex I/O

Figure 4-3. MTS8 Self-Test ITA

Figure 4-4. Impact Sensor ITA #1, 03-1039-0200 (Static Test)

Figure 4-5. Impact Sensor ITA #2, 03-1162-0900 (Dynamic Test)

Figure 4-6. Rotary Switch ITA #1 (Loadbox and Interface Chassis), 03-1249-0500

Figure 4-7. Rotary Switch ITA #1 Loadbox (Internal View)

Figure 4-8. Rotary Switch ITA #2, 03-1249-0700

Figure 4-9. Rotary Switch ITA #3, PN 03-1162-0800

Figure 4-10. Warhead Arming Device ITA #1 (Loadbox and Chassis), 03-1039-0300

Figure 4-11. Warhead Arming Device ITA #1 Loadbox (Internal Views)

Figure 4-12. Warhead Arming Device ITA #2, 03-1162-0400

Figure 4-13. HP 3458A DMM

Figure 4-14. Tektronix TDS 420A Oscilloscope

Figure 4-15. HP 4338B Milliohmmeter

Figure 4-16. Endevco 2775B Signal Conditioner

Figure 4-17. HYPOT 7550DT

Figure 4-18. AC Distribution Box Rear View

Figure 4-19. AC Distribution Box Internal View

Figure 4-20. AC Box Enable and Emergency Stop Switch

Figure 4-21. 66103A and 66104A DC Power Supplies

Figure 4-22. ALCM A&S Tests

Figure 4-23. Warhead Arming Device A&S Test

Figure 4-24. A&S Test Monitor Screen

Figure 4-25. Impact Sensor A&S Test

Figure 4-26. Impact Sensor Dynamic Test

Figure 4-27. Rotary Switch A&S Test

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

Figure 5-2. TDS 420 Oscilloscope IO Connections

Figure 5-3. 7550DT Dielectric Analyzer (Hypot Tester) IO Connections

Figure 6-1. Facility Air Supply Connection

Figure 6-2. Air Isolation and Armature Support Controls

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

Figure 6-4. Safe Link

Figure 6-5. WAD Orientation 1

Figure 6-6. Chamber Access Hole

Figure 6-7. Orientation 1 - Cable Connections

Figure 6-8. Orientation 1 - Accelerometer Placement

Figure 6-9. Accelerometer Cable Routing

Figure 6-10. Close Chamber Door

Figure 6-11. Accelerometer Breakout Box

Figure 6-12. Chamber Touch Screen

Figure 6-13. Shaker Controller Main Power Switch

Figure 6-14. Controller Desktop

Figure 6-15. Mode Key Switch

Figure 6-16. WAD Orientation 2

Figure 6-17. Orientation 2 - Cable Connections

Figure 6-18. Orientation 2 - Accelerometer Placement

Figure 6-19. WAD Orientation 3

Figure 6-20. Orientation 3 - Cable Connections

Figure 6-21. Orientation 3 - Accelerometer Placement

Figure 6-22. Mechanical Safing Link

Figure 6-23. Calibration Certificate

Figure 6-24. Accelerometer Simulator On/Off Switch

Figure 6-25. Accelerometer Simulator Output Connection

Figure 6-26. Pump Fluid Level

Figure 6-27. He Leak Tester Power Switch

Figure 6-28. Extension Cable P4 connected to He Leak Test Stand J4

Figure 6-29. Pressure Gauge LED

Figure 6-30. He Regulator

Figure 6-31. Facility Air Supply

Figure 6-32. Removing Excess Paint from Leak Test Port

Figure 6-33. Removing Leak Test Port Screw

Figure 6-34. Clean Sealing Area

Figure 6-35. Clean Tester Base Plate

Figure 6-36. Remove Protective End Cap

Figure 6-37. Install Test Port Washer

Figure 6-38. Install Leak Test Adapter

Figure 6-39. Place Rubber Pad on Base Plate

Figure 6-40. Place Rotary Switch on Rubber Pad

Figure 6-41. Connect Vacuum Line

Figure 6-42. Clean Bell Jar Base

Figure 6-43. Place Bell Jar Over Rotary Switch

Figure 6-44. Apply Thin Bead of Vacuum Grease

Figure 6-45. Install Bell Jar Guard

Figure 6-46. Facility Air Supply

Figure 6-47. Air Isolation and Armature Support Controls

Figure 6-48. RS Adapter Mounted to L Fixture

Figure 6-49. Rotary Switch Orientation 1

Figure 6-50. Chamber Access Hole

Figure 6-51. Rotary Switch Orientation 1 Cable Connections

Figure 6-52. Accelerometer Placement

Figure 6-53. Accelerometer Cable Routing

Figure 6-54. Close Chamber Door

Figure 6-55. Accelerometer Breakout Box

Figure 6-56. Shaker Controller Main Power Switch

Figure 6-57. Controller Desktop

Figure 6-58. Mode Key Switch

Figure 6-59. Chamber Touch Screen Activated

Figure 6-60. Rotary Switch Orientation 2

Figure 6-61. Accelerometer Placement

Figure 6-62. Close Chamber Door

Figure 6-63. RS Orientation 3 Cable Connections

Figure 6-64. Accelerometer Placement

Figure 6-65. Close Chamber Door

Figure 10-1. WAD A&S Unique Test Flow (Less He Leak Test)

Figure 10-2. WAD He Leak Test Flow

Figure 10-3. WAD Basic Functional Test Flow

Figure 10-4. WAD Environmental Test Flow

Figure 10-5. WAD A&S Extended Functional Test Flow

Figure 10-6. Impact Sensor A&S Static Test Flow

Figure 10-7. Impact Sensor A&S Dynamic Test Flow

Figure 10-8. Rotary Switch A&S Test Flow

Figure 10-9. A&S Test Top Level Flow Diagram

Figure 12-1. Power Switch

Figure 12-2. Optical Reader

Figure 12-3. Optical Reader I/O Cable

Figure 12-4. Card Cage BNC (Optical Reader Output Signal)

Figure 12-5. Test Set Up

1 Safety Summary

1.1 General WARNINGS

DO NOT operate the MTS-8 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.

1.2 High Potential Test WARNINGS

The HYPOT generates voltages and currents that can cause harmful or fatal electric shock and must be operated by a skilled worker, trained in its use.

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 MTS-8 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 A&S tests various test components were either developed or acquired. Those components are identified in the following paragraphs.

ALCM Impact Sensors

Part number 76965-3, serial numbers 347, 523, 661, and 1369

These four impact sensors were set aside for use as part of an age sensitivity item analysis (ASIA). They are not A&S test assets.

ALCM Warhead Arming Device (WAD)

Part number 76560-5, serial numbers 265, 348, 368, and 786.

WADs 265, 348, 368, and 786 were set aside for use as part of an age sensitivity item analysis

ALCM Rotary Switch

Part number 76410-4, serial numbers 90, 413, 1025, and 1276

These four rotary switches were set aside for use as part of an age sensitivity item analysis

Accelerometer Simulator, Endevco Model 4830A

The accelerometer simulator is a battery-operated instrument that is used to electronically simulate a variety of outputs from various types of transducers. It has a menu driven LCD display to establish the appropriate settings.

Accelerometer, Endevco Model 2221D

This accelerometer is used during impact sensor testing to monitor impact switch impact and is designed specifically for vibration measurement on small structures and objects.

Accelerometer, Endevco Model 6251-10

This accelerometer is used during Warhead Arming Device and Rotary Switch 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.

Programmable Filter, Endevco Model 35771

This is a plug-in filter designed for use in the Endevco Model 2775B signal conditioner.

Accelerometer Cable, Endevco Model 3090C-240

This cable is a high reliability, low-noise softline coaxial cable. It is a premium general purpose cable designed specifically for use with piezoelectric accelerometers in severe environments.

10-32 Female to BNC Male Adapter

This adapter is used during the impact test alignment check to adapt the 3090C-240 cable, which has a 10-32 coax male plug, to one of the female BNC connectors on the Model 4830A Accelerometer Simulator.

Accelerometer Simulator Model 4830A

The ENDEVCO® Model 4830A is a battery operated instrument that is used to electronically simulate a variety of outputs from various types of transducers. A tachometer output signal is also provided, making the Model 4830A a convenient and portable means of calibrating and servicing instrumentation.

The Model 4830A uses a menu-driven 80-character LCD display to establish the appropriate settings. The key panel contains only four sealed switches (per IP65) marked with arrows for cursor control. In addition to the manual on/off switch, the unit can be set for automatic power shutdown. The last setup is automatically stored in nonvolatile memory. Power is supplied by internally mounted NiCad rechargeable batteries, which can be recharged with a regulated 9 Vdc source.

Output signals available include single-ended and differential charge (pC), single-ended voltage (mV), current-sinking ISOTRON® and a tachometer (TTL) output signal. The frequency range is 1 to 10 000 Hz and the output amplitude is adjustable up to 10 000 pC or mV pk. Outputs can be provided in acceleration, velocity or displacement.

2.2 Ancillary Handling Fixtures and Test Fixtures

Table 2-1. Handling Fixtures and Test Fixtures

Item Nomenclature Part Number Manufacturer Quantity

1 Warhead Arming Device Vibration Fixture 03-1249-0250 E-Spectrum 1 2 Rotary Switch Vibration Fixture 03-1249-0550 E-Spectrum 1 3 Rotary Switch Timing Test Fixture 03-1249-0710 E-Spectrum 1 4 Rotary Switch Force Displacement Test Fixture 03-1249-0800 E-Spectrum 1 5 Shock Test Machine Holding Fixture 03-1162-0950 E-Spectrum 1 6 Furnace Mag 20 Layman 1

Figure 2-1. Warhead Arming Device Vibration Fixture

Figure 2-2. Rotary Switch Vibration Fixture

Figure 2-3. Rotary Switch Timing Test Fixture

Figure 2-4. Rotary Switch Force Displacement Test Fixture

Figure 2-5. Shock Test Machine Holding Fixture

Figure 2-6. Furnace

2.3 Consumables

Table 2-2. Consumables

Item Nomenclature Purpose Source Part Number

1 Potting Compound Securing WAD & RS vacuum port screws Elsworth Adhesive EE-4215 Base

HD-3561 Catalyst

2 Insulating Washer for Endevco Accelerometer (Top)

Isolate accelerometer from metal surface Thermotron 1239911

3 Insulating Washer for Endevco Accelerometer (Bottom)

Isolate accelerometer from metal surface Thermotron 1239929

4 High Vacuum Grease Used on bell jar vacuum seal / test port washer seal DOW Corning #976V

5 Nitrogen Used during leak test Local Supply 95% Ni / 5% He

6 Vacuum Pump Oil Vacuum pump lubricant Varian 695409005

7 Epoxy, Polyamide Primer Priming metal surfaces 81349 MIL-P-24441/28 Type I, Class 2

8 Aliphatic Polyurethane Color No. 16187 or 16251 Painting metal surfaces 81349 MIL-C-85285

9 Wash Primer Paint touchup 81349 MIL-C-8514

10 Isopropyl Alcohol To clean leak port washer Local Purchase NA

11 Vacuum Port Washer Seal WAD leak test adapter McMaster Carr 93783A009

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.

Thermotron Temperature/Humidity Controlled Chamber. The Thermotron temperature/humidity chamber (Model Number SM-8C) is integral to the overall A&S program. Dedicated Impact Sensor and Warhead Arming Device 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 early CY 2000.

Cincinnati Sub-Zero MicroClimate Series Temperature/Humidity Controlled Chamber. The Cincinnati Sub-Zero MicroClimate temperature/humidity chamber (Model Number MCBHS- 1.2-.33-.33-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.

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) or Rotary Switch 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.

Varian Model 979 Series Helium Mass Spectrometer Leak Detector. The Model 979 Helium Leak Detector is the heart of this test system. Other components include a Varian Vacuum Pump (DS 302VAC, Model 949-9325), a custom automated pneumatic control system, and a specially designed and precision-machined stainless steel work platform that allows for adequate vacuum sealing between the work surface and a bell jar. The leak detector system is used to conduct the o-ring seal tests on the WAD. The MTS-8 has been configured with an Interface Test Adapter (ITA) to allow automated control of the leak detector system and to conduct data acquisition and analysis.

Dillon Quantrol TC2 (Tension-Compression-Cyclic) Force Measurement System (TC2-FMS).

The TC2-FMS includes a Mecmesin Advance Force Gauge (AFG 500N) that provides accurate measurements of force and displacement. The system is ideal for use in gathering displacement data specified in the ALCM A&S Rotary Switch Test Requirements Document. The TC2-FMS has been augmented with a Rotary Switch Force Displacement Test Fixture to satisfy positioning and alignment requirements for the device under test. The MTS-8 utilizes the ACM Separation Switch Interface Test Adapter (ITA) to allow automated control of the TC2-FMS and to conduct data acquisition and analysis.

Avex Shock Machine. This shock machine (Model 105-MP) provides a means of applying G forces to Impact Sensors to validate switch opening versus G-level applied. An adapter plate with attached storage containers is mounted on the machine to accommodate testing of one of the three sensors at any one time. The MTS-8 has been configured with an Interface Test Adapter (ITA) to allow automated control of the shock machine and to conduct data acquisition and analysis.

4 Test Station Description

4.1 Hardware

MTS-8 Test Station. The MTS-8 is an analog/digital automatic test station that provides a wide range of test capability. The original specifications for the MTS-8 included sufficient capacity to meet the Aging & Surveillance electrical stimulus application and data acquisition test requirements for the ALCM Impact Sensor Assembly, Warhead Arming Device, and Rotary Switch. Further, all electrical production/acceptance test requirements for the WAD can be met with the MTS-8.

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 ALCM A&S Test Complex. The following figure depicts the MTS-8 and in its current configuration.

Figure 4-1. MTS-8 Test Station and Station Control PC

Station Control PC. The control PC is external to the instrumentation rack. It includes a 3 GHz Intel processor, 1 GB DDR memory operating at 400MHZ, a 17-inch LCD monitor, a Sony IDE DVD/CDRW, a 3½-inch floppy drive, an 80 GB internal hard drive, a 250 MB zip drive, and 80 GB external USB drive, 5 serial ports, and a standard keyboard and mouse. Figure 4-2 shows the

I/O connections between the controller, the MTS8 main frame test set, and other various other ALCM A&S Test Complex components.

Figure 4-2. Controller (Rear View) and ALCM A&S Test Complex I/O

4.2 Interface Test Adapters.

Various interface test adapters (ITAs) have been designed and developed in support of the ALCM A&S Program (see Table 4-1). The ITAs are described in the following paragraphs.

MTS8 Self-Test ITA. A self-test ITA is provided to allow for a comprehensive internal test of the MTS-8. 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.

Nomenclature # PN Figure Remarks

MTS8 Self Test ITA None 03-1039-0100 4-3

Impact Sensor ITA 1 03-1039-0200 4-4 Static Test

Impact Sensor ITA 2 03-1162-0900 4-5 Dynamic Test

Rotary Switch Assembly ITA 1 03-1249-0500 4-6 & 4-7 Interface Chassis & Load Box

Rotary Switch ITA 2 03-1249-0700 5-8

Rotary Switch ITA 3 03-1249-0800 4-9

Warhead Arming Device Assembly ITA 1 03-1039-0300 4-10 & 4-11 Interface Chassis & Load Box

Warhead Arming Device ITA 2 03-1162-0400 4-12

Table 4-1. Interface Test Adapters

(Not Used)

Front and back views of the MTS8 self-test ITA are shown in figure 4-3.

Front Rear

Figure 4-3. MTS8 Self-Test ITA, 03-1039-0100 Air Launched Cruise Missile Impact Sensor Static Test ITA#1. The ALCM Impact Sensor Static Test ITA #1, PN 03-1039-0200, includes a Virginia panel interface mounted at the rear of the ITA along with a hinged door on the front that provides access to mount the Impact Sensors internally to protect the operators from high voltages and currents that are present during the test sequence. Two safety features have been designed into the ITA to ensure operator safety during High Potential testing. First, the ITA lid must be closed to satisfy a switch activated interlock.

And secondly, the hardware interlock pins are monitored at the Virginia Panel interface in the test software to verify the lid is closed prior to continuation of the test. The following figures depict the rear and front views of the ITA respectively.

Figure 4-4. Impact Sensor ITA #1, 03-1039-0200 (Static Test) Air Launched Cruise Missile Impact Sensor Dynamic Test ITA#2. The ALCM Impact Sensor Dynamic Test ITA #2, PN 03-1162-0900, includes a Virginia panel interface mounted at the rear of the ITA along with a hinged door on the front panel where shorting connectors are mounted for use in loop back testing of the ITA to Impact Sensor interface cable. The interface cable mates at J1 on the ITA and is then routed to the Avex Shock Machine for automated control of the machine and to the Impact Sensor to monitor switch activation circuitry and measure circuit path resistances. The following figure depicts the ITA.

Figure 4-5. Impact Sensor ITA #2, 03-1162-0900 (Dynamic Test)

Air Launched Cruise Missile Rotary Switch ITA Assembly #1. ALCM Rotary Switch ITA Assembly #1, PN 03-1249-0500, includes a Virginia panel interface mounted at the rear of the ITA. The interface chassis mounts to the MTS-8 and includes interface cables and surface mount loop-back connectors for the ITA self-test function. Figure 4-6 depicts the load box with the lid closed and a front view of the ITA. Figure 4-7 shows the load box with the lid open.

Load Box Interface Chassis

Figure 4-6. Rotary Switch ITA Assembly #1, 03-1249-0500 (Loadbox / Interface Chassis)

Figure 4-7. Rotary Switch ITA Assembly #1 Loadbox (Internal View)

Air Launched Cruise Missile Rotary Switch ITA #2. ALCM Rotary Switch ITA #2, PN 03- 1249-0700, includes a Virginia panel interface mounted at the rear of the ITA.

Figure 4-8. Rotary Switch ITA #2, 03-1249-0700

Air Launch Cruise Missile Rotary Switch ITA #3. ALCM Rotary Switch ITA #3, PN 03-1249- 0800, includes a Virginia panel interface mounted at the rear of the ITA along with a hinged door on the front that use to provides access to internal wiring. The following figure depicts the front view of the ITA. ITA cables enable the MTS8 Test Set to communicate with the Dillon Quantrol TC2 (Tension-Compression-Cyclic) Force Measurement System during Rotary Switch detent pin insertion/extraction testing.

Figure 4-9. Rotary Switch ITA #3, PN 03-1249-0800

Air Launched Cruise Missile Warhead Arming Device ITA #1. ALCM WAD ITA #1, PN 03- 1039-0300, includes a loadbox along with a typical Virginia panel interface chassis and interconnect cables. WAD ITA #1 is used in conjunction with the MTS-8 to perform the WAD Basic Functional Test, Environmental Tests and the WAD Extended Functional Test. The interface chassis mounts to the MTS-8 and is interconnected with the loadbox during self-test of the ITA or the WAD during testing. Similarly the loadbox includes an external cable leg that mates to the interface chassis for self-test and is connected and disconnected from the chassis during WAD testing as directed during the test sequence. The following figure shows external views of the two WAD ITA #1 assemblies.

Load Box Interface Chassis

Figure 4-10. Warhead Arming Device ITA Assembly #1 (Loadbox / Chassis), 03-1039-0300 The following figure shows internal views of the Load Box.

Figure 4-11. Warhead Arming Device ITA #1 Loadbox (Internal Views)

Air Launched Cruise Missile Warhead Arming Device ITA #2. ALCM WAD ITA #2, PN 03- 1162-0400, is a typical Virginia panel interface chassis and interconnect cables. WAD ITA #2 is used in conjunction with the MTS-8 to perform the WAD and Rotary Switch A&S Unique Tests as well as the WAD and Rotary Switch Helium Leak Test. The interface chassis mounts to the MTS-8 and includes WAD interface cables and surface mount loop-back connectors for the ITA self-test function. The following figure shows an external view of WAD ITA #2.

Figure 4-12. Warhead Arming Device ITA #2, 03-1162-0400

4.3 Instrumentation Rack.

The rack contains common COTS instrumentation as well as some custom hardware. Two National Instrument PXI-1000B Chassis’s are daisy chained within the MTS-8 to provide sufficient capacity to meet the test requirements and data acquisition needs. The following paragraphs describe the various Tester Replaceable Units.

4.3.1 Digital Multi-Meter

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

Figure 4-13. HP 3458A DMM

4.3.2 Oscilloscope

The scope is a standard commercial off the shelf TEK TDS 420A Oscilloscope. Option bundle TDS420AXL was also included to allow data sampling at a higher resolution. The bundle includes the 120K extended record length that is necessary to obtain the high resolution.

Combined the standard scope and option bundle are advertised as model number TDS

420A_00XL.

Figure 4-14. Tektronix TDS 420A Oscilloscope

4.3.3 Milliohmmeter

This is a standard commercial off the shelf HP 4338B Milliohmmeter.

Figure 4-15. HP 4338B Milliohmmeter

4.3.4 Impact Sensor Accelerometer Signal Conditioner

This is a standard off the shelf Endevco 2775B Signal Conditioner. An optional Endevco Model 35771 Programmable Filter is included. This is a plug-in filter designed for use in the Endevco Model 2775B signal conditioner as a high pass, low pass or band pass filter. The plug-in filter is configured in a low pass mode for use in the MTS-8. Selectable jumpers are set as follows:

CARRIER JUMPER SETTING

a. LP/BP/HP LP

b. 1 kHz/2 kHz/5 kHz/10 kHz 2 kHz

c. CUST/10 Hz/2 Hz/SP 2 Hz

d. CUST/100 Hz/200 Hz/500 Hz No Jumper

Figure 4-16. Endevco 2775B Signal Conditioner

4.3.5 HYPOT

The HYPOT instrumentation includes the basic 7550DT Dielectric Analyzer along with the HS- 8A Matrix Scanner. The Scanner increases signal channel capability from the basic 8 channels to 16.

Figure 4-17. HYPOT 7550DT

4.3.6 AC Power Distribution Box

This is a custom designed power control box that implements a ground fault interrupt, provides emergency shut off capabilities for all AC power within the MTS-8, and filters the input power to the test station. The box also includes a 24-volt DC power supply. This DC supply powers the contactors in the box, the display lamps on the box, and the Green lamp indicator in the PUSH ON push button located on the MTS-8 front panel. The following figures show the rear view and internal view of the box along with a front panel view of the Enable and Emergency stop switches for the box.

Figure 4-18. AC Distribution Box Rear View

Figure 4-19. AC Distribution Box Internal View

Figure 4-20. AC Box Enable and Emergency Stop Switch

4.3.7 Power Supplies

Three power supplies have been incorporated to satisfy the various test requirements. Two are used in the WAD test, as the 0-35 Volt/0-4.5A DC Modular Supply is necessary to function the WAD relays and the 0-35Volt/15A DC Power Supply provides main bus power. The Agilent 66103A and 66104A dc power supplies are housed in a 66000A Modular Power Supply Mainframe while the 6653A dc power supply (0-35V/15A) is a typical rack mount unit. All three power supplies are controlled via the GPIB.

66103A 0-35 Volt/0-4.5A DC Power Module

66104A 0-60 Volt/0-2.5A DC Power Module

6653A 0-35 Volt, 15A DC Power Supply

Figure 4-21. DC Power Supplies

4.4 Software

The executable ALCM 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 Rotary Switch and WAD ITAs, test the WAD, Rotary Switch and Impact Sensors (except G-testing), acquire the data and archive the results.

Version Description. The ALCM A&S Test Program (ALCM A&S.exe, dtd x/x/xx, x.x MB) was originally released on xx Month 2009. It currently consists of the support files listed in Table 4-1 that are required for the executable program to run properly.

Table 4-2. Test Program Support Files (Sheet 1 of 5)

Name Directory Size Date daqdrv E:\ALCM A&S\Executable 5 KB 8/26/1998

A&S impact sensor selftest E:\ALCM A&S\Impact Sensor\Scripts 86 KB 11/7/2005

ALCMresistancea&s.dss E:\ALCM A&S\Impact Sensor\Scripts 2 KB 4/1/2005

ALCMselftestg110a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 7 KB 11/4/2005

ALCMselftestg220a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 6 KB 11/4/2005

ALCMsw1g110a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 7 KB 11/4/2005

ALCMsw1g220a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 19 KB 11/4/2005

ALCMsw2g110a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 7 KB 11/4/2005

ALCMsw2g220a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 19 KB 11/4/2005

ALCMsw3g110a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 7 KB 11/4/2005

ALCMsw3g220a&s.dss E:\ALCM A&S\Impact Sensor\Scripts 19 KB 11/4/2005

Cycle Test.dss E:\ALCM A&S\Impact Sensor\Scripts 8 KB 11/4/05

Impact Sensor A&S.dss E:\ALCM A&S\Impact Sensor\Scripts 21 KB 11/22/2002

Impact Sensor ITA.dss E:\ALCM A&S\Impact Sensor\Scripts 18 KB 11/20/2001

Impact Sensor ITA2.dss E:\ALCM A&S\Impact Sensor\Scripts 6 KB 3/30/2005

Scalign.dss E:\ALCM A&S\Impact Sensor\Scripts 3 KB 11/8/2005

Figure 1.jpg E:\ALCM A&S\Impact Sensor\Images 16 KB 11/15/2001

Figure 2.jpg E:\ALCM A&S\Impact Sensor\Images 17 KB 11/15/2001

Figure 3.jpg E:\ALCM A&S\Impact Sensor\Images 17 KB 11/15/2001

Figure 4.jpg E:\ALCM A&S\Impact Sensor\Images 16 KB 11/15/2001

Figure 5.jpg E:\ALCM A&S\Impact Sensor\Images 17 KB 11/15/2001

Figure 6.jpg E:\ALCM A&S\Impact Sensor\Images 18 KB 11/15/2001

Figure 7.jpg E:\ALCM A&S\Impact Sensor\Images 15 KB 11/15/2001

Figure 8.jpg E:\ALCM A&S\Impact Sensor\Images 14 KB 11/15/2001

Figure 9.jpg E:\ALCM A&S\Impact Sensor\Images 16 KB 11/20/2001

Figure 10.jpg E:\ALCM A&S\Impact Sensor\Images 15 KB 11/20/2001

Figure 11.jpg E:\ALCM A&S\Impact Sensor\Images 15 KB 11/20/2001

Figure15.jpg E:\ALCM A&S\Impact Sensor\Images 11 KB 3/30/2005

Figure16.jpg E:\ALCM A&S\Impact Sensor\Images 11 KB 3/30/2005

Figure17.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Figure18.jpg E:\ALCM A&S\Impact Sensor\Images 11 KB 3/30/2005

Figure19.jpg E:\ALCM A&S\Impact Sensor\Images 11 KB 3/30/2005

Figure20.jpg E:\ALCM A&S\Impact Sensor\Images 8 KB 3/30/2005

Figure21.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Figure22.jpg E:\ALCM A&S\Impact Sensor\Images 7 KB 3/30/2005

Figure23.jpg E:\ALCM A&S\Impact Sensor\Images 9 KB 3/30/2005

Figure24.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Figure25.jpg E:\ALCM A&S\Impact Sensor\Images 9 KB 3/30/2005

Figure26.jpg E:\ALCM A&S\Impact Sensor\Images 10 KB 3/30/2005

Figure27.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Figure28.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Figure29.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Table 4-2. Test Program Support Files

(Sheet 2 of 5) Name Directory Size Date

Figure30.jpg E:\ALCM A&S\Impact Sensor\Images 12 KB 3/30/2005

Figure31.jpg E:\ALCM A&S\Impact Sensor\Images 9 KB 3/30/2005

Figure32.jpg E:\ALCM A&S\Impact Sensor\Images 10 KB 3/30/2005

Figure33.jpg E:\ALCM A&S\Impact Sensor\Images 10 KB 3/30/2005

Figure34.jpg E:\ALCM A&S\Impact Sensor\Images 9 KB 7/12/2005

Figure35.jpg E:\ALCM A&S\Impact Sensor\Images 17 KB 10/24/2005

Figure36.jpg E:\ALCM A&S\Impact Sensor\Images 20 KB 10/24/2005

Figure37.jpg E:\ALCM A&S\Impact Sensor\Images 25 KB 10/24/2005

Figure38.jpg E:\ALCM A&S\Impact Sensor\Images 25 KB 10/24/2005 selfita1.jpg E:\ALCM A&S\Impact Sensor\Images 6 KB 11/8/2001 selfita2.jpg E:\ALCM A&S\Impact Sensor\Images 10 KB 11/8/2001 selfita3.jpg E:\ALCM A&S\Impact Sensor\Images 13 KB 11/8/2001 selfita4.jpg E:\ALCM A&S\Impact Sensor\Images 14 KB 11/8/2001 selfita5.jpg E:\ALCM A&S\Impact Sensor\Images 15 KB 11/8/2001

A&S Armdisarm selftest good.dss E:\ALCM A&S\Armdisarm\Scripts 86 KB 11/30/2005

A&S Armdisarm selftest E:\ALCM A&S\Armdisarm\Scripts 86 KB 11/30/2005

Armdisarm A&S Unique.dss E:\ALCM A&S\Armdisarm\Scripts 40 KB 11/15/2005

Armdisarm A&S.dss E:\ALCM A&S\Armdisarm\Scripts 91 KB 11/17/2005

Armdisarm Basic Env TEST VIB.dss E:\ALCM A&S\Armdisarm\Scripts 201 11/16/2005

Armdisarm Basic Env.dss E:\ALCM A&S\Armdisarm\Scripts 202 KB 11/28/2005

Armdisarm Basic Env2.dss E:\ALCM A&S\Armdisarm\Scripts 201 11/16/2005

Armdisarm Basic.dss E:\ALCM A&S\Armdisarm\Scripts 96 KB 11/7/2005

Armdisarm ITA #2.dss E:\ALCM A&S\Armdisarm\Scripts 6 KB 11/15/2005

Armdisarm ITA.dss E:\ALCM A&S\Armdisarm\Scripts 20 KB 11/15/2005

Helium Leak Test.dss E:\ALCM A&S\Armdisarm\Scripts 20 KB 11/23/2005

WAD Test.dss E:\ALCM A&S\Armdisarm\Scripts 91 KB 6/15/2004

ApplyVacGrease.jpg E:\ALCM A&S\Armdisarm\Images 13 KB 10/15/2004

BellJar.jpg E:\ALCM A&S\Armdisarm\Images 12 KB 10/15/2004

BellJarGasket.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 10/13/2004

BellJarGuard.jpg E:\ALCM A&S\Armdisarm\Images 17 KB 10/13/2004

BellJarWithGuard.jpg E:\ALCM A&S\Armdisarm\Images 10 KB 10/20/2004

Cable_Connectors.jpg E:\ALCM A&S\Armdisarm\Images 20 KB 10/20/2004

CleanBasePlate.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 10/15/2004

CleanBellJarBase.jpg E:\ALCM A&S\Armdisarm\Images 12 KB 10/18/2004

CleanPort.jpg E:\ALCM A&S\Armdisarm\Images 19 KB 10/18/2004

CleanScrew.jpg E:\ALCM A&S\Armdisarm\Images 18 KB 10/18/2004

ConnectJ4.jpg E:\ALCM A&S\Armdisarm\Images 8 KB 10/15/2004

Figure 8.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 11/15/2001

Figure61.jpg E:\ALCM A&S\Armdisarm\Images 8 KB 5/13/2005

Figure62.jpg E:\ALCM A&S\Armdisarm\Images 5 KB 5/13/2005

Figure63.jpg E:\ALCM A&S\Armdisarm\Images 10 KB 5/13/2005

(Sheet 3 of 5)

Name Directory Size Date

Figure64.jpg E:\ALCM A&S\Armdisarm\Images 5 KB 5/13/2005

Figure65.jpg E:\ALCM A&S\Armdisarm\Images 10 KB 5/13/2005

Figure66.JPG E:\ALCM A&S\Armdisarm\Images 8 KB 5/13/2005

Figure80.jpg E:\ALCM A&S\Armdisarm\Images 28 KB 8/29/2005

Figure81.jpg E:\ALCM A&S\Armdisarm\Images 22 KB 8/29/2005

Figure82.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 8/29/2005

Figure83.jpg E:\ALCM A&S\Armdisarm\Images 15 KB 8/29/2005

Figure84.jpg E:\ALCM A&S\Armdisarm\Images 17 KB 8/29/2005

Figure85.jpg E:\ALCM A&S\Armdisarm\Images 32 KB 8/29/2005

Figure86.jpg E:\ALCM A&S\Armdisarm\Images 20 KB 8/29/2005

Figure87.jpg E:\ALCM A&S\Armdisarm\Images 32 KB 8/29/2005

Figure88.jpg E:\ALCM A&S\Armdisarm\Images 18 KB 8/29/2005

Figure89.jpg E:\ALCM A&S\Armdisarm\Images 29 KB 8/29/2005

Figure90.jpg E:\ALCM A&S\Armdisarm\Images 28 KB 8/29/2005

Figure91.jpg E:\ALCM A&S\Armdisarm\Images 29 KB 8/29/2005

Figure92.jpg E:\ALCM A&S\Armdisarm\Images 32 KB 8/29/2005

Figure93.jpg E:\ALCM A&S\Armdisarm\Images 28 KB 8/29/2005

Figure94.jpg E:\ALCM A&S\Armdisarm\Images 25 KB 8/29/2005

Figure95.jpg E:\ALCM A&S\Armdisarm\Images 15 KB 8/29/2005

Figure96.jpg E:\ALCM A&S\Armdisarm\Images 24 KB 8/29/2005

Figure97.jpg E:\ALCM A&S\Armdisarm\Images 25 KB 8/29/2005

Figure98.jpg E:\ALCM A&S\Armdisarm\Images 24 KB 8/29/2005

HeLeakTestITA.jpg E:\ALCM A&S\Armdisarm\Images 18 KB 10/15/2004

Image1.jpg E:\ALCM A&S\Armdisarm\Images 20 KB 1/29/2003

Image10.jpg E:\ALCM A&S\Armdisarm\Images 22 KB 1/29/2003

Image11.jpg E:\ALCM A&S\Armdisarm\Images 13 KB 1/29/2003

Image12.jpg E:\ALCM A&S\Armdisarm\Images 13 KB 1/29/2003

Image13.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 1/29/2003

Image2.jpg E:\ALCM A&S\Armdisarm\Images 16 KB 1/29/2003

Image3.jpg E:\ALCM A&S\Armdisarm\Images 17 KB 1/29/2003

Image4.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 1/29/2003

Image5.jpg E:\ALCM A&S\Armdisarm\Images 14 KB 1/29/2003

Image6.jpg E:\ALCM A&S\Armdisarm\Images 15 KB 1/29/2003

Image7.jpg E:\ALCM A&S\Armdisarm\Images 16 KB 1/29/2003

Image8.jpg E:\ALCM A&S\Armdisarm\Images 17 KB 1/29/2003

Image9.jpg E:\ALCM A&S\Armdisarm\Images 16 KB 1/29/2003

Install_Cables_on_ITA.jpg E:\ALCM A&S\Armdisarm\Images 19 KB 10/20/2004

Install_ITA.jpg E:\ALCM A&S\Armdisarm\Images 20 KB 10/20/2004

Pad.JPG E:\ALCM A&S\Armdisarm\Images 9 KB 10/13/2004

ReinstallEndCap.jpg E:\ALCM A&S\Armdisarm\Images 15 KB 10/18/2004

RemoveDustCaps.jpg E:\ALCM A&S\Armdisarm\Images 13 KB 10/18/2004

RemoveEndCap.JPG E:\ALCM A&S\Armdisarm\Images 11 KB 10/20/2004

RemoveScrew.jpg E:\ALCM A&S\Armdisarm\Images 10 KB 10/13/2004

(Sheet 4 of 5) Name Directory Size Date

Name Directory Size Date

Sverify.jpg E:\ALCM A&S\Armdisarm\Images 16 KB 10/13/2004

TestAdapterInstalledInA.. E:\ALCM A&S\Armdisarm\Images 14 KB 10/15/2004

TorqueFittingToAdapter... E:\ALCM A&S\Armdisarm\Images 20 KB 10/15/2004 uutadapter.jpg E:\ALCM A&S\Armdisarm\Images 17 KB 10/19/2004

UUTConnected.JPG E:\ALCM A&S\Armdisarm\Images 11 KB 10/13/2004

UUTonStand.jpg E:\ALCM A&S\Armdisarm\Images 13 KB 10/15/2004

Washer.jpg E:\ALCM A&S\Armdisarm\Images 10 KB 10/18/2004

A&S sep switch selftest.dss E:\ALCM A&S\Sep Switch\Scripts 86 KB 11/7/2005

Sep Switch A&S.dss E:\ALCM A&S\Sep Switch\Scripts 39 KB 11/8/2005

Sep Switch ITA bkp.dss.txt E:\ALCM A&S\Sep Switch\Scripts 22 KB 1/26/2005

Sep Switch ITA.dss E:\ALCM A&S\Sep Switch\Scripts 22 KB 6/16/2005 figure 1.jpg E:\ALCM A&S\Sep Switch\Images 9 KB 1/18/2005 figure 10.jpg E:\ALCM A&S\Sep Switch\Images 15 KB 1/18/2005 figure 11.jpg E:\ALCM A&S\Sep Switch\Images 13 KB 1/18/2005 figure 12.jpg E:\ALCM A&S\Sep Switch\Images 12 KB 1/18/2005 figure 13.jpg E:\ALCM A&S\Sep Switch\Images 12 KB 1/18/2005 figure 14.jpg E:\ALCM A&S\Sep Switch\Images 10 KB 1/19/2005 figure 15.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/19/2005 figure 16.jpg E:\ALCM A&S\Sep Switch\Images 12 KB 1/19/2005 figure 17.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/19/2005 figure 18.jpg E:\ALCM A&S\Sep Switch\Images 12 KB 1/19/2005 figure 19.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/19/2005 figure 2.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/18/2005 figure 20.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/25/2005 figure 21.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/25/2005 figure 22.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/25/2005 figure 23.jpg E:\ALCM A&S\Sep Switch\Images 12 KB 1/25/2005 figure 24.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/25/2005 figure 25.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/25/2005 figure 26.jpg E:\ALCM A&S\Sep Switch\Images 10 KB 1/25/2005 figure 27.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/25/2005 figure 28.jpg E:\ALCM A&S\Sep Switch\Images 9 KB 1/25/2005 figure 3.jpg E:\ALCM A&S\Sep Switch\Images 10 KB 1/18/2005 figure 4.jpg E:\ALCM A&S\Sep Switch\Images 10 KB 1/18/2005 figure 5.jpg E:\ALCM A&S\Sep Switch\Images 11 KB 1/18/2005 figure 6.jpg E:\ALCM A&S\Sep Switch\Images 13 KB 1/18/2005 figure 7.jpg E:\ALCM A&S\Sep Switch\Images 13 KB 1/18/2005 figure 8.jpg * E:\ALCM A&S\Sep Switch\Images 14 KB 11/15/2001 figure 9.jpg E:\ALCM A&S\Sep Switch\Images 14 KB 1/18/2005 selfita1.jpg E:\ALCM A&S\Sep Switch\Images 6 KB 11/8/2001 selfita2.jpg E:\ALCM A&S\Sep Switch\Images 10 KB 11/8/2001 selfita3.jpg E:\ALCM A&S\Sep Switch\Images 13 KB 11/8/2001 selfita4.jpg E:\ALCM A&S\Sep Switch\Images 14 KB 11/8/2001

(Sheet 5 of 5) Name Directory Size Date

Name Directory Size Date selfita5.jpg E:\ALCM A&S\Sep Switch\Images 15 KB 11/8/2001

A&S wh mount selftest.dss E:\ALCM A&S\Warhead Mounts\Scripts 86 KB 11/7/2005

Durometer Selftest.dss E:\ALCM A&S\Warhead Mounts\Scripts 14 KB 11/14/2005

WH Mount A&S.dss E:\ALCM A&S\Warhead Mounts\Scripts 28 KB 11/14/2005

Figure 8.jpg E:\ALCM A&S\Warhead Mounts\Images 14 KB 11/15/2001

Figure39.jpg E:\ALCM A&S\Warhead Mounts\Images 8 KB 5/19/2005

Figure40.jpg E:\ALCM A&S\Warhead Mounts\Images 6 KB 5/17/2005

Figure41.jpg E:\ALCM A&S\Warhead Mounts\Images 6 KB 5/17/2005

Figure42.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure43.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure44.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure45.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure46.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure47.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure48.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/17/2005

Figure50.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure51.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure52.jpg E:\ALCM A&S\Warhead Mounts\Images 5 KB 5/13/2005

Figure53.jpg E:\ALCM A&S\Warhead Mounts\Images 5 KB 5/13/2005

Figure54.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure55.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure56.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure57.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure58.jpg E:\ALCM A&S\Warhead Mounts\Images 11 KB 5/13/2005

Figure59.jpg E:\ALCM A&S\Warhead Mounts\Images 8 KB 5/13/2005

Figure60.jpg E:\ALCM A&S\Warhead Mounts\Images 7 KB 5/13/2005

Figure61.jpg E:\ALCM A&S\Warhead Mounts\Images 8 KB 5/13/2005

Figure62.jpg E:\ALCM A&S\Warhead Mounts\Images 5 KB 5/13/2005

Figure63.jpg E:\ALCM A&S\Warhead Mounts\Images 10 KB 5/13/2005

Figure64.jpg E:\ALCM A&S\Warhead Mounts\Images 5 KB 5/13/2005

Figure65.jpg E:\ALCM A&S\Warhead Mounts\Images 10 KB 5/13/2005

Figure66.jpg E:\ALCM A&S\Warhead Mounts\Images 8 KB 5/13/2005

Figure67.jpg E:\ALCM A&S\Warhead Mounts\Images 22 KB 11/4/2005

Figure68.jpg E:\ALCM A&S\Warhead Mounts\Images 22 KB 11/4/2005

Figure69.jpg E:\ALCM A&S\Warhead Mounts\Images 24 KB 11/4/2005

Figure70.jpg E:\ALCM A&S\Warhead Mounts\Images 22 KB 11/4/2005

Figure71.jpg E:\ALCM A&S\Warhead Mounts\Images 23 KB 11/4/2005

4.4.1 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 or enter the A&S test sequence. Upon entry into the test sequence four test routines are displayed as shown in Figure 4-20.

Figure 4-22. ALCM A&S Tests

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

4.4.2 Warhead Arming Device Routines

Upon selecting the Warhead Arming Device button, the following screen is displayed.

Figure 4-23. Warhead Arming Device A&S Test

The following paragraphs describe the functionality of the various routines.

Self Tests

1. WAD ITA #1 Self Test selection opens the Operator Notebook Entry panel where the operator enters the associated WAD 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.

NOTE

The test monitor screen (as shown in Figure 4-24) 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 PC’s hard drive.

Figure 4-24. A&S Test Monitor Screen

The operator is prompted to install the Warhead Arming Device A&S ITA #1. As the test progresses the operator is prompted to connect and disconnect the ITA to the load simulator as required to check the continuity and isolation of all ITA wiring. When completed, the software returns to the Warhead Arming Device A&S Test screen.

2. ITA #2 Self Test selection opens the Operator Notebook Entry panel where the operator enters the associated WAD 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.

The operator is prompted to install the Warhead Arming Device A&S ITA #2. As the test progresses the operator is prompted to connect and disconnect the ITA cables to ITA chassis mounted connectors as required to check the continuity and isolation of all ITA wiring.

When completed, the software returns to the Warhead Arming Device A&S Test screen.

3. A&S Test Set Self Test opens the Operator Notebook Entry panel where the operator enters the associated WAD 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 Set Self Test screen. This screen offers three options. The operator can select either a Complete Self Test, a Single Test Step, or Cancel to return to the Warhead Arming Device A&S Test screen. The Single Test Step mode requires the entry of a test number to activate that selection. Selection of either the Complete Self Test or the Single Test Step launches the A&S Test Monitor screen.

4. 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 Warhead Arming Device A&S Test screen.

Unique Test

1. Warhead Arming Device A&S Unique Test selection launches the OPERATOR NOTEBOOK ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen, select a Clear All option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen. Operator instructions are provided to complete the test.

2. Test Subset by Category launches the A&S SUBTEST ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen or select a Test Subset from a dropdown menu and select Continue. Selecting Continue launches the A&S Test Monitor screen. The test subset selected is executed.

3. Single Test Step Only launches the A&S TEST STEP ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen or enter the desired test step and select Continue. Once selected, the Continue button launches the A&S Test Monitor screen. Only a single test step is executed.

4. Helium Leak Test selection launches the OPERATOR NOTEBOOK ENTRY screen.

The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen, select a Clear All option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen. Operator instructions are provided to complete the test.

Basic Functional & Environmental Tests

1. Warhead Arming Device Basic Functional Test selection launches the OPERATOR NOTEBOOK ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen, select a Clear All option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen. Operator instructions are provided to complete the test.

2. Warhead Arming Device Environmental Test selection launches the OPERATOR NOTEBOOK ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen, select a Clear All option to reset data, or enter the appropriate data and Continue. Selecting Continue launches the A&S Test Monitor screen. Operator instructions are provided to complete the test.

3. Test Subset by Category launches the A&S SUBTEST ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen or select a Test Subset from a dropdown menu and select Continue. Selecting Continue launches the A&S Test Monitor screen. The test subset selected is executed.

4. Single Test Step Only launches the A&S TEST STEP ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen or enter the desired test step and select Continue. Once selected, the Continue button launches the A&S Test Monitor screen. Only a single test step is executed.

Extended Functional Test

1. Warhead Arming Device Extended Functional Test selection launches the OPERATOR NOTEBOOK ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen, select a Clear All option to reset data, or enter the appropriate data and Continue. If Continue is selected, the A&S Test Monitor screen is launched.

2. Test Subset by Category launches the A&S SUBTEST ENTRY screen. The operator has the opportunity to Cancel and return to the Warhead Arming Device A&S Test screen or select a Test Subset from a dropdown menu and select Continue. Selecting Continue launches the A&S Test Monitor screen. The test subset selected is executed.

3. Single Test Step Only launches the A&S TEST STEP ENTRY screen.