409079C ATP for the Converter PS Module.doc

409079C

SHAPE \* MERGEFORMAT

REVISIONS

STILLWATER, OKLAHOMA 74076-1023

FOR THE CONVERTER POWER

SUPPLY MODULE

(P/N 500190)

CODE IDENT.

63812 409079C

ACCEPTANCE TEST PROCEDURES

FOR THE CONVERTER POWER

SUPPLY MODULE

(P/N 500190)

TABLE OF CONTENTS

Section Title Page

GENERAL

1.1

SCOPE

1.2

PURPOSE

1.3

TEST EQUIPMENT

1.4

GENERAL REQUIREMENTS

1.4.1 Production Routers 1.4.2 Test Conditions

1.4.3 Failure Reporting

1.4.4 Test Data

PRETEST EVALUATION

2.1

UNLOADED POWER SUPPLY CHECK

2.2

LOADED POWER SUPPLY TEST

BURN-IN

FACTORY ACCEPTANCE TEST

4.1

UNLOADED POWER SUPPLY CHECK

4.2

LOADED POWER SUPPLY TEST

APPENDIX A

PRODUCTION ROUTERS

A-1

APPENDIX B

NON-CONFORMANCE REPORTS

B-1

APPENDIX C

BURN-IN LOG

C-1

TABLE OF CONTENTS (Continued)

LIST OF FIGURES

Figure Title Page 1.1-1 Testing Flow

LIST OF TABLES

Table Title Page 1.3-1 Test Equipment

3-1 Burn-In Test Information

SECTION 1

GENERAL

1.1

SCOPE

This document contains the test requirements for the acceptance testing of the Frontier Converter Power Supply Module (P/N 500190). This document contains the following sections:

Section 1. General Requirements

Section 2. Pretest Evaluation

Section 3. Burn-In

Section 4. Factory Acceptance Test

Figure 1.1-1 illustrates the order of testing.

Figure 1.1-1. Testing Flow

1.2

PURPOSE

The purpose of this document is to demonstrate that the Converter Power Supply Module, as manufactured by Frontier Electronics Systems, meets or exceeds all functions identified within this document.

1.3

TEST EQUIPMENT

Table 1.3-1 lists the equipment required to perform the procedures contained in this document. Enter the serial number and calibration expiration date for each piece of test equipment.

Table 1.3-1. Test Equipment

OR P/N

SPECIFICATIONS

CALIBRATION

EXP. DATE

Fluke

NOTE

Equivalent or superior equipment may be substituted for the equipment listed above.

1.4

GENERAL REQUIREMENTS

1.4.1 Production Routers

Insert the Production Routers for the module into Appendix A.

1.4.2 Test Conditions

Unless otherwise specified herein, testing will be performed at standard room ambient temperature, 60 to 80F.

1.4.3 Failure Reporting

Non-Conformance Reports (NCRs) will be used to document test failures in accordance with FES-QSP-8.3-3 when required. Each NCR will be inserted into Appendix B.

1.4.4 Test Data Successful completion of each test will be annotated within these procedures.

SECTION 2

PRETEST EVALUATION

This section contains the steps for conducting a preliminary test of the Converter Power Supply Module before subjecting it to a burn-in cycle.

2.1

UNLOADED POWER SUPPLY CHECK

The unloaded Power Supply check verifies initial power-up of the Power Supply in an unloaded condition.

1.

Using a multimeter set to measure resistance; verify the resistance between the AC input connector contacts of the Power Supply Module (P/N 500190) with its AC power switch in both the ON and OFF positions.

*OPEN = Multimeter reading of O.L. or a resistance greater than 2 MOhms.

**OPEN = Multimeter reading of greater than 100 KOhms in the ON position.

2.

Ensure the Power Supply Module’s AC power switch is set to the OFF position.

3.

Install the Power Supply Module (P/N 500190) into the Converter chassis that contains no modules.

4. Verify the part number of both fuses on the Converter Power Supply Module is GMA-5A or equivalent for the 500190.

VERIFIED:

5.

Set Converter chassis POWER Switch to the ON position.

6.

Set power switch on the Power Supply Module to the ON position.

7.

Verify +5V, +12V, -12V LEDs and POWER Switch are "LIT" green on the Power Supply Module.

VERIFIED:

8. Set the Power Supply Module switch to the OFF position.

9. Set the Converter chassis POWER Switch to the OFF position.

2.2 loadED POWER SUPPLY TEST

The power supply/indicators test verifies correct wiring and function of the Power Supply and module indicators in a standard loaded configuration.

1. Install a Formatter, Synchro, and Serializer Module into the appropriate slots of the Converter chassis:

Qty. 1 of Formatter Module (P/N 204570-1, 350176-1 or 500060-1) Qty. 1 of Serializer Module (P/N 204523-1 or 350074-2)

Qty. 1 of Synchro Module (P/N 204575-1 or 350174-1)

2.

Set the Converter chassis POWER Switch to the ON position.

3.

Set the Power Supply Module switch to the ON position.

4.

Using a multimeter set for DC voltage measurements, verify that the DC voltages at each of the following Power Supply Module test points are within the specified tolerances, measured with respect to the GND test point. Record and verify the measurements.

Converter Power Supply (P/N 500190)

5.

Verify +5V, +12V, -12V LEDs and POWER Switch are "LIT" green on the Power Supply Module.

VERIFIED:

6. Set the Power Supply Module switch to the OFF position.

7. Set the Converter chassis POWER Switch to the OFF position.

SECTION 3

BURN-IN

This section contains the procedures to be followed to accomplish a burn-in cycle on the Converter Power Supply Module.

3.1 Place the Power Supply Module into the power supply test fixture as called out in Table 1.3-1.

3.2 Place the test bed into a thermal chamber.

3.3 Complete a 48 hour (minimum) burn-in cycle at 45 C + 5C with power applied to the module.

3.4 Record the date and time at the beginning and end of the cycle.

Table 3-1 Burn-in Test Information

Date/Time

VERIFIED:

3.5 Insert the temperature burn-in chart into Appendix C.

SECTION 4

FACTORY ACCEPTANCE TEST

This section details functional testing of the Converter Power Supply Module for both unloaded and loaded conditions.

4.1 UNLOADED POWER SUPPLY Check

The unloaded Power Supply check verifies initial power-up of the Power Supply in an unloaded condition.

1.

Install the Power Supply Module (P/N 500190) into a Converter chassis that contains no modules.

2.

Set Converter chassis POWER Switch to the ON position.

3.

Set power switch on the Power Supply Module to the ON position.

4. Verify +5V, +12V, -12V LEDs and POWER Switch are "LIT" green on the Power Supply Module.

VERIFIED:

5. Set the Power Supply Module switch to the OFF position.

6. Set the Converter chassis POWER Switch to the OFF position.

4.2

LOADED POWER SUPPLY TEST

This test verifies acceptable Converter Power Supply voltages in a loaded condition.

1. Install a Formatter, Synchro, and Serializer Module into the appropriate slots of the Converter chassis.

Qty. 1 of Formatter Module (P/N 204570-1, 350176-1 or 500060-1)

Qty. 1 of Serializer Module (P/N 204523-1 or 350074-2)

Qty. 1 of Synchro Module (P/N 204575-1 or 350174-1)

2.

Set the Converter chassis POWER Switch to the ON position.

3.

Set the Power Supply Module switch to the ON position.

4.

Using a multimeter set for DC voltage measurements, verify that the DC voltages at each of the following Power Supply Module test points are within the specified tolerances. Record and verify the measurements.

Converter Power Supply (P/N 500190)

5.

Verify +5V, +12V, -12V LEDs and POWER Switch are "LIT" green on the Power Supply Module.

VERIFIED:

6.

Set the Power Supply Module switch to the OFF position.

7. Set the Converter chassis POWER Switch to the OFF position.

Comments:

VALIDATION

This sheet is supplied as a validation of the completion and accuracy of the data contained herein. The Test Technician will sign and date as an indication that all instructions have been followed and that each test step has been successfully completed. Signature by the Quality Engineer is an acknowledgement that the test data has been reviewed for completion and accuracy. Test stamps will be affixed by the signature blocks.

Test Technician: _________________________________________

Quality Engineer: _______________________________________

APPENDIX A

PRODUCTION ROUTERS

APPENDIX B

NON-CONFORMANCE REPORTS

APPENDIX C

BURN-IN LOG

ACCEPTANCE TEST PROCEDURE

FOR THE CONVERTER POWER �SUPPLY MODULE

(P/N 500190-__)

S/N: _________________

Prepared For:

Combat Direction Systems Activity

Dahlagren Division, Code F31

1922 Regulus Avenue

Virginia Beach, VA 23461-2097

08 DECEMBER 2011

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only due to protecting technical, operational, or operational use information from automatic dissemination under the International Exchange Program or by other means as determined on or after date of task order award. Other requests for this document shall be referred to NAVSEA CDSA Code F31.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

Prepared By:

FRONTIER ELECTRONIC SYSTEMS CORP.

P.O. BOX 1023

STILLWATER, OKLAHOMA 74076-1023

_1113369098