455048J ATP for the SDC.doc

455048J

SHAPE \* MERGEFORMAT

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STILLWATER, OKLAHOMA 74076-1023

FOR THE SIGNAL DATA CONVERTER

(P/N 456008-1)

CODE IDENT.

63812 455048J

ACCEPTANCE TEST PROCEDURE

FOR THE SIGNAL DATA CONVERTER

(P/N 456008-1)

TABLE OF CONTENTS

Section Title Page

GENERAL

11.1

SCOPE

11.2

PURPOSE

11.3

TEST OVERVIEW

11.3.1 SDC Unit Level Testing

21.3.2 Script Files

21.4

TEST EQUIPMENT

31.5

LRADDS TEST RACK

31.6

GENERAL REQUIREMENTS

31.6.1 As-Built Documentation

41.6.2 Test Conditions

41.6.3 Failure Reporting

41.6.4 Test Data

FACTORY ACCEPTANCE TEST PROCEDURES

52.1

UNIT SERIAL NUMBER

52.2

SDC POWER CHECK SECTION

52.2.1 AC Power Check

62.3

SDC POWER-UP SECTION

62.3.1 SDC Power-Up

2.3.2 Unloaded Power Supply Check

2.3.3 VME Chassis Power Check Procedure 102.4

TEMPERATURE WARNING SECTION

102.4.1 Temperature Warning SDC Test

122.4.2 Module Installation Procedure

2.4.3 Ethernet Fiber Cable Installation 142.4.4 Power Supply/Indicators Test

TABLE OF CONTENTS (Continued)

Section Title Page 162.4.5 Automated Test

APPENDIX A

AS BUILT CONFIGURATION DATA SHEETS

A-1

APPENDIX B

PRODUCTION ROUTERS

B-1

APPENDIX C

NON-CONFORMANCE REPORTS (NCRs) C-1

LIST OF FIGURES

Figure Title Page 31.5-1 Functional Test Setup

72.3.1-1 Backplane Connector Lower J9 Pin-out Locations

102.3.3-1 Extender Pin-out Locations

172.4.5-1 LRADDS Test Rack Configuration

LIST OF TABLES

Table Title Page 11.3.1-1 SDC Input/Output Script File Summary

21.3.2-1 Signal Data Converter (SDC) (P/N 456008-1) Test Script Files

21.4-1 Test Equipment

52.2.1-1 Fuse Table for the SDC Configuration

92.3.3-1 VME Pin-outs

122.4.2-1 SDC Module Slot Installation

132.4.2-2 Radar Interface Module (RIM) Switch Settings

142.4.3-1 Ethernet Fiber Cable Assembly Installation Table

152.4.4-1 Power Supply Test Point Voltages

2.4.5-1 Test Table

SECTION 1

GENERAL

1.1 SCOPE

This document contains the test requirements for the production/acceptance testing of the Signal Data Converter (SDC) (P/N 456008-1), referred to herein as the unit. The unit consists of four Radar Interface Modules (RIM) and a SPY Signal Splitter Module (SSSM). This document contains the following sections:

Section 1: General Information

Section 2: Factory Acceptance Test

1.2 PURPOSE

The purpose of this document is to provide a test procedure to demonstrate that the unit, as manufactured by Frontier Electronics Systems (FES), meets or exceeds all limits and tolerances specified within this document.

1.3 TEST OVERVIEW

1.3.1 SDC Unit Level Testing

Table 1.3.1-1 is a list of input/output tests that shall be used to validate the SDC.

Table 1.3.1-1. SDC Input/Output Script File Summary

* Frontier Document Number 455005A

1.3.2 Script Files

The script files required for testing are shown in the table below. Controlled copies of the SDC script files reside in Document Control under Mstr_software\456271\ -01 Rev X\ (where X is the latest revision).

NOTE

Table 1.3.2-1. Signal Data Converter (SDC) (P/N 456008-1) Test Script Files

1.4 TEST EQUIPMENT

Table 1.4-1 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 listed in the table.

Table 1.4-1. Test Equipment

SPECIFICATIONS

CALIBRATION

EXP. DATE

Tektronix

Fluke

Note 1: FES maintains calibration of equipment IAW ISO 9001, procedures FES-QSP-7.6-1-1 and FES-QSP-7.6-2.

Note 2: Equivalent or superior equipment may be substituted for the equipment listed above.

1.5 LRADDS TEST RACK

Figure 1.5-1 illustrates the equipment required to perform the procedures contained in this document.

Figure 1.5-1. Functional Test Setup

1.6 GENERAL REQUIREMENTS

1.6.1 As-Built Documentation

As-Built Configuration Tracking Sheets for the unit are inserted into Appendix A. Insert the routers for all assemblies of the unit into Appendix B.

1.6.2 Test Conditions

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

1.6.3 Failure Reporting

Non-Conformance Reports (NCRs) shall be used to document test failures in accordance with FES-QSP-8.3-3 when required. Copies of each NCRs shall be inserted into Appendix C.

1.6.4 Test Data

Successful completion of each test shall be annotated within these procedures. Test data recorded during automated testing shall be maintained on the FES network at data3\Shared Data\Naval Systems\Test Data\part number\serial number.

SECTION 2

FACTORY ACCEPTANCE TEST PROCEDURES

2.1

UNIT SERIAL NUMBER

Enter the Serial Number of the Signal Data Converter (SDC) (P/N 456008-1)) on the front of test procedure.

2.2

SDC POWER CHECK SECTION

2.2.1 AC Power Check The AC power check verifies correct wiring of the AC input and the two Power Supply Modules.

1.

Ensure the SDC chassis has no modules installed.

2. Before attaching AC power entry cable to J43 on SDC unit, place the MAIN POWER switch to the OFF position.

3. Place the TEMPERATURE WARNING switch to the DISABLE position.

4. Remove all fuses from the SDC and verify the part numbers and amp rating of fuses F1 thru F4 as per Table 2.2.1-1.

Table 2.2.1-1. Fuse Table for the SDC Configuration

Amp

Rating 5 Amp

Slo-Blo 5 Amp

Slo-Blo 5 Amp

Slo-Blo 5 Amp

Slo-Blo

Verified:___________

5. Check connector J43 (AC power connector) on unit with a multimeter set for ohms measurements, to ensure that there is no short between pins A (B, C (B, and A (C and that Pin B is connected to ground (chassis).

6. Check connectors J33, J34, J41, J42 (Synchro AZ connectors) on the unit with a multimeter set for ohms measurements to ensure that there is no short between pins A→B, A→C, A→D, A→E, B→C, B→D, B→E, C→D, C→E, D→E.

2.3

SDC POWER-UP SECTION

2.3.1 SDC Power-Up The SDC power-up procedure verifies the functioning of the cooling fans and power indicators.

1.

Ensure the SDC Chassis has no modules installed.

2. Apply AC power to J43 of the SDC unit.

3. Install the Power Supply Load Tester into Power Supply 2 slot.

4. On the SDC, set the MAIN POWER switch to the ON position.

5. Ensure that the DS1 Power ON indicator is illuminated and that the three (3) cooling fans are rotating and exhausting air upwards.

Verified:___________

WARNING

J9 and J16 connector pins carry 115 VAC. Avoid touching or shorting between contacts.

6. Using a multimeter set for AC voltage measurements, verify the following voltages between the lower J9 connector pins on the backplane of the SDC Chassis Power Supply. See Figure 2.3.1-1 for J9 pin layout.

a) 115 VRMS (+10/-5 VRMS) pin 30 (Line) to pin 32 (Ground)

b) 115 VRMS (+10/-5 VRMS) pin 30 (Line) to pin 28 (Neutral)

c) Less than 5 VRMS pin 28 (Neutral) to pin 32 (Ground)

Verified:___________

Figure 2.3.1-1. Backplane Connector Lower J9 Pin-out Locations

7. Turn on the Power Supply Load Tester.

8. Using a multimeter set for AC voltage measurements, verify the following voltages between test points on the Power Supply Load Tester.

a) 115 VRMS (+10/-5 VRMS) TP1 (Line) to TP3 (Ground)

b) 115 VRMS (+10/-5 VRMS) TP1 (Line) to TP2 (Neutral)

c) Less than 5 VRMS TP2 (Neutral) to TP3 (Ground)

Verified:___________

9. On the SDC, set the MAIN POWER switch to the OFF position.

10. Remove the Power Supply Load Tester from the SDC chassis.

2.3.2 Unloaded Power Supply Check

The Power Supply check verifies the presence of correct DC Power Supply voltages in an unloaded condition with no modules installed.

1. On the SDC, set the MAIN POWER switch to the OFF position.

2.

Install Converter Power Supply (Part Number 500190-2) into the POWER SUPPLY 1 slot of the SDC Chassis.

3.

On the SDC, set the MAIN POWER switch to the ON position and set POWER SUPPLY 1 switch in the upper SDC Chassis to the ON position.

4.

Verify that the three voltage indicators and PWR switch are illuminated.

Verified:___________ 5.

Set POWER SUPPLY 1 switch to the OFF position.

6.

On the SDC, set the MAIN POWER switch to the OFF position.

7.

Install the second Power Supply Module (500190-2) into the POWER SUPPLY 2 slot of the SDC Chassis.

8.

Repeat steps 3 through 6 for POWER SUPPLY 2.

Verified:___________ 9.

On the SDC, set the MAIN POWER switch to the OFF position.

10.

Set POWER SUPPLY1 and POWER SUPPLY 2 switches to the ON position.

11.

On the SDC, set the MAIN POWER switch to the ON position. Verify that the DC indicators on POWER SUPPLY 2 light up approximately one (1) second after the DC indicators on POWER SUPPLY 1 light up.

Verified:___________

12.

On the SDC, set the MAIN POWER switch and the POWER SUIPPLY switches to the OFF position.

2.3.3 VME Chassis Power Check Procedure The VME Chassis Power Check procedure verifies correct wiring and that the voltage is applied to the backplane connectors.

1.

Install an Extender Module (P/N 456104-1) into RIM 1 Chassis slot.

2. On both SDC Power Supply Modules, set the POWER switch to the ON position.

3. Using a multimeter set for DC voltage measurements, verify the following voltages in the RIM 1 slot are within the specified range, using the GND pin as a common reference for each voltage listed in Table 2.3.3-1. See Figure 2.3.3-1 for VME pin layout.

WARNING

P1 and P2 connector pins have the potential of sourcing high current. Avoid touching or shorting between contacts.

Table 2.3.3-1. VME Pin-outs

+5.35 max.

+4.875 min.

+11.64 min.

-11.64 max.

Figure 2.3.3-1. Extender Pin-out Locations

2.4

TEMPERATURE WARNING SECTION

2.4.1 Temperature Warning SDC Test

This procedure includes testing instructions that verify the SDC Temperature Warning Components are functioning and cabled correctly.

1.

On the SDC, set the MAIN POWER switch to the ON position and ensure that the DS1 Power On indicator is lit and the cooling fans are operating.

2.

On both Power Supply Modules, set the POWER switch to the ON position and ensure their DC voltage indicators and switches are illuminated.

3.

Set the TEMPERATURE WARNING switch to DISABLE and verify DS2 is OFF and no alarm is sounding.

Verified:___________ 4.

Set the TEMPERATURE WARNING switch to ENABLE and verify DS2 is OFF and no alarm is sounding.

Verified:___________

WARNING

Keep Heat Gun approximately 4 to 6 inches away from Thermostats to prevent excessive heating. Use a directional nozzle if available to focus heat exclusively on the Thermostats.

5.

Use a heat gun to apply heat to Thermostat RT1 located on the left side, closest to connector J1 until the SDC’s TEMPERATURE WARNING lamp DS2 illuminates.

6.

Verify the Warning Horn LS1 is sounding, then set the SDC’s TEMPERATURE WARNING switch to DISABLE and observe Audible Alarm sounding has ceased.

Verified:___________

7.

Allow the Thermostat Assembly to cool and TEMPERATURE WARNING lamp to go OFF.

Verified:___________ 8.

Set the TEMPERATURE WARNING switch to ENABLE and verify DS2 is OFF and no alarm is sounding.

Verified:___________

9.

Use a heat gun to apply heat to Thermostat RT2 located on the right side until the SDC’s TEMPERATURE WARNING lamp DS2 illuminates.

Verified:___________ 10.

Verify the Warning Horn LS1 is sounding, then set the SDC’s TEMPERATURE WARNING switch to DISABLE and observe Audible Alarm sounding has ceased.

Verified:___________ 11.

Allow the Thermostat Assembly to cool and TEMPERATURE WARNING lamp to go OFF.

Verified:___________

2.4.2 Module Installation Procedure

The module installation procedure verifies the default system level module configuration and all visual indicators.

1.

On both Power Supply Modules, set the POWER switch to the OFF position.

2.

On the SDC, set the MAIN POWER switch to the OFF position.

NOTE

Do not secure modules to the chassis during installation. Modules shall be removed for DIP switch selection at a later step.

3. Table 2.4.2-1 illustrates the position of each module to be installed in the SDC chassis.

Table 2.4.2-1. SDC Module Slot Installation

4.

Set all Front Panel switches to the OFF position On Signal Splitter Module (P/N 500034-1), then install into the SDC Chassis.

SWITCH

SIGNAL SPLITTER

S1-1 thru S1-8

OFF

5.

Set the following switch settings then sequentially install RIM 1 thru RIM 4 Modules (P/N 456354-1) into the SDC Chassis.

NOTE

Use the ID panel as a guide for selecting the module from a designated slot.

Table 2.4.2-2. Radar Interface Module (RIM) Switch Settings

SETTING

RIM 2

SETTING

RIM 3

SETTING

RIM 4

SETTING

6.

Install Spy Signal Splitter Module (P/N 456045-1) into the SDC Chassis.

7.

Install the Extender Card (P/N 456104-1) into the SDC Chassis.

2.4.3 Ethernet Fiber Cable Installation This section describes where to attach the external Ethernet Fiber Cable Assemblies.

1. Install the following cable assemblies according to Table 2.4.3-1.

Table 2.4.3-1. Ethernet Fiber Cable Assembly Installation Table

Ethernet Cable

Assembly

RIM

Connector

SDC

Connector

2.4.4 Power Supply/Indicators Test The Power Supply/Indicators test verifies correct wiring and function of the Power Supplies and module indicators.

1. On the SDC, set the MAIN POWER switch to the ON position.

2. Ensure that the DS1 Power On indicator is lit and the cooling fans are operating.

3. Set POWER SUPPLY 1 Module switch to the ON position.

4. Verify +5V, +12V, -12V LEDs and POWER Switch are lit on POWER SUPPLY 1 Module.

Verified:___________

5. Using a multimeter set for DC voltage measurements, check POWER SUPPLY 1 test point voltages and record the findings in Table 2.4.4-1. Set POWER SUPPLY 1 Module to the OFF position.

Table 2.4.4-1. Power Supply Test Point Voltages

+5.00

+5.35 max.

+4.875 min.

+12.00

+12.60 max.

+11.64 min.

-12.00

-12.60 min.

-11.64 max.

6. Set POWER SUPPLY 2 Module switch to the ON position.

7. Verify +5V, +12V, and -12V LEDs and POWER Switch are lit on POWER SUPPLY 2 Module.

Verified:___________

8. Using a multimeter set for DC voltage measurements, check POWER SUPPLY 2 test point voltages and record the findings in Table 2.4.4-1. Set POWER SUPPLY 1 Module to the ON position.

9. Verify that all measurements are within acceptable limits.

Verified:___________

10. Verify the status of the following displays on the SDC modules.

MODULE

DISPLAY

STATUS

SIGNAL SPLTR

ACTIVITY

ACP (GREEN LED)

OFF

ARP (GREEN LED)

TM (GREEN LED)

TE (GREEN LED)

V1

GP 1 (GREEN LED)

GP 2 (GREEN LED)

GP 3 (GREEN LED)

GP 4 (GREEN LED)

V2

GP 1 (GREEN LED)

GP 2 (GREEN LED)

GP 3 (GREEN LED)

GP 4 (GREEN LED)

RIM 1

LINK (GREEN LED)

TX (GREEN LED)

RX (GREEN LED)

SIM (GREEN LED)

AZ (GREEN LED)

RIM 2

RIM 3

RIM 4

SPY SIGNAL SPLITTER

NORMAL (GREEN LED)

ON

BYPASS (RED LED)

2.4.5 Automated Test This section contains the procedures for running an automated test on the SDC Unit section of the unit.

1.

Configure the Signal Data Converter (SDC) (P/N 456008-1) and Test Equipment as shown in Figure 2.4.5-1.

2.

Turn ON the power to all equipment associated with the SDC Unit Testing.

3.

Connect the LRADDS Test Rack cables to the DIU as shown in Figure 2.4.5-1.

Figure 2.4.5-1. LRADDS Test Rack Configuration 4.

Select the LRADDS Tester ICON on the initial windows screen and follow the displayed prompts.

5.

From the displayed Main Screen Menu, select the “Load Test” option. A dialog box with the names of the tests that can be run will be displayed.

6.

Select Unit Level Testing followed by Signal Data Converter and then select all tests listed in Table 2.4.5-1.

7.

The Main Screen will be displayed showing the entered information. From this display, select the BEGIN TEST option. The program will now display dialog boxes to provide the operator with step-by-step instructions for completing each test. Upon completion of each test, annotate the appropriate entry in Table 2.4.5-1.

Table 2.4.5-1. Test Table

8. Upon completion of all testing, copy the test data files(s) to the network drive data3\Shared Data\Naval Systems\Test Data\part number\serial number.

Verified: ______________

Comments:

VALIDATION

Signatures below serve as a validation of the successful completion and accuracy of the data contained herein. The Test Technician shall sign and date as an indication that all instructions have been followed and that each test step has been successfully completed. The Quality Engineer shall sign and date as an acknowledgement that the test data has been reviewed for completion and accuracy. Appropriate stamps shall be affixed by the signature blocks.

Test Technician: ____________________________________ Date:________________ Quality Assurance: __________________________________ Date:________________

APPENDIX A

AS BUILT Configuration Data Sheets

APPENDIX B

PRODUCTION ROUTERS

APPENDIX C

NON-CONFORMANCE REPORTS (NCRs)

ACCEPTANCE TEST PROCEDURE

FOR THE SIGNAL DATA CONVERTER (P/N 456008-1)

S/N: ________________

24 APRIL 2014

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

_1349681653.vsd text

Interface Panel RIU

LRADDS Test Fixture

SPY 6 Wire RHI

Sin/Cos

Synchro

ACP/ARP

SPY 6-Wire PPI

Azimuth Radar Data

NW Sw (up to 4)

NW Sw (up to 4)

Protocol Analyzer H/W and SW (LEDA Plus)

Test System Configured for RIM Test

(Heavy Weight Lines Indicate Paths used in this test)

Backplane

Power Supply

RIM (UUT)

RADDS

ACP/ARP

RIM (Slot 2)

RIM (Slot 3)

RIM (Slot 4)

Interface Panel DIU

DIM (Golden)

DIM (Slot 2)

DIM (Slot 3)

DIM (Slot 4)

SpySSM

SSM

Interface Panel IIU

IIM (Slot 1)

IIM (Slot 2)

IIM (Slot 3)

IIM (Slot 4)

RIM Test Chassis (RIU)

DIM Test Chassis (DIU)

IIM Test Chassis (IIU)

IIM (Slot 5)

IIM (Slot 6)

IIM (Slot 7)

SBC

QSC

LRADDS Test Rack

NW Sw

NW Sw (up to 14)

NAWCAD SIM

Video

Iron Box 24 port Network Switch

Dual Scan Cvtr Comupter

Dual Scan Cvtr Comptuer

HMI Computer w/RS422 conv

Power Conditioner

2 -T

To RIU Lx (up to 4)

To DIU Lx (up to 4)

To IIU Lx (up to 14)

To CDS Lx (up to 13)

CDS Emulator

Lx (1)

Test Computer (Supermicro X7DBN Motherboard w/ 3 ea Intel EXPI9404PTL Quad Port NIC)

To Port Under test

RADDS to 6W

NAV Data (RS-422)

6 Wire Out

3 Wire

_1366544673.vsd