455054D ATP for Spare Power Conditioner.doc

455054D

REVISIONS

STILLWATER, OKLAHOMA 74076-1023

FOR THE SPARE POWER CONDITIONER ASSEMBLY (P/N 456037-1)

CODE IDENT.

63812 455054D

CONTRACT NO.

ACCEPTANCE TEST PROCEDURE

FOR THE POWER CONDITIONER

ASSEMBLY (P/N 456037-1)

TABLE OF CONTENTS

Section Title Page

1GENERAL INFORMATION

11.1

SCOPE

11.2

PURPOSE

11.3

TEST EQUIPMENT

11.4

GENERAL REQUIREMENTS

11.4.1 Production Routers

11.4.2 Test Conditions

11.4.3 Failure Reporting

11.4.4 Document References

11.4.5 Script Files and Firmware

11.4.6 Test Data

11.4.7 Vendor Specifications

1TEST PROCEDURES

12.1 Setup

12.2 TEST Power CONDITIONER CONTROLS AND OUTPUT

12.3 UShA CARD CONFIGURATION

12.4 Load Test

1Addendum A Input Power Verification

1Addendum B Setting up a Linux tftp Server

1APPENDIX A

PRODUCTION ROUTERS

A-

1APPENDIX B

NON-CONFORMANCE REPORTS (NCRs) B-

LIST OF FIGURES

Figure Title Page 1.1-1 Testing Flow 2.1-1 Power Conditioner Assembly Test Configuration 2.2-1 Power Conditioner Front Panel 2.2-2 Output Connector AC-1 through AC-4 Signal and Contact Locations 2.3-1 USHA Configuration Utility Main Menu 2.3-2 USHA Configuration Menu 2.3-3 System Group Configuration Menu 2.3-4 Parameter Group Configuration Menu 2.3-5 IPv4 Configuration Menu 2.3-6 Date and Time Menu 2.3-7 Control Group Configuration Menu 2.4-1 USHA Configuration Utility Main Menu 2.4-2 USHA Configuration Menu 2.4-3 System Group Configuration Menu 2.4-4 IPv4 Configuration Menu Add A-1 AC Power Cable Signal and Contact Locations

LIST OF TABLES

Table Title Page 1.3-1 Test Equipment 1.4.5-1 Script Files and Firmware

SECTION 1

GENERAL INFORMATION

1.1 SCOPE

This document contains the test requirements for the acceptance testing of the Power Conditioner Assembly (P/N 456037-1). This document contains the following sections:

Section 1: General Information

Section 2: Test Procedures The figure below illustrates the order of testing.

Figure 1.1-1. Testing Flow

1.2 PURPOSE

The purpose of this document is to demonstrate that the Power Conditioner Assembly as manufactured by Frontier Electronic Systems meets or exceeds all requirements 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

SPECIFICATIONS

CALIBRATION

EXP. DATE

Fluke

N/A

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.

1.4 GENERAL REQUIREMENTS

This section lists the general requirements for this document.

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 shall be performed at standard room ambient temperature, 60( to 80(F.

1.4.3 Failure Reporting

Non-Conformance Reports (NCRs) shall be used to document test failures in accordance with FES-QSP-8.3-3 when required. A copy of the NCR shall be included under Appendix B.

1.4.4 Document References

These documents are referenced in the body of this document:

455045 Network Requirements for the AN/SPQ-15(V) Data Distribution System (DDS)

1.4.5 Script Files and Firmware

Table 1.4.5-1 lists the script files and firmware required to perform the procedures listed in this document.

Table 1.4.5-1. Script Files and Firmware

1.4.6 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.

1.4.7 Vendor Specifications

Vendor part number:

UPR1-4.0K-1G-SRNDTI-JS2E

Vender Series:

4Kva SRNDTI

Vender Reference:

008-4Kvasrndtiupsj.pdf

Output Tolerance:

120VAC ± 3%

SECTION 2

TEST PROCEDURES

This section contains the steps for conducting the test of the Power Conditioner Assembly before shipment as a spare unit or installation into the next higher assembly.

2.1 Setup

If a new power cord is made or an assembly needs to be checked, refer to Addendum A – Input Power Verification. If not, then connect the Power Conditioner Assembly and test equipment per Figure 2.1-1.

Figure 2.1-1. Power Conditioner Assembly Test Configuration

2.2 TEST Power CONDITIONER CONTROLS AND OUTPUT

This section verifies the Power Conditioner front panel controls function correctly and output voltages are within specification. Refer to Figure 2.2-1 for the following steps.

Figure 2.2-1. Power Conditioner Front Panel

1. On the Power Conditioner, set the INPUT POWER switch and SYSTEM ON/OFF switch to OFF.

2. Apply power to the Power Conditioner.

3. On the Power Conditioner, set the INPUT POWER switch to ON.

4. On the Power Conditioner, set the SYSTEM ON/OFF switch to ON.

5. Upon power ON, the Power Conditioner completes a self-diagnostic routine that will cause some of the front panel indicators to flash several times. Allow a few moments for its indicators to settle before proceeding.

6. On the Power Conditioner front panel, under the STATUS heading, verify the AC IN OK indicator is ON.

Verified:___________

7. On the Power Conditioner front panel, under the STATUS heading, verify the INV indicator is ON.

8. On the Power Conditioner front panel, under the LOAD heading, verify that all indicators are OFF.

9. On the Power Conditioner front panel, verify the AC INPUT indicator is ON.

10. Verify the Power Conditioner’s fan is operating by verifying the air is being exhausted out the back of the unit.

11. Use a multimeter set for AC voltage measurements to verify the following voltages between the contacts of the Power Conditioner output connectors AC-1 through AC-4, located at the rear on the unit. See Figure 2.2-2 for contact locations.

WARNING

AC-1 through AC-4 connector contacts carry 120 VAC. Avoid touching or shorting between contacts or chassis.

Figure 2.2-2. Output Connector AC-1 through AC-4 Signal and Contact Locations

(Orientation: Looking at the pins of the connector)

a) 120 VRMS (+5/-5 VRMS) contact 1 (Line) to contact 3 (GND)

b) Less than 5 VRMS contact 3 (GND) to chassis

2.3 UShA CARD CONFIGURATION

This section configures the Power Conditioner.

1. Using the LRADDS Linux Test Computer, login to root using the user name: root and password: admin12.

2. Open a Terminal Window by right-button clicking on the desktop and selecting “Open Terminal” with a left-button click.

3. At the prompt of the Terminal, type “chkconfig --list tftp” and press “Enter“. Observe that the response is “tftp on”. If it is not, then follow the procedure in Addendum B to enable tftp.

4. At the prompt of the Terminal, access the Power Conditioner via Minicom by typing “minicom” in the Terminal and press “Enter“.

5. Sign in to the Power Conditioner by entering “admin12” for the password and press “Enter.” This will bring up the USHA Configuration Utility Main Menu which can be seen in Figure 2.3-1.

Figure 2.3-1. USHA Configuration Utility Main Menu

6. At the “=>” prompt, enter ‘1’ and press “Enter” for the USHA Configuration. This will bring up the USHA Configuration Menu which can be seen in Figure 2.3-2.

Figure 2.3-2. USHA Configuration Menu

7. At the “=>” prompt, enter ‘1’ and press “Enter” for System Group. Refer to Figure 2.3-3, System Group Configuration Menu, and verify that the USHA card firmware version is v6.01 or above.

Figure 2.3-3. System Group Configuration Menu

8. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Menu which can be seen in Figure 2.3-2.

9. At the “=>” prompt, enter ‘3’ and press “Enter” for Parameter Group. This will bring up the Parameter Group Configuration Menu which can be seen in Figure 2.3-4.

Figure 2.3-4. Parameter Group Configuration Menu

10. At the “=>” prompt, enter ‘6’ and press “Enter” to configure the Default Language.

11. Enter ‘2’ to set the Default Language as English.

12. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Menu which can be seen in Figure 2.3-2.

13. At the “=>” prompt, enter ‘1’ and press “Enter” for System Group. This will bring up the System Group Configuration Menu which can be seen in Figure 2.3-3.

14. At the “=>” prompt, enter ‘1’ and press “Enter” to configure the IP Address. This will bring up the IPv4 Configuration Menu which can be seen in Figure 2.3-5.

Figure 2.3-5. IPv4 Configuration Menu

15. At the “=>” prompt, enter ‘1’ and press “Enter” to set the IP Address.

16. Enter 172.16.0.53 and press “Enter” to set the new IP Address.

17. At the “=>” prompt, enter ‘3’ and press “Enter” to set the Network Mask.

18. Enter 255.255.254.0 and press “Enter” to set the new Network Mask.

19. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the System Group Configuration Menu which can be seen in Figure 2.3-3.

20. At the “=>” prompt, enter ‘3’ and press “Enter” for Date and Time. This will bring up the Date and Time Menu which can be seen in Figure 2.3-6.

Figure 2.3-6. Date and Time Menu

21. At the “=>” prompt, enter ‘1’ and press “Enter” to set the System Date. Set to the current date (dd/mm/yyyy) and press “Enter.”

22. At the “=>” prompt, enter ‘2’ and press “Enter” to set the System Time. Set to the current time (hh:mm:ss) and press “Enter.”

23. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the System Group Configuration Menu which can be seen in Figure 2.3-3.

24. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Menu which can be seen in Figure 2.3-2.

25. At the “=>” prompt, enter ‘2’ and press “Enter” for Control Group. This will bring up the Control Group Configuration Menu which can be seen in Figure 2.3-7.

Figure 2.3-7. Control Group Configuration Menu

26. At the “=>” prompt, enter ‘2’ and press “Enter” to change the Read-Only Community String.

27. Enter “dfltRO_AN-SPQ-15V-C” and press “Enter” to set the New Community Name.

28. At the “=>” prompt, enter ‘4’ and press “Enter” for BOOT/DHCP Control.

29. At the “=>” prompt, enter ‘2’ and press “Enter” to Disable.

30. At the “=>” prompt, enter ‘5’ and press “Enter” for TFTP/HTTP Upgrade Control.

31. At the “=>” prompt, enter ‘2’ and press “Enter” to Disable.

32. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Menu which can be seen in Figure 2.3-2.

33. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Utility Main Menu which can be seen in Figure 2.3-1.

34. At the “=>” prompt, enter ‘0’ and press “Enter” to exit the USHA Configuration.

35. At the “Ready” prompt, press “Ctrl-a” to access the Minicom menu.

36. Press ‘x’ and press “Enter” to leave the Minicom session.

37. At the prompt, type “exit” and press “Enter” to close the Terminal window.

2.4 Load Test

This section tests that the Power Conditioner USHA Card responds to a change in the load.

1. On the Test Computer, open the Terminal by right-clicking on the desktop and selecting “Open Terminal.”

2. At the Terminal Prompt, enter “LNST-001” and press “Enter” to run the load test script.

3. Follow the directions on the screen to complete the load test. When it asks for the Power Conditioner to be loaded down, plug in the AC OUT power strip into the back of the Power Conditioner, plug in two (2) Flood Lamps, and turn them on. When finished with the test script, turn them off. Verify the test indicates the Power Conditioner has no problems or irregularities.

Verified:___________

4. Open a Terminal Window by right-button clicking on the desktop and selecting “Open Terminal” with a left-button click.

5. At the prompt of the Terminal, access the Power Conditioner via Minicom by typing “minicom” in the Terminal and press “Enter“.

6. Sign in to the Power Conditioner by entering “admin12” for the password and press “Enter.” This will bring up the USHA Configuration Utility Main Menu which can be seen in Figure 2.4-1.

Figure 2.4-1. USHA Configuration Utility Main Menu

7. At the “=>” prompt, enter ‘1’ and press “Enter” for the USHA Configuration. This will bring up the USHA Configuration Menu which can be seen in Figure 2.4-2.

Figure 2.4-2. USHA Configuration Menu

8. At the “=>” prompt, enter ‘1’ and press “Enter” for System Group. This will bring up the System Group Configuration Menu which can be seen in Figure 2.4-3.

Figure 2.4-3. System Group Configuration Menu

9. At the “=>” prompt, enter ‘1’ and press “Enter” to configure the IP Address. This will bring up the IPv4 Configuration Menu which can be seen in Figure 2.4.4.

Figure 2.4-4. IPv4 Configuration Menu

10. At the “=>” prompt, enter ‘1’ and press “Enter” to set the IP Address.

11. Enter 172.16.0.250 and press “Enter” to set the new IP Address. This is the spare power conditioner IP Address.

12. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the System Group Configuration Menu which can be seen in Figure 2.3-3.

13. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Menu which can be seen in Figure 2.4-2.

14. At the “=>” prompt, enter ‘0’ and press “Enter” to return to the USHA Configuration Utility Main Menu which can be seen in Figure 2.4-1.

15. At the “=>” prompt, enter ‘0’ and press “Enter” to exit the USHA Configuration.

16. At the “Ready” prompt, press “Ctrl-a” to access the Minicom menu.

17. Press ‘x’ and press “Enter” to leave the Minicom session.

18. At the prompt, type “exit” and press “Enter” to close the Terminal window.

19. On the Power Conditioner, set the SYSTEM ON/OFF switch to OFF.

20. On the Power Conditioner, set the INPUT POWER switch to OFF.

21. Remove power from the Power Conditioner.

22. Copy all data files to the network drive data3\Shared Data\Naval Systems\Test Data\part number\serial number.

Verified:___________

Addendum A Input Power Verification This section verifies the AC power input for the Power Conditioner Assembly is correct.

1. Using a multimeter set for AC voltage measurements, ensure 115 VAC voltage between Line and Return contacts of the AC input cable. Refer to Figure Add A-1 for contact locations.

WARNING

Power cable connector contacts carry 115 VAC. Avoid touching or shorting between contacts.

Figure Add A-1. AC Power Cable Signal and Contact Locations

(Orientation: Looking at the pins of the connector)

a) 115 VRMS (+10/-5 VRMS) contact 1 (Line) to contact 3 (Ground)

b) 115 VRMS (+10/-5 VRMS) contact 1 (Line) to contact 2 (Return)

c) Less than 5 VRMS contact 2 ( Return ) to contact 3 (Ground)

2. Remove AC power to the power input cable.

Addendum B Setting up a Linux tftp Server

This sections describes the process of setting up a Linux tftp server on the Tester.

1. Edit the file /etc/xinetd.d/tftp by changing into the file location by typing “cd /etc/xinetd.d/”.

2. Edit the file /etc/xinetd.d/tftp to match the following by typing “vi tftp” in the Terminal window.

3. Set the line numbering by typing “:set nu”. Note the line number for “disable = yes”.

4. Change the word yes to no by typing “:[noted line number]s/yes/no/g”, for example: “:14/s/yes/no/g”. The file should look similar to the following:

service tftp socket_type = dgram protocol = udp wait = yes user = root server = /usr/sbin/in.tftpd server_args = -s /tftpboot disable = no

5. To save and quit vi editor, type “:wq”.

6. To turn the tftp service on, type “chkconfig tftp on”.

7. Restart the tftpd daemon by typing “service xinetd reload”.

8. To check if the tftpboot directory is available, type “ls –d /tftpboot”. It will return /tftpboot if the directory exists.

9. To create a tftp folder if it does not exist, type “mkdir /tftpboot” followed by “chmod 777 /tftpboot”.

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. The applicable test / inspection stamp will be affixed by the signature blocks.

Test Technician: ________________________________Date:____________

Quality Engineer: _______________________________Date:____________

APPENDIX A

PRODUCTION ROUTERS

APPENDIX B

NON-CONFORMANCE REPORTS (NCRs)

ACCEPTANCE TEST PROCEDURE

FOR SPARE POWER CONDITIONER ASSEMBLY (P/N 456037-1)

MFG. S/N: _________________

S/N: _________________

8 FEBRUARY 2013

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

| [ USHA Configuration Utility Main Menu ] |

1. USHA Configuration

2. UPS Parameters

3. Access Control Table

4. Domain User Table

5. Trap Receiver Table

6. SNMPv3 USM Table

7. Reset Configuration To Default

8. Restart USHA

9. UPS Pass-Through

0. Exit

| [ USHA Configuration Menu ] |

1. System Group

2. Control Group

3. Parameter Group

4. Email Group

5. Web Authentication Group

6. Ping Group

0. Return to previous menu

| [ System Group Configuration Menu ] |

USHA Version : USHA Pro II Mini Card v6.01 (SN 1121001919086)

Ethernet address : 00 E0 D8 13 74 D9

1. IPv4 Configuration

2. IPv6 Configuration

3. Date and Time

4. DNS IP Address : 192.168.7.3

| [ Parameter Group Configuration Menu ] |

1. sysContact : Technical Support Team

2. sysName : USHA

3. System Location :

4. EMD Configuration : Disabled

5. Temperature Unit : Celsius

6. Default Language : Auto

| [ IPv4 Configuration Menu ] |

1. IPv4 Address : 192.168.18.54

2. IPv4 Gateway Address : 192.168.18.254

3. IPv4 Network Mask : 255.255.254.0

| [ Date and Time Menu ] |

1. System Date (dd/mm/yyyy) : 02/07/2009

2. System Time (hh:mm:ss) : 21:32:47

3. NTP Server :

4. NTP Time Zone : 00:00

5. Daylight Saving Time Control : Disabled

6. NTP Control : Disabled

| [ Control Group Configuration Menu ] |

1. HTTP Login Username : USHA

2. Community Read-Only : public

3. Community Read/Write : *

4. BOOTP/DHCP Control : Enabled

5. TFTP/HTTP Upgrade Control : Enabled

6. PING Echo Control : Enabled

7. Telnet Control

8. HTTP Control

9. SNMP Control

A. SMTP Port : 25

B. SSH Control

| [ USHA Configuration Utility Main Menu ] |

1. USHA Configuration

2. UPS Parameters

3. Access Control Table

4. Domain User Table

5. Trap Receiver Table

6. SNMPv3 USM Table

7. Reset Configuration To Default

8. Restart USHA

9. UPS Pass-Through

0. Exit

| [ USHA Configuration Menu ] |

1. System Group

2. Control Group

3. Parameter Group

4. Email Group

5. Web Authentication Group

6. Ping Group

| [ System Group Configuration Menu ] |

USHA Version : USHA Pro II Mini Card v6.01 (SN 1121001919086)

Ethernet address : 00 E0 D8 13 74 D9

1. IPv4 Configuration

2. IPv6 Configuration

3. Date and Time

4. DNS IP Address : 192.168.7.3

| [ IPv4 Configuration Menu ] |

1. IPv4 Address : 192.168.18.54

2. IPv4 Gateway Address : 192.168.18.254

3. IPv4 Network Mask : 255.255.254.0

_1421819355.vsd

SILENCE

_1421819358.vsd

_1423049949.vsd

120 VAC

Conditioned Power (1-Line, 2-Rtn, 3-Gnd)

LRADDS TESTER

P/N 456124 (Linux Test Computer)

RS232

115 VAC

Input Power

Copper Ethernet (CAT5)

Ethernet

Vendor Supplied RS-232 to RJ45 Serial Cable

LRADDS TESTER

RX-4 NETWORK

SWITCH

Output Test Power Strip

POWER

CONDITIONER ASSEMBLY

P/N 456037-1

Port 12

COM 2

_1421819356.vsd

_1421819352.vsd

MODULE TEST

Start Test

Test Complete

Input Power Verification and Setup

USHA Card Configuration

Test Power Conditioner Controls and Output

Load Test

Pass Tests?

Yes

Yes

USHA Card Firmware Upgrade

Firmware Version at least V6.01?

No

Correct Fault Para 1.4.3

No