455060J ATP for the RVC.doc

455060J

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STILLWATER, OKLAHOMA 74076-1023

FOR THE RADAR VIDEO CONVERTER (RVC) (P/N 456012)

CODE IDENT.

63812 455060J

ACCEPTANCE TEST PROCEDURE

FOR THE RADAR VIDEO CONVERTER

(RVC) (P/N 456012)

TABLE OF CONTENTS

Section Title Page

GENERAL

1.1

SCOPE

1.2

PURPOSE

1.3

TEST OVERVIEW

1.3.1 Script Files 1.4

TEST EQUIPMENT

1.5

LRADDS TEST RACK

1.6

GENERAL REQUIREMENTS

1.6.1 As-Built Documentation 1.6.2 Test Conditions 1.6.3 Failure Reporting 1.6.4 Test Data

FACTORY ACCEPTANCE TEST PROCEDURES

2.1

UNIT SERIAL NUMBER

2.2

RVC POWER CHECK SECTION

2.2.1 AC Power Check 2.3

RVC POWER-UP SECTION

2.3.1 RVC Power-Up 2.3.2 Unloaded Power Supply Check 2.3.3 VME Chassis Power Check Procedure

2.4

TEMPERATURE WARNING SECTION

2.4.1 Temperature Warning RVC Test

TABLE OF CONTENTS

Section Title Page 2.4.2 Module Installation Procedure 2.4.3 Ethernet Fiber Cable Installation 2.4.4 Power Supply/Indicators Test 2.4.5 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 1.5-1 Functional Test Setup 2.3.1-1 Backplane Connector Lower J9 Pin-out Locations 2.3.3-1 Extender Pin-out Locations 2.4.5-1 RVC LRADDS Test Rack Configuration A TABLE OF CONTENTS (Continued)

LIST OF TABLES

Table Title Page 1.3.1-1 RVC (P/N 456012) Test Script Files

1.4-1 Test Equipment 2.2.1-1 Fuse Table for the RVC Configuration 2.3.3-1 VME Pin-outs 2.4.2-1 RVC Module Slot Installation 2.4.2-2 DIM Switch Settings 2.4.2-3 RIM 3 Switch Settings 2.4.3-1 Ethernet Fiber Cable Assembly Installation Table 2.4.4-1 Power Supply Test Point Voltages 2.4.4-2 Power Supply Test Point Voltages 2.4.5-1 Automated Switching Test Record

SECTION 1

GENERAL

1.1

SCOPE

This document contains the test requirements for the production/acceptance testing of the Radar Video Converter (RVC) (P/N 456012), referred to herein as the unit. The unit consists of one, two, or four Display Interface Modules (DIMs). This document contains the following sections:

Section 1: General Information

Section 2: Factory Acceptance Test Procedures

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, meets or exceeds all limits and tolerances specified within this document.

1.3

TEST OVERVIEW

1.3.1 Script Files

The script files required for testing are shown in Table 1.3.1-1 below. Controlled copies of the RVC script files reside in Document Control under Mstr_software\456271\ -01 Rev X (where X is the latest revision).

Table 1.3.1-1. RVC (P/N 456012) 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 Radar Video Converter (RVC) (P/N 456012) on the front of test procedure.

2.2

RVC 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 RVC chassis has no modules installed.

2. Before attaching AC power entry cable to J41 on RVC 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 RVC 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 RVC Configuration

Amp

Rating 5 Amp

Slo-Blo 5 Amp

Slo-Blo 5 Amp

Slo-Blo 5 Amp

Slo-Blo

Verified:___________

5. Check connector J41 (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 J9, J19, J29 and J39 (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 and D→E.

2.3 RVC power-up SECTION

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

1.

Ensure the RVC Chassis has no modules installed.

2. Apply AC power to J41 of the RVC unit.

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

4. On the RVC, 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.

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 RVC 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)

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 RVC, set the MAIN POWER switch to the OFF position.

10. Remove the Power Supply Load Tester from the RVC 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 RVC, set the MAIN POWER switch to the OFF position.

2.

Install Converter Power Supply (P/N 500190-2) into the POWER SUPPLY 1 slot of the RVC Chassis.

3.

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

4.

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

5.

Set POWER SUPPLY 1 switch to the OFF position.

6.

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

7.

Install the second Power Supply Module (P/N 500190-2) into the POWER SUPPLY 2 slot of the RVC Chassis.

8.

Repeat steps 1 through 5 for POWER SUPPLY 2.

9.

On the RVC, 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 RVC, 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 RVC, 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 DIM 1 Chassis slot.

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

3. Using a multimeter set for DC voltage measurements, verify the following voltages 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 min.

Figure 2.3.3-1. Extender Pin-out Locations

4. Measure Backplane voltages located in DIM 1 slot. Verify voltages are in accordance with Table 2.3.3-1.

2.4

TEMPERATURE WARNING SECTION

2.4.1 Temperature Warning RVC Test This procedure includes testing instructions that verify the RVC Temperature Warning components are functioning and cabled correctly.

1.

Ensure all modules are removed from the RVC Chassis to gain access to both Thermostats located above the VME Chassis and under the fan assembly.

2.

On the RVC, 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.

3.

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

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

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

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.

6.

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

7.

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

8.

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

Verified:___________

9.

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

10.

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

11.

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

12.

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. For units that have less than four DIM modules, Test Fixture gold boards or production boards shall be used to populate the empty slots for Power and Automated Tests.

1.

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

2.

On the RVC, 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.

Install the following modules into the RVC Chassis using the ID panel as an installation guide for correct placement.

Table 2.4.2-1. RVC Module Slot Installation

Set the following switch settings then sequentially install DIM 1 thru DIM 4 Modules (P/N 456357-1) into the RVC Chassis.

NOTE

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

Table 2.4.2-2. DIM Switch Settings

SETTING

Set the following switches to the RIM 1 & 2 Modules (P/N 456005-1 or 456354-1), located in slots 1 & 2 of the SDC chassis in the LRADDS tester.

Table 2.4.2-3. RIM 3 Switch Settings

SETTING

NOTE

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

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

RVC

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 RVC, 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.

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 max.

-11.64 min.

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. With both Power Supplies ON verify that all measurements are within acceptable limits and record the findings in Table 2.4.4-2.

Table 2.4.4-2. Power Supply Test Point Voltages

+5.00

+5.25 max.

+4.875 min.

+12.00

+12.60 max.

+11.64 min.

-12.00

-12.60 max.

-11.64 min.

10. Place DIM 1 thru DIM 4 switches in SIM Mode by using the switch located on the front panel.

11. Verify the status of the following displays on the RVC modules and that they are to be shipped with the unit. Link will be lit if GiGE is present. TX & RX will be blinking if Ethernet is present.

(ID Panel Description)

MODULE

DISPLAY

STATUS

DIM 1

LINK (GREEN LED)

ON

TX (GREEN LED)

BLINKING

RX (GREEN LED)

TM (GREEN LED)

TE (GREEN LED)

SIM (GREEN LED)

AZ (GREEN LED)

RADDS (GREEN LED)

OFF

SYNCHRO (GREEN LED)

3 WIRE (GREEN LED)

ACP/ARP (GREEN LED)

DIM 2

DIM 3

DIM 4

12.

Set the SIM Mode switch to OFF on DIM 1 thru DIM 4.

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

1.

Configure the Radar Video Converter (RVC) (P/N 456012) and Test Equipment as shown in Figure 2.4.5-1.

2.

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

3.

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

Figure 2.4.5-1. RVC LRADDS Test Rack Configuration A 4.

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

A dialog box “Interface Configuration” appears showing the expected Comm Port Assignments and GPIB Addresses.

Verify that the Communication Ports and GPIB Addresses are set as they appear in the display.

Select OK when complete.

6.

Select Test Info.

7.

A dialog box prompting for “Tester Identification” shall now be displayed. Enter the test operator's name and press ENTER.

8.

A dialog box appears requesting the unit Serial Number. Enter the Radar Video Converter (RVC) Serial Number and press ENTER.

9.

Select test type “Unit Level Testing” and then “Final”.

10. At the Unit Selection Screen, select “Radar Video Converter (RVC) (456012)”.

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

12.

The Main Screen shall be displayed showing the entered information. From this display, select the “Begin Test” option.

13. The program will display dialog boxes to provide the operator with step-by-step instructions for completing the Factory Acceptance Testing. Upon completion of each test, annotate the appropriate entry in Table 2.4.5-1.

Table 2.4.5-1. Automated Switching Test Record

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

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 RADAR VIDEO CONVERTER (RVC) (P/N 456012-_)

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

_1349681781.vsd text

Interface Panel RIU

LRADDS Test Ficture

NW Sw (up to 4)

Power Supply

3-Wire

RADDS

Azimuth Radar Data and Video

Protocol Analyzer H/W and SW (LEDA Plus)

Backplane

RIM (Golden)

Card Extender

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

QSDM

LRADDS Test Rack

NW Sw

NW Sw (up to 14)

CP-1273 Emulator

Fans, Controls and Indicators

120Vac

Big Iron 24 port Network Switch

Dual Scan Cvtr Computer

Dual Scan Cvtr Computer

HMI Computer w/RS422 conv

Power Conditioner

2 -T

To SDC Lx (up to 4)

To RVC Lx (up to 4)

To CRC 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

ACP/ARP

Synchro

Interface Panel DIU

SPA-25G/H Display

DIM (Slot 1)

DIM (Slot 2)

DIM (Slot 3)

DIM (Slot 4)

RVC (UUT)

Sin/Cos

Video

NW Sw (up to 4)

Test System Configuration for DIU

_1336478915.vsd