455088F ATP for the Media Converter.doc

455088F

SHAPE

REVISIONS

STILLWATER, OKLAHOMA 74076-1023

FOR THE MEDIA CONVERTER

MODULE (MC)

(P/N 456170)

CODE IDENT.

63812 455088F

ACCEPTANCE TEST PROCEDURE

FOR THE MEDIA CONVERTER

MODULE (MC)

(P/N 456170)

TABLE OF CONTENTS

Section Title Page

GENERAL INFORMATION

1.1

SCOPE

1.2

PURPOSE

1.3

TEST EQUIPMENT

1.4

LRADDS TEST RACK

1.5

GENERAL REQUIREMENTS

1.5.1 Production Routers

1.5.2 Test Conditions

1.5.3 Failure Reporting

1.5.4 Test Files

1.5.5 Test Data

PRE-TEST EVALUATION

2.1

CONTINUITY TEST

2.2

INSTALLATION AND SETUP PROCEDURE

2.2.1 Ethernet Fiber Cable Installation 2.2.2 Program the Module 2.3

AUTOMATED TEST PROGRAM

BURN-IN

FINAL TEST

4.1

AUTOMATED TEST PROGRAM

TABLE OF CONTENTS (Continued)

Section Title Page

APPENDIX A

PRODUCTION ROUTERS

A-1

APPENDIX B

NON-CONFORMANCE REPORTS (NCRs) B-1

APPENDIX C

BURN-IN LOG

C-1

LIST OF FIGURES

Figure Title Page

1.1-1 Testing Flow

1.4-1 Functional Test Setup

2.2.1-1 Ethernet Fiber Cable Assembly Installation

LIST OF TABLES

Table Title Page

1.3-1 Test Equipment

1.5.4-1 Test Files

2.1-1 Short Test Table

2.2-1 DIM Switch Settings for 456063-1 2.2-2 DIM Switch Settings for 456357-1 2.2-3 RIM Switch Settings for 456005-1 or 456354-1 2.2-4 Media Converter Switch Settings for 456170-1 Program Mode 2.2.2-1 Media Converter Module (MC) Switch Settings

2.3-1 Pre-Test Verification Table 3-1 Burn-in Test Information 4.1-1 Final Test Verification Table

SECTION 1

GENERAL INFORMATION

1.1

SCOPE

This document contains the test requirements for the acceptance testing of the Media Converter Module (MC) (P/N 456170). This document contains the following sections:

Section 1: General Information

Section 2: Pre-Test Evaluation Procedures

Section 3: Burn-In Procedures

Section 4: Final Test Procedures

The figure below illustrates the order of testing.

SHAPE

Figure 1.1-1. Testing Flow

1.2

PURPOSE

The purpose of this document is to demonstrate that the Media Converter Module (MC), 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

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 LRADDS Test rack

Figure 1.4-1 illustrates the equipment required to perform the procedures contained in this document.

Figure 1.4-1. Functional Test Setup

1.5

GENERAL REQUIREMENTS

1.5.1 Production Routers

Insert the Production Routers for the module into Appendix A.

1.5.2 Test Conditions

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

1.5.3 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.

1.5.4 Test Files

The test files required for testing are shown in the table below. A controlled copy of the MCM script file resides in Document Control under Mstr_software\456271\ -01 Rev X\ (where X is the latest revision).

Table 1.5.4-1. Test Files

1.5.5 Test Data

Successful completion of each test shall be annotated within these procedures.

SECTION 2

PRE-TEST EVALUATION

This section contains the steps for conducting a preliminary test of the Media Converter Module (MC) before subjecting it to a burn-in cycle.

2.1

CONTINUITY TEST

Using a digital multi-meter (DMM), verify that the power planes are not shorted together or to ground. Refer to schematic drawing 456168 to locate measuring points.

1.

Verify that there is no short between the following points, where a short is less than 5 Ohms. Measure points for a maximum duration of 5 seconds. Test points TP1 through TP6 are GND.

Table 2.1-1. Short Test Table

GND

TP1–6

+1.2V R66 +2.5V

R67 +3.3V R68

+1.2V R66

+2.5V R67

+3.3

R68

+5V C1

VERIFIED: _____________

2.2

INSTALLATION AND SETUP PROCEDURE

The installation and setup procedure verifies the test configuration.

1. Set the Test Chassis’ Power Supply Module switch to the OFF position.

2. Configure the switches on the Media Converter Module (MC) (P/N 456170) as shown on the label of the module and then reinstall the module into the Test Fixture securing the fasteners.

3.

Install the Media Converter Module (MC) into slot labeled as MC of the CRC Test Chassis in the LRADDS Test Rack (456124).

3. Loosen fasteners and remove Display Interface Module (DIM slot2) from the Display Interface Unit (DIU) Module Test Chassis. Verify the following switch settings as shown in Table 2.2-1 or Table 2.2-2 depending on assembly number used and reinstall module.

Table 2.2-1. DIM Switch Settings for 456063-1

SWITCH

3 WIRE OUTPUT 8192

S1-2

Display Type

S1-3

S1-4

Azimuth Rate

S1-5

S1-6

Primary/Secondary

S1-7

Video SIM

S1-8

AZ True/Relative

S4-2

S4-3

S4-4

S4-5

S4-6

Table 2.2-1. DIM Switch Settings for 456063-1 (Continued)

SWITCH

3 WIRE OUTPUT 8192

S4-7

S4-8

S5-2

ON

S5-3

ON

S5-4

S11

SIM

S16

Local Select

S17

S18

ON

S19-2

ON

S19-3

ON

S19-4

ON

Table 2.2-2. DIM Switch Settings for 456357-1

SWITCH

3 WIRE OUTPUT 8192

S1-2

Display Type

S1-3

S1-4

Azimuth Rate

S1-5

S1-6

Primary/Secondary

S1-7

Video SIM

S1-8

AZ True/Relative

S2-2

S2-3

S2-4

S3-2

S3-3

S3-4

S3-5

Table 2.2-2. DIM Switch Settings for 456357-1 (Continued)

SWITCH

3 WIRE OUTPUT 8192

S3-6

S3-7

S3-8

ON

S4-2

ON

S4-3

ON

S4-4

ON

S9-2

ON

S9-3

ON

S9-4

S10

SIM

S11

Local Select

S12

S13

*Closed = ON; Open/Blank = OFF 5.

Loosen fasteners and remove Radar Interface Module (RIM slot2) from the Radar Interface Unit (RIU) Module Test Chassis. Verify the following switch settings as shown in Table 2.2-3 and reinstall module securing fasteners.

Table 2.2-3. RIM Switch Settings for 456005-1 or 456354-1

SWITCH

PPI/RHI INPUT 8192

S1-2

S1-3

S1-4

ON

S1-5

S1-6

AZ True/Relative

S1-7

Not used

S1-8

Not used

Table 2.2-3. RIM Switch Settings for 456005-1 or 456354-1 (Continued)

SWITCH

PPI/RHI INPUT 8192

S2-2

S2-3

EOS

S2-4

TM SPLT

S2-5

S2-6

RM

S2-7

VID 1 SPLT

S2-8

VID 1

S3-2

ARP

S3-3

DY

S3-4

ACP SPLT

S3-5

ACP

S3-6

DX

S3-7

VID 2 SPLT

S3-8

VID 2

*Closed = ON; Open/Blank = OFF

Table 2.2-4. Media Converter Switch Settings for 456170-1 Program Mode

SWITCH

MC SETTING

2.2.1 Ethernet Fiber Cable Installation

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

1. Install the following cable assemblies according to Figure 2.2.1-1.

Figure 2.2.1-1. Ethernet Fiber Cable Assembly Installation

2.2.2 Program the Module

Note: The Aardvark user interface software can be found at 456272.

1. Plug in the Aardvark programming cable into J3. Place the board into the VME chassis and apply power to the board.

2. Open the Aardvark programming software.

3. Click on Configure Aardvark Adapter.

4. Click Refresh List. Select Port 0 and Batch Mode and click OK

5. Click Load and navigate to the following location:

Data3:\Document Control\Mstr_software\456187\-01 RevX\ (where X is the Rev)

6. Select the 456187 xml file and click Open

7. Click on Execute.

8. The program will load the xml file and show a Stopped status when complete.

9. Turn off power to the VME chassis and remove the board. Move the Aardvark programming cable from J3 to J4 and repeat the process in this document for the second part of the Media Converter board.

10. The module is now programmed with firmware and software. Turn off power to the VME chassis and refer to the ATP for the next steps.

11. Record below the firmware and software revisions used.

456187 Rev:_____________

12. Verify that the firmware and software have been loaded without failures.

13. Create and apply the label for Part Numbers flashed per Assembly Drawing 456170-1. Verify below

14. Set the Test Chassis’ Power Supply Module switch to the OFF position.

15. Remove the Media Converter Module (MC) (P/N 456170) and configure the switches as shown in Table 2.2.2-1.

Table 2.2.2-1. Media Converter Module (MC) Switch Settings

SWITCH

MC SETTING

Table 2.2.2-1. Media Converter Module (MC) Switch Settings (Continued)

SWITCH

MC SETTING

16. Reinstall the Media Converter Module into the Test Fixture, securing the fasteners.

2.3

AUTOMATED TEST PROGRAM

These procedures are performed using the LRADDS Test Rack and computer.

1.

Set the IIU Module Test Chassis’ Power Supply Module switch to the ON position. Also turn ON LRADDS computer tester power.

2.

Select the LRADDS Automated Tester icon on the initial windows screen and follow the displayed instructions.

3.

A dialog box “Interface Configurations” appears showing the expected Comm Port Assignments.

a.

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

b.

Select OK when complete.

4.

Select Test Info.

A dialog box prompting for “Tester Identification” will now be displayed. Enter the test operator's ID and press ENTER from the key module.

6.

A dialog box appears requesting a Serial Number. Enter the Media Converter (MC) Serial Number and press ENTER.

7.

Select test type “Module Level Testing” and then “Preliminary”.

8.

At the Module Selection screen, select “Media Converter (456170-1)”.

9.

For Script files in Table 2.3-1 the DIM needs to be in slot 2 of the DIU and the RIM needs to be in slot 2 of the RIU.

10.

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.

11.

Select all scripts in Table 2.3-1.

12.

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 the test. Upon completion of each test, annotate the appropriate entry in Table 2.3-1.

Table 2.3-1. Pre-Test Verification Table

NOTES

To re-run any test, execute step 11.

13.

After the test is complete, select Close File from the menu to save the test data.

14.

Set the IIU Module Test Chassis’ Power Supply Module 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 Media Converter Module (MC).

1.

Place the Media Converter Module (MC) into a test bed capable of providing power to the module per VMEbus standards.

2.

Place the test bed into a thermal chamber.

3.

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

4.

In Table 3-1 record the time and date of the beginning and end of the cycle and the total burn-in time.

Table 3-1. Burn-in Test Information

Date/Time

Insert the temperature burn-in chart into Appendix C.

Completion Verified: ________________

SECTION 4

FINAL TEST

This section details the functional testing of the Media Converter Module (MC).

4.1

AUTOMATED TEST PROGRAM

These procedures are performed using the LRADDS Test Rack and computer.

1.

Connect all cable per Figure 2.2.1-1

2.

Set the IIU Module Test Chassis’ Power Supply Module switch to the ON position. Also turn ON LRADDS computer tester power.

3.

Flash the Media Converter under test with firmware number 456187. Steps to flash are located in the 456187 folder. There are two flashes per board. Folders are located in Data3\Document Control\Mstr_software\NUMBER

4.

Select the LRADDS Automated Tester icon on the initial windows screen and follow the displayed instructions.

5.

A dialog box “Interface Configurations” appears showing the expected Comm Port Assignments.

a.

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

b.

Select OK when complete.

6.

Select Test Info.

7.

A dialog box prompting for “Tester Identification” will now be displayed. Enter the test operator's ID and press ENTER from the key module.

8.

A dialog box appears requesting a Serial Number. Enter the Media Converter (MC) Serial Number and press ENTER.

9.

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

10.

At the Module Selection screen, select “Media Converter (456170-1)”.

11.

For Script files in Table 4.1-1 the DIM needs to be in slot 2 of the DIU and the RIM needs to be in slot 2 of the RIU.

12.

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.

13.

Select all scripts in Table 4.1-1.

14.

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 the test. Upon completion of each test, annotate the appropriate entry in Table 4.1-1.

Table 4.1-1. Final Test Verification Table

NOTES

To re-run any test, execute step 12.

15.

After the test is complete, select Close File from the menu to save the test data.

16.

Set the IIU Module Test Chassis’ Power Supply Module switch to the OFF position.

17.

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

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 or 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)

APPENDIX C

BURN-IN LOG

ACCEPTANCE TEST PROCEDURE

FOR THE MEDIA CONVERTER

MODULE (MC)

(P/N 456170-1)

S/N: _________________

Prepared For:

Naval Surface Warfare Center Dam Neck (NSWCDN)

Dahlgren Division, Code F31

1922 Regulus Avenue

Virginia Beach, VA 23461-2067

17 SEPTEMBER 2012

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

YES

NO

NO

YES

Pre-test Evaluation

FINAL TEST

START MODULE TEST

INSTALLATION AND SETUP

SECTION 2.1

AUTOMATED TEST PROGRAM SECTION 2.2

SECTION 2.2

Pass Test?

BURN-IN

BOARD

SECTION 3

INSTALLATION

AND SETUP

SECTION 2.1

AUTOMATED

TEST PROGRAM

SECTION 4.1

Pass Test?

Module Test complete

REPAIR

BOARD PER

PARA 1.4.3

MODULE TEST

_1409380750.vsd text

Interface Panel RIU

LRADDS Test Fixture

SPY 6 Wire HRI

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)

3-Wire

Backplane

Power Supply

RIM (Golden)

RADDS

ACP/ARP

Synchro

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)

QSDM (Slot 8)

MC (Slot 9)

LRADDS Test System

NW Sw

NW Sw (up to 14)

NAWCAD SIM

Video

Big Iron 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 (Dell T7400 w/ 3 ea Intel EXPI9404PTL Quad Port NIC)

Fiber Jumper

To Port Under test

Serial Data (2)

Copper Jumper

NAV Data (RS-422)

Test System Configured For Media Converter Test

IFF Vid (2)

SBC (Slot 10)

456115-1

RIM (Golden)

RIM (Slot 1)

DIM (Slot 1)

DIM (Golden)

_1399880234.vsd