455278A RIM ATP (PN 456354-2).doc

455278A

SHAPE \* MERGEFORMAT

REVISIONS

STILLWATER, OKLAHOMA 74076-1023

FOR THE RADAR INTERFACE

MODULE (RIM)

(P/N 456354-2)

CODE IDENT.

63812 455278A

ACCEPTANCE TEST PROCEDURE

FOR THE RADAR INTERFACE

MODULE (RIM)

(P/N 456354-2)

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 Script Files 1.5.5 Test Data

PRE-TEST EVALUATION

2.1

SHORT TEST

2.2

INSTALLATION AND SETUP PROCEDURE

2.2.1 Software and Firmware Installation 2.3

AUTOMATED TEST PROGRAM 456271-1 REMOTE RACK

2.4

AUTOMATED TEST PROGRAM 456271-2 LOCAL RACK

BURN-IN

FINAL TEST

4.1

AUTOMATED TEST PROGRAM 456271-1 REMOTE RACK

4.2

AUTOMATED TEST PROGRAM 456271-2 LOCAL RACK

APPENDIX A

PRODUCTION ROUTERS

A-1

TABLE OF CONTENTS (Continued) Section Title Page

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 LRADDS Test Rack Configuration

LIST OF TABLES

Table Title Page 1.3-1 Test Equipment

1.5.4-1 Script Files for 456271-1 1.5.4-2 Script Files for 456271-2

2.1-1 Short Test Table 2.2-1 RIM Switch Settings 2.2-2 DIM Switch Settings for 456063-1 2.2-3 DIM Switch Settings for 456357-1 or 456357-2 2.3-1 Pre-Test Verification Table 2.4-1 Test Verification Table 3-1 Burn-in Test Information

LIST OF TABLES

Table Title Page 4.1-1 Final Test Verification Table 4.2-1 Test Verification Table

SECTION 1

GENERAL INFORMATION

1.1

SCOPE

This document contains the test requirements for the acceptance testing of the Radar Interface Module (RIM) (P/N 456354-2). 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.

Figure 1.1-1. Testing Flow

1.2

PURPOSE

The purpose of this document is to demonstrate that the RIM, as manufactured by Frontier Electronic Systems (FES), 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

Tektronix

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 80(F.

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 Script Files There are two dash numbers for the script files. Dash one is ran on the Windows machine located on the remote rack and dash two is ran on the Red Hat machine located on the local rack.

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

Table 1.5.4-1. Script Files for 456271-1

The dash two script files required for testing are shown in the table below. Controlled copies of the RIM script files reside in Document Control under Mstr_software\456271\-02 Rev X\ (where X is the latest revision).

Table 1.5.4-2. Script Files for 456271-2

1.5.5 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 \\Fes-dc\data3\Shared Data\Naval Systems\Test Data\part number\serial number.

SECTION 2

PRE-TEST EVALUATION

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

2.1 short TEST

Using a Digital Multi-Meter (DMM), verify that the power planes are not shorted together or to ground. The RIM Baseboard PWB, 456461, may be used 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 TP12 are GND. In the following table, enter a checkmark as each reading is checked and no short is present.

Table 2.1-1. Short Test Table

GND

TP1–12

+1.2V

U3 PIN4

+1.8V

U9 PIN5

+2.5V

U5 PIN4

+3.3V

U6 PIN4

+5V

R14 +12V

R13

+1.2V

U3 PIN4

+1.8V

U9 PIN5

+2.5V

U5 PIN4

+3.3

U6 PIN4

+5V

R14

+12V

R13

-12V

P1 A31

VERIFIED: _____________

2.2

INSTALLATION AND SETUP PROCEDURE

The installation and setup procedure verifies the test configuration.

1. Set the Gold Board Radar Interface Unit (RIU) Test Chassis’ Power Supply Module switch to the OFF position.

2. Configure the switches on the Radar Interface Module as shown below.

Table 2.2-1. RIM Switch Settings

SWITCH

SWITCH

S9

S1-2

S10

S1-3

Radar Select

S11

SIM

S1-4

ON

S12

S1-5

TBI Use/over ride

S13

S1-6

AZ True/Relative

S1-7

Not used

S14-39

S1-8

Not used

S14-40

S14-41

S2-2

TE

S14-42

S2-3

S2-4

TM SPLT

S14-5

S2-5

TM

S14-4

S2-6

S14-3

S2-7

VID 1 SPLT

S14-2

S2-8

VID 1

S14-1

S14-0

S3-2

ARP

S3-3

S16-2

S3-4

ACP SPLT

S16-3

ON

S3-5

ACP

S16-4

ON

S3-6

ON

S3-7

VID 2 SPLT

S17-2

ON

S3-8

VID 2

S17-3

ON

S17-4

ON

S4-2

S4-3

S4-4

S4-5

S4-6

S4-7

S4-8

*Blank is OFF (Open). ON = Closed

S5-2

S5-3

S5-4

3. Install the RIM into slot 1 of the RIU Test Chassis in the LAN Radar Data Distribution System (LRADDS) Test Rack (456124).

4. On SIGNAL SPLITTER Module (P/N 500034-1) located in the Gold Board RIU Test Chassis, set all Front Panel switches to the OFF position.

SWITCH

SIGNAL SPLITTER

S1-1 thru S1-8

OFF

5. Loosen fasteners and remove Display Interface Module (DIM 1) (P/N 456063-1, 456357-1 or 456357-2) from the Gold Board Display Interface Unit (DIU) Test Chassis. Verify the following switch settings and reinstall module securing fasteners. If DIM board is P/N 456063-1, use the settings in Table 2.2-2. If DIM board is P/N 456357-1, use the settings in Table 2.2-3.

Table 2.2-2. 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

S1-7

Video SIM

S1-8

AZ True/Relative

S4-2

S4-3

S4-4

S4-5

S4-6

S4-7

S4-8

S5-2

S5-3

S5-4

S11

SIM

S16

Local Select

S17

S18

ON

S19-2

ON

S19-3

ON

S19-4

ON

*Closed = ON; Open = OFF

Table 2.2-3. DIM Switch Settings for 456357-1 or 456357-2

SWITCH

3 WIRE OUTPUT 8192

S1-2

Display Type

S1-3

S1-4

Azimuth Rate

S1-5

S1-6

S1-7

Video SIM

S1-8

AZ True/Relative

S2-2

S2-3

S2-4

S3-2

S3-3

S3-4

S3-5

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

S12

S13

*Closed = ON; Open = OFF

6. Connect the LRADDS Test Rack cables as shown in Figure 2.2-1.

Figure 2.2-1. LRADDS Test Rack Configuration 2.2.1 Software and Firmware Installation

This step of the procedure details the loading of the Firmware and Software listed on Assembly Number 456354-2 using Software Part Number 456294. These procedures are performed using the LRADDS Test and Scripting Processor.

1. Apply power to the LRADDS Tester and set the RIU Test Chassis’ Power Supply Module switch to the ON position.

2. Log into the LRADDS test fixture.

3. Start xBash.exe on the Desktop.

4. Type “cd /cygdrive/c/456294/” without the quotes and press Enter.

5. Type “c:/Python26/python 456294X.py –a456354-2” (where “X” is the latest revision number). Press Enter.

6. Follow the onscreen prompts and type “y” when asked. Record below the firmware and software revisions used.

PC Firmware Version 456475 Rev:______________

Interface Firmware Version 456476 Rev:______________

Software Version 456477 Rev:______________

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

8. Copy log file from c:\456294\reports\456354-2_SSS_YYYY-MMM-DD_HH-mm-ss-AM.txt to \\Fes-dc\data3\Shared Data\Naval Systems\Test Data\part number\serial number where “SSS” is the serial number “YYYY” is the year “MMM” is the month (i.e., Jan) “DD” is the day “HH” is the hour “mm” is the minute “ss” is the second and “AM” can be AM or PM, depending on the time of day.

Verify that the file has been copied.

NOTE: USB port parameters: COM Port: 3 (Windows), Baud Rate: 115200, Data bits: 8, Parity: None, Stop bits:1, Flow Control: None. Verify software has been loaded.

9. Using the following procedure, record the MAC Address below.

a. Do a board reset and plug a USB cable into the unit.

b. From the desktop, run LRADDS.ht.

c. On the RIM, press the CPU Reset button.

d. From the LRADDS.ht window, record the following values:

MAC Address:_________________________________________

e. Press “v” inside the Hyperterminal window and record the versions displayed.

PC Firmware Version (456475):______________

Interface Firmware Version (456476):______________

Software Version (456477):______________

10. Verify the Mac Address displayed in the LRADDS.ht window matches the MAC address in the spreadsheet “IM MAC Address Log” located at \\Fes-dc\data3\Document Control\Mstr_software\NAVAL_MacAddress

11. Create and apply the label for Part Numbers flashed per Assembly Drawing 456354-2. Verify below.

2.3

AUTOMATED TEST PROGRAM 456271-1 REMOTE RACK

These procedures are performed using the LRADDS Test Rack and the Scripting Processor.

1. Set the Gold Board RIU and DIU Test Chassis’ Power Supply Module switch to the ON position. Also turn ON LRADDS tester power.

2. Select the LRADDS 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 correctly.

b.

Select OK when complete.

4. Select “Test Info”.

5. A dialog box prompting for “Tester Identification” will now be displayed. Enter the Tester Information and press the Enter key.

6. A dialog box appears requesting a Serial Number. Enter the RIM Serial Number and press Enter.

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

8. At the Module Selection screen, select “Radar Interface Module (RIM) (456354-2)”.

9. 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.

10. Select the Radar Interface Module (RIM) test and select all scripts in Table 2.3-1.

11. 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

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

13. Copy and verify data files have been copied to:

\\Fes-dc\data3\Shared Data\Naval Systems\Test Data\ part number\serial number.

2.4 AUTOMATED TEST PROGRAM 456271-2 LOCAL RACK

Table 2.4-1 lists the name and description of the automated test to be ran on the Local Rack Test Rack.

1. Start the RTLEDA on the HMI computer.

2. Power ON the RSIM chassis.

3. Log onto the Red Hat Dell test computer Username root and Password admin12

4. Open a terminal and type “cd /home/tester/” without the quotes

5. Then type “python 456416X.py –u(user) –a –n(P_456354_SNYYY) (script file name)” (where “X” is the latest revision number and YYY is the serial number) Example: python 456416–.py –umsh –a –nP_456354_SN012 RIM–016.xls.

Table 2.4-1. Test Verification Table

6. Copy and verify data files have been copied to:

7. Set RIM switch S12 to 0.

8. Remove test stand fibers from the RIM and DIM.

9. Replace with a short copper Ethernet cable connected directly between the RIM and the dumb switch in the Test Fixture.

10. Set RIM switch S16-1 to Close (ON) and the rest of S16 to Open (OFF).

11. Cycle power to the RIM.

12. Verify that the RIM resets after 60 to 90 seconds (LEDs will go out and come back ON).

SECTION 3

BURN-IN

This section contains the procedures to be followed to accomplish a burn-in cycle on the RIM.

1. Place the RIM 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 RIM.

4.1

AUTOMATED TEST PROGRAM 456271-1 REMOTE RACK

These procedures are performed using the LRADDS Test Rack and the Scripting Processor.

1. Perform Section 2.2, Installation and Setup Procedure.

2. Apply power to the LRADDS tester and set the Gold Board RIU and DIU Test Chassis’ Power Supply Module switch to the ON position.

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

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

a.

Verify that the Communication Ports and GBIP Address are set correctly.

b.

Select OK when complete.

5. Select “Test Info”.

6. A dialog box prompting for “Tester Identification” will now be displayed. Enter the Tester Information and press Enter.

7. A dialog box appears requesting a Serial Number. Enter the RIM Serial Number and press Enter.

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

9. At the Module Selection screen, select “Radar Interface Module (RIM) (456354-2)”.

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 the Radar Interface Module (RIM) test and select all scripts in Table 4.1-1.

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 4.1-1.

Table 4.1-1. Final Test Verification Table

13. Copy and verify data files have been copied to:

4.2

AUTOMATED TEST PROGRAM 456271-2 LOCAL RACK

Table 4.2-1 lists the name and description of the automated test to be ran on the Local Rack Test Rack.

1. Start RTLEDA on the HMI computer.

2. Power ON the RSIM chassis.

3. Log onto the Red Hat Dell test computer Username root and Password admin12

4. Open a terminal and type “cd /home/tester/” without the quotes.

5. Then type “python 456416X.py –u(user) –a –n(F_456354_SNYYY) (script file name)” (where “X” is the latest revision number and YYY is the serial number)

Example: python 456416–.py –umsh –a –nF_456354_SN012 RIM–016.xls.

Table 4.2-1. Test Verification Table

6. Copy and verify data files have been copied to:

7. Set RIM switch S12 to 0.

8. Remove test stand fibers from the RIM and DIM.

9. Replace with a short copper Ethernet cable connected directly between the RIM and the dumb switch in the Test Fixture.

10. Set S16-1 to Close (ON) and the rest of S16 to Open (OFF).

11. Cycle power to the RIM.

12. Verify that the RIM resets after 60 to 90 seconds (LEDs will go out and come back ON).

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

MODULE TEST

REPAIR

BOARD PER

PARA 1.5.3

Module Test complete

Pass�Test?

ACCEPTANCE TEST PROCEDURE

FOR THE RADAR INTERFACE

MODULE (RIM)

(P/N 456354-2)

S/N: _________________

01 DECEMBER 2016

Prepared By:

FRONTIER ELECTRONIC SYSTEMS CORP.

P.O. BOX 1023

STILLWATER, OKLAHOMA 74076-1023

AUTOMATED

TEST PROGRAM

SECTION 4.1

INSTALLATION

AND SETUP

SECTION 2.2

BURN-IN

BOARD

SECTION 3

Pass�Test?

AUTOMATED TEST PROGRAM SECTION 2.3

INSTALLATION AND SETUP

SECTION 2.2

START�MODULE �TEST

FINAL TEST

Pre-test Evaluation

YES

NO

NO

YES

_1349680536.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

_1391319320.vsd