455280B IIM ATP (PN 456370-2).doc

455280B

REVISIONS

STILLWATER, OKLAHOMA 74076-1023

FOR THE IFF INTERFACE

MODULE (IIM)

(P/N 456370-2)

CODE IDENT.

63812 455280B

ACCEPTANCE TEST PROCEDURE

FOR THE IFF INTERFACE

MODULE (IIM)

(P/N 456370-2)

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

2.4

VIDEO TEST

2.5

RX AND TX TIME OUT TEST

BURN-IN

FINAL TEST

4.1

AUTOMATED TEST PROGRAM

TABLE OF CONTENTS (Continued)

Section Title Page 4.2

VIDEO TEST

4.3

RX AND TX TIME OUT TEST

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 LRADDS Tester Configuration

LIST OF TABLES

Table Title Page 1.3-1 Test Equipment 1.5.4-1 Script Files 2.1-1 Short Test Table

2.2-1 IIM 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 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 IFF Interface Module (IIM) (P/N 456370-2). 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

Figure 1.1-1 illustrates the order of testing.

Figure 1.1-1. Testing Flow

1.2

PURPOSE

The purpose of this document is to demonstrate that the IIM, 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

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.

1.4 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 The script files required for testing are shown in the table below. Controlled copies of the IIM 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

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 IIM 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 IIM II Baseboard PWB, drawing 456369, 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

+2.5V

U4 PIN4

+3.3V

U5 PIN4

+5V

R2 +12V

R1

+1.2V

U3 PIN4

+2.5V

U4 PIN4

+3.3

U5 PIN4

+5V

R2

+12V

R1

-12V

P1 A31

VERIFIED: _____________

2.2

INSTALLATION AND SETUP PROCEDURE

The installation and setup procedures ensure the correct test configuration.

1. Set the IFF Interface Unit (IIU) Test Chassis’ Power Supply Module switch to the OFF position.

2. Configure the switches on the IIM being tested as shown in Table 2.2-1.

Table 2.2-1. IIM Switch Settings

SWITCH

IIM

S1-2

S1-3

S1-4

S1-5

S1-6

S1-7

S1-8

ON

S2-2

ON

S2-3

ON

S2-4

ON

S3-2

S3-3

S3-4

ON

S6-2

S6-3

S6-4

*Blank is OFF (Open). ON = Closed

3. Install the IIM into slot 1 of the IIU Test Chassis.

4. Remove the Display Interface Module (DIM) Gold Board from Slot 2 of the 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 or 456357-2, 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

S17

S18

ON

S19-2

ON

S19-3

S19-4

*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

S4-4

S9-2

S9-3

S9-4

S10

SIM

S11

S12

S13

*Closed = ON; Open = OFF

5. Connect the LRADDS Tester cables as shown in Figure 2.2-1.

Figure 2.2-1. LRADDS Tester 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 456370-2 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 IIU 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 –a456370-2” (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 456481 Rev:______________

Software Version 456482 Rev:______________

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

8. Copy log file from c:\456294\reports\456370-2_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. Plug a USB cable into the USB port on the IIM front panel.

b. From the desktop, run LRADDS.ht.

c. Power cycle the IIM.

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 (456481):______________

Software Version (456482):______________

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. In the xBash command window Type:

cd /cygdrive/c/456495 This is the directory of the test file. Press Enter.

12. In the xBash command window Type:

make run TEST=spansion_flash_test.elf.

NOTE: “TEST” is case sensitive. Press Enter.

13. In the LRADDS.ht window, verify SPANSION FLASH TEST = PASS

14. Using the following procedure, verify the MAC Address, PC Firmware version and Software version.

a. Power cycle the IIM.

b. Verify the data in the LRADDS.ht window is the same as was previously recorded above.

15. Create and apply the label for Part Numbers flashed per Assembly Drawing 456370-2. Verify below.

2.3

AUTOMATED TEST PROGRAM

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

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

2. Click on the “IIF_Server.py” icon that is located on the Desktop. Once loaded type 1 then Enter.

3. Select the LRADDS Automated Tester icon on the Desktop 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 GPIB Address are set as they appear in the display.

b.

Select OK when complete.

5. Click on the Test Info button.

6. A dialog box prompting for “Tester Identification” will now be displayed. Enter the test operator's name, initials or employee number and press Enter.

7. A dialog box appears requesting a Serial Number. Enter serial number of the IFF Interface Module being tested and press Enter.

8. Select test type “Preliminary”.

9. At the Module Selection screen, select the “IFF Interface Module”.

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. Click on the “Select All” button.

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

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

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

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

2.4

VIDEO TEST

The IIM Video Test (IMM-004) will perform the initial setup for conducting this test.

1.

Trigger the scope on Channel 2 (TM/RADDS). On the scope between TM and TM there will be two pulses. The next measurements are in reference to these two pulses.

2.

Set the first vertical cursor at the rising edge of TM (the pulse on Channel 2).

3.

Set the second vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 121us and 123us.

4.

Set the second vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 243us and 245us.

5.

Measure the pulse width of the first video pulse. Set the first vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

6.

Measure the pulse width of the second video pulse. Set the first vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

7.

On the IIU move Video 1 (J8) to Video 2 (J9).

8.

On DIM front panel, set Video Select to 1.

9.

Trigger the scope on Channel 2 (TM/RADDS). On the scope between TM and TM there will be two pulses. The next measurements are in reference to these four pulses.

10.

Set the first vertical cursor at the rising edge of TM. (the pulse on Channel 2)

11.

Set the second vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 121us and 123us.

12.

Set the second vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 243us and 245us.

13.

Measure the pulse width of the first video pulse. Set the first vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

14.

Measure the pulse width of the second video pulse. Set the first vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

15.

On the IIU move Video 2 (J9) to Video 1 (J8).

16.

On DIM front panel, set Video Select to 1.

17.

Put the IIM under test into SIM mode (S7 ON) . Verify that there are two pulses on channel 1 of the scope.

18. Take the IIM under test out of SIM mode (S7 OFF).

2.5

RX AND TX TIME OUT TEST

1. Remove test stand fibers from the IIM and DIM.

2. Replace with a short copper Ethernet cable connected directly between the IIM and the dumb switch on the Text Fixture.

3. Set IIM switch S6-1 to Close (ON) and the reset of S6 to Open (OFF).

4. Cycle power to the IIM.

5. Verify that the IIM 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 IIM.

1.

Place the IIM 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 IIM.

4.1

AUTOMATED TEST PROGRAM

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

1. Perform section 2.2, Installation and Setup Procedure and apply power to the LRADDS Tester.

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

3. Select the LRADDS Automated Tester icon on the Desktop 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 GPIB Address are set as they appear in the display.

b.

Select OK when complete.

5. Click on the “Test Info” button.

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

7. A dialog box appears requesting a Serial Number. Enter the serial number of the IFF Interface Module being tested and press Enter.

8. Select test type “Final”.

9. At the Module Selection screen, select the “IFF Interface Module”.

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. Click on the “Select All” button.

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:

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

4.2

VIDEO TEST

The IIM Video Test (IIM-004) will perform the initial setup for conducting this test.

1.

Trigger the scope on Channel 2 (TM/RADDS). On the scope between TM and TM there will be two pulses. The next measurements are in reference to these two pulses.

2.

Set the first vertical cursor at the rising edge of TM (the pulse on Channel 2).

3.

Set the second vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 121us and 123us.

4.

Set the second vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 243us and 245us.

Measure the pulse width of the first video pulse. Set the first vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

6.

Measure the pulse width of the second video pulse. Set the first vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

7.

On the IIU move Video 1 (J8) to Video 2 (J9).

8.

On DIM front panel, set Video Select to 1.

9.

Trigger the scope on Channel 2 (TM/RADDS). On the scope between TM and TM there will be two pulses. The next measurements are in reference to these four pulses.

10.

Set the first vertical cursor at the rising edge of TM (the pulse on Channel 2).

11.

Set the second vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 121us and 123us.

12.

Set the second vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 243us and 245us.

13.

Measure the pulse width of the first video pulse. Set the first vertical cursor on the rising edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the first video pulse (first pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

14.

Measure the pulse width of the second video pulse. Set the first vertical cursor on the rising edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Set the second vertical cursor on the falling edge of the second video pulse (second pulse on Channel 1 after the pulse on Channel 2). Verify the width is between 24us and 26us.

15.

On the IIU move Video 2 (J9) to Video 1 (J8).

16.

On DIM front panel, set Video Select to 1.

17.

Put the IIM under test into SIM mode (S7 ON) . Verify that there are two pulses on channel 1 of the scope.

18.

Take the IIM under test out of SIM mode (S7 OFF).

4.3

RX AND TX TIME OUT TEST

1. Remove test stand fibers from the IIM and DIM.

2. Replace with a short copper Ethernet cable connected directly between the IIM and the dumb switch on the Test Fixture.

3. Set IIM switch S6-1 to Close (ON) and the reset of S6 to Open (OFF).

4. Cycle power to the IIM.

5. Verify that the IIM 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. Applicable inspection or test stamps 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 IFF INTERFACE

MODULE (IIM)

(P/N 456370-2)

S/N: _________________

01 DECEMBER 2016

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

AUTOMATED

TEST PROGRAM

SECTION 4.1

INSTALLATION AND SETUP

SECTION 2.2

INSTALLATION

AND SETUP

SECTION 2.2

BURN-IN

BOARD

SECTION 3

Pass�Test?

AUTOMATED TEST PROGRAM SECTION 2.3

SHORT TEST

SECTION 2.1

START�MODULE �TEST

FINAL TEST

Pre-test Evaluation

YES

NO

NO

YES

_1349681850.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 (UUT)

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

Video

Big Iron 24 port Network Switch

Dual Scan Cvtr Computer

Dual Scan Cvtr Computer

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

Serial Data (2)

RADDS to 6W

NAV Data (RS-422)

6 Wire Out

Test System Configured For IIM Test

IFF Vid (2)

_1485072228.vsd