ESS21202-02a.docx

DOCUMENT ESS21202-02

ENVIRONMENTAL STRESS SCREENING (ESS) TEST PROCEDURE

FOR THE GUN MOUNT CONTROL PANEL (GMCP)

CDRL A001

An AS9100 Certified Company

DOCUMENT REVISION HISTORY INITIALLY DEVELOPED FOR JOB 21202

PAGE REVISION STATUS

REVISION

REVISION

SECHAN ELECTRONICS, INC.

525 Furnace Hills Pike Lititz, PA 17543 CAGE: 7Z941 www.sechan.com

(717) 627-4141 FAX: (717)-627-4144

PREPARED BY:

GORDON GOEBEL

SR. QUALITY ENGINEER

REVIEWED BY:

DAVID CHRIST

ENVIRONMENTAL ENGINEER

REVIEWED BY:

KEVIN PERIGO

PROJECT ENGINEER

DISTRIBUTION STATEMENT

D: DISTRIBUTION AUTHORIZED TO DOD AND DOD CONTRACTORS ONLY; OPERATIONAL USE; 11JUN14. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO NSWCPHD, CODE L45

DOCUMENT NUMBER

ESS21202-02

REVISION

A

SHEET

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

table 5.0-I: GMCP thermal cycle programming TABLE 13

1.0 SCOPE

This document presents the Environmental Stress Screening (ESS) Test Procedure for the Gun Mount Control Panel (GMCP), part number 7402675-002. This test procedure is prepared in accordance with CDRL A001, Statement of Work (SOW) paragraph 3.2.1, MIL-HDBK-2164 and Data Item Description (DID) DI-ENVR-81014.

APPLICABLE DOCUMENTS

The following documents of the revision shown were used in the preparation of this ESS Test Procedure.

Customer Documents N63394-11-R-1236 13 Sept 2011 Statement of Work (SOW)

Sechan Documents ESU7402675-002 Rev. - Environmental Setup Sheet for P/N 7402675

ATP7402675 Rev. B Acceptance Test Procedure for Gun Mount Control Panel Assembly

Military Specifications and Standards MIL-HDBK-2164 Rev. A Environmental Stress Screening Process for Electronic Equipment

TEST REquirement AND SUMMARY

TEST REQUIREMENT

The following requirement for ESS is reproduced from the contract SOW, paragraph 3.2.1:

“The contractor shall conduct Environmental Stress Screening (ESS) on all GMCP MK 437 units as a complete assembly less shock mounts, using MIL-HDBK-2164A as guidance.

The ESS shall be conducted in a facility that has the equipment that can perform temperature and vibration testing on the GMCP with weight and dimensional parameters in accordance with the specifications listed below. The ESS shall be conducted on one GMCP MK 437 unit at a time with the unit under power at a temperature range of 0°C to +35°C and random vibration at:

- Spectral Density of 6G rms

- Frequency Limits 100-1000Hz

- Axis - 3

- Duration 10 minutes

The initial and final operational tests of the ESS process shall be in accordance with the operational testing requirements in Appendix D. The contractor shall provide all necessary equipment and software to conduct this testing.”

Note: Appendix D reference is to Appendix of Contract.

test overview The following provides the overall ESS program flow and details. Each of the following sections provides additional summarized details.

The Operational Test will be performed per ATP7402675.

1. Random Vibration

1. Random Vibration initial profile: 6.00 GRMS, 100Hz to 1000Hz

1. 3 axes

1. 10 minutes per axis

1. Room Ambient Temperature

1. One GMCP MK 437 at a time

1. Vibration survey will be conducted at 1 GRMS input across the frequency range

1. Profile will be notched based on survey results

1. No failures allowed after Thermal Cycling Defect Free period

1. Thermal Cycling

1. Temperature extremes of 0°C to +35°C

1. 10 cycles minimum with dwells determined by the thermal survey

1. Chamber air rate of change of 10°C per minute

1. One GMCP MK 437 at a time

1. Powered during low temperature to high temperature ramps as well as while dwelling at high temperature

1. No failures allowed during Defect Free period

2.0 ESS RANDOM VIBRATION

2.1 test summary ESS Vibration consists of two iterations of random vibration in three mutually perpendicular axes for a total duration of 10 minutes in each axis. The GMCP or Unit Under Test (UUT) will be hard mounted. In accordance with MIL-HDBK-2164, the first iteration of ESS Vibration is a “Confidence” vibration and any failures during Confidence Vibration (CV) shall be accrued and repaired at the conclusion of the 10 minute period. CV shall be repeated until a passing result is achieved. After CV is completed, the UUT shall be subject to the ESS Thermal requirements as defined in Section 5.0. The second iteration of ESS Vibration is an “Acceptance” vibration and any failures during the Acceptance Vibration (AV) will require additional ESS Thermal Cycling and a repeat of AV until no further defects are uncovered.

In all cases the Program QAE must be notified and will provide disposition on any failure during the Acceptance Vibration iteration.

2.2

2.3 Required Test Equipment

The following test equipment (or its equivalent) shall be used to conduct this test.

2.4 Test Procedure

Note 1: If test failure occurs, allow the current vibration cycle to continue through to completion and document on a Malfunction Report (MR). Contact the Program QAE if there is any failure during ESS Testing.

1. Test Set-up

A1) Verify that the Pre-ESS functional step on the router is completed.

A2) Mount the Vibration Test Fixture, Item 2, in the first test axis, per Figure 4.0-1, on the Vibration Shaker, Item 1.

A3) Mount the UUT onto the Vibration Test Fixture, in the first test axis, per Figure 4.0-1 using ESU7402675-002.

A4) Prepare UUT to be powered on as follows. Refer to ATP7402675 as required.

· Connect test cable P/N TFCW35262 between A2J5 and A3J1

· Connect test cable P/N TFCW35263 between A3J2 and A1J1

· Ensure the ground braids are connected between A1 and A3 and A1 and A2.

· Connect facility AC power (115 VAC 60 Hz) to A2J4 using test cable P/N TFC7402675, AC Power Cable. Ensure the AC power cable ground (Green banana jack) is tied to one of the UUT ground studs.

A5) Place 2 total control Accelerometers, Item 4, onto the Vibration Test Fixture, Item 2, using ESU7402675-002.

A6) Load the vibration profile for the first text axis (Figures 4.0-2 through 4.0-4) into the Vibration Controller, Item 3.

A7) Power on the UUT by depressing the Main Power switch, then GMCP, then Velocimeter. Ensure all indicators illuminate “ON” and the touchscreen display boots up and the X cursor appears.

A8) This completes test set-up.

1.

1. Test Procedure

A) FIGURE 4.0-1, GMCP axis definition

Z-Axis

X-Axis

Y-Axis

DISTRIBUTION STATEMENT

D: DISTRIBUTION AUTHORIZED TO DOD AND DOD CONTRACTORS ONLY; OPERATIONAL USE; 11JUN14. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO NSWCPHD, CODE L45

DOCUMENT NUMBER

ESS21202-02

REVISION

A

SHEET

FIGURE 4.0-2, GMCP ESS VIBRATION PROFILE – X-AXIS

UDCO VIB01 VWIN II CONTROLLER

Random Test Report

SETUP NAME: GUNMOUNT ESS- X-AXIS

SETUP DESC: 6GRMS ESS X-AXIS

SETUP LAST CHANGED: 2/6/2014 4:22:53 PM

RUN NAME: run1

SAVE NUMBER: 1

STATUS INFORMATION

TEST EVENT TIME: Friday, February 14, 2014 at 11:11:10 AM

TEST STATUS: READY

TOTAL TIME ELAPSED (HH:MM:SS): 0:0:0

AUTO TIME ELAPSED (HH:MM:SS): 0:0:0

TEST LEVEL: -12.0 dB REFERENCE: 3.54 g rms CONTROL: 0.00 g rms

UNHOLTZ-DICKIE Vwin II Version 3.00

DISTRIBUTION STATEMENT

D: DISTRIBUTION AUTHORIZED TO DOD AND DOD CONTRACTORS ONLY; OPERATIONAL USE; 11JUN14. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO NSWCPHD, CODE L45

DOCUMENT NUMBER

ESS21202-02

REVISION

A

SHEET

FIGURE 4.0-3, GMCP ESS VIBRATION PROFILE – Y-AXIS

Random Test Report

SETUP NAME: GUNMOUNT ESS- Y-AXIS

SETUP DESC: 6GRMS ESS Y-AXIS

SETUP LAST CHANGED: 2/6/2014 4:22:19 PM

RUN NAME: run1

SAVE NUMBER: 1

STATUS INFORMATION

TEST EVENT TIME: Friday, February 14, 2014 at 11:06:22 AM

TEST STATUS: READY

TOTAL TIME ELAPSED (HH:MM:SS): 0:0:0

AUTO TIME ELAPSED (HH:MM:SS): 0:0:0

TEST LEVEL: -12.0 dB REFERENCE: 2.57 g rms

FIGURE 4.0-4, GMCP ESS VIBRATION PROFILE – z-AXIS

Random Test Report

SETUP NAME: GUNMOUNT ESS- Z-AXIS

SETUP DESC: 6GRMS ESS Z-AXIS

SETUP LAST CHANGED: 2/10/2014 11:43:57 AM

RUN NAME: run3

SAVE NUMBER: 1

STATUS INFORMATION

TEST EVENT TIME: Friday, February 14, 2014 at 11:01:49 AM

TEST STATUS: READY

TOTAL TIME ELAPSED (HH:MM:SS): 0:0:0

AUTO TIME ELAPSED (HH:MM:SS): 0:0:0

TEST LEVEL: -12.0 dB REFERENCE: 4.69 g rms

3.0 TEMPERATURE CYCLING

3.1 TEST summary

After completion of Confidence Vibration, the UUT shall be subject to ESS Thermal Cycling. ESS Thermal shall consist of 10 cycles that transition between the hot and cold operating temperatures. The UUT shall be powered cold to hot thermal transitions and during the hot temperature dwell time until 40 total powered hours are accumulated. At the completion of the 40 hours of powered on time, the UUT shall be subject to an Acceptance Test. If the UUT passes the Acceptance Test, the unit will proceed to Acceptance Vibration. If the UUT fails the Acceptance Test, the unit will repeat 10 cycles until 40 total powered hours are accumulated and the process will repeat. The UUT shall not be subject to more than 80 total powered hours without the approval of the Program QAE. If testing will result in the UUT exceeding 80 total powered hours or more than 20 total thermal cycles, the Program QAE must be notified prior to the start of retesting.

3.2 Required Test Equipment

The following test equipment (or its equivalent) shall be used to conduct this test.

3.3 Test Procedure

Note 1: If any test failure occurs, stop testing immediately and document on a Malfunction Report (MR). Contact the Program QAE if there is any failure during ESS Thermal testing.

A) Test Set-up

A1) Verify that the Confidence Vibration step on the router is completed.

A2) Verify the Temperature Chamber, Item 1, is in calibration and the interior is clean.

A3) Load the UUT into the chamber.

A4) Prepare UUT to be powered on as follows. Refer to ATP7402675 as required.

· Connect test cable P/N TFCW35262 between A2J5 and A3J1

· Connect test cable P/N TFCW35263 between A3J2 and A1J1

· Ensure the ground braids are connected between A1 and A3 and A1 and A2.

· Run test cable P/N TFC7402675, AC Power Cable, through the chamber port hole and connect to the Event Box. The Event Box will automatically supply AC power (115 VAC 60 Hz) at the appropriate times. Ensure the AC power cable ground (Green banana jack) is tied to one of the UUT ground studs.

A5) Manually trigger the Event Box to supply AC power to the UUT. Power on the UUT by depressing the Main Power switch, then GMCP, then Velocimeter. Ensure all indicators illuminate “ON” and the touchscreen display boots up and the X cursor appears. Keep switches depressed during the duration of the testing. Manually trigger the Event Box to remove power from the UUT. Ensure all indicators extinguish.

A6) Program the chamber to achieve the thermal profile of Figure 5.0-1 using the programming information in Table 5.0-I. Testing shall consist of 10 consecutive thermal cycles per the profile of Figure 5.0-1.

A7) This completes test set-up.

B) Test Procedure B1) Initiate the chamber to perform the thermal profile of Figure 5.0-1.

B2) UUT Power ON will be automated from this point forward. The event box will provide power to the UUT at the appropriate times.

B3) If a test failure is noted, document the results on a Malfunction Report and immediately contact the program QAE.

B4) Verify the accuracy of the electronic chart for the thermal run. Print out a copy and place it in the router pack. Verify that the thermal chart saved correctly on the network.

B5) De-energize the UUT by depressing switch indicators Velocimeter, then GMCP, then Main Power. Observe the UUT for physical damage and document any discrepancies on a Malfunction Report.

B6) This completes ESS Thermal testing. Annotate router to indicate the UUT is complete through ESS Thermal if no discrepancies are noted.

table 5.0-I: GMCP thermal cycle programming TABLE

RECIPE ID

SETPOINT CHANNEL 2

EVENT 2:

EVENT 3:

EVENT 4:

EVENT 5:

EVENT 6:

EVENT 7:

EVENT 8:

RECYCLES

Stored on Command Cartridge #___________________ Side _______________

Programmed by: ___________________________ Date _____________

FIGURE 5.0-1, GMCP ess thermal profile, 1 cycle

+35º

TEMPERATURE ºC

+25º

0º

8 Hr.

8 Min.

8 Hr.

5 Min 4 Hr.

5 Min 4 Hr.

2 Min.

2 Min

TIME

Rate of Change: 10ºC/Minute or greater Unpowered Legend =

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