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Doc. No.: ATL/RCI/ASB-TME/SOFT/01 AS9100C & ISO-9001:2008 Certified Company
Ananth Technologies Ltd.
1. INTRODUCTION
SCOPE OF THE DOCUMENT
The document brings out the detailed Functional test specifications and
procedure is required to be carried out as a deliverables of TELEMETRY ENCODER.
References documents, system description, functional specification covered
in chapter 2 to 4, physical inspection and screening test and functional test
procedure covered in chapters 5 &6 gives the functional testing procedures at
package level and system level, environmental specifications are covered in
chapter7 for the Telemetry Encoder unit.
Test reports, Integration details are covered in Appendixes.
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Ananth Technologies Ltd.
2. REFERENCES DOCUMENTS
RCI SUPPLY Order No. RCI/DCMM/LP/LPD-II/00353(C) Dt: 08.11.2011
Technical Specification Document Doc. No.ATL/RCI/ASB-TME/TSD/01 BOM Document Doc. No. ATL/RCI/ASB-TME/BOM/01
MDI document Doc No. ATL/RCI/ASB-TME/MDI
MIL STANDARDS
Electronic / Electrical Components (Capacitors, Resistors, Relays, Connectors,
IC’s etc.) – MIL, LCSO, QML references.
Test Method Standards – Microcircuits – MIL-STD-883E
Test Method Standards for Electrical / Electronics Parts – MIL-STD-202
Micro Circuits Manufacturing, General Specifications – MIL-STD-38535E
Screening as per CEMILAC directive no. CEMILAC/5390/1 Dt. 10-01-2004 Part
B.
ENTEST document No:RCI/412/ASB/02
Environmental Testing
o JSS 55555 (Ground Equipment)
o JSS 0256-01 (On-board Units)
o MIL-STD-810Go MIL-STD-1670A (Environmental Criteria and Guidelines for Air
Launched Weapons)
o MIL-STD-461E
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3. SYSTEM DESCRIPTION
The Programmable Telemetry Encoder is an IRIG compatible Pulse Code
Modulated (PCM) Encoder, with user programmable features and multiple datainterfaces to acquire data in real time, and provides serial streams in NRZ-L and
BiØ-L formats after commutation. The Telemetry Encoder has the provision for 128
analog channels(includes one References channel) with input range of ±2.5V, 32
Discrete channels with input range of TTL to 28V compatible and Four RS-422
channels. The unit has MIL-STD-1553 interface through which complete data
transactions on the 1553 bus can be captured and merged with other TELEMETRY
data.
The unit is user programmable for Bit rate, Word length, Frame Sync code,
Frame Sync length, Words / Frame and Frames / Sub frame. The formats can be
programmed by a Personal Computer (PC) connected through an RS-422 serial
interface even after integration of the package.
The TELEMETRY ENCODER is part of Telemetry system it is mainly an
airborne data acquisition system. it process the data received from various signal
conditioned packages, and direct analog channels the Telemetry Encoder acceptsthe input range from -2.5V to +2.5V, in Analog module the analog channels data is
processed through a Multiplexer, ADC and ADC output is given to the FPGA and will
be used in commutation. The discrete event data is processed by discreet module
the digital data and the data processed is fed into the internal FIFO of FPGA and
data stored will be used for commutation, The Telemetry Encoder has MIL-STD-1553
Bus interface through the Telemetry Encoder communicates with other sub systems
over the Missile Bus. The telemetry Encoder 1553 Bus operates in Both RT and MT
mode. The 1553 Bus data will be captured by the Telemetry encoder and the data isused in commutation and the Telemetry Encoder will send the PCM output data as
serial streams in NRZ-L and BiØ-L formats and sent through Transmitter to ground
station.
The Telemetry Encoder output will be decommuated in the Ground station
and the data of various parameters analyzed.
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Figure No: 1. TELELMETRY ENCODER
The entire hardware is implemented using Three PCBs & DC-DC module. The
Telemetry Encoder Consists of following Three PCB’s which are connected with
stackable connectors. The PCBs are interfaced directly to front panel by Flexi Rigid
PCBs which are connected to connectors.
1. Analog Card
2. Discrete Card
3. Microcontroller Card
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32 DiscreteChannels
4 RS- 422Channels
TELEMETRY ENCODER
128 AnalogChannels
RS-422 SerialLink
Output inRS-422 Format
1553 BUS A
1553 BUS B
Biphasel Output tothe Transmitter
28V ± 6V PWR
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1. BLOCK DIAGRAM OF TELEMETRY ENCODER
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2 DISCRETEHANNELS
ADDR
FPGA
DA
TA
DATA
CONTROL
OPTOCOUPL
ER
BUFFER
28NALOGHANNELS
OPTOCOUPL
ER
4 RS-422CHANNELS
SDRAM
ADDRCTRL
C
TRL
DA
TA ADD
RCLK
FLASH
CTRL
DATA
Driver
4-RS-422CHANNELS
DAC PREMODFILTER
AMP
MICROCONTROLLER-1
XTALOSC
DDS
BUSIC
MUX ADC
ADDR
BIT2CLK
CLK
CTRL
ADDR
DATA
CTRL
1553 BUS
O/P’s
CTRL
DATA
DC/DCCONVERT
ER
28±6V
±15V+3.3V
MICROCONTROLLER-2
QUADUART
XTALOSC
DA
TA
ADDR
DA
TA
T/F
Transmitter ADDR
SDRAM
Figure No: 2. TELELMETRY ENCODER BLOCK DIAGRAM
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3.1 MECHNICAL SPECIFICATIONS
Mechanical enclosure will be made with HE-15 T5246 Aluminum materialwith Chromatisation.
• DIMENSIONSHeight : 90 mm (Max)Length : 147 mm (Max)Width : 130 mm (Max)
• MATERIALChassis : HE-15 Forged Aluminum as per T5246
• WEIGHTWeight : 2Kgs (Max)
• COOLING REQUIREMENTSCooling not required, as there are no heating components
• OPERATING AND STORAGE LIFE: 12 Years
• MOUNTING DETAILS: At the nose cap of the ASB Glide
• MAINTENANCE REQUIREMENTS: - Nil -
3.2 ELECTRICAL SPECIFICATIONS
The FPGA used is ACTEL make AGL1000V5FGG484I i.e. 484pin re-
programmable flash family device. The Commutation will be done in FPGA,
according with format loaded in Flash.
The MIL-Standard 1553 Interface is implemented with DDC make Total ACE
CMOS device have the 64kb Internal RAM.
The Flash memory having 1Mbit (128Kx8) is used for storing the user
formats.
Silicon Laboratories High Speed Mixed Signal ISP Flash Micro controller used
is a very small TQFP Package.
Micron make High Capacity SDRAM of 512Mb is used for delay data
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transmission.
3.2.1 POWER SUPPLY REQUIREMENTS
This interface consists of DC-DC converter with combination EMI Filters
provides total power for all modules with an input of 28V ± 6V. This DC-DC
converter module provides output voltages in range of ±15V with 1A and +3.3 V
with 3A current ratings. This DC-DC converter module has a provision for Reverse
Polarity protection and input transient protection.
3.2.2 POWER CONSUMPTION
DC Supply Input : 28V ± 6V
DC-DC Output : ±15V/1A, +3.3 V /3A
Reverse Polarity and input transient Protection.
CURRENT : 350mA (Approx)
RANGE OF OPERATIONAL: -55°C to +85°C Temperatures,
3.2.3 INPUT SPECIFICATIONS
Analog Channels : 128 (16 of 8 KHz frequency & 112 of 200Hz
frequency)
I/P Voltage : +2.5V, 0V, -2.5V
Discrète Channels : 32 Channels
I/P Voltage : 5V & 28V
RS 422 Channels : 04 Rx Channels
3.2.4 PCM SPECIFICATIONS:
Bit Rate : Upto 4 Mbps
Word length : 8-12 data bits (MSB First)
Frame length : 2-2048
Format length : 1-256 frames
Frame Sync : 1 to 4 word lengths (Pattern Selectable)
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Format Sync : Binary Count 0 to 255 Frames ID,
Delayed Data : Provision to select parameters for delayed
Transmission with programmable delay time
Bus Interface : MIL-STD 1553B Simultaneous RT/MT
terminals
Programme Enable : Format modification through RS-422
3.2.5 OUTPUT SPECIFICATIONS:
Data : BiØ-L Data in RS-422
BiØ-L Output Pre-modulation filter output for
Transmitter
Out put level : BiØ-L signal of 0 to 5Vp-p Adjustable.
Note: Among 128 channels last channel is references channel.
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alog CH-112
alog CH-128
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4. FUNCTIONAL SPECIFICATIONS
4.1. ANALOG MODULE:
The Telemetry Encoder supports 128 analog channels with the input range of
+2.5V to -2.5V. The analog interface consisting of analog multiplexers to support up
to 128 analog channels with 2 tier multiplexing, and ADC containing sample and
hold, instrumentation amplifier, analog to digital converter and an output buffer
integrated into single component. The analog data is available in bi-polar (±2.5V);
hence ADC is operated in bi-polar mode. Final multiplexer output is given to ADC
through the buffer.
The analog Module mainly consists of the following
1. Analog Multiplexer
2. Input RC-Filter
3. Analog to Digital Converter (ADC)
Figure No: 3. ANALOG MODULE DIAGRAM
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Mux Sel line8
ADG406BP
Multiplexer
Analog CH-16
ADG406BPMultiplexer
ADG406BP
Final
Multiplexer
-15V+15V
Mux Sel line1
ADC Enable
LT1360
Mux O/P
Mux O/P
Mux OP
LTC1412
ADC
Control S/g
ADC Data
lines to FPGA
Analog CH-1
Final Mux Sel
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4.2 DISCRETE MODULE:
The Telemetry Encoder provides 32 discrete channels for monitoring discrete
events (i.e. 0 or 1). The signal levels 5V to 28V. The Opto-isolated event information
goes as discrete bit information to the TM stream.
To provide 32 discrete channels, we use 8 Optocouplers. Each Optocouplers
can handle 4 inputs. The outputs of the each two Optocouplers are given to buffers.
In the system as per the application, only one buffer is activated at a time and the
control signals for enabling the buffer issued by FPGA.
The outputs of the Optocouplers are given to buffer system as per the
application, only one buffer is activated at a time and the control signals for
enabling the buffer will come from FPGA.
The Discrete Module mainly consists of the following
1. Opto Isolator
2. Buffer
3. FPGA
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Figure No: 4. DIGITAL MODULE DIAGRAM
4.3 MICROCONTROLLER MODULE:
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4 choptocoupler -1
OctalBuffer -1
Buff Enable
32
OPTO
ISOLATED
INPUT
S
OctalBuffer -4
Buff Enable
FPGA
OUTPUT
OUTPUT
OUTPUT
4 channelOptocoupler -2
4 channelOptocoupler -7
4 channelOptocoupler -8
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The MICROCONTROLLER Module is heart of the Telemetry Encoder and it has
the following sub-modules.
MIL-STD-1553 B Interface
Format Interface
Delayed RAM Interface
RS 422 Channels Interface
Output Interface
The Telemetry Encoder provides 1553 channels, 4 RS 422 channels and the PCM
output.
4.3.1 MIL-STD- 1553 B Interface:
The Telemetry Encoder has MIL-STD-1553 bus interface for connectivity to
missile bus. The node is connected in Transformer coupled configuration. The
Telemetry Encoder node acts as simultaneous bus Monitor Terminal (MT) cum
Remote Terminal (RT) and monitors the bus transactions and captures the required
messages from the bus. The monitor (MT) mode is useful to capture all the data on
the bus or selectively capture the messages. The messages to be captured can be
specified in a lookup table stored in Total ACE RAM.
Features of Total ACE:
MIL-STD-1553 Module – Provides an interface for MIL–STD–1553 Data.
The Total-ACE is software and architecturally compatible with DDC's enhanced
series of devices.
It integrates dual transceivers, dual transformers, protocol engine and either 4K
or 64K words of internal RAM.
The Total-ACE's flexible processor interface allows direct connection with little or
no glue logic to a variety of 8, 16 and 32-bit processors.
The advanced architecture is key to the Total-ACE series’ high performance.
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The advanced bus controller architecture gives the Total-ACE a high degree of
flexibility and autonomy.
This creates advantages in a number of areas: improving message scheduling
control, minimizing host overhead for asynchronous message insertion,
facilitating bulk data transfers and double buffering, message retry and bus
switching strategies, and data logging and fault reporting.
In addition, its remote terminal architecture provides flexibility in meeting all
common MIL-STD-1553 protocols.
RT data buffering and interrupt options offer support for synchronous and
asynchronous messaging, ensure data sample consistency, and support bulk
data transfers.
The Total-ACE is the industry's smallest, fully integrated MILSTD-1553 terminal &transformer solution, enabling its use in applications where PC board space is at
a premium
The Total-ACE integrates dual +3.3V transceivers, protocol logic, 4K or 64K
words of internal RAM, and isolation transformers.
World’s Smallest CQFP MIL-STD-1553 Device 80-pin Ceramic Flat/Gull Wing
Package or 324-Ball BGA Package
IMPLEMENTATION
• The Total ACE BU64863I8E02 device is connected to Microcontroller and it fully
controls the TOTAL ACE. The Microcontroller issues the control signals for the
TOTAL ACE for 1553 data processing.
• The data Bus and Address Bus of Total Ace is connected to FPGA and
Microcontroller.
• FPGA issues the controls signals like STRB, CSB ACE and clock (16MHz) to the
Total Ace.
• To function the Total Ace in RT mode the Microcontroller sets the RT address of
the device.
• The Telemetry Encoder works in both RT and MT mode.
• The Telemetry Encoder receives the data from the MIL-STD-1553 Bus and
processed in the Total Ace.
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• Total Ace used is fully integrated MIL-STD-1553B chip equipped with Transceiver
and Transformer inside.
• The data over MIL-STD-1553 Bus is captured by Telemetry Encoder and the
Transceiver in Total receives the data and processed in Total Ace.
• The data Received by the Transceiver is processed and stirred in the shared Ram
of the Total ACE; the RAM is of 64K capacity.
• The Microcontroller takes the Data from the internal Sheered RAM of Total Ace
and sent to the FPGA through the Data Bus.
• The Data stored in internal FIFO of FPGA will be used during commutation of
data and will be sent in Telemetry serial stream.
• The 1553 Bus interface from Telemetry Encoder is provided by the Raychemmake connectors which are mounted on front plate of Telemetry Encoder
chassis.
• The MIL-STD -1553Bus communication in Telemetry Encoder is Transformer
coupled configuration.
4.3.2 RS-422 INTERFACE
The Telemetry Encoder has a provision for 4 Rx RS-422 channels. The baud
rates for these channels are user programmable.
RS-442 QUAD UART IC (XR16L784IV) is used to fulfill these specifications. The
UART IC will have individual internal FIFO for receive and transmit channels
internally. Dedicated microcontroller is used for this interface, which interfaces
QUAD UART and it takes the data of internal FIFO’s and puts into the FPGA Internal
FIFO, whenever digital sync comes from FPGA during commutation. All input receive
RS-422 channels are opt-coupled internally.
The RS-422 Interface Mainly consists of the following devices
• Optocouplers
• QUAD UART
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• Microcontroller
• FPGA
FEATURES OF OPTOCOUPLER
Ultra-low IDD current: 1.3 mA/channel maximum
Low input current: 1.6 mA
Built-in slew-rate controlled outputs
FEATURES OF UART IC
XR16L7841 (784) is a quad Universal Asynchronous Receiver and
Transmitter (UART)
1. 5V and 3.3V Operation with 5V Tolerant s
2. 64-pin TQFP Package
3. Up to 3.12 (16x) and 6.25 (8x) Mbps Data Rate
4. A General Purpose 16-bit Timer/Counter
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ADDR ADDR
DATA
4 RS-422 Receivechannels
0PTOCOUPLER
4 RS-422 Receivechannels inputs
4 RS-422 Receive
channels
RS 422 _1
RS 422 _4
CRYSTALOSC
QUAD
UART
FPGA
MICROCONTROLLER
DATA
inputs
control
0PTOCOUPLER
2 RS-422 Transmitchannels
Figure No: 5. RS-422 INTERFACE BLOCK DIAGRAM
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5. Programmable TX and RX FIFO Trigger Levels
IMPLEMENTATION:
• The Telemetry Encoder has provision for acquiring 4 RS-422 Receive
channels data.
• For RS-422 Receive channels interface a QUAD UART of EXAR make
XR16L784 device is used.
• The RS-422 channels are received by Telemetry Encoder by the Front Panel
connectors and they are connected to the Opto couplers.
• The Rs-422 channels data received are first opto coupled internally and theyare given to the FPGA.
• The FPGA converts the differential output opt couplers to single ended and
will be given to the QUAD UART IC.
• There is Dedicated Microcontroller for the QUAD UART operation and control.
• The QUAD UART receives the data at the fixed Baud rates and the Baud rate
is decided by the external clock oscillator frequency, there is crystal oscillator
for this operation.
• The QUAD UART has separate FIFO’s for each RS-422 channels.
• The Microcontroller takes the data from the internal FIFO of the QUAD UART
and keeps it into the FIFO of FPGA.
• The data stored in the FIFO is used during commutation and mixed in the
Telemetry Stream.
4.3.3 PCM OUTPUT SECTION
The Telemetry Encoder provides the output to Transmitter and checkout systems
for the recording and verification of the data from different parameter, the output is
connected to the Front panel connectors which will be connected to Transmitter or
ground station. The PCM Outputs section block diagram is explained as below:
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FPGA
Buffer
BIPHASE
CLOCK
NRZ-L
Controls
CLOCK
AD5424YRU
DAC
BIPHASE Buff Out
NRZL Buff Out
Clock Buff Out
DAC_IN_0o 7
RD/WR
Control
BIPHASE Buff Out
3.3V
LMH6644
PRE MOD
FILTER
+5V
-5V
DACOUTPUT
LMH6718
GAIN
BUFFER
+5V
-5V
3.3V
ADTTITRANSFORMER
OUTPUT HIGH
OUTPUT LOW
DIRECTOUTPUT
DS26LS31
Line driver
BIPHASE
BIPHASE #
Output inform of RS-422 for checkout
Output fo
Transmitt
3.3V
Figure No: 6. PCM OUTPUT SECTION BLOCK DIAGRAM
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The PCM Output section is categorized as following
BiΦ – L: This is BiΦ -L – L data which is generated by the FPGA and given to the a
Buffer and the output of Buffer is connected to the DAC, which controls the outputamplitude, the output of the DAC is connected to the 6th order Bessel Filter to
suppress the harmonics and is connected to the Gain Amplifier and to the
Transformer, the transformer output is connected to the Output Connector placed
on the front panel, the BiΦ – L data is connected to the Transmitter.
BiΦ – L in RS-422 format: This is BiΦ – L data after buffering the data is connected to
RS-422 Line driver and the output is connected to the front panel connector.
NRZ-L: The NRZ-L data is generated by the FPGA is given to the Buffer.
The above module is implemented using the following components
1. FPGA
2. DAC
3. Pre Mod Filter
4. Gain Buffer5. Transformer
6. RS-422 Line driver
4.4 Model Number and Serial Number of the System/ sub-system
Serial No Name Model Number
12-002 ASB Telemetry Encoder ATL-TE-1202/0112-003 ASB Telemetry Encoder ATL-TE-1202/01
5. PHYSICAL INSPECTION AND SCREENING TESTS
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5.1 Physical and visual inspection
After receiving all the components / materials from stores, visual inspection is
to be carried out for all of them for any physical damages and subsequently the
following steps are to be followed in the card fabrication process
♦ Bare PCB cleaning
♦ Baking of bare PCB
♦ Preparation of part leads
♦ Components mounting
Lead trimming
Soldering
Cleaning
Inspection
♦ Connectors Mounting
Connector fixing and torque
Inspection
Connector soldering
Cleaning
Inspection
♦ Final inspection before functional test
Note: 1) each step is followed by inspection and rework (if any).
2) All stages of inspection should be as per the respective QC-checklists and
the
observations to be recorded subsequently by the concerned personnel
(Fabricator
and Online QC Inspector).
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SL NO. Inspection Type Attribute Status(PASS/FAIL)
1
Solder-ability
Clean
Smooth
BrightConcaveLead visibleCompletewetting
Thin edgeNo excesssolder
2Dip components flushed on to theboard
3 Alignment
4 Orientation
5 Components are as per BOM.
6 Lacing provided where required
7Is there any damage on thePCB/tracks?
8Is there any damage on thecomponent?
9Impedance Check conducted for allVCC signals
5.2 ELECTRICAL CONTINUITY & INSULATION TESTS
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Electrical Checks
The following electrical checks are required to be conducted to confirm whether the
Telemetry is meeting the power supply requirements.
Isolation Check:
Check the isolation as per the appendix ’A’ between the connector pins to body with
a Digital Multimeter. The IR measured shall be more than 10 MΩ.
Continuity Check:
Check the continuity between the DC-DC converter mating to the PCB mount
mating connector and PCB test points to the front plate connectors as per
integration details given in appendix ‘A’
Insulation Checks:
Insulation check is done as per the appendix ’A’ , in between the pins of J6
connectors and the chassis using a Megger of 250V. The IR measured shall be more
than 20 MΩ.
Stabilization time:
The functionality of the system should be instantaneous. The system should getstabilized with proper power and current level within 3 seconds after switching ON.
Current Consumption Check:
The Current drawn by the Telemetry at 28 V ± 6V shall be 0.26 A +/- 0.05A.
Screening tests:
Screening for Non-MIL components carried out as per CEMILAC directive No
CEMILAC/5390/1 Dt.10-01.-2004.
Reverse Polarity Check:
Reverse the connections of power supply source of PCM encoder (at 28 V ± 6V) and
note down the current reading of the variable power supply. The current drawn
should be negligible
(Almost zero).
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6. FUNCTIONAL TEST PROCEDURE
The Telemetry Encoder consists of three types of cards, and a chassis
mountable DC-DC converter, which are placed inside the package. The three
different types of cards interconnected through Flexi, which are Analog, Discrete
and microcontroller Card.
Telemetry Encoder is tested using Bit synchronizer, Decommutator system
and input simulators. The input data is given from different sources i.e. Analog,
Discrete, 1553 and RS-422 channels and the output data are monitored in the
Decommutator system.
The Telemetry Encoder Test set up is shown in Figure 7 below. Initially power
up the unit through J7 connector from High precision 28 V DC power supply. The
required formats will be stored in FLASH through RS-422 serial link. The output
connector J6 will be connected to Decommutator system. After powering on the
Decommutator system, Checkout system parameters to be modified/stored. Then
the Decommutator system will give lock status, like format, frame etc. The PCM
Encoder Lock status is O.K then it will display the data on screen as per history files,
which is generated from format.
The Analog, Discrete and 1553 data will be connected through J1, J2 and J4, J5
respectively. The respective data will be monitored in the Checkout system. All
parameters that are within the specified limits then the unit will be processed for
further environmental tests as per user requirements.
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Fig 7: Telemetry Encoder Test Setup
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A B
C
TELEMETRY ENCODER
DECOMMUTATOR SYSTEM WITHBIT SYNCHRONISER
1553 SIMULATOR RS-422 SIMULATOR CARD(MOXA) INTEGRATED IN PC
ANALOG CHANNELSSIMULATOR (PRECISION
POWER SUPPLY)/FUNCTIONGENERATOR
DISCRETE CHANNELSSIMULATOR (PRECISION
POWER SUPPLY)
POWER SUPPLY(28V, 2A)
RS-422CHANNELS INPUT
1553 DATA INPUT
DATA DATA #DATA
LOW
VOLTAGEINPUT
GND
VOLTAGEINPUT
GND
28V RETURN28V HIGH
BIT SYNCHRONISER UNIT
(BSU)
DECOMMUTATORSYSTEM (TELEMETRY
ACQUISTION CARD-TAC)INTEGRATED IN PC FOR
MONITORING DATA
TELEMETRYOUTPUT
DATA CLK
DIGITAL MUTLIMETERFOR CHECKING
VOLTAGE INPUTS
J1&J2
J2
J4, J5 J2
J6
J7
HIGH
D
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The following parameters to be monitored while functional testing of TelemetryEncoder
SL. No Name of the Test
1. Sync lock status
3. Functioning of analog channels
4. Functioning of Discrete channels
5. Functioning of 1553 data
6. Functioning of RS-422
As shown in fig 7. The following equipments required for testing of
TELEMETRY Encoder.
• Bit synchroniser
• Decommutator system integrated with TAC add-on card in PC
• 1553 Simulator
• RS-422 simulator card integrated in PC.
• 28V DC Power supply of for Telemetry Encoder.
• Discrete channels (28 V DC Power supply – 2Nos.)
• Analog channels simulator (Power Supply 0-5V DC)/Function Generator
• Digital Multi-meter
Telemetry Encoder is tested using Bit-Synchroniser, Decommutator system
and input simulators. The input data is given to different sources i.e. Analog,
Discrete, 1553 and RS-422 channels and the output data are monitored in the
Decommutator system.
Telemetry Encoder analog channels are tested by giving the input voltage to
analog channel and output is monitored in the Decommutator system. As per the
specifications the analog channels is tested in bipolar voltage i.e., -2.5V to +2.5V.
The input is given through precision power supply.
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Telemetry Encoder discrete channels are tested by giving input voltage to
discrete channel and output is monitored in the Decommutator system. As per the
specifications the discrete channels is tested for 5V & 28V. The input is given
through precision power supply.
Telemetry Encoder 1553 channels are tested by giving any data
message from the standard 1553 simulator and the same data is monitored in
Decommutator system.
Telemetry Encoder RS-422 channels are tested by giving the data
message from the standard RS-422 simulator and the same data is monitored in
Decommutator system. The Telemetry encoder has 4 channels, in which the data
message is given through standard simulator by selecting the desired baud rate.
Telemetry encoder is tested in the following modes
a) Functional test mode – used to verify system resources during Lab
level/Environmental testing.
b) Software Loader Mode – used to load all software programs in respectiveFPGA, Microcontroller and flash memories of Telemetry Encoder.
Note: Software loading done externally without opening the unit.
Cables and connectors Interconnection details with Telemetry Encoder and Test Jig
SL.No.
Description Cable or connectorconnected to TelemetryEncoder
Cable or connectorconnected to Test Jig orTest Equipment
1. Analogchannels
J1 ( 100 pin connector) & J2 (79 pin connector)connected using shieldedor bare cable
Connected to Power Supply28 V DC with an input toanalog channels of ±2.5V.
2. Discretechannels
J2 (79 pin connector)connected using shieldedor bare cable
Connected to Power Supply28V DC with an input todiscrete channels of 5V or28V.
3. RS-422 J2 (79 pin connector) Connected to RS-422
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channels connected using shieldedor bare cable.
simulator ( Moxa card)using 9 pin D-subconnectors – 4 Nos
4. 1553 channel J4 and J5 (Raychem)connected using shieldedcable.
Connected to 1553standard simulator usingRaychem connectors.
5. Power supply J6 (5 Pin connector)connected using shieldedor bare cable.
Connected to Power Supply28V
6. TelemetryOutput
J7 (triaxial connector)connected using triaxial orshielded cable.
Connected to BitSynchroniser using BNCconnector
6.1 Typical precondition settings:Before switching on the telemetry unit the following settings have to be made
a) Bit synchronizer settings:
Bit rate: 1Mbps (Depends on the format)input code: BiΦ -L
b) Telemetry Encoder & Decommutator Settings:
Format: The required formats will be stored in FLASH through RS-422 serial link
in telemetry encoder. The Decommutator system is configured as per the
history file which was generated from format. Then only we can see the lock
status on the screen. The format details are given in the appendix ‘B’.
c) RS 422 Settings:
In MOXA RS-422 simulator we have set the port and the required baud rate.
Port: depend on the PC system configuration.
Baud Rate: 115200
d) 1553 simulator :
In 1553 simulator we send standard message (i.e.: 0, 1,2,……9).
e) Analog Simulator:
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For Analog channels from a DC power supply set the voltages of +2.5V, 0 V &
-2.5V apply to required channels and observed the required count as given in
appendix ‘D’.
Set the Function generator for required frequency as per specification
f) Discrete Simulator: (5 V & 28 V)
For Discrete channels from a DC power supply set the voltage of 5V/28V applyto required channels.
Observables:
• Scaling of analog channels for the applied voltages is given in the
appendix’C’
• Discrete channels a bit set is observed as given in appendix’D’
• 1553 configured data will be observed
• What ever the Messages are sent to RS422 channels those messages areobserved in Decommutator for all the 4 channels
Note:
Bit rates: It can be tested for 1, 2 & 3 Mbps with reloading of software.
The BiΦ -L o/p may be 0 – 5 Vpp (max) – programmable
Format settings as per history file, is shown in appendix ‘B’
The Telemetry encoder is configured for bit rate and corresponding bit rate is
set in decommutator.
Function generator is set to <= 8 KHz
6.2 The functional tests are performed on SOFT unit.
1. Test case 1 : Bit Sync lock
Description : To check whether the Telemetry output and the
bit synchronizer
bit rate matches.
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Test procedure : Connect the Telemetry Encoder output at connector J7
to the bit
synchronizer system input through Trompeter to BNC
Cable.
Expected Result : The lock status appears in green as lock when the
Format
matches on bit synchronizer system, else it will show red
color as
Unlocked
2. Test case 2 : Frame Sync lock
Description : To check the validity of the Telemetry data
format.
Test procedure : Connect the Telemetry Encoder output at connector J7
to
Decommutator through bit synchronizer system as show
in fig 7.
Test setup.
Expected Result : The lock status appears in green as lock when the
Format
matches on Decommutator system, else it will show red
color as
unlocked.
3. Test case 3 : PCM OUTPUT (Pre-mod filter)
Description : To check PCM out and the lock status in
Decommutator
Test procedure : Connect probe to the J7 connector cable and monitor
signal using Oscilloscope. And also connect the output
to bit synchronizer.
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Expected Result : 1.The lock status in decommutator
2. BiΦ– L waveform on oscilloscope.
3. BiΦ -L output level 0 – 5 Vp-p (max) as programmed.
4. Test case 4 : Data rate
Description : To check Data rate of the PCM Encoder.
Test procedure : Connect probe at pin numbers 8 & 9 of J3 connector and
monitor signal using Oscilloscope.
Expected Result : Output is measured in oscilloscope, Frequency depends
on
the bit rate. For Ex: for 3Mbps bit rate we get 3MHz.
5. Test case 5a : Analog Channel with frequency.
Description : To check the analog channels functionality
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
Fig7 and from function generator give an input sine
signal of < 8
KHz to any one analog channel in J1/J2 connector and
check the
output in the Decommutator
Expected Result : Record the channel data to which we have applied the
input and plot the wave form in mat lab as per the
recorded data and also monitored lock status on
Decommutator.
6. Test case 5b : Analog Channel with DC power supply.
Description : To check the analog channels functionality
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Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. And From DC supply Apply +2.5V, 0V, -2.5V as
input to
Analog channels in J1/J2 connectors and check the out
put in the
Decommutator.
Expected Result : The count of 255, 127, and 0 with ±2 count tolerances
w.r.t above
voltages monitored on Decommutator. AS per test report
in
appendix ’D’ and also observe the lock status.
7. Test case 6 : Analog channel cross talk
Description : To check whether any interferences between
analog channels.
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. Give input to both the channels with different
voltages. (Ex:
+2.5, 0V & -2.5 V)
Expected Result : Count must be as per the test report .i.e (255,127, 0)
with ± 3
counts and also observe the lock status.
8. Test case 7 : Discrete Channel with DC power supply.
Description : To check the Discrete Channel functionality
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Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. And From DC supply Apply +5V/28V as input to
Discrete
channel in J2 connectors and check the out puts in the
decommutator.
Expected Result : One bit is set from 0 to 1 w.r.t above voltages monitored
on
decommutator. AS per test report in appendix ’D’ and
also
observe the lock status.
9. Test case 8 : 1553 Channels
Description : To check 1553 bus communication.
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. Inputs are given to Telemetry from 1553 simulator
and
check the out puts in the Decommutator
Expected Result : standard message is sent through 1553 simulator the
same
message is monitored on Decommutator and also
observe the
lock status.
10. Test case 9 : RS-422 Channels
Description : To check the status of communication
Establishment.
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Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. Inputs are given to Telemetry from RS-422
simulator
(MOXA Card.) And check the out puts in the
Decommutator
Expected Result : What ever data is sent through RS422 simulator the
same data is
monitored on Decommutator on all 4 channels and also
observe the lock status.
11. Test case 10 : Delay Data
Description : To check, after how much delay the data is
received.
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. On the Telemetry unit and check the delay data
window
note down the time after how much time the data is
received.
Expected Result : The time tag which gives the status of 1553 bus. The
same time
tag will be received after a time delay in delay datawindow of
Decommutator and also observe the lock status.
6.3 Functional test when conducting environmental tests
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1. Test case 1 : Analog Channel with DC power supply.
Description : To check the analog channels functionality
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. And From DC supply Apply +2.5V, 0V, -2.5V as
input to
analog channels in J1/J2 connectors and check the out
put in the
Decommutator
Expected Result : The count of 255, 127, and 0 with 2 count tolerancesw.r.t above
voltages monitored on Decommutator. AS per test report
in
appendix ’D’ and also observe the lock status.
2. Test case 2 : Discrete Channel with DC power supply.
Description : To check the Discrete Channel functionality
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. And From DC supply Apply +5V/28V as input to
Discrete
Channel in J2 connectors and check the out puts in the
Decommutator
Expected Result : One bit is set from 0 to 1 w.r.t above voltages monitored
on
Decommutator. AS per test report in appendix’D’. And
also
observe the lock status.
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3. Test case 3 : 1553 Channels
Description : To check 1553 bus communication.
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. Inputs are given to J4 connector from 1553
simulator and
check the out puts in the Decommutator
Expected Result : Standard message is sent through 1553 simulator the
same data
is monitored on Decommutator.
4. Test case 9 : RS-422 Channels
Description : To check the status of communication
Establishment.
Test procedure : Connect the Telemetry Encoder as per the test setup
shown in
fig7. Inputs are given to Telemetry from RS-422
simulator
(MOXA Card.) And check the out puts in the
Decommutator
Expected Result : What ever data is sent through RS422 simulator the
same data is
monitored on Decommutator and also observe the lock
status.
Note: when conducting environmental test optimal channels are monitored.
As per requirement bit rate is up to 3 Mbps only.
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Among 128 channels 1 channel is reference channel.
7. Environmental Stress Screening Test
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7.1 ESS Test Specifications
7.2 ESS test procedure for SOFT
7.2.1 Random Vibration
Test Objective:
To determine the suitability of equipment to withstand specified severities of
vibration and to bring out the workmanship and latent defect.
Test Level
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S
l
.
N
o
Description Level Remarks
ESS
1
.
Random
Vibration
Spectral Density – 0.04g2/Hz
20Hz- 80Hz +3db/octave
80Hz-350Hz 0.04 g2/Hz
350Hz-2000Hz -3db/octave
Duration: 5 minutes/axis
Along all the three axis
PREET at Room
condition
INSET at given level
POET at room condition
2
.
Temperature
Cycling
-40°C dwell 2Hr
+71°C dwell 2Hr
Rate of change of temp : 5°C /
minute
No. of cycles : 6 cycles
PREET at Room temp.
INSET at each high and
low temp. Cycles.
POET after thermal
cycling at room
temperature3
.
Random
Vibration
Spectral Density – 0.04g2/Hz
20Hz- 80Hz +3db/octave
80Hz-350Hz 0.04 g2/Hz
350Hz-2000Hz -3db/octave
Duration: 5 minutes/axis
Along all the three axis
PREET at Room
condition
INSET at given level
POET at room condition
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Description Level
RandomVibration
Spectral Density – 0.04g2/Hz
20Hz- 80Hz +3db/octave
80Hz-350Hz 0.04 g2/Hz350Hz-2000Hz -3db/octave
Duration: 5 minutes/axis
Along all the three axis
PREET at Room condition
INSET at given level
POET at room condition
Test Procedure
The random vibration test will be carried out along all three mutually
perpendicular axes for duration of five minutes each, as per profile gives in fig. 8 on
all the test items. The equipment shall be kept energize during the vibration test.
Visual examination will be carried out after the test to check for appearance of any
defect.
Fig 8: Random Vibration test Profile
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1hr
1hr
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7.2.2 Temperature Cycling
Test Objective:
To bring out the workmanship and latent defects in the test item by
subjecting it to rapid temperature cycling stress.
Test Level
Description Level
Temperature
Cycling
-40°C dwell 2 Hr
+71°C dwell 2 Hr
Rate of change of temp : 5°C /
minute
No. of cycles : 6 cycles
PREET at Room temp.
INSET at each high and
low temp. Cycles.
POET after thermal cycling
at room temperature
Test Procedure
The test item will be subjected to the temperature extremes of -40oC and
+71oC for ten cycles as per profile given in fig 9 as applicable to the test item. The
rate of change of temperature from minimum to maximum, and vice versa, shall be
at an average rate of 5oC /min. The item shall be at an average rate of 5 oC /min. The
test item shall be powered and the PC taken as indicated in the figure, during each
cycle.
Fig 9: Thermal cycling Test Profile
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+710C
-400C
//
Inset Measurement at
this stage
Inset Measurement at
this stage
2 Hr
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7.2.3 Random Vibration
Test Objective:
To determine the suitability of equipment to withstand specified severities of
vibrationand to bring out the workmanship and latent defect
Test Level & Test Procedure
The random vibration test will be carried out along all three mutually
perpendicular axes for duration of five minutes each, as per profile gives in fig. 8 on
all the test items. As given in section 7.2.1
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8. ENVIRONMENTAL SPECIFICATIONS
8.1 Test Specifications for SOFT
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S
l.
N
o
.
Descr
iption
Level Remarks
1. Continuou
s
Run Test
8 hrs continuous operation with
parameter checks every 2 hrs
PREET, INSET, POET
2 EMI/EMC CS101, CS114, CS115,
CS116, RS103, HESD,
CE102, RE102
PREET, INSET & POET
3 Power
supply
compatibili
ty
Normal 22-29V
Abnormal 20-31.5V
Transient surge: 59V for
50ms
0V for 7 sec
Emergency operation: 16V
same as normal
Power interruption: 0V for
50ms (AC & DC)4 Random
Vibration
a) Sub system mounted at nose
Section
20Hz 0.0018 g2/Hz
70Hz 0.01 g2/Hz
160Hz 0.0064 g2/Hz
250Hz 0.0081 g2/Hz
430Hz 0.013 g2/Hz
750Hz 0.007 g2/Hz
1350Hz 0.0027 g2/Hz
1600Hz 0.0022 g2/Hz
2000Hz 0.0016 g2/Hz
Over all Grms=3.25
Duration – 15 minutes/axis, in all
the three axes
Duration PREET at
Room condition
INSET at given level
POET at room condition
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S
L
.
N
o.
Descr
iptio
n
Level Remarks
5 High
Temperature
storage cum
operation
0 - 6 Hrs 35 ºC
6 - 11½ Hrs 35 to 71 ºC
11½ - 13½ Hrs 71 ºC ON
13½ - 14 Hrs 71 to
85 ºC
14 - 15½ Hrs 85 ºC
15½ - 16 Hrs 85 to 65 ºC
16 - 19 Hrs 65 ºC ON
19 - 24 Hrs 65 to 35 ºC
One Cycle of 24 Hrs each.
Test profile is shown in Fig. 10
PREET at Room
temp.
INSET at specified
level ’ON*
Visual inspection
after test.
POET Reading after
test.
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6 Combined
Altitude,
Temperature &
Humidity
(CATH)
15 min ramp to temperature
OFF
4 Hr -40 ºC OFF
30 min ramp to altitude ON
30 Min -40 ºC 12 KmON*
10 min ramp to humidity and
temperature
ON
30 Min +43 ºC 95%RH ON*
15 min ramp to temp & humidity
ON
2 Hr +55 ºC <30% RHON
15 min ramp to altitude
ON
4 Hr +55 ºC 12 Km <30% RH
ON *
Four cycles each of app.12 Hrs
duration.
Test profile is shown in Fig.11
PREET at Room
temp.
INSET at specified
level ’ON*’ Visual
inspection aftertest.
POET Reading after
test.
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S
L
.
N
o.
Descr
iptio
n
Level Remarks
7 Accelerati
on
As per MIL STD 810G
Method 513.6. Table 513.6 –
II & I
a)Operational :
Procedure IIDirections : Severity
Fore : 7g
Aft : 8g
Up : 9g
Down : 5.4g
Lat L : 3g
Lat R : 3g
Duration: 1 min/direction
b) StructuralProcedure -I
Directions : SeverityFore : 10.5g
Aft : 12g
Up : 13.5g
Down : 8.2g
Lat L : 4.5g
Lat R : 4.5g
Duration: 1 min/direction
Equipment in
ON condition
during the
test.
VE (visual
Examination) and
PC (parameter
check) before and
after test.
Equipment in OFF
condition during the
test VE (visual
examination) and
PC (parameter
check) before and
after test
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8 Mechanical Shock
As per MIL STD 810G
Method 516.6
Severity : 20g, 11 m sec
Pulse Shape: Half Sine pulse
No. of Shocks: 3 shocks oneach of 6 directions
Total of 18 shocks.
PREET at
Room Temp.
Inset during
test.
POET aftertest.
8.2 Environmental test procedure for SOFT
8.2.1. Continuous Run
Test Objective
To bring out the workmanship and latent defects in the test item by
subjecting it to continuous power on.
Test level
Sl.
No
Descr
iption
Level
1. Contin
uous
Run
Test
8 hrs continuous operation with
parameter checks every 2 hrs
PREET, INSET,
POET
Test Procedure
Carry out the functional test as per appendix ‘D’, at room temperature andnote down the outputs for the same as per the format in appendix ’D’. Now power
on the equipment for 8 hours continuously. For every 2 hrs note down the outputs
as per the format in appendix ’D’.
Acceptance Criteria
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There should be no deviation in observed values before, during and after
continuous run.
8.2.2. RANDOM VIBRATION
Test Objective
To determine the suitability of equipment to withstand specified severities of
vibration and to bring out the workmanship and latent defects.
Test level
Sl.
No
Descr
iption
Level
1. Rando
m
Vibrati
on
20Hz 0.0018 g2/Hz
70Hz 0.01 g2/Hz
160Hz 0.0064 g2/Hz
250Hz 0.0081 g2/Hz
430Hz 0.013 g2/Hz
750Hz 0.007 g2/Hz
1350Hz 0.0027 g2/Hz
1600Hz 0.0022 g2/Hz
2000Hz 0.0016 g2/Hz
Over all Grms=3.25
Duration – 15 minutes/axis, in all
the three axes
PREET at Room
condition
INSET at given level
POET at room condition
Test Procedure
Carry out the functional test as per appendix ’D’, at room temperature and
note down the outputs for the same as per the format in appendix ’D’. Now fix the
equipment on the Vibration table and apply vibration to the specified level along all
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three axes. Carry out the functional test at the given level and note down the
outputs as per the format in appendix ‘D’. Now carry out the functional test at room
temperature and note down the outputs in the same manner.
Acceptance Criteria There should be no deviation in observed values before, during and after
vibration.
8.2.3. HIGH TEMPERATURE CYCLE
Test Objective
To bring out the workmanship and latent defects in the test item by
subjecting it to rapid temperature cycling stress.
Test Level
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6 11.5 13.5 14 15.5 16 19 24
Duration in Hours
Tempo C)
35
65
71
85
ON
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Test Procedure
Keep the equipment in the chamber and switch on the equipment and Carry
out the functional test at room temperature and note down the outputs as per
Appendix ’D’. Now increase the temperature to the specified levels and keep it for
the mentioned time. Carry out the functional test at the 71 o C and note down the
outputs as per Appendix ’D’. Now decrease the temperature to room level. Carry
out the functional test and note down the outputs as per Appendix ’D’.
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1. High
Temperature
storage cum
operation
0 - 6 Hrs 35
ºC
6 - 11½ Hrs 35
to 71 ºC
11½ - 13½ Hrs 71 ºC13½ - 14 Hrs 71
to 85 ºC
14 - 15½ Hrs 85 ºC
15½ - 16 Hrs 85 to
65 ºC
16 - 19 Hrs 65 ºC
19 - 24 Hrs 65 to 35
ºC
One Cycles of 24 Hrs each.
Test profile is shown in Fig. 10
PREET at Room temp.
INSET
Visual inspection after
test.
POET Reading after test
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ON
Fig No: 10 High Temperature Storage cum Operation
Acceptance Criteria
There should be no deviation in observed values before, during and after the
test.
8.2.4. COMBINED ALTITUDE, TEMPERATURE & HUMIDITY (CATH)
Test Objective
To bring out the workmanship and latent defects in the test item by
subjecting it to CATH Test.
Test Level
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TEST PROCEDURE
Keep the equipment in the chamber and switch on the equipment and Carry
out the parameters checks test at room temperature as per Appendix ‘D’. Now
change the temperature to the specified levels and keep it for the mentioned time.
Carry out the parameters checks at the specified level’s and note down the outputs
as per Appendix ‘D’. After completion of cycles decrease the temperature to room
level. Carry out the parameters checks and note down the outputs as per Appendix
‘D’.
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1. Combined
Altitude,
Temperature &
Humidity
(CATH)
15 min ramp to temperature
OFF
4 Hr -40 ºC OFF
30 min ramp to altitude ON
30 Min -40 ºC 12 Km
ON*
10 min ramp to humidity and
temperature
ON
30 Min +43 ºC 95%RH ON*
15 min ramp to temp & humidity
ON
2 Hr +55 ºC <30% RH
ON
15 min ramp to altitude ON
4 Hr +55 ºC 12 Km <30% RH
ON *
Four cycles each of app.12 Hrs
duration.
Test profile is shown in Fig.11
PREET at room Temp.
INSET at specified level
'ON*’.
POET at room Temp.
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Note: Ramp rates are subjects to tailoring and facility limitations.
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1 2 3 4 5 6 7 8 13
Time in HoursFig NO:-11 Combined Altitude – Temperature & Humidity
empC)
titudekm)
umidity%)
-40
43
55
0
18
95
Parameter checkOFFON
ON
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Acceptance Criteria
There should be no deviation in observed values before, during and after the
test.
8.2.5. ACCELERATION
Test Objective
To demonstrate the ruggedness of the systems under vibration.
Test Level
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1
.
Acceleration As per MIL STD 810G
Method 513.6. Table 513.6 –
II & I
a)Operational :
Procedure IIDirections : Severity
Fore : 7g
Aft : 8g
Up : 9g
Down : 5.4g
Lat L : 3g
Lat R : 3g
Duration: 1 min/direction
b) StructuralProcedure -I
Directions : Severity
Fore : 10.5g
Aft : 12g
Up : 13.5g
Down : 8.2g
Lat L : 4.5g
Lat R : 4.5g
Duration: 1 min/direction
PREET and POET at
room temp.
Equipment is off during
test.
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Test Procedure
Carry out the parameter checks at room temperature and note down the
outputs as per appendix ‘D’. Now fix the equipment on the Acceleration bench and
apply the acceleration to the specified level along all six directions. Now carry out
the parameter checks after completion of test and note down the outputs as perappendix ‘D’.
Acceptance Criteria
There should be no deviation in observed values before and after
Acceleration.
8.2.6. MECHANICAL SHOCK
Test Objective
To expose any defects in the test item by subjecting it to Mechanical Shock
test.
Test level
Test Procedure
Carry out the Parameter checks at room temperature and note down theoutputs as per appendix ‘D’. Now fix the equipment on the Shock bench and apply 3
shocks in one direction. Carry out the parameter checks in all 6 directions. Now
carry out the parameter checks after completion of test and note down the outputs
as per appendix ‘D’.
Acceptance Criteria
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1
.
Mechanical
Shock
As per MIL STD 810G
Method 516.6
Severity : 20g, 11 m
sec
Pulse Shape: Half Sine pulse
No. of Shocks: 3 shocks on
each of 6 directions
Total of 18 shocks.
PREET at Room Temp.
INSET during test.
POET at room Temp.
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There should be no deviation in observed values before, during and after the
test.
8.2.7. Power Supply Compatibility
Test Objective
To demonstrate the ruggedness of the Power supply module.
Test level
1
.
Power supply
compatibility
Normal 22-29V
Abnormal 20-31.5V
Transient surge: 59V for 50ms0V for 7 sec
Emergency operation: 16V same as
normal
Power interruption: 0V for 50ms (AC & DC)
Test Procedure
Carry out the parameter checks at room temperature and note down the
outputs as per appendix ‘D’. Now apply the specified voltage and check.
Acceptance Criteria
There should be no deviation in observed values before, during and after the
test.
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EMI/EMC SPECIFICATION
8.2.8 CONDUCTED SUSCEPTIBILITY (CS101) TEST
Test Description: Conducted Susceptibility power leads, 30Hz to 150 KHz
Applicability: `
Applicable to subsystem AC and DC input power leads, not including returns. On AC
lines this requirement is applicable starting from the second harmonic of the
equipment under test power frequency.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration:
The test signal voltage shall be applied on to the each power lead
separately for the complete band of frequency. That is approx. 30 minutes for each
test run.
Specification Limit Lines
The EUT shall not exhibit any malfunction, degradation of performance, or
deviation from specified indications, beyond the tolerances indicated in the
individual equipment or subsystem specification, when subjected to a calibrated
test signal with voltage levels as per Curve #2 specified in Figure: 1 CS101-1.
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Figure: 1 CS101-1 Voltage limit for all applications
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Fig: 2 CS101 TEST SETUP
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
8.2.9 CONDUCTED SUSCEPTIBILITY (CS114) TEST
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Test Description: Conducted Susceptibility, bulk cable injection, 10 KHz to
200MHz
Applicability:
Applicable to all interconnecting cable bundles, power cable, and separately
on positive (high) line/wire, excluding neutral/ground lines.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration:
The test signal current shall be applied on to the each cable for the complete
band of frequency. That is approx. 90 minutes for each test run.
Specification Limit Line
The EUT shall not exhibit any malfunction, degradation of performance, or
deviation from specified indications beyond the tolerances indicated in the
individual equipment or subsystem specification, when subjected to a pre-calibrated
current limit CURVE #3, shown in fig: 4 CS114-1 test limit (selected from Table VI
applicable for platform) and is modulated as specified in test procedures of Mil-Std-
461E, i.e., 1 kHz pulse modulation, 50% duty cycle.
The test shall be performed for a complete band of frequency on each connector.
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Figure No: 3 RS114 test levels
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Figure No: 4 Table VI CS114 Curve
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Fig: 5 CS114 Test Setup
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
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8.2.10. CONDUCTED SUSCEPTIBILITY (CS115) TEST
Test Description: Conducted Susceptibility bulk cable injection, impulse excitation
Applicability:
Applicable to all interconnecting cable bundle, power cable and separately on
positive line/wire excluding neutral / ground line.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration:
The test signal voltage shall be applied on to the each cable for duration of 60
seconds.
Specification Limit Line:
The EUT shall not exhibit any malfunction, degradation of performance, or
deviation from specified indications, beyond the tolerances indicated in theindividual equipment or subsystems specification, when subjected to a pre-
calibrated signal having rise and fall times, pulse width, and amplitude as specified
in Figure 6 CS115-1 at a 30 Hz rate for one minute.
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Fig: 6 CS115 Signal characteristics
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Fig: 7 CS115 Test Setup
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
8.2.11. CONDUCTED SUSCEPTIBILITY (CS 116) TEST
Test Description:
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Conducted Susceptibility, damped sinusoidal transients 10 KHz to 100MHz
Applicability:
Applicable to all interconnecting cable bundles, power cable, and separatelyon positive (high) line/wire, excluding neutral/ground lines.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration:
The test signal current shall be applied on to the each cable for six spot
frequencies. That is approx. 45 minutes for each test run.
Specification Limit line:
The EUT shall not exhibit any malfunction, degradation of performance, or
deviation from specified indications, beyond the tolerances indicated in the
individual equipment or subsystem specification, when subjected to a signal having
the waveform shown in Figure: 8 CS116-1 and having a maximum current limit of 5
Amperes as specified in Figure: 9 CS116-2. As a minimum, compliance shall be
demonstrated at the following frequencies: 0.01, 0.1, 1, 10, 30, and 100
MHz, if there are other frequencies known to be critical to the equipment
installation, such as platform resonances, compliance shall also be demonstrated at
those frequencies. The test signal repetition rate shall be no greater than one pulse
per second and no less than one pulse every two seconds. The pulses shall be
applied for duration of five minutes on each Connector.
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Fig: 8 Typical CS116 Sinusoidal waveform
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Fig: 9 CS116 limit wave
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Fig: 10 CS116 Test setup
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
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8.2.12. RADIATED SUSCEPTIBILITY (RS103) TEST
Test Description: Radiated Susceptibility electric field 2 MHz to 18GHz
Applicability:
Applicable to all equipment / subsystem enclosures with interconnecting cables.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration:
The electric field shall be applied for completed band of frequency with the
scan rates specified or minimum 10 minutes in each band.
Specification limit line
The EUT shall not exhibit any malfunction, degradation of performance, or
deviation from specified indications, beyond the tolerances indicated in the
individual equipment or subsystem specification, when subjected to the radiated
electric fields 20 V/m and 60V/m in the frequency range of 2 MHz to 1 GHz and
1GHz to 18 GHz respectively (selected from the Table VII RS103 limits applicable for
Plat form Air force) with 1 kHz pulse modulated, 50% duty cycle. Up to 30 MHz, the
requirement shall be met for vertically polarized fields. Above 30 MHz, the
requirement shall be met for both horizontally and vertically polarized fields.
The duration of the test shall be as per the Mil-Std-461E susceptibility
requirements or minimum of 10 minutes in each frequency band.
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Fig: 11 RS103 test levels
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Fig: 12 RS103 Test Setup
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
8.2.13. RADIATED EMISSIONS ELECTRIC FIELD (RE102) TEST
Test description: Radiated Emissions Electric field 10 KHz to 18GHz
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Applicability:
Emissions from equipment and their interconnecting cables at 1 meter
distance from the equipment shall be measured.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration: NA
Specifications limit lines:
Radiated Electric Field emissions from the on board equipment and
interconnecting /associated cables shall not be radiated in excess of those shown in
Figures RE102-3 CURVE for Fixed wing internal <25 meters nose to tail. Above 30
MHz, the limits shall be met for both horizontally and vertically polarized fields.
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Fig: 13 RE102 Test level waveform
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Fig: 14
RE102 Test Setup
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
8.2.14. CONDUCTED EMISSIONS POWER (CE102) TEST
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Test Description: Conducted Emissions Power leads 10 KHz to 10MHz
This requirement is applicable for radiated emissions from equipment and
subsystems on AC and DC input power leads, including returns (which are not
grounded internally), that power from other sources.
Emissions on 28V power leads shall not be exceeded the values shown in figure
CE102-1(basic curve) in the frequency range of 10 KHz to 100 MHz
Applicability:
Applicable on AC and DC input power leads, including returns (which are not
grounded internally), that power from other sources.
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration: NA
Specification Limit Line
Conducted emissions on power leads (AC and DC) shall not exceed the
applicable values as shown in Figure CE102-1 limit line.
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Figure: 15 CE102-1 limit lines (EUT power leads, AC and DC) for all
applications
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Fig: 16 CE102 Test Setup
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.
8.2.15 HUMAN ELECTROSTATIC DISCHARGE (HESD) TEST
Test Description: Human Electrostatic Discharge
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The EUT shall not be exhibit any malfunction, degradation of performance,
deviation from specified indication, beyond the tolerances indicated in the individual
equipment or subsystem specification when subjected to a 20kV pulse amplitude (A
150 pF capacitor is charged to an amplitude of 20 KV Pulse and discharged through
150 resistor) on each connector of EUT and the chassis. Two pulses shall be
discharged on each of the connector and EUT chassis with a time interval of 5
seconds between the pulses
Applicability:
Applicable to all interfacing connectors mounted on the equipment and chassis
Test setup and Test Procedure: As per MIL-STD- 461E
Test Duration: 2 pulses to be discharged on each connector and equipmentchassis.
Specification limit line
The EUT shall not be exhibit any malfunction, degradation of performance,
deviation from specified indication, beyond the tolerances indicated in the individual
equipment or subsystem specification when subjected to a 20kV pulse amplitude
(A 150 pF capacitor is charged to an amplitude of 20 KV Pulse and discharged
through 150 resistor) on each connector of EUT and the chassis.
Test Method: Take PREET, INSET and POET as per the appendix ‘D’.