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Acceptance Test Procedures Final inspection and control of MIL-STD-1553 databus harnesses
GC8181
Issue 18-12-02
Acceptance test procedures of 1553 databus harnesses GC 8144, IP-BEH-35, NEBT-1553 13 Number of appendices Word processor Visa : 2 WORD
Associated document(s) Total number of pages (w/o appendices) : File name and location : Autor : C. COFFINET H:\Gammes-1553\GC\eGC8181.doc
Endorser :
G. ROUCHAUD
Visa :
Quality endorser :
M. PICHOT
Visa :
Distribution list Names (Optional) Dpt. or company INTERNAL (I) or EXTERNAL (E) I I E E Number of copie(s) 1 3 1 1 X X X For INFORMATION APPLICATION X
List of editions Issue DATE OF MODIFICATION N OF PAGES MODIFIED, ADDED, DELETED NA Creation REASONS FOR MODIFICATIONS
08-01-93
03-07-95
ALL
General modification of instructions. Necessity to control the connectors present in the section along with their technical sheet. Addition of tolerances for shielding continuity for Double Braid cables and High immunity cables following EN3375. Verification of the presence of batch numbers of cables used for the harness. Addition of an appendix to better describe the use of the automatic test bench. Obligation when possible, of dynamic control of the phase of the bus lines with the help of the test bench. Addition of option of burn-in before the final control. Addition of the withstanding voltage test for the space applications. Added tolerances for resistance measurements between the wires of the bus line. Added calculation of the limit tolerance for measuring the linear resistance and the parallel resistance of the bus line. General changes and addition of drawings. Obligation to record branch lengths on the plan drawing (written manually). Use of a new version of ATR in English for each databus harness. Braid continuity check (test B-4) : Record the controlled values and the relevant requirement on the ATR in addition to the lineic value. Addition of new cables references. Addition of the specific case of dismountable coupler. Modification of the tolerances for the following cables : P 5 0 2 8 1 0 & P 5 1 2 2 9 6 ( 4 5 m /m 3 0 m/ m ) e t P 8 1 2 2 9 4 & P 8 1 2 3 0 2 ( 4 5 m/m 2 5 m /m) Parallel resistance check (Test B-6). : Record the relevant requirements on the ATR in addition to the controlled values. Use of the tolerance correction formula cancelled. Bus line resistance per unit of length (Test B-7) : Modification of the tolerance correction formula. Addition of new cables references and of the specific case of a dismountable coupler. Electrostatic discharge resistance control (Test B-8) : Addition of the resistance measurement to check the presence of the resistance cabling. Multipin non databus cabled points test (test B-9) : Addition of the control of continuity high voltage insulation for each cabled points of multipin connectors.
16-10-95
D E
07-09-98 16-06-99
ALL ALL
10-01-00
18-12-02
All pages
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Modif.
In case the harnesses or couplers are destined for space applications, the operations described in these procedures shall be performed in an environment conforming to the ESA PSS-01-708 standard (BEH clean room). In case thermal shocks are requested, (space applications, Ariane V harnesses, etc.) perform this test before proceeding to the final inspection. During the thermal shocks, a 1553 transmission test with error count (of transmission or no-responses) following procedure GC8144. The limits of the MIL1553 standard are to be used (1 error per 107 words maximum). The temperature cycle generally used is the following (unless requested otherwise) :
+ 125C
30mn - 40C 1 cycle = 60mn 10 cycles de 60 mn. Temps de transition < 5mn
The acceptance test of each 1553 databus harness implies completing of an Acceptance test report in English ( cf. appendix 2). Generally speaking all the controls and inspections included in this procedure will be unitary performed on each produced harness.. The list of devices to be used for the testing is included in Appendix 1.
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A) General inspection
A-1) Aspect
Verify the general cleanliness of the harness. Inspect the general state of the cable jacket, the heat shrinkable pieces, and the connectors ( no folds, scratches, shocks, bent or off-centered contacts). Verify the quality of the adherence of the various heat shrinkable pieces on the cable. For each criteria previously defined, validate the inspection in the corresponding box of the ATR.
For each criteria previously defined, validate the inspection in the corresponding box of the ATR.
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Modif.
Note : the mass shall be tested for each harness even if it is not specified in the production drawing and plan.
For each criteria previously defined, validate the inspection in the corresponding box of the ATR.
Bus Line
95802
Bus Line
AMB/X/I
95692
95804
Stub Line
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MEGOHMMETER (500VDC )
BUS LINE
BUS
SERIAL NUMBER
BUS STUB
MEGOHMMETER (500VDC )
STUB LINE
BUS STUB
SERIAL NUMBER
BUS
Remark : The insulation will only be measured at one end of the bus line. Requirement : RI > 1000 M at 500 V DC
For each insulation test, record the obtained insulation value and the configuration of the measurement in the corresponding boxes of the ATR labeled at once. Then commit on the conformance.
BUS Line
MEGOHMMETER (250VDC)
BUS
SERIAL NUMBER
BUS STUB
STUB Line
Requirement : RI > 1000 M at 250 V DC
For each insulation test, record the obtained insulation value and the configuration of the measurement in the corresponding boxes of the ATR labeled at once. Then commit on the conformance.
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MEGOHMMETER (500VDC)
Test cable
Note : The measurement is only taken at one end of the line. Requirement : RI > 1000 M at 500 V DC
Record the measured value or eventually the non applicability of the test corresponding box of the ATR. Commit then on the conformity.
in the
Note : If any ends of bus line is accessible for measurement a stub line shall be taken as reference.
Record the obtained value and the configuration of the measurement in the corresponding boxes of the ATR. Convert this measurement per unit of length ( /m) by dividing the resistance with the nominal lengths marked in the production drawings. Record the result on the ATR and compare it with the following table
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(*) In the particular case of dismountable coupler (no cable length) the value in Ohms will not be converted by unit of length and the requirement will be expressed in Ohms. Take care to remove the length of test cable to get only the relevant resistance.
Record the applicable sanction on the ATR and commit then on the conformity.
Take care : When test cable jigs are used, think to remove its own resistance before to convert the value by unit of length. The following chart is not exhaustive. In case of a cable that is not included in the list, deduce the applicable requirement from the braid construction (Ask to the bus technical team).
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Modif.
BUS
STUB
STUB Line
Sanction : RSTUB < 5
@ Record for each stub at once the measured value and the configuration of the test
(name of the stub tested) in the corresponding boxes of the ATR. Commit then on the conformance.
BUS Line
BUS
SERIAL NUMBER
BUS STUB
Record the obtained values in the corresponding boxes of the ATR (the conformance and configuration of the measurement is labeled at once), then compare the values with the values listed in the table below :
Table 2 : Parallel DC resistance versus the number of stubs within a databus harness.
Harness configuration Number of stub N=1 N=2 N=3 N=4 N=5 N=6 N=7 N=8 N=9 N=10 N=11 N=12 N=13 N=14 N=15 N=16 N=17 N=18 N=19 N=20 N=n Requirements Resistance tolerance 58.5<R<125 39<R<117 29.2<R<58.5 23.4<R<39 19.5<R<29.2 16.7<R<23.4 14.6<R<19.5 13<R<16.7 11.7<R<14.6 10.6<R<13 9.7<R<11.7 9 <R<10.6 8.35<R<9.7 7.8<R<9 7.31<R<8.35 6.88<R<7.8 6.5<R<7.31 6.15<R<6.88 5.85<R<6.5 5.57<R<6.15 (Rnom (n+1) < R <Rnom (n-1)) Nominal values Rnom = 117 Rnom = 58.5 Rnom = 39.0 Rnom = 29.2 Rnom = 23.4 Rnom = 19.5 Rnom = 16.7 Rnom = 14.6 Rnom = 13.0 Rnom = 11.7 Rnom = 10.6 Rnom = 9.7 Rnom = 9.0 Rnom = 8.35 Rnom = 7.8 Rnom = 7.31 Rnom = 6.88 Rnom = 6.5 Rnom = 6.15 Rnom = 5.85 (Rnom=117/n)
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Table 3 (continuation)
Harness configuration N=1 N=2 N=3 N=4 N=5 N=6 N=7 N=8 N=9 N=10 N=11 N=12 N=13 N=14 N=15 N=16 N=17 N=18 N=19 N=20 N=n Requirements 33.2<R<50 25.9<R<46.5 21.2<R<33.2 17.9<R<25.9 15.6<R<21.2 13.7<R<17.9 12.3<R<15.6 11.1<R<13.7 10.1<R<12.3 9.3<R<11.1 8.6<R<10.1 8.0<R<9.3 7.5<R<8.6 7.1<R<8 6.7<R<7.5 6.3<R<7.1 6<R<6.7 5.7<R<6.3 5.4<R<6 5.2<R<5.7 (Rnom (n+1) < R <Rnom (n-1)) Rnom = 46.5 Rnom = 33.2 Rnom = 25.9 Rnom = 21.2 Rnom = 17.9 Rnom = 15.6 Rnom = 13.7 Rnom = 12.3 Rnom = 11.1 Rnom = 10.1 Rnom = 9.3 Rnom = 8.6 Rnom = 8.0 Rnom = 7.5 Rnom = 7.1 Rnom = 6.7 Rnom = 6.3 Rnom = 6.0 Rnom = 5.7 Rnom = 5.4 Rnom =[(117/n)x76.8] / [ (117/n) + 76.8]
@ Record the applicable sanction on the ATR and commit then on the conformity.
Note : The requirement given in the chart comes from a simplified model that doesnt take into account the effect of the resistance of the cable between couplers. In case of the obtained values are not included within the required interval, a mathematical model more accurate shall be used. This model use the exact resistance of each type of coupler and the resistance of the different cable lengths that constitute the harness.
@ If the harness is accepted using a new value calculated more accurately, this new value
shall be noted on the corresponding box of the ATR.
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Modif.
BUS STUB
Record the obtained values in the corresponding boxes of the ATR. These resistance values shall be converted per unit of length by taking the nominal lengths marked in the production drawings. Compare theses results with the values listed in the table below Table 4 : Resistance per unit of length of the databus cable wires :
Cable reference P504621 P517417 P511981 P530781 P507991 P502805 P512806 P512807 P502810 P512296 P815721 P819005 P819845 & GSC-12-254800 P819846 & GSC-122549-00 P812294 P812302 Dismountable coupler (ADBR, JN1056, JN1168) Primary wires constitution Nature Gage Construction Required maximum value of the cable per unit of length resistance (Rl) 145 m /m = 0.145 /m
SPC
AWG 26
19x0.102 mm
SPC SPC
AWG 24 AWG 24
19x0.118mm 19x0.120 mm
SPC
AWG24
19x0.127 mm
93.14 m /m = 0.093 /m
NPC SPC NA
AWG 22 AWG 22 NA
19x0.160 mm 19x0.160 mm NA
(*) In the particular case of dismountable coupler (no cable length) the value in Ohms will not be converted by unit of length and the requirement will be expressed in Ohms. Take care to remove the length of test cable to get only the relevant resistance. Take care : When test cable jigs are used, think to remove its own resistance before to convert the value by unit of length. The following chart is not exhaustive. In case of a cable not included in the list ask the bus technical team for the applicable requirement or consult the production drawing of the conductor.
Record the applicable sanction on the ATR and commit then on the conformity.
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Remark : The requirements given in the table above do not take into account the coupler resistance, the connectors resistance and the test assemblies. . In questionable cases, the required resistance value must be calculated in the following fashion : Corrected value (m ) = Measured value (m ) - N x 10 (m ) C*10 (m ) - RT (m ) with : N : number of STUBs (10 m per stub) C : number of connectors on the bus line (10 m per connector) RT : Test assembly jig Ohmic resistance
Note : If the harness is accepted using a corrected value according to the above formula, this value shall be recorded on the corresponding box of the ATR.
BUS Line
BUS
SERIAL NUMBER
BUS STUB
BUS STUB
SERIAL NUMBER
BUS
Take Care : The ESD resistance can be installed inside terminators, couplers or connectors. This depends on the customer need or way of thinking. They can be put either on BUS or STUB line. In any case, pay attention to the production electrical plan before to begin the test , to understand how they are cabled. The value and the way to connect the ESD resistance are not covered by any standard and depends only on the customer application. In each case the used requirement must come form the production plan or calculated. Ask the bus technical team if needed for the relevant requirement.
Record the obtained values in the corresponding boxes of the ATR (the conformance and configuration of the measurement is labeled at once), then commit on the test conformance.
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B-9) Other cabled contacts checking : non databus wires (if applicable)
In some case some wires not used for bus purpose can be also cabled on the connector. They dont belong to a bus or stub line. This wires shall also be tested in continuity and insulation. See the electrical production plan to understand the cabling design. Addressing wiring or power supply wires are examples of wiring not used for transmission purpose that must be tested. B-9-1) Wire-shield Insulation
Measure the insulation resistance between the shield (the braid of the connector shell) and each cabled wires short-circuited all together. A megohmmeter that delivers a test voltage of 500VDC set to 30 seconds will be used for this test. Requirement : RI > 1000 M under 500 V DC Take care : If the bus or stub lines are already tested do not perform again this test on theses wires. In any case the bus pair or the stub pair must be short circuited when applying the voltage.
Remark : By default only the insulation against the shield shall be tested . See the electrical production plan if others insulation tests are necessary or required.
@ Record the obtained values in the corresponding boxes of the ATR (the conformance
and configuration of the measurement is labeled at once), then commit on the test conformance.
B-9-2) Continuity
Control the continuity between cabled contacts. Cabled wire links are named net : net is an electrical link. For instance addressing group of wires, power supply wires continuity For each group of net, the control shall be performed in regards with a reference wire. Use a micro-ohmmeter with a maximum current of 100 mA for this measurement. Sanction : R < 500 m (for groups of contacts that belong to the same connectors) Note : In the case of net between two connectors, the requirement shall be calculated. Add the resistance due to the length of cable to the 500 m used as reference. Example : Net between 2 different connectors with a wire length of conductor, AWG 2419 with a lineic resistance of 93 m /m. The requirement is : 500m + 5 x 93m = 965 m . 5 m. Silver platted
@ Check the totality of the results obtained during all the static tests named B-1 to B9 then record the global conformance in the corresponding box of the ATR.
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Modif.
A more detailed explanation of the functioning and the instructions for connecting the harness to the bench is given in the procedure instruction IP-BEH-35. Nevertheless the parameters which follow will be used by default among the different possible options: It is possible to control : either assembled harnesses in standard bus configuration or individually the sections that constitute the databus network.
Nominal & redundant lines shall be tested individually When an harness overpasses 11 stubs, the harness shall be tested in several steps. It is strongly recommended to share the harness uniformly : even number in the first run and odd in the second number in order to follow the table below. Table 5 : Preferred sequence of dynamic test for harnesses above 11 stubs. Example of test sequences for an harness with 18 stubs numbered from de 1 to 18 Sequence strongly recommended Sequence to be avoided Test 1: A1, A3, A5 ,A7, A9, A11, A13, A15, A17 Test 2: A2, A4, A6, A8, A10, A12, A14, A16, A18 Test 1: A1, A2, A3 ,A4, A5, A6, A7, A8, A9 Test 2: A10, A11, A12, A13, A14, A15, A16, A17, A18
Run the test following the instruction procedure IP-BEH-35. The report of the dynamic test which will be edited indicates all the measured values and the eventual non-conformities that are detected. This report will be written in English.
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Modif.
At the end of these internal operations, the Axon controller must record the conformity of the harness and validate the control in the boxes of the routing cards that follow the harness production. The ATR will be validated by someone given the right to do so from the quality department. In presence of a inspector from the customer , he/she must validate the ATR . A copy of the ATR is systematically packaged with the harness. The test report from the test bench is only supplied on request. In any case each ATR, routing card and test report are stored and stocked during 10 years.
@ @
GC 8181 - Annexe 1
Tooling list
Tooling reference P506506 P516173 MMG 500 (Sefelec) or equivalent OM21 (AOIP) or equivalent Fluke 11 or equivalent Ohmmeter
Equipment designation Mil-std-1553 automatic test bench 11 RT Mil-std-1553 Test bench 1553 (two ways) Megohmmeter Micro-ohmmeter
GC 8181 - Annexe 2
ANNEXE 2