DEPARTEMENT ASSURANCE QUALITE

Acceptance Test Procedures Final inspection and control of MIL-STD-1553 databus harnesses

Reference Date of validity Subject

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

Function : R&D project engineer

Endorser :

G. ROUCHAUD

Function : Databus Manager

Visa :

Quality endorser :

M. PICHOT

Function : Quality Engineer

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

Laboratoire Equipe bus G. KERR L. LIM

QUALITE BEH AXON JAPAN AXON CHINA

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

Modification of pages 1 and 2

D E

07-09-98 16-06-99

ALL ALL

10-01-00

Pages 6/9 and 7/9

18-12-02

All pages

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GC 8181 Final inspection and control of MIL-STD-1553 databus harnesses

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.

A-2) Inspection of conformance to fabrication drawings

Verify the conformance of the cable lengths to production plans ( possibility to use the corresponding cabling boards as guides if they have been validated by the Quality department ). The lengths measured shall be noted manually on the relevant fabrication drawing and this will be stored with the others documents (routing cards, ATR). Verify the conformance ( marking, dimensions, etc.) and the placement of identification sleeves. Verify the conformance and the reference of all the components used to complete the harness regarding the plan nomenclature. Verify the reference and the main characteristics of the connectors used. A test connector shall be used to test the 'plug-ability' of the connector (connector shall mate with its opposite). This test (mating) should be done during the electrical test to limit the number of connector mating/demating. The relevant area of the ATR shall only be validated when each connector has been tested. For each criteria previously defined, validate the inspection in the corresponding box of the ATR.

A-3) Inspection of production sheets

For each harness, verify the presence and conformity (completeness, conformance, dynamic test results, etc..) of the following routing sheets : routing card number 11 of coupler circuit production (one per coupler) routing card number 6 : Dynamic test of coupler (one per coupler) routing card number 10 : Harness production follow up. routing card number 7 : Dynamic test of each coupler of the harness during production (one per coupler).

For each criteria previously defined, validate the inspection in the corresponding box of the ATR.

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A-4) Mass control

Measure the total mass of the harness, then note the measured value in the corresponding case of the ATR after having verified it with the production drawings.

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.

B) Static electrical tests

Static or dynamic electrical tests cannot be performed without mounting the correct opposing connectors to the harness being tested. Note : For harnesses with a lot of stubs, fill, if needed, the second page (continuation) of the ATR to record data. The terms used in the following instructions are described in the drawing below :

STUB LINE ( Identification sleeves )

Bus Line
95802

Bus Line
AMB/X/I

95692

95804

Databus Terminator Coupler Serial number

Braid Wires Bus cable Stub Line Stub Line

Stub Line

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B-1) Insulation measurement between wires/shield (if applicable)

Take care : If the harness is implemented with an Electro Static Discharge (ESD) resistance protection, this test is not applicable (see the fabrication plan). Measure the insulation resistance between the shield and the two joined wires of the bus line and each stub line. A megohmmeter that delivers a test voltage of 500VDC set to 30 seconds will be used for this test.

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.

B-2) Insulation measurement between lines

Measure the insulation resistance between joined wires of the bus line and joined wires of each stub. A megohmmeter that delivers a test voltage of 250VDC set to 30 seconds will be used for this test.

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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B-3) Insulation measurement between the cable wires (extensions only)

Take care : This test is only applicable to extensions (harness without coupler) Measure the insulation resistance between the two wires (hot and cold points) of the extension. A megohmmeter that delivers a test voltage of 500VDC set to 30 seconds will be used for this test.

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

B-4) Measurement of the shield continuity

Measure the shield resistance between one end of a bus line taken as a reference and each stub line and then the other end of the bus. When the braid is not directly accessible, the connector or receptacle body shall be used. Use AOIP OM21 micro-ohmmeter with a maximum current of 1A for this measurement.

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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Table n 1 : braid resistance per unit of length versus cable reference.

Cable reference Braid definition Construction P502805 P502810 P504621 P512296 P812294 P812302 P819845 & GSC-12-2548-00 P819846 & GCS-12-2549-00 P507991 P512806 P517417 P530781 P815721 P819005 P502807 P511981 Coupleur dmontable (ADBR, JN1056, JN1168) Single braid (PR EN3375.03) Single braid (MIL-C-17/176-0002) Single braid Single braid (SSQ 21655) Single braid (SSQ 21655) Single braid (SSQ 21655) Single braid Double braid (PAN 64621) Double braid (PR EN3375.04) Double braid (ECS 0700) Double braid Double braid Double braid + mtal tapes (PR EN 3375.05) Double braid + mta tapesl NA Nature SPC SPC SPC SPC SPC NPC SPC SPC SPC SPC SPC SPC SPC SPC NA Maximum resistance per unit of length of braid (RT) RT < 45 m / m RT < 30 m / m RT < 72 m / m RT < 30 m / m RT < 25 m / m RT < 25 m / m RT < 38 m / m RT < 20 m / m RT < 15 m / m RT < 25 m / m RT < 30 m / m RT < 20 m / m RT < 15 m / m RT < 25 m / m RT < 500 m (*)

(*) 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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B-5) Measurement of the Stub lines resistance

Measure the resistance between the wires (hot and cold points) of each stub line. Use a micro-ohmmeter with a maximum current of 100 mA for this measurement.
BUS
SERIAL NUMBER

MICRO-OHMMETER ( 100 mA max.)

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.

B-6) Resistance measurements of bus lines

Measure the resistance between the wires (hot and cold points) of each bus line. Use a micro-ohmmeter with a maximum current of 100 mA for this measurement.

MICRO-OHMMETER ( 100 mA max.)

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)

Harness without any terminator

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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]

Harness with 1databus terminator (DBT)

@ 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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B-7) Measurement of the Bus line continuity

Take care : This test is not applicable if the harness is implemented with at least one inline terminator (77 ). Measure the resistance of each wire of the twisted pair of the Bus line (Hot wire then cold wire). Use a micro-ohmmeter with a maximum current of 100 mA for this measurement.

Ligne BUS MICRO-OHMMETER ( 100 mA max.) BUS Line

BUS
SERIAL NUMBER

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

112.1 m /m = 0.112 /m 109 m /m = 0.109 /m

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

60.36 m /m = 0.060 /m 57.40 m /m = 0.057 /m 50 m (*)

(*) 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.

B-8) Control of the Electrostatic discharge resistance (if applicable)

Take care: This test is only applicable if the concerned bus or stub line is implemented with an ESD resistance cabled between the shield and the primary wires (see the production electrical plan). In this case this test replaces the Insulation test (see B1). Measure the resistance between the shield and the short-circuited inner wires (pair). Use an ohmmeter that delivers a maximum voltage of 20VDC for this measurement.

OHMMETER (20 VDC max.)

BUS Line
BUS
SERIAL NUMBER

BUS STUB

OHMMETER (20 VDC max.)

STUB Line
Remark :

BUS STUB

SERIAL NUMBER

BUS

When testing the bus line check only the resistance @

one end of the harness.

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

B-10) Validation of the static electrical control

@ 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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C) MIL-STD-1553 dynamic test performed by automatic test benches

This measurements are performed by automatic test benches developed by axon. Their handling instructions are the IP-BEH-35 for the P506506 and the NEBT-1553 for the P516173. These tests follow the MIL-STD-1553B specifications and the SAE-AS4115 test plan. By these tests we check that the signal received by each equipment can be understood. This is called Waveform integrity test.

C-1) Use of the test bench reference : P506506

Dynamic electrical tests cannot be performed without mounting the correct opposite connectors to the harness being tested. Connect the bus harness (or section) to the 1553 automatic test bench ( P506506A ), in order to control the parameters indicated below in different possible configurations of emission/reception: Phase : Phase of the signal V+ : Positive signal amplitude V- : Negative signal amplitude Amplitude : Minimum value of the signal amplitude ( >1 Vpp ) Offset : Maximum value of the shift in signal voltage (< 0.2 V ) Vmin : Minimum value of the signal voltage ( > 0.66 Vpp ) Rise Time, Fall Time : Maximum value of rise and fall time ( < 270 nS ) Zero-crossing : Maximum value of the zero crossing ( < 125 nS ) Symmetry : Trailing at the end of the frame ( < 250mV )

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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C-2) Use of the test bench reference : P516173

Note : This test bench allows the control of harnesses with only a maximum of 2 stubs. General case of single or double ways coupler sales Connect the harness to be tested respecting the relevant opposite connectors. Run the dynamic test following the procedure instruction given in the NEBT-1553 . At the end of the test, a test report that gives all the measured electrical parameters and the presence or not of non conformance is printed. Test passed is printed for positive test otherwise Test Failed .

C-3) Validation of the MIL-STD-1553 dynamic test

Compare the worst case measurements records found by the test bench with the relevant requirements : Phase : Phase of the signal Amplitude : Minimum value of the signal amplitude ( >1 Vpp ) Offset : Maximum value of the shift in signal voltage (< 0.2 V ) Vmin : Minimum value of the signal voltage ( > 0.66 Vpp ) Rise Time, Fall Time : Maximum value of rise and fall time ( < 270 nS ) Zero-crossing : Maximum value of the zero crossing ( < 125 nS) Symmetry : Trailing at the end of the frame ( < 250mV )

Record the conformity in the corresponding box of the ATR.

D) Validation of the final control

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

Acceptance Test Report