MST-0430 MWA Octal Temperature Sensor 90% build



Notes:

MW & IM review of 10 June 2010 added in cyan

This document is a first draft list of tests on MWA masters. It also includes a brief description of jigs that are envisaged for these tests. I have not named or numbered the tests but the order within each master is the intended order in which they would be done. The order of the masters in this document is close to an assembly order but don’t take it as such. Some masters will need interleaved tests and assembly instructions.

[my comments in orange– mwaterson, 8/06/10]

Test and jig descriptions are italicised and indented after a heading TEST or JIG. Eg

JIG

This is a real jig, not just an example of the font used.

PSI needs to buy an I2C test jig, eg

This would allow us to test I2C on Temp Monitor, PSU, ASC & ATIM transition, otherwise we will end up testing these boards twice for different functions, US$300 will be worthwhile. The software that comes with this allows sequences of I2C commands to be sent which will allow PSI to write semi-automatic testing of some I2C peripherals.

MW has cheaper option on order and can add one more to the order – also add bus monitor

Commentary text is interleaved in normal font. Some comments are underlined to draw attention to some particular need to action. Red comments denote where information needs to be extracted from MWA. Green comments are notes that I want to flag to myself.

Many of the tests still need requirements filled in and some need sequences of I2C commands to be worked out. Some need software to be developed. Some requirements will be easiest to fill in by measuring the result on the first board.

[most of the I2C codes exist for the V1 receiver and will be provided; exception is the I/V monitor which I need to work out myself]

Once general agreement is reached on the tests I will define the jigs more fully with sketch diagrams.

At this stage the document is intended for discussion on where testing needs to be expanded or reduced.

MST-0430 MWA Octal Temperature Sensor 90% build.

This board is sufficiently simple that spending significant time testing it will be wasteful. Expected failure rate is low and any faulty units can be picked out at higher level than board testing; therefore, no testing on this master.

MST-0431 MWA Dual Octal Temperature Sensor

TEST

Photograph top and bottom of both customised MST-0430 boards before assembly.

Assemble boards into stack.

JIG

A cable with a 5V reg and diode protection to connect a bench supply to the D9 connector so Vin = 5V. Also connect an I2C2PC dongle cable to this connector.

D9 connections:

Pin 5 = output of regulator via two flying ith banana plugs to allow insertion of multimeter for current monitoring

Pin 9 = GND of PSU + wire 3 of dongle cable

Pin 2 = SCL = wire 4 of dongle cable

Pin 6 = SDA = wire 1 of dongle cable

TEST

Plug the board into the jig, power it up and check 3.3V appears across pins of P1 on top board. Check current draw less than 1mA using flying leads and a multimeter.

Further testing of this master requires either a large part of a functioning MCC module or a custom jig (eg based on a COTS USB-I2C adapter and software). Preference is for the jig – yes, we have the I2C jig.

JIG

Connector #1 connect pins 1,3,5,7 & 10 (0V on chans 1,3,5 &7) and

connect pins 2,4,6,8 & 15 (Vref on chans 2,4,6 & 8).

Connector #2 connect pins 1,2,3,4,5,6,7,8 & 9 (1.625V on all channels)

Purpose of test at this level is to check that there are no shorts between adjacent channels and that there is connectivity and basic functionality of ADC.

TEST

Connect I2C2PC dongle to jig to interrogate all channels.

Plug Connector #1 into each input connector in turn and check that the channels 1,3,5 & 7 read 0x000 (+/- 2 bits?) and channels 2,4,6 & 8 read 0xFFF (+/- 2 bits?) on that particular board

Repeat with Connector #2 and look for 0xA66 (+/- 0x20?) on each channel.

[also verify that the boards respond to the correct address]

Do a bus scan

TEST

Photograph the assembly.

MST-0417 MWA 550-ATIM_I&C PCB

This board sits between the SBC and the rest of the hardware. It contains a Lattice Semiconductor CPLD. No information on the programming of the CPLD has been supplied to PSI.

In order for PSI to manufacture/test these boards we will need to purchase a programming cable: Lattice Semiconductor part HW-USBN-2A ispDOWNLOAD Cable (US$149) and be supplied with the MWA design file for the CPLD. [production cpld file to be provided as soon as available; we should discuss adding test features to this now, since it needs work anyway. Alternatively we can compile a specific test version that exercises the pins in some obvious way.]

CPLD can be configured to “test” or “run” state via “spare” inputs on J3. Consider cable jig for detecting ripple outputs on P2, P3 etc

Need for simulated clock to generate signals – unlocked - MW to send info on existing circuits

Without the CPLD design file the amount of testing that can be performed is very limited. All I/O pins on the CPLD will be weakly pulled-up to Vcc. If PSI is provided with the design file and can program the devices then comprehensive testing will require a definition of the CPLD function.

With the existing information available to PSI we can do the following:

Test I2C on-board peripherals via RS232 port

Test the Beam Former clock generator

Test the Beam Former power control

Test the legacy fan controls

Testing beyond these items would be simplest if this board was plugged into a functioning SBC, so see tests in the next higher level in the tree.

Also testing of I2C bus expansion can be delayed until other peripheral boards (with tested I2C peripherals on them) can be plugged into the otherwise verified ATIM and used as transponders.

[may be worth using a more specific diagnostic board to verify I2C bridge performance, marginal conditions may still work in lab]

MW to get one of these from

TEST

Photograph top and bottom of board.

TEST

Resistance check.

J1 pin 1 to pin 10 greater than xx(

J1 pin 3 to pin 10 greater than xx(

TEST

Apply power through J1 (+5V & +12V) using sample always-on PSU and cable jig

Check LED 1 & LED2 light.

Check current draw: on 5V < ??mA on 12V < ??mA

Check 3.3V at pin 3 of U5 (there is a pad near positive end of C13 since there is no designated test point)

TEST

I2C/U1/U6 verification

Short pin45 of J10 to pin 49 of J10 to enableU9 & U10

Connect RS232 port to J9. Baud rate is 57600.

Verify visually that SL3 is closed, SL4 open

Use terminal program to send ASCII commands to read temperature from U6, warm U6 and verify change in code.

Command sequence should simply be to read from temperature register G1S9302wxyzP where wxyz is the returned hex value. wx is four sign bits and should be 0, xy and high bit of z are temperature reading, low three bits of z are status bits – ignore.

Send ASCII commands to U1 to initialise clock to 100kHz and to ignore Powerdown and Enable inputs. Verify 100kHz signal at upper end of R1 (upper in relation to upright reading of S/N). I need to work out these codes.

Make sure no temperature monitor boards are plugged in – just in case the ADS7828 addresses are not set correctly as happened to me.

Note Cannot test OUT1 clock until CPLD is programmed to pull the CTL1 input low! Should be able to test OUT0 but it is not connected to anything.

Send: S B0 02 10 00 R 02 rr rr ; Turns on OUT0 with default CTLx signals and sets prescaler to 1 rr rr should be 10 00 confirming write to MUX register

Observe 40MHz on U1 pin 2 (OUT0)

Send: S B0 01 17 80 R 02 rr rr ; Changes prescaler to 8, rr rr should confirm 17 80

Observe 5MHz on U1 pin 2

First ATIM board passes this!

[MWA will supply codes & sample programming for clock IC, this work has been done]

TEST

CPLD programming and verification

Connect ispDOWNLOAD Cable to J2, load design file into CPLD

PSI needs more info on the function performed by the CPLD to expand any testing here.

MST-0421 MWA 100_ASC PCB

This is the bare board as received from the board stuffer, these tests to be done before it is fully screwed into its housing. The approach at this stage is to test the board as much as possible either before putting it into the housing or with it loosely fitted. Once the initial production process has been demonstrated to be reliable we can move most of these tests up one level and perform them after full assembly.

This board contains a PIC16LF877A. PSI has been given no information on the program required for this device. PSI has appropriate programming tools for this family of devices.

[complete source and object code will be provided. This code contains a test mode which exercises the address,data and attenuator bits.]

MW to look into putting PIC into test mode via RB6/7 and ICSP header

Note that the inclusion of D100 in the reset circuit may cause problems; PSI recommends the reset configuration of the PIC16 be reviewed and that the circuit be modified if necessary.

[please review this with mfw!]

MW to decide on course of action

R33 on each channel should not be populated so that the digital side of this can be verified without powering all the RF sections. The R33s can be fitted one at a time as the RF testing proceeds.

Use resistance to ground test (MW has a list) then just power up with all sections powered – make a jig with fans.

File of resitance checks supplied see C:\Documents and Settings\ian_m\My Documents\Temp\MWA 22078\ASC Test\ASC test checklist.xls

[I found no problems with testing with all R33s installed, provided the first test is of the output voltages on the RF regulators, a fan bank was used to cool the boards, only one channel at a time driven (though that probably does not matter). Testing OUT of the heatsink allows simple probing of the RF path with a scope (apply a 100-200MHZ tone at suitable level). Test mode of PIC program cycles all atten bits or values in sequence, we can modify this to be the power-on default for testing]

It is not convenient to do preliminary testing on this board without some form of program in the PIC.

[unless manual control board used]

This goes in via P102 and drive the lines directly while main PIC is held in reset. Existing boards need connector modified.

MW to provide existing PIC code for PSI to use as a basis.

Before the PIC is programmed, all the select lines to the DAT-31PP step attenuators will be tri-state. The DAT-31PPs are wired to power up at 31dB attenuation. The expected insertion loss of each channel in the pass band would therefore be in the range:

Min = 14.5 – 32.5 + 12 – 32.5 + 12 – 3 = -29.5dB

Max = 17.5 – 32.5 + 13.5 – 32.5 + 13.5 – 3 = -23.5dB

With additional 6dB loss from a matching pad, this level of attenuation is inconvenient for verifying that the RF channels are functional before the board is inserted into its housing. If the PIC is programmed with the final code then it needs to be sent commands via the I2C to set the attenuator settings.

There are two choices:

1. PSI writes an alternative test program for the PIC. A test jig that connects an LED between pin 6 and GND of P100 and connects two push buttons between pin 8 & GND and pin 10 and GND respectively will allow manual input to the PIC. The test program will monitor these lines and in response to one button will set the digital attenuators on all channels to 0dB, and in response to the other button will increase alternately the attenuation of each DAT-31PP in 1dB increments. The LED can be used for visual output from the test program, flashing at N+1 times then off for 1 second where N is the total attenuation set above 0dB.

2. PSI deciphers the method of driving the PIC via I2C and sets up command sequences to set the attenuators to desired points. This has the advantage of testing the final code in the PIC and means the PIC only has to be programmed once.

I actually favour option 1 because it means we can move the ASC around testing stations without having to follow it with the I2C jig which may be required for testing other boards while the ASC is being tested, particularly when it is in environmental testing.

[MWA has copies of a manual control pcb which can be used to test the ASC attenuators assuming that the PIC is erased (outputs are tristated). A switch is provided to allow use a monitor (no control lines active). Issues were observed with the original high-density connectors used, this may need modification to match the new ASC layout)]

Need to provide MW with PDF of genesis layout for comparison with Altium – done 17/6/10.

TEST

Photograph RF side of board

TEST

Verify R33 removed from each channel.

Resistance checks:

On P100 pin 1 (or 2) to pin 3 (or 4) > ??(

On each channel U8 pin 1 to GND > ?? (

Visually check that 9V & 5V rails are not shorted by optional 0R installation – only one of R7/R8 & R14/R15 resistors should be installed..

TEST

Apply +12V to P100 using cable jig

Verify that LED lights (powered via R102)

Check 3.3V appears at U100 pin 1

Either program the PIC with PSI’s test program and verify that LED begins to flash or

progam the PIC with MWA code and check its function via I2C

TEST

Preliminary RF gain and frequency response.

Loosely fit the PCB into the housing.

For each channel:

Connect multimeter on current range in place of R33, power up board and check current is in range 400mA to 600mA.

Power down board, insert 0R link in place of R33 on channel under test

Connect VNA port 1 to input via 50( - 75( impedance matching pad and quick-F connector. [Can VNA be configured to 75Ohm source/ref?] No

Example quick F connector, look for an easy source

Connect VNA port 2 to output via quick-SMA connector (PSI has some of these already) and a 10dB pad.

Set VNA power level to -10dBm, start 10MHz stop 600MHz

Power up board, verify 1Hz blinking LED, press ZERO button if required

Measure frequency response of channel

Verify lower 3dB point 80 MHz +/- 5 MHz

Verify upper 3dB point 300 MHz +/- 15 MHz

Verify passband is flat to +/- 1dB

Verify gain in passband is in range 15 dB to 23 dB

Increase attenuation of alternate DAT-31PPs either via buttons or I2C

Verify gain decreases 1dB

Verify frequency response remains flat +/-1dB in pass band

Repeat last step until gain reaches -10dB.

Remove 0R link and go to next channel.

[somewhat faster to drive each data line & confirm 1/2/4/8/16dB change unless automated delta measurement routine is written for VNA]

Gain calculations for reference

Input -10 dBm

After matching pad -16 dBm

After 1st gain stage -1.5 to 1.5 dBm (gain 14.5dB to 17.5dB, P1dB 16.5dBm)

After transformer -2 to +1 dBm

After DAT-31PP #1 -3.5 to -0.5 dBm

After 2nd gain stage 8.5 to 14 dBm (gain 12dB to 13.5dB, P1dB 26.5dBm)

After DAT-31PP #2 6 to 12.5 dBm

After third gain stage 18 to 26 dBm (gain 12dB to 13.5dB, P1dB 26.5dBm)

After filter 15 to 23 dBm

After 10dB pad 5 to 13 dBm = 15 to 23 dB gain

TEST

Connect I2C jig and interrogate temperature monitor on PCB.

Verify temperature is correct, warm and cool temperature monitor and verify readout changes.

Need to work out codes for DS75S [MWA has, will provide code] [Verify I2C address]

After these tests are completed, install the PCB fully in its housing and install all 8 Ferrite 119-3419 components at R33 locations.

TEST

Photograph digital side of board and enclosure mounting.

MST-0422 MWA Analogue Signal Conditioning Module

This is the tested MST-0421 PCB installed in the Aluminium housing.

TEST

Install 8 x 50( 1W terminators on output SMAs.

Connect +12V to P100 connector and verify current draw is equal to sum of currents for all 8 channels as measured in lower level assembly test +/- 50mA.

TEST

For pre-production units or samples only

Put ASC module in environmental chamber, connect 8 sets of extension cables out to where they can be connected to the mobile VNA.

Set all attenuators to 0dB and verify frequency response and gain of all 8 channels at 25C.

Repeat at 45C and 5C. See previous test for expected results.

Power down and cycle temperature from -5C to 80C, 5C/min ramps and 15min dwell

Repeat measurements of frequency response and gain

If necessary program the PIC with final code at this point.

TEST

Connect I2C jig and send command sequences to PIC and verify it responds either by I2C responses or if the MWA code doesn’t have responses, by sending a command to set Attenuator 1 and checking that ALatch1 pulses with an oscilloscope.

Need definition of how PIC responds to I2C commands

[normal command response returns temperature reading from on-board sensor or error code]

If the board was put through temperature cycles then re-test the on-board temperature monitor.

Need to measure noise floor of early units with terminated input (remember 75() & Channel isolation, VSWR, P1dB, Spurs v power level.

MST-0491 MWA 820_PwrDis PCB

This is the PCB that distributes power from the Cosel PSU to the front panel of the power supply rack unit.

All we want to test at this level is that there are no shorts on the board that will cause smoke when the Cosel PSU is connected.

TEST

Verify resistances:

P5 pin 1 to pin 2 > 10k

P5 pin 3 to pin 4 > 10k

P5 pin 5 to pin 6 > 10k

P5 pin 7 to pin 8 > 10k

P5 pin 9 to pin 10 > 10k

J1 pin 12 to pin 13 > 1k

MST-0429 MWA Power Supply Module

This is the complete module including metalwork. For safety it is probably sensible to assemble the Cosel PSU, the tested MST-0491 into the metalwork with cables before attempting to test any thing.

JIG

A D25 connector to mate with J1 and connected to a breadboard and to flying leads for connection to a bench PSU for 5V (series diode protected).

On the breadboard a set of DIP switches to allow pins 15, 16, 17, 18 & 19 to be selectively shorted to ground (to turn power supply units on) and,

A set of LEDs between pins 2, 3, 4, 5, 6 & 7 and ground to show state of “alarm” signals. LEDs will go out if ALARM condition exists, good supply = LED lit.

Make sure there is enough cable between the D25 and breadboard so that if required the PSU can be put in the environmental chamber with the breadboard outside.

Also put a connector on this JIG to allow I2C tester to be plugged into J1.

TEST

Switch all DIP switches off

Connect +5V via jig to J1

Verify all LEDS are off

Verify 3.3V at U1 pin 1

Turn on 240VAC switch to power Cosel unit.

Verify ALARMPRIbar LED (pin 2) comes on)

Switch pin 15 DIP switch on (pin goes low)

Verify ALARM5bar LED (pin 3) comes on

Verify 5V on pin A1 (A2 = 0V) of P2, P3, P6 & P9

Switch pin 15 DIP off

Switch pin 16 DIP on

Verify ALARM12bar LED (pin 4) comes on

Verify 12V on pin A3 (A2 = 0V) of P2, P3, P6 & P9

Switch pin 16 DIP off

Switch pin 17 DIP on

Verify ALARM48Abar LED (pin 5) comes on

Verify 48V on between pins A1 and A2 of P12 and P15 (A1 = 0V)

Switch pin 17 DIP off

Switch pin 18 DIP on

Verify ALARM48Bbar LED (pin 6) comes on

Verify 48V on between pins A1 and A2 of P12 and P15 (A1 = 0V)

Switch pin 18 DIP off

Switch pin 19 DIP on

Verify ALARM48Cbar LED (pin 7) comes on

Verify 48V on between pins A1 and A2 of P12 and P15 (A1 = 0V)

Switch all DIP switches on

Verify all LEDs light up.

JIG

High power load resistors on heatsinks. Cables to mating plugs for P2 & P12

Banana sockets for test points to measure voltages across load resistors.

5V load = 4 x RS 158-301 1( 50W switched in parallel.

200W capacity, nom. 20A = 100W

12V load = 3 x RS 136-200 3.3( 100W switched in parallel.

300W capacity, nom. 10.9A = 131W

48V load = 16 x RS 107-4131 5.6( 50W 4 switched parallel ranks of 4 resistors in series.

800W capacity, nom. 8.6A = 413W

Total max power = 100 + 131 + 413 = 644W

Power resistors are +/-5% and 1.05 x 644 = 676W is above Cosel capacity.

Add facility for trim resistors.

Allow for hardwiring in options such as:

On 5V load:

10m( in series with 5V load -5% is 0.2475(, 20.2A, 101W

10 m( will dissipate 4.1W RS 160-269 is 25W

5( in parallel with 5V load +5% is 0.2494(, 20.05A, 100.2W

5( will dissipate 5W RS 159-758 is 15W

On 12V load:

50m( in series with 12V load -5% is 1.095(, 10.96A, 131.5W

50m( will dissipate 6W RS 107-3481 is 10W

22( in parallel with 12V load +5% is 1.097(, 10.94A, 131.3W

22( will dissipate 6.5W RS 159-916 is 10W

On 48V load:

270m( in series with 48V load -5% is 5.59(, 8.59A, 412W

270m( will dissipate 20W RS 615-0381 is 25W

120( in parallel with 48V load +5% is 5.605(, 8.56A, 411W

120( will dissipate 19.2W RS 161-004 is 50W

Use 2 x RS 264-670 heatsinks, 1 for 48V load and one for both 5V & 12V load

These are 0.3C/W in free air, use fan forced cooling on at least the 48V heatsink

TEST

At room temperature.

Plug the load jig into the completed module – use P9 for 5V/12V, P15 for 48V.

Plug the 5V supply and switch jig into J1.

Turn on 240VAC, switch on all supplies and run at nominal loads as in jig spec.

Verify 5V, 12V and 48V lines are all within 5% at connectors P6 & P12.

As a one-off design test, leave running for 1hour verify the maximum rise in surface temperature of the PCB is < 40(C

TEST

To be performed while load is connected.

Connect I2C test jig to P1 test jig.

Interrogate 5 x ADCs to measure current and voltages – switch load resistors and verify correct currents are measured.

TEST

Photograph both sides of the board and mounted Cosel unit

MW to review codes for using I2C chips on PSU board

Possible get Python library for SBC to allow customisation of tests

MST-0418 MWA 540_ATIM_Transition PCB

Testing of this board will cover: resistance check, continuity between connectors and no-shorts on connectors, function of 48V switching and correct ADC function.

JIG

Connectors to mate with J1, J2, J3, J4, P1, & P2 and a breadboard with testpoints TPn.

The following connections to be hardwired:

TP1 – P1:8 TP3 – P1:20 TP5 – P1:26 TP7 – P1:13

J1:2 – J1:5 J1:3 – J1:6 J4:5 – J4:8 J2:4 – J3:3

P1:18 – P1:14 P1:3 – P1:12 P1:30 – P1:34 P1:21 – P1:32

J1:8 – J2:2 J2:3 – J2:7 J4:2 – J3:7 J4:3 – J4:7

P1:1 – P1:5 P1:7 – P1:33 P1:25 – P1:31 TP8 – P1:28

J2:5 – J2:8 J3:2 – J3:5 J2:6 – J3:4

P1:9 – P1:29 P1:23 – P1:27 P1:11 – P1:16

J3:6 – J4:4 J3:8 – J4:6 J1:4 – J1:7

TP2 – P1:22 TP4 – P1:24 TP6 – P1:10

Need to do one more check that these columns connect non-neighbouring pins and are continuous between TPs at the ends.

Also connect TP9 – P2:4, TP10 – P2:A1, TP11 – P2:A2, TP12 – P2:1, TP13 – P1:2

DIP switches between P1:1 – P1:6, P1:8 – P1:6, P1:33 – P1:6 P1:34 – P1:6

Needs an adaptor to allow I2C jig to be connected through this to P1.

TEST

To check for basic continuity and no-shorts under SMT connectors.

Connect JIG to P1, J1, J2, J3, J4.

Turn 4 DIP switches to OFF

“Beep” verify continuity between TP1-TP2, TP3-TP4, TP5-TP6, TP7-TP8.

Verify >1M( between TP1-TP3, TP1-TP5, TP1-TP7, TP3-TP5, TP3-TP7, TP5-TP7

That checks continuity of signal traces between P1 and J1 thru 4 and no shorts between any neighbouring signal pins.

Verify >1M( between TP9 and all of TP1, TP3, TP5, TP7, TP12

Verify >1M( between TP10-TP11

Unplug J1, J2, J3 & J4 from jig but leave P1.

Connect P2 to completed PSU.

Turn DIP switches on and verify LEDs light one at a time.

Verify 3.3V at TP13

Connect I2C jig to P1 via jig. Leave DIP switches closed.

Interrogate LTC4151s and confirm they return correct value on their “Vin” pins.

TEST

Photograph both sides of the board

MST-0420 MWA Air Conditioner Control Box

Schematic for control box to MW – PSI probably needs to generate this.

PSI can write code for AC testing once library supplied for accessing ATIM

Before this is wired to the AC unit.

TEST

Visually check and photograph wiring.

Verify earth continuity to case

Earth leakage “megger” test on mains level wiring.

MST-0424 MWA Air Conditioner Unit

Tests to be carried out after the unit cabling is modified and unit is connected to MST-0420.

Test unit in wooden crate as delivered. Unit will be sent on to MWA in that crate and integration will be on-site.

JIG (Already exists)

Breadboard with pushbutton control to switch AC SSR using 12V bench PSU.

TEST

Connect the JIG and a bench PSU.

Turn the evaporator fans on and verify they spin.

Turn the condenser fan on and verify it spins.

Turn the compressor on and verify it starts.

Verify that the evaporator begins to cool.

Turn off in reverse order.

See also the additional testing near the end of this document.

MST-0423 MWA Digital Rack

TEST

Photograph both sides of the boards.

Assemble the rack.

TEST

Verify no short across the power supply inputs of the assembled rack.

PSI has no information on which to base further testing.

MST-0425 MWA Clock Unit

TEST

Photograph both sides of the board.

Assemble the PCB into the rack unit.

TEST

Verify no shorts across power inputs.

PSI has no information on which to base further testing.

MST-0426 MWA SBC Module

Testing interleaved with assembly.

Install always-on PSU components and complete 240VAC wiring.

TEST

Megger test AC wiring and earth-to-case continuity.

Apply 240VAC and verify PSU delivers +5V and +12V.

Complete assembly by installing fan on lid, front panel connectors, 2 x MST-0431, SBC, MST-0417, IMC. Do not connect cables between sub units.

TEST

Power down. Connect fan to PSU, turn on power, Verify fan spins.

Power down. Connect IMC to PSU, turn on power and verify IMC LEDs light up.

Power down. Connect SBC to PSU, turn on power and verify SBC LEDs light up.

Power down. Connect SBC to ATIM. Turn on power and verify ATIM LEDs light up.

Power down. Connect MST-0431s to ATIM. Connect IMC to SBC. Turn on power and re-verify all previous LEDs light up.

Need some information here on how to test the SBC via the IMC so that we can verify it works and then software to interrogate I2C peripherals from SBC etc.

Can check via Ethernet link port on SBC front panel. Verify IMC separately. May need 4 port hub plugged in for MWA testing not PSI related.

[Yup.]

TEST

Close up SBC module, place in temperature chamber, connect optical-fibre to communicate with SBC and 240VAC power.

Power up and verify function of SBC.

Monitor module internal temperature via ATIM temperature monitor and by thermocouple.

Raise temperature until internal temp reaches 60C, hold for 1 hour.

Verify SBC, IMC, ATIM and Temp Monitors boards continue to function.

Decrease temperature to -10C, hold for 1 hour and re-verify.

MWA to decide if testing to the limits eg 85C is required.

MST-0448 MWA Internal Rack

Install tested rack units: 1 x PSU (MST-0429) and 1 x SBC Module (MST-0426).

Connect J1 on PSU to SBC module, turn on 240VAC power switches for both modules.

TEST

Issue commands to read manual power switch state and verify it functions.

Issue commands via SBC to turn on 5V, 12V and 48V rails and verify that rails turn on and off under SBC control.

Turn on all rails, reach in to PSU and one-at-a-time:

Unplug J3, verify SBC reports general PSU alarm, re-plug J3

Unplug P4, verify SBC reports 5V alarm, re-plug P4

Unplug P7, verify SBC reports 12V alarm, re-plug P7

Unplug P10, verify SBC reports 48VA alarm, re-plug P10

Unplug P13, verify SBC reports 48VA alarm, re-plug P13

Unplug P16, verify SBC reports 48VA alarm, re-plug P16

Install tested rack units: 2 x ASC Modules (MST-0422).

Connect cables from PSU to each ASC and from SBC to each ASC.

TEST

Run software on SBC to turn on power to ASC and interrogate PIC and Temp monitor on each ASC unit.

Install tested rack unit: 1 x Digital Crate (MST-0423+MST-0425)

TEST

Run software on SBC to turn on power to Digital crate and clock unit and interrogate them for function. PSI has insufficient information to allow it to write this software. [MWA should be able to provide this functionality with receiver control software.]

Mount 2 x tested MST-0418 on connector panel (not inserted into main enclosure). Connect these to SBC module.

TEST

Run software on SBC to turn on 48V to each antenna interface, verify LEDs light accordingly.

Run software to interrogate I2C monitors on MST-0418 boards.

MST-0432 MWA Receiver Node enclosure

TEST

I’m assuming that MWA will be able to provide information so that we can put noise, or a known chirp, or something, into each channel and verify that it comes out the back end of the receiver node correctly. Seems to be the really important test.

Or there might be a noise floor test?

[In principle broadband noise to illuminate the passband shape is sufficient test, the issue is collecting and analysing the output data without using the correlator (total data rate is 3x2.7Gbs, would require special HW to decode. Some loop-back testing functionality is available in the AGFO code, alternatively the “VSIB” interface may be available to capture decimated output data. TBD…]

PSI not to test at this level for proto.

Loop-back test might be used for final acceptance test.

MWA would have to deliver test jig and code for this. PSI would perform the test in dumb mode.

Additional one-off testing.

TEST

Install the modified test AC unit into PSI test enclosure

Connect PSI test jig and 12V PSU

Confirm all three motors can be switched on and off.

Put a 400W heat source (lamp) into the enclosure

Use a thermocouple to monitor the enclosure air temperature (location of thermocouple to be determined)

Turn on the evaporator fans

Turn compressor and condenser fan off

Allow enclosure temperature to rise to 45(C (may have to think about letting this go to 60(C in view of MWA request; but need to check that this is possible for AC unit, it was never designed or selected for this)

Connect current probe to AC supply and oscilloscope

Turn on condenser fan and compressor – check compressor starts and observe startup current – surge current not to exceed ?5? A/C cycles at ?20A? peak.

Leave running for ?? minutes – temperature of enclosure to drop below ?? (C

Turn off compressor and condenser fan.

Allow enclosure temperature to rise to 20(C and start a timer – measure the time it takes to rise to 30(C – not to be less than ?? minutes.

Check on breaker cut-out in AC box in case compresser stalls.

TEST

Install AC unit, rack unit containing only SBC module and module metalwork (no PCBs), AC control box and power conditioning into insulated main enclosure. Put 500W of heat load (lamps) (simulates additional heat load through insulation) into the enclosure. Connect SBC to external world via optical fibre. Install software on SBC to control AC as per previously supplied control algorithm and log AC temperatures and enclosure temperatures. Run unit for 1 day at room temp and monitor and review results.

TEST

Repeat the previous test, but this time arrange ducting to mix exhaust air from AC unit back to the condenser inlet and adjust mix until air entering condenser is at 45C while compressor is running. Alternatively arrange for heating of inlet air, for example using hot-air guns.

PSI does not have facilities for testing at lowered inlet temperatures. If MWA requires testing at lower than room temperature then this will need to be negotiated. We might need to find a friendly cool-room owner.

Ignore this for now. Air temperature not expected to drop below 0.

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