TS1000-0903

All printed copies of this document are un-maintained.

The latest copy of this document may be found on the Kelvin Hughes Intranet

A part of smiths aerospace– marine systems © Kelvin Hughes Limited 2005

This document is supplied on the express terms that it is to be treated as confidential and that itmay not be copied, or disclosed to others for any purpose except as authorised in writing by thecompany.

KELVIN HUGHES

TS1000-0903

Test Specification for Data Acquisition Unit (DAU)

Data Acquisition Unit VDR-A1

Author: Steve Tucker

Checked by: Martin Taylor

ISSUE STATUS

Issue 11 12 13 14 15 16 17

Date 04.02.04 24.03.04 26.04.04 01.07.04 17.02.05 22.06.05 09.02.05

DCR 53173A 53401 53487A 53732 54511D 54563 54355

REF: TS1000-0903

SHEET: 2 of 30Kelvin HughesISSUE: 16

CHANGE HISTORY

DATE ISSUE SUMMARY OF CHANGE NAME

26/04/02 1 First issue S. Tucker

21/06/02 2 Release of ZM1912 V1.00 S. Tucker

09/07/02 3 Improved video testing S. Tucker

22/05/03 6 Incorporation of all configuration and test requirements todate

S. C. Mills

09/06/03 7 Amended System Log to show KH codes for the newCD-ROM and motherboard. Amended VHF audio testprocedure.

S. C. Mills

24/06/03 8 Amended to for use with software release ZM1912 V1.3 S. C. Mills

01/09/03 9 Minor changes to clarify testing procedures S. C. Mills

21/11/03 10 Minor changes to clarify testing procedures S. C. Mills

04/02/04 11 Changes for new motherboard 45-975-0106-001

Soak time reduced to 50 Hours

C. E. Clarke

24/03/04 12 Fit a jumper on JAV link. Install NT Apm/Legacy Support,paragraph 5.12.

S. C. Mills

26/04/04 13 Serial test changed to 38400bps, paragraph 6.2.9 and6.2.21.

S. C. Mills

01.07.04 14 Serial 1 and 2 to be tested at 19200bps.

Bios setting ‘System after AC Back’ set to OFF.

S. C. Mills

17.02.05 15 Remove motherboard Link and Bios Settings. Refer toKSD-1298.

Changes to paragraph 6.3 (serial device setup) and 6.15(crash module setup).

List of inclusive parts and Master Inspection Recordinput, now detailed on assembly drawing.

S. C. Mills

22.6.05 16 Changes to Serial Device Set-Up, paragraphs 6.3.16 to6.3.18.

DRT

09.02.05 17 Changes to paragraphs 5.14.1, 5.7.4 and Appendix 1 A. Fromings

REF: TS1000-0903


GLOSSARY

WP008 Change Control

WP009 Calibration Control

WP022 Design Control

WI.3032-1 Preparation of Test Specification

wrt With respect to

NB (nota bene) means “note well”.

WI.3005-6 External Master Inspection Record Inputting Procedure

UUT Unit Under Test

REF: TS1000-0903


CONTENTS

1. FOREWORD....................................................................................................................... 6

2. RELATED DOCUMENTS AND PARTS.............................................................................. 6

3. TEST EQUIPMENT............................................................................................................. 6

3.1 Proprietary ................................................................................................................... 6

3.2 Bespoke ....................................................................................................................... 6

4. ELECTRICAL SAFETY CHECK ......................................................................................... 7

5. CONFIGURATION.............................................................................................................. 7

5.1 Voltages and Fans....................................................................................................... 7

5.2 Link and BIOS Settings............................................................................................... 7

5.3 Windows 2000 Pro Installation Procedure................................................................. 7

5.4 Create User VDR.......................................................................................................... 8

5.5 Automatic Logon......................................................................................................... 8

5.6 Driver Installation ........................................................................................................ 9

5.7 Screen Resolution ....................................................................................................... 9

5.8 Start up Delay .............................................................................................................. 9

5.9 Default time out ........................................................................................................... 9

5.10 Network ...................................................................................................................... 10

5.11 Software Updates & Network Check ........................................................................ 10

5.12 Add New Hardware.................................................................................................... 10

5.13 Install Kelvin Hughes software................................................................................. 10

5.14 Background ............................................................................................................... 11

5.15 Install Utilities ............................................................................................................ 11

5.16 Install KH VDR software............................................................................................ 12

5.17 Install Printer ............................................................................................................. 12

5.18 Removable Hard drive............................................................................................... 13

5.19 UPS Set-Up ................................................................................................................ 13

5.20 Emergency Boot disk................................................................................................ 16

6. TEST PROCEDURE ......................................................................................................... 16

6.1 Front Panel Tests ...................................................................................................... 16

6.2 Serial Tests ................................................................................................................ 17

6.3 Serial Device Set-up .................................................................................................. 19

6.4 Video Tests ................................................................................................................ 19

6.5 Audio Tests................................................................................................................ 20

6.5.1 Radio Audio Inputs ............................................................................................................... 20

6.5.2 Microphone Audio Inputs ...................................................................................................... 20

REF: TS1000-0903


6.6 CSM Configuration .................................................................................................... 21

6.7 Vibration Test ............................................................................................................ 21

6.8 Battery Test................................................................................................................ 22

6.9 Soak Test ................................................................................................................... 22

6.10 Post Soak Front Panel Tests .................................................................................... 22

6.11 Post Soak Serial Tests .............................................................................................. 22

6.12 Post Soak Video Tests .............................................................................................. 22

6.13 Post Soak Audio Tests.............................................................................................. 22

6.14 Set IP Address ........................................................................................................... 23

6.15 Crash Module Set-Up ................................................................................................ 23

6.16 System Logs .............................................................................................................. 24

6.17 Mechanical Tests....................................................................................................... 24

6.18 Final............................................................................................................................ 24

FIGURE 1- SERIAL INTERFACE BOARD VDR-A105 ............................................................ 25

FIGURE 2 -COMBINED AUDIO VIDEO CARD VDR-A101...................................................... 26

APPENDIX 1 - TEST COMPUTER CONFIGURATION............................................................ 27

APPENDIX 3 - VIDEO ADJUSTMENTS ................................................................................. 28

TEST RECORD 1..................................................................................................................... 29

REF: TS1000-0903


Purpose

To ensure the unit under test is fully operational and functional in accordance with WP022. Thisdocument has been produced in accordance with WI.3032-1.

Amendments

Any amendments to this document shall be performed in accordance with WP008.

Equipment Calibration

All test equipment shall be calibration in accordance with WP009.

1. Foreword

The following procedure details the test of the Data Acquisition Unit VDR-A1.

2. Related Documents and Parts

2.1 External Master Inspection Record (MIR) Inputting Procedure WI3005-6.

2.2 ZM-1912, VDR-A1 software

2.3 KSD-1298, LINK & BIOS settings

3. Test Equipment

3.1 Proprietary

3.1.1 Monitor, 1280 X 1024 85 Hz

3.1.2 PS2 keyboard & mouse

3.1.3 Video Splitter, 4 channel o/p, type ACU9903-4 BLACK BOX, or equivalent

3.1.4 Test Microphone, type VDR-A6 KELVIN HUGHES

3.1.5 Ethernet cable

3.1.6 Test Computer, 1280 x 1024 85 Hz video output (including monitor, keyboard andmouse)

3.1.7 Portable Appliance Tester PAT, type IT4900 DI-LOG INSTRUMENTS, or equivalent

3.1.8 Digital Voltmeter, DVM

3.1.9 USB Network Cable, type UN7B2 WIRETEK, or equivalent.

3.2 Bespoke

3.2.1 Microphone load LTE1567-1, 4 off

3.2.2 Sound Source LTE1567-2

3.2.3 Loop-back leads, serial RS232 LTE1567-3, 7off

3.2.4 Loop-back lead, serial RS422 LTE1567-4

3.2.5 Vibration trolley LTE1567-5

3.2.6 Hard Drive Test Caddy, formatted Windows 2000, LTE1570

REF: TS1000-0903


4. Electrical Safety Check

4.1 Test for Earth Continuity, Insulation and Leakage in accordance with IEC60950-1 orKH WI.3050. Identify the UUT as successfully tested for electrical safety by visiblyaffixing a label to the inside the unit.

5. Configuration

5.1 Voltages and Fans

5.1.1 Measure and record the voltages on a spare PSU connector and they should be asfollows:

5 + 0.5 V on the red lead with respect to Black

12 + 0.7 V on the yellow lead with respect to Black

5.1.2 Ensure there is 24 to 28 V at PL43 on the interface pcb VDR-A105. Crash Survivalmodule DC supply (CSM DC).

Pin 1 – 24 to 28 V (record result)

Pin 2 – 0 V

NB: Check that all the LED’s on the interface PCB are on. Problems with the PS2sockets can cause the –12 V supply to short resulting a fail to initialise themotherboard.

5.1.3 Ensure the ‘processor fan’ and ‘unit fan’ is operating.

5.2 Link and BIOS Settings

5.2.1 Ensure the motherboard LINK and BIOS settings are as defined in KSD-1298.

5.3 Windows 2000 Pro Installation Procedure

5.3.1 Restart the system with the Windows 2000Pro in the CD-ROM drive. The system will“Boot” directly from the CDROM.

5.3.2 The message along the bottom of the screen will read “Press any key to install fromCD” press ‘enter’.

5.3.3 Unit will start up and the Windows 2000 blue screen with a progress bar at the bottom

5.3.4 Microsoft License Agreement will appear Press ‘page down’ until you get to thebottom then press F8 to agree. NTFS Needs to be selected when requested.

5.3.5 Then it will change to the file loading window again with a bar displaying the progress.When copying files into the system finished the system will reboot automatically.

5.3.6 Then system will boot into windows mode, and ask for the regional settings

5.3.7 Select “Customize” the scroll for English (United Kingdom), click “OK”, you will beasked this again, select “English (United Kingdom)” and “OK”

5.3.8 The next screen will require to enter the name “VDR” and the company “KELVINHUGHES”. The work group is to be KH.

5.3.9 Next you will need to enter the product key, Which is supplied with the CDROM, whenyou have done this affix the product key label to the top of the battery cover.

5.3.10 Next is the computer name “VDR” and the administrator password “KHENG”

5.3.11 Time zone as GMT and yes to daylight savings. Network settings, select ‘typical’ andworkgroup as ‘KH’

REF: TS1000-0903


5.3.12 The system will then reboot and the “Network Identification Wizard” appears.

5.3.13 Click Cancel to exit the Network Identification Wizard. Network configuration will becompleted at a later stage.

5.3.14 The windows “Getting Started” screen will appear, deselect the check box in the lowerleft and the click exit

5.3.15 Before removing Windows 2000 CD from the drive, copy i386 directory from Windows2000 CD into the Root Directory on drive C. (C:\i386)

5.3.16 Open Control Panel. Select Automatic Update and untick Keep my computer up todate.

5.4 Create User VDR

5.4.1 From the Start Menu, go to Settings and open the Control Panel.

5.4.2 Double click the Users and Passwords icon. Click the Advanced tab and click theAdvanced button in the Advanced User Management section.

5.4.3 Click the Users folder under the Local Users and Groups heading. Click Action onthe menu and then click New User...

5.4.4 Enter the details of the new user as: -

User name: VDR

Full name: Voyage Data Recorder

Description: KELVIN HUGHES Data Acquisition Unit

Password: KHENG.

Retype the password to confirm.

5.4.5 Un-tick User must change password at next logon.

5.4.6 Tick User cannot change password and Password never expires.

5.4.7 The Account is disabled box must also be un-ticked.

5.4.8 When all the details have been entered click Create and then click Close.

5.4.9 Double click the user VDR in the Local Users and Groups window. Click the MemberOf tab and then click the Add... button. Double click Administrators and then click OK.

5.5 Automatic Logon

5.5.1 Click Run... on the Start Menu and type Regedit32.exe and then click OK to start theregistry editor.

5.5.2 Find the key - HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\WindowsNT\CurrentVersion \Winlogon

5.5.3 Set the Following values (add new values of type REG_SZ if they don’t already exist):

DefaultDomainName “KH”

DefaultUserName “VDR”

DefaultPassword “KHENG”

AutoAdminLogon “1”

REF: TS1000-0903


5.6 Driver Installation

5.6.1 Insert the driver CD-ROM that is supplied with the motherboard. It will autorun (if notselect setup.exe).

5.6.2 Select VGA Driver (VT8601 VGA Driver) and follow the on-screen instructions. Whenprompted to restart the system, select NO.

5.6.3 Highlight Network Driver and ensure that it tells you that Windows2000 has thenecessary drivers other wise select Network Driver (Realtek 8139 LAN Driver) andfollow the on-screen instructions. When prompted to restart the system, select No.

5.6.4 Select Audio Driver (VIA686 Audio Driver) and follow the on-screen instructions. If anotification for “digital signature not found” is displayed, click Yes to continue. Whenprompted to restart the system, select YES.

5.6.5 When all the software has been loaded, remove the CD-ROM.

5.6.6 Open Control Panel. Double click the System icon. Click the Hardware tab and thenclick Device Manager.

5.6.7 Click to expand Other Devices, and double click on Multimedia Controller. Set thisdevice to Disabled.

5.6.8 Open Control Panel and select Sound Effect Manager. Select General and untickShow icon in systems tray.

5.7 Screen Resolution

5.7.1 Right click anywhere on the desktop and click Properties on the pop-up menu. Thenclick the Settings tab. Set the screen resolution to 1024 x 768 and colour to HighColor (16 Bit), then click Apply.

5.7.2 The screen resolution will change and you will have 15 seconds to click Yes to keepthe new settings.

5.7.3 Right click anywhere on the desktop to bring up the pop-up menu, and un-tick the AutoArrange option in the Arrange Icons sub-menu.

5.7.4 Right click anywhere on the desktop and click Properties on the pop-up menu. Thenclick the Settings tab. Click the Advanced button and set the font size to Large Fonts.Select the Monitor tab and set the Refresh Frequency to 60Hz. Click Apply. Thesystem will reboot.


5.7.6 Click View on the menu bar and then select the Large Icons option. (Note: This isnormally enabled by default).

5.8 Start up Delay

5.8.1 Set the startup delay to 3 sec. (Use the Start – Settings – Control Panel – System –hardware – hardware profiles) select the first profile listed and set the box to 3.

5.9 Default time out

5.9.1 To set time before starting Windows 2000 in standard mode, right click My Computericon and click on Properties on the pop-up menu.

5.9.2 Click the Advanced tab followed by the Startup and Recovery... button. Ticks areneeded in Display list of operating systems for 5 seconds and Write event to thesystem log only. Un-tick the others.

REF: TS1000-0903


5.10 Network

5.10.1 Go to “Start” – “Settings” – “Network and Dial-up Connections”.

5.10.2 Right click “Local Area Connection”. Click Rename. Enter “CSM Network”.

5.10.3 Right click “CSM Network”. Select “Properties”. Click on “Internet Protocol (TCP/IP)” soit's highlighted then click on the “Properties” button.

5.10.4 Click on “Use the following IP address” and type in 222.222.222.100 (for connect toTest Computer). Subnet mask 255.255.255.0, and Add Default Gateway222.222.222.1. Select “OK”. Press enter or click “OK” back to the desktop.

5.10.5 Select Show icon in taskbar when connected.

5.11 Software Updates & Network Check

5.11.1 Software updates for Direct X are required, check for the correct issue as supplied onthe Motherboard Utility CD. Verify that it is available from the Test Computer.(Installing the files from the Test Computer will check the Ethernet interface on theUUT).

5.11.2 Ensure the Ethernet Network Cable is connected between the Test Computer and theUUT. Ensure the test computer has been configured as detailed in Appendix 1. Doubleclick the My Network Places icon on the UUT. Right click “Local Area Connection”.Click Rename. Enter “CSM Network” to connect to the Test Computer.

5.11.3 Run the setup program for DirectX by double clicking on C:\VDRUtilities\Directx81\DX81Nteng.exe and follow the on screen instructions.

5.12 Add New Hardware

5.12.1 Open Control Panel, and then double-click Add Hardware.

5.12.2 When the Hardware Wizard completes searching for new hardware, click Yes, I havealready connected the hardware, and then click Next.

5.12.3 Scroll to the bottom of the Installed Hardware list, click Add a new hardware device,and then click Next.

5.12.4 Click Install the hardware that I manually select from a list (Advanced), and thenclick Next.

5.12.5 Under Common Hardware Types, click NT Apm/Legacy Support, and then click Next.

5.12.6 Click NT Apm/Legacy Interface Node, and then click Next.

5.12.7 Click Next again, and then click Finish.

5.13 Install Kelvin Hughes software

5.13.1 Insert the VDR software ZM1912 into the UUT. Open Windows Explorerand doubleclick the Install.bat batch file. This will automatically create the required folders for theVDR software and copy the files on to the system.

5.13.2 During the file copying process the system will ask for confirmation before adding newentries to the registry, click OK when prompted and ensure that the registry entrieswere successfully added. When all files have been copied press any key to close theinstallation window.

5.13.3 The system must now be restarted before the new registry entries can functioncorrectly.

5.13.4 Remove the VDR CD.

REF: TS1000-0903


5.14 Background

5.14.1 Open Explorer and copy the desktop image from the C:\VDR Utilities\Splash Screenfolder called Compass into C:\winnt. Depending on software issue this may alreadybe there.

5.14.2 Right click anywhere on the desktop, and select properties from the drop down menu.

5.14.3 Select the background tab, and locate Compass. Highlight this and then select“Apply”. Select “Picture display” to ‘stretch’ in drop down menu and apply.

5.15 Install Utilities

5.15.1 Run the setup program for the PCI-Fast16 Serial Card by double clicking on C:\VDRUtilities\PCI-Fast16 SerialCard\Update.exe and follow the on-screen instructions.

5.15.2 Run the setup program for Serial Test program by double clicking on C:\VDRUtilities\SerialTest\Setup V1.5 \setup.exe and follow the on-screen instructions.

5.15.3 Run the setup program for ECDIS Simulator by double clicking on C:\VDRUtilities\EcdisSimulator\Setup\DISK1\Setup.exe and follow the on-screeninstructions.

5.15.4 Run the setup program for WinZip by double clicking on C:\VDRUtilities\Winzip\winzip81.exe and follow the on-screen instructions.

5.15.5 When prompted, select Start with WinZip Wizard. Click next. Select Quick Search(faster). Click next. Follow on-screen instructions until WinZip Wizard Setup iscomplete appears. At this prompt select Close. Icons are automatically placed asrequired.

5.15.6 Run the setup program for Acrobat Reader by double clicking on C:\VDRUtilities\ADOBE\AcRd05SA.exe and follow the on-screen instructions.

5.15.7 When prompted to restart the UUT, select NO. Icons are automatically placed asrequired.

5.15.8 Run the setup program for Remote Administrator by double clicking on C:\VDRUtilities\Remote Administrator\RADMIN21.exe and follow the on-screen instructions.Icons are automatically placed as required.

5.15.9 When password window appears enter KHENGVDR (upper case) and apply. Whenprompted to restart the UUT, select NO.

5.15.10 Run the setup program for Wiretek USB Network Driver by double clicking on C:\VDRUtilities\Wiretek USB Network Driver\Setup.exe and follow the on-screeninstructions.

5.15.11 When prompted, connect the USB Network Cable from Test Computer to UUT. Followon-screen instructions.

5.15.12 Restart the UUT. On startup close VDR control window and cancel any alarms bypressing the LED on the UUT door.

5.15.13 Go to “Start” – “Settings” – “Network and Dial-up Connections”.

5.15.14 Select Show icon in taskbar when connected.

5.15.15 Right click “Local Area Connection”. Click Rename. Enter “USB Network”.

5.15.16 Right click “USB Network”. Click on “Properties”. Click on “Internet Protocol(TCP/IP)” so it's highlighted then click on the “Properties” button.

5.15.17 Click on “Use the following IP address” and type in 222.222.222.101 (for connectto Test Computer). Subnet mask 255.255.255.0, and Add Default Gateway222.222.222.1. Select “OK”. Press enter or click “OK” back to the desktop.

REF: TS1000-0903


5.15.18 Double click “My Network Places”. Double click “Entire Network”. Click “entirecontents”. Click “kh” to show both systems (UUT and Test Computer).

5.15.19 Select Test Computer and open C:\Kelvin Hughes.

5.15.20 Drag VDRTestPattern.bmp from the Test Computer C:\Kelvin Hughes to thedesktop of the UUT.

5.15.21 Drag VDRTestPattern.bmp from the UUT desktop back to Test Computer C:\KelvinHughes.

5.15.22 When prompted, click YES to confirm file replacement.

5.15.23 Delete VDRTestPattern.bmp from the UUT desktop.

5.16 Install KH VDR software

5.16.1 Create shortcuts for the following files on the desktop: -

C:\Program Files\EcdisSim\EcdisSim.exe as Ecdis Sim

C:\Winnt\Explorer.exe as Explorer

5.16.2 Arrange the shortcuts across the bottom of the screen to give a layout as shown below.Right click anywhere on the desktop and click Line Up Icons on the pop-up menu.

(Right click on the desktop & select “Line Up icons”). To give a layout as shown below

5.17 Install Printer

5.17.1 Go to “Start” – “Settings” – “Printers”.

5.17.2 Double click “Add printer”

5.17.3 “Welcome to the Add printer Wizard. Click “next”

5.17.4 Take tick out of “Automatically detect” and select local printer and press enter.

5.17.5 Printer port LPT1 is highlighted go “next”

5.17.6 Manufacturers and models select Epson then scroll down list for LQ300 ESC/P 2 andthen press Enter.

5.17.7 Name of printer; leave as LQ300 ESC/P 2 and “next”.

5.17.8 Share or not? Select “not shared” and “next”.

REF: TS1000-0903


5.17.9 Print test page select “Yes”

5.17.10 Details of the printer set up will be displayed press “enter”

5.17.11 When test page is printed add the sheet to the pack of data for the UUT. And click OKto clear the test page window.

5.18 Removable Hard drive

5.18.1 Switch OFF UUT. Remove UUT Caddy and plug in Hard Drive Test Caddy LTE1570.

5.18.2 Switch Caddy ON with the key supplied. Switch ON UUT. When windows finds the newhardware (Hard Drive) it will ask to restart the system, select NO.

5.18.3 Double click on “My Computer” icon. Select E Drive. Open TESTCADDY.doc file.Once successfully open; select Save As and save file as TESTCADDY2 on E Drive.

5.18.4 Once successfully saved, delete TESTCADDY2 on E Drive.

5.18.5 Switch OFF UUT. Remove LTE1570 and refit UUT Caddy. Switch ON UUT.

5.19 UPS Set-Up

NB: The UPS is setup and configured automatically by the VDR installation program.No further changes are required. This section is for verification purposes only.


5.19.2 Double click on the Power Options icon. Set the Power Schemes to Always On. SetTurn off monitor to Never and set Turn off hard drives to Never. (Default)

5.19.3 Click the Advanced tab and tick the Show icon in task bar box.

5.19.4 If available, click on the APM tab and tick Enable Advanced Power Managementsupport as shown:

REF: TS1000-0903


5.19.5 Click on UPS tab and the Uninterruptible Power Supply screen will appear. No manualsetting of UPS options is required because the status and details sections have beenautomatically set and should be appear as shown:

5.19.6 Click on “Select” button and you will get the “UPS Selection” screen:

5.19.7 Make sure “On port” is set to COM1, and Select manufacturer as “Generic”, thenhighlight “Custom” and click “Next”. You will get the “UPS Interface Configuration onCOM1” screen.

REF: TS1000-0903


5.19.8 Ensure that the boxes and buttons are set as shown below:

5.19.9 Click “Finish”. You will be taken back to UPS screen where you can click on“Configure” button, which will give you the “UPS Configuration” screen.

5.19.10 The “Enable all Notifications” box should not be ticked. The “Critical Alarm” section.Set the “Minutes on before critical alarm” to 2 and tick the box.

5.19.11 The box marked When the alarm occurs, run this program should be ticked, theprogram to run is called VDRKiller.exe. The drop-down menu will show Shutdownand the Finally, turn off the UPS box should be ticked.

5.19.12 Click “OK” then click “Apply” and “OK”. This should take you back to the desktopscreen.

5.19.13 Double click on the clock in the lower right corner of the screen to bring up the systemclock.

5.19.14 At a convenient time, remove the power from the unit. After 2 min. the system shouldshut down.

5.19.15 Ensure that the ‘Power Failure’ window appears. The system will SHUT DOWN.

REF: TS1000-0903


5.19.16 Reconnect the power and the system should restart automatically.

5.19.17 From the Control Panel, (Start – Settings) click on “Power Options”.

5.19.18 Click on UPS tab and the Uninterruptible Power Supply screen will appear.

5.19.19 Click on “Configure” button, which will give you the “UPS Configuration” screen.

5.19.20 Set the “Minutes on before critical alarm” to 120 and tick the box.

5.19.21 Click “OK” then click “Apply” and “OK”. This will take you back to the desktop screen.

5.20 Emergency Boot disk

5.20.1 Open “My Computer”, right click on the “C” drive, click on properties, then tools, andthen back up now.

5.20.2 Select the “Emergency repair disk”; follow the instructions on the screen. You will need1 3 ½ floppy and label. Make the label as follows:

EMERGENCY REPAIR DISK

SER. No. 010XXX DD/MM/YY

5.20.3 Remove all disks from the system and place then in the motherboard box.

6. Test Procedure

6.1 Front Panel Tests

6.1.1 Press and hold SW1 on the UUT, then remove PL1 (power) on Status module PCBVDR-A121, then re-apply the power by connecting PL1.

6.1.2 Release SW1. The unit is now in test mode.

6.1.3 Press SW1. Observe that the LCD back light, and the LED’s light in sequence, eachtime the button is pressed.

6.1.4 Press SW2. Observe that the LED in the button is flashing and the sounder makes anaudible beep.

6.1.5 Press SW3. Observe that the LCD fills with black rectangles from left to right.

6.1.6 Remove PL1 (power), then re-apply the power by connecting PL1.

SW1

SW2

SW3

SW4

POWER VDR ON ALARM

REF: TS1000-0903


6.2 Serial Tests

6.2.1 Run the serial test software, start – programs – serial test

6.2.2 Select “VDR (16 ports)”, then start.

6.2.3 Ensure that when prompted, the following connectors are connected to each other vialoop-back leads LTE1567-3 & LTE1567-4.

SERIAL 01 to SERIAL 02








6.2.4 Start the Serial Test on the PC.

6.2.5 Untick serial 1 and serial 2 (these ports will be tested using HyperTerminal). Ensurethat ports serial 3 to serial 14 pass. The remaining ports will be tested withHyperTerminal.

6.2.6 Select the HyperTerminal from; Start – Programs – Accessories – Communications– HyperTerminal. The “New Connection” screen will be shown.

6.2.7 Enter COMP17 as the name and click OK; you will then get the “Connect to” screen.

6.2.8 Select the “COM17” port from the drop down list. This represents “Serial 15” on theinterface board. Click “OK” this takes you to the COM17 Properties screen

6.2.9 Using the drop down menus select the following settings and click OK.

Serial 1 + 2 Serial 15 + 16

Bits per Second 19200 38400

Data Bits 8 8

Parity None None

Stop bits 1 1

Flow control None None

6.2.10 Select the right most Icon from the tool bar at the top of the screen. There will be awindow with 2 tabs. Select “Settings”, select “ASCII Set-up”.

REF: TS1000-0903


6.2.11 Make sure that the 1st, 2nd, 3rd & 5th boxes are ticked, and the 4th box is unticked. Click“OK” twice to get back to the main terminal screen.

6.2.12 To create the second terminal, follow the same procedure, but do not close the existingwindow.

6.2.13 Select the HyperTerminal from; Start – Programs – Accessories – Communications– HyperTerminal. The “New Connection” screen will be shown.

6.2.14 Enter COMP18 as the name and click OK; you will then get the “Connect to” screen.

6.2.15 Select the “COM 18” port from the drop down list. This represents “Serial 16” on theinterface board. Click “OK” this takes you to the COM16 Properties screen.

6.2.16 Repeat section 6.2.9 to 6.2.11.

6.2.17 There are now two windows adjust the size and position so that they are both visible atthe same time.

6.2.18 Click on the left telephone Icon “CALL”, in both windows.

6.2.19 Type in one of the windows and see that it appears in the other. Change to the otherwindow and repeat the typing. This completes the test.

6.2.20 Click on the right telephone Icon, in both windows to break the connection. SaveHyperTerminal connections for post soak test.

6.2.21 Repeat 6.2.6 to 6.2.20 for COM3 and COM4 (Serial 1 and Serial 2) at 19200bps.

6.2.22 Remove the loop-back leads from the interface pcb, but leave connected Serial 3 toSerial 4.

REF: TS1000-0903


6.3 Serial Device Set-up

NB: Having confirmed that all 16 serial ports are operating correctly, now set-up theVDR to have some simulated serial inputs for the soak tests.

6.3.1 Run the ECDIS simulator by double clicking on the shortcut at the bottom of thescreen.

6.3.2 Select the Messages tab

6.3.3 Select Position 1 tab

6.3.4 Tick all output messages (i.e. GLL, GGA, VTG, DTM & ZDA)

6.3.5 Select Output tab

6.3.6 Click on “Select all COM ports” & set to COM5, 4800, None, 8, 1

6.3.7 Click on “Auto start”. Select Enabled & set to Start Route.

6.3.8 Click on Route Data tab, & Select Dover to Calais route. Click on Start buttonunderneath Route indicator.

6.3.9 Run the “VDR Setup” program by double clicking on the shortcut at the bottom of thescreen.

6.3.10 Ensure that Serial/Video/Audio inputs check boxes are checked, & then click on Next.

6.3.11 On the “NMEA Device configuration” page highlight the “Generic GPS” device fromthe available devices list and click on the “>>” button to move the device into the list ofactive devices.

6.3.12 Click on “Modify Device”. Select Port Serial 4.

6.3.13 Set the ZDA decoder. Enable the trigger alarm check box. Set the timeout to 10seconds and the description to ‘Time Source Lost’

6.3.14 Set the GGA decoder. Enable the trigger alarm check box. Set the timeout to 10seconds and the description to ‘Position Source Lost’

6.3.15 Click on TEST. Ensure that serial data is being received from the looped-backsimulator. Click on OK & then Done. Close the ECDIS Simulator window.

6.3.176.3.16 Highlight the Remote Status & Alarm Module device from the available deviceslist.

Click “Create New Device”, Rename the device Internal Status & Alarm Module, Setthe Port Number to 16.

6.3.186.3.17 Click Modify Device and then click the TEST button.

6.3.196.3.18 Press the Alarm Cancel button on the front panel. Ensure that '$Ack' isdisplayed in the window each time the button is pressed. Click OK and then Done.

6.4 Video Tests

6.4.1 Ensure the resolution of the Test Computer is set to 1280 x 1024 @ 85 Hz.

6.4.2 Open the test pattern VDRTestPattern.bmp in C:\Kelvin Hughes on the TestComputer, using the Paint program (Start - Programs - Accessories - Paint). PressCtrl+F to view the image in full screen mode. Move the mouse cursor to the bottomright hand corner of the screen until it is no longer visible.

6.4.3 Ensure the 1280x1024 @ 85 Hz test image is input to the capture card in channel A(SKT3 on VDR-A101), using a standard video cable with 15-way high-density D-Typeconnectors.

6.4.4 With the VDR setup program still running, click Next on the UUT and select Channel 0.

6.4.5 Click the Auto detect button. The video mode must be detected as VESA 1280x102485 Hz.

REF: TS1000-0903


6.4.6 Adjust the vertical offset to 47. Click the advanced tab, and adjust the Horizontaloffset to 370. Adjust the Top Level for each colour to 210 and set the gain to 1.6

6.4.7 Click the Capture button and ensure that a faithful replica of the test image is shown.Pan round the image to ensure that whole image has been captured successfully. Payspecial attention to the right hand edge of the image for distortion, as this will happen atthe limit of the board bandwidth.

6.4.8 Save the captured image as TestImage.BMP in C:\VDR Utilities\VideoTest. Closethe capture window.

6.4.9 Open the Video Test folder in Windows Explorer (C:\VDR Utilities\VideoTest) anddouble click the VideoTest icon.

6.4.10 Click the Image Comparison tab. The source image is VDR Test Pattern, click theBrowse button and double click VDRTestPattern.BMP to select it. The capturedimage is the image that has just been saved. Click the Browse button and double clickTestImage.BMP to select it.

6.4.11 Click the Compare Images button. The error value must be less than 0.05 to pass thetest. If the value is greater than 0.05 the test has failed. Go to Appendix 2 to adjust thesettings for this batch of boards.

6.4.12 Click the View Differences button; white numbers indicate a pass, orange numbersindicate a borderline pass, and red numbers indicate a fail.

6.4.13 Press 'Alt+Tab' to return to the Video Test program. Click OK to exit the program.

6.4.14 Repeat for Channel 1 (SKT2 on VDR-A101).

6.5 Audio Tests

6.5.1 Radio Audio Inputs

6.5.1.1 Step through to the audio channel setup section by clicking NEXT

6.5.1.2 Plug the sound source LTE1567-2 into PL28. Select TX to generate a tone into thetransmitter input.

6.5.1.3 Select radio channel 1 on the PC, check that when the transmitter gain is moved to theleft the displayed level increases, and vice versa.

6.5.1.4 Select RX on the sound source to generate a tone into the receiver input; check thatwhen the receiver gain is moved to the left the displayed level increases, and viceversa.

6.5.1.5 Connect the sound source into PL27 and select Radio channel 2 on the PC.

6.5.1.6 Repeat the above tests to check channel 2 transmitter and receiver gain.

6.5.1.7 Remove the sound source.

6.5.2 Microphone Audio Inputs

6.5.2.1 Ensure LK17 on the interface pcb VDR-A105 is in position B. Measure the dc voltagebetween PL50 (MIC 4A connector) pin 2 and pin 3. Ensure this voltage is between15.5 and 17.5 Volts.

6.5.2.2 For each channel in turn (1A, 1B, 1C, 2A, . . ., 4C) plug the test microphone VDR-A6into the appropriate audio channel plug. The microphone will beep twice when fitted ina good socket.

REF: TS1000-0903


6.5.2.3 Check each channel in turn. In the Audio Configuration window, select the channel themicrophone is connected. Ensure the gain setting is set to 20. Click the test button forthat channel. A figure will be displayed. Ensure this figure is greater than 100,000. Setgain back to 24.

6.5.2.4 Repeat for all other channels. Allow 30 seconds between ‘test beep’ (if not the next testwill fail).

6.5.2.5 Remove the test microphone.

6.6 CSM Configuration

6.6.1 With the VDR setup program still running, click on Next to get to the Crash survivablemodule setup page.

6.6.2 Select “Virtual Module” & tick the “Logging to Disk” check box. Change the Loggingdestination to “BOTH” from the dropdown box in the window, for all channels.

6.6.3 Select the “C:\VDR Logging” directory to log the data.

6.6.4 Click on Next to go to the “Configuration Details” page.

6.6.5 Enter the following data:

IMO vessel “IMO123”

Vessel Name: “MV Kelvin Hughes”

Navigation : “0”

6.6.6 Select Finished & ignore the subsequent warnings.

6.6.7 Say YES to overwrite the previous configuration.

6.6.8 At the “create backup to floppy”, select “NO”

6.6.9 Ensure that the error log is cleared prior to starting the soak tests. Delete the fileC:\Temp\VDRError.log

6.7 Vibration Test

6.7.1 Place the UUT on the vibration trolley LTE1567-5.

6.7.2 Run ECDIS Simulator

6.7.3 Run the unit for 60 minutes varying the vibration speed occasionally.

6.7.4 At the end of the test, ensure that the unit is still operating normally & that no errorshave been generated in the error log.

REF: TS1000-0903


6.8 Battery Test

6.8.1 Run unit for 10 hours on mains input to fully charge the internal UPS batteries.

6.8.2 Disconnect mains and ensure that the unit continues to run for 2 hours from batteryinput. Check that the UUT shuts down at 120 min.

6.8.3 Without touching the on/off switch, re-connect the mains input & check that the unit re-starts correctly.

6.9 Soak Test

NB: Ignore any Microphone fail warnings. This is because microphone loads are fitted.The Microphone ports will be rechecked in the post soak testing.

6.9.1 Fit Microphone Loads LTE1567-1 or Microphone VDR-A6 in positions PL30, 44, 47,51, on the interface PCB VDR-A105.

6.9.2 Double click on the ECDIS icon and select “Dover to Calais”

6.9.3 Open the Task Manager, by Ctrl+Alt+Del. Select “Performance” and then drag thescreen to the right of the screen.

6.9.4 Notice that at regular intervals a spike occurs. This means that video compression istaking place.

6.9.5 Click VDR Logger on the taskbar at the bottom of the screen (to find, move the cursorover each task in turn to identify VDR Logger, select but clicking it) Press Ctrl+D. thiswill open the data box ‘VDRLogger – Debug Messages’. Check that data, with theAD, VD, and NM prefix is being regularly updated.

6.9.6 Run unit for 50 hours checking occasionally that no alarms have been generated.

6.9.7 If any alarms are generated, please note down text on the LCD screen & time whenalarm occurred. This will also appear in a window at the top of the monitor screen.

6.9.8 At the end of the test, check the error log.

6.9.9 If the error log contains any entries, print & attach to the test report. Contact thedocument author to assess the fault before proceeding any further.

6.9.10 Remove Microphone Loads LTE1567-1 or Microphone VDR-A6.

6.10 Post Soak Front Panel Tests

6.10.1 Repeat Front Panel Tests in accordance with section 6.1.

6.11 Post Soak Serial Tests

6.11.1 Repeat Serial Tests in accordance with section 6.2.

6.12 Post Soak Video Tests

6.12.1 Repeat Video Tests in accordance with section 6.4.

6.13 Post Soak Audio Tests

6.13.1 Repeat Audio Tests in accordance with section 6.5.

REF: TS1000-0903


6.14 Set IP Address

NB: If the network address is configured as below, ignore this section.

6.14.1 Click on “Start - Settings - Network - Dial-up Connections”

6.14.2 Click “Local Area Connection” then right click, bottom of menu, click properties, andclick on Internet Protocol (TCP/IP) so its highlighted then click on the Properties button.

6.14.3 Click on “Use the following IP address” and type in 222.222.222.100. Subnet mask255.255.255.0, and Add Default Gateway 222.222.222.1 “OK” this. Press enter or click“OK” back to the desktop

6.15 Crash Module Set-Up

6.15.1 With the VDR set-up program running, click on Next to go to the Crash SurvivableModule Configuration page.

6.15.2 Select “Virtual Module” & tick the “Logging to Disk” check box. Change the Loggingdestination to “BOTH” from the dropdown box in the window, for all channels.

6.15.3 Select the “C:\VDR Logging” directory to log the data.

6.15.4 Click on Next to go to the Configuration Details page.

6.15.5 Enter the following data:

6.15.6 Select Finished & ignore any subsequent warnings.

6.15.7 Say YES to overwrite the previous configuration. At the “create backup to floppy”,select “NO”

REF: TS1000-0903


6.16 System Logs

6.16.1 Click on “Start” - Settings - Control Panel” and then double click “AdministrativeTools”, double click on Event Viewer and clear all the files within Application log,Security log and System log.

6.16.2 Delete the data in C:\Temp\VDRError.log, not the folder

6.16.3 Delete all log files in C:\VDR Logging, not the folder

6.16.4 Right click on “Recycle Bin”, Select “Empty recycle bin”, left click to empty therecycle bin.

6.16.5 This concludes the testing of this unit.

6.16.6 Shut the machine down by “Start” - “Shut down”, select shutdown and then “OK”. Whenthe monitor has gone blank, turn the power off with the switch next to the floppy drive.

6.17 Mechanical Tests

6.17.1 Ensure doors fit, open/close and lock properly.

6.17.2 Ensure that the paint finish is without imperfections.

6.18 Final

6.18.1 Ensure that the unit has a Green and White ‘Tested For Electrical Safety’ sticker on theinside of the case to indicate a successful PAT test and the Windows 2000Pro OEMlabel is stuck to the top plate of the battery case inside the unit.

6.18.2 Ensure that all other labels are fitted and correctly filled out.

REF: TS1000-0903


Figure 1- Serial Interface Board VDR-A105

AB

C

D

E

H I J K M

D

H

N

NS

O

Q

R

G D LF

P

TUVWXY

A +24 V Out N Microphones Inputs

B +24 V In O Video Out

C Mains In P Audio/Video Capture Card Input

D Fuse Q Sync Out

E VHF Channels R PL41

F Txfmrs S Sync In

G DC to DC converter T PL37

H Serial Inputs U Relay

I Power to Motherboard V PL18 PSU connector

J Multi-Channel Serial Card Input W Remote Alarms

K PL21 X Mains Out

L Heading & Azimuth Y CSM DC

M Video In N/C

REF: TS1000-0903


Figure 2 -Combined Audio Video Card VDR-A101

SL3

TP6

TP5

SL4TP1

SL5

TP2

TP3

TP4

TP7

SL1

SL2

C261

IC10IC9 IC8 IC7

R122R171R121

IC17

IC1

3

IC12

R2

0

REF: TS1000-0903


Appendix 1 - Test Computer Configuration

NB: the test computer must be capable of producing 1280 x1024 @ 85Hz video output. Theoperating system must be Windows 2000.

1. Copy the entire the Kelvin Hughes directory from the VDR software ZM1912 to theTest Computer C:\Kelvin Hughes.

2. Copy the entire the VDR Utilities directory from the VDR software ZM1912 to the TestComputer C:\VDR Utilities.

3. Copy the entire Directx?? folder from the Motherboard Utility CD to the TestComputer C:\VDR Utilities\Directx??. Note the ?? indicates the version of DirectXwhich will depend on the version of software installed.

4. Set the video resolution to 1280 x 1024 @ 85Hz. Using the Test Computer. SelectControl Panel> Display Settings> Settings. Set Screen area to 1280 by 1024 pixels.Select Advanced> Monitor. Set Refresh Frequency to 85Hertz. Apply these settings.

5. Go to “Start” – “Settings” – “Network and Dial-up Connections”. Right click“Local Area Connection”. Click Rename. Enter “Ethernet Network”. Right click“Ethernet Network”. Select “Properties”. Click on “Internet Protocol (TCP/IP)” soit's highlighted then click on the “Properties” button. Click on “Use the following IPaddress” and type in 222.222.222.110 (for connect to Test Computer). Subnetmask 255.255.255.0, and Add Default Gateway 222.222.222.1. Select “OK”. Pressenter or click “OK” back to the desktop. Select Show icon in taskbar whenconnected.

6. Run the setup program for Wiretek USB Network Driver by double clicking on C:\VDRUtilities\Wiretek USB Network Driver\Setup.exe and follow the on-screeninstructions. When prompted, restart the Test Computer.

7. Go to “Start” – “Settings” – “Network and Dial-up Connections”. Right click “Local AreaConnection”. Click Rename. Enter “USB Network”. Right click “USB Network”. Click on“Properties”. Click on “Internet Protocol (TCP/IP)” so it's highlighted then click on the“Properties” button. Click on “Use the following IP address” and type in222.222.222.111(for connect to Test Computer). Subnet mask 255.255.255.0, andAdd Default Gateway 222.222.222.1. Select “OK”. Press enter or click “OK” back tothe desktop. Select Show icon in taskbar when connected.

REF: TS1000-0903


Appendix 2 - Video Adjustments

NB: Setting the video gain levels. After the first capture, set the video levels in the followingmanner

1. Positioning

1.1 Zoom in to the top left hand corner of the captured image and ensure that no blacklines are visible and that the red corner of the captured starts exactly in the corner ofthe screen.

1.2 Adjust the horizontal and vertical offsets to ensure that this is so.

1.3 Ensure that the colour gain levels are set.

2. White level adjustments

2.1 Locate the cursor over a white area of the captured image, and note the RGB levels inthe bottom off the tool bar for the captured image.

2.2 Select the ‘advanced video set-up’ tab.

2.3 Adjust the ‘Red’, ‘Green’ and ‘Blue’ gain levels, to achieve as close to 250 as possible,without going over. (course adjustment)

2.4 Re-capture the image and check again. Repeat this as often as necessary to achievethe best possible result.

3. Top level settings

3.1 Locate the cursor over a white area of the captured image, and note the RGB levels inthe bottom off the tool bar for the captured image.

3.2 Select the ‘advanced video set-up’ tab.

3.3 Adjust the ‘Red’, ‘Green’ and ‘Blue’ top levels, to achieve as close to 250 as possible.(fine adjustment)

3.4 Re-capture the image and check again. Repeat this as often as necessary to achievethe best possible result.

3.5 Once the position Offsets and the Colour levels of the captured image are correctlyadjusted, save the image by selecting ‘File->Save’, into the following locationC:\VDRUtilities\VideoTest\TestImage.bmp

4. Image Testing

4.1 Using ‘Explorer’, run ‘C:\VDRUtilities\VideoTest\VideoTest.exe’

4.2 Select the ‘Image Comparison’ Tab

4.3 Use the browse button to select ‘C:\VDRUtilities\VideoTest\VDRTestPattern.bmp asthe source image.

4.4 Use the browse button to select ‘C:\VDRUtilities\VideoTest\TestImage.bmp as thecaptured image.

4.5 Click on the ‘compare images’ button.

4.6 Ensure that the score achieved is LESS than 0.05. Click ‘OK’

4.7 Set to capture image every 15 sec.

REF: TS1000-0903


TEST RECORD 1

EQUIPMENT No. DESCRIPTION SERIAL No.

VDR-A1 Data Acquisition Unit (DAU)

DEVIATIONS SOFTWARE FAULTS

DEV………. ZM-1912 Iss…. Yes No

The unit bearing the above serial number has been tested in accordance with TS1000-0903.Each satisfactory test result shall be ticked when completed. Each person involved shall add hisor her name and stamp at the end of this document. The test section or supplier shall retain thistest record. The test record shall be available on request.

REF. TEST PROCEDURE PASS - ��

FAIL - X

4.1 Electrical Safety Check successful. Label affixed to unit. �

5.1.1 Ensure voltages PSU voltages 5 +/- 0.5V ……………V �

12 +/- 0.7V ……………V �

5.1.2 Ensure VDR-A105 PL43 Pin1 24 to 28V ……………V �

5.1.3 Processor and unit fan operating �

5.2.1 LINK and BIOS set as defined in KSD-1298 �

5.3 Windows 2000 Pro Installation Procedure �

5.4 Create User VDR �

5.5 Automatic Logon �

5.6 Driver Installation �

5.7 Screen Resolution �

5.8 Start up Delay �

5.9 Default time out �

5.10 Network �

5.11 Software Updates �

5.12 Add New Hardware �

5.13 Install Kelvin Hughes software �

5.14 Background �

5.15 Install Utilities �

5.16 Install KH VDR software �

5.17 Install Printer �

5.18 Removable Hard drive �

REF: TS1000-0903


REF. TEST PROCEDURE PASS - ��

FAIL - X

5.19 UPS Set-Up �

5.20 Emergency Boot disk �

6.1 Front Panel Tests �

6.2 Serial Tests �

6.3 Serial Device Set-up �

6.4 Video Tests �

6.5 Audio Tests �

6.6 CSM Configuration �

6.7 Vibration Test �

6.8 Battery Test �

Pre-soak tested by…………………… Date………..….. Stamp…..……….

6.9 Soak Test ………….hrs �

6.10 Post Soak Front Panel Tests �

6.11 Post Soak Serial Tests �

6.12 Post Soak Video Tests �

6.13 Post Soak Audio Tests �

6.14 Set IP Address �

6.15 Crash Module Set-Up �

6.16 System Logs �

6.17 Mechanical Tests �

6.18 Final �

Post-soak tested by………………….. Date……………. Stamp……………

TS1000-0903

Documents

vdr utilitiesvideotest

vdrutilitiesvideotesttestimage

vdr software

compare images

sound source

interface

enter usb

vdr setup