During flight hardware integration, priority and precedence
must be given to completion of the electrical power interface Safe-To-Mate
procedures. Priority and precedence for testing flight hardware implies that
Safe-To-Mate is the first test procedure during integration. No other
electrical integration procedures should commence until Safe-To-Mate procedure
is completed. Incorrect power interfaces have caused more flight hardware
damage than any other electronic hardware failure mode.
It is recommended that serious attention and care must be
taken by project and systems engineering management to ensure that all
Safe-To-Mate procedures are given significant priority during the component
electrical integration.
The key elements to
successful application flight hardware power are continual diligence and a
detailed understanding of the risks involved with an initial power-on
integration operation. This attentive diligence is particularly necessary
during early flight hardware integration efforts, because the hardware test
configuration is continually changing. Breakout boxes are instrumental pieces
of equipment used during Safe-To-Mate procedures.
The initial application of power is a continuous process.
This process proceeds from component acceptance through flight instrument
hardware and systems level integration and test. It cannot be understated the
risk associated with the initial application of power to flight hardware. Particularly,
when the test configuration is changed from component to subsystem or systems
level testing, which involves a change in the power cable and harness
interface.