ISC4ESAINDIA

POWER SUPPLIES IN AVIONICS

Power supplies are foundational to aerospace engineering, providing precise, stable, and programmable electrical power to validate the safety, reliability, and performance of electronic components, subsystems, and complete aircraft systems. In an industry where components operate in extreme environments and safety is paramount, these power supplies are essential for simulating flight conditions, adhering to strict industry standards (such as DO-160 and MIL-STD-810), and identifying potential failures before deployment.

Key applications of power supplies in aerospace engineering include:

Simulation of Power Anomalies: Programmable AC and DC power supplies replicate in-flight electrical scenarios, such as over-voltage, under-voltage, surges, and transients, to test the robustness of onboard equipment.
400 Hz Frequency Testing: They provide stable 115/200V, 400Hz three-phase AC power to simulate the aircraft’s electrical network for avionics testing.
Automated Test Equipment (ATE) Powering: They serve as the core power source in ATE systems, automatically delivering precise voltage and current levels to electronic components (DUT - Device Under Test) during production and quality control, ensuring high-volume, reliable testing.
Avionics and Electronics Verification: They are used in testing guidance systems, communication systems, and flight controls, ensuring high-precision, low-noise power that prevents interference during sensitive measurements.

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AMETEK PROGRAMMABLE POWER SUPPLY APPLICATIONS IN AVIONICS

AMETEK Programmable Power serves a wide range of test applications throughout the aerospace and defence industry—from avionics tests for carrier- and shore-launched combat-ready aircraft to power-system tests for commercial manned and unmanned spacecraft.

MIL-STD-704 and DO-160 Standards Testing

The Ametek Tahoe Series (formerly California Instruments) is highly suitable for MIL-STD-704 and DO-160 standards testing due to its high-power density (15kVA to over 1MVA), ability to act as both an AC/DC source, and optional software that directly supports avionics power testing

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Comprehensive Test Suites: Optional, pre-installed software supports MIL-STD-704 (A-F) and DO-160 Section 16, allowing operators to run tests by selecting specifications from a menu rather than manual programming.
Wide Power & Frequency Range: Tahoe units support 400 Hz and "wild frequency" (360Hz-800Hz) AC testing, as well as 28VDC and 270VDC testing required for aircraft power buses.
Transient Generation: The system can produce voltage sag, surge, step, and frequency sweep transients with a 500µs resolution, meeting the rigorous requirements for abnormal and emergency power conditions.
Regenerative/Bidirectional Power: With the optional SNK (sink) mode, the Tahoe series can regenerate up to 100% of rated power back to the grid, saving on energy costs and eliminating the need for bulky load banks during tests.

High Crest Factor Support: It can drive non-linear loads common in modern avionics, handling high repetitive peak currents
Output Voltage: 0 - 333VAC, Power output -15kVA to 1MVA
Dual Voltage ranges that support over-voltage testing on 480V-based systems
High Power AC and DC Source
Arbitrary & Harmonic Waveform Generation
Standard LXI LAN, USB, and RS-232, Optional GPIB
Complete avionics power quality test suites
Internationally accepted test routines for EMI/EMC, Safety Compliance

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MIL-STD-1399 Standards Testing

The AMETEK Asterion AC - Single & Three Phase AC Power Source series is suitable for MIL-STD-1399-300B standards testing, particularly for naval shipboard and submarine equipment.

MIL-STD-1399-300B Power Groups: The test software covers all necessary power groups, including Type I (60 Hz), and Type II/III (400 Hz) shipboard equipment requirements, ensuring compatibility between user equipment and shipboard AC power systems.
High Power Density & Scaling: Asterion provides high power density in 1U, 2U, 4U, and 14U chassis with power levels ranging from 500VA to 36kVA (when paralleled).
iX2™ Technology: The series employs iX2™ current doubling technology, allowing for higher output currents at lower voltages (up to 2 times the full voltage current as voltage decresases), which is crucial for testing nonlinear loads common in shipboard systems.

Comprehensive Harmonic Analysis: Asterion units can analyze up to 50 harmonics of the fundamental voltage and current, with detailed amplitude and phase information displayed in graphical or tabular formats to ensure adherence to harmonic distortion standards (5% total max for MIL-STD-1399 Type I).
High power density in 1U/2U/4U/14U chassis up to 18 kVA.
Combine units for multi-phase configurations
Complete optional avionic test suites.
ATE version available
CSW5550 Emulation on AST6003A1 model

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Broad range of commercial and military electronics test applications

Asterion DC Series 1.7kW – 10kW

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Advanced Features:

High power density DC power supply in a 1U chassis (up to 5 kW) or a 2U chassis (up to 10 kW)
Intuitive touch panel control
Available in either Fixed or Autoranging output
Multi-language display for global operation
Auto paralleling for higher power
Full remote control via Virtual Panels™

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AC/DC ELECTRONIC LOADS

Electrical loads play a critical role in avionics testing by simulating the real-world power consumption of aircraft systems, ensuring the electrical generation and distribution architecture can handle operational demands. During testing, these loads (typically resistive, inductive, or capacitive) help verify that generators, batteries, and buses can maintain stable voltage and frequency under normal, abnormal, and emergency conditions

Ametek Reflex Power Series - Modular AC/DC/Loads

Elgar ReFlex Power™ Module Series

ReFlex Power™ is a high density, programmable power module system providing DC, AC and electronic load assets all under control of a single controller. ReFlex Power™ (RFP™) provides a reconfigurable, flexible platform ideal for ATE and production test environments where RFP™ can provide programmable stimulus and bias power as well as programmable loads for the device(s) under test.

Programmable AC/DC/Loads Power Module Systems:

Truly Modular Design
100% Digital System
Control up to 95 assets across 8 mainframes
Control multiple AC / DC supplies and loads in one or more mainframes
Create "virtual assets"
Highest Power Density
World-wide AC or DC input

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To address high-power satellite and other aerospace test applications, AMETEK Programmable Power offers m-SAS Series (mini-Solar Array Simulator for Small Satellite Test Applications

Satellites in Earth orbit and other spacecraft within Jupiter's orbit (or any planet) typically rely on photovoltaic arrays, supplemented by batteries, as their main power sources. These arrays, composed of multiple solar cells, supply power to satellites and have distinct current-voltage (I-V) characteristics. The power output fluctuates based on environmental factors (e.g., temperature, irradiation) and operational conditions (e.g., eclipse, spin).

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Advanced Features:

High Resolution IV curve simulates static and dynamic conditions
Designed for high-speed Maximum Power Point Tracking (MPPT)
250HZ PP tracking speed
Low output capacitance
Active power factor correction (PFC)
Standard LAN interface
Full remote control via AMETEK m-SAS software and via SCPI commands

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Microscopes in Avionics

Microscopy is indispensable in the avionics industry for the high-precision inspection of high-density PCB assemblies and microelectronic components that must withstand extreme flight conditions. In aerospace and space applications, inspection accuracy is critical to ensure zero-defect manufacturing and long-term reliability. In addition to PCB applications, advanced imaging is essential for analysing aerospace grade plastics and carbon fiber composites to detect internal delamination or resin voids that could compromise structural safety. These systems allow technicians to identify microscopic solder defects and foreign object debris (FOD), ensuring the absolute integrity of mission-critical hardware.

Vision Engineering Microscopes

Vision Engineering has Space / Aerospace qualified Microscopes with unparalleled clarity and depth perception. Vision Engineering solutions drive both manufacturing yield and the long-term flight reliability required by global aerospace standards, is a precision optical inspection tool for Mission Critical electronics.

Vision Engineering microscopes are complied with

IPC-A-610 – Class 3 inspection
J-STD-001 – Solder quality verification
AS9100 – Process traceability
IPC-7711/7721 – Inspection during rework

Mantis series of Microscopes

The Mantis Series Microscopes from Vision Engineering deliver high-precision, eyepiece-less inspection ideal for avionics electronics and PCB assemblies.

Ergonomic design and superior 3D imaging enhance defect detection, ensuring reliability in critical aerospace manufacturing and maintenance.

The various models in this family of microscopes include:

MANTIS OPTA
MANTIS IOTA
MANTIS ERGO
MANTIS PIXO

MANTIS OPTA

With magnification up to 8X, integrated LED illumination, and clear image quality, MANTIS OPTA enables reliable defect detection and component analysis. Designed for compact workspaces, OPTA microscopes ensure consistent performance in aerospace manufacturing and maintenance environments

Eyepiece-less Ergonomic Design with 3D Stereo View
Delivers a crystal-clear 3D viewing experience with excellent depth perception, improving precision in avionics inspection tasks.
Magnification Options up to 8x (4x / 6x Objectives)
Suitable for detailed inspection of PCB assemblies, connectors, and micro-components used in avionics systems.
Long Working Distance (up to 96 mm)
Enables easy handling of tools and components during inspection, rework, and assembly operations.
High-Intensity LED Illumination (20 LEDs, ~9400 LUX)
Provides uniform, shadow-free lighting with ~7000K color temperature for accurate defect detection.
Ergonomic, Fatigue-Free Operation (Glasses-Free Viewing)
Reduces eye strain and operator fatigue, ensuring consistent productivity during long inspection cycles.

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MANTIS IOTA

The Mantis IOTA is a compact and cost-effective stereo microscope ideal for routine avionics inspection and rework. With magnification up to 8x, interchangeable lenses, and integrated LED illumination (~26 k lux), it delivers clear, high-contrast imaging. Its space-saving design makes it suitable for production lines and lab environments where efficiency and reliability are critical.

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Compact Eyepiece-less Design with 3D Viewing- Provides clear stereo visualization with depth perception for precise avionics component inspection.
Magnification up to 8x- Ideal for basic inspection and assembly tasks in avionics electronics and wiring systems.
Long Working Distance- Enables comfortable handling of tools and components during inspection and rework.
Interchangeable Objective Lenses- Offers flexibility to adapt magnification based on inspection requirements.
Synchronized LED Illumination- Ensures consistent, shadow-free lighting for accurate defect detection.

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MANTIS ERGO

The Mantis ERGO is an ergonomic, eyepiece-less stereo microscope designed for precision avionics inspection tasks. Featuring magnification from 3x to 15x, dynamic 3D lighting, and long working distance, it ensures accurate defect detection in PCB assemblies. Its operator-friendly design reduces fatigue during long inspection cycles, improving productivity in aerospace manufacturing.

ERGO Stereo Microscope

Advanced Eyepiece-less Optical System with Dynamic 3D View
Enhances depth perception and inspection accuracy for complex avionics assemblies.
Magnification Range: 3x – 15x (Multi-view Turret)
Enables quick switching between magnifications for detailed inspection tasks.
Dynamic 3D Lighting with White/UV Options
Provides superior illumination control for inspecting coatings, PCB defects, and fine structures.
Long Working Distance for Tool-Based Operations
Supports precise rework, soldering, and inspection activities.
Ergonomic Design for Reduced Operator Fatigue
Ensures comfortable, long-duration usage with improved productivity.

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MANTIS PIXO

The Mantis PIXO from Vision Engineering combines optical stereo viewing with a 5MP digital camera for advanced avionics inspection and documentation. It offers magnification from 3x to 15x, high-definition image capture, and real-time annotation for traceability and training. With long working distance, 3D illumination, and USB connectivity, PIXO enhances collaboration and quality control in aerospace electronics.

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Integrated 5MP Digital Camera with Optical Stereo View
Enables high-resolution image capture for documentation and quality analysis.
Magnification Range: 3x – 15x
Suitable for detailed avionics inspection, repair, and validation processes.
Live Image Capture, Annotation & Overlay Features
Supports real-time analysis, comparison, and reporting for traceability.
Dynamic 3D Lighting with Advanced Illumination Control
Ensures accurate visualization of defects, coatings, and micro-features.
USB Connectivity & Software Integration
Allows seamless data sharing, reporting, and training application

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Lynx EVO Stereo Microscope

Is an advanced eyepiece-less stereo microscope designed for high-precision inspection in avionics and aerospace applications. It combines patented optical technology with true 3D stereo vision to deliver high-resolution, high-contrast images, enabling accurate defect detection and component analysis. With its ergonomic design and wide magnification range, Lynx EVO ensures comfortable, fatigue-free operation while improving productivity and inspection efficiency.

Advanced Eyepiece-less Optical System with 3D Stereo Vision
Provides high-resolution, distortion-free 3D viewing for precise inspection of avionics assemblies and components.
Wide Magnification Range: 6x – 60x (Expandable)
Enables detailed analysis from general inspection to fine micro-feature evaluation.
High-Resolution Optics with Large Field of View
Delivers exceptional clarity and contrast, allowing faster detection of defects and anomalies.
Long Working Distance for Tool-Based Operations
Supports comfortable rework, soldering, and manipulation of components during inspection.
Ergonomic Design for Reduced Fatigue & Enhanced Productivity
Promotes natural posture and minimizes eye strain, ideal for extended avionics inspection tasks.

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PRECISION SOLERING & REWORK SOLTIONS FOR AVIONICS

High-precision soldering in avionics is the specialized joining of electronic components in aircraft systems using advanced, targeted methods to ensure maximum reliability, minimal thermal damage, and IPC Class 3 compliance. It involves meticulous techniques to handle miniaturized components, high-density PCBs, and extreme vibration/pressure environments.

JBC Tools – Aerospace Qualified Soldering Solutions

JBC is a globally recognized leader in high-performance soldering and rework systems, trusted across aerospace, defense, medical, and high-reliability electronics industries.

JBC soldering stations are specifically suited for Class 3 high-reliability applications, where precision and repeatability are critical.

Features Includes:

Ultra-Fast Heating & Thermal Recovery

Reaches working temperature in seconds
Maintains stable tip temperature during soldering
Prevents thermal stress on sensitive avionics components

Intelligent Heat Management

Automatic sleep & hibernation modes extend tip life up to 5X
Ensures consistent soldering quality across long production cycles

High Precision for Micro-Soldering

Ideal for SMD, BGA, and fine-pitch components
Designed for use under microscopes in avionics assembly

ESD-Safe Design

Fully compliant with ANSI/ESD S20.20
Tip-to-ground resistance < 2Ω ensures protection of sensitive electronics

Process Traceability & Connectivity

Data logging and software integration for process control
Supports aerospace quality systems and audit requirements

RMSD System Rework with DT530

RMSD achieves high-quality soldering with JBC Most Efficient Soldering System, while Intelligent Heat Management helps extend tip life and reduce energy consumption. The solution includes

DDE 2-Tool Control Unit manages up to two tools simultaneously and is fully compatible with 10 different JBC Tools, delivering up to 150 W per tool.
RMSD works simultaneously with DT530 Angled Desoldering Iron, T245 General Purpose Handle and JTT Heater Hose Set.
MSE Electric Desoldering Module provides exceptional suction power, reaching up to 85% vacuum, ensuring precise and efficient solder removal.
JTSE Hot Air Station controls the rework task using temperature and airflow profiles.

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Specifications

JTSE Control Unit
Nominal power	700 W
Selectable temperature	150 to 450 °C / 300 to 840 °F
Air flow regulation	5 to 50 SLPM
Vacuum	30% / 228 mmHg / 9 inHg
Profiles	25 (up to 10 steps for each), 1 preset profile
Type K TC connector	1 for Control & Protection
ESD safe	Meet ANSI / ESD S20.20-2021
DDE Control Unit
Peak power	150 W per tool
Selectable temperature	90 to 450 ºC / 190 to 840 ºF
Temperature accuracy	±3%
ESD safe	Meet ANSI/ESD S20.20-2021
Equipotential bonding	Optional connection to EPA
Tip-to-ground resistance	<2 ohms
Tip-to-ground voltage	<2 mV RMS
FAE / Robot connector	Remote control or FAE Fume Extractor connection
MSE Module
Vacuum	85 % / 640 mmHg / 25.4 inHg
Flow rate	35 SLPM
ESD safe	Meet ANSI/ESD S20.20-2021

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NASE-2 - Tool Nano Rework Station

Ideal for soldering and reworking the smallest SMD component size packages like 0201. It provides all the advantages of JBC’s Most Efficient Soldering System. With this system one can have ‘Rework beyond limits’

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Features include

Improved the soldering quality techniques with JBC Intelligent Heat Management and Sleep & Hibernation Modes, that can extend the tip life 5 times more.
Complete Tip Cleaning System with an integrated wiper and brush
Cartridge Holder and JBC Exclusive Cartridge Exchanger, which increases efficiency
NT115 Nano Handle and AN115 Adjustable Nano Tweezers, which work with our C115 Cartridge Range

Specifications

Specification
Peak power	14W per tool
Selectable temperature	90 - 450°C / 190 - 840ºF
Temperature accuracy	±3%
ESD safe	Meet ANSI/ESD S20.20-2021
Equipotential bonding	Connection to EPA
Tip-to-ground resistance	< 2 ohms
Tip-to-ground voltage	< 2 mV RMS

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CDB Soldering Sation

The JBC CDB Station delivers high-precision soldering with advanced thermal performance for reliable electronics assembly. Designed for efficiency and compactness, it ensures consistent results across demanding Avionics applications

Specifications

Specification
Nominal power	175W
Peak power (Tool)	130W
Selectable temperature	90 - 450°C / 190 - 840°F
Idle temp. stability (still air)	±1.5ºC / ±3ºF (Meets and exceed IPC J-STD-001)
Temperature accuracy	±3% (Using reference cartridge)
Temp. adjustment	±50ºC / ±90ºF (Through station menu setting)
Tip-to-ground resistance	<2 ohms
Tip-to-ground voltage	<2 mV RMS
USB-B	PC communications
FAE / Robot connector	Remote control or FAE Fume Extractor connection
Earthing fuse	F 1.25A
ESD safe	Meet ANSI/ESD S20.20-2021

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Integrated Services and Consultancy

Email: sales@isc4esaindia.com

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Email: service@isc4esaindia.com

Avionics

POWER SUPPLIES IN AVIONICS

AMETEK PROGRAMMABLE POWER SUPPLY APPLICATIONS IN AVIONICS

MIL-STD-704 and DO-160 Standards Testing

MIL-STD-1399 Standards Testing

Broad range of commercial and military electronics test applications

Asterion DC Series 1.7kW – 10kW

AC/DC ELECTRONIC LOADS

Ametek Reflex Power Series - Modular AC/DC/Loads

Elgar ReFlex Power™ Module Series

To address high-power satellite and other aerospace test applications, AMETEK Programmable Power offers m-SAS Series (mini-Solar Array Simulator for Small Satellite Test Applications

Microscopes in Avionics

Vision Engineering Microscopes

Mantis series of Microscopes

MANTIS OPTA

MANTIS IOTA

MANTIS ERGO

MANTIS PIXO

Lynx EVO Stereo Microscope

PRECISION SOLERING & REWORK SOLTIONS FOR AVIONICS

JBC Tools – Aerospace Qualified Soldering Solutions

RMSD System Rework with DT530

NASE-2 - Tool Nano Rework Station

CDB Soldering Sation