Attachment J.13 FAA-G-2100H.pdf

FAA-G-2100H

May 9, 2005

U.S. Department of Transportation

Federal Aviation Administration

U.S. Department of Transportation

Federal Aviation Administration

Specification

ELECTRONIC EQUIPMENT, GENERAL REQUIREMENTS

SIR 693KA8-20-R-00008

FAA-G-2100H May 9, 2005 i

TABLE OF CONTENTS

1 SCOPE AND PURPOSE

1.1 SCOPE

1.2 INTENDED USE

1.3 TAILORING OF THIS SPECIFICATION

1.4 CLASSIFICATION

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

2.2 NON-GOVERNMENT DOCUMENTS

3 REQUIREMENTS

3.1 GENERAL

3.1.1 Electrical Power

3.1.2 Mechanical

3.1.3 Equipment Software/Firmware

3.2 CHARACTERISTICS

3.2.1 Environmental Conditions

3.2.2 Physical Characteristics

3.2.3 Reliability

3.2.4 Maintainability

3.2.5 External Equipment Interfaces

3.2.6 Electrostatic Discharge

3.2.7 Transportability

3.3 EQUIPMENT DESIGN AND CONSTRUCTION

3.3.1 Materials, Processes, and Parts

3.3.2 Electromagnetic Compatibility

3.3.3 Nameplates and Marking

3.3.4 Interchangeability

3.3.5 Personnel Safety and Health

3.3.6 Human Engineering

3.4 DOCUMENTATION

3.5 PERSONNEL AND TRAINING

4 QUALITY ASSURANCE PROVISIONS

4.1 QUALITY SYSTEM REQUIREMENTS

4.1.1 Material Evaluation

4.1.2 Quality Conformance Evaluation

4.2 VERIFICATION/COMPLIANCE TO REQUIREMENTS

4.2.1 Requirements Verification Matrix

4.2.2 Classification of Tests

4.2.3 Test Equipment

5 PREPARATION FOR DELIVERY

6 ACRONYMS AND DEFINITIONS

ii

6.1 ACRONYMS AND ABBREVIATIONS

6.2 DEFINITIONS

6.2.1 Commercial-off-the-shelf (COTS)

6.2.2 Developmental item

6.2.3 Equipment Software/Firmware

6.2.4 Fail-safe

6.2.5 Fail-soft

6.2.6 Lowest Replaceable Units (LRUs)

6.2.7 Internal/building wiring

6.2.8 Modified COTS/commercial type product

6.2.9 Nationally Recognized Testing Laboratory (NRTL)

6.2.10 Non-developmental Item (NDI)

6.2.11 Rack/Equipment

6.2.12 Rack, and/or standalone equipment, Power Input Location

6.2.13 Series Combination System Overcurrent

APPENDIX A

A.1 ITI (CBEMA) CURVE APPLICATION NOTE

A.2 FAA INPUT POWER TOLERANCE ENVELOPE APPLICATION NOTES ..69

APPENDIX B

B.1 GOVERNMENT DOCUMENTS

B.1.1 SPECIFICATIONS:

B.1.2 STANDARDS:

B.1.3 OTHER PUBLICATIONS:

APPENDIX C

C.1 NON-GOVERNMENT DOCUMENTS

C.1.1 STANDARDS:

APPENDIX D

LIST OF FIGURES

Figure 1 Inrush Current Limit Measurements Figure 2 Inrush Current Limit Ratios Figure 3 Standard FAA Nameplate Figure 4 Internal/building Electrical Power Wiring Diagram

LIST OF TABLES

Table 1 Limits of Individual Harmonics Table 2 Abbreviations for Thermocouple Materials Table 3 Electrical Clearance and Leakage (Creepage) Distances Table 4 Type Test Equipment Selection

1 SCOPE AND PURPOSE

1.1 Scope

This specification is the technical baseline for ground based electronic equipment acquired for applications in the National Airspace System (NAS). This specification defines the conditions under which electronic equipment must operate satisfactorily and reliably: identifies acceptable fabrication materials and processes, selection and application of parts, installation of equipment, and methods to verify electronic equipment meets requirements. Individual electronic equipment specifications must identify applicable requirements of this specification. This specification is intended for use in the procurement of all electronics hardware, prototype systems, developmental equipment or commercial off the shelf integrated systems, delivered in any quantity to satisfy an established air traffic need or proof of concept configuration.

1.2 Intended Use

This specification is to be used in conjunction with the equipment specification to establish the procurement requirements. This specification is not to be invoked on a blanket basis in equipment specifications or as a criterion for system acceptance. The approved equipment or system specification determines the superceding requirements for a particular procurement. The interfaces between equipment are beyond the scope of this document and should be addressed in a System Level Specification, Interface Requirements Document, or an Interface Control Document. Software is not part of this specification.

Existing contracts are permitted to use the revision level approved at the time of contract award. These contracts will be subjected to all specifications and testing requirements from the approved revision of this document at the time that contract was awarded. In cases where the new revision of this document can easily be adapted, the affected contract will be subject to all specification and testing requirements of current version of this standard.

1.3 Tailoring of this Specification

The requirements set contained in Section 3 of this general specification need to be tailored by the responsible FAA acquisition program office so that the applicable requirements of FAA-G-2100h are stated in the individual system or subsystem specifications.

1.4 Classification

Electronic equipment acquisition alternatives that are available include NDI, COTS, and developmental items. To meet the functional requirements of the system and the requirements of the specification, various components of the system may need to be acquired by all three alternatives. Tailoring of system component acquisition alternatives to comply with the specification is the responsibility of the FAA acquisition program office.

2 APPLICABLE DOCUMENTS

2.1 Government documents

The listing of government documents referenced in this document is contained in Appendix B.

2.2 Non-Government documents

The listing of non-government documents referenced in this document is contained in Appendix C.

3 REQUIREMENTS

3.1 General

3.1.1 ELECTRICAL POWER

a. All internal wiring to the equipment shall be in accordance with paragraph 3.3.1.3.10, Wiring.

Refer to Section 6.2.6 for wiring interface points.

b. The equipment shall interface to building wiring in accordance with NFPA 70, FAA-STD-032, and FAA-C-1217F, in that order of precedence.

c. Electrical enclosures, cabling, and wiring shall be approved by a nationally recognized testing laboratory.

d. When a piece of equipment, or subcomponent of a system, is being replaced with different equipment, the new equipment shall have same, or better power characteristics or the whole system has to be retested. The relevant power characteristics are in the sections 3.1.1.3 to 3.1.1.7.

3.1.1.1 Physical Requirements

3.1.1.1.1 Physical Construction

a. Accessibility:

The accessibility of test equipment or maintenance equipment shall be in accordance with NFPA 70 Article 110.

(1) All access for electrical components, connections, wiring, etc., shall comply with the accessibility requirements of section 3.1.2.4 of this document.

b. Equipment Directly Connected to Line Power:

(1) Controls and indicators for electrical line voltage of an equipment rack shall be located in accordance with NFPA 70. When switches or circuit breakers function as main power disconnecting means, operating either directly or through a contactor, they shall break the incoming line immediately before the line filter, terminal block or connector, fuses or other parts without compromising RFI, EMI shielding integrity.

(2) Equipment Connected By Cord and Plug to Line Power. Cord connected equipment/systems may be disconnected by means of the plug.

c. Plugs and receptacles provided for connection of the equipment to the AC supply line shall be of the locking type and in accordance with the requirements of W-C-596, W-C-596G, and installed in accordance with the requirements of NFPA-70.

d. Power cords provided for the connection of the equipment to the AC supply line shall be a 3 conductor cord for 120V, or 4 conductor cord for 220V, in accordance with the requirements of UL62 and installed in accordance with the requirements of NFPA-70.

e. Detachable power cords rated 125V (volts) maximum and 15A (amperes) maximum shall be 3 conductor type SF.

(1) The supply end shall have a plug in accordance with the requirements of W-C-596/100A.

(2) The equipment end shall have a female connector per DESC 87204 (Connector, Plug, Electrical, Midget Locking, Specific Purpose, General Grade, Grounding, 2 Pole, 3 Wire, 15 A, 120V, 50/60Hz (Hertz) (Female)).

f. Convenience outlets provided in or with the equipment shall be duplex receptacles in accordance with W-C-596/12-2, installed and wired in accordance with the requirements of NFPA-70. The equipment design shall include the provisions required to provide power to these outlets from a source independent of the equipment power source.

g. Where sensitive test equipment must be connected to the same power source as the equipment, receptacles for this purpose shall be in accordance with W-C-596/12-3, clearly identified, and protected from general use.

3.1.1.2 Electrical Power Measurements

a. All Rack power measurements shall be taken at the distribution panel circuit breaker feeding the Rack being tested.

b. All standalone equipment power measurements shall be taken at the distribution panel circuit breaker feeding the standalone equipment being tested.

c. For system level, testing shall be preformed at circuit breaker controlling all power for each main power bus system under test.

3.1.1.3 Load Power Characteristics

3.1.1.3.1 Power Factor

a. The power factor measurement shall be in conformance with 3.1.1.2.

b. The rack, and/or standalone equipment power factor requirements at non ARTCC and large TRACON locations with loads of greater than 2 amperes rms shall be in accordance with 3.1.1.3.1.

c. The rack, and/or standalone equipment power factor requirements at ARTCC and large TRACON locations with loads of greater than 5 amperes rms shall be in accordance with 3.1.1.3.1.

d. The power factor shall be within the ranges specified for the following ranges of equipment WATTS capacity measured at the Rack, and or standalone equipment, power input location:

W (watts) PF (power factor) W < 2000 0.7(lag) – 0.7(lead)

2000 < W < 5000 0.8(lag) – 0.9(lead) W > 5000 0.9(lag) – 1.0

e. Power factor (PF) shall be defined as the absolute value of the product of the displacement component of power factor and the distortion component of power factor.

PF = |PFdisp x PFdist|

f. The displacement component of the power factor, PFdisp, is equal to the cosine of the angle between voltage and current which can be calculated by dividing the power dissipation in watts by the apparent power in volt-amperes (VA).

PFdisp = COS(θ) = Watts/VA

g. The distortion component of the power factor, PF dist , is equal to the reciprocal of the square root of one plus the square of the total harmonic distortion of the equipment (THD) as defined in IEEE STD 519.

( )2dist

THD1

PF

3.1.1.3.2 Inrush Current

Inrush current is defined as the peak amount of current that a load or device draws when first energized.

a. The inrush current measurement shall be in conformance with 3.1.1.2

b. Inrush current shall be measured by energizing the load or device within ten degrees of the positive (80 to 90 degrees), and the negative (260 to 270 degrees) peaks of the sine wave of applied voltage as shown in Figure 1.

c. The rack, and/or standalone equipment inrush current requirements at non ARTCC and large TRACON locations with loads of greater than 2 amperes rms shall be in accordance with 3.1.1.3.2.

d. The rack, and/or standalone equipment inrush current requirements at ARTCC and large TRACON locations with loads of greater than 5 amperes rms shall be in accordance with 3.1.1.3.2.

e. The steady state values of root mean square (rms) current shall be measured.

f. The test voltage source shall have at least five (5) times the full load or steady state rms current rating of the load or device under test at the point of connection of the device or load under test. Total voltage distortion of the source shall not exceed three percent (3%).

g. Cord connected equipment shall be connected to the test voltage source with the same size, type and length of cord to be furnished with the load or device under test. All other devices or loads shall be connected to the test voltage source with four (4) foot long conductors sized for their rms current in accordance with NFPA-70. All cords and conductors shall be directly connected to the test voltage source.

h. The ratio of peak inrush current to rms current for loads or devices up to 40A, measured on the phase conductor with highest current, shall be equal to or less than the ratio defined by Figure 2.

i. The ratio of peak inrush current to rms current for loads or devices greater than 40A and equal to or less than 80A, measured on the phase conductor with the highest current, shall be equal to or less than the ratio defined by Figure 2.

j. The inrush current limits for all direct current (DC), and all AC devices or loads whose rms current is greater than 80A shall be defined in the system level specification for that device or load.

Figure 1 Inrush Current Limit Measurements

Figure 2 Inrush Current Limit Ratios

Inrush Current Limits

0.001

0.01

0.1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Inrush to RMS Current Ratio

T im e In

S ec on ds

0-40 Amps Circuit Breaker Rating

40-80 Amps Circuit Breaker Rating

NOTE: Iovercurrent = Imax. peak ISS(rms)

3.1.1.4 Electrical Load Balance

The current load on each phase of all multiple phase power sources, including 3-wire 120/240, shall be balanced within ten percent (10%), i.e. the smallest current shall be greater than or equal to ninety percent (90%) of the largest current.

3.1.1.5 Harmonics

a. The harmonics measurement shall be in conformance with 3.1.1.2

b. The individual current harmonic distortion (IN) produced by each individual equipment item or subsystem (consisting of several items combined in a single power circuit) shall be less than the limits listed in Table I measured at the input side of the power distribution where the rack or equipment is attached.

c. The total current harmonic distortion (THD) for equipment or subsystems requiring power of 40 kilowatts or more shall be limited to 10 percent. THD is defined in IEEE STD 519.

Table 1 Limits of Individual Harmonics

Harmonic

Order

Maximum Limits (mA) for 50 < W ≤ 600

(1 phase)

Maximum Limits (mA) for 600 < W < 40000 (1 or 3 phases)

2 1.00 x W 400+ (0.05 x W) 3 3.60 x W 1440+ (1.20 x W) 4 1.00 x W 400+ (0.05 x W) 5 2.00 x W 800+ (0.66 x W) 6 0.50 x W 200+ (0.02 x W) 7 1.50 x W 600+ (0.5 x W) 8 0.50 x W 200+ (0.02 x W) 9 1.00 x W 400+ (0.33 x W) 10 0.10 x W 100+ (0.01 x W) 11 0.60 x W 240+ (0.20 x W) 12 0.10 x W 100+ (0.01 x W) 13 0.51 x W 203+ (0.17 x W) 14 0.10 x W 50+ (0.01 x W) 15 0.44 x W 176+ (0.15 x W) 16 0.10 x W 50+ (0.01 x W) 17 0.39 x W 155+ (0.13 x W) 18 0.10 x W 50+ (0.01 x W) 19 0.35 x W 139+ (0.12 x W) 20 0.10 x W 50+ (0.01 x W)

Notes:

1. W equals power in Watts

2. Power is active power in Watts for both single phase and polyphase circuit as defined by ANSI/IEEE standard 100. “IEEE Standard Dictionary of Electrical and Electronic Terms”

d. Harmonic current requirements will be waived for individual equipment item or subsystem that meets the following:

(1) Individual equipment item or subsystem installed in ARTCC or large TRACONs with specified power less than or equal to 5 amps RMS steady state that meets harmonic current limits IEC 61000-3-2 “Limits for harmonic current emissions”, Class D equipment, Table 3 “Maximum permissible harmonic current (A).”

(2) Individual equipment item or subsystem installed in Radar, ATCTs etc. with the equipment specified power less that or equal to 2 amps RMS steady state that meets harmonic current limits in IEC 61000-3-2 “Limits for harmonic current emissions”, Class D equipment, Table 3 “maximum permissible harmonic current (A).”

(3) Individual equipment item or subsystem with less than 50 watts cord connected load (IEC 61000-3-2, paragraph 7, Note 1).

Application and testing of above IEC 61000-3-2 requirements on individual equipment item or subsystem using 120 volts line to neutral shall be done with the same precision, percentages and ratios as IEC specifies for 230 and 400V systems.

Compliance shall be established by demonstration, certification or independent test lab.

3.1.1.6 Circuit Overload Protection

a. Current Overload protection:

(1) Current overload protection for the equipment shall be provided by fuses, circuit breakers, or other protective devices for primary circuits.

(2) Overcurrent devices shall have a minimum of 10,000-Ampere Interrupting Capacity (AIC) rating.

b. Devices/components shall be protected from damage due to a loss of power or loss of one or more phases of power.

c. Overcurrent protective devices shall provide selective fault isolation rated for the available fault current calculated at the device location.

d. Available fault current shall be calculated from information concerning the facility in which the equipment is located.

e. Series combination system overcurrent protection shall not be permitted.

f. Transient protection shall be provided in accordance with IEEE C62.41, IEEE Recommended Practice on Surge Voltages in Low Voltage AC Power Circuits, Reference Table 2, and verified by testing in accordance with IEEE C62.45, IEEE Guide on Surge Testing for Equipment Connected to Low-Voltage AC Power Circuits.

3.1.1.7 Input Power Conditions

The equipment shall operate in accordance with the following power parameters.

a. Voltage

Nominal FAA Voltage Voltage Range Remarks 208/120 3 Phase +10%, -15% 480/277 3 Phase +10%, -15% 240/120 3 Phase +10%, -15% 120/240 1 Phase +10%, -15%

DC 48 Volts +/- 20% AC Ripple < 5% DC 25 Volts +/- 20% AC Ripple < 5% DC 12 Volts +/- 20% AC Ripple < 5%

b. Voltage phase imbalance, phase to phase: 2% as defined by Paragraph 3.8.2 of IEEE STD

Phase-voltage imbalance = Maximum deviation from average phase voltage Average phase voltage

c. Frequency

(1) Steady State

(a) Steady state 60 Hz +/– 3 Hz

(b) Steady state rate of change 1.5 Hz/sec

(c) Steady state frequency variation + /– 0.5 Hz

(2) Momentary deviations (.5 seconds to 3 seconds)

(a) 60 Hz + 5 Hz, - 7 Hz

(b) Rate of change 5 Hz per sec.

d. Voltage Harmonic Distortion

(1) 10% Voltage Total Harmonic Distortion, VTHD

(2) 3% Any one Harmonic

e. Voltage/Time Events: In accordance with the voltage and current values given by Tables 3 and 4 of IEEE Standard IEEE C62.41. For appropriate exposure locations, see sections 7.3.3,

8.3 and Table 5, earthed neutrals.

f. Voltage/Time events for 120V single phase applications.

(1) The equipment shall maintain normal operation during the voltage time events as defined by the ITI/CBEMA curve in Appendix A.

(2) The equipment shall maintain normal operation during voltage time events as defined by the Federal Aviation Administration Input Power Tolerance Envelope in Appendix A, as required by system level specification.

3.1.1.8 Performance Upon Fault Condition of Radio Frequency Equipment Output Circuit

a. All equipment output circuits shall be designed to include circuit protection and to prevent damage to equipment upon occurrences of opens or shorts on the output terminals.

b. When the short or open is removed, circuit performance shall show no sign of performance degradation. In addition, transmitter output circuitry shall be so designed that, when operated at any voltage standing wave ratio (VSWR), the unit shall not be damaged nor shall any part exceed dissipation limits.

c. The transmitter may shut itself down upon detection of a high VSWR.

3.1.1.9 Grounding and Bonding

a. The ground reference for the equipment/system shall be in accordance with most recent edition of FAA-STD-019 Section 14, FAA-STD-020, FAA-C-1217, NFPA 70 Article 250, and chapters 8 and 9 of IEEE 1100. FAA facilities utilize the following ground systems: (1) "multi-point"; (2) "single point"; (3) NEC power; and (4) "transient": as identified in FAA-

STD-019.

b. Shielding and bonding shall be per FAA-STD-019 and FAA-STD-020.

c. Rack-mounted Equipment: Any rack-mounted, i.e., drawer type or removable, equipment whose chassis is intended for multi-point grounding shall have a flexible grounding strap or braid connecting each unit, assembly, or subassembly of equipment to the rack, using bonding connections per FAA-STD-020.

d. Enclosure and rack doors shall have grounding straps or braids across the hinges to ensure grounding of the door, bonded properly per FAA-STD-020.

e. Isolated ground receptacles shall be wired per NFPA-70.

f. For equipment connected to an AC supply line, the DC resistance to ground for each line input shall be at least 1 megohm.

3.1.1.10 Corona Prevention (High Voltage/High Current)

a. Corona prevention shall be as follows:

(1) When equipment is terminated with the cabling or other accessory equipment, with which it is intended to be used, and when operated under the specified service conditions of humidity, temperature, condensation and barometric pressure with the specified power source frequencies and voltages (including commonly recurring transients), the corona level shall be compatible with the specified electromagnetic interference requirements.

(2) The corona level shall not degrade the equipment performance beyond the specified limits and shall not produce long-term degradation of the properties of materials or parts that may cause premature equipment failure.

(3) The corona extinction voltage shall be at least 150 percent of the peak circuit voltage, corresponding to the maximum specified steady-state root mean square supply voltage, at any point that does not involve materials resistant to the effects of corona.

(4) Corona inception and extinction voltages shall be in accordance with ASTM D1868.

(5) Sharp edges and points shall be avoided on all metal parts which are included in high-intensity electric fields. These are elements that contribute to formation of corona discharge.

b. Electrical breakdown prevention shall be as follows:

(1) The equipment shall be designed and manufactured with electrical clearance spacing, leakage (migration/creepage) distances, and insulation levels adequate to prevent electrical breakdown under the specified service conditions of humidity, condensation, barometric pressure, temperature, service life, contamination, and operating voltage (including transients).

(2) Liquid dielectrics, gases other than ambient air, or pressurization to prevent electrical breakdown shall not be used.

3.1.1.11 Transformer Isolation of Non-Switching DC Power Supplies

a. All non-switching DC power supplies energized from the AC line power source shall be isolated from the AC line through a power transformer with separate primary and secondary windings.

b. The DC resistance from each input line terminal (with fuses in place and AC line control contacts closed) to the signal or chassis ground shall be greater than 1 megohm.

3.1.2 MECHANICAL

3.1.2.1 Removable Parts and Mating Connectors

a. Electronic equipment shall be furnished with a complete set of installed fuses, lamps, plug- in relays, plug- in crystals, ferrule-type resistors, and other parts which are used in the equipment and which are similarly designed for quick removal and replacement. Plug- in parts that provide expanded equipment capabilities are waived from this requirement.

b. Parts that may be damaged by shipment in the operating sockets shall be packed in the normal part shipping container along with information to identify the operating socket.

c. Mating connectors of equipment mounted coaxial or cable connectors shall be provided.

d. Mating connectors shall be provided when two or more pieces of equipment require interconnection.

e. Circuit card guides shall support and retain the card in the guides during all phases of removal and insertion.

3.1.2.2 Installation

The equipment shall be designed for installation, removal and reinstallation without special tools unless approved by the FAA.

3.1.2.3 Construction

a. The equipment shall be constructed so that no fixed part shall become loose during transport and during normal maintenance and operations functions.

b. The total load from the equipment/enclosure to the floor shall not exceed 125 pounds per square foot.

c. The total load from equipment/enclosures supported directly to the building foundation may exceed 125 pounds per square foot but shall be less than the designed load bearing capacity of the foundation.

3.1.2.3.1 Equipment Racks

3.1.2.3.1.1 Pullout Drawers

a. All equipment pullout drawers shall be of a full-suspension roller type with latching stops.

Friction-slide construction is prohibited.

b. Slides shall be of sufficient rigidity to prevent bowing and/or having rollers jump their track when the drawer is fully extended and components are being replaced/maintained.

c. Drawers shall be equipped with handles to permit withdrawing the drawer into the open position and latches on active panel fasteners to secure the drawer in the closed position.

d. The rack cabinet shall not tip over during normal operation and all maintenance activities.

3.1.2.3.1.2 Rack Panels

a. Where rack panels are used, they shall be in accordance with ANSI/EIA 310-D.

b. Panel slot/hole pattern shall be the universal hole spacing pattern for 1U, 2U, and 3U panels and the wide hole spacing for panels 4U and higher.

c. Nominal thickness for aluminum panels shall be 3/16 inch, or greater.

d. Nominal thickness for steel panels shall be at 1/8 inch or greater.

3.1.2.3.2 Shelf Life

Materials and the processes shall ensure the equipment will meet performance requirements after a period of two years in a non-operational state after Government acceptance.

3.1.2.3.3 Moisture

a. Equipment in its operational environment shall not collect moisture.

b. Equipment shall have drainage or purging capability to remove moisture.

c. Removal of moisture shall be considered as part of the Mean Time To Repair (MTTR) calculations.

3.1.2.3.4 Windows

a. Equipment windows, including dial windows, shall be made of shatterproof transparent material.

b. Windows shall be secured to the panels in bezels by means of clips or other devices to prevent displacement of the window.

c. The use of adhesives to secure windows shall require FAA approval.

3.1.2.4 Accessibility

3.1.2.4.1 General

a. Equipment shall be designed for accessibility, operating compatibility, maintenance, electromagnetic compatibility, and enclosure requirements.

b. All non-hinged shields or plates that are normally opened or removed in servicing equipment, shall be secured with captive fasteners.

c. Captive fasteners shall be spaced on centers not exceeding 10 inches and shall be located around the entire periphery of the shields or plates.

3.1.2.4.2 Connections

Connections to parts inside a removable container shall be arranged to permit removal of the container without threading connection leads through the container.

3.1.2.4.3 Lowest Replaceable Units (LRUs)

a. Lowest Replaceable Units (LRUs) shall be removable and replaceable.

b. LRU Mounting devices shall provide the capability of the LRU to be repeatedly installed and removed without degrading performance.

c. Where LRU plug- in modules or assemblies are used, they shall be capable of being inserted in the proper location when correctly oriented without damage to equipment or parts being engaged.

d. LRU plug- in modules and assemblies shall be designed to prevent insertion into the improper location or incorrect orientation.

3.1.2.4.4 Enclosures

a. No enclosure, or part thereof, shall support or sustain combustion in excess of the requirements of NEMA 250.

b. Enclosures for equipment or systems, up to 1,000 volts, installed outside a building (outdoors) shall be either NEMA Type 4 or Type 4X as directed by the system specification.

c. Enclosures for equipment or systems, up to 1,000 volts, installed inside a building in any location where dripping or splashing liquids, or dust, may normally be present shall be NEMA Type 12 or Type 13.

d. Enclosures for equipment or systems, up to 1,000 volts, installed inside a building where no dripping or splashing liquids or dust are normally expected shall be NEMA Type 1.

e. Enclosures for indoor use in hazardous locations classified as Class 1, Division 1, Groups A, B, C, or D as defined in NFPA 70 shall be NEMA Type 7.

f. Enclosures for outdoor use in hazardous locations classified as Class 1, Division 1, Groups A, B, C, or D as defined in NFPA 70 shall be NEMA Type 8.

g. Enclosures for indoor use in hazardous locations classified as Class II, Division 1, Groups E, F, or G as defined in NFPA 70 shall be NEMA Type 9.

h. Accessibility to chassis, assemblies, or parts contained within cabinets, consoles or other enclosures shall be provided from outside the basic equipment.

i. Mounting such items on withdrawal slides, swinging doors, through cable extenders and cable retractors, and provisions for circuit card extenders shall allow part or module operation in the open position.

j. Locks shall be provided to lock the chassis in the servicing position.

k. When withdrawal slides are used they shall be of guided sectional construction.

l. Complete removal and access for servicing of electronic equipment contained within cabinets, consoles or other enclosures shall be provided from either the front or rear of the equipment.

m. Guide pins (or locating pins), or the equivalent, shall be provided for mechanical alignment during mounting.

3.1.2.5 Thermal Design

a. The equipment shall be capable of operating in the environment specified.

b. When air filters are required with forced air cooling, the air filters shall be in accordance with Federal Specification A-A-1419.

c. The difference between the exhaust air temperature (measured inside the cabinet or console in front of the exhaust air vent) and input air temperature (measured outside the cabinet or console directly in front of the input air vent) shall be less than 15°C with the equipment operating under normal service conditions.

d. All ventilation openings shall be designed and located to comply with electromagnetic interference, undesired radiation and enclosure requirements.

e. Air exhaust shall be directed away from operating personnel.

NOTE: MIL-HDBK-251 may be used as a guide for detail information on thermal design of electronic equipment.

f. Cooling methods such as liquid, evaporative coolants, and vapor cycle refrigerants shall not be used.

g. When required, a visual or aural warning device shall be used to indicate failure of a cooling device.

h. Equipment that requires forced cooling to operate shall have control features to prevent equipment damage due to failure of the forced cooling.

3.1.3 EQUIPMENT SOFTWARE/FIRMWARE

a. Any maintenance, modification, and/or replacement of software/firmware programs and data shall be accomplished according to specific system requirements and procedures, such as by electronic means or replacement of PROM-type devices, called out in an approved program specific software/firmware management plan.

b. Firmware/software programs shall be in accordance with the requirements for performance, reliability and maintainability in the system/subsystem specification.

c. Modified and/or newly written software shall be in accordance with the requirements in FAA Standard 026, NAS Software Development, or the applicable standard in effect at the time of development.

3.2 Characteristics

3.2.1 ENVIRONMENTAL CONDITIONS

3.2.1.1 Operating Conditions

3.2.1.1.1 Seismic Zone Design

a. All equipment and systems shall be designed to seismic forces and seismic relative displacement associated with seismic design category D using techniques of IBC 2000, in conjunction with the current version of FEMA 302, NEHRP Recommended Provisions for Seismic Regulations for New Buildings and Other Structures, Chapter 6. For facilities located in regions located very close to major active faults, seismic design categories E or F shall be used as applicable.

b. All equipment and enclosures shall be designed and installed so that the enclosure and the mounted LRU and/or components will remain upright and in place, and all access panels, doors, and drawers shall remain secured to the enclosure under the above conditions.

3.2.1.1.2 Common Outdoor Operating Environmental Conditions

The equipment and system that operate in outdoor environment shall be in accordance with:

a. Elevation from sea level in feet: -300 to +10,000.

b. Wind velocity, any direction: 0 to 100 miles per hour.

c. Ice loading as defined by ASCE Manual 74.

d. Temperature, Solar Radiation and Humidity as defined in Table C-1 of MIL-STD-810F for the entire set of conditions defined as BASIC in the column headed CLIMATIC

CATEGORY.

e. The system level specification shall define the required CLIMATIC CATEGORIES of HOT, COLD, and SEVERE COLD as defined in Table C-1 of MIL-STD-810F.

3.2.1.1.3 Indoor Operating Environments

The equipment and system that operate in indoor environment shall be in accordance with:

a. Elevation from sea level in feet: -300 to +10,000.

b. Temperature and Humidity of unmanned or unattended facility and storage or equipment areas of any facility: 0°F to +100°F, uncontrolled humidity.

c. Temperature and humidity of manned or attended facilities: +55°F to +85ºF with relative humidity of 30% to 80% in the defined temperature range.

d. The system level specification shall define the required operating environment(s).

3.2.1.2 Non-Operating Conditions

Equipment to be delivered to the government packaged for storage, shipping or transporting (non-operating) shall, as packaged, withstand the following environmental conditions:

a. Temperature -50°C to +56°C

b. Relative humidity 0% to 100% including condensation due to temperature changes

c. Altitude 0 to 50,000 feet above sea level

3.2.2 PHYSICAL CHARACTERISTICS

3.2.2.1 Electronic Equipment Assembly Requirements

Equipment assemblies, subassemblies, printed circuit boards assemblies, terminal board assemblies, electronic modules, shall be Class 2 or Class 3 as defined in ANSI/J-STD-001B.

3.2.2.1.1 Component Mounting

Component mounting shall be in accordance with IPC-CM-770 or ANSI/IPC-CM-780, as applicable, except the term “not recommended” shall be interpreted as “reject.”

3.2.2.1.2 Printed Circuit Boards

Printed circuit boards shall be in accordance with IPC-A-600E.

3.2.2.1.3 Assembly

Assembly shall be in accordance with ANSI/IPC-A-610 and ANSI/J-STD-001B.

3.2.2.2 Wire Wrap

Wire wrap shall not be used on printed circuit boards.

3.2.3 RELIABILITY

The reliability of the equipment shall be such that the availability requirements in NAS-SR-1000 are met or exceeded. The reliability of the equipment can be ensured by the establishment of a reliability program that includes but is not limited to, subcontractor surveillance and control, program reviews, failure reporting, analysis and correction, reliability predictions, and parts control.

3.2.4 MAINTAINABILITY

The maintainability of the equipment shall be such that the availability requirements in NAS-SR- 1000 are met or exceeded. The equipment maintainability can be ensured by the establishment of a maintainability program that includes but is not limited to, subcontractor surveillance and control, program reviews, maintainability predictions, and maintainability demonstrations.

In addition, the following maintainability requirements apply:

a. Unsoldering of wires, wire harnesses, parts or assemblies shall not be required in order to gain access to terminals, soldered connections, mounting screws and the like during routine servicing and maintenance.

b. When it is necessary to displace a part in order check or remove another part, the former part shall be wired and mounted so that it can be moved without being disconnected and without causing circuit detuning or instability.

c. Removal of the front panel or any sub-chassis for maintenance purposes shall be accomplished without unsoldering or soldering of connections.

d. Replacement of air filters shall be accomplished without the shutdown of fans.

e. The equipment shall automatically return to normal operation when input power is restored after a power interruption.

f. Built- in test equipment devices shall maintain their accuracy under all operating conditions required by the specification.

g. Built- in test equipment devices shall be provided with connections or access for their operational checkout or calibration.

h. Test points and controls for adjustment shall not be located in compartments with voltage points of 300 volts or more.

i. All test points and controls for adjustments shall be located to preclude accidental shock to personnel engaged in normal operating or maintenance activities.

j. Protection shall be provided in the test point circuitry to prevent equipment damage caused by the external grounding of test points.

k. Provisions for testing shall be so designed that any failure of built- in-test (BIT) devices will not degrade equipment operation or cause equipment shutdown unless equipment is specifically designed to shut down in case of BIT device failure.

l. Test points on plug- in circuit cards shall be immediately accessible inside the electronic component cabinet.

3.2.5 EXTERNAL EQUIPMENT INTERFACES

External systems interfacing with the equipment shall be in accordance with the requirements in the system level specification. Failure of external systems, such as remote maintenance monitoring systems, shall not affect the operation of the equipment or cause the equipment to fail.

3.2.6 ELECTROSTATIC DISCHARGE

No system failures or service interruptions shall occur due to electrostatic discharge to the equipment case under the following conditions:

a. While in a non-operating state, when subjected to either a voltage discharge of 12kV, as stored in a 100 picofarad (pF) capacitor and discharged to the case through a series impedance of 100 ohms, or a transient current with an energy content of 7.2 millijoules (mJ).

b. During operation, when subjected to either a voltage discharge of 7kV, as stored in a 100 pf capacitor and discharged to the case through a series impedance of 500 ohms, or a transient current with an energy content of 2.45 mJ.

3.2.7 TRANSPORTABILITY

The equipment transportability shall be in accordance with the requirements in the system level specifications.

3.3 Equipment Design and Construction

3.3.1 MATERIALS, PROCESSES, AND PARTS

3.3.1.1 Materials

3.3.1.2 Dissimilar Metals

a. Selection of metals for use in electronic equipment shall be made in accordance with the requirements of MIL-STD-889.

b. Where electronic design requirements preclude the isolation from one another of incompatible metal combinations as identified in MIL-STD-889, the incompatible materials shall be isolated from exterior environments.

3.3.1.2.1 Metals, Corrosion Resistance

a. Metals shall be corrosion resistant or shall be coated or metallurgically processed to resist corrosion.

b. Materials and processes for metallic parts shall conform to applicable requirements in MIL- STD-889 and MIL-HDBK-1516.

c. Coatings shall be selected from MIL-HDBK-1516.

d. Non-corrosion resistant steel alloys, except where specifically required for electronic purposes shall not be used.

3.3.1.2.1.1 Corrosion-resisting Ferrous Alloys

a. Austenitic corrosion-resisting steel shall be used for all structural parts that will be subjected to severe corrosive conditions, such as exposure to sea water and combustion gases.

b. Corrosion-resisting steels shall be given a passivation treatment.

c. Other protective finishes or platings are permitted for electrical or mechanical reasons.

3.3.1.2.2 Flammable Materials

Materials used in the end item configuration shall be noncombustible or fire retardant in the most hazardous conditions of the equipment environment.

3.3.1.2.2.1 Additives

a. Fire retardant additives may be used provided they do not adversely affect the specified performance requirements of the basic materials.

b. Fire deterrence shall not be achieved by use of nonpermanent additives to the basic material.

3.3.1.3 Equipment Manufacturing Processes

3.3.1.3.1 Strain Relief

Each part lead terminating at a connection point shall have allowance for strain relief to minimize tensile or shear stress.

3.3.1.3.2 Painted Finish

a. Metal surfaces not otherwise protected as described herein shall be painted.

b. The painted surfaces shall withstand the environmental conditions defined by the equipment specification for the entire service life of the equipment without flaking, cracking, or allowing any corrosion of the underlying surface.

c. Painted finish shall be in accordance with FAA-STD-001.

d. Leaded paint or paints containing isocyanates and hazardous substances shall not be used.

3.3.1.3.3 Cadmium Plating

a. Cadmium plating shall not be used if it is in direct contact with other FAA equipment, located in confined spaces adjacent to waxes, phenolics, or other organic materials that react with the cadmium to cause growth or the formation of cadmium soaps.

b. Cadmium plating shall not be used if the surface is subjected to wear from friction. (Note:

This requirement addresses the cancerous hazards or risks of cadmium.)

c. Cadmium plating shall be in accordance with Type II, Class 1 of ASTM B766 plating with the following exceptions:

(1) Bolts, studs, washers, nuts, and articles with portions externally threaded. These parts have a minimum of class 3 thickness.

(2) Parts whose dimensional tolerances will not permit a class 2 thickness shall be given the maximum thickness of plating compatible with dimensional tolerances.

(3) Holes, recesses, internal threads, and other areas where a controlled deposit cannot be obtained normally shall not be subject to a thickness requirement.

(4) Corrosion-resistant internal-threaded inserts, or protective anti-seize compounds, or internal threads, shall be used where necessary in cadmium-plated parts.

3.3.1.4 Electrical Parts

3.3.1.4.1 Batteries

Batteries sha ll not be used unless specifically required to meet the equipment specification, and shall be in accordance with the following:

a. Batteries shall be in accordance with ANSI/NEMA C18.1, ANSI/NEMA C18.2M, ANSI/UL 1236 and applicable recognized industry standards.

(1) Equipment containing batteries shall be able to operate and be maintained in accordance with their formally documented maintenance procedures for a minimum of 2 years before the batteries require replacement.

(2) The replacement of the batteries shall not exceed 30 minutes.

(3) Batteries shall not leak or generate toxic, corrosive or combustible fumes.

b. Battery compartments shall be provided in accordance with the following:

(1) Contain devices to firmly secure the batteries.

(2) Provide access for battery installation, maintenance, testing, and removal without disassembly of equipment.

(3) Prevent build-up of heat, gases, liquids, or chemicals released during battery operation, charging, deterioration, or rupture.

(4) Prevent build-up of heat, gases, liquids, or chemicals from entering the electronic compartment.

(5) Prevent accidental battery discharge during battery installation, maintenance, testing, and removal.

c. Batteries used with or assembled to microelectronics used to supply power to microelectronics shall not require a dedicated battery compartment. Non volatile RAM ICs and button-type batteries are examples of batteries not requiring a dedicated battery compartment.

d. Connections, polarity, minimum acceptable voltage for equipment operation, nominal voltage, and type(s) of batteries required shall be marked as applicable in a prominent place on or adjacent to the battery compartment.

3.3.1.4.2 Circuit Breakers

3.3.1.4.2.1 Selection and Application

a. Circuit breakers shall be selected based on the environmental conditions specified in the System Level Specification.

b. Circuit breakers shall be in accordance with the requirements of UL 489.

c. Each pole of all circuit breakers shall provide complete overcurrent protection by having inverse time and instantaneous tripping characteristics.

d. Circuit breakers shall be operated by a toggle type handle and have a quick-make, quick-break, over-center switching mechanism, operating all poles, that is mechanically trip free from the handle so that the contacts cannot be closed against short circuit currents.

e. Circuit breakers shall be capable of manual operation to the open (off) and closed (on) conditions.

f. Circuit breakers shall not be used as switches unless they are specifically approved and listed for switching duty.

g. Circuit breakers operating handles shall clearly indicate, by visual or tactile means, the open (off), closed (on), and tripped states of the breaker.

h. Equipment or system circuit breakers shall be coordinated with the circuit breaker providing power to the equipment or system circuit breakers. The coordination shall be complete so that any overcurrent condition in the equipment or system will trip one or more equipment or system circuit breakers without tripping their power feed circuit breaker protecting the facility bus.

i. Equipment and system circuit breakers shall provide complete continuous overcurrent protection for the load served and be unaffected by load harmonics and inrush current.

j. Circuit breakers shall be full size units or multiples thereof.

k. Circuit breakers shall be permanently identified as to their continuous ampere rating.

l. Standard trip curve circuit breakers shall be used to the limits possible.

m. Circuit breakers that are used in an Underwriters Laboratory approved equipment item or load are not required to meet the requirements of b., j., and l.

n. Circuit breakers shall not perform the function of thermal overload relays.

3.3.1.4.3 Electrical Connectors

Electrical connectors shall function in the environmental conditions stated in the System Level Specification.

3.3.1.4.3.1 Selection

a. All electrical connectors shall be UL listed for their application and use.

b. Intended use information contained in the individual connector specifications shall be considered prior to making connector selections.

c. Contact crimp, installing, and removal tools shall be in accordance with the individual connector specifications.

(1) Tools shall be selected from the FAA tools list.

3.3.1.4.3.2 Connectors with Thermocouple Contacts

a. All connectors used in conjunction with thermocouples shall have their contact materials identified by one of the following methods:

(1) Nameplate securely attached to each connector half or mounted on the panel mounted receptacles.

(2) By means of insulation sleeving or other markers designed for attachment around wire bundles.

b. Markers shall be attached adjacent to the plug.

c. Contact materials shall be identified with abbreviations in accordance with Table II.

Table 2 Abbreviations for Thermocouple Materials Chromium Cr Cobalt Co Alumel AL Tungsten Rhenium W Re Iron Fe Tungsten W Constantan CN Iridium Ir Copper Cu Rhodium Rh Platinum Pt Iridium Rhodium Ir Rh Platinum Rhodium Pt Rh Molybdenum Mo Rhenium Re Gold Au

3.3.1.4.3.3 Power Connectors

a. All power connectors shall be in accordance with NEMA WD 6 standards.

b. Polarized connectors are required and shall be used to ensure safety of equipment and personnel.

3.3.1.4.3.4 Protective Measures

a. All unmated connectors shall be protected with metal or plastic caps or otherwise suitably protected during maintenance, storage and shipment.

b. Unmated connectors with exposed contacts that may contain electrically hot circuits shall be covered with moisture-proof and vapor-proof caps.

c. Protective caps shall remain linked to the equipment when not in active use.

3.3.1.4.4 Fuses, Fuse-holders, and Associated Hardware

3.3.1.4.4.1 Selection

a. Fusing shall be coordinated so that fuses in branch circuits will open before the fuses in the main circuit.

b. Fuses shall not perform the function of thermal overload relay devices.

c. Fuse ratings shall be compatible with both starting and operating currents.

d. Each individual fuse shall be replaceable in 5 minutes.

e. Connections to extractor post type fuse holders shall be such that the load is connected to the fuse terminal that terminates in the removable cap assembly.

f. Fuses shall have a minimum interrupting capacity of 10,000 A when used in any AC line whose voltage exceeds 100V.

3.3.1.4.5 Indicating Meters

a. Meters used solely for indication of equipment status may be digital or analog type. Meter accuracy shall be no less than ten percent (10%) of the parameter measured.

(1) Analog meters shall indicate normal conditions using the upper half of their scale.

(2) Digital meters shall indicate normal in the approximate center of their range.

b. Meters used for calibration shall have accuracy, and display of reading, at least ten (10) times more accurate than the value being calibrated.

3.3.1.4.6 Printed Wiring Board Modification

Modifications to printed wiring boards such as the use of cuts and/or jumpers or any other changes shall require FAA approval.

3.3.1.4.7 Conformal Coating of Printed Circuit Boards

a. Printed circuit boards exposed to extreme environmental conditions as defined in the System Level Specification shall have conformal coating.

b. When conformal coating is required, coating material shall conform to ANSI/IPC CC-830.

3.3.1.4.8 Electromagnetic Shielding

a. Magnetically sensitive devices shall be shielded to control the effects of electromagnetic fields.

b. Such devices shall be protected to ensure that the ir performance will not be degraded beyond equipment specification limits, by fields external to the equipment, nor produce emissions in excess of the specified operating limits per commercial specification as appropriate to the environment.

c. Shielding shall be in accordance with FAA-STD-020 Section 3.10.

3.3.1.4.9 Switches

Switches shall maintain their indicated state, i.e., open or closed, when subjected to any accidental force on the switch or the switch mounting equivalent to a 10g acceleration of either switch or mounting.

3.3.1.4.10 Wiring

The selection, application, and wiring practices for cable and wire shall be in accordance with the following subparagraphs:

3.3.1.4.10.1 Clearance and Leakage (creepage) Distances

Clearance between solder connections or bare conductors (such as terminal strips, stand-offs, or similar connections), shall not allow accidental contact occurring between adjacent connections when subject to service conditions specified in the equipment specification. (For electrical clearance and leakage distances, see Table 3.)

3.3.1.4.10.2 Marking

a. All signal, control, and power wiring shall be uniquely identified…