Attachment 0007 - System Safety Checklist.docx

Attachment 0004: Safety Checklist Solicitation #: W31P4Q-XX-X-XXXX Dated: 16 Sep 21

Attachment 0004: Safety Checklist Solicitation #: W31P4Q-18-Q-0101 Dated: 17 Jul 17

SYSTEM SAFETY DESIGN VERIFICATION CHECKLIST

US Army Aviation and Missile Command (AMCOM) Candidate for: Radio, Test Set TS-4549/T

Applicability

This checklist is a tool used to help verify the safety of systems design. This checklist is not a requirements document in itself, but is used to verify certain design requirements detailed in the system specification. This checklist should not be considered to be all-inclusive, or as a substitute for items requiring verification through test.

Identification of Inspected Item

Solicitation Number:

Parent System:

National Stock Number: (NSN):

Serial Number:

Contract Number:

Software Version:

Specification Number:

Date:

Program/Equipment Phase:

Completion State of the Equipment:

Date of Inspection:

Inspector:

Organization and Address:

COMM:

COMM:

EMAIL:

This form supersedes SEL Form 1183, dated Feb 01

INSTRUCTIONS

1) Enter the system information on the first page.

2) Review available safety data, to include the System Specification, Hazard Analysis Reports, Safety Assessment Reports, Test Reports, Schematics, Drawings, and Technical Manuals.

3) Select the sections of this checklist that apply to the item to be inspected, and document this in the table below. Sections 1 – 5 are to be completed for all equipment and systems, whereas sections 6 – 13 are to be completed when applicable. Refer to page 3 for a description of each section.

4) Review each question and eliminate those that do not apply by marking NA (not applicable) in the Conformance block.

5) Evaluate each applicable question and record conformance or nonconformance by a Y (yes) or N (no), respectively. Questions should be considered from an individual equipment standpoint, as well as from a systems integration standpoint.

6) Where a NO response is recorded, provide details in the remarks column specifying the reason of non-conformance, and mitigative actions taken or required to ensure safety.

7) The proponent of this form is the Communications-Electronics Lifecycle Management Command (C-E LCMC) Directorate for Safety (DS). Users are invited to send comments on DA Form 2028 (Recommended Changes to Publications and Blank Forms) to CE LCMC DS, ATTN: AMSEL-SF, Bldg 2539 Laboratory Rd., Fort Monmouth NJ 07703-5024. Questions and comments can also be forwarded via email to AMSEL-SF@MAIL1.MONMOUTH.ARMY.MIL

Below is a brief summary of each section.

1. ELECTRICAL SAFETY – completion of this section is mandatory. This section addresses voltage and current hazard protection, grounding, wiring, switches, overcurrent protection, and other electrical safety aspects. Commercial off-the-shelf equipment that has been safety evaluated by industry is also addressed.

2. MECHANICAL SAFETY – completion of this section is mandatory. This section addresses enclosure and guard design, interlocks, mechanical stops, pinch points, sharp edges, loading, equipment weight and surface temperatures, and other mechanical safety aspects.

3. OTHER SAFETY – completion of this section is mandatory. This section addresses other equipment safety topics such as warning devices, labeling, and color-coding of indicators.

4. HEALTH HAZARDS – completion of this section is mandatory. This section addresses personnel health hazards such as exposure to noise, hazardous materials, heat stress, and air quality.

5. ENVIRONMENTAL IMPACT – completion of this section is mandatory. This section addresses the impact of the equipment, chemicals, batteries, and/or radiation on the environment.

6. RADIATION SAFETY – to be completed if the system is a source of nonionizing radiation (RF, microwave, etc.), ionizing radiation (X-ray; radioactive isotopes), or contains a laser system. ALL RADIOACTIVE ISOTOPES, INCLUDING UNLICENSED QUANTITIES, MUST BE REPORTED TO THE DEPARTMENT OF THE ARMY.

7. ANTENNAS AND MASTS – to be completed if the system uses an antenna or a mast. This section also addresses requirements for lightning protection for antenna masts.

8. BATTERIES – to be completed if the system uses batteries. This section addresses rechargeable and nonrechargeable batteries, battery enclosures, venting, and other related topics.

9. GENERATORS – to be completed if the system is integrated or fielded with a generator that is not an Army standard set. This section supplements sections 1 – 5 with additional generator specific safety topics covering shock hazards, fuel systems, fire extinguishers, interlocks, etc.

10. EQUIPMENT INTEGRATION OF SHELTERS AND TRAILERS – to be completed if equipment is integrated into a shelter or onto a trailer, to include the back (squad area) of a HMMWV or other vehicle platform. This section supplements sections 1 - 5 and addresses safety topics such as egress pathways, center of gravity and roadability, rack integration, multiple power sources, and operations on-the-move.

11. EQUIPMENT INTEGRATION OF VEHICLE CABS – to be completed if equipment is integrated into vehicle cabs. This section supplements sections 1 - 5 and addresses safety topics such as egress pathways, the potential for aggravated injuries, impact to driver field of view, durability of equipment mounts, cable runs, etc.

12. TRANSIT CASE MOUNTED EQUIPMENT – to be completed if equipment is integrated into and transported by transit cases. This section supplements sections 1 - 5 and addresses safety topics such as equipment exposure to rain, grounding and GFCI protection, stacking of cases, etc.

13. SOFTWARE SAFETY – to be completed if the equipment contains software that could create a hazard, controls hazardous processes, or controls information upon which users make critical decisions.

Section 1: Electrical Safety

¨ COMMERCIAL OFF-THE-SHELF EQUIPMENT ¨

1.1 Are Commercial Off-The-Shelf (COTS) equipment Listed or certified by a nationally recognized testing laboratory (NRTL)?

1.2 Are Listed COTS used in accordance with the manufacturer’s manuals, in the intended environment, and within the limitations of the Listing?

1.3 Have any modifications to the equipment been reevaluated by the Listing NRTL?

1.4 Is maintenance not required on Listed COTS equipment beyond that specified in the manufacturer’s manuals?

¨ PROTECTION AGAINST SHOCK AND ARCING ¨

1.5 Are personnel suitably protected from access to hazardous voltages ( >30 volts between live parts and/or ground) when setting up, operating, or tearing down the equipment?

1.6 Are personnel suitably protected from accidental contact with hazardous voltages (>30 volts between live parts and/or ground) during maintenance and when maintenance covers are opened?

1.7 If the answer to question 1.6 is NO, is a bypassable safety interlock incorporated to kill all power within the compartment once the maintenance cover is removed?

1.8 Are enclosures or guards that protect terminals or like devices exhibiting 30600 volts, marked "WARNING, XXX Volts" in black on an orange background?

1.9 Are portions of assemblies operating at potentials above 600 volts completely enclosed from the remainder of the assembly, and is this enclosure provided with nonbypassable safety interlocks?

1.10 Are enclosures for potentials, which exceed 600 volts, marked "DANGER, HIGH VOLTAGE, XXX VOLTS" in white on a red background?

1.11 Are all terminals, conductors, etc., capable of supplying greater than 25 amperes, protected against accidental short circuit by tools, removable conductive panels and assemblies, etc.?

1.12 Are all high voltage circuits (>600 V) and capacitors (>30 V or >20 joules energy) reliably and automatically discharged to less than 30 volts / 20 joules within two seconds after power is removed?

1.13 Are all test points, required to be measured by maintainers, limited to less than 300 V (between test points and/or accessible dead metal/ground)?

1.14 If voltage dividers are used to reduce test point potentials, are two resistors used between the test points and/or neutral (not ground)?

1.15 Where test point voltages are to be measured through holes in protective barriers, is the maximum voltage labeled?

1.16 Is sufficient space provided between live parts and/or dead metal parts to prevent shorting or arcing?

1.17 Are parts and components suitably affixed to prevent loosening or rotation that could lead to shorting or arcing?

1.18 If a tool is required to make adjustments while equipment is powered, is spacing and insulation adequate to prevent contact with energized parts by the tool?

¨ CONNECTORS AND PLUGS ¨

1.19 Have connectors, used for multiple electric circuits/voltages, been selected to preclude mismating?

1.20 Has the use of similar configuration connectors in close proximity avoided?

1.21 Are plugs and receptacles coded and marked to clearly indicate mating connectors, where those of similar configuration are in close proximity?

1.22 Are plugs and receptacles designed to preclude electrical shock and burns while being disconnected?

1.23 Are male plugs deenergized when disconnected?

1.24 Is the operator protected from potential arcing if accidentally disconnecting RF power cables?

1.25 Are all receptacles marked with their voltage, amperage, phase, and frequency characteristics where these ratings differ from the standard ratings?

¨ WIRING ¨

1.26 Is the wiring and insulation suitable for the intended load and operating voltage?

1.27 Is the wiring insulation suitable for the anticipated environment, temperature, and/or possible exposure to fuel, grease, or other chemicals?

1.28 Are wires and cables supported, protected, and terminated in a manner that prevents shock and fire?

1.29 Is wiring protected when passing though openings, near sharp edges, and near hot surfaces?

1.30 Is suitable strain relief provided for conductors and cords at their terminations to prevent stress from transmitting to terminals, splices or internal wiring?

1.31 Where the user has access to wiring that carries hazardous voltage/current, does the wiring have a 2nd barrier of protection (i.e. jacketed cord, conduit, etc.)?

1.32 Are singlephase line conductors color coded black, or otherwise clearly identified?

1.33 Are threephase line conductors color coded as follows: A – black, B – red, C – blue, or otherwise clearly identified?

1.34 Are DC power conductors color coded red for positive polarity and black for negative polarity?

¨ GROUNDING ¨

1.35 Are all equipment noncurrent-carrying metal parts and surfaces at ground potential when the equipment is powered (excluding self-powered equipment)?

1.36 Does self-powered equipment have all external surfaces at the same potential?

1.37 Is the path from various equipment points to ground continuous and permanent (hinges and slides not relied upon as the ground path)?

1.38 Are the noncurrent-carrying parts of internal components grounded where they can be accessed by maintainers?

1.39 Are panels and doors containing meters, circuit breakers, etc., grounded in a reliable manner, whether in a closed or open/removed position (less than 0.1 ohm)?

1.40 Does the grounding path have capacity to safely conduct any currents that might be imposed thereon?

1.41 Is the impedance of the grounding path sufficiently low to limit the potential drop and to allow overcurrent devices to clear quickly?

1.42 Does the path from the equipment tie point to ground have sufficient mechanical strength to minimize accidental grounding disconnection?

1.43 Do cables that carry a grounded conductor (neutral) also carry an Equipment Grounding Conductor (EGC) that terminates in the same manner as the other conductors?

1.44 Are insulated grounding wires color coded green with or without yellow stripes?

1.45 Are neutral / grounded conductors color coded white or natural grey?

1.46 Is green and white color coding applied ONLY to grounding and grounded conductors, respectively?

1.47 Do power attachment plugs automatically ground equipment?

1.48 When the grounded power plug is mated with the receptacle, does the ground pin contact make first/break last?

1.49 Are noncurrent-carrying metal parts, grounding wires, etc (except RF cable shields) not used to complete electrical circuits?

1.50 Is the grounding wire separate from electrical circuits, i.e., not tied to neutral other than at the power source?

1.51 If a neutral-ground bond point is provided at the equipment’s secondary supply circuit, is it isolated from the primary power source neutral-ground bond point in order to prevent ground loops?

1.52 On transmitting equipment, is a grounding stud provided that permits attachment of a portable shorting rod?

1.53 Is a ground stud provided on equipment intended to be interconnected to remote systems via long lengths of signal cables?

1.54 Has a test been conducted to verify that the equipment (as well as equipment systems) allows less than 5 Measurement Indication Units (MIU) of residual leakage current to flow to ground under the most adverse conditions of input voltage/frequency (3.5 MIU if the system can be powered from GFCI protected circuits)?

1.55 Where equipment has excessive leakage current, are redundant EGCs provided?

¨ POWER DISCONNECTS AND SWITCHES ¨

1.56 Is a means provided so that power can be cut off while installing, replacing, or servicing a complete system or any Line Replaceable Unit (LRU)?

1.57 If a main power switch is provided, does it cut off all power to the complete system?

1.58 Is the switch located on the front panel and clearly identified?

1.59 Are power and control switches selected and located to prevent accidental actuation or stopping of the equipment?

1.60 Are switches provided to deactivate mechanical drive units without disconnecting other parts of the equipment?

1.61 Are power/maintenance switches provided at equipment which can be powered or controlled remotely?

1.62 Can lockout/tagout devices be applied to switches that are relied upon to deactivate power during maintenance?

1.63 Is protection provided against accidental contact with the supply side of the main power switch?

1.64 Are emergency controls readily accessible and clearly identified?

¨ INTERLOCKS ¨

1.65 Where safety interlocks are used, is the interlock actuator recessed or otherwise protected against contact?

1.66 Are safety interlock circuits designed to be fail-safe?

1.67 Are live parts of safety interlocks protected from contact?

1.68 Where bypassable safety interlocks are used, do they automatically reset once the cover or guard is replaced?

1.69 Are battle short interlocks provided with an indicator to show when active?

¨ OVERLOAD AND OVERCURRENT PROTECTION ¨

1.70 Is equipment that is designed to have multiple-input power capabilities, or powered by a generator with multiple-voltage output capabilities, protected from damage when connected to incorrect input power/voltage levels?

1.71 Are overcurrent and/or overload protective devices provided to protect equipment and conductors?

1.72 If overcurrent protective devices are provided in series with any conductor grounded at the power source, does this device simultaneously open all other load conductors in the circuit?

1.73 Are multi-pole circuit breakers provided for multi-phase circuitry which will open all phases during a fault in any one?

1.74 If circuit breakers are used to power up/down equipment, have they specifically been designed for this purpose?

1.75 Do circuit breakers provide a visual indication when tripped?

1.76 Can fuses be removed safely (no exposed live parts) and without the use of tools?

1.77 Are fuse replacement types and ratings labeled?

1.78 Is surge protection incorporated to protect the user and the equipment?

¨ ENCLOSURES AND GUARDS ¨

2.1 Are equipment enclosures suitably designed to protect the equipment and personnel when considering the anticipated environment and rough handling?

2.2 Are equipment openings and vents sized and located to prevent access to hazardous parts, as well as to prevent objects from falling inside and contacting hazardous parts?

2.3 Are fasteners and methods of securing doors and peripheral components sufficiently strong to prevent breakaway during normal use?

2.4 Are snag hazards due to exposed gears, cams, fans, belts, guy wires, and other moving parts avoided?

2.5 Does the equipment enclosure material and any enclosure openings limit fire propagation?

2.6 Are switches and other electrical components adequately protected against water entry due to rain or equipment washdown?

2.7 Is the equipment designed to provide personnel adequate and safe access (free of obstructions) during installation, operation, and maintenance?

2.8 Are "no step" markings provided at necessary locations to prevent injury and equipment damage?

¨ STOPS, LIMITS AND INTERLOCKS ¨

2.9 Are selflocking or other failsafe devices incorporated into expandable and collapsible structures, such as shelters, jacks, masts, and tripods, to prevent accidental or inadvertent collapsing or falling?

2.10 Are reliable stops/limits integrated to protect moving parts from damage due to over-extension or by being driven into fixed parts?

2.11 Where pins or latches are applied during equipment stowage, transportation or maintenance to secure moveable components, is damage prevented if the pins are left in and the drive mechanism activated?

2.12 Are doors and drawers and associated hinges, supports, slides, and stops positively locked or otherwise secured to prevent unintended movement when in the open or closed position?

¨ PINCH POINTS AND SHARP EDGES ¨

2.13 Are telescoping ladders and assemblies provided with adequate clearance between rungs/parts to prevent pinch points?

2.14 Are hinged brackets and such devices designed and located so that fingers are not exposed to pinch points during adjustment?

2.15 Are sharp corners, edges, and projections avoided?

2.16 Is hand-held equipment designed without sharp edges or protrusions that could cause injury if hit or felled upon while carried in a pocket?

2.17 Is the installed equipment free of overhanging edges and corners that may cause injuries?

2.18 Are door and cover edges not at eye level when in an open position?

¨ HANDLING ¨

1 37 2 74 3 102 4 130

2.20 Is a caution label specifying weight and lifting requirements affixed to equipment exceeding the single soldier handling criteria?

2.21 Are suitable carrying handles or hand grasp areas provided?

2.22 Does the equipment’s size and weight distribution allow for easy handling, moving, and positioning?

2.23 Is the temperature of all exposed parts subject to momentary contact less than 60oC (140oF) for metal, 68oC (155oF) for glass, or 85oC (185oF) for plastic/wood at an ambient temperature of 25oC (77oF), regardless of the condition of operation?

2.24 If the answer to question 2.23 is NO, are the hot surfaces adequately labeled and protected against accidental contact?

2.25 Where prolonged contact is required (handles, controls, etc.), are surface temperatures less than 49oC (120oF) for metal, 59oC (138oF) for glass, or 69oC (156oF) for plastic/wood at an ambient temperature of 25oC (77oF), regardless of the condition of operation?

¨ MISCELANEOUS ¨

2.26 Is the equipment likely to remain upright under normal use and in strong wind, considering its means of support, center of gravity, and slope?

2.27 Is the weight bearing capacity of hoists, jacks, and other such equipment suitable for the expected loading conditions and is the load capacity labeled?

2.28 Are pressurized systems or components provided with relief valves that will vent in a safe direction and manner?

2.29 Are positive means provided to prevent mismating of fittings; couplings; fuel, oil, hydraulic, and pneumatic lines; and mechanical linkages?

2.30 Are there provisions to prevent injury from the implosion of cathode ray tubes?

2.31 Is all glass of the nonshatterable type?

3.1 Is the system designed to preclude injury or equipment damage due to operator induced error?

3.2 Is equipment designed to prevent accidental ignition when used in hazardous atmospheres? (Applicable to equipment that is intended for use in atmospheres of explosive gas or vapors, combustible dusts, or ignitable fibers and flyings.)

3.3 Are emergency controls readily accessible and clearly identified?

3.4 Are switches, indicators, panel instruments, and control devices adequately labeled to prevent confusion which could lead to a hazard?

3.5 Is an audible/visual warning device provided to warn personnel of impending danger, or to indicate malfunction that could cause injury or equipment damage?

3.6 Is proper color coding provided for safety critical indicators (green: power on, ready; amber: caution; red: danger; white: info)?

3.7 Is adequate separation provided between critical warning lights and other lights?

3.8 Are audible warning signals distinguishable from other sounds under normal operating conditions?

3.9 Is the display lighting of aircraft electronics (avionics) compatible to the use of night vision goggles?

3.10 Have all equipment related mechanical, electrical, chemical, and health hazards been suitably addressed through warning labels?

3.11 Are guards, covers, and barriers marked to indicate the hazard which may be present upon removal of such devices?

3.12 Are labels sized and placed so that the associated hazard is identified before the user is exposed to the hazard?

3.13 When possible, are labels located such that they are not removed when the barrier or access door is removed?

3.14 Do warning labels comply with the marking, design, and color requirements detailed in the system specification?

3.15 Are warning labels capable of lasting for the normal life expectancy and operational environments of the equipment to which they are affixed?

3.16 Is PMCS established for safety critical circuits such as safety interlocks, voltage dividers, capacitor discharge circuits, etc.?

3.17 Are all maintenance procedures within the qualifications of the designated Military Occupational Specialty (MOS)?

4.1 Are noise levels less than the below listed limits at both operator and maintainer locations?

Steady state, 8 hr TWA: 85 dBA Steady state, 16 hr TWA: 82 dBA Impulse: 140 dBP

4.2 Where safe noise levels can be exceeded during operation or maintenance, are appropriate warning labels provided on the equipment?

4.3 If headsets or earphones are to be used with the equipment, are labels provided on the equipment to warn users to keep the volume at the lowest, useable level?

4.4 Is the equipment (considering operation, maintenance, storage, and/or disposal) free from hazardous or potentially hazardous materials?

4.5 Have non-hazardous substitute materials been utilized as much as possible?

4.6 Are potential exposures to hazardous materials controlled to levels below the Occupational Safety and Health Administration (OSHA) Permissible Exposure Limit (PEL) and/or American Conference Of Governmental Industrial Hygienists (ACGIH) Threshold Limit Values (TLV); which ever is the more stringent requirement?

4.7 Is the release of toxic, corrosive, or explosive fumes or vapors prevented?

4.8 Is the equipment free of advanced composite materials (e.g. textile glass fiber, carbon/graphite fiber, aramid fiber, ceramic fiber, composite matrix)?

4.9 Are the outer coverings of cables, wires, and other components free of glass fiber materials?

4.10 Are personnel not required to occupy the shelter during normal operations for extended periods? If the answer is NO, answer questions 4.11 – 4.13.

4.11 Is an environmental control unit provided that maintains temperatures within the shelter between 65-85 degrees F (18-29oC) to prevent heat or cold stress?

4.12 Do shelter air temperatures at the floor level and head level differ by less than 10 degrees F (6oC)?

4.13 Is adequate ventilation provided within the shelter (20 cfm/person of fresh air)?

4.14 Where generators and vehicles are to be operated within the vicinity (<25 ft) of the shelter, has air sampling been conducted to ensure compliance with the diesel exhaust PELs listed below?

Permissible Limits (PPM) Substance 8 Hr TWA STEL Carbon Monoxide 25 N/A Formaldehyde - 0.3 Sulfur Dioxide 2 5 Acrolein 0.1 0.3 Nitric Oxide 25 N/A Nitrogen Dioxide 3 5

4.15 Is the system free of insulating materials (e.g., asbestos, fibrous glass, mineral wool, polystyrene foam, polyurethane foam)? If the answer is NO, are appropriate warnings and/or safeguards provided on the equipment and in the technical manuals?

4.16 Is a fixed type fire suppression system provided? If YES, specify type, concentration by volume, and answer questions 4.17 and 4.18.

4.17 Is an audible or visual alarm activated prior to release of the fire suppression agent?

4.18 Is there a time delay prior to release of the fire suppression agent?

4.19 Is the system free of all other health related hazards (vibration, shock, trauma, biological hazards, etc.)?

5.1 Is the item or component free of hazardous or potentially hazardous materials as defined by the Federal Standard 313, EPA (40 CFR), DOT (49 CFR), OSHA ACGIH or other federal law, regulation or standard?

5.2 Is the item or component free of reactive or flammable chemicals such as solvents, thinners or diluents?

5.3 Is the item or component free of toxins and carcinogens (e.g. polychlorinated biphenyl’s, elemental mercury, beryllium oxide, asbestos, etc.)?

5.4 Is it free of ozone depleting chemicals (ODC, i.e., ozone depleting substances (ODS)) refrigerant gases, chlorofluorocarbons, etc?

5.5 Are electrical and electronic components free of lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls (PBB) or polybrominated diphenyl ethers (PBDE) (batteries excepted)?

5.6 If the answer to any of questions 5.1 through 5.5 is “no”, has every effort been made to substitute non-hazardous materials.

5.7 Have Material Safety Data Sheets for all hazardous materials been completed and submitted to the government?

5.8 Does the equipment avoid the use of batteries? If NO, complete section 8, Battery Safety.

5.9 Is the system free of ionizing radiation sources (radioactive isotopes, etc.)? If NO, complete section 6, Radiation Safety. All radioactive isotopes, regardless of quantity, must be reported to Department of the Army.

5.10 Is the system free of nonionizing radiation sources (radiofrequency, laser, etc.)? If NO, complete section 6, Radiation Safety.

5.11 Have all components that are routinely replaced in the course of maintenance been selected so as not to require special handling or disposal?

5.12 Have electrical and electronic components been designed to facilitate the economic recovery, reclamation and/or disposal of components?

5.13 Have all materials that have the potential for the evolution or release of hazardous gases, vapors or fumes in violation of federal, state or local regulations been eliminated?

5.14 Has the system been designed so as not to release combustion products, emit objectionable odors, or create airborne particulates?

5.15 Has the potential for the release of toxic or hazardous substances onto the soil, or to surface or subsurface water been eliminated?

<100 See DODI 6055.11 100-300 1.0 300-3000 f/300 3000-300000 10

6.2 For transmitting equipment, where antennas can develop RF currents on nearby dead metal objects, is the maximum current through an impedance equivalent to that of the human body for conditions of grasping the dead metal object limited to the following values: I = 1000f mA for (0.003 < f 0.1 MHz); I = 100 mA for (0.1 < f 100 MHz)?

6.3 Have all devices that exceed 10,000 volts been evaluated for X radiation?

6.4 Are Xray producing devices shielded to reduce personnel exposure to < 2.0 mR/hour and no more than 50 mR/year?

6.5 Are Xray producing devices and the components in which they are located labeled with an Xradiation hazard warning symbol?

6.6 Has the use of any amount of radioactive material in the design and manufacture of any part or component been avoided?

6.7 If the answer to question 6.6 is NO, has the manufacturer identified the physical form, isotope, and quantity of ANY radioactive material utilized in each component / system?

6.8 If the answer to question 6.6 is NO, does the manufacturer have the appropriate authorization (NRC License or CECOM Authorization) for radioactive material?

6.9 Are optical products (lenses, mirrors, windows, fiber optics, etc.) free of ANY amounts of radioactive material?

6.10 Are radiation markings and labels affixed to all parts or components containing radioactive material?

6.11 Are filters, goggles, or other protective devices identified and/or provided, and are warning signs posted, for all sources of radio frequency, ultraviolet, infrared, highenergy visible, laser, and any other type of hazardous radiant energy?

6.12 If lasers are used, has output power been limited to the lowest power density that could meet the performance requirements?

6.13 Are warning labels affixed near the beam exit port and the laser fire button (as applicable) for all Class III and IV lasers?

6.14 Do lasers conform to the Code of Federal Regulations requirements as detailed in the system specification? If the answer is NO, answer questions 6.15 – 6.17.

6.15 Has a military exemption been approved through the contracting office?

6.16 Do exempt laser systems comply with MIL-STD-1425A?

6.17 Are exempt laser systems provided with a permanent caution label notifying of such?

Section 7: Antenna and Mast Safety

7.1 Are antenna elements and terminals located and/or insulated to prevent shock hazards and RF burns?

7.2 Are antenna tips designed to prevent puncture wounds?

7.3 Are labels provided near the antenna to warn against contact with overhead electrical lines?

7.4 Are antennas provided with blocking capacitors or coated with dielectric material to insulate against overhead electrical lines?

7.5 Where whip antennas can contact overhead electrical lines, are tie down means provided and locations identified?

7.6 Are antennas (extended or tied down) located to avoid RF shock hazards or unacceptable RF radiation levels at seats, hatches, gunner’s rings, and other locations that may be occupied by personnel?

7.7 Are lockout devices provided for remotelyoperated antennas posing a mechanical, RF hazard to maintainers?

7.8 Are winches, collapsible parts, tensioners, and other similar devices provided with safety latches or the like to prevent unintended collapse, free-wheeling, or uncontrolled release of guy cable?

7.9 If the answer to question 7.8 is YES, are the safety latches designed to prevent accidental or intentional bypass?

7.10 For masts greater than 45 feet in height, is a means provided (pulley & rope, etc) to raise any warning beacons that may be required at a particular locality?

7.11 Are level indication devices provided to ensure that the mast is level?

7.12 Are tripping and "clothes- hanger" hazards due to guy wires minimized?

7.13 Can the designated crew size safety setup and tear down the antenna mast?

7.14 Are alternative methods of recovering the mast during emergencies, component failure, ice buildup, or jamming safe?

7.15 Are maximum wind speed limits identified for safe mast assembly, removal, and maintenance?

7.16 Are stakes suitably sized to prevent pull-out in all soil conditions for worst case wind load conditions?

7.17 Are tripods designed so that adjustments can be safely made at any time during erection of the mast should any of the legs sink?

Questions 7.18 through 7.22 pertain to antenna masts integrated onto vehicles or shelters.

7.18 Is an audible and visual warning provided to the driver when movement of the vehicle is attempted while the antenna mast is extended?

7.19 Are mast controls located to assure that the user can continuously and responsibly observe the environment overhead during the raising or lowering of the mast?

7.20 Are positive means, such as momentary contact (continuous pressure) switches, used to raise and lower the mast?

7.21 Are mast controls (hardware and software) designed to avoid unintentional extension of the mast when the vehicle is moving?

7.22 Do antenna signal cables incorporate discharge units to limit voltages due to lightning or unintentional contact with high voltage lines?

Questions 7.23 through 7.34 pertain to Lightning Protection Adequacy. Note: if the mast is electrically continuous, treat it as the down conductor.

7.23 If antenna acts as an aerial terminal, does conductivity equal or better that of #3 AWG solid copper?

7.24 If the answer to question 7.23 is NO (e.g. dish antenna), is the antenna contained within a 45o cone from the tip of a provided air terminal?

7.25 Is down conductor equivalent to #3 AWG solid copper with a minimum strand size of #17 AWG?

7.26 Are joints mechanically strong & corrosion resistant?

7.27 Are resistance of joints less than that of 2 ft.(0.6 m) of down conductor? [R=0.002 ohms or less – negligible resistance]

7.28 Will the down conductor remain free of bends or kinks after repeated use?

7.29 Is down conductor straight as possible with any turns not less than 90 degrees with 8 inch radius of turn?

7.30 Is ground rod at least 1/2 inch in diameter, 8 ft long, copper clad steel or equivalent?

7.31 Is ground rod free of paint?

7.32 Does antenna mast configuration during erection, storage, take-down or operation prevent any component of the lightning protection system from mechanical damage or wear?

7.33 If mast is electrically continuous and is acting as the down conductor, is the ground stud adequate?

7.34 Is a safety tip cap provided for the air terminal?

8.1 For each battery type, identify the manufacturer, model number, chemistry, its purpose, and the quantity used.

8.2 Are the batteries in the Government inventory? If YES, indicate the battery's nomenclature (BAxxx, BBxxx, etc.) and NSN.

8.3 Does the equipment prevent the charging of non-rechargeable batteries when installed?

8.4 Does the equipment incorporate a voltage cutoff to prevent over-discharge of the battery during usage or long term storage?

8.5 Are design features incorporated to prevent charging of rechargeable batteries at high temperatures?

8.6 Are design features incorporated to prevent overcharging of rechargeable batteries?

8.7 Are battery terminals adequately marked with polarity and protected against accidental shorting?

8.8 Is the battery enclosed and protected from mechanical shock and the environment?

8.9 Are battery compartments/enclosures adequately vented to prevent the buildup of explosive gasses?

8.10 Is the battery compartment designed to prevent any leaking liquid/gas from entering the main equipment?

8.11 Is the use of conductive battery covers avoided?

8.12 Where battery boxes house non-rechargeable lithium batteries, are they designed to prevent injury or damage in the event of a violent battery venting or rupture IAW CECOM TB 7, Battery Box Design?

8.13 Has a test been conducted on a CECOM certified test apparatus to verify question 8.12 above?

8.14 Are battery compartments oriented so that in the event of a battery venting, gasses or liquids are directed away from the user’s face and body?

8.15 Is adequate spacing/guarding provided around battery terminals so that tools cannot create an electrical short while working near the batteries or disconnecting the battery cables?

8.16 If the equipment utilizes two batteries in parallel, is electrical circuitry incorporated to prevent reverse or parallel battery charging and to limit any imbalance in current draw?

8.17 Are mechanical or electrical features incorporated to prevent equipment and battery damage due to the incorrect insertion of batteries, as well as the insertion of different batteries having similar dimensions?

9.1 Is a main circuit breaker provided and located in an easily accessible location?

9.2 Are the following protective devices present with suitable indicators to safeguard against operator injury and/or equipment damage: over-speed, over-temperature, over-voltage, overload and short circuit, low oil pressure and low fuel?

9.3 Is the battle short switch provided and located on the main control panel?

9.4 Are all supply connection points clearly marked with terminal information and polarity?

9.5 Are all convenience receptacles provided with overcurrent protection as well as ground-fault circuit interrupter protection?

9.6 Are outdoor receptacles protected from the weather whether or not the attachment plug cap is inserted?

9.7 Is a suitable grounding terminal lug provided and identified for connection to an earth grounding electrode?

9.8 Is an Army approved grounding system fielded with the generator set and is a storage location provided for it?

9.9 Are components, conductors and shielding appropriately located such that overheating, arching, shorting and contact with moving parts is avoid?

9.10 Are battery terminals and cables marked for polarity and provided with nonconductive guards to prevent accidental shorting?

9.11 Are tools to be used near high voltages, such as load terminal wrench, adequately insulated?

9.12 Are fuel lines adequately supported and separated from live wires and cables?

9.13 Are fuel lines projecting through metal apertures protected by grommets and secured to framing members?

9.14 Is thermal and sound insulating material treated with fire retardant, free from noxious fumes, unaffected by battery electrolyte or petroleum derivatives, capable of maintaining it shape position and consistency inherently or by retaining methods, and replaceable?

9.15 Where safe noise levels can be exceeded during operation or maintenance, are appropriate warning labels provided on the equipment?

9.16 Is a type B:C Dry Chemical extinguisher provided with the generator? Specify size.

9.17 Is CARC paint applied only to surfaces that will not exceed 400 deg. F?

9.18 Is the generator exhaust located and directed away from operator designated areas?

9.19 Is the air intake at a sufficient distance from the exhaust?

9.20 Is the fuel tank designed and located in a manner that will not allow spills or overflow to run into the engine, exhaust or electrical equipment?

9.21 Is the fuel tank equipped with a float valve to prevent fuel from overflowing when the set is being fueled from the auxiliary fuel connection?

9.22 Where an auxiliary refueling system is integrated, is a fuel line and jerry can adapter provided for connection to the external fuel container.

9.23 Is the center of gravity and weight of the set distinctly marked?

9.24 Are tie-downs and lifting positions clearly marked?

9.25 Are lifting rings, slings and folk-lift eyes provided?

10.1 Is the vehicle weight properly distributed and is the vehicle laterally stable?

10.2 Does the shelter/equipment center of gravity (COG) fall within the prime mover COG envelope?

10.3 Is the center of gravity and equipment weight distinctly marked?

10.4 Does the system weight (including crew gear and trailer pintle weight) not exceed the load capacity of the prime mover?

10.5 Has the vehicle satisfactorily passed road worthiness testing (e.g. Munson road test)?

10.6 Have no vehicle speed restrictions been placed on the prime mover as a result of system integration?

10.7 Are adequate instructions provided for placement of detached trailers?

10.8 Are safety chains provided to prevent the trailer from detaching from the towing vehicle?

10.9 Will the lifting rings support the total weight of the shelter and the installed equipment?

10.10 Are entries and exits free of obstructions?

10.11 Do the entryway ladders or steps allow safe entrance and exit?

10.12 Is an emergency exit provided and is its location and means of operation labeled?

10.13 Is the emergency exit readily accessible and simple to operate in a high stress, zero visibility situation?

10.14 Where extended operations are required on top of the shelter, are ladders, nonslip surfaces, and guardrails or chains provided for the shelter roof?

10.15 Are egress paths and stairs provided with permanent non-skid surfaces?

10.16 Is adequate illumination provided in all areas?

10.17 Are wall, floor, and ceiling fastenings sufficient to prevent equipment from breaking away, falling, or accidentally dislodging?

10.18 Are accessories secured or stowed to prevent damage when the vehicle is moving?

10.19 Is equipment that is designed to have multiple-input power capabilities, or powered by a generator with multiple-voltage output capabilities, protected from damage when connected to incorrect input power/voltage levels?

10.20 Is an Army approved earth grounding system (ground rod, SWGK, etc) provided?

10.21 Do the grounded and grounding circuits remain isolated throughout the shelter, including at the supply side of the power panel?

10.22 Where a switch is provided to switch between different power sources, is the grounded/neutral conductor also switched to avoid ground loops?

10.23 If commercial inverters are used to generate AC voltage, do they internally provide a neutral-ground bond that is disconnected when an external AC power source is connected?

10.24 Is a ground stud provided at the power entry box and is it suitably identified?

10.25 Are no parts of the vehicle/shelter enclosure or frame used as the AC ground path?

10.26 Are the ground pins of the convenience outlets hard wired to the shelter/system ground point?

10.27 Is lightning surge protection provided at the power and signal entry panels for all cables?

10.28 Are all outdoor receptacles groundfault circuit interrupter (GFCI) protected?

10.29 If the answer to question 10.28 is NO, is the socket configuration of each outdoor receptacle that is not connected to a GFCI unique to its special application and unusable for other applications or as a convenience outlet?

10.30 Are outdoor receptacles protected from the weather whether or not the attachment plug cap is inserted?

10.31 Has the amount of residual leakage current to ground for the entire system been verified through test to be less than 5 mA (3.5 mA if system can be powered from a GFCI protected circuit)? If YES, indicate the amount of current that was measured.

10.32 Is a main power switch provided at the shelter entrance?

10.33 Are safety switches provided at remotelylocated assemblies to protect maintainers?

10.34 Are terminals, plugs, and other exposed parts located within power distribution panels that may exhibit over 30 volts or 20 amps, guarded against accidental contact if exposed during maintenance?

10.35 Where transmitting equipment exists, and room permits, are shorting rods provided?

10.36 Are fuel lines that are inside the shelter made as short as possible?

10.37 Is there a heater fuel shutoff valve inside the shelter?

10.38 Is a fuel line and jerry can adapter provided for connection to the external fuel tank or container?

10.39 Are fuel lines and fuel sources suitably protected from potential damage and sources of heat?

10.40 Are battery compartments designed to prevent gas buildup within the shelter (i.e. forcedair ventilated to the outside)?

10.41 Is a warning device provided to indicate when either the battery vent lid or door is closed or when the ventilation fan is inoperable?

10.42 Is the vehicle exhaust sufficiently separated from shelter openings to avoid an accumulation of carbon monoxide in the shelter?

10.43 Is a Carbon Monoxide (CO) alarm provided and does it meet the storage temperature requirements for the system?

10.44 Is a type B:C Carbon Dioxide or Dry Chemical extinguisher provided for electrical equipment and located near shelter exit? Specify size.

10.45 Are ceilings, walls, and other surfaces adjacent to aisles free of electrical components and switches that are vulnerable to damage by being hit or snagged?

10.46 Are controls, connectors, or other parts that project into walkways or located a foot level protected from mechanical damage?

10.47 Are climbing rings, handholds, rails, etc., provided where needed?

10.48 Are handles recessed rather that extended where they might be hazardous?

10.49 Can EMI emitted by the equipment cause any degraded or erratic operation of other equipment?

10.50 Where equipment is installed on platforms with weapons or turrets, has a test been conducted to ensure that EMI cannot cause uncontrolled turret movement or weapons misfire?

10.51 Where shelter equipment is operated unattended with the vehicle on-the-move, is a smoke alarm provided to warn the vehicle driver of a fire condition in the shelter?

¨ OPERATION ON-THE-MOVE ¨

10.52 Is the shelter to be occupied and operated only when the system is stationary (No on-the–move operations)? If NO, answer questions 10.53 – 10.63.

10.53 Have suitable seats and restraints been provided for the required number of users?

10.54 Is equipment positioned so that personnel will not bump or rub against it when riding over rough terrain?

10.55 Where equipment requires frequent viewing and access, is the operator not required to twist in his seat, which could diminish set belt effectiveness in an accident?

10.56 Is the equipment suitably mounted to prevent loosening or dislodging when the vehicle is driven over rough terrain or in the event of an accident or rollover?

10.57 Can users in the shelter maintain reliable communication with the driver at all times?

10.58 Can operators access fire suppression systems, communications systems, and other critical controls while in a seated position?

10.59 Is adequate air flow and temperature control maintained and can the user access the ECU controls while in a seated position?

10.60 Is the use of batteries that can vent poisonous gasses, such as lithium sulfur dioxide batteries, avoided?

10.61 Is emergency power and lighting available in the event of primary power loss?

10.62 Is adequate noise protection provided for the users?

10.63 Do critical commands that can be accidentally keyed require a second confirming action?

11.1 Does placement of equipment or interconnecting cables avoid interference with pre-existing controls, indicators, or other equipment & panels requiring access?

11.2 Are equipment and associated cables located so that they will not trip, snag, or significantly impede soldier egress through primary or secondary egress paths?

11.3 Is equipment positioned so that personnel will not bump or rub against it when riding over rough terrain?

11.4 Does the equipment location prevent increased personnel injury in the event of a vehicle accident or rollover?

11.5 Are any required corner guards or padding suitable to protect against injury and are they designed so they are not lost or removed during LRU swap-out?

11.6 Is the equipment suitably mounted to prevent loosening or dislodging when the vehicle is driven over rough terrain or in the event of an accident or rollover?

11.7 Where the equipment is installed in up-armor variants, is the equipment suitably mounted to prevent dislodging in the event of blast-induced shock?

11.8 Is the mounting hardware designed and installed such that when the equipment is removed, the remaining mounting hardware does not pose a mechanical hazard to personnel?

11.9 Are sharp or protruding edges, surfaces, or corners avoided with equipment in operating or stowed position?

11.10 Do hinged or adjustable mounting hardware avoid pinch/shear hazards?

11.11 Are mounting screws and bolts properly sized to prevent projections?

11.12 Is the equipment located so that it will not be stepped on or otherwise damaged by personnel during ingress or egress?

11.13 Does equipment location avoid intrusion into step or standing locations?

11.14 Are equipment controls and switches protected from accidental activation?

11.15 Do critical commands that can be accidentally keyed require a second confirming action?

11.16 Are interconnecting cables run neatly and tied down to avoid any tripping and snag hazards?

11.17 Are cables routed and equipment connectors protected against damage from personnel, crew gear, and cargo storage?

11.18 Are cable ties and adhesives suitable to withstand the environment and rough handling?

11.19 Are power cables jacketed and rated for heavy usage?

11.20 Are conductors that supply equipment power properly fused?

11.21 Is the connection of equipment power cables directly to the vehicle battery terminals avoided?

11.22 Where equipment power cables connect to the vehicle power source, are wires properly tagged to show proper polarity and connection?

11.23 Are sharp bends in cables avoided?

11.24 Is the vehicle alternator adequately rated for the added equipment electrical power load?

11.25 If commercial inverters are used to generate AC voltage, do they internally provide a neutral-ground bond that is disconnected when an external AC power source is connected?

11.26 Has the equipment been designed or shielded to prevent degraded or erratic operation of other mission equipment due to electromagnetic interference (EMI)?

11.27 Where equipment is installed on platforms with weapons or turrets, has a test been conducted to ensure that EMI or co-hosted software cannot cause uncontrolled turret movement or weapons misfire?

11.28…