0405-2001 Telemetry Phased Array Antenna Specifications.pdf

0405-2001 Telemetry Phased Array Antenna Specifications Document

SPECIFICATIONS DOCUMENT FOR THE

USAF E-9A

AIRBORNE TELEMETRY PLATFORM

PHASED ARRAY ANTENNA UPGRADE

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Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only; CUI unclassified documents; 23 November 2020. Other requests shall be referred to E-9A Program Office.

0405-2001 Telemetry Phased Array Antenna Specifications Document 2004

TABLE OF CONTENTS

Scope

1.0 Background

2.0 Applicable Documents

2.1 Contractor Provided Documentation

3.0 Specifications

3.1 Phased Array (PA) Definition

3.1.1 Block Diagram

3.1.2 External Interfaces

3.1.2.1 TOC Interface Description

3.1.2.2 RF Receiver(s) Interface Description

3.2 Characteristics

3.2.1 Performance Characteristics

3.2.1.1 Phased Array

3.2.1.1.1 Frequency Range

3.2.1.1.2 Number of Beams

3.2.1.1.3 Gain & G/T

3.2.1.1.4 Polarization

3.2.1.1.5 VSWR

3.2.1.1.6 Sidelobes, Undesired Responses, and Resonances

3.2.1.1.7 Scan Volume

3.2.1.1.8 Beam Update Rate

3.2.1.1.9 Active Gain Characteristics

3.2.1.1.10 Antenna Heading/Orientation

3.2.1.1.11 Power Requirement

3.2.1.1.12 Out of Band Response

3.2.1.2 Processing Requirements

3.2.1.2.1 TOC Commands

3.2.1.2.2 On-Board Command Processing

3.2.1.2.3 Processor Utilization

3.2.1.3 Modes of Operation

3.2.1.3.1 Initialization Mode

3.2.1.3.2 Acquisition Mode

3.2.1.3.3 Tracking Mode

3.2.1.3.4 Coasting Mode

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3.2.2 Physical Characteristics

3.2.2.1 Dimensions

3.2.2.2 Weight

3.2.2.3 DC Power Consumption

3.2.2.4 PA Installation

3.3 Environmental Conditions

3.3.1 Cabin Mounted Equipment

3.3.2 Externally Mounted Equipment

3.4 Materials, Processes, Parts

3.4.1 Developed Equipment

3.4.2 Materials

3.4.3 Arc-resistant Material

3.4.4 Fibrous Material, Organic

3.4.5 Fungus Inert Material

3.4.6 Insulating Material

3.4.7 Lubrication

3.4.8 Magnesium

3.4.9 Rubber

3.4.10 Fasteners

3.4.11 Sandwich Core Material

3.4.12 Flammable Materials

3.4.13 Prohibited Materials

3.5 Processes

3.5.1 Brazing

3.5.2 Finishing

3.5.3 Soldering

3.5.4 Welding

3.5.5 Aluminum Surface Treatment

3.6 Parts

3.6.1 Component Selection Requirements

3.6.2 Limited Use parts and Materials

3.7 Electromagnetic Effects (EME)

3.7.1 Electrostatic Discharge from Human Source

3.8 Nameplates and Product Marking

3.9 Workmanship

3.9.1 Interchangeability

3.9.2 Safety and Human Performance

3.10 Hazardous materials

3.11 Commonality

3.12 Documentation

3.12.1 Engineering Drawings

3.12.2 Engineering Reports/Documentation

3.12.3 Software Documentation

3.12.3.1 Software Functional Requirements Document

3.12.3.2 Software Functional Design Document

3.12.3.3 Software Test Plan

3.13 Logistics

3.13.1 Maintenance

3.13.2 Test Equipment and Special Tools

3.13.3 Fault Detection and Fault Isolation

3.13.3.1 Power On Mode

3.13.3.2 Operation Mode

3.13.3.3 Off-Line Test Mode

3.14 Quality Assurance Provisions

3.14.1 General

3.14.2 Responsibility for Tests

3.14.3 Verification Methods

3.14.3.1 Analysis

3.14.3.2 Demonstration

3.14.3.3 Test

3.14.3.4 Inspection

3.14.4 Qualification Verification Matrix

3.14.4.1 Verification Overview

Scope

This document describes the specifications for the E-9A phased array (PA) antenna.

Two additional specification documents shall be produced for the PA mechanical installation and the new telemetry operators’ console. These specifications have been tailored to produce a

PA that meets the E-9A mission performance standards. The specifications outlined in this document will be explicitly delineated in the verification matrix attached to this document.

This specifications document has been created in response to FY04/05 POM (Program

Objective Memorandum) funding for the upgrade of the E-9A Telemetry Relay System (TMRS).

The primary and most complex portion of the TMRS upgrade is the replacement of the PA antenna used to track S-Band telemetry sources. This document establishes the performance, design, interface, and environmental requirements for the S-Band PA antenna for the US Air

Force E-9A aircraft. The performance requirements for the PA are derived from present and future operational requirements outlined in the “E-9A Roadmap” dated FY04, maintenance considerations, and the Inter-Range Instrumentation Group (IRIG) standards. This document includes all of the PA requirements and specifications down to the antenna subsystem level.

1.0 Background

At the time of its design in the early 1980s, the E-9A phased array antenna was considered state-of-the-art technology. Today, the phased array antenna is 18 years old and contributes to the E-9A operating at max electrical power consumption and gross weight limits.

The antenna components that were designed and built in 1984-87 are obsolete and no longer supported by the original manufacturer. They are unique, custom-built units, many of which are single point failure items becoming unreliable, expensive, and difficult to procure. The Antenna

Control Computer (ACC) consists of a 286 (8 MHz) processor that controls all of the antenna functions. The computer is application design specific with no allowance for spares or manufacturer support. The communication link between the antenna and the ACC is very cumbersome and made of heavy gauge copper wire which is very difficult to troubleshoot and contributes to the 3,100 pound weight of the phased array antenna. Additionally, the software that controls the antenna and displays the status of the antenna is not owned by the government, eliminating the capability for the government or CLS contractor to modify or repair the software.

The antenna has a 120-degree horizontal field of view and fixed 10-degree vertical field of view. Although the antenna is directional, it is not steerable in the vertical field of view, thus requiring changes in aircraft bank angle by the pilot (based on the test profile) to capture telemetry data. Using the aircraft to steer the antenna impacts the tracking capability of the antenna and degrades telemetry data. Due to the over water operating environment, the antenna is very susceptible to corrosion and numerous maintenance man-hours are spent treating corrosion on the antenna components and trying to prevent further corrosion. When the

TMRS upgrade was initially approved (FY97), the only cost-effective means to prolong the life of the phased array antenna was to replace its internal components, providing minor performance enhancements and minimal weight reduction. With the advent of affordable silicon-based micro-circuitry in the late 1990s, it has now become cost-effective to replace the entire phased array antenna rather than attempt to remanufacture and redesign existing components. New phased array antennas are now made of materials similar to silicon-based personal computer boards.

Circuitry which once took up the space of a handheld computer are now located in a single component barely visible to the naked eye with greater performance and one tenth the weight.

The combination of lighter weights, reduced size, and increased circuitry performance will increase the capabilities of the E-9A phased array antenna, allowing for greater loiter times, increased mission payload, and support of high-altitude profiles.

The current antenna was designed to support telemetry signals residing in S-Band (2.2 -

2.4 GHz) operating at data rates of 2 Mb/s in an over the horizon (OTH) environment. Since its inception, new requirements have evolved to include telemetry data rates up to 20 Mb/s and mission profiles with altitudes greater than 50,000 feet. The Eglin Gulf Range (EGR) ground stations have the capability to track and receive telemetry data from sources at and above

50,000 ft. but a serious risk of data loss arises when mission profiles start at high altitudes and terminate at low altitude targets near or on the surface. In those instances, the ground stations lose telemetry when the source goes OTH while the E-9A does not. The E-9A is the only EGR asset with Line Of Sight (LOS) capability for missions both preplanned as OTH and missions in which telemetry reception begins as LOS and transitions to OTH. The following document details the requirements and specifications for the new E-9A phased array antenna.

2.0 Applicable Documents

The following documents form a part of this specifications document to the extent specified herein. Unless a specific issue or revision is listed, the referenced documents shall be of that issue or revision in effect on the date of initial release of this document. In the event of a conflict between the documents referenced and the contents of this specifications document, the contents of this document shall apply.

Document Title Document Description

IRIG 106-01 Telemetry Standards, Range Commanders Council (Revised Feb 01) http://jcs.mil/RCC/PUBS/pubs.htm

IRIG 118-03 Test Methods for Telemetry Systems and Subsystems, Volume I: Test Methods for Vehicle Telemetry Systems

IRIG 118-02 Test Methods for Telemetry Systems and Subsystems, Volume II: Test Methods for Telemetry RF Subsystems

MIL-STD-810E Environmental Test Methods and Engineering Guidelines MIL-STD-461E Control of Electromagnetic Interference, Emissions, and Susceptibility MIL-STD-1472E Human Engineering Design Criteria for Military Systems MIL-STD-882C System Safety Program Requirements MIL-STD-810E Environmental Engineering Considerations & Lab Tests MIL-STD-45662A Calibration System Requirements MIL-STD-1132 Switches And Associated Hardware, Selection And Use Of MIL-STD-1285 Marking Of Electrical And Electronic Parts MIL-STD-1331 Parameters To Be Controlled For The Specification Of Microcircuits MIL-STD-1353 Electrical Connectors, Plug-In Sockets And Associated Hardware MIL-STD-202 Test Methods For Electronic And Electrical Component Parts

MIL-STD-461 Requirements For The Control Of Electromagnetic Interference Emissions

MIL-STD-462 Measurement Of Electromagnetic Interference Characteristics MIL-STD-704 Aircraft Electric Power Characteristics MIL-STD-792 Identification Marking Requirements For Special Purpose Components

MIL-STD-981 Design, Manufacturing And Quality Standards For Custom Electromagnetic Devices

MIL-HDBK-454 General Guidelines for Electronic Equipment (30 June 92) MIL-HDBK-217F Reliability Prediction of Electronic Equipment MIL-HDBK-1530 Aircraft Structural Integrity Program General Guidelines For

2.1 Contractor Provid

The following docume documentation related to this

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Table 2.0-1 Applicable Documents ed Documentation nts shall be developed to ensure the government receives all upgrade. KING AEROSPACE shall provide expert input and documentation to include critical reviews of all vendors’ documentation. The following documents, delineated by vendor, shall be produced by this effort:

Document Vendor PA Antenna Software Interface Control Document (ICD) Ball Aerospace & Technologies

PA Software Functional Requirements Document Ball Aerospace & Technologies

PA Software Functional Design Document Ball Aerospace & Technologies

PA Software Test Plan Ball Aerospace & Technologies

PA Final Acceptance Test Data Report Ball Aerospace & Technologies

Telemetry Operator Console (TOC) Software ICD Orbital Network Engineering

PA Mechanical Installation ICD Ball Aerospace & Technologies and King Aerospace

PA Radome Mechanical ICD King Aerospace & TBD

TOC Mechanical ICD Orbital Network Engineering and King Aerospace

PA Antenna Electrical ICD Ball Aerospace & Technologies

TOC Electrical ICD Orbital Network Engineering and King Aerospace

PA Antenna RF ICD Ball Aerospace & Technologies

Amended E-9A Antenna Radiation Study Report Ball Aerospace & Technologies

3.0 Specifications

3.1 Phased Array (P

The S-Band phase which receives 2200 – 240 include the following: recei the Antenna Control Com power condition system.

analysis. The array is act in Section 3.1.1. The PA simultaneously and shall telemetry receivers. In n second beam solely for tr operator shall also have th system shall have internal

Magnetic Interference (EM

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Table 2.1-1 Required Vendor Documentation

A) Definition d array (PA) antenna is an assembly installed on the E-9A Aircraft

0 MHz RF signals. The PA is comprised of several subsystems that ve phased array antenna, array power and control signal distribution, puter (ACC) for antenna beam processing functions, and the DC

The ACC shall record mission parameters real time for post mission ive and electronically steerable. An antenna block diagram is shown shall be capable of receiving ten independent signal sources interface with the Telemetry Operator Computer (TOC) and the oisy signal environments, the PA shall allow the operator to use a acking while another beam shall be used for data. The telemetry e capability to direct the PA to search in pre-defined quadrants. The filtering at the element level to protect the array from external Electro-

I). The PA shall have a single face consisting of 30 sub-array panels.

A section of the existing PA Radome will be supplied to BATC for evaluation and consideration during the design of the PA.

The sub-array panel contains the antenna elements, EMI filters, limiter/Low Noise

Amplifiers (LNA) modules, power splitters, phase shifters, and power combining networks. In addition to these RF components, the panels shall contain an embedded controller that distributes the control signals for the phase shifters for each beam and performs Built In Testing

(BIT) on the panel. The antenna assembly shall be designed for installation on the E-9A aircraft on the same location as the current E-9A PA antenna.

3.1.1 Block Diagram

The PA sub-system block diagram (proposed by BATC) showing all the external interfaces is shown below in Figure 3.1.1-1.

Figure 3.1.1-1 Antenna Assembly Block Diagram

3.1.2 External Interfaces

The external interfaces to the ACC shall include two serial ports to the TOC and the ability to convert 20 analog signals (10 AGC and 10 Track AM) from the telemetry receivers.

Additionally, 28 VDC aircraft power will also be provided. The exact scaling and format of the parameters being sent to and from the ACC & TOC shall be explicitly defined in the

PA Software ICD.

3.1.2.1 TOC Interface Description

The ACC interfaces with the TOC for control, exchange of equipment/aircraft parameters, and real time antenna status. The real time status provides the telemetry operator with a visual perspective of how the antenna is functioning. The update rate from the ACC to the TOC for real time display shall be 50 samples per second. The data from the ACC shall be sent to the TOC where it will be displayed for the telemetry operator. Serial port one from the

ACC to the TOC shall provide real time information to include the following parameters:

ACC TO TOC

Beam (1..10)

AGC

Track AM

Azimuth

Azimuth Offset

Elevation

Elevation Offset

Beam State (Search, Track, Coast)

System Status (BIT)

The second ACC serial port shall provide the capability for the TOC and ACC to exchange the following parameters:

TOC TO ACC (mission)

Beam Frequency (1..10)

Azimuth Offset (right & left)

Elevation Offset (up & down)

IRIG Time, 1/200 seconds

Receiver Type

Record (low or high speed)

Panel XX per beam (on or off)

Sector Search

Offline Test

Transfer Mission Data

Pre-mission Setup Parameters

Providing this capability on the second serial port eliminates interrupting serial port one during a mission. This serial port shall also act as the interface for all off-line testing and real time user input to include changing beam width by de-activating panels and providing aircraft position information to the antenna controller. All threshold values and constants for the antenna tracking algorithms will be able to be changed from the TOC. The parameters to change threshold values shall be provided by BATC in the PA Software ICD. The commands to test the antenna for both BIT and system testing shall be provided by BATC in the BATC

Software ICD. The TOC will be connected to a network analyzer and shall interrogate the ACC through the second serial port to measure and record the PA performance. During real-time missions, the telemetry operator shall have the capability to adjust the beamwidth by turning on or off specific LNA’s on the antenna.

3.1.2.2 RF Receiver(s) Interface Description

The telemetry receiver utilized by the current E-9A phased array is the MTR-602. This receiver and its modern counterpart, the Compact Telemetry Receiver (CTR) shall be interface tested into the new PA.

For both receivers, the Track AM output is via an absolute value detector with best signal selected between channel 1 and channel 2. The Track AM outputs up to 4 volts peak-peak (vpp) into 75 ohm load with less than 2% distortion at 50% modulation and less than 5% distortion at 90% modulation. Track AM sensitivity is 2 vpp into 75 ohms at 50% modulation.

The AGC monitor output is 0-5 vdc with linearity of 50 mv/dB +/-10% over any 30 dB range from 10 dB IF SNR to –10 dBm at the receiver input and 50 mv/dB +/-20% from –6 dB IF

SNR to –10 dBm at the receiver input. AGC time constants for the MTR-602 are 0.1, 1, 10, 100, and 1000 msec while the AGC time constants for the CTR are 0.01, 0.1, 1, 10, and 100 msec.

The remote capability of the MTR-602 is limited to only frequency reporting while the

CTR is fully remote controllable. Regardless, the frequency of each receiver, for squint correction, shall be made available in the TOC to ACC serial link.

Both receivers shall be provided to BATC for integration & test with the PA. The TOC shall have the capability to communicate to the ACC which receiver type is on each beam. This information shall be provided on the second serial port.

3.2 Characteristics

3.2.1 Performance Characteristics

The antenna shall search, acquire, track, and receive telemetry from up to 10 spatially separated sources. Acquisition and tracking shall be accomplished on any S-Band frequency within the range specified in 3.2.1.1.1. The difference in antenna gain, between two emitters separated in frequency by up to 30 MHz should not be greater than 1.5 dB. The array shall be positioned mechanically such to minimize the effects of the aircraft wing and engine nacelle.

The mechanical angle of declination from the horizontal axis shall be 4° degrees based on the current PA mechanical installation. In addition, design of the PA shall include considerations to minimize blind spots, resonances, grating lobes, and surface wave effects.

3.2.1.1 Phased Array (PA)

3.2.1.1.1 Frequency Range

The PA shall operate and meet all the performance specifications over the operating bandwidth at S-Band from 2200 MHz to 2400 MHz for all stated RF performance parameters.

The instantaneous bandwidth shall be ≤ 30MHz. The band center frequency, designated f0, shall be 2300 MHz.

3.2.1.1.2 Number of Beams

The S-Band array shall be capable of receiving 10 independent signals from 10 separate independent sources simultaneously with each beam producing a single agile electronically steerable beam. If the source signal levels are excessively low, the operator shall have the option to use two beams per source - one beam shall act as a tracking beam (using dither) while the other beam shall be used to receive telemetry data. The beam dither shall operate using a default beamwidth but will also have the capability to increase/decrease dither beamwidth with operator input from the TOC.

3.2.1.1.3 Gain & G/T

The current E-9A PA has a 60 dB/MHz dynamic range from incident signal to the receiver IF output. To maintain this dynamic range without redesigning the receivers, the gain from the new PA cannot exceed 28 dB.

The S-Band array G/T shall be referenced to the antenna input, and shall include all losses with the antenna element, filter, limiter, LNA, phase shifters, power splitters and combiners, transmission lines, connectors, etc. Each beam shall have a G/T ≥ 10.5 dB/K at the array plane’s boresight. The G/T for any scan angle within ±60° in azimuth and ±15° in elevation from the array plane’s boresight shall be ≥ 4.5 dB/K. The G/T at the extreme edges of the array and at max frequency shall have a monotonic Cos2 roll off. All G/T measurements will not include any radome loss.

3.2.1.1.4 Polarization

The S-Band array shall be capable of receiving orthogonal linearly polarized signals

(slant left & slant right). The slant left to slant right beam isolation shall be ≥ 20 dB.

3.2.1.1.5 VSWR

The S-Band array output VSWR shall be ≤ 2.0:1 over the band of operation, and shall include effects of all components in the system and be valid for all scan angles of the array.

3.2.1.1.6 Sidelobes

The worse case sidelobes of the S-Band array shall be no greater than –11 dB in azimuth and –11 dB in elevation below the level of the main lobe for 95% of the scan volume.

The 5% is located at the upper and lower corners of the array at max frequency.

3.2.1.1.7 Scan Volume

The PA shall provide beam steering of ± 60° in azimuth and ± 15° in elevation from the boresight of the array. The electrical boresight of the antenna shall be defined by BATC.

3.2.1.1.8 Beam Update Rate

The beam update rate shall be fast enough to provide sufficient closed loop tracking for sources that are 10 to 100 miles away at speeds up to mach 5. This update rate includes the time to calculate the next beam state, distribute this to the panels, and update the phase shifters. For paired beams (tracking 5 independent targets) the tracking beam will be updated at a rate of 1000 Hz and the data beam will be updated at a rate of 200 Hz. As the number of targets being tracked decreases, the update rate will increase. For the case where all beams are independent, the beams will be updated at a 500 Hz rate. This would be the slowest update rate possible.

3.2.1.1.9 Active Gain Characteristics

The PA shall be stable from oscillations at the RF signal outputs over all operating temperature and load ranges specified sections 3.3.1 & 3.3.2 and with loads that can vary from short circuit to open circuit due to patch panel operator inputs.

3.2.1.1.10 Aircraft Heading/Orientation Adjustment

The TOC shall not provide the PA with the aircraft heading and orientation (pitch and roll). It is not envisioned that the PA will require this information to operate properly. In the future, if the need arises for this information, it shall be available from the TOC.

3.2.1.1.11 Power Requirement

The PA power requirements shall be 28 VDC +/-15%, ≤ 66 amps. The ACC shall be capable of being remotely powered on by an illuminated power switch.

3.2.1.1.12 Out of Band Response

The onboard emitters will primarily drive the out of band response requirements for the

PA. BATC shall amend the E-9A Antenna Radiation Study Report to determine the filter requirements and maximum safe incident field strength. This will include using analysis to determine the amount of filter rejection required and how it should be distributed using

MIL-STD-461E for guidance. After completion of the antenna design, BATC shall provide KA with the system filter rejection limitations.

3.2.1.2 Processing Requirements

3.2.1.2.1 TOC Commands

The TOC shall be capable of accepting commands from the ACC.

3.2.1.2.2 On-Board Command Processing

The PA ACC shall have sufficient on-board processing and memory to control pointing and shaping of the beams and recording of tracking parameters to be defined in the PA ACC

Software ICD. Recording of parameters shall be initiated remotely from the TOC and will have three different modes: none, slow (100 samples per second up to 6.0 hours), and fast (200 samples per second up to 45 min). The parameters to be recorded shall be:

ACC RECORD PARAMETERS

Beam (1..10)

AGC

Track Error

Azimuth

Azimuth Offset

Elevation

Elevation Offset

Beam State (Search, Track, Coast)

System Status (BIT)

IRIG Time, 1/200 seconds

3.2.1.2.3 Processor Utilization

The PA ACC processor software shall not exceed 70 percent utilization of memory capacity used for program execution, processing, and configuration storage of channel mapping to the selected beam.

3.2.1.3 Modes of Operation

The ACC shall provide for initialization of the antenna system, execution of the tracking mission, system status output to the TOC, and generation of mission status files.

3.2.1.3.1 Initialization Mode

The initialization of the PA shall consist of loading frequencies for telemetry beams to be used for squint correction, setting the initial tracking state as acquisition, and turning on the antenna’s phased array panels.

3.2.1.3.2 Acquisition Mode

During a mission, the PA ACC shall be responsible for target acquisition, tracking, and

Continuous Built-In Tests (CBIT). The acquisition phase of the mission shall be concerned with locating the target. Acquisition shall perform a sequence of scans, during which the ACC will search a given sector incrementally. At each increment the receiver’s signal strength shall be read and the maximum signal encountered during the scan will be retained. The presence of a target is indicated when the retained maximum signal exceeds a predetermined (user-adjustable) threshold value. The beam direction for this maximum signal return shall be saved and additional smaller scans are performed to locate the target more precisely. This is done because of the possible position change that could occur during the large sector scans. When the last scan is small enough to insure a small initial pointing error, the state of the beam shall be changed to track. If a scan does not produce a signal return that exceeds the threshold, the previous larger sector space is scanned.

Except for the initial scan, scan sectors shall be determined by the target bearing related to the maximum signal strength encountered during the previous scan, or to where the target disappeared during tracking. A half space is added to and subtracted from this bearing to define the endpoints of the sector. There shall be a minimum of five scan sectors implemented in the acquisition scheme. The first sector shall search the antenna’s entire 120-degree azimuth field of view and 30-degree elevation field of view simultaneously in a maximum of 1.0 second.

If a target has been detected, the second (smaller) sector shall be scanned around the vicinity of target detection in a maximum of 0.15 seconds. The time thresholds for acquisition shall be user changeable from the TOC. If the target is again detected, the third sector shall be scanned. This scanning of narrow search sectors continues until the completion of the final scan sector in which the state of the beam is changed to track. If the target is lost at any scan sector, the search returns to the previous scan sector (e.g. if the target was lost following the 4th scan sector, the next scan sector implemented would be the 3rd sector).

3.2.1.3.3 Tracking Mode

The tracking mode shall confirm the presence of the target by comparing the received target signal strength (AGC level) with a minimum acceptable value. If the AGC level drops below this minimum, the beam state will be changed to coast. While the target is present, the

PA ACC shall compute the next target bearing, based on tracking error signal developed on that beam’s tracking circuitry. The tracking algorithm shall predict the target’s bearing. This bearing shall be adjusted by positive and negative offsets to define a pair of lobes. The actual location of the target shall be determined from signals received by the offset lobes.

3.2.1.3.4 Coasting Mode

The coast mode shall be executed if the indicated signal strength drops below a minimum level during mission track. Coasting is provided to allow recovery of a target lost through short-term signal fading, without requiring reversion to the acquisition mode, and thus a search of the entire antenna’s field of view.

The coast algorithm shall extrapolate the target motion, as estimated from the two previous target bearings maintained by the track function. During coast, the beam command angle shall advance at this rate until:

a. Increased AGC level indicates reappearance of the target, or

b. An adjustable max/min time interval has elapsed, without the target’s appearance.

In the case of AGC recovery, the beam state shall return to track and normal tracking will resume. In the case of timeout, the beam state shall revert to acquisition, and a search for the target shall be conducted over a reduced scan area centered around the last valid pointing angle.

3.2.2 Physical Characteristics

3.2.2.1 Dimensions

The PA shall be designed within the array envelope dimensions shown in Table 3.2.2–1 while the ACC shall be designed to fit in an EIA 19” rack. BATC shall provide, as a minimum, the drawings defining the items listed below:

a. Physical Dimensions:

Parameter Per Unit Measurement Count Total Panel Size 24" x 12" x 3" 30 720" x 36" x 3” ACC Height 3U – 28” deep 1 N/A

Combiner Size 8" x 8" x 2" 100 N/A

b. Mo

c. Ele

d. Co

e. P

f. M

g. Th ch

Table 3.2.2-1 Phased Array Size “Not-to-Exceed” Characteristics unting Requirements and Interfaces ctrical Connector Locations, Orientation and Part Number Identification nnector Reference Designator in Assignments ethod of Subsystem Identification e RF cable between the PA assembly and the Receiver defining the cable aracteristics in the Receiver-Antenna ICD.

3.2.2.2 Weight

The total combined weight of the PA (including power supply, antenna controller, control electronics, RF electronic & radiating elements, cable and harness between envelopes, and calibration hardware) shall be designed to not exceed the parameters in Table 3.2.2-2.

Parameter Per Unit Measurement Count Total Panel Weight 14 Lbs 30 420 Lbs ACC Weight 30 Lbs 1 30 Lbs

Combiner Weight 2 lbs 100 200 Lbs Power/Control Cable N/A N/A 100 Lbs

RF Cable N/A N/A 200 Lbs

3.2.2.3 D

The m environmenta

Table 3.2.2-3.

Para

Pane

ACC

3.2.2.4 P

The P accessible for installation pa

3.2.2.5 Co

The po sealed (MIL-C combiner con

Table 3.2.2-2 Phased Array Weight “Not-to-Exceed” Characteristics C Power Consumption aximum power consumption of the PA during any operating mode and over all l conditions shall be designed to within the array power consumption shown in meter Per Unit Measurement Count Total l Power 2 amps (28 VDC) 30 60 amps (28 VDC) Power 6 amps (28 VDC) 1 6 amps (28 VDC)

Table 3.2.2-3 Phased Array Power “Not-to-Exceed” Characteristics A Installation

A shall be installed on the E-9A aircraft and shall be under a radome that is routine maintenance and repair. When completed, the antenna mechanical ckage shall be made available to BATC.

nnectors wer and control connectors used for the ACC and PA shall be environmentally

-26482 Series I and II). The RF connectors shall be SMA for all panel and RF nections. The RF connectors to interface with the aircraft shall be TNC.

3.3 Environmental Conditions

3.3.1 Cabin Mounted Equipment

The PA equipment installed in the interior of the aircraft shall withstand the following environmental conditions (items a, b, and d shall be tested via approved methods while the remaining items shall be validated using analytical methods):

a. Temperature/Altitude.

1. Operating. The cabin-installed equipment shall be capable of continuous operation in a cabin temperature range of -10°C (14°F) and 36°C (97°F); and a pressurized cabin altitude of 0 to 10,000 feet.

2. Non-Operating. -35°C (-31°F) to +85°C; 0 to 30,000 feet.

b. Humidity. The cabin installed equipment shall continually withstand the effects of humidity up to 95%, including conditions of condensation when non-operating and up to 75% humidity, non-condensing, when operating.

c. Shock.

1. Operating. All cabin equipment shall meet 9 G’s, 11 ms half sine pulse in each of the 6 principle axis directions.

2. Non-Operating. All cabin equipment shall meet 15 G’s, 11 ms half sine pulse in each of the 6 principle axis directions. A higher shock rating is required for non-operating conditions for transportation and storage.

d. Vibration. The cabin located equipment shall continually operate during takeoff and landing. This equipment must meet the following sinusoidal vibration levels:

i. 0.010 in. DA 5-55 Hz

) ii. 1.5 G 55-500 Hz

e. Sand and Dust. The internally mounted equ both operating and non-operating conditions, e

f. Fungus. All equipment shall be resistant to the

g. Salt Spray. The equipment mounted internally operating and non-operating conditions, expos

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(All 3 major axes with operating equipment ipment shall continually withstand, in xposure to sand and dust particles.

promotion or growth of fungus.

shall continually withstand, in both the ure to a salt-sea atmosphere.

h. Acoustic Environment. The internal PA equipment shall continually withstand the acoustic conditions. The acoustic level is 140 dB (dB referenced to 2 X 104 dynes/cm2).

3.3.2 Externally Mounted Equipment

The PA antenna equipment installed on the exterior (outside the pressurized fuselage) shall withstand the following environmental conditions (items a, b, and d shall be tested via approved methods while the remaining items shall be validated using analytical methods):

a. Temperature/Altitude.

1. Operating -35°C (-31°F) to +71°C (160°F) 0 to 30,000 feet

2. Non-operating -35°C (-31°F) to +85°C (185°F) 0 to 30,000 feet

b. Humidity. The equipment externally mounted shall continually withstand the effects of humidity up to 100% including conditions wherein condensation takes place. The equipment shall withstand these humid conditions both operating and non-operating.

c. Shock.

1. Operating. All externally mounted equipment shall meet 9 G’s, 11 ms half sine pulse in each of the 6 principle axis directions.

2. Non-Operating. All externally mounted equipment shall meet 15 G’s, 11 ms half sine pulse in each of the 6 principle axis directions. A higher shock rating is required for non-operating conditions for transportation and storage.

d. Vibration. The equipment externally mounted shall continually operate during takeoff and landing. This equipment must meet the following sinusoidal vibration levels:

i. 0.010 in. DA 5-55 Hz (All 3 major axes with operating equipment) ii. 1.5 G 55-500 Hz

e. Fluid Susceptibility. Fluids encountered in airborne and ground operations shall not adversely affect exposed materials. These fluids include but are not limited to; fuel, hydraulic fluid (Skydrol), lubricating oil, alcohol, de-icing fluid, and water.

f. Sand and Dust. The externally mounted equipment shall continually withstand, in both operating and non-operating conditions, exposure to sand and dust particles.

g. Fungus. All externally mounted equipment shall be resistant to the promotion or growth of fungus.

h. Salt Spray. The externally mounted equipment shall continually withstand, in both the operating and non-operating conditions, exposure to a salt-sea atmosphere.

i. Acoustic Environment. The externally mounted PA components shall continually withstand acoustic conditions. The acoustic level is 140 dB (dB referenced to 2 X

104 dynes/cm2).

3.4 Materials, Processes, and Parts

3.4.1 Developed Equipment

The selection of materials and processes for newly manufactured equipment shall use

MIL-HDBK-1587 and MIL- HDBK–1568 for guidance only.

3.4.2 Materials

All materials shall be selected IAW the following paragraphs and shall be assessed to be suitable for their intended function.

3.4.3 Arc-resistant Material

Material used for insulation of electrical power circuits, where arcing is possible (such as connector inserts, relays, circuit breakers, etc.) shall be IAW MIL-STD-454, Requirement 26.

3.4.4 Fibrous Material, Organic

The selection and use of organic fibrous material shall be IAW MIL-STD-454, Requirement 44. The use of wood and wood products is prohibited in all structural applications, interior or exterior.

3.4.5 Fungus Inert Material

The selection of material for the control of moisture and fungus shall be lAW MIL-STD-

454, Requirement 4.

3.4.6 Insulating Material

Electrical insulating materials shall be selected and used IAW MIL-STD-454, Requirement.

3.4.7 Lubrication

The criteria for the choice of lubricants shall be IAW MIL-STD-454, Requirement 43.

3.4.8 Magnesium

All magnesium alloys shall be subject to approval by the government prior to use.

3.4.9 Rubber

Rubber materials shall conform to the criteria defined in ASTM D 2000.

3.4.10 Fasteners

Ferrous alloy components and inside/outside-threaded assemblies/fasteners shall be cleaned and plated with cadmium per QQ-P-4l6 to a minimum of 0.0003 inches unless thread tolerances dictate a different thickness. Aluminum fasteners shall be anodized per MIL-A-8625.

3.3.11 Sandwich Core Material

If polyurethane is used as a foamed, skin stabilizing sandwich core material in structural areas such as walls, only the polyether, non-reverting type shall be used.

3.3.12 Flammable Materials

Flammable materials shall not be used except as permitted by MIL-STD-454, Requirement 3. Interior coated fabrics; seat cushion coverings, carpeting, etc. shall be made of self-extinguishing materials. Interior materials containing wood, polyvinyl chloride (PVC), PVC coated fabrics, modified aramid, and phosphorous based fire retardant treated cotton are prohibited due to the toxic level of their thermal decomposition products should a fire occur.

3.3.13 Prohibited Materials

Vinyl, polyvinyl chloride, household/architectural type caulking compounds and corrosive type RTV (yields acetic acid during curing) materials are prohibited for use in all forms, interior or exterior.

3.5 Processes

3.5.1 Brazing

Brazing shall be IAW MIL-STD-454, Requirement 59.

3.5.2 Finishing

Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be used in contact with each other IAW MIL-STD-889. Metals shall be of corrosion resistant type, treated to resist corrosion due to atmospheric conditions likely to be encountered in storage or normal service IAW MIL-STD-810 and MIL-STD-210. Surfaces shall be given a protective finish lAW MIL-STD-171E for new equipment.

3.5.3 Soldering

Soldering shall be IAW MIL-STD-454, Requirement 5.

3.5.4 Welding

Welding shall be IAW MIL-STD-454, Requirement 13.

3.5.5 Aluminum Surface Treatment

Chemical conversion coating and/or anodizing of aluminum alloys shall conform to

MIL-C-5541 and/or MIL-A-8625 respectively.

3.6 Parts

3.6.1 Component Selection Requirements

The following limitations apply to electronic parts selected for use on newly designed equipment:

• Wet tantalum capacitors shall not be used in the design without specific written approval from the government.

• Custom designed integrated and hybrid circuits shall be avoided unless no reasonable alternative exists.

• Certain chemicals have been identified in the Occupational Safety and Health Act

(OSHA) as cancer producing substances (carcinogens). Before using any materials that might contain these chemicals, they should be evaluated lAW the Code of

Federal Regulations, Title 29, Part 1990. Consideration of the toxicity of a substance shall be given priority in material selection. Materials that contain polychlorinated biphenols (PCB) shall not be used.

• Polyvinyl chlorides (PVC) shall not be used in any application including, but not limited to, insulation, wire/cable sheathing, sleeving and/or as a structural material for part or component fabrication. PVC insulated wire and/or cable shall not be used;

rather, the contractor shall select one of the many suitable non-PVC insulated wires and/or cables.

3.6.2 Limited Use Parts and Materials

The parts identified below are limited use parts and materials and shall not be used in the system unless the following criterion has been met: (1) a trade study demonstrates that no acceptable alternative exists. (2) suitable protection against the part weakness has been incorporated (3) approval by the government has been granted.

1) Silicon-controlled rectifiers and triacs.

2) Semiconductors in hot-weld cap-to-header hermetically sealed metal cases, particularly power transistors of the stud mount case styles including TO-3, TO-11, TO-59, TO-61, and TO-66.

3) Non-metallurgical bonded diodes.

4) Non-locking microcircuit and semiconductor sockets except for test or ground support equipment not subject to shock and vibration.

5) Non-solid aluminum electrolytic capacitors (prohibited for infrequent use or long term storage applications; do not use with excessive ripple currents or reverse voltage; and not recommended for airborne applications, especially high altitude).

6) Non-solid electrolytic (wet slug) capacitors other than MIL-C-39006/22 or

MIL-C-39006/25 tantalum case capacitors (greater concern for high altitude applications).

7) Non-hermetic plastic dielectric capacitors, especially in high moisture environments.

8) Non-trip-free circuit breakers.

9) Reed relays in airborne applications.

10) Open type construction or grades of transformers and inductors - use only in hermetically sealed or encapsulated assemblies.

11) Tin or tin alloy plated connector contacts (use gold plating).

12) Gold connector contacts with less than 50 micro inches of gold outer plating.

13) Aluminum electrical aircraft wire.

14) Gold wire for fly leads in hybrids subject to radiation environments.

15) Silver-plated wire and braid and cables containing silver-plated wire or braid in high humidity or corrosive environments.

16) Wire and cable having polyvinyl chloride (PVC) or polyimide (Kapton) (MIL-W-

81381) insulating material for airborne applications (not first choice due to restrictions and disadvantages).

17) Wire insulation with cotton or linen in the insulation material, unless the material is cut off from the atmosphere.

18) Cotton and linen as filler material in electrical insulator.

19) Type GE woven glass base, epoxy glass Printed Wiring Board (PWB).

20) Plastic sheets for PWB that are laminated thermosetting, cotton-fabric base, phenolic resin.

21) Sheet spring nuts.

22) MIL-A-46106 room-temperature-vulcanizing materials (corrosive; prohibited for spacecraft).

23) Threaded fasteners with graphite-based anti-seize threads.

24) Carbon or graphite marking inks used on Electronic, Electrical and

Electromechanical (EEE) parts.

25) Lubricants with silicone compound (concern with silicone particles migrating to other surfaces and forming a non-removable coating).

26) Graphite-based lubricants (corrosion concern).

27) Anti-seize compound that is white lead based (for threaded fittings) (corrosion concern).

28) Regulated materials such as carcinogens.

29) Polyurethane foam material (flammability and toxicity hazards must be eliminated).

30) Cadmium, zinc, or selenium, except internal to hermetically sealed parts with leak rates less than 1x10^4 atm-cm/sec^2.

31) Zinc outer plating finish (corrosion concern in salt air).

32) Materials (encapsulants) subject to reversion used in parts such as transformers and hybrids.

33) Electrical tape with linen or cotton.

34) Non-fungus resistant electrical tape.

35) Use of cleaning solvents that degrade non-hermetic components such as Plastic

Encapsulated Microcircuits (PEMs) and plastic encapsulated semiconductors.

36) Cleaning fluids and other chemicals used on titanium parts, which can cause stress corrosion cracking (e.g., hydrochloric acid, trichloroethylene, carbon tetrachloride, all chlorides, chlorinated cutting oils, Freon, and methyl alcohol).

37) Cleaning of aluminum and aluminum alloy parts with abrasives containing iron, such as steel wool, iron oxide, or steel wire.

38) Cleaning solder joints with steel wool.

39) Tin coatings, except that tin-plated electrical wire is acceptable and electrical/electronic part terminals and leads may be coated with a tin alloy containing not less than 3% lead only when necessary for solderability.

40) Mercury.

41) Magnesium.

42) Asbestos.

43) Class I and II ODS materials.

44) Environmental Protection Agency (EPA)-17 materials.

45) MIL-W-22759 wire with single Tetrafluoroethylene (TFE) insulation for space (and missiles in space) applications.

46) Aluminum connectors with electroless nickel outer plating finish.

47) Kapton/polyamide insulation on the outer surface of wires.

48) PVC.

3.7 Electromagnetic Effects (EME)

3.7.1 Electrostatic Discharge from Human Source

The PA shall perform without degradation to specified performance requirements when subjected to Electrostatic Discharge (ESD) from a human source in accordance with

International Electro-technical Commission (IEC) 801.2, Class 4. This requirement shall be validated using analytical methods

3.8 Nameplates and Product Marking

Product marking or nameplates shall be provided to identify the PA and all peculiar support equipment, to include as a minimum:

i. Product Nomenclature

ii. Manufacturers Name

iii. Product Serial Number

iv. Product Part Number

v. Date of manufacturer

3.9 Workmanship

The PA will use MIL-HDBK-454 as a guide for workmanship.

3.9.1 Interchangeability

The PA development will incorporate the following interchangeability requirements:

i) The PA shall provide interchangeability using MIL-HDBK-454, Guideline 7 as guidance.

ii) The PA interchangeable assemblies, components, and parts shall be capable of being installed, removed, or replaced without alteration, misalignment, or damage to parts being installed or to adjacent parts.

iii) All PA new development equipment and all Non-Developmental Items (NDIs) shall maximize the use of standard design layouts and modularity for common functions to enhance interchangeability.

3.9.2 Safety and Human Performance

The PA shall be designed in accordance with safety criteria guidance per

MIL-HDBK-454. COTS equipment shall be Underwriters Laboratories (UL) listed or approved, incorporated by UL 1950, where practicable.

3.10 Hazardous Materials

The PA, when properly packaged, shall comply with the following requirements for the transport of hazardous materials.

i) Title 49, Parts 100-199 of the Code of Federal Regulations

ii) The International Maritime Dangerous Goods Code

iii) The International Civil Aviation Organization Technical Instructions

The PA shall not utilize materials listed in Table 3-10-1 and Table 3-10-2.

Table 3-10-1 Class I and Class II Ozone Depleting Chemicals

Class I Ozone Depleting Chemicals Class II Ozone Depleting Chemicals

Chlorofluorocarbon-

11 (CFC-11) CFC-214

Hydrochlorofluorocarbon-21 Hydrochlorofluorocarbon

(HCFC-21)

HCFC-226

CFC-12 CFC-215 HCFC-22 HCFC-231

CFC-13 CFC-216 HCFC-31 HCFC-232

CFC-111 CFC-217 HCFC-121 HCFC-233

CFC-112 Halon-1211 HCFC-122 HCFC-234 CFC-113 Halon 1301 HCFC-123 HCFC-235 CFC-114 Halon 2402 HCFC-124 HCFC-241 CFC-115 Carbon Tetrachloride HCFC-131 HCFC-242

CFC-211 Methyl Chloroform (1,1,1-Trichloroethane) HCFC-132 HCFC-243

CFC-212 Methyl Bromide HCFC-133 HCFC-244

CFC-213 HCFC-141 HCFC-251

HCFC-142 HCFC-252

HCFC-221 HCFC-253

HCFC-222 HCFC-261

HCFC-223 HCFC-262

HCFC-224 HCFC-271

HCFC-225

s

Benzene Methyl Ethyl K

Methylene Chloride (Di Perchloroeth

Cyanide Toluene

Trichloroeth Mercury & com Methyl Isobutyl

3.11 Commonality

The PA shall incorp which enhance standardi

MIL-STD-1472 as guidance

PA design and NDI commonality of interfaces, m

3.12 Documentation

BATC shall supply

Documentation shall confor

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Table 3-10-2 EPA-17 Hazardous Material Xylene etone Cadmium & compounds chloromethane) Carbon Tetrachloride ylene Chloroform s Trichloroethylene ane pounds Ketone orate and document common processes, procedures, and items, zation and interoperability for hardware and software using selection of components shall implement standardization; including odules, and parts based on form, fit, and function.

documentation to define the form, fit, and functions of the PA.

m to the requirements specified herein.

3.12.1 Engineering drawings

New Engineering drawings shall be per Engineering Development Drawings Level 1

MIL-STD-1000. Existing drawings, regardless of level, are acceptable for any existing or modified hardware use for the PA. Existing drawings may be used as is, or modified, for fabrication or assembly of new hardware that was designed using existing technology.

3.12.2 Engineering Reports/Documentation

All engineering documentation shall be provided to the government in Adobe Acrobat 5.0

(or later versions). Prior to document acceptance, KING AEROSPACE will sign-off the documentation as acceptable.

3.12.3 Software Documentation

Three software documents will be produced for this effort:

1. Software Functional Requirements Document (SFRD)

2. Software Functional Design Document (SFDD)

3. Software Test Plan (STP)

3.12.3.1 Software Functional Requirements Document

This document describes the functions to be performed by the ACC, but does not show how these functions will be implemented. An outline will be produced of all software requirements. For each outlined item, a Hierarchy, Inputs, Processing, Outputs (HIPO) format will be used for each required function.

3.12.3.2 Software Functional Design Document

This document describes the logical structure of the computer programs in support of the functional requirements document. The features of this document are:

a. Data Flow Diagrams. These define the processing modules and external devices.

All data interfaces are depicted with data directions and specific parameters. This defines all functions and procedures. For this document, actual coded procedures will be grouped into common function procedures.

b. Data Dictionary. This is an alphabetized list of all shared data items listing their description, reference locations, type, range, etc. This is important for software maintenance.

c. Internal Interface Description. All function and procedure calling parameters are described.

d. External Interface Description. This defines the software interface to external equipment. This is similar to an ICD.

e. Description of algorithms used.

f. Descriptions of the processing methods for each procedure. For this document, the actual coded procedures will be grouped into all procedures supporting a common function.

3.12.3.3 Software Test Plan

The software test plan will define testing on the primary functional requirements. That is, groups of related functions in support of the real time telemetry mission. It will follow the outline of the SFRD and SFDD documents and it will include the following for each system level test:

a. Test Title

b. Purpose of test

c. Test environment setup and required equipment and auxiliary programs.

d. Valid range of inputs and list of input values.

e. Expected outputs. Defines what constitutes the verification.

f. Verification method: e.g. printed output, external device status, and visual inspection.

g. Test personnel…