FAA Specification-FAA-G-2100J.pdf

FAA-G-2100J

April 19, 2022

U.S. Department of Transportation

Federal Aviation Administration

U.S. Department of Transportation

Federal Aviation Administration

Specification

ELECTRONIC EQUIPMENT, GENERAL REQUIREMENTS

ii

FAA-G2100J

TABLE OF CONTENTS

1 SCOPE AND PURPOSE

1.1 SCOPE

1.2 INTENDED USE

1.3 TAILORING OF THIS SPECIFICATION

1.4 CLASSIFICATION

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

2.2 NON-GOVERNMENT DOCUMENTS

3 REQUIREMENTS

3.1 GENERAL

3.1.1 Electrical Power and Other Electrical Energy

3.1.2 Mechanical

3.1.3 Equipment Software/Firmware

3.2 CHARACTERISTICS

3.2.1 Environmental Conditions

3.2.2 Physical Characteristics

3.2.3 Reliability

3.2.4 Maintainability

3.2.5 External Equipment Interfaces

3.2.6 Electrostatic Discharge

3.2.7 Transportability

3.3 EQUIPMENT DESIGN AND CONSTRUCTION

3.3.1 Materials, Processes, and Parts

3.3.2 Electromagnetic Compatibility

3.3.3 Nameplates and Marking

3.3.4 Interchangeability

3.3.5 Personnel Safety and Health

3.3.6 Human Engineering

3.4 DOCUMENTATION

3.5 PERSONNEL AND TRAINING

4 QUALITY ASSURANCE PROVISIONS

4.1 QUALITY SYSTEM REQUIREMENTS

4.1.1 Material Evaluation

4.1.2 Quality Conformance Evaluation

4.2 VERIFICATION/COMPLIANCE TO REQUIREMENTS

4.2.1 Requirements Verification Matrix

4.2.2 Classification of Tests

4.2.3 Test Equipment

5 PREPARATION FOR DELIVERY

6 ACRONYMS AND DEFINITIONS

iii

6.1 ACRONYMS AND ABBREVIATIONS

6.2 DEFINITIONS

6.2.1 Commercial-off-the-shelf (COTS)

6.2.2 Developmental item

6.2.3 Equipment Software/Firmware

6.2.4 Fail-safe

6.2.5 Fail-soft

6.2.6 Lowest Replaceable Units (LRUs)

6.2.7 Internal/building wiring

6.2.8 Modified COTS/commercial type product

6.2.9 Nationally Recognized Testing Laboratory (NRTL)

6.2.10 Non-developmental Item (NDI)

6.2.11 Rack/Equipment

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

6.2.13 Series Combination System Overcurrent

APPENDIX A

A.1 ITI (CBEMA) CURVE APPLICATION NOTE

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

A.3 DUAL CORD SYSTEMS

APPENDIX B

B.1 GOVERNMENT DOCUMENTS

B.1.1 SPECIFICATIONS

B.1.2 STANDARDS

B.1.3 OTHER PUBLICATIONS

APPENDIX C

C.1 NON-GOVERNMENT DOCUMENTS

C.1.1 STANDARDS

APPENDIX D

REQUIREMENTS VERIFICATION MATRIX

APPENDIX E

HARMONICS CALCULATIONS

LIST OF FIGURES

Figure 1. Power Quality Tests and Measurements Flow Figure 2. Typical Pure Inrush Current Figure 3. Inrush Current Limit Measurements Figure 4. Point-on-Wave Inrush Current Measurements Figure 5. Inrush Current Ratio Limits Figure 6. Standard FAA Nameplate Figure 7. Internal/building Electrical Power Wiring Diagram iv

Figure A.1-1. ITI (CBEMA) Curve Figure A.1-2. Typical Low-Frequency Decaying Ringwave

LIST OF TABLES

Table 1. Limits of Individual Harmonics Table 2. Power Factor Displacement Limits Table 3. Abbreviations for Thermocouple Materials Table 4. Electrical Clearance and Leakage (Creepage) Distances Table 5. Type Test Equipment Selection

FAA-G-2100J April 19, 2022

1 SCOPE AND PURPOSE

1.1 Scope

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

1.2 Intended Use

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

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

1.3 Tailoring of this Specification

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

1.4 Classification

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

2 APPLICABLE DOCUMENTS

2.1 Government documents

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

2.2 Non-Government documents

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

3 REQUIREMENTS

3.1 General

3.1.1 ELECTRICAL POWER AND OTHER ELECTRICAL ENERGY

This section addresses National Airspace System (NAS) electrical requirements inside equipment, interfaces to the facility electrical system, power-related radio frequency (RF) issues, corona control, and other electrical energy issues.

a. The equipment shall interface to building wiring in accordance with National Fire Protection

Agency (NFPA) 70, NFPA 70E, FAA-STD-032, and FAA-C-1217, in that order of precedence.

Electrical enclosures, cabling, and wiring shall be approved by an Occupational Safety and Health Act (OSHA) nationally recognized testing laboratory.

b. When a piece of equipment or subcomponent of a system is being replaced with different equipment, the new equipment shall have the same or better power characteristics. Otherwise, the whole system must be retested according to this section and subsections.

3.1.1.1 Physical Requirements and Construction

a. Accessibility:

The installation of all NAS equipment, including test equipment and maintenance equipment, shall be in accordance with NFPA 70.

Accessibility for maintenance and operations shall allow access to electrical components in accordance with NFPA 70E, including connections, wiring, etc, when the equipment is fielded.

Permanent installations of critical equipment should be hard wired whenever possible.

b. Equipment hardwired to line power shall meet the following requirements:

1) The main disconnecting means shall break all incoming lines immediately before the line filter, terminal block or connector, fuses, or other parts.

2) The main disconnecting means shall consist of disconnect switches or circuit breakers.

3) Where radio frequency interference (RFI) and electromagnetic interference (EMI) shielding integrity would be compromised, the disconnect must be located at the power panelboard or other location, as defined in NFPA 70.

4) Controls and indicators for electrical line voltage of an equipment rack shall be located in accordance with NFPA 70.

c. Equipment and systems connected by cord and plug to line power shall meet the following requirements:

1) Provide plugs and receptacles connecting the equipment to the AC supply line with twist-lock types in accordance with the requirements of W-C-596, and install in accordance with the requirements of NFPA 70. If installed inside the equipment, use plugs and receptacles that are FAA-approved, or industry-recognized, latching type.

2) Use power cords for connecting equipment to the AC supply in accordance with the requirements of UL62, and install in accordance with NFPA 70:

a. For 120V circuits, use a three-conductor cord (hot, neutral and ground).

b. For 208V or 240V systems circuits, use a three-, four- , or five-conductor cord, dedicated ground pin mandatory.

3) Detachable power cords shall be UL-listed for its intended purpose.

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

5) For all critical power circuits, receptacles shall be twist lock type except where the receptacles are not subject to be kicked or bumped (e.g., receptacles mounted inside an equipment rack).

6) When the equipment has a female connector, it shall have additional security to prevent inadvertent mechanical disconnection. This type of connector shall have locking/latching, or retaining capability. Examples include DESC 87204 (CannonTM connector); International Electrotechnical Commission (IEC) 60320-C13 or IEC-60320-C19 with locking or latching provisions suitable for IT equipment; or as otherwise approved by FAA.

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

e. Unless otherwise specified, provide convenience outlets at the front bottom of each equipment rack. Outlets shall be duplex receptacles in accordance with W-C-596/12-2 (or ground fault circuit interrupter type where required), installed and wired in accordance with the requirements of NFPA 70, with provisions included to provide power to these outlets from a source independent of the equipment power source.

3.1.1.2 Power Quality Requirements

Power quality testing is essential for ensuring the efficient generation, distribution, and use of electrical energy. Power quality defines a set of limits that allow electrical systems to operate in their intended manner without significant loss of performance or product life. Without the proper power quality, an electrical device (or load) may malfunction, fail prematurely, or not operate at all.

Power quality is described by a set of parameters such as continuity of service, variation in voltage magnitude, transient voltages and currents, and harmonic content in waveforms. The main test measurements on the supply or the load that can be made to determine these factors are:

• Harmonics and Total Harmonic Distortion (THD)

• Power Factor Displacement

• Inrush currents (start-up effects of motors and inductive loads)

Power quality tests and measurements shall be conducted at the equipment level, subsystem level, rack level, or branch circuit breaker level as appropriate. In lieu of the cord connected requirement, equipment may be submitted for compliance as an integrated system. Testing at the rack or branch circuit breaker shall be performed.

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

Figure 1 shows the mandated power test and measurement decision flow.

START

IEC 61000-3-2

Certified?

Is Load <= 5A?

APPROVED

Is Load <= 16A?

Test Harmonics per Section 3.1.1.2.1.2 or IEC

61000-3-2

Test Power Factor Displacement per section

3.1.1.2.2.2

Test Inrush per section 3.1.1.2.3.2

NOT APPROVED

FURTHER STUDY MAY BE

REQUIRED

No

Y

PASS

PASS

PASS

Test Harmonics per Section 3.1.1.2.1.2

Yes

Yes

PASS

FAIL

FAIL

FAIL

No

No

H ar m on ic s

Po w er F ac to r a nd

In ru sh

FAIL

Figure 1. Power Quality Tests and Measurements Flow

Figure 1. Power Quality Tests and Measurements Flow

True Power Factor (PF) shall be defined as the product of the displacement and distortion power factors components:

The power factor displacement, 𝑃𝑃𝑃𝑃𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷, is defined by:

Where P and S are the real and apparent powers in [watt] and [VA], respectively and 𝜑𝜑𝑉𝑉 and 𝜑𝜑𝐼𝐼 are voltage and current phase angles.

The distortion power factor, 𝑃𝑃𝑃𝑃𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 is defined based on IEEE STD 519 as below:

𝑃𝑃𝑃𝑃 = 𝑃𝑃𝑃𝑃𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 × 𝑃𝑃𝑃𝑃𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷

𝑃𝑃𝑃𝑃𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 =

𝑃𝑃

𝑆𝑆

= 𝐶𝐶𝐶𝐶𝐶𝐶(∅), ∅ = 𝜑𝜑𝑉𝑉 − 𝜑𝜑𝐼𝐼

𝑃𝑃𝑃𝑃𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 =

√1 + 𝑇𝑇𝑇𝑇𝑇𝑇2

Where THD is the Total Harmonic Distortion.

3.1.1.2.1 Harmonics

Harmonics are a mathematical way of describing distortion to a voltage or current waveform. Power system harmonics are defined as sinusoidal voltage and currents at frequencies that are integer multiples of the fundamental frequency. Mathematical calculations are provided in Appendix E.

3.1.1.2.1.1 Requirement

Equipment or systems shall meet IEC 61000-3-2, “Limits for harmonic current emissions (with specified current less than or equal to 16 amps root mean square [RMS] steady state),” Table 3 (Limits for Class D Equipment), Maximum permissible harmonic current (A) for individual equipment item or subsystem. If all subcomponents meet the requirements, then the entire piece of equipment also meets the requirement. Documentation showing compliance with IEC 61000-3-2 shall be submitted in lieu of the test.

For individual equipment or systems certified to IEC 61000-3-2, harmonics testing may be waived (see Figure 1).

Note: If the equipment has an IEC stamp/certification for 230V and 400V (50 Hz) systems, any 120/240V (60 Hz) applications shall be considered compliant, with no additional testing required.

Systems not certified to IEC harmonic requirements above shall be tested in accordance with the following Test Procedure Section.

3.1.1.2.1.2 Test Procedure

Measure the individual current harmonic distortion (IN) produced by each individual equipment item or subsystem (consisting of several items combined in a single power circuit) at the input side of the power distribution where the rack or equipment is attached.

3.1.1.2.1.3 Limits

Table 1 describes the limits for various size systems. If the load exceeds 40,000 watts, THD shall be under 10 percent. The individual current harmonic distortion produced by each individual equipment item or subsystem shall be less than the limits shown in Table 1.

Table 1. Limits of Individual Harmonics

Harmonic Order

Maximum Limits (mA) 50 < W ≤ 600

(1 phase)

Maximum Limits (mA) 600 < W < 40,000 (1 or 3 phases)3

2 1.00 x W 400+ (0.05 x W) 3 3.60 x W 1440+ (1.20 x W) 4 1.00 x W 400+ (0.05 x W) 5 2.00 x W 800+ (0.66 x W)

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

Notes:

1. W equals power in watts.

2. Power is active power in watts for both single phase and polyphase circuit as defined by

ANSI/IEEE standard 100. “IEEE Standard Dictionary of Electrical and Electronic Terms.”

3. Maximum THD for W > 40,000 shall be less than 10%.

4. Equipment less than 50W are waived.

3.1.1.2.2 Power Factor Displacement

3.1.1.2.2.1 Requirement

The power factor displacement test is waived for equipment loads less than or equal to 5 A.

3.1.1.2.2.2 Test Procedure

Measure the power factor displacement with an appropriate power-factor meter. Test at steady-state RMS operation.

3.1.1.2.2.3 Limits

The power factor displacement shall be within the ranges specified for the following ranges of equipment watts capacity measured at the rack, and or standalone equipment, power input location (Table 2).

Table 2. Power Factor Displacement Limits

W (watt) PF (power factor displacement)

W < 2000 + 0.7 (lag)

- 0.7 (lead)

2000 < W < 5000 + 0.8 (lag)

- 0.9 (lead)

W > 5000 + 0.9 (lag)

1.0

3.1.1.2.3 Inrush Current

When a magnetic-core device or load (such as transformers, motors, capacitors, etc.) is energized, the core flux and the corresponding exciting current undergo a decaying transient before reaching the steady state values. This transient current is called magnetizing inrush current and typically starts at a high value and decays to zero. See Figure 2.

Figure 2. Typical Pure Inrush Current

3.1.1.2.3.1 Requirement

Equipment-caused current transients, including inrush currents, shall not cause nuisance tripping of the electrical system circuit breakers.

The inrush current test is waived for equipment loads less than or equal to 5 A.

If overcurrent is caused by internal crowbars, its protection shall be coordinated with overall protection that includes the electrical system devices and the equipment protective devices.

3.1.1.2.3.2 Test Procedure

Perform testing in conformance with the following:

a. Perform the Inrush current measurement by energizing the load or device within ten degrees of the positive (80 to 90 degrees), and the negative (260 to 270 degrees) peaks of the sine wave of applied voltage as shown in Figure 3.

b. The test source shall be able to provide at least five times the rating peak current of equipment under test (full load, steady state current or name plate rating). Total voltage distortion of the source shall not exceed three percent (3%).

c. Connect the cord connected equipment to the test voltage source with the same size, type, and length of cord to be furnished with the load or device under test. Connect all other devices or loads to the test voltage source with 4-ft long conductors sized for their RMS current in accordance with NFPA 70. All cords and conductors shall be directly connected to the test voltage source.

3.1.1.2.3.3 Limits

a. The inrush current limits for all direct current (DC), and all alternating (AC) devices or loads whose RMS current is greater than 80A, shall be in accordance with the system level specification for the specific device/load. Figure 4 shows the first two cycles of the inrush current that indicate the test energization time.

b. The ratio of peak inrush current to steady state RMS current shall be equal to or less than the ratio defined by Figure 5.

Figure 3. Inrush Current Limit Measurements

Figure 4. Point-on-Wave Inrush Current Measurements

Figure 5. Inrush Current Ratio Limits

3.1.1.3 Cord-connected equipment

Unless otherwise specified, NAS electronic and information technology (IT) equipment shall be dual-corded, with each cord feeding its own power supply. The dual-cord system shall meet the requirements of the Uptime Institute (Appendix A.3). The dual-cord system shall be capable of receiving AC input from two different AC power sources. Each power supply shall be capable of handling the full load. The power supplies shall be of the type having no internal switching.

3.1.1.4 Electrical Load Balance

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

3.1.1.5 Protection of Equipment from AC/DC Power Anomalies

Protection of equipment from AC/DC power anomalies shall comply with the following:

a. Provide current overload protection for the equipment by fuses, circuit breakers, or other protective devices for primary circuits.

1) The interrupting current of overcurrent protection devices shall not be less than 10 kA ampere interruption capacity (AIC) rating. For larger facilities (e.g., large air traffic control towers [ATCT], TRACONs, or ARTCCs), check the facility records to determine if higher

AIC ratings are required. If the records are not available, perform a detailed fault calculation for the location in which the equipment is to be located.

2) Overcurrent protection devices shall provide selective fault isolation.

3) Series combination system overcurrent protection were the branch breaker allows the main breaker to clear heavy faults shall not be permitted.

b. Provide protection against a total loss of power.

c. Provide protection against the loss of one or more phases of power.

d. Provide protection against a sustained undervoltage condition.

e. Provide transient protection (addressed separately in this document).

3.1.1.6 Input Power Conditions

The equipment shall operate in accordance within the following power parameters:

a. Voltage

(1) Steady State Voltages:

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

DC 48 Volts +/- 20% AC Ripple < 5% DC 24 Volts +/- 20% AC Ripple < 5% DC 12 Volts +/- 20% AC Ripple < 5%

(2) Transients and Surge/Sag Voltages:

(a) Maintain normal operation as defined by the Information Technology Industry Council/Computer and Business Equipment Manufacturer’s Association (ITI/CBEMA) curve in Appendix A.

(b) Voltage/Time Events:

In accordance with the voltage and current values given by Tables 2, 3, and 5 of IEEE Std C62.41.2 (2002).

b. Voltage phase imbalance:

Phase to phase: 5% as defined by IEEE STD 141:

𝑉𝑉𝐶𝐶𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 𝐼𝐼𝐼𝐼𝐼𝐼𝑉𝑉𝑉𝑉𝑉𝑉𝐼𝐼𝐼𝐼𝑉𝑉 =

𝑀𝑀𝑉𝑉𝑀𝑀𝑀𝑀𝐼𝐼𝑀𝑀𝐼𝐼 𝐴𝐴𝐴𝐴𝑉𝑉𝐴𝐴𝑉𝑉𝑉𝑉𝑉𝑉 𝑅𝑅𝑀𝑀𝑆𝑆 𝑉𝑉𝐶𝐶𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 𝑇𝑇𝑉𝑉𝐴𝐴𝑀𝑀𝑉𝑉𝑉𝑉𝑀𝑀𝐶𝐶𝐼𝐼

𝐴𝐴𝐴𝐴𝑉𝑉𝐴𝐴𝑉𝑉𝑉𝑉𝑉𝑉 𝑅𝑅𝑀𝑀𝑆𝑆 𝑉𝑉𝐶𝐶𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉

c. Frequency:

Frequency Frequency range Rate of Change Frequency Variation

Steady State 60 Hz +/– 3 Hz 1.5 Hz/sec + /– 0.5 Hz Momentary Deviations (0.5 seconds to 3 seconds) 60 Hz + 5 Hz, - 7 Hz 5 Hz/sec -

d. Voltage Harmonic Distortion:

Voltage THD% Individual Harmonic % 10% 3%

3.1.1.7 Lightning and Surge Protection, Grounding, Bonding and Shielding (LPGBS) For LPGBS protection of equipment and systems, follow these requirements:

a. All matters related to LPGBS for NAS electronic equipment, systems, and facilities shall be in accordance with most recent editions of FAA-STD-019 and NFPA 780.

b. All procurement of NAS electronic equipment shall be in accordance with FAA-STD-019, Section 5.6, NAS Electronic Equipment – Interface and Procurement Requirements.

c. The program office procuring the equipment is responsible to ensure that:

1) The installation of NAS electronic equipment shall be in accordance with the requirements specified in FAA-STD-019.

2) The facility receiving new modern NAS electronic equipment shall be in compliance with the latest revision of that standard.

d. Surge protection devices (SPD) requirements for NAS electronic equipment shall be in accordance with FAA-STD-019 section 5.6.4 Equipment Power Entrance – Transient Protection and its subsections.

3.1.1.8 Special Requirement (VFDs, LEDs, UPS, etc.)

Equipment and systems shall meet the following:

a. Evaluate the equipment to verify that new equipment does not cause harmful interference.

b. Ensure switching frequencies in the 3 kHz < f < 3 MHz range are in full compliance with Federal

Communications Commission (FCC), United Laboratories (UL), and other listings. Switching frequencies in this range can cause radio interference problems.

c. Variable frequency drives (VFD) must meet the requirements of IEC 61800-3 rating for the “1st Environment.”

d. Lighting systems and light-emitting diode (LED) equipment must meet the RF requirements of FCC Part 15, Subpart B, Class B, and power harmonics requirements of IEC 61000-3-2 Class C.

e. Fluorescent systems must meet FCC eCFR Part 15, Subpart B, Radio Frequency Devices, and Part

18, Industrial, Scientific, and Medical Equipment.”

f. Power conditioning systems (PCS) or mini-uninterruptible power supplies (MUPS) shall not be used to meet power requirements in 3.1.1.1 through 3.1.1.10 for systems that will be installed on facility critical power. If absolutely required, the PCS/MUPS shall be dual-corded and dual-redundant power supplies. Each power supply shall be capable of handling the full load. PCS and MUPS shall be tested per FAA-G-2100, Section 3.1. The power test report shall be included in an NCP for review along with justification of the PCS and/or MUPS.

3.1.1.9 Protection of Outputs of Radio Frequency Equipment, Audio Equipment and

Other Electronic Circuits

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

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

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

3.1.1.10 Corona Prevention

a. Corona prevention shall be as follows:

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

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

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

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

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

b. Electrical breakdown prevention shall be as follows:

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

2) Do not use liquid dielectrics, gases other than ambient air, or pressurization to prevent electrical breakdown.

3) Insulations exposed to continuous corona decomposition shall not emit hazardous gases.

3.1.1.11 Isolation of Power Supplies

a. All power supplies energized from the AC line power source shall be isolated from the AC input to reduce shock hazard and other circuit issues. Isolation can be by a power transformer with separate primary and secondary windings or other techniques.

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

3.1.2 MECHANICAL

3.1.2.1 Removable Parts and Mating Connectors

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

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

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

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

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

3.1.2.2 Installation

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

3.1.2.3 Construction

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

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

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

3.1.2.3.1 Equipment Racks

3.1.2.3.1.1 Pullout Drawers

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

Friction-slide construction is prohibited.

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

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

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

3.1.2.3.1.2 Rack Panels

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

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

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

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

3.1.2.3.2 Shelf Life

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

3.1.2.3.3 Moisture

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

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

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

3.1.2.3.4 Windows

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

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

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

3.1.2.4 Accessibility

3.1.2.4.1 General

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

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

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

3.1.2.4.2 Connections

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

3.1.2.4.3 Lowest Replaceable Units (LRUs)

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

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

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

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

3.1.2.4.4 Enclosures

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

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

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

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

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

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

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

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

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

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

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

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

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

3.1.2.5 Thermal Design

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

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

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

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

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

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

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

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

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

3.1.3 EQUIPMENT SOFTWARE/FIRMWARE

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

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

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

3.2 Characteristics

3.2.1 ENVIRONMENTAL CONDITIONS

3.2.1.1 Operating Conditions

3.2.1.1.1 Seismic Zone Design

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

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

3.2.1.1.2 Common Outdoor Operating Environmental Conditions

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

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

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

c. Ice loading as defined by ASCE Manual 74.

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

CATEGORY.

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

3.2.1.1.3 Indoor Operating Environments

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

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

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

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

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

3.2.1.2 Non-Operating Conditions

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

a. Temperature -50°C to +56°C

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

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

3.2.2 PHYSICAL CHARACTERISTICS

3.2.2.1 Electronic Equipment Assembly Requirements

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

3.2.2.1.1 Component Mounting

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

3.2.2.1.2 Printed Circuit Boards

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

3.2.2.1.3 Assembly

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

3.2.2.2 Wire Wrap

Wire wrap shall not be used on printed circuit boards.

3.2.3 RELIABILITY

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

3.2.4 MAINTAINABILITY

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

In addition, the following maintainability requirements apply:

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

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

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

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

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

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

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

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

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

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

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

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

3.2.5 EXTERNAL EQUIPMENT INTERFACES

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

3.2.6 ELECTROSTATIC DISCHARGE

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

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

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

3.2.7 TRANSPORTABILITY

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

3.3 Equipment Design and Construction

3.3.1 MATERIALS, PROCESSES, AND PARTS

3.3.1.1 Materials

3.3.1.2 Dissimilar Metals

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

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

3.3.1.2.1 Metals, Corrosion Resistance

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

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

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

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

3.3.1.2.1.1 Corrosion-resisting Ferrous Alloys

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

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

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

3.3.1.2.2 Flammable Materials

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

3.3.1.2.2.1 Additives

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

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

3.3.1.3 Equipment Manufacturing Processes

3.3.1.3.1 Strain Relief

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

3.3.1.3.2 Painted Finish

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

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

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

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

3.3.1.3.3 Cadmium Plating

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

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

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

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

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

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

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

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

3.3.1.4 Electrical Parts

3.3.1.4.1 Batteries

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

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

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

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

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

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

(1) Contain devices to firmly secure the batteries.

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

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

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

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

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

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

3.3.1.4.2 Circuit Breakers

3.3.1.4.2.1 Selection and Application

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.3.1.4.3 Electrical Connectors

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

3.3.1.4.3.1 Selection

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

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

c. Contact crimp, installing, and removal tools shall be in accordance with…