13 49 20.00 10.pdf

FY 24 MCON Project P-222 eProject Work Order No: 1737012 MQ-25 Aircraft Laydown Facilities Naval Station, Norfolk, Virginia

SECTION 13 49 20.00 10

RFI SHIELDING

10/07

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A568/A568M (2019a) Standard Specification for Steel, Sheet, Carbon, Structural, and High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, General Requirements for

ASTM A653/A653M (2023) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM B194 (2008) Standard Specification for Copper-Beryllium Alloy Plate, Sheet, Strip, and Rolled Bar

ASTM B545 (2013) Standard Specification for Electrodeposited Coatings of Tin

ASTM C1396 (2017) Standard Specification for Gypsum Board

ASTM D1000 (2017) Standard Test Methods for Pressure-Sensitive Adhesive-Coated Tapes Used for Electrical and Electronic Applications

ASTM D3273 (2016) Standard Test Method for Resistance to Growth of Mold on the Surface of Interior Coatings in an Environmental Chamber

ASTM D4935 (2018) Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials

ASTM E90 (2023) Standard Test Method for Laboratory

SECTION 13 49 20.00 10 Page 1

Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 142 (2007; Errata 2014) Recommended Practice for Grounding of Industrial and Commercial Power Systems - IEEE Green Book

IEEE 299 (2006; R 2012) Standard Method for Measuring the Effectiveness of Electromagnetic Shielding Enclosures

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023; ERTA 7 2023; TIA 23-15) National Electrical Code

NFPA 77 (2014) Recommended Practice on Static Electricity

NFPA 80 (2022) Standard for Fire Doors and Other Opening Protectives

NFPA 80A (2017) Recommended Practice for Protection of Buildings from Exterior Fire Exposures

NFPA 101 (2021; TIA 21-1) Life Safety Code

NFPA 780 (2023) Standard for the Installation of Lightning Protection Systems

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-HDBK-419 (1987; Rev A) Grounding, Bonding, and Shielding for Electronic Equipments and Facilities Volumes 1 of 2 Basic Theory

MIL-STD-188-124 (1998; Rev B; Notice 2 1998; Notice 3 2000; Notice 4 2013) Grounding, Bonding and Shielding for Common Long Haul/Tactical Communications Systems, Including Ground Based Communications - Electronics Facilities and Equipments

MIL-STD-188-125-1 (1998; Basic; Notice 1 2005) High-Altitude Electromagnetic Pulse (HEMP) Protection for Ground-Based C41 Facilities Performing Critical, Time-Urgent Missions, Part I Fixed Facilities

UNDERWRITERS LABORATORIES (UL)

UL 486A-486B (2018; Reprint Jul 2023) UL Standard for

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Safety Wire Connectors

UL 1283 (2017) UL Standard for Safety Electromagnetic Interference Filters

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Installation ; G Approved Drawings ; G

SD-03 Product Data

Shielding System ; G Installation ; G Quality Control Plan ; G Qualifications ; G Shielded Door ; G Filter Assemblies ; G

SD-06 Test Reports

Field Testing

SD-10 Operation and Maintenance Data

Operating and Maintenance Manuals ; G Service Organization ; G

1.3 QUALITY ASSURANCE

Work performed under this section shall be supervised and inspected by the shielding specialist. Materials and equipment shall be approved and verified by the shielding specialist before being submitted to the Contracting Officer for approval. The submittal shall be date stamped and signed by the shielding specialist. The shielding specialist shall be responsible for coordinating the required shielding work with the work of all other trades that will interface or affect the shielding work in any way.

1.3.1 Shielding Specialists, Installers and Testing Specialists

Provide the name and background qualifications of individuals who will be responsible for installation, supervision, and testing of the shielding systems on this project. Shielding and testing specialist credentials shall include a bachelor's degree in science or engineering and post-degree training and experience with shielding.

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1.3.1.1 Testing Experience

The testing specialist shall have experience during the previous 5 years in shielded enclosure leak detection system (SELDS), IEEE 299 , and other methods of shielded enclosure testing.

1.3.1.2 Work Experience

The shielded system shall be provided by an experienced firm or individual that has been regularly and successfully engaged in the installation, supervision, and/or testing of equivalent shielded systems for at least the previous 5 years. The principal work of this firm or individual shall be the satisfactory installation and construction of shielded protection systems. Such experience shall include achieving specified requirements for shielded system attenuation and maintainability of attenuation levels on work performed.

1.3.1.3 Project Experience

Furnish a project experience list on projects of similar scope which have been completed during the previous 5 years. Include project completion dates and the name and telephone number of the user and/or owner of each project. Project experience for installers shall indicate the installation responsibilities, performance, materials, and methods used.

Project experience for the shielding specialist shall indicate the responsibilities performed. Project experience for the testing specialist shall indicate the test methods performed.

1.3.2 Filter and Electrical Work Requirements

Filter and electrical work shall comply with NFPA 70 , UL 486A-486B , and UL 1283 . The label and listing of the Underwriters Laboratories or other nationally recognized testing laboratory will be acceptable evidence that the material or equipment conforms to the applicable standards of that agency. In lieu of the label or listing, a certificate may be furnished from an acceptable testing organization adequately equipped and competent to perform such services. The certificate shall state that the items have been tested and that they conform to the specified standard.

1.3.3 Pre-Installation Meeting

Hold a pre-installation meeting with the subcontractors and installers working in, on, or near the shield. Discuss coordination requirements and instructions shall be stated to ensure the integrity of the shield.

1.4 DELIVERY, STORAGE, AND HANDLING

Protect equipment delivered and stored from excessive humidity and temperature variation, dirt, and other contaminants.

1.5 PROJECT/SITE CONDITIONS

Shielding shall not be installed until the building has been weather enclosed.

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1.6 MAINTENANCE

1.6.1 Maintenance Supplies and Procedures

Provide maintenance supplies sufficient for a 3 year period or 50,000 open-close cycles, whichever is greater, for each shielded door. The maintenance instructions required to maintain the door through the cycle count shall be prominently displayed nearby.

1.6.2 Extra Materials

1.6.2.1 Filters

One extra communications filter of each different type furnished on the project shall be furnished as a spare.

1.6.2.2 Shielded Doors

Furnish one set of finger stock and gaskets (if used) for each hinged shielded door provided. In addition, provide one set of manufacturer recommended and Contracting Officer approved spare parts for shielded doors of each style installed.

1.6.2.3 Tools

Furnish one full set of tools that are required to maintain the doors and are not typically available from tool vendors. Furnish environmentally safe lubricants, cleaning solvents, or coatings in sufficient quantities to last for 6 months.

1.6.2.4 Special Tools

Provide one set of special tools, calibration devices, and instruments required for operation, calibration, and maintenance of the equipment as follows: SELDS Test Set

1.6.3 Operating and Maintenance Manuals

Submit manufacturer's written instructions for operation and maintenance of Shielding system. The manual shall address all components and aspects of the shielding and shall include, but not be limited to, the following:

a. A complete set of assembly drawings to include penetration locations and installation details.

b. The construction specification on shielding.

c. Shield penetration schedule.

d. Power/signal filter schedule.

e. Test plan.

f. The prepared preventive maintenance instructions for periodic inspection, testing and servicing, lubrication, alignment, calibration, and adjustment events normally encountered. Complex preventive maintenance events shall be extracted from or shall refer to detailed vendor or manufacturer data. This information shall be derived from an evaluation of engineering data considering local

SECTION 13 49 20.00 10 Page 5 environmental conditions, manufacturer's recommendations, estimated operating life for the specific application and use of the equipment, and types of job skills available at the operating site.

g. Spare parts data approved and verified by the shielding specialist prior to submission. The data shall include a complete list of recommended parts and supplies with current unit prices and source of supply.

PART 2 PRODUCTS

2.1 SYSTEM REQUIREMENTS

2.1.1 General

The RF shielded enclosure shall be designed/fabricated/installed by shield component manufacturer (or their designee) and shall meet or exceed the attenuation decibel (dB) levels identified. The shielding system shall include, but is not limited to, the following (refer also to drawings):

a. RFI Shielding (mesh) membrane: per IEEE 299 , ASTM D4935.

b. RFI Shielding (aluminum) membrane: Per IEEE 299 , ASTM D4935.

c. RFI Shielding shielding tape: Per ASTM D1000.

d. Acoustical glue: Per ASTM D3273, ASTM E90.

e. Sound damping gypsum panel: Per ASTM C1396, ASTM E90, IEEE 299 .

f. Shielded doors for access into the facility.

g. Electrical and electronic penetrations of the shield.

h. Shielded pull boxes and junction boxes.

i. Shielded conduit runs.

j. Special protective measures for mission-essential equipment outside the shield.

k. Structural penetrations.

l. Mechanical and utility penetrations (such as air ducts, gas, and water).

m. Instrumentation and control.

n. Equipment door/access panels.

o. Sufficient supervisory and/or quality control personnel onsite to supervise the installation crew and to conduct in-progress quality assurance tests.

2.1.2 Factory Tests

Perform factory tests as specified. The Contracting Officer reserves the right to witness the specified factory tests. Notify the Contracting Officer at least 30 days before factory tests are scheduled to be

SECTION 13 49 20.00 10 Page 6 performed. Test data shall include a detailed description of the test instrumentation and equipment, including calibration dates, a detailed description of the test procedure, and the recorded test data.

2.2 MATERIALS AND EQUIPMENT

2.2.1 Standard Products

Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of such products and essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Support equipment by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

2.2.2 Nameplates

Each major item of equipment shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment.

2.2.3 Testability

Equipment and materials of the shielding shall be designed and built to facilitate testing and maintenance.

2.3 SHIELDING EFFECTIVENESS

The shield enclosure, complete with all filters, doors, and/or waveguides, shall have the minimum RF attenuation efficacy identified by the SSO and provided to the J&A RF manufacturer.

2.4 SHIELDING ENCLOSURE REQUIREMENTS (WELDED CONSTRUCTION)

2.4.1 Metal Members

Structural steel shapes, plates, and miscellaneous metal shall conform to

ASTM A36/A36M.

2.4.2 Miscellaneous Materials and Parts

Miscellaneous bolts and anchors, supports, braces, and connections necessary to complete the miscellaneous metal work shall be provided. The necessary lugs, rebars, and brackets to assemble work shall be provided.

Holes for bolts and screws shall be drilled or punched. Poor matching of holes will be cause for rejection. Thickness of metal and details of assembly and supports shall provide ample strength and stiffness. The materials shall be galvanically similar.

2.5 SHIELDED DOORS

2.5.1 General

Material in shielded doors and frames shall be steel conforming to ASTM A36/A36M or ASTM A568/A568M and shall be stretcher-leveled and installed free of mill scale. Metal shall be thicker where indicated or required for its use and purpose. Metal thresholds of the type for proper shielding at the floor shall be provided. Fire rated shielded doors and assemblies shall meet NFPA 80 and NFPA 80A requirements and shall bear the

SECTION 13 49 20.00 10 Page 7 identifying label of a nationally recognized testing agency qualified to perform certification programs. The shielded doors shall be provided by a single supplier who has been regularly engaged in the manufacture of these items for at least the previous 5 years. The assemblies shall be supplied complete with a rigid structural frame, hinges, latches, and parts necessary for operation. The products supplied shall duplicate assemblies that have been in satisfactory use for at least 2 years. The door and frame assembly shall have a sound rating of STC 53 minimum. Testing shall be performed in accordance with ASTM E90.

2.5.1.1 Door Latch

The door latch shall be lever controlled with roller cam action requiring not more than (15 pounds) of operating force on the lever handle for both opening and closing. The door shall be equipped with a latching mechanism having a minimum of three latching points that provides proper compressive force for the seal. The mechanism shall be operable from both sides of the door and shall have permanently lubricated ball or thrust bearings as required at points of pivot and rotation.

2.5.1.2 Hinges

Doors shall be equipped with a minimum of three well-balanced adjustable ball-bearing or adjustable radial thrust bearing hinges suitable for equal weight distribution of the shielded doors. Hinges shall allow adjustment in two directions. Force necessary to move the doors shall not exceed (5 pounds).

2.5.1.3 Threshold Protectors

Threshold protectors, where required, shall be furnished for each shielded door. Protectors shall consist of portable ramps that protect the threshold when equipment carts or other wheeled vehicles are used to move heavy items across the threshold. The ramps may be asymmetrical to account for different floor elevations on each side, but the slope of the ramp shall not exceed 4:1 on either side. Ramps shall be designed to support a (500 pound) vertical force applied to a (3 by 1/2 inch) area for a personnel door. The force shall be applied to the contact area between the threshold and the door. Mounting brackets, convenient to the entry, shall be provided to store the ramp when not in use.

2.5.1.4 Frequency of Operation

With proper maintenance, door assemblies shall function properly through 100,000 cycles and 15-year service life minimum without the shielding effectiveness decreasing below the overall shield required attenuation.

2.5.1.5 Electric Connectivity

Electric connectivity for sensors, alarms, and electric interlocking devices shall be installed in accordance with the door manufacturer's instructions, and the approved drawings . Submit detail drawings showing location, number, and method of penetrating the shielding material.

Fabrication details for penetrations of the shielding material and the complete shielded enclosure to include doors and filters. Drawings shall show erection details and sequence of erection and shall clearly indicate the methods necessary to ensure shield integrity under all columns and other structural members.

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2.5.1.6 Emergency Exit Hardware

Emergency exit shielded doors shall be equipped with single motion egress hardware. The force required to latch and unlatch emergency exit hardware on shielded doors shall meet life safety code NFPA 101 . Field alterations or modifications to panic hardware will not be allowed.

2.5.1.7 Finish

shielded doors shall be factory prime painted with zinc chromate primer.

Doors may be factory finish painted or galvanized. Touch up any damaged finish.

2.5.2 Latching Type Doors

Doors shall be steel type. Steel doors shall be a minimum of (10 gauge) thick steel sheet electrically and mechanically joined by welded steel frames overlapping joints with continuous welds. The closure seal shall utilize an extruded brass channel containing a recess into which two sets of beryllium copper condition HT in accordance with ASTM B194 contact fingers and a closed cell foam rubber air seal are fitted and can be easily removed and replaced without the use of special tools and without the application of solders. The door shall mate to the frame in a manner that allows the insertion of a brass knife edge between the two rows of the radio frequency finger stock, to obtain optimum conductivity and electromagnetic shielding. High-temperature silver solder shall be used to attach the brass knife edge components to the door panels and the frame. The fingers that form a contact between the door and its frame shall be protected from damage due to physical contact and shall be concealed within the door and frame assembly.

2.5.3 Shielded Door Factory Test

Test data shall be provided on at least one shielded door of each type provided for the facility to verify that the shielded doors of the design supplied have been factory tested for compliance with this specification.

Test doors shall not be furnished on the project. Test data reports shall be submitted in accordance with paragraph SUBMITTALS.

2.5.3.1 Swinging Door Static Load Test

The door shall be mounted and latched to its frame, then set down in a horizontal position such that it will open downward with only the frame rigidly and continuously supported from the bottom. A load of (40 lb/psf) shall be applied uniformly over the entire surface of the door for at least 10 minutes. The door will not be acceptable if this load causes breakage, failure, or permanent deformation which causes the clearance between door leaf and stops to vary more than (1/16 inch) from the original dimension.

2.5.3.2 Swinging Door Sag Test

The door and its frame shall be installed normally and opened 90 degrees.

Two (100 pound) weights, one on each side of the door, shall be suspended from the door within (5 inch) of the outer edge for at least 10 minutes.

The door will not be acceptable if this test causes breakage, failure, or permanent deformation which causes the clearance between the door leaf and door frame to vary more than (1/16 inch) from the original dimension.

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2.5.3.3 Door Closure Test

Each door design shall be operated 100,000 complete open-close cycles.

The door will not be acceptable if the closure test causes any breakage, failure, or permanent deformation which causes the clearance between the door and door frame to vary more than (1/16 inch) from the original dimension.

2.5.3.4 Handle-Pull Test

The door shall be mounted and latched to its frame. The handle shall have a force of (250 pounds) applied outward (normal to the surface of the door) at a point within (2 inch) of the end of the handle. The door will not be acceptable if this test causes any breakage, failure, or permanent deformation exceeding (1/8 inch).

2.5.3.5 Door Shielding Test

The shielded door shall be factory tested in accordance with the requirements of this specification both before and after the mechanical tests described above.

2.6 FILTERS

A filter shall be provided for each power, data, and signal line penetrating the enclosure. These lines shall include, but are not limited to, power lines, lines to dummy loads, alarm circuits, lighting circuits, and signal lines such as telephone lines, antenna lines, HVAC control, and fire alarm. Filters and ESAs shall be enclosed in metallic cases which shall protect the filter elements from moisture and mechanical damage.

All external bonding or grounding surfaces shall be free from insulating protective finishes. All exposed metallic surfaces shall be suitably protected against corrosion by plating, lead-alloy coating, or other means. The finish shall provide good electrical contact when used on a terminal or as a conductor, shall have uniform texture and appearance, shall be adherent, and shall be free from blisters, pinholes and other defects. The filter and ESA assemblies shall also meet the requirements of UL 1283 . Insertion loss in the stop band between the load side of the filter and the power supply side shall be not less than the shielding attenuation specified. The filter used for 400 Hz shall be provided with power factor correcting coil to limit the reactive current to 10 percent maximum of the full load current rating. Each filter unit shall be capable of being mounted individually and shall include one filter for each phase conductor of the power line and the neutral conductor. The signal filters shall include one filter for each conductor.

2.6.1 Enclosure

Filter units shall be mounted in an modified NEMA Type 1 enclosure in accordance with NEMA ICS 6 and meet the requirements of UL 1283 .

Enclosures shall be made of corrosion resistant steel of (14 gauge) minimum thickness with welded seams and galvanized bulkhead cover plates.

The enclosure nonconductive surfaces shall be finished with a corrosion-inhibiting primer and two coats of baked or finish enamel. The input compartment shall house the individual line filters and the input terminals of the filters and mounting for the surge arrestor. Live parts shall be spaced in accordance with NFPA 70 . Filter leads shall be copper. Filter enclosures shall be shielding effectiveness tested in accordance with IEEE 299 and Table I of this specification.

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2.6.1.1 Filter Unit Mounting

Each filter unit shall be mounted individually in an enclosure containing one filter for each penetrating conductor. One end of the individual filter case shall be attached to the rf barrier plate between the two compartments to provide a rf tight seal between the rf barrier plate and the filter case. The terminals of the filters shall project through openings in the rf barrier plate into the inner terminal compartment. The case of each filter shall be attached to both the enclosure and to the barrier plate to prevent undue stress being applied to the rf seal between the filter case and the rf barrier plate. Individual filters shall be removable from the enclosure. Like filters shall be interchangeable.

2.6.1.2 Conduit Connections to Enclosures

The load terminal and input compartments shall have no knockouts, and each compartment shall have weldable threaded conduit hubs. The hubs shall be circumferentially welded in place and shall be sized and located as required for the conduits indicated.

2.6.1.3 Access Openings and Cover Plates

Enclosures shall have separate clear front access cover plates on terminal and power input compartments. Access cover plates shall be hinged with gaskets and (3 inch) maximum bolt spacing. The design shall include thick cover plates and folded enclosure edges to prevent enclosure deformation, bolt spacers to prevent uneven gasket compression, and gasket mounting to facilitate replacement. All gasket contact areas shall be tin-plated using the electrodeposited type I method in accordance with ASTM B545.

Nuts and bolts shall be permanently fastened to the enclosure by welding or captive attachments.

2.6.1.4 Operating Temperature

The filter and ESA assembly shall be rated for continuous operation, with filters at rated voltage and full-load currents, in ambient temperatures from minus (measured outside the filter enclosure). Filter components shall be suitable for continuous full load operation at a temperature from minus .

2.6.1.5 Short Circuit Withstand

Filters shall be labeled and built to have standard short circuit withstand ratings in accordance with UL 1283 .

2.6.1.6 Filter Connections

Individual filters shall have prewired standoffs and solderless lugs. The lugs shall be of the hexagonal head bolt or screw type and shall conform to UL 486A-486B . Live parts shall be spaced in accordance with NFPA 70 .

2.6.2 Internal Encapsulated Filters (Filter Units)

2.6.2.1 Filter Construction

Individual filters shall be heavy-duty type sealed in a steel case. After the filter is filled with an impregnating or encapsulating compound, the seams shall be welded. When a solid potting compound is used to fill the

SECTION 13 49 20.00 10 Page 11 filter, the filters may be mechanically secured and sealed with solder.

Hermetically sealed impregnated capacitors shall be used, or the complete filter assembly shall be vacuum impregnated. Individual filter cases shall be fabricated of not less than(14 gauge) thick steel and finished with a corrosion-resistant plating,or one coat of corrosion-resistant primer and two coats of finish enamel. The filter shall be filled with an impregnating or potting compound that is chemically inactive with respect to the filter unit and case. The compound, either in the state of original application or as a result of having aged, shall have no adverse effect on the performance of the filter. The same material shall be used for impregnating as is used for filling. Filter terminals shall be copper that can withstand the pull requirements specified and measured in accordance with paragraph FILTERS.

2.6.2.2 Ratings

Filters shall be provided in the current, voltage, and frequency ratings indicated on the drawings.

2.6.2.3 Dielectric Withstand Voltage

Filters shall be provided which conform to the minimum values of dielectric withstanding voltage. Filter dielectric withstand voltage test shall be in accordance with paragraph "Dielectric Withstand Voltage Test". Each filter shall be capable of withstanding a 20-kV or 4-kA peak transient pulse of approximately 20 ns pulse width at full operating voltage, without damage.

2.6.2.4 Insulation Resistance

The insulation resistance between each filter terminal and ground shall be greater than 1 megohm when tested in accordance with paragraph Insulation Resistance Test.

2.6.2.5 Parallel Filters (Current Sharing)

Where two or more individual filters are electrically tied in parallel to form a larger filter, they shall equally share the current. Equally sharing is defined to be within 5 percent of the average current. The tests shall be in accordance with paragraph FILTERS.

2.6.2.6 Harmonic Distortion

Harmonics generated by the insertion of a filter shall not increase line voltage distortion more than 2.5 percent when measured with a unity power factor in accordance with the paragraph FILTERS.

2.6.3 Marking of Filter Units

Each filter case shall be marked with HCI tags and with the rated current, rated voltage, manufacturer s name, type of impregnating or potting compound, operating frequency, and model number. In addition, individual filter cases, the filter enclosures, and supply and load panelboards of filtered circuits shall be marked by the manufacturer with the following:

"WARNING: Before working on filters, terminals shall be temporarily grounded to ensure discharge of capacitors. Nameplates and warning labels shall be securely attached.

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2.6.4 Minimum Life

Filter assemblies shall be designed for a minimum service life of 15 years. Submit filter schedule including voltage, amperage, enclosure type (low, high, band pass), location, cut-off frequency, band pass frequencies, and electrical surge arresters (ESA). Submit data and/or calculations for design of door including schedule of penetrations.

2.6.5 Power and Signal Line Factory Testing

Factory test report data shall be submitted for each filter configuration, voltage, and amperage which shall show the ability of filters to meet the specified requirements. Filter test reports shall be based on prior tests of the same filter assembly design and components. Test data reports shall be submitted in accordance with paragraph SUBMITTALS. Test data shall include the following:

a. Voltage Drop Measurements.

b. Insertion Loss Measurements.

c. Filter Life Test.

d. Thermal Shock Test.

e. Overload Test.

f. Reactive Shunt Current Measurements.

g. Dielectric Withstand Voltage.

h. Insulation Resistance Test.

i. Current Sharing.

j. Harmonic Distortion.

k. Terminals.

2.6.5.1 Voltage Drop Measurements

The voltage drop measurements on both ac and dc filters shall be performed with the components mounted in the filter/ESA assembly enclosure or mounted on a metal plate by the same holding method that will be used for mounting in the enclosure. For ac rated filters, measurements shall be made by using expanded scale-type meters. For dc rated filters, measurements shall be made by using a dc meter when the filter is carrying rated current and rated voltage.

2.6.5.2 Insertion Loss Measurements

Insertion loss measurements for power filters shall have the following modifications. The filters shall be installed in the filter/ESA assembly enclosure. The load current power supply shall operate at the rated voltage of the filters and shall be capable of providing any current from no-load through rated full-load current. The rf signal generator shall be a swept continuous wave (cw) source. The buffer networks shall be modified to permit valid measurements over the entire frequency band on which insertion loss requirements are specified (14 kHz-1 Ghz). The

SECTION 13 49 20.00 10 Page 13 receiver or network analyzer shall be capable of operating over the entire frequency band on which insertion loss requirements are specified (14 kHz-1 Ghz). Sensitivity shall be adequate to provide a measurement dynamic range at least 10 dB greater than the insertion loss requirement.

The load impedance shall be resistive and shall be capable of dissipating the rated full-load filter current. Insertion loss measurements shall be made at 20 percent, 50 percent, and 100 percent of the filter full-load operating current. Insertion loss measurements for communication/signal line filters shall be performed the same as for power filters except that the insertion loss measurements are required at a load impedance equal to the image impedance of the filter. No load insertion loss measurements shall be performed over the frequencies defined in the shielding effectiveness attenuation requirements for both power and communication filters. Testing shall be load to source for TEMPEST.

2.6.5.3 Filter Life at High Ambient Temperature

This test is conducted for the purpose of determining the effects on electrical and mechanical characteristics of a filter, resulting from exposure of the filter to a high ambient temperature for a specified length of time, while the filter is performing its operational function.

Surge current, total resistance, dielectric strength, insulation resistance, and capacitance are types of measurements that would show the deleterious effects due to exposure to elevated ambient temperatures. A suitable test chamber shall be used which will maintain the temperature at the required test temperature and tolerance. Temperature measurements shall be made within a specified number of unobstructed (inches) from any one filter or group of like filters under test. This test shall be made in still air. Specimens shall be mounted by their normal mounting means.

When groups of filters are to be tested simultaneously, the mounting distance between filters shall be as specified for the individual groups otherwise the mounting distance shall be sufficient to minimize the temperature on one filter affecting the temperature of another. Filters fabricated of different materials shall not be tested simultaneously. The test temperature shall be (184 + 34 degrees F). The length of the test shall be for 5,000 hours. Specified measurements shall be made prior to, during, or after exposure.

2.6.5.4 Thermal Shock Test

This test is conducted for the purpose of determining the resistance of a filter to exposures at extremes of high and low temperatures, and to the shock of alternate exposures to these extremes. Suitable temperature controlled systems shall be used to meet the temperature requirements and test conditions. Environmental chambers shall be used to meet test requirements and to reach specified temperature conditions. Filters shall be placed so that there is no obstruction to the flow of air across and around the filter. The filter shall be subjected to the specified test condition. The first five cycles shall be run continuously. After five cycles, the test may be interrupted after the completion of any full cycle, and the filter allowed to return to room ambient temperature before testing is resumed. One cycle consists of steps 1 through 4 of the applicable test condition for dual environmental test chambers (one low temperature and one high temperature test chamber) and steps 1 and 3 for single compartment test chambers where both high and low temperatures are achieved without moving the filter. The test conditions are as follows:

1. -55 deg C. 0 deg and -3 deg

2. 25 deg C. +10 deg and -5 deg

SECTION 13 49 20.00 10 Page 14

3. 85 deg C. + 3 deg and -0 deg

4. 25 deg C. +10 deg and -5 deg

The effective total transfer time from the specified low temperature to the specified high temperature shall not exceed 5 minutes. The exposure time in air at the extreme temperatures is a function of the weight of the filter. The minimum exposure time per the weight of the filter shall be as follows:

1 oz. and below 15 minutes

Above 1 oz. to 4.8 oz. 30 minutes

Above 4.8 oz. to 3 lb. 1 hour

Above 3 lb. to 30 lb. 2 hours

Above 30 lb. to 300 lb. 4 hours

Above 300 lb. 8 hours

Specified measurements shall be made prior to the first cycle and upon completion of the final cycle, except that failures shall be based on measurements made after the specimen has stabilized at room temperature following the final cycle.

2.6.5.5 Overload Test

Filters shall be mounted in the filter/ESA assembly enclosure or mounted on a metal plate by the same holding method that will be used for mounting in the enclosure. A specified current shall then be applied for a specified period of time. After the filter has returned to room temperature, the insulation resistance and voltage drop shall be measured. The insulation resistance shall be measured using the method in paragraph FILTERS. AC voltage drop measurements shall be made by using expanded scale-type meters which will enable voltage differences of less than 1 volt to be read. DC voltage drop measurements shall be made by using a dc reading meter when the filter is carrying rated current and rated voltage. The insulation resistance and the voltage drop will be measured after each separate overload test. Filters will also be visually examined for evidence of physical damage after each test.

2.6.5.6 Reactive Shunt Current Measurements

The reactive shunt current measurements shall be performed with the filters mounted in the filter/ESA assembly enclosure or mounted on a metal plate by the same holding method that will be used for mounting in the enclosure. The filter shall be terminated in the inner compartment in an open circuit. Rated ac voltage shall be applied between the filter outer compartment terminal and the enclosure or metal plate. The ac current into the outer compartment terminal shall be monitored. The measured current is equal to the filter reactive shunt current.

2.6.5.7 Dielectric Withstand Voltage Test

The dielectric withstanding voltage test (also called high-potential, over

SECTION 13 49 20.00 10 Page 15 potential, voltage breakdown, or dielectric-strength test) consists of the application of a voltage higher than rated voltage for a specific time between mutually insulated portions of a filter or between insulated portions and ground. Repeated application of the test voltage on the same filter is not recommended as even an overpotential less than the breakdown voltage may injure the insulation. When subsequent application of the test potential is specified in the test routine, succeeding tests shall be made at reduced potential. When an alternating potential (ac) is used, the test voltage shall be 60 Hz. and shall approximate a true sine wave in form. All ac potentials shall be expressed as root-mean-square values.

The KVA rating and impedance of the source shall permit operation at all testing loads without serious distortion of the waveform and without serious change in voltage for any setting. When a direct potential (dc) is used, the ripple content shall not exceed 5 percent rms of the test potential. A voltmeter shall be used to measure the applied voltage to an accuracy of 5 percent. When a transformer is used as a high-voltage source of ac, a voltmeter shall be connected across the primary side or across a tertiary winding provided that the actual voltage across the filter will be within the allowable tolerance under any normal load condition. Unless otherwise specified, the test voltage shall be dc and shall be as follows:

For filters with ac and dc ratings 2.5 times rated dc voltage

The duration of the dc test voltages shall be 5 seconds minimum, 1 minute maximum, after the filter has reached thermal stability at maximum operating temperature produced by passage of rated current. The test voltage shall be applied between the case (ground) and all live (not grounded) terminals of the same circuit connected together. The test voltage shall be raised from zero to the specified value as uniformly as possible, at a rate of approximately 500 volts (rms or dc) per second.

Upon completion of the test, the test voltage shall be gradually reduced to avoid voltage surges. The changing current shall be 50 mA maximum.

During the dielectric withstanding voltage test, the fault indicator shall be monitored for evidence of disruptive discharge and leakage current.

The sensitivity of the breakdown test equipment shall be sufficient to indicate breakdown when at least 0.5 mA of leakage current flows through the filter under test. The test shall be performed with the components mounted in the filter/ESA assembly enclosure. Filters for ac circuits shall be tested with an ac source while filters for dc circuits shall be tested with a dc source. After the test the filter shall be examined and measurements shall be performed to include insulation resistance measurements to determine the effect of the dielectric withstanding voltage test on specific operating characteristics.

2.6.5.8 Insulation Resistance Test

This is a test to measure the resistance offered by the insulating members of a filter to an impressed direct voltage tending to produce a leakage current through or on the surface of these filters. Insulation-resistance measurements shall be made on an apparatus suitable for the characteristics of the filter to be measured such as a megohm bridge, megohm-meter, insulation-resistance test set, or other suitable apparatus. The test shall be performed with the components mounted in the filter/ESA assembly enclosure or mounted on a metal plate by the same holding method that will be used for mounting in the enclosure. The bleeder resistor shall be disconnected. The direct potential applied to

SECTION 13 49 20.00 10 Page 16 the specimen shall be the largest test condition voltage (100, 500, or 1,000 volts +10 percent) that does not exceed the rated peak ac voltage or the rated dc voltage. A separate dc power supply may be used to charge the filters to the test voltage. The measurement error at the insulation-resistance value required shall not exceed 10 percent. Proper guarding techniques shall be used to prevent erroneous readings due to leakage along undesired paths. Insulation-resistance measurements shall be made between the mutually insulated points or between insulated points and ground. The insulation resistance value shall be read with a megohmmeter and recorded after the reading has stabilized. When more than one measurement is specified, subsequent measurements of insulation resistance shall be made using the same polarity as the initial measurements.

2.6.5.9 Current Sharing

Testing shall be performed with the filters mounted in the filter/ESA assembly enclosure or mounted on a metal plate by the same holding method that will be used for mounting in the enclosure. The filter inner compartment terminals shall be loaded with a resistor equal in value to the rated operating voltage divided by the sum of the current ratings of the devices in parallel. The resistor shall be capable of dissipating the total current. Rated operating voltage shall be applied at the filter outer compartment terminals. The current into each filter outer compartment terminal shall be monitored.

2.6.5.10 Harmonic Distortion Test

Harmonic distortion measurements shall be made using a spectrum analyzer having a dynamic range of 70 dB and a frequency range from 10 kHz to 1.7 GHz. Total harmonic distortion shall be measured at the input and output terminals of the filter when operating at 25, 50, and 100 percent of rated full-load current.

2.6.5.11 Terminals Pull Test

The purpose of this test is to determine whether the design of the filter terminals can withstand the mechanical stresses to which they will be subjected during installation or disassembly in equipment. Testing shall be performed with the components mounted in the filter/ESA assembly enclosure or mounted on a plate by the same holding method that will be used for mounting in the enclosure. The force applied to the terminal shall be (20 pounds). The point of application of the force and the force applied shall be in the direction of the axes of the terminations. The force shall be applied gradually to the terminal and then maintained for a period of 5 to 10 seconds. The terminals shall be checked before and after the pull test for poor workmanship, faulty designs, inadequate methods of attaching of the terminals to the body of the part, broken seals, cracking of the materials surrounding the terminals, and the changes in electrical characteristics such as shorted or interrupted circuits. Measurements are to be made before and after the test.

2.7 PENETRATION PLATES

Penetration plates shall be minimum (1/4 inch) thick and sized as shown on the drawings. The penetration plate shall overlap the shield penetration cutout dimension by a minimum of (6 inch) on each side. The penetration plate shall be welded to the shield with continuous circumferential welds.

SECTION 13 49 20.00 10 Page 17

2.8 GALVANIZING

Galvanizing, when practical and not otherwise indicated, shall be hot-dipped processed after fabrication. Galvanizing shall be in accordance with ASTM A123/A123M , or ASTM A653/A653M , as applicable.

Exposed fastenings shall be galvanically compatible material.

Electrolytic couples and dissimilar metals that tend to seize or gall shall be avoided.

2.9 SHIELDED CABINETS AND PULL BOXES

Cabinets and pull boxes shall be modified NEMA 1 in accordance with NEMA ICS 6 made of corrosion resistant steel of not less than (14 gauge) thick with welded seams and galvanized bulkhead cover plates. Access cover plates shall be hinged with gaskets and (3 inch) maximum bolt spacing. Design shall include thick cover plates, folded enclosure edges, and bolt spacers to prevent uneven gasket compression and enclosure deformation. Gasket shall be easy to replace. Gasket contact areas shall be tin-plated using the electrodeposited type I method in accordance with ASTM B545. Conduit hub shall be circumferentially welded to the enclosure. The cabinets shall be finished with a corrosion-inhibiting primer and two coats of baked or finish enamel. Cabinets shall be provided with mounting brackets for wall mounting or legs for floor mounting. Cabinets and boxes of each type shall be factory tested in accordance with IEEE 299 and Table I of this specification.

2.10 QUALITATIVE MONITORING SYSTEM

A built-in shield monitoring system for SELDS testing shall be provided.

The system shall consist of either multiple injection points or a surface loop system. Driving conductors shall be brought to a single lockable shielded connection box, located outside the shield in a controlled space.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, verify dimensions in the field, and advise the Contracting Officer of any discrepancy before performing the work.

3.2 INSTALLATION

3.2.1 Coordination

The shielding installer shall instruct other trades in the presence and with the direction of the Government representative, in advance of the shielding system installation, to ensure that all individuals are aware of the critical installation requirements. Submit manufacturer's data, catalog cuts, and printed documentation regarding the work. Cleaners, solvents, coatings, finishes, physical barriers, and door threshold protectors shall be provided as required to protect the shielding system from corrosion, damage, and degradation. The shielding installation plan shall be approved before construction begins.

3.2.2 Verification

Before, during, and after the shielding and penetration protection subsystem installation, the shielding specialist shall verify and approve

SECTION 13 49 20.00 10 Page 18 the installation for compliance with the specifications. Materials and methods, shop drawings, and other items for the shielding subsystem shall bear an approval stamp of the shielding specialist. Compliance notification shall be provided to the Contracting Officer before materials are installed or methods performed.

3.2.3 Inspection

During and after shielding and penetration protection subsystem installation, including filters and waveguides, a qualified shielding specialist shall inspect the installation for compliance with the specifications. Complete the inspection before a finish or concrete topping coat is installed.

3.2.4 Manufacturer's Services

Provide the services of a manufacturer's representative who is experienced in the installation, adjustment, and operation of the equipment specified. The representative shall supervise the installation, adjustment, and testing of the equipment.

3.2.5 Posting Framed Instructions

Post framed instructions containing wiring and control diagrams under glass or in laminated plastic. Condensed operating instructions, prepared in typed form, shall be framed as specified above and posted beside the diagrams before acceptance testing of the system.

3.3 ENCLOSURE INSTALLATION - WELDED STEEL CONSTRUCTION

3.3.1 Formed Closures

Install formed closures where indicated and/or necessary to completely close all joints, openings, enclosures of pipe chases, and structural penetrations, columns, and beams.

3.3.2 Door Assemblies

Mount doors to perform as specified. The structural system supporting the door frame shall provide proper support for doors and frame.

3.4 SHIELDING PENETRATION INSTALLATION

Penetrations shall be installed in accordance with requirements of the penetration schedule and coordinated with system installation.

3.5 FIELD QUALITY CONTROL

Develop a quality control plan to ensure compliance with contract requirements; maintain quality control records for construction operations required under this section; and submit the quality control plan to the Contracting Officer. Furnish a copy of testing records, as well as the records of corrective actions taken. The in-progress and final acceptance testing of shielding and penetration protection system work shall be performed as specified. Correct deficiencies at no additional cost to the Government. Legible copies of the daily inspection reports shall be maintained by the shielding specialist at the project site, and the copies of the Construction Quality Control Report shall be delivered to the Contracting Officer on the third workday following the date of the

SECTION 13 49 20.00 10 Page 19 report. The daily inspections shall include the type of work being performed during the report period and locations, type of testing, deficiencies, corrective actions, unsolved problems, and recommendations to assure adequate quality control. Results of inspections and tests performed in accordance with this specification shall be attached to the daily Construction Quality Control Report.

3.6 FIELD TRAINING

Provide a field training course for designated operating and maintenance staff members. Training shall be provided for a total period of 8 hours of normal working time and shall start after the system is functionally complete but prior to the final acceptance test. Field training shall cover all the items contained in the Operating and Maintenance Manuals.

3.7 SHIELDING QUALITY CONTROL

The Contractor's organizational structure for shielding quality control shall be integrated into the jobsite management. Testing must be performed by Contractor with CTTA oversight.