RCC319-19_FTS_Commonality.pdf

Range Safety Group

DOCUMENT 319-19

FLIGHT TERMINATION SYSTEMS

COMMONALITY STANDARD

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ABERDEEN TEST CENTER

DUGWAY PROVING GROUND

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DOCUMENT 319-19

FLIGHT TERMINATION SYSTEMS

COMMONALITY STANDARD

June 2019

Prepared by

RANGE SAFETY GROUP

Published by

Secretariat Range Commanders Council

US Army White Sands Missile Range New Mexico 88002-5110

Flight Termination Systems Commonality Standard – RCC 319-19 June 2019 iii

Table of Contents Preface ......................................................................................................................................... xiii Acronyms ..................................................................................................................................... xv

Chapter 1. Introduction ........................................................................................................ 1-1

1.1 Background ...................................................................................................................... 1-1

1.2 Basis of Authority ............................................................................................................ 1-3

1.3 Scope ................................................................................................................................ 1-3

1.4 Acceptability at any Test Range within the Major Range and Test Facility Bases ......... 1-4

1.5 Lead Range Safety Office ................................................................................................ 1-4

1.6 Operational Constraints ................................................................................................... 1-5

1.7 Procurement of FTS-Peculiar Test Equipment ................................................................ 1-6

1.8 Tailoring ........................................................................................................................... 1-6

1.9 Waivers and ELS Certifications ....................................................................................... 1-7

1.10 Grandfathering ................................................................................................................. 1-7

1.11 Range User-Provided Hardware ...................................................................................... 1-8

1.12 Responsibilities and Authorities ...................................................................................... 1-8

Chapter 2. Tailoring.............................................................................................................. 2-1

2.1 Tailoring Overview .......................................................................................................... 2-1

2.2 Tailoring Process ............................................................................................................. 2-1

Chapter 3. Common FTS and Component Performance Requirements ......................... 3-1

3.1 FTS Functional Requirements ......................................................................................... 3-1

3.2 FTS Design ...................................................................................................................... 3-4

3.3 Environmental Design ................................................................................................... 3-11

3.4 Command Termination System ..................................................................................... 3-22

3.5 Automatic, Inadvertent-Separation, Fail-Safe, or AFTS ............................................... 3-23

3.6 FTS Safing and Arming Devices ................................................................................... 3-31

3.7 Liquid-Propellant Shutdown .......................................................................................... 3-32

3.8 FTS Monitoring ............................................................................................................. 3-33

3.9 FTS Electrical Components and Electronic Circuitry ................................................... 3-34

3.10 FTS Monitor, Checkout, and Control Circuits............................................................... 3-42

3.11 FTS Ordnance Path ........................................................................................................ 3-42

3.12 Radio Frequency Receiving System .............................................................................. 3-44

3.13 FTR ................................................................................................................................ 3-46

3.14 Wiring and Connectors .................................................................................................. 3-60

3.15 Laser-Initiated Ordnance Fiber-Optic Cable Assembly ................................................ 3-63

3.16 Batteries ......................................................................................................................... 3-64

3.17 Electromechanical Safe-and-Arm Devices with a Low-Voltage Initiator ..................... 3-73

3.18 High-Energy Electronic Initiator Firing Unit ................................................................ 3-77

3.19 Laser Firing Unit ............................................................................................................ 3-79

3.20 Ordnance Interrupter ...................................................................................................... 3-82

3.21 Ordnance Initiators......................................................................................................... 3-85

3.22 Devices Containing Percussion Initiators ...................................................................... 3-89

3.23 Propellant-Actuated Devices/Cartridge-Actuated Devices ............................................ 3-91 iv

3.24 Explosive Transfer System ............................................................................................ 3-92

3.25 Destruct/Terminate Charge ............................................................................................ 3-93

3.26 Parachute Systems ......................................................................................................... 3-95

3.27 FTS Shutdown Valves ................................................................................................... 3-95

3.28 Vibration and Shock Isolators ........................................................................................ 3-99

3.29 Autonomous Flight Termination Unit ........................................................................... 3-99

3.30 Miscellaneous Components ......................................................................................... 3-103

Chapter 4. FTS Component Test and Analysis Requirements ......................................... 4-1

4.1 Scope and Compliance ..................................................................................................... 4-1

4.2 Component Tests and Analyses ....................................................................................... 4-1

4.3 Test Plans and Procedures ............................................................................................... 4-1

4.4 Test Anomalies and Failures ............................................................................................ 4-1

4.5 Failure Analysis ............................................................................................................... 4-2

4.6 Test Tolerances ................................................................................................................ 4-3

4.7 Test Equipment ................................................................................................................ 4-4

4.8 Rework and Repair of Components ............................................................................... 4-10

4.9 Test and Analysis Reports ............................................................................................. 4-10

4.10 Component Test and Analysis Tables ............................................................................ 4-11

4.11 Component Examination ............................................................................................... 4-15

4.12 Acceptance Testing and Analysis .................................................................................. 4-17

4.13 General Qualification Testing and Analysis Requirements ........................................... 4-26

4.14 Qualification Non-Operating Environments .................................................................. 4-28

4.15 Qualification Operating Environments .......................................................................... 4-34

4.16 Radio Frequency Receiving System .............................................................................. 4-53

4.17 FTR - Analog/Tone-Based ............................................................................................. 4-56

4.18 EFTR .............................................................................................................................. 4-71

4.19 Autonomous Flight Termination Unit ........................................................................... 4-86

4.20 FTS Shutdown Valves ................................................................................................... 4-93

4.21 Miscellaneous Components ......................................................................................... 4-103

4.22 Electrical Connectors and Harnesses ........................................................................... 4-105

4.23 Remotely Activated Silver-Zinc Batteries ................................................................... 4-107

4.24 Thermal Batteries ......................................................................................................... 4-113

4.25 Manually Activated Silver-Zinc Batteries ................................................................... 4-119

4.26 Nickel-Cadmium Batteries ........................................................................................... 4-131

4.27 Lithium-Ion Batteries ................................................................................................... 4-148

4.28 Lead-Acid Batteries ..................................................................................................... 4-163

4.29 Safe-and-Arm Devices, Low-Voltage Initiators, Rotor Leads, and Booster

Charges ........................................................................................................................ 4-179

4.30 High-Energy Firing Units ............................................................................................ 4-195

4.31 LFUs, Fiber-Optic Cable Energy Transfer Systems, and LIDs ................................... 4-209

4.32 Ordnance Interrupters .................................................................................................. 4-225

4.33 Percussion-Initiated Device ......................................................................................... 4-232

4.34 Explosive Transfer System, Ordnance Manifolds, and Destruct Charges ................... 4-239

4.35 Ordnance Interfaces and Manifold Qualification ........................................................ 4-244

4.36 Shock and Vibration Isolators ...................................................................................... 4-246 v

Chapter 5. FTS Component, Subsystem, and System Pre-launch Test and Launch Requirements ................................................................................................... 5-1

5.1 General ............................................................................................................................. 5-1

5.2 Pre-flight Component Tests ............................................................................................. 5-4

5.3 Pre-launch Subsystem and System-Level Tests ............................................................ 5-10

5.4 Range and Vehicle Compatibility .................................................................................. 5-16

5.5 Special Tests .................................................................................................................. 5-17

5.6 Post-Mission Data Analysis ........................................................................................... 5-17

Chapter 6. FTS Ground Support and Monitoring Equipment Design Requirements.................................................................................................................. 6-1

6.1 General ............................................................................................................................. 6-1

6.2 Ordnance Initiator Simulator ........................................................................................... 6-1

6.3 Laser Test Equipment ...................................................................................................... 6-2

6.4 Range Safety Console ...................................................................................................... 6-2

6.5 Ground Support Equipment Provided by the Range User ............................................... 6-4

Chapter 7. FTS Analysis ....................................................................................................... 7-1

7.1 General ............................................................................................................................. 7-1

7.2 System Reliability ............................................................................................................ 7-1

7.3 Single-Point Failure ......................................................................................................... 7-1

7.4 Fratricide .......................................................................................................................... 7-1

7.5 Bent Pin ............................................................................................................................ 7-2

7.6 Radio Frequency Link...................................................................................................... 7-2

7.7 Sneak Circuit .................................................................................................................... 7-2

7.8 Software and Firmware .................................................................................................... 7-2

7.9 Battery Capacity............................................................................................................... 7-3

7.10 Component Maximum Predicted Environment ............................................................... 7-3

7.11 Failure Analysis ............................................................................................................... 7-4

7.12 Qualification-by-Similarity Analysis ............................................................................... 7-4

7.13 Vehicle Power Analysis ................................................................................................... 7-5

7.14 Radio Frequency Radiation Analysis............................................................................... 7-5

7.15 FTS Breakup Analysis ..................................................................................................... 7-5

7.16 Tip-Off Analysis .............................................................................................................. 7-5

7.17 Automatic Destruct System Timing Analysis.................................................................. 7-6

7.18 Ordnance Initiator Simulator Analysis ............................................................................ 7-6

7.19 In-Flight FTS Analysis .................................................................................................... 7-6

7.20 FTS Laser-Initiated Detonator Heat Dissipation Analysis .............................................. 7-6

Chapter 8. Documentation ................................................................................................... 8-1

8.1 General ............................................................................................................................. 8-1

8.2 FTSR ................................................................................................................................ 8-1

8.3 FTSR Submittal Process .................................................................................................. 8-1

8.4 Final Approval ................................................................................................................. 8-2

8.5 FTSR Format ................................................................................................................... 8-2

8.6 Telemetry Measurement .................................................................................................. 8-5 vi

8.7 FTSR Appendixes ............................................................................................................ 8-5

Appendix A. Safety Software Requirements ....................................................................... A-1

A.1 Introduction ..................................................................................................................... A-1 A.2 Scope ............................................................................................................................... A-1 A.3 Software Safety Considerations ...................................................................................... A-2 A.4 Safety-Critical Software Requirements for Partitioned and Non-Partitioned

Systems ........................................................................................................................... A-6 A.5 Support-Critical Software Requirements for Partitioned Systems ............................... A-21 A.6 Assessment (IV&V) Level of Effort Determination Guidance .................................... A-22

Appendix B. Electronic Piece-Part Procurement Requirements ...................................... B-1

B.1 Piece-Part Program Plan ................................................................................................. B-1 B.2 US Military-Quality Piece-parts ..................................................................................... B-4 B.3 Custom or Non-Military Piece-parts ............................................................................... B-5 B.4 AQEC and AEC Grade 0 or 1 Piece-parts or Equivalent ............................................... B-6

Appendix C. Electronic Piece-Part Derating Requirements ............................................. C-1

C.1 General ............................................................................................................................ C-1 C.2 Capacitors ....................................................................................................................... C-2 C.3 Connectors Reliability Application Derating Guidelines ............................................... C-6 C.4 Crystal Reliability Application Derating Guidelines ...................................................... C-7 C.5 Diode Reliability Application Derating Guidelines ........................................................ C-8 C.6 Electromagnetic Interference Filters - Reliability Application Derating

Guidelines ....................................................................................................................... C-9 C.7 Fuses - Reliability Application Derating Guidelines .................................................... C-10 C.8 Inductor and Transformer Reliability Application Derating Guidelines ...................... C-11 C.9 Integrated Circuits ......................................................................................................... C-12 C.10 Motors - Derating Criteria ............................................................................................ C-14 C.11 Printed Wiring Boards and Printed Circuit Boards....................................................... C-14 C.12 Relays Derating Criteria ............................................................................................... C-17 C.13 Resistors ........................................................................................................................ C-18 C.14 Slip Rings - Derating Criteria ....................................................................................... C-24 C.15 Substrates - Derating Criteria........................................................................................ C-24 C.16 Switches - Derating Criteria .......................................................................................... C-24 C.17 Transistors - Derating Criteria ...................................................................................... C-24 C.18 Wire and Cable - Derating Criteria ............................................................................... C-25

Appendix D. Planning and Executing a Successful FTS Acquisition using RCC 319 ..... D-1

D.1 Purpose ............................................................................................................................ D-1 D.2 Milestones ....................................................................................................................... D-1 D.3 FTS Development Flow Charts ...................................................................................... D-2 D.4 Contract Obligation ......................................................................................................... D-8 D.5 System-Level PDR with Range User or their Prime Contractor .................................. D-10 D.6 Flow of Requirements to Sub-Contractors ................................................................... D-14 D.7 Individual PDR(s) for each New Component ............................................................... D-18 D.8 Individual CDR(s) for each New Component .............................................................. D-19 vii

D.9 System-Level CDR with Range User or their Prime Contractor .................................. D-21 D.10 FTS Certification/Mission Support ............................................................................... D-22

Appendix E. Glossary ............................................................................................................ E-1

Appendix F. Citations ............................................................................................................ F-1

Appendix G. References ........................................................................................................ G-1

List of Figures Figure 1-1. Typical Flight Safety System with Flight Termination System ........................... 1-1 Figure 3-1. Battery Performance Operational Capacity Overview ...................................... 3-66 Figure 4-1. Example of Allowable Spikes .............................................................................. 4-6 Figure 4-2. Example Cross-Talk Response Acceptable Region ............................................. 4-7 Figure 4-3. Acceptance Thermal Cycle Temperatures - Non-Ordnance .............................. 4-18 Figure 4-4. Workmanship Random Vibration Profile .......................................................... 4-23 Figure 4-5. Qualification Thermal Cycle Temperature Requirements - Non-Ordnance, Upper Maximum Predicted Environment .......................................................... 4-34 Figure 4-6. Qualification Thermal Cycle Temperature Requirements - Non-Ordnance, Lower Maximum Predicted Environment ......................................................... 4-35 Figure 4-7. Pressure Lapse Rate for the Altitude (Low Pressure) Step ................................ 4-42 Figure 4-8. Temperature/Humidity/Altitude Test Profile ..................................................... 4-43 Figure 4-9. Sample of Conflict Between Qualification and Acceptance Test Margins ....... 4-46 Figure 4-10. Procedure for Hardmount Acceptance and Qualification of Components on Vibration Isolators ........................................................................................ 4-48 Figure 4-11. Electrostatic Discharge Test ............................................................................ 4-190 Figure B-1. Illustration of Piece-Part Screening .................................................................... B-2 Figure B-2. Capacitors ......................................................................................................... B-13 Figure B-3. Crystals ............................................................................................................. B-13 Figure B-4. Filters ................................................................................................................ B-14 Figure B-5. Connectors and Contacts................................................................................... B-14 Figure B-6. Fuses ................................................................................................................. B-14 Figure B-7. Heaters .............................................................................................................. B-15 Figure B-8. Magnetics .......................................................................................................... B-15 Figure B-9. Microcircuits, Hybrid ........................................................................................ B-15 Figure B-10. Microcircuits, Monolithic ................................................................................. B-15 Figure B-11. Plastic Encapsulated Devices ............................................................................ B-16 Figure B-12. Relays ................................................................................................................ B-16 Figure B-13. Semiconductor Devices, Discrete ..................................................................... B-16 Figure B-14. Thermistors ....................................................................................................... B-17 Figure B-15. Switches ............................................................................................................ B-17 Figure B-16. Crystal Oscillators ............................................................................................. B-17 Figure B-17. Resistores .......................................................................................................... B-18 Figure C-1. Example of a Derating Curve Plot ...................................................................... C-1 Figure C-2. Ceramic or Ceramic Chip (CKR, CCR, CKS, CDR) ......................................... C-4 Figure C-3. Glass, Porcelain (CYR) ....................................................................................... C-4 Figure C-4. Mica (CMS) ........................................................................................................ C-5 viii

Figure C-5. Tantalum Foil (CLR 25, 27, 35, 37) ................................................................... C-5 Figure C-6. Solid Tantalum (CSR, CSS) ............................................................................... C-6 Figure C-7. Wet Tantalum-Tantalum (CLR 79) .................................................................... C-6 Figure C-8. Solid-Body Fuses .............................................................................................. C-10 Figure C-9. Printed Circuit Board Derating Curves - Full Scale ......................................... C-15 Figure C-10. Printed Circuit Board Derating Curves - Expanded Scale ................................ C-16 Figure C-11. Carbon Composition Resistor (RCR) ............................................................... C-21 Figure C-12. Metal Film Resistor (RLR) ............................................................................... C-22 Figure C-13. Metal Film Resistor (RNC, RNR) .................................................................... C-22 Figure C-14. Wire-Wound Accurate Resistor (RBR) ............................................................ C-23 Figure C-15. Wire-Wound Power Resistor (RWR, RER)...................................................... C-23 Figure D-1. Work Prior to Contractual Obligation................................................................. D-2 Figure D-2. Entry Criteria for the System-Level PDR ........................................................... D-3 Figure D-3. Criteria to Flow Requirements to Subcontractors ............................................... D-4 Figure D-4. New Component PDR(s) and CDR(s) ................................................................ D-5 Figure D-5. Entry Criteria for the System-Level CDR .......................................................... D-6 Figure D-6. From System-Level CDR to an FTS Mission ..................................................... D-7

List of Tables Table 3-1. Fail-Safe Cross-Strapping Logic........................................................................ 3-27 Table 3-2. Tone Logic for 4-Tone FTR with Fail-Safe (Commanded Fail-Safe

Enable/Disable) .................................................................................................. 3-28 Table 4-1. Test Tolerances .................................................................................................... 4-3 Table 4-2. Workmanship Random Vibration Profile .......................................................... 4-22 Table 4-3. Minimum Transportation Random Vibration Profile ........................................ 4-30 Table 4-4. Minimum Qualification Random Vibration Profile ........................................... 4-46 Table 4-5. Minimum Breakup Qualification Shock Profile ................................................ 4-51 Table 4-6. RF Receiving System Acceptance Test Requirements ...................................... 4-53 Table 4-7. RF Receiving System Qualification Test Requirements ................................... 4-54 Table 4-8. FTR Acceptance Test Requirements ................................................................. 4-57 Table 4-9. FTR Qualification Test Requirements ............................................................... 4-58 Table 4-10. Out-of-Band Signal Rejection Test Frequencies for FTRs ................................ 4-67 Table 4-11. Thermal Performance Tests for FTRs................................................................ 4-71 Table 4-12. EFTR Acceptance Test Requirements ............................................................... 4-71 Table 4-13. EFTR Qualification Test Requirements ............................................................. 4-72 Table 4-14. RSTO Voltage Levels ........................................................................................ 4-76 Table 4-15. Out-of-Band Rejection Test Frequencies for EFTRs......................................... 4-83 Table 4-16. Thermal Performance Tests for EFTSs.............................................................. 4-85 Table 4-17. AFTU Acceptance Test Requirements .............................................................. 4-86 Table 4-18. AFTU Qualification Test Requirements ............................................................ 4-87 Table 4-19. Electro-Mechanical Valve Acceptance Test Requirements1 ............................. 4-93 Table 4-20. Electro-Mechanical Valve Qualification Test Requirements1 ........................... 4-94 Table 4-21. Pneumatically Actuated Valve Acceptance Test Requirements1 ....................... 4-95 Table 4-22. Pneumatically Actuated Valve Qualification Test Requirements1 .................... 4-96 Table 4-23. Electro-Pneumatic (Pilot) Valve Acceptance Test Requirements1 .................... 4-97 ix

Table 4-24. Electro-Pneumatic (Pilot) Valve Qualification Test Requirements1 ................. 4-98 Table 4-25. Miscellaneous Component Acceptance Test Requirements ............................ 4-104 Table 4-26. Miscellaneous Component Qualification Test Requirements.......................... 4-104 Table 4-27. Electrical Connector and Harness Test Requirements ..................................... 4-105 Table 4-28. Remotely Activated Silver-Zinc Battery LAT Requirements1 ........................ 4-107 Table 4-29. Remotely Activated Silver-Zinc Battery Qualification Test Requirements .... 4-108 Table 4-30. Thermal Battery LAT Requirements1 .............................................................. 4-113 Table 4-31. Thermal Battery Qualification Test Requirements .......................................... 4-115 Table 4-32. Manually Activated Silver-Zinc Coupon Cell and Battery Acceptance Test

Requirements ................................................................................................... 4-119 Table 4-33. Manually Activated Silver-Zinc Cell and Battery Qualification Test

Requirements ................................................................................................... 4-120 Table 4-34. Manually Activated Silver-Zinc Cell Age Surveillance Test Requirements ... 4-122 Table 4-35. Nickel-Cadmium Cell LAT Requirements ...................................................... 4-131 Table 4-36. Nickel-Cadmium Battery Acceptance Test Requirements .............................. 4-132 Table 4-37. Nickel-Cadmium Cell Lot and Battery Qualification Test Requirements ....... 4-133 Table 4-38. Nickel-Cadmium Cell Lot and Battery SLE Test Requirements ..................... 4-134 Table 4-39. Li-Ion Cell LAT Requirements ........................................................................ 4-148 Table 4-40. Li-Ion Battery Acceptance Test Requirements ................................................ 4-148 Table 4-41. Li-Ion Cell Lot and Battery Qualification Test Requirements ........................ 4-149 Table 4-42. Li-Ion Cell and Battery Age Surveillance and SLE Test Requirements ......... 4-151 Table 4-43. Lead-Acid Cell LAT Requirements ................................................................. 4-163 Table 4-44. Lead-Acid Battery Acceptance Test Requirements ......................................... 4-164 Table 4-45. Lead-Acid Cell Lot and Battery Qualification Test Requirements ................. 4-165 Table 4-46. Lead-Acid Cell and Battery SLE Test Requirements ...................................... 4-166 Table 4-47. SAD Acceptance Test Requirements ............................................................... 4-179 Table 4-48. SAD Qualification Test Requirements ............................................................ 4-180 Table 4-49. Low-Voltage Initiator LAT Requirements ...................................................... 4-181 Table 4-50. Low-Voltage Initiator Qualification Test Requirements ................................. 4-182 Table 4-51. Low-Voltage Initiator SLE Test Requirements ............................................... 4-183 Table 4-52. S&A Rotor Lead and Booster Charge LAT Requirements1 ............................ 4-184 Table 4-53. S&A Rotor Lead and Booster Charge Qualification Test Requirements1 ....... 4-185 Table 4-54. S&A Rotor Lead and Booster Charge SLE Test Requirements1 ..................... 4-185 Table 4-55. Default Test Frequencies and Modulation ....................................................... 4-193 Table 4-56. High-Energy Firing Unit Acceptance Test Requirements ............................... 4-195 Table 4-57. High-Energy Firing Unit Qualification Test Requirements ............................. 4-196 Table 4-58. EBW And EFI LAT Requirements .................................................................. 4-197 Table 4-59. EBW and EFI Qualification Test Requirements .............................................. 4-198 Table 4-60. EBW and EFI SLE Test Requirements ............................................................ 4-200 Table 4-61. Default Test Frequencies and Modulation ....................................................... 4-208 Table 4-62. Laser Firing Unit Acceptance Test Requirements ........................................... 4-210 Table 4-63. Laser Firing Unit Qualification Test Requirements......................................... 4-210 Table 4-64. Laser-Initiated Detonator LAT Requirements ................................................. 4-211 Table 4-65. Laser-Initiated Detonator Qualification Test Requirements ............................ 4-213 Table 4-66. Laser-Initiated Detonator SLE Test Requirements .......................................... 4-214 Table 4-67. Fiber-Optic Cable Assembly Acceptance Test Requirements ......................... 4-215 x

Table 4-68. Fiber-Optic Cable Assembly Qualification Test Requirements ...................... 4-216 Table 4-69. Default Test Frequencies and Modulation ....................................................... 4-224 Table 4-70. Ordnance Interrupter Acceptance Test Requirements ..................................... 4-225 Table 4-71. Ordnance Interrupter Qualification Test Requirements ................................... 4-225 Table 4-72. Ordnance Interrupter Rotor Lead and Booster Charge LAT Requirements1 ... 4-226 Table 4-73. Ordnance Interrupter Rotor Lead and Booster Charge Qualification Test

Requirements1 .................................................................................................. 4-227 Table 4-74. Ordnance Interrupter Rotor Lead and Booster Charge SLE Test

Requirements1 .................................................................................................. 4-228 Table 4-75. PID LAT Requirements1 .................................................................................. 4-232 Table 4-76. PID Lot Qualification Test Requirements ....................................................... 4-233 Table 4-77. Percussion Primer Charge LAT Requirements1 .............................................. 4-234 Table 4-78. Percussion Primer Charge Qualification Test Requirements ........................... 4-235 Table 4-79. Percussion-Initiated Detonator SLE Test Requirements ................................. 4-235 Table 4-80. ETS, Ordnance Manifold, and Destruct Charge LAT Requirements .............. 4-239 Table 4-81. Destruct Charge Qualification Test Requirements .......................................... 4-240 Table 4-82. ETS and Ordnance Manifold Qualification Test Requirements ...................... 4-241 Table 4-83. ETS, Explosive Manifold, and Destruct Charge SLE Test Requirements ...... 4-242 Table 4-84. Shock and Vibration Isolator Acceptance Test Requirements ........................ 4-246 Table 4-85. Shock and Vibration Isolator Qualification Test Requirements ...................... 4-246 Table A-1. Safety-critical Software Documentation Listing .............................................. A-20 Table A-2. Support-Critical Software Documentation Listing ........................................... A-22 Table A-3. IV&V LOE Example Mapping ......................................................................... A-23 Table A-4. Factors and IV&V Level of Effort Refinement ................................................ A-24 Table B-1. Preferred Piece-part Screening Through Lot Sampling .................................... B-11 Table B-2. Test Definitions and Methods ........................................................................... B-18 Table B-3. Case-by-case Piece-part Screening Through Board-level Testing ................... B-22 Table C-1. Capacitors, Mil-Spec Listing (For Reference) .................................................... C-2 Table C-2. Capacitor Derating .............................................................................................. C-2 Table C-3. Derating Curve Figures by Capacitor Type ........................................................ C-3 Table C-4. Connectors .......................................................................................................... C-7 Table C-5. Connector Derating ............................................................................................. C-7 Table C-6. Crystals ............................................................................................................... C-7 Table C-7. Diode (Switching, Small-Signal, Rectifier, and Transient Suppressors) ............ C-8 Table C-8. Diode (Step Recovery, Varactor, and Varicap) .................................................. C-8 Table C-9. Zener Diode (Reference and Regulator) ............................................................. C-8 Table C-10. Diode, Shottky Barrier ........................................................................................ C-9 Table C-11. Diode (Tunnel, Germanium)1 ............................................................................. C-9 Table C-12. Diode (Photo, Light-Emitting Diode) ................................................................. C-9 Table C-13. Electromagnetic Filters ....................................................................................... C-9 Table C-14. Fuse Derating .................................................................................................... C-10 Table C-15. Inductors and Transformers .............................................................................. C-11 Table C-16. Complementary Metal Oxide Semiconductor and Transistor-Transistor

Logic Integrating Circuits ................................................................................. C-12 Table C-17. Integrated Circuit, Linear, Operational Amplifier, Comparator1 ...................... C-12 Table C-18. Integrated Circuit, Linear Voltage Regulator ................................................... C-13 xi

Table C-19. Values for K ...................................................................................................... C-13 Table C-20. Motor Derating.................................................................................................. C-14 Table C-21. Relay Derating .................................................................................................. C-17 Table C-22. Mil-Spec Listing (For Reference) ..................................................................... C-18 Table C-23. Resistor Derating .............................................................................................. C-19 Table C-24. Derating Curve Figures by Resistor Type ........................................................ C-20 Table C-25. Bipolar Junction and Junction-gate Field Effect Transistors ............................ C-24 Table C-26. GaAs Field Effect Transistor ............................................................................ C-25 Table C-27. Metal Oxide Semiconductor Field Effect Transistors, Small-Signal, and

Power Transistors.............................................................................................. C-25 Table C-28. Wire Derating1,2 ................................................................................................ C-25 Table D-1. FTS Development Milestones............................................................................. D-1 Table D-2. Figure Legend ..................................................................................................... D-1 xii xiii

Preface

This document presents the results of Task RS-63 assigned to the Range Safety Group/Flight Termination Systems Committee to update Range Commanders Council (RCC) Document 319, Flight Termination Systems Commonality Standard. This standard has been written to conform to the intent of a guide specification per Defense Standardization Program SD-15.1 The intent of the format is to levy performance requirements, allow the range user flexibility to develop innovative technical solutions, and simultaneously ensure adequate detail for contractual enforcement. The format includes performance requirements in plain text with text boxes placed directly after each performance requirement. Text boxes present recommended solutions that reflect the standard practice and lessons learned and are tailored for each unique application. Once tailored, these text boxes become mandatory, contractually enforceable requirements. Details on this format can be found in Chapter 1 and Chapter 2.

Please direct any questions to:

Secretariat, Range Commanders Council

ATTN: TEWS-RCC

1510 Headquarters Avenue White Sands Missile Range, New Mexico 88002-5110 Telephone: (575) 678-1107, DSN 258-1107 E-mail: usarmy.wsmr.atec.list.rcc@mail.mil

1 Department of Defense. Guide for Performance Specifications. SD-15. 24 August 2009. May be superseded by update. Available at http://www.navair.navy.mil/nawctsd/Resources/Library/Acqguide/SD_15%202009.pdf.

mailto:usarmy.wsmr.atec.list.rcc@mail.mil http://www.navair.navy.mil/nawctsd/Resources/Library/Acqguide/SD_15%202009.pdf xiv xv

Acronyms

AC alternating current ADS automatic destruct system AEC Automotive Electronics Council AFTS autonomous flight termination system AFTU autonomous flight termination unit Ag-Zn silver-zinc AM amplitude modulation AQEC Aerospace Qualified Electronics Components ATP acceptance test procedure AWG American Wire Gauge BIT built-in test BPSK binary phase shift keying CC constant current CCTO check channel telemetry output (EFTR) CDR critical design review CFS flight self-discharge in amp-hours CONOPS Concept of Operations COTS commercial off-the-shelf CR remaining capacity for determining operational stand time capacity CRC cyclic redundancy check CRF remaining capacity for determining capacity loss due to self-discharge C-SAM C-mode scanning acoustic microscopy CV Constant Voltage CVTO command valid telemetry output (EFTR) CW continuous wave DC direct current DoD Department of Defense DOE Department of Energy DPA destructive physical analysis DSCC-VQ Defense Supply Center, Columbus Sourcing and Qualification Unit DVT design verification test DWV dielectric withstanding voltage EAFD electronic arm-and-fire device EBW exploding bridgewire EED electro-explosive device EFI exploding foil initiator EFTR enhanced flight termination receiver EFTS enhanced flight termination system ELS equivalent level of safety EMC electromagnetic compatibility EMI electromagnetic interference EOCV end-of-charge voltage EODV end-of-discharge voltage ESAD electronic safe-and-arm device xvi

ESD electrostatic discharge ESS environmental stress screening ETL explosive transfer line ETS explosive transfer system FAA Federal Aviation Administration FM frequency modulation FMECA failure modes, effects, and criticality analysis FPGA field-programmable gate array FSS flight safety system FTR flight termination receiver FTS flight termination system FTSR flight termination system report GIDEP Government/Industry Data Exchange Program GPS Global Positioning System GSE ground support equipment HAST highly accelerated stress testing HTOL high-temperature operating life IAW in accordance with IEEE Institute of Electrical and Electronics Engineers IF intermediate frequency IMU inertial measurement unit INS inertial navigation system ISDS inadvertent separation destruct system IV&V independent verification and validation LAT lot acceptance test lbf pound-force LFU laser firing unit Li-ion lithium-ion LID laser-initiated detonator LOE level of effort LRSO lead range safety office LVI low-voltage initiator MDL mission data load MEOP maximum expected operating pressure MISRA Motor Industry Software Reliability Association MPE maximum predicted environment MRTFB Major Range and Test Facility Base ms millisecond MSL mean sea level N Newtons N/A not applicable NASA National Aeronautics and Space Administration Ni-Cd nickel-cadmium OCV open circuit voltage PAD propellant-actuated device PCB printed circuit board PDR preliminary design review xvii

PI percussion initiator PID percussion-initiated device PIND particle impact noise detection PMPCB Parts, Materials, and Process Control Board PPAP production part approval process PWB printed wiring board QA quality assurance QBS qualification by similarity QTP qualification test procedure RCC Range Commanders Council RF radio frequency RH relative humidity RMS root mean square RSC range safety console RSO range safety office RSTO receiver status telemetry output RV re-entry vehicle RVM requirements verification matrix S&A safe-and-arm SAD safe-and-arm device SDD software design description sDOF statistical degrees of freedom SLC standard leak conditions SLE service life extension SOC state of charge SRS shock response spectrum SS statistical sample SSTO signal strength telemetry output TIM technical interchange meeting TM telemetry UAV unmanned aerial vehicle UDDP user-defined data port UML Unified Modeling Language VSWR voltage standing wave ratio xviii

1-1

CHAPTER 1

Introduction

1.1 Background

In an effort to establish a set of common design and testing requirements for programs operating from or on multiple ranges, several key organizations have worked together and set forth this standard to assist the range users in the determination of flight termination system (FTS) design and test requirements. These organizations include the major Department of Defense (DoD) test ranges, Department of Energy (DOE), Federal Aviation Administration (FAA), and National Aeronautics and Space Administration (NASA) launch and test facilities.

1.1.1 Terms and Use of…