SOW ARSR-4 Antenna Hatch Safety Railing rev b packet.pdf

STATEMENT OF WORK

For the

ARSR-4 Antenna Hatch Safety Railing 31 May, 2022

Federal Aviation Administration Mike Monroney Aeronautical Center

6500 S. MacArthur Blvd.

Oklahoma City, OK 73169

May 31, 2022 ARSR-4 Antenna Hatch Safety Railing SOW i

TABLE OF CONTENTS

1.0 INTRODUCTION

1.1 Background

1.2 Purpose

1.3 Scope

1.4 Definitions

1.5 Quantities

2.0 APPLICABLE DOCUMENTS

2.1 FAA Specifications

2.2 FAA Standards

2.3 Military Standards

2.4 Other FAA Documents

2.5 Non-Government Documents

3.0 SYSTEM REQUIREMENTS

3.1 Program Management

3.1.1 Project Control

3.1.2 Meetings, Reviews, and Conferences

3.1.2.1 Post Award Conference (PAC) / Preliminary Design Review (PDR)

3.1.2.2 Final Design Review (FDR)

3.1.2.3 Physical Configuration Audit (PCA)

3.1.3 Schedule Planning and Control

3.1.4 Configuration Management (CM)

3.2 Systems Engineering and Modification Kit Production

3.2.1 System Requirements

3.2.1.1 Modification Kit Contents

3.2.1.2 Individual Component Requirements

4.0 SUPPORT

4.1 COTS Manuals and Documentation

4.2 Packaging, Handling, Storage, and Transportation

4.3 Labels

APPENDIX A ACRONYMS AND ABBREVIATIONS

APPENDIX B SYSTEM PARTS LIST

APPENDIX C SYSTEM DRAWING PACKAGE

1.0 INTRODUCTION

1.1 Background

The ARSR-4 radar system is the United States’ newest long range radar system and completed deployment in year 2000. This system provides radar coverage for the Federal Aviation Administration (FAA), the Department of Defense (DoD), and the Department of Homeland Security (DHS). The antenna deck of the radar tower has an access hatch to allow personnel to enter the radome area. The FAA has identified this hatch as a safety hazard. This hazard will be mitigated by the installation of a safety railing. FAA engineers have completed the design of the safety railing system, and the design package is ready for manufacture and production.

1.2 Purpose

This Statement of Work (SOW) describes the tasks the Contractor must perform for the manufacturing, production, test, and delivery of the ARSR-4 Antenna Hatch Safety Railing (AHSR) for these radar sites according to the design, form, and intent of the design package attached in appendix A.

1.3 Scope

This SOW defines the tasks involved in producing the safety rail. These include:

a) Procure and/or manufacture all individual parts, materials, and equipment needed to produce the design;

b) Modify the design to allow for packaging, shipping and assembly;

c) Assemble, manufacture, and produce the design;

d) Test each system produced;

e) Provide spare parts and assemblies in order to support the design;

f) Ship completed units;

g) Support operational testing by the Government.

The FAA national engineering office En Route Surveillance, AJW-142, in Oklahoma City, OK, designed this modification. The scope of this SOW allows for design or engineering changes to the existing design to facilitate packaging such that the system can be lifted through the equipment hatch, measuring 4’ x 6’, assembled and installed on-site. All such changes, and any additional changes the Contractor deems necessary for any reason, require the express written permission and approval of the Government.

1.4 Definitions

All reference to the “Government” in this SOW shall mean by authority of the Contracting Officer or designee. Reference to Government approval shall be limited to the Contracting Officer and his/her Technical Representative.

Any reference to the acronym Antenna Hatch Safety Railing (AHSR) in this SOW shall mean all systems and components that comprise a modification kit for one radar site installation.

For the purposes of this SOW, any item manufactured or modified by the Contractor is defined to be non-COTS if there are no commercial customers other than the U.S. Government.

1.5 Quantities

This contract is to provide one first article for testing at Oklahoma City, 2 additional units for Key site testing and 44 additional complete AHSR units for a total of 47 units. This number includes 3 spare kits. The additional 44 AHSR units can be ordered in phased delivery of no less than 3 a month once the first three articles are tested and approved by AJW-142.

2.0 APPLICABLE DOCUMENTS

The following specifications, handbooks, orders, standards, and drawings form a part of this SOW and are applicable to the extent specified herein. The design presented was designed according to these specifications and as delivered conforms to all applicable sections and regulations.

2.1 FAA Specifications

None

2.2 FAA Standards

None

2.3 Military Standards

MIL-PRF-28000B Initial Graphic Exchange Specification (IGES)

2.4 Other FAA Documents

FAA Order 4650.30 Management of NAS F&E Project / Material

2.5 Non-Government Documents

ASTM-D-3951 Standard Practice for Commercial Packaging

3.0 SYSTEM REQUIREMENTS

The Contractor must produce a first article modification kit consisting of all components needed to install a complete system at an operational ARSR-4 facility in Oklahoma City. The government will then have no greater than a two-month period, unless communicated to the vendor, to test the modification kit and provide feedback to the vendor on any necessary design changes. Any major changes identified, such as the safety rail obstructs the antenna rotation, will be the responsibility of the vendor to rectify. Once approved, the contractor must produce a second and third modification kit to be installed at two more ARSR-4 facilities. The second and third kits will be installed and tested for a period of time no longer than 2 months unless otherwise communicated to the vendor. Any changes to the design at this level will be the responsibility of the vendor. Once all three initial kits have been installed and tested, AJW-142 will review the modification kits for any necessary changes. Once AJW-142 deems the kits complete, the remaining quantity 44 kits will be produced and ordered from the contractor. The Contractor must not make any changes to the design of these systems without the express written approval of the Government. The Contractor must acquire Government approval of any variation in the new design that may be necessary throughout the development of these systems due to parts obsolescence or equipment unavailability. The Contractor must ensure that the AHSR units are fabricated, tested, and delivered in accordance with (IAW) the requirements in this SOW.

In performance of the above, the Contractor must provide qualified personnel, management, administrative materials, and facilities including assembly and manufacturing space. The Contractor’s assembly and manufacturing practices must adhere to all of the elements in this SOW. The Contractor must provide all plans, procedures, reports, and testing documentation.

The term Limited Production (LP) applies to the first production article kit. The Contractor must manufacture and deliver the LP kit to the ARSR-4 installation at the Mike Monroney Aeronautical Center (MMAC) for installation and site acceptance test.

Subsequent to the successful conclusion of development and testing of the LP kit, the Contractor must refurbish and maintain the LP modification to the production article configuration baseline throughout the lifecycle of this SOW.

The Contractor must perform IAW all plans developed in response to this SOW and as approved by the Government. The Contractor must interpret this SOW as taking precedence over any conflicts with said plans. Throughout this SOW, the Contractor must interpret the requirements to “record” information or data to mean ‘set down in a manner that can be retrieved and viewed’, unless otherwise specified. The result may take many forms, including, but not limited to, hand-written notes, hard copy, electronic documents, and data recorded in Computer Aided System Engineering (CASE) and project management tools. The Contractor must provide to the Government any software required to read or use the documents and data (as identified in this contract). All documentation, data, hardware, firmware, software, and CASE tools delivered by the Contractor as part of this contract, must become the property of the Government.

The Contractor must grant to the Government unlimited rights to all documentation (including, but not limited to, Contractor generated drawings and installation manuals for the safety rail.)

3.1 Program Management

The Contractor must submit for Government approval a Program Management Plan (PMP), and must revise such plan as necessary. Upon approval of the PMP, the Contractor must apply this plan. The Contractor must identify in the PMP the Contractor’s management, organization, authority, responsibility, controls, and the extent to which these apply to the AHSR. The Contractor must detail in the PMP the Contractor’s methodology to ensure the program management requirements set forth in this SOW are met. At a minimum, the Contractor must perform the following tasks in managing this Contract:

a) Produce the schedules of work that reflect and track the delivery of products as specified by this SOW;

b) Designate a Contractor’s Program Manager (PM) who is responsible for integrating and maintaining the total Contractor effort as described in this SOW and the Program Management Plan (PMP).

The Contractor’s PM must be prepared at all times, given reasonable notice, to present and discuss with the Government the status of contract activities.

3.1.1.1 Post Award Conference (PAC) / Preliminary Design Review (PDR) The Contractor must plan for, host, support, and participate in a combined Post Award Conference (PAC) and Preliminary Design Review (PDR) of not less than one work day, to be held via video conference within six weeks of contract award. The PAC and PDR have been combined in this SOW because the AHSR has been designed by the Government, and the intent of the PDR is to communicate the design to the Contractor. The design baseline is included with this SOW. Any deviations from this baseline must require the written approval of the Government. At this conference, it is assumed by the Government that the Contractor’s overall knowledge of the operation of the system will be limited. However, the Contractor must make every effort to address the plans, schedules, and work efforts for this contract. The Contractor must provide preliminary details of its plans for acquiring and developing the required materials, components, hardware, and equipment to meet contract requirements. The Contractor must discuss the production and manufacturing strategies, sequence of events, and resources.

At this conference, the Government must:

a) Work with the Contractor to develop an effective meeting plan and minutes for the

PAC/PDR;

b) Provide an engineering level briefing on the function, operation, and design of the

AHSR;

c) Provide engineering level expertise on all systems of the AHSR;

d) Discuss methods, procedures, and resources needed for system testing;

e) Provide any information on possible sources for parts and materials requested by the contractor;

f) Take Action Items to provide information needed in order for the Contractor to manufacture, produce, and deliver the AHSR unit;

g) Deliver the AHSR data.

h) Any requests of the government by the contractor will be identified during the meeting and a timeline for addressing these requests will be identified

To successfully complete the PAC/PDR, the Contractor must:

a) Obtain Government approval of the conference and meeting minutes for this meeting;

b) Identify COTS and non-COTS items and the manufacturing approach for each item in the parts list;

c) Identify commercial COTS documentation, any licensing agreements, and any usage limitations;

d) Identify any production issues in the design including, but not limited to, manufacturing risks or methods, assembly risks or issues, or procurement issues that present risk to the manufacturing and delivery of the AHSR kits according to the requirements of this SOW;

e) Identify any resources needed for system testing;

f) Review overall program risks on a technical, cost, and schedule basis.

3.1.1.2 Post Award Visit

The contractor must plan for a visit to the Oklahoma City ARSR-4 system for an in person demonstration of the environment in which the ASHR will be installed. This visit will be used to demonstrate the narrow clearances the for the AHSR units and demonstrate the necessity for specific tolerances.

3.1.1.3 Final Design Review (FDR)

The Contractor must conduct a Final Design Review (FDR). The Government will support this review by providing engineering knowledge needed in order to manufacture, assemble, operate, check-out, and fully test the proposed design in addition to the presentation in the PAC/PDR.

All open items or issues must be addressed. The intent of this meeting must be to remove as much risk as possible and begin manufacturing of the first article LP kit.

The Contractor must not conduct a FDR before obtaining Government approval of the PDR, and all PDR action items for both the Contractor and the Government must be closed prior to conducting the FDR, unless the Government has given permission to proceed.

In the FDR, the Government must:

a) Work with the Contractor to develop an effective meeting plan and minutes for the FDR;

b) Provide engineering level expertise on all systems of the AHSR;

c) Take Action Items to provide any additional information needed in order for the

Contractor to manufacture, produce, and deliver the AHSR unit.

In the FDR, the Contractor must present sufficiently detailed information to permit the Government to evaluate risk areas on a technical, cost, and schedule basis.

The Contractor must provide further details of its acquisition and development of the required components and materials needed to meet contract requirements.

As part of the FDR, the Contractor must present and review in detail the following items with the

Government:

a) Manufacturing schedule;

b) Production ability analysis;

c) Testing schedule;

d) Delivery schedule.

To successfully complete the FDR, the Contractor must:

a) Obtain Government approval of the conference and meeting minutes for this meeting;

b) Establish an initial allocated baseline based on the detailed design;

c) Obtain Government approval of the Factory Acceptance Test for LP kit 1.

3.1.2 Schedule Planning and Control

The Contractor must establish a schedule based on a logical and efficient sequence of events designed to accomplish the tasks described in the contract, including all options. The Contractor must include both planned dates and actual completion dates, and measured progress of individual schedule elements.

3.1.3 Configuration Management (CM)

The Contractor must use an internal CM system for the control of all configuration documentation, software, physical media, and physical parts representing or comprising the ARSR-4 AHSR modification. The Contractor must maintain this system and related procedures throughout this contract. The Contractor must use and maintain configuration baselines and their documentation. Incremental product baselines may be permitted if proposed and approved by the Government.

3.2 Systems Engineering and Modification Kit Production

The Contractor must execute a systems engineering program for fulfilling, verifying, integrating, and testing the requirements. The Contractor must designate and purchase (after Government approval) long lead-time hardware items (those that would impact the schedule if not ordered prior to production turn-on) necessary to implement the design.

The Contractor must provide a modification kit that meets all requirements in this SOW.

The Contractor must maintain effective control over the system engineering process, including subcontract items and services, to ensure that cost, performance, and schedule are met, to provide early detection and resolution of problems, and to reduce risk. The Contractor must specify a single authority that will serve as a Point of Contact (POC) for systems engineering issues.

The Contractor must establish an initial hardware and software baseline for a LP kit prior to the completion of the FDR. The Contractor must document all changes from FDR through the last production article to traceable hardware or software baselines.

3.2.1 System Requirements

The Contractor must procure, manufacture, assemble, and deliver complete AHSR modification kits.

3.2.1.1 Modification Kit Contents

The Contractor must include all of the system and materials required to assemble an ARSR-4 AHSR kit.

3.2.1.2 Individual Component Requirements

The Contractor must follow the manufacturing specifications and directions on the drawings for parts and assemblies without exception. In addition to the requirements identified in the drawing package, the Contractor must ensure that the ARSR-4 AHSR units comply with the following general requirements:

a) AHSR Units:

1. Safety rail must match the specifications of the attached schematics, in dimension and location

2. Safety rail must allow for ARSR-4 antenna rotation without obstruction in all tilt configurations

3. Safety rail must allow for antenna deck hatch to be opened and closed without obstruction

4. Design must be divided into 3 or more sections to allow for easier shipping

5. Individual sections must be manufactured, welded, whole pieces

6. Individual sections must be created to be bolted together on site by customer

7. Piping must meet OSHA and ANSI standards listed in schematics such as OSHA

1910.29 and ANSI 1264.1-2017

8. Piping shall be 1-1/4” galvanized steel unless otherwise discussed and approved by customer.

9. All burrs or sharp points caused by the fabrication and galvanizing process will be removed or made smooth by contractor

10. Safety Rail must mount to collars that will be bolted to ¼” floor decking with bolts provided by contractor

11. Contractor will create drill templates to indicate the locations to drill for the mounting collars

12. The AHSR must include a self-closing gate that opens outwards onto the antenna deck

13. The AHSR must be delivered in crates measuring no greater than 4’ L x 6’H

14. Shipping crates must be labeled in the label style attached

4.0 SUPPORT

The Contractor shall perform the tasks in the following subsections.

4.1 COTS Manuals and Documentation

The Contractor must provide documentation and final drawings of the modification kit with a parts list and installation instructions.

4.2 Packaging, Handling, Storage, and Transportation

The Contractor must provide all Packaging, Handling, Storage, and Transportation (PHS&T) requirements IAW ASTM-D-3951 and FAA Order 4650.30. Upon completion of the remaining production units, the Contractor must ship the completed AHSR units to the FAA logistics center address listed below.

4.3 Labels

The Contractor must provide labels IAW FAA-G-2100H for all the affected equipment unless otherwise specified, as part of each ARSR-4 AHSR unit delivery.

APPENDIX A ACRONYMS AND ABBREVIATIONS

AHSR Antenna Hatch Safety Railing ARSR Air Route Surveillance Radar CASE Computer Aided System Engineering CDRL Contract Data Requirements List CM Configuration Management COTS Commercial-Off-The-Shelf DHS Department of Homeland Security DoD Department of Defense DT Development Test FAA Federal Aviation Administration FDR Final Design Review HA High Ambient HTML Hypertext Markup Language IAW In Accordance With IGES Initial Graphic Exchange Specification LP Limited Production MMAC Mike Monroney Aeronautical Center NSN National Stock Number OT Operational Test PAC Post Award Conference PCA Physical Configuration Audit PDF Portable Document Format PDR Preliminary Design Review PHS&T Packaging, Handling, Storage, and Transportation PM Program Manager PMP Program Management Plan POC Point Of Contact SAT Site Acceptance Test SOW Statement of Work TRR Test Readiness Review U.S. United States XML Extensible Markup Language

APPENDIX B SYSTEM PARTS LIST

Contractor will provide parts list

APPENDIX C SYSTEM DRAWING PACKAGE

Appendix C contains the drawing package for each component of the Antenna Hatch Safety Railing.

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FEDERAL AVIATION ADMINISTRATION

DEPARTMENT OF TRANSPORTATION

AIR ROUTE RADAR SYSTEMS

6500 S. MACARTHUR BLVD. OKLAHOMA CITY, OK 73169

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FEDERAL AVIATION ADMINISTRATION DRAWN BY: DATE:

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SELF-CLOSING SWING GATE

Panel 1

FAA-G-2100H

May 9, 2005

U.S. Department of Transportation

Federal Aviation Administration

U.S. Department of Transportation

Federal Aviation Administration

Specification

ELECTRONIC EQUIPMENT, GENERAL REQUIREMENTS

Downloaded from http://www.everyspec.com

FAA-G-2100H May 9, 2005 i

TABLE OF CONTENTS

1 SCOPE AND PURPOSE

1.1 SCOPE

1.2 INTENDED USE

1.3 TAILORING OF THIS SPECIFICATION

1.4 CLASSIFICATION

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

2.2 NON-GOVERNMENT DOCUMENTS

3 REQUIREMENTS

3.1 GENERAL

3.1.1 Electrical Power

3.1.2 Mechanical

3.1.3 Equipment Software/Firmware

3.2 CHARACTERISTICS

3.2.1 Environmental Conditions

3.2.2 Physical Characteristics

3.2.3 Reliability

3.2.4 Maintainability

3.2.5 External Equipment Interfaces

3.2.6 Electrostatic Discharge

3.2.7 Transportability

3.3 EQUIPMENT DESIGN AND CONSTRUCTION

3.3.1 Materials, Processes, and Parts

3.3.2 Electromagnetic Compatibility

3.3.3 Nameplates and Marking

3.3.4 Interchangeability

3.3.5 Personnel Safety and Health

3.3.6 Human Engineering

3.4 DOCUMENTATION

3.5 PERSONNEL AND TRAINING

4 QUALITY ASSURANCE PROVISIONS

4.1 QUALITY SYSTEM REQUIREMENTS

4.1.1 Material Evaluation

4.1.2 Quality Conformance Evaluation

4.2 VERIFICATION/COMPLIANCE TO REQUIREMENTS

4.2.1 Requirements Verification Matrix

4.2.2 Classification of Tests

4.2.3 Test Equipment

5 PREPARATION FOR DELIVERY

6 ACRONYMS AND DEFINITIONS

ii

6.1 ACRONYMS AND ABBREVIATIONS

6.2 DEFINITIONS

6.2.1 Commercial-off-the-shelf (COTS)

6.2.2 Developmental item

6.2.3 Equipment Software/Firmware

6.2.4 Fail-safe

6.2.5 Fail-soft

6.2.6 Lowest Replaceable Units (LRUs)

6.2.7 Internal/building wiring

6.2.8 Modified COTS/commercial type product

6.2.9 Nationally Recognized Testing Laboratory (NRTL)

6.2.10 Non-developmental Item (NDI)

6.2.11 Rack/Equipment

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

6.2.13 Series Combination System Overcurrent

APPENDIX A

A.1 ITI (CBEMA) CURVE APPLICATION NOTE

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

APPENDIX B

B.1 GOVERNMENT DOCUMENTS

B.1.1 SPECIFICATIONS:

B.1.2 STANDARDS:

B.1.3 OTHER PUBLICATIONS:

APPENDIX C

C.1 NON-GOVERNMENT DOCUMENTS

C.1.1 STANDARDS:

APPENDIX D

LIST OF FIGURES

Figure 1 Inrush Current Limit Measurements Figure 2 Inrush Current Limit Ratios Figure 3 Standard FAA Nameplate Figure 4 Internal/building Electrical Power Wiring Diagram

LIST OF TABLES

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

1 SCOPE AND PURPOSE

1.1 Scope

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

1.2 Intended Use

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

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

1.3 Tailoring of this Specification

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

1.4 Classification

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

2 APPLICABLE DOCUMENTS

2.1 Government documents

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

2.2 Non-Government documents

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

3 REQUIREMENTS

3.1 General

3.1.1 ELECTRICAL POWER

a. All internal wiring to the equipment shall be in accordance with paragraph 3.3.1.3.10, Wiring.

Refer to Section 6.2.6 for wiring interface points.

b. The equipment shall interface to building wiring in accordance with NFPA 70, FAA-STD-032, and FAA-C-1217F, in that order of precedence.

c. Electrical enclosures, cabling, and wiring shall be approved by a nationally recognized testing laboratory.

d. When a piece of equipment, or subcomponent of a system, is being replaced with different equipment, the new equipment shall have same, or better power characteristics or the whole system has to be retested. The relevant power characteristics are in the sections 3.1.1.3 to 3.1.1.7.

3.1.1.1 Physical Requirements

3.1.1.1.1 Physical Construction

a. Accessibility:

The accessibility of test equipment or maintenance equipment shall be in accordance with NFPA 70 Article 110.

(1) All access for electrical components, connections, wiring, etc., shall comply with the accessibility requirements of section 3.1.2.4 of this document.

b. Equipment Directly Connected to Line Power:

(1) Controls and indicators for electrical line voltage of an equipment rack shall be located in accordance with NFPA 70. When switches or circuit breakers function as main power disconnecting means, operating either directly or through a contactor, they shall break the incoming line immediately before the line filter, terminal block or connector, fuses or other parts without compromising RFI, EMI shielding integrity.

(2) Equipment Connected By Cord and Plug to Line Power. Cord connected equipment/systems may be disconnected by means of the plug.

c. Plugs and receptacles provided for connection of the equipment to the AC supply line shall be of the locking type and in accordance with the requirements of W-C-596, W-C-596G, and installed in accordance with the requirements of NFPA-70.

d. Power cords provided for the connection of the equipment to the AC supply line shall be a 3 conductor cord for 120V, or 4 conductor cord for 220V, in accordance with the requirements of UL62 and installed in accordance with the requirements of NFPA-70.

e. Detachable power cords rated 125V (volts) maximum and 15A (amperes) maximum shall be 3 conductor type SF.

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

(2) The equipment end shall have a female connector per DESC 87204 (Connector, Plug, Electrical, Midget Locking, Specific Purpose, General Grade, Grounding, 2 Pole, 3 Wire, 15 A, 120V, 50/60Hz (Hertz) (Female)).

f. Convenience outlets provided in or with the equipment shall be duplex receptacles in accordance with W-C-596/12-2, installed and wired in accordance with the requirements of NFPA-70. The equipment design shall include the provisions required to provide power to these outlets from a source independent of the equipment power source.

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

3.1.1.2 Electrical Power Measurements

a. All Rack power measurements shall be taken at the distribution panel circuit breaker feeding the Rack being tested.

b. All standalone equipment power measurements shall be taken at the distribution panel circuit breaker feeding the standalone equipment being tested.

c. For system level, testing shall be preformed at circuit breaker controlling all power for each main power bus system under test.

3.1.1.3 Load Power Characteristics

3.1.1.3.1 Power Factor

a. The power factor measurement shall be in conformance with 3.1.1.2.

b. The rack, and/or standalone equipment power factor requirements at non ARTCC and large TRACON locations with loads of greater than 2 amperes rms shall be in accordance with 3.1.1.3.1.

c. The rack, and/or standalone equipment power factor requirements at ARTCC and large TRACON locations with loads of greater than 5 amperes rms shall be in accordance with 3.1.1.3.1.

d. The power factor shall be within the ranges specified for the following ranges of equipment WATTS capacity measured at the Rack, and or standalone equipment, power input location:

W (watts) PF (power factor) W < 2000 0.7(lag) – 0.7(lead)

2000 < W < 5000 0.8(lag) – 0.9(lead) W > 5000 0.9(lag) – 1.0

e. Power factor (PF) shall be defined as the absolute value of the product of the displacement component of power factor and the distortion component of power factor.

PF = |PFdisp x PFdist|

f. The displacement component of the power factor, PFdisp, is equal to the cosine of the angle between voltage and current which can be calculated by dividing the power dissipation in watts by the apparent power in volt-amperes (VA).

PFdisp = COS(θ) = Watts/VA

g. The distortion component of the power factor, PF dist , is equal to the reciprocal of the square root of one plus the square of the total harmonic distortion of the equipment (THD) as defined in IEEE STD 519.

( )2dist

THD1

PF

3.1.1.3.2 Inrush Current

Inrush current is defined as the peak amount of current that a load or device draws when first energized.

a. The inrush current measurement shall be in conformance with 3.1.1.2

b. Inrush current shall be measured by energizing the load or device within ten degrees of the positive (80 to 90 degrees), and the negative (260 to 270 degrees) peaks of the sine wave of applied voltage as shown in Figure 1.

c. The rack, and/or standalone equipment inrush current requirements at non ARTCC and large TRACON locations with loads of greater than 2 amperes rms shall be in accordance with 3.1.1.3.2.

d. The rack, and/or standalone equipment inrush current requirements at ARTCC and large TRACON locations with loads of greater than 5 amperes rms shall be in accordance with 3.1.1.3.2.

e. The steady state values of root mean square (rms) current shall be measured.

f. The test voltage source shall have at least five (5) times the full load or steady state rms current rating of the load or device under test at the point of connection of the device or load under test. Total voltage distortion of the source shall not exceed three percent (3%).

g. Cord connected equipment shall be connected to the test voltage source with the same size, type and length of cord to be furnished with the load or device under test. All other devices or loads shall be connected to the test voltage source with four (4) foot long conductors sized for their rms current in accordance with NFPA-70. All cords and conductors shall be directly connected to the test voltage source.

h. The ratio of peak inrush current to rms current for loads or devices up to 40A, measured on the phase conductor with highest current, shall be equal to or less than the ratio defined by Figure 2.

i. The ratio of peak inrush current to rms current for loads or devices greater than 40A and equal to or less than 80A, measured on the phase conductor with the highest current, shall be equal to or less than the ratio defined by Figure 2.

j. The inrush current limits for all direct current (DC), and all AC devices or loads whose rms current is greater than 80A shall be defined in the system level specification for that device or load.

Figure 1 Inrush Current Limit Measurements

Figure 2 Inrush Current Limit Ratios

Inrush Current Limits

0.001

0.01

0.1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Inrush to RMS Current Ratio

T im e In

S ec on ds

0-40 Amps Circuit Breaker Rating

40-80 Amps Circuit Breaker Rating

NOTE: Iovercurrent = Imax. peak ISS(rms)

3.1.1.4 Electrical Load Balance

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

3.1.1.5 Harmonics

a. The harmonics measurement shall be in conformance with 3.1.1.2

b. The individual current harmonic distortion (IN) produced by each individual equipment item or subsystem (consisting of several items combined in a single power circuit) shall be less than the limits listed in Table I measured at the input side of the power distribution where the rack or equipment is attached.

c. The total current harmonic distortion (THD) for equipment or subsystems requiring power of 40 kilowatts or more shall be limited to 10 percent. THD is defined in IEEE STD 519.

Table 1 Limits of Individual Harmonics

Harmonic

Order

Maximum Limits (mA) for 50 < W ≤ 600

(1 phase)

Maximum Limits (mA) for 600 < W < 40000 (1 or 3 phases)

2 1.00 x W 400+ (0.05 x W) 3 3.60 x W 1440+ (1.20 x W) 4 1.00 x W 400+ (0.05 x W) 5 2.00 x W 800+ (0.66 x W) 6 0.50 x W 200+ (0.02 x W) 7 1.50 x W 600+ (0.5 x W) 8 0.50 x W 200+ (0.02 x W) 9 1.00 x W 400+ (0.33 x W) 10 0.10 x W 100+ (0.01 x W) 11 0.60 x W 240+ (0.20 x W) 12 0.10 x W 100+ (0.01 x W) 13 0.51 x W 203+ (0.17 x W) 14 0.10 x W 50+ (0.01 x W) 15 0.44 x W 176+ (0.15 x W) 16 0.10 x W 50+ (0.01 x W) 17 0.39 x W 155+ (0.13 x W) 18 0.10 x W 50+ (0.01 x W) 19 0.35 x W 139+ (0.12 x W) 20 0.10 x W 50+ (0.01 x W)

Notes:

1. W equals power in Watts

2. Power is active power in Watts for both single phase and polyphase circuit as defined by ANSI/IEEE standard 100. “IEEE Standard Dictionary of Electrical and Electronic Terms”

d. Harmonic current requirements will be waived for individual equipment item or subsystem that meets the following:

(1) Individual equipment item or subsystem installed in ARTCC or large TRACONs with specified power less than or equal to 5 amps RMS steady state that meets harmonic current limits IEC 61000-3-2 “Limits for harmonic current emissions”, Class D equipment, Table 3 “Maximum permissible harmonic current (A).”

(2) Individual equipment item or subsystem installed in Radar, ATCTs etc. with the equipment specified power less that or equal to 2 amps RMS steady state that meets harmonic current limits in IEC 61000-3-2 “Limits for harmonic current emissions”, Class D equipment, Table 3 “maximum permissible harmonic current (A).”

(3) Individual equipment item or subsystem with less than 50 watts cord connected load (IEC 61000-3-2, paragraph 7, Note 1).

Application and testing of above IEC 61000-3-2 requirements on individual equipment item or subsystem using 120 volts line to neutral shall be done with the same precision, percentages and ratios as IEC specifies for 230 and 400V systems.

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

3.1.1.6 Circuit Overload Protection

a. Current Overload protection:

(1) Current overload protection for the equipment shall be provided by fuses, circuit breakers, or other protective devices for primary circuits.

(2) Overcurrent devices shall have a minimum of 10,000-Ampere Interrupting Capacity (AIC) rating.

b. Devices/components shall be protected from damage due to a loss of power or loss of one or more phases of power.

c. Overcurrent protective devices shall provide selective fault isolation rated for the available fault current calculated at the device location.

d. Available fault current shall be calculated from information concerning the facility in which the equipment is located.

e. Series combination system overcurrent protection shall not be permitted.

f. Transient protection shall be provided in accordance with IEEE C62.41, IEEE Recommended Practice on Surge Voltages in Low Voltage AC Power Circuits, Reference Table 2, and verified by testing in accordance with IEEE C62.45, IEEE Guide on Surge Testing for Equipment Connected to Low-Voltage AC Power Circuits.

3.1.1.7 Input Power Conditions

The equipment shall operate in accordance with the following power parameters.

a. Voltage

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

DC 48 Volts +/- 20% AC Ripple < 5% DC 25 Volts +/- 20% AC Ripple < 5% DC 12 Volts +/- 20% AC Ripple < 5%

b. Voltage phase imbalance, phase to phase: 2% as defined by Paragraph 3.8.2 of IEEE STD

Phase-voltage imbalance = Maximum deviation from average phase voltage Average phase voltage

c. Frequency

(1) Steady State

(a) Steady state 60 Hz +/– 3 Hz

(b) Steady state rate of change 1.5 Hz/sec

(c) Steady state frequency variation + /– 0.5 Hz

(2) Momentary deviations (.5 seconds to 3 seconds)

(a) 60 Hz + 5 Hz, - 7 Hz

(b) Rate of change 5 Hz per sec.

d. Voltage Harmonic Distortion

(1) 10% Voltage Total Harmonic Distortion, VTHD

(2) 3% Any one Harmonic

e. Voltage/Time Events: In accordance with the voltage and current values given by Tables 3 and 4 of IEEE Standard IEEE C62.41. For appropriate exposure locations, see sections 7.3.3,

8.3 and Table 5, earthed neutrals.

f. Voltage/Time events for 120V single phase applications.

(1) The equipment shall maintain normal operation during the voltage time events as defined by the ITI/CBEMA curve in Appendix A.

(2) The equipment shall maintain normal operation during voltage time events as defined by the Federal Aviation Administration Input Power Tolerance Envelope in Appendix A, as required by system level specification.

3.1.1.8 Performance Upon Fault Condition of Radio Frequency Equipment Output Circuit

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

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

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

3.1.1.9 Grounding and Bonding

a. The ground reference for the equipment/system shall be in accordance with most recent edition of FAA-STD-019 Section 14, FAA-STD-020, FAA-C-1217, NFPA 70 Article 250, and chapters 8 and 9 of IEEE 1100. FAA facilities utilize the following ground systems: (1) "multi-point"; (2) "single point"; (3) NEC power; and (4) "transient": as identified in FAA-

STD-019.

b. Shielding and bonding shall be per FAA-STD-019 and FAA-STD-020.

c. Rack-mounted Equipment: Any rack-mounted, i.e., drawer type or removable, equipment whose chassis is intended for multi-point grounding shall have a flexible grounding strap or braid connecting each unit, assembly, or subassembly of equipment to the rack, using bonding connections per FAA-STD-020.

d. Enclosure and rack doors shall have grounding straps or braids across the hinges to ensure grounding of the door, bonded properly per FAA-STD-020.

e. Isolated ground receptacles shall be wired per NFPA-70.

f. For equipment connected to an AC supply line, the DC resistance to ground for each line input shall be at least 1 megohm.

3.1.1.10 Corona Prevention (High Voltage/High Current)

a. Corona prevention shall be as follows:

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

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

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

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

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

b. Electrical breakdown prevention shall be as follows:

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

(2) Liquid dielectrics, gases other than ambient air, or pressurization to prevent electrical breakdown shall not be used.

3.1.1.11 Transformer Isolation of Non-Switching DC Power Supplies

a. All non-switching DC power supplies energized from the AC line power source shall be isolated from the AC line through a power transformer with separate primary and secondary windings.

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

3.1.2 MECHANICAL

3.1.2.1 Removable Parts and Mating Connectors

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

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

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

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

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

3.1.2.2 Installation

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

3.1.2.3 Construction

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

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

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

3.1.2.3.1 Equipment Racks

3.1.2.3.1.1 Pullout Drawers

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

Friction-slide construction is prohibited.

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

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

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

3.1.2.3.1.2 Rack Panels

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

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

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

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

3.1.2.3.2 Shelf Life

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

3.1.2.3.3 Moisture

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

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

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

3.1.2.3.4 Windows

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

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

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

3.1.2.4 Accessibility

3.1.2.4.1 General

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

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

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

3.1.2.4.2 Connections

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

3.1.2.4.3 Lowest Replaceable Units (LRUs)

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

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

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

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

3.1.2.4.4 Enclosures

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

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

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

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

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

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

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

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

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

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

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

l. Complete removal and access for servicing of electronic equipment contained…