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…02…CPS/AUX/009
QUALITY REQUIREMENTS FOR EQUIPMENT…02…EV/810717…02……02…#
PURCHASED FOR THE CAMPS PROJECT
…02…Issue 2…02…CAMPS
T̲A̲B̲L̲E̲ ̲O̲F̲ ̲C̲O̲N̲T̲E̲N̲T̲S̲
1 SCOPE AND PURPOSE ...........................
5
1.1 PURPOSE ...................................
5
1.2 GENERAL ...................................
5
1.3 PRODUCTS FROM OTHER SUPPLIERS .............
5
1.4 DOCUMENT DESCRIPTION ......................
6
2 APPLICABLE DOCUMENTS AND TERMS ..............
7
2.1 APPLICABLE DOCUMENTS ......................
7
3 CONSTRUCTION REQUIREMENTS ...................
8
3.1 PRINTED WIRING AND CIRCUITS ...............
8
3.2 COMPONENTS ................................
9
3.2.1 General ...............................
9
3.2.2 Pre-set and Variable Controls .........
9
3.2.3 Wire-Wrapping .........................
10
3.2.4 Integrated Circuits ...................
10
3.3 FLUX AND SOLDERING ........................
10
3.3.1 Flux ..................................
10
3.3.2 Soldering .............................
11
3.4 MOUNTING OF PARTS .........................
11
3.5 RESOLDERING AND STRAPPING .................
11
3.5.1 Resoldering ...........................
11
3.5.2 Strapping .............................
11
3.6 CONNECTORS AND SWITCHES ...................
12
3.6.1 Connectors for Printed Wiring .........
12
3.6.2 High-Density Connectors ...............
12
3.6.3 Potting ...............................
12
3.6.4 Potted Connectors .....................
12
3.6.5 Connectors for Flat Conductor Cable ...
12
3.6.6 Connections for External Power ........
13
3.6.7 Connectors, Electrical ................
13
3.6.8 Switches ..............................
13
3.7 WIRING ....................................
14
3.7.1 Preparation of Conductors and Terminals
14
3.7.2 Stripping Insulation ..................
14
3.7.3 Cleaning of Conductors and Terminals ..
15
3.7.4 Pretinning (presolder coating
conductors and terminals) .............
16
3.8 ATTACHMENT OF WIRES AND LEADS .............
16
3.8.1 Number of Wires per Terminal ..........
16
3.8.2 Lead and Wire Wrap Around .............
16
3.9 CABLING,FITTINGS AND GROUNDING ............
16
3.9.1 Cabling and Fittings ..................
17
3.9.2 Grounding .............................
17
3.10 MOUNTED HARDWARE INSTALLATION ...........
18
3.10.1 Cleaning ............................
18
3.10.2 Threaded Parts or Devices ...........
18
3.10.3 Tightness ...........................
18
3.10.4 Riveting ............................
18
3.10.5 Wiring ..............................
19
3.10.6 Insulation ..........................
19
3.10.7 Splicing ............................
19
3.10.8 Clearance ...........................
20
3.10.9 Shielding ...........................
20
3.10.10 Materials ...........................
20
3.10.11 Mechanical ..........................
20
3.10.12 Cover Plates ........................
21
3.11 PERSONNEL SAFETY ........................
21
3.12 INTERCHANGEABILITY ......................
22
3.13 TESTING AND TEST EQUIPMENT ..............
22
3.13.1 General .............................
22
3.13.2 Testing .............................
23
3.13.3 Signal and Waveform Tracing Points ..
23
3.13.4 Built-in Test Equipment .............
24
3.13.5 Testpoints ..........................
24
3.13.6 Utility Outlet Sockets ..............
25
4 ENVIRONMENTAL LIMITS .........................
26
4.1 DEFINITIONS ...............................
26
4.2 ALTITUDE ................................
26
4.3 TEMPERATURE .............................
26
4.4 HUMIDITY ................................
27
4.5 VIBRATION ...............................
27
4.6 SHOCK ...................................
27
4.7 DUST, FUMES .............................
27
4.8 SUNSHINE, RAIN, FUNGUS, SALTFOG .........
28
4.9 ELECTRICAL EMMISSION ....................
28
4.10 ELECTRICAL SUSCEPTIBILITY ...............
28
4.11 BENCH HANDLING ..........................
29
4.12 VENTILATION AND COOLING .................
29
4.13 ACOUSTIC NOISE ..........................
29
1 S̲C̲O̲P̲E̲ ̲A̲N̲D̲ ̲P̲U̲R̲P̲O̲S̲E̲
1.1 P̲u̲r̲p̲o̲s̲e̲
The purpose of this requirement is to establish general
guidelines for the acceptable workmanship criterias
for design and manufacture of equipment for CAMPS.
The requirements is especially directed towards equipment
purchased from other suppliers as mainly "off the shelf"
equipment.
1.2 G̲e̲n̲e̲r̲a̲l̲
Workmanship shall be in accordance with the requirements
herein and any requirements of the detail equipment
specification applicable to soldering, marking of parts
and assemblies, wiring, welding and brazing, plating,
riveting finishes, machine operations, screw assemblies,
and freedom of parts from burrs, sharp edges, or any
other damage or defect that could make the part (or
equipment) unsatisfactory for the purpose intended.
1.3 P̲r̲o̲d̲u̲c̲t̲s̲ ̲F̲r̲o̲m̲ ̲O̲t̲h̲e̲r̲ ̲S̲u̲p̲p̲l̲i̲e̲r̲s̲
a) Equipment supplied by OEMs not quoted as sub-contractors
- i.e. standard equipment from stock - is chosen
in accordance with the requirements stated compared
to the specification given by the OEMs.
b) Quality Assurance shall check and ensure that the
quality of such equipment fulfil all requirements
in respect of:
1) performance (in accordance with specifications
given by manufacturer)
2) durability
3) stability under extreme working condition
4) maintainability
5) quality level of mechanical and electrical
characteristics described in chapter 3 and
4.
1.4 D̲O̲C̲U̲M̲E̲N̲T̲ ̲D̲E̲S̲C̲R̲I̲P̲T̲I̲O̲N̲
The document consists of the following four chapters.
Chapter 1, SCOPE AND PURPOSE, which introduces the
document.
Chapter 2, APPLICABLE DOCUMENTS, which contains the
list of documents constituting the requirements baseline.
Chapter 3, CONSTRUCTION REQUIREMENTS, which defines
the design, construction, safety and test requirements
for the CAMPS project.
Chapter 4, ENVIRONMENTAL CONDITIONS, which defines
conditional requirements to be fulfilled by the equipment.
2 A̲P̲P̲L̲I̲C̲A̲B̲L̲E̲ ̲D̲O̲C̲U̲M̲E̲N̲T̲S̲ ̲A̲N̲D̲ ̲T̲E̲R̲M̲S̲
2.1 A̲P̲P̲L̲I̲C̲A̲B̲L̲E̲ ̲D̲O̲C̲U̲M̲E̲N̲T̲S̲
The following documents are applicable to the Quality
Requirements for Equipment Purchased for the CAMPS
Project.
a) CPS/210/SYS/0001
System Requirement Specification
b) NGTS-40 issue 2 (Commented)
Environmental Test Methods
3 C̲O̲N̲S̲T̲R̲U̲C̲T̲I̲O̲N̲ ̲R̲E̲Q̲U̲I̲R̲E̲M̲E̲N̲T̲S̲
3.1 P̲R̲I̲N̲T̲E̲D̲ ̲W̲I̲R̲I̲N̲G̲ ̲A̲N̲D̲ ̲C̲I̲R̲C̲U̲I̲T̲S̲
Printed circuit, single-sided, double-sided, and multi-layer,
having plated-through holes and plated-up wiring shall
conform to IPC requirements.
Printed boards shall be electrically connected to the
equipment by means of connectors, solder terminals,
faston tabs, etc., of known reliability. Wiring connections
to connectors shall be made by any approved method.
Where modular, thin film, or solid state devices are
used, these should be complete electrical networks
having input-output characteristics that can be measured.
The inputs and outputs shall be readily accessible
for testing.
Complete circuits should consist of a series of readily
replaceable standardised panels or printed circuits.
When identical functions are required in different
areas of any equipment, common printed circuit boards
or printed board modules shall be used.
Means shall be provided for the easy diagnosis of a
fault to a particular printed panel. Consideration
shall also be given, where necessary, to the design
concurrently with the main equipment of test jigs for
board testing purposes.
The mounting of components on both sides of a board
should normally be avoided.
The connection of a power supply to an equipment in
which semi-conductor devices are used should be possible
in one way only. Alternatively, connection to a supply
of incorrect polarity should not damage the equipment.
The operating voltage and, if appropriate, the frequency
of the power supply to be used with such an equipment,
shall be clearly marked in a position adjacent to the
power supply and/or to the switch controlling power
supply.
A semi-conductor device should have an operational
life consistent with that of the reliability requirement
of the equipment in which it is used. This operational
life should be retained over the temperature range
stated in the product specification.
Where semi-conductor devices are used, associated reactive
circuit elements should be so arranged that generation
of transients during normal use and testing will not
damage the semi-conductor junctions.
3.2 C̲O̲M̲P̲O̲N̲E̲N̲T̲S̲
3.2.1 G̲e̲n̲e̲r̲a̲l̲
The use of electrolytic capacitors should be avoided
wherever possible, and preferably limited to decoupling
purposes. Where they are used they shall be:
Adequately rated in all respects for their function
and location.
Of the tantalum type wherever feasible.
Where polarised components are used polarity markings
shall be placed adjacent to such components.
3.2.2 P̲r̲e̲-̲s̲e̲t̲ ̲a̲n̲d̲ ̲V̲a̲r̲i̲a̲b̲l̲e̲ ̲C̲o̲n̲t̲r̲o̲l̲s̲
Pre-set controls should not be inter-dependent or not
over-critical in their setting. They should have an
adjustment range adequate for alignment purposes.
After the initial setting-up of a new component there
should be at least one-third of the total travel left
at either end. They shall remain stable at their pre-set
value. Slot-ended control spindles for screwdriver
operation may be used, but the head shall be sufficiently
robust to withstand continual adjustment without damage.
Controls used only by maintenance personnel should
not be readily accessible to anyone else. All such
controls shall be clearly labelled.
3.2.3 W̲i̲r̲e̲ ̲W̲r̲a̲p̲p̲i̲n̲g̲
The wrapping wire shall make direct contact with the
post.
Not more than three connections shall be made to any
one single-ended post.
Only one connection shall be made to the short end
of a double ended pin.
They shall not be overwrapped or interleaved.
Soldered connections shall not be made to either end
of a post after wrapped connection has been made.
Ample room for the insertion of wrapping and unwrapping
tools shall be allowed between individual wrapped joint
connections and adjacent parts.
Only approved wrapping tools shall be used, and posts
shall be selected to be compatible with them.
3.2.4 I̲n̲t̲e̲g̲r̲a̲t̲e̲d̲ ̲C̲i̲r̲c̲u̲i̲t̲s̲
Wherever possible integrated circuits of established
reliability should be chosen from the preferred parts
list as appropriate, and should be those which can
be reasonably anticipated will be available during
the whole life of the equipment.
3.3 F̲L̲U̲X̲ ̲A̲N̲D̲ ̲S̲O̲L̲D̲E̲R̲I̲N̲G̲
3.3.1 F̲l̲u̲x̲
Rosin fluxes conforming to recommended engineering
practices shall be used for making electrical electronic
connections. For fluxing purposes, a soldered joint
the functions of which are both a mechanical and an
electrical connection (for example in grounding applications
through a chassis) shall be considered an electrical
connection.
3.3.2 S̲o̲l̲d̲e̲r̲i̲n̲g̲
All soldered connections shall be clean and smooth
in appearance. Sufficient solder shall be used to ensure
a continuous strong concave fillet feathered into the
base metals. Flux or other foreign residue must be
removed. The insulation of soldered wires shall not
show damage from the heat of the soldering operation.
Discolouration is permitted, but not charring, cracking,
decomposition and distortion.
3.4 M̲O̲U̲N̲T̲I̲N̲G̲ ̲O̲F̲ ̲P̲A̲R̲T̲S̲
Parts, or hardware shall be assembled, and secured
or mounted in the specified manner to satisfactorily
accomplish the purpose for which intended, and should
preferably be mounted such that values and part numbers
containing values are visible. Terminal designations
of transformers, inductors, relays, etc., should be
visible if possible to facilitate repair. Electronic
equipment having missing, defective, broken, or otherwise
damaged parts shall not be acceptable.
3.5 R̲E̲S̲O̲L̲D̲E̲R̲I̲N̲G̲ ̲A̲N̲D̲ ̲S̲T̲R̲A̲P̲P̲I̲N̲G̲
3.5.1 R̲e̲s̲o̲l̲d̲e̲r̲i̲n̲g̲
Care should be taken to avoid the need for resoldering.
When resoldering is required, the quality standards
for the resoldered connection shall be the same as
for the original connection. A cold-solder or disturbed
joint will require only reheating and reflowing of
the solder.
3.5.2 S̲t̲r̲a̲p̲p̲i̲n̲g̲
13 straps or less is acceptable for one printed circuit
board. Straps longer than 30 mm must be fixed with
glue or similar.
3.6 C̲O̲N̲N̲E̲C̲T̲O̲R̲S̲ ̲A̲N̲D̲ ̲S̲W̲I̲T̲C̲H̲E̲S̲
3.6.1 C̲o̲n̲n̲e̲c̲t̲o̲r̲s̲ ̲f̲o̲r̲ ̲P̲r̲i̲n̲t̲e̲d̲ ̲W̲i̲r̲i̲n̲g̲
Printed circuit connectors shall be suitable design
and construction, and correct operation shall not entail
possible risk of damage to the printed circuit due
to excessive tightness of terminals or clamps.
3.6.2 H̲i̲g̲h̲-̲d̲e̲n̲s̲i̲t̲y̲ ̲C̲o̲n̲n̲e̲c̲t̲o̲r̲s̲
Connectors with high-contact densities shall be of
suitable design and construction for the application.
Arrangement and spacing of terminals and selection
of materials shall be such as to ensure that there
will be no arcing or burning between terminals or terminals
and shell.
3.6.3 P̲o̲t̲t̲i̲n̲g̲
When potting is used for environmental protection,
extreme care shall be given to selection of materials
and processes such that the potting will not deteriorate
in either chemical, physical or electrical properties,
under the specified system/equipment environment.
3.6.4 P̲o̲t̲t̲e̲d̲ ̲C̲o̲n̲n̲e̲c̲t̲o̲r̲s̲
For potted connectors, each unused contact shall have
a maximum gauge wire of 15 cms minimum length attached
and identified with the contact designation for future
use.
3.6.5 C̲o̲n̲n̲e̲c̲t̲o̲r̲s̲ ̲f̲o̲r̲ ̲F̲l̲a̲t̲ ̲C̲o̲n̲d̲u̲c̲t̲o̲r̲ ̲C̲a̲b̲l̲e̲
Connectors for use with flexible flat conductor cable
and flat ribbon cable shall be of suitable design and
construction for the application.
3.6.6 C̲o̲n̲n̲e̲c̲t̲i̲o̲n̲s̲ ̲f̲o̲r̲ ̲E̲x̲t̲e̲r̲n̲a̲l̲ ̲P̲o̲w̲e̲r̲
Application of power to externally powered test equipment
shall meet the following requirements:
a) Power shall be controlled by a power ON-OFF switch.
b) Neither side of the supply voltage shall be directly
connected to the chassis.
3.6.7 C̲o̲n̲n̲e̲c̲t̲o̲r̲s̲,̲ ̲E̲l̲e̲c̲t̲r̲i̲c̲a̲l̲
Connectors used to provide separation of or connection
to multiple electric circuits shall be selected so
that it will be impossible to insert the wrong plug
in a receptable or other mating unit. Where design
considerations require plug and receptacles of similar
configuration in close proximity, the mating plugs
and receptacles shall be suitably coded or marked to
clearly indicate the mating connections.
3.6.8 S̲w̲i̲t̲c̲h̲e̲s̲
Interlocks. Unless otherwise specified, interlock
switches shall conform to one or more of the following:
a) A two-piece type in which the electrical circuit
is broken by the physical separation of the two
parts.
b) A two-piece type in which the electrical circuit
is broken by the physical separation of the two
parts together with an associated electrically
integral bypass device. This bypass switch or
device shall be of a manually operated type, and
shall be such that returning the chassis to the
operating position or closing the door, cover,
or plate will automatically open the bypass switch
and leave the interlock in position to function
properly. Visual means shall be provided to indicate
when the interlock switch is bypassed.
c) One-piece switch assembly with an integral bypass
device. This shall operate so that returning the
chassis to the operating position or closing the
door, cover, or plate will automatically leave
the interlock in position to function properly.
Visual means shall be provided to indicate when
the interlock switch is bypassed.
3.7 W̲I̲R̲I̲N̲G̲
3.7.1 P̲r̲e̲p̲a̲r̲a̲t̲i̲o̲n̲ ̲o̲f̲ ̲C̲o̲n̲d̲u̲c̲t̲o̲r̲s̲ ̲a̲n̲d̲ ̲T̲e̲r̲m̲i̲n̲a̲l̲s̲
3.7.2 S̲t̲r̲i̲p̲p̲i̲n̲g̲ ̲I̲n̲s̲u̲l̲a̲t̲i̲o̲n̲
Sufficient insulation shall be stripped from the wire
or leads, so that no insulation will touch the solder
connection. In stripping insulation, care should be
taken to avoid nicking or otherwise damaging the wire
or remaining insulation.
The number of damaged or severed strands in a single
lead shall not exceed the limits given in Table 3.7.2.1.
Only slightly insulation discoloration resulting from
thermal stripping shall be permissible.
̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲
̲ ̲ ̲
Number of Strands Maximum allowable nicked or
broken strands
̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲
̲ ̲ ̲
Less than 7 0
7 - 15 1
16 - 18 2
19 - 25 3
26 - 36 4
37 - 40 5
41 or more 6
̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲
̲ ̲ ̲
…01…T̲a̲b̲l̲e̲ ̲3̲.̲7̲.̲2̲.̲1̲ ̲ ̲L̲i̲m̲i̲t̲s̲
3.7.3 C̲l̲e̲a̲n̲i̲n̲g̲ ̲o̲f̲ ̲C̲o̲n̲d̲u̲c̲t̲o̲r̲s̲ ̲a̲n̲d̲ ̲T̲e̲r̲m̲i̲n̲a̲l̲s̲
Conductor surfaces to be soldered shall be cleaned
prior to soldering as follows:
a) Grease and oil shall be removed from conductors
and terminals by applying a non-corrosive solvent
such as: Trichloroethane, Ethyl alcohol, Isopropyl
alcohol and drying with clean, lint-free wipers
or dry air (vacuum preferred).
b) Oxides and varnishes shall be removed by methods
which do not damage leads or parts, and which do
not cause contemination or hinder solder wetting.
c) Sand blasting shall not be used.
d) Dust or other loose matter shall be removed.
3.7.4 P̲r̲e̲t̲i̲n̲n̲i̲n̲g̲ ̲(̲p̲r̲e̲s̲o̲l̲d̲e̲r̲ ̲c̲o̲a̲t̲i̲n̲g̲ ̲c̲o̲n̲d̲u̲c̲t̲o̲r̲s̲ ̲a̲n̲d̲ ̲t̲e̲r̲m̲i̲n̲a̲l̲s̲)̲
Tinning of a stranded wire shall not obscure the wire
contour at the termination end of the insulation to
permit inspection of the wire for damage. Heat sinks
shall be applied to leads of heat sensitive parts during
the tinning operation. Wicking - the capillary flow
of solder along the wire - is permitted, however, solder
shall not obscure the contour of the conductor at the
termination of the insulation.
3.8 A̲T̲T̲A̲C̲H̲M̲E̲N̲T̲ ̲O̲F̲ ̲W̲I̲R̲E̲S̲ ̲A̲N̲D̲ ̲L̲E̲A̲D̲S̲
3.8.1 N̲u̲m̲b̲e̲r̲ ̲o̲f̲ ̲W̲i̲r̲e̲s̲ ̲p̲e̲r̲ ̲T̲e̲r̲m̲i̲n̲a̲l̲
No wire terminal shall have more than three component
leads or wires attached. Exceptions are the multi-section
turret terminal and the multi-hole lug terminal which
shall have no more than three wires or leads per section
or hole. When high density requires a greater number
of wires than those specified herein, specific approval
shall be obtained.
3.8.2 L̲e̲a̲d̲ ̲a̲n̲d̲ ̲W̲i̲r̲e̲ ̲W̲r̲a̲p̲ ̲A̲r̲o̲u̲n̲d̲
Wires and component leads shall be mechanically secured
to the wire terminals before soldering with sufficient
securing to prevent motion between the parts of a joint
during the soldering operation. This shall be done
by wrapping the wires and component lead around the
terminal for a minimum of one-half and no more than
one full turn. Exception is made in the case of those
small parts used for terminating conductors and to
solder caps, slotted terminals, posts, etc. Lead extension
shall be restricted to the limits required by design
to prevent equipment malfunction. In no case shall
wires be wrapped on each other when attaching wires
to terminals.
3.9 C̲A̲B̲L̲I̲N̲G̲,̲ ̲F̲I̲T̲T̲I̲N̲G̲S̲ ̲A̲N̲D̲ ̲G̲R̲O̲U̲N̲D̲I̲N̲G̲
3.9.1 C̲a̲b̲l̲i̲n̲g̲ ̲a̲n̲d̲ ̲F̲i̲t̲t̲i̲n̲g̲s̲
For wiring and cabling the following shall apply:
a) Where inter-connecting cabling between assemblies
is run in steel conduit or in shielded cables,
electrical continuity of the conduit or shielding,
as appropriate, shall be ensured to permit the
correct grounding.
b) Wiring shall be identified by colour coding, numbering,
or by other feasible means such as marking of terminals
at both ends of lead. All wires shall carry corresponding
identification numbers at each end. Colour coding
for chassis wiring shall be comforming to good
engineering practice.
c) Where bus bars are used for interconnection between
assemblies and subassemblies they may be colour
coded to permit quick identification.
3.9.2 G̲r̲o̲u̲n̲d̲i̲n̲g̲
a) The grounding system shall provide effective protection
for personnel and material against insulation defects.
It shall be arranged so that there are four separate
and isolated ground circuits, namely:
1) AC power neutral
2) Equipment frame ground
3) Signalling and control ground
4) Secure ground
b) The AC power neutral shall provide a return for
the primary current so that the equipment frame
ground is used only to establish a safety ground
and is not used as a normal current grounding element.
No place in the equipment or power filters shall
the AC power neutral be connected directly to equipment
frame ground.
c) All panels, drawers and other sub-assemblies, whether
fixed or removable, shall be fastened, or connected
to the associated frame, in a manner that ensures
they are securely grounded.
d) The signalling and control ground is to be routed
via the interconnecting wires and cables as appropriate.
3.10 M̲O̲U̲N̲T̲E̲D̲ ̲H̲A̲R̲D̲W̲A̲R̲E̲ ̲I̲N̲S̲T̲A̲L̲L̲A̲T̲I̲O̲N̲
3.10.1 C̲l̲e̲a̲n̲i̲n̲g̲
After fabrication, parts shall be cleaned of smudges,
loose, spattered, or excess solder; metal chips;
or any other foreign material which might detract from
intended operation, functions, or appearance of the
equipment. (This would include any particles that
could loosen or become dislodged during the normal
expected life of the equipment). All corrosive materials
shall be removed. Whenever possible, this cleaning
shall take place before the parts are assembled into
the equipment. Cleaning processes shall have no deleterious
effect on the equipment or parts.
3.10.2 T̲h̲r̲e̲a̲d̲e̲d̲ ̲P̲a̲r̲t̲s̲ ̲o̲r̲ ̲D̲e̲v̲i̲c̲e̲s̲
Screws, nuts, and bolts shall show no evidence of cross
threading mutilation, detrimental or hazardous burrs.
3.10.3 T̲i̲g̲h̲t̲n̲e̲s̲s̲
All screw-type fasteners shall be tight. The word
tight means the screw shall be firmly secured and that
there shall be no relative movement possible between
the attached parts.
3.10.4 R̲i̲v̲e̲t̲i̲n̲g̲
The riveting operation shall be carefully performed
in order to assure that rivets are tight and satisfactorily
headed with the rivet heads tightly seated against
their bearing surface.
3.10.5 W̲i̲r̲i̲n̲g̲
Insulated wire running between equipments, or subassemblies
within an equipment, such as between drawers or chassis
module subassemblies, shall be formed into cables or
ducted wherever practicable. wires or cables shall
be positioned or protected to avoid contact with rough
or irregular surfaces and sharp edges.
Wire dress or cabling or wires shall not result in
improper electrical operation or interference with
mechanical operation that will lead to subsequent damage
of the wire or cable. Wires and cables subject to
flexing shall be protected to prevent abrasion.
Lacing of cabling shall be neat in appearance. The
lacing shall be applied firmly, yet not with excessive
pressure which could cut into conductor insulation.
Cabling or wiring harnesses shall be anchored to avoid
damage to conductors or adjacent parts.
3.10.6 I̲n̲s̲u̲l̲a̲t̲i̲o̲n̲
There shall be no evidence of burns, abrading, or large
pinch marks in the insulation that could cause short
circuits or leakage. Slightly discolouration after
soldering shall be acceptable.
3.10.7 S̲p̲l̲i̲c̲i̲n̲g̲
Wires in a continuous run between two terminals shall
not be spliced during the assembly of the equipment,
except where a stranded conductor is spliced to a solid
conductor and the two are supported at the splice.
It shall be acceptable, as part of modification or
repair, to splice wires in a continuous run between
two terminals provided the splice can be sufficiently
supported.
3.10.8 C̲l̲e̲a̲r̲a̲n̲c̲e̲
The clearance between wires or cables and heat generating
parts, such as electron tubes and resistors, shall
be such as to avoid deterioration of the wires or cables
from the heat dissipated by these parts under the specified
service conditions of the equipment.
3.10.9 S̲h̲i̲e̲l̲d̲i̲n̲g̲
Shielding on wire and cables shall be secured in a
manner which will prevent it from contacting or shorting
exposed current-carrying parts. The shielding shall
terminate at a sufficient distance from the exposed
conductors of the cable to prevent shorting or arcing
between the cable conductors and shielding. The ends
of the shielding or braid shall be secured against
fraying.
3.10.10 M̲a̲t̲e̲r̲i̲a̲l̲s̲
Materials used for encapsulation and embedment shall
be selected for their electrical, operational, environmental
and storage characteristics. Hard curing compounds
to hold replaceable parts are prohibited. (Parts soldered
to terminals, printed wiring boards etc. are not considered
replaceable in this context).
3.10.11 M̲e̲c̲h̲a̲n̲i̲c̲a̲l̲
The design of the equipment shall be such as to provide
maximum convenience and safety to personnel while installing,
operating, and maintaining the equipment. Suitable
protection shall be provided to prevent contact with
moving mechanical parts such as fans, when the equipment
is complete and operating. Sharp projections on cabinets,
doors and similar parts shall be avoided. Doors or
hinged covers shall be rounded at the corners and provided
with stops to hold them open. Equipment design shall
include provisions to prevent
accidental pulling out of drawers or rack-mounted equipment
components which could cause equipment damage and injury
to personnel. Equipment power switches shall be so
designed and located that accidental contact by personnel
will not place equipment in operation.
3.10.12 C̲o̲v̲e̲r̲ ̲P̲l̲a̲t̲e̲s̲
Cover plates shall have a minimum of fasteners consistent
with normal mechanical strength requirements. All such
fasteners should preferably be of the "captive" type.
3.11 P̲E̲R̲S̲O̲N̲N̲E̲L̲ ̲S̲A̲F̲E̲T̲Y̲
a) Interlocks or key locks shall be incorporated where
appropriate to prevent any major assembly carrying
high tension voltages from being opened by unauthorised
personnel.
b) With the equipment assembled and set up for operation,
personnel shall be protected from contact with
potentials in excess of 30 volts to ground, chassis
or frame, including potentials or charged capacitors.
c) Relevant notice and markings on equipment or documents
are to be provided to draw the attention of operating
and maintenance personnel to points where dangerous
voltages may be encountered.
d) Where a voltage of 50 or more volts is exposed
during the maintenance activities a suitable warning
shall be provided. It should be made according
to the following principles:
1) "DANGER (xxx) VOLTS WHEN COVER REMOVED" (in
aluminium or white lettering l.5 cm high on
a red background) where (xxx) is the nominal
voltage.
2) "DANGER HIGH VOLTAGE (xxx) VOLTS" where (xxx)
is the nominal voltage.
3) "CAUTION (xxx) VOLTS. DISCONNECT POWER BEFORE
REMOVAL OF COVER" where (xxx) is the nominal
voltage.
3.12 I̲N̲T̲E̲R̲C̲H̲A̲N̲G̲E̲A̲B̲I̲L̲I̲T̲Y̲
a) Modular hardware construction should be used wherever
feasible.
b) The items shall be designed to use the minimum
number practicable of the different types of electrical
cable, connectors, component and accessories.
c) Electrically identical units, assemblies, subassemblies
and replaceable parts shall be physically interchangeable
without modification of such items or of the equipment.
d) Interchangeable items shall be as defined in specifications,
drawings, and/or documentation to permit their
installation as interchangeable units, assemblies,
subassemblies, and parts without regard to the
source of manufacture or supply.
e) Provision shall be made for design tolerances such
that items having the dimensions and characteristics
permitted by the item specification may be used
as replacement without selection or departure from
the specified equipment performance.
3.13 T̲E̲S̲T̲I̲N̲G̲ ̲A̲N̲D̲ ̲T̲E̲S̲T̲ ̲E̲Q̲U̲I̲P̲M̲E̲N̲T̲
3.13.1 G̲e̲n̲e̲r̲a̲l̲
Equipment shall be designed for ease of functional
testing. Requirements for detailed specification testing
shall be kept to a minimum. The philosophy of testing
shall take into account the following considerations:
The range of operational testing in the field shall
be kept to the minimum necessary for the determination
of the condition of equipment and the diagnosis of
failures.
Individual tests shall be as simple as possible.
Testing shall as far as practicable be capable of being
performed by automatic means.
Alignment procedures should be simple. Stability of
circuits should be high, rendering the results of drift
insignificant. The replacement of any assembly, sub-assembly,
etc. should necessitate the minimum of subsequent adjustment.
3.13.2 T̲e̲s̲t̲i̲n̲g̲ ̲S̲h̲a̲l̲l̲ ̲b̲e̲ ̲a̲s̲ ̲R̲a̲p̲i̲d̲ ̲a̲s̲ ̲P̲o̲s̲s̲i̲b̲l̲e̲
During feasibility studies and early design stages
of new system development it is essential that system
parameters are given the widest possible tolerances
consistent with meeting System Requirements. During
detailed design stages, the maximum permissible tolerances
should be accorded to all assemblies to provide, the
widest field standard limits to ease the repair and
maintenance commitments.
As a consequence of the large number of components
in electronic systems, it is essential that tests can
be readily performed in a logical sequence permitting
the rapid tracing of faults to their origin. Test
equipment whose function is solely for overall performance
checking is, therefore not by itself sufficient for
maintenance and repair purposes. Diagnostic test equipment,
selected either from the general purpose range or specially
developed, shall always be specified for use either
separately or in conjunction with the overall performance
test equipment.
3.13.3 S̲i̲g̲n̲a̲l̲ ̲a̲n̲d̲ ̲W̲a̲v̲e̲f̲o̲r̲m̲ ̲T̲r̲a̲c̲i̲n̲g̲ ̲P̲o̲i̲n̲t̲s̲
Tracing points should be provided as necessary on material
to the extent they form part of the maintenance/repair
concept. This includes points for:
the injection of test signals
the measurement of signals
the monitoring of waveforms
the monitoring of voltages or currents
Individual tracing points shall be readily identifiable
and should be in close proximity to the circuit under
test. Where possible they should be located on a front
or rear panel of material.
Signal and/or waveform tracing points should be capable
of being used without degradation of circuit performance.
Externally located test and tracing points shall:
be provided with adequate mechanical protection.
not constitute an electrical hazard to operating and
maintenance personnel.
3.13.4 B̲u̲i̲l̲t̲-̲i̲n̲ ̲T̲e̲s̲t̲ ̲E̲q̲u̲i̲p̲m̲e̲n̲t̲
Wherever practicable, test facilities shall be built
into material to enable routine monitoring checks to
be made during use.
3.13.5 T̲e̲s̲t̲p̲o̲i̲n̲t̲s̲
a) Testjacks can be of the banana plug type.
b) Test points/tracing points for monitoring voltage/currents
and measuring/injecting signals/wave forms shall
only be provided to the extent they form part of
the maintenance/repair concept.
3.13.6 U̲t̲i̲l̲i̲t̲y̲ ̲O̲u̲t̲l̲e̲t̲ ̲S̲o̲c̲k̲e̲t̲s̲
Utility outlet sockets for the operation of test equipment
etc. shall be located in close proximity to all major
racks or cabinets. Installation of utility outlets
will be the responsibility of purchaser.
4̲ ̲ ̲E̲N̲V̲I̲R̲O̲N̲M̲E̲N̲T̲A̲L̲ ̲L̲I̲M̲I̲T̲S̲
In designing the equipment to meet the specified requirements
no account needs to be taken of catastrophic events
such as fire, flood, explosion, etc., which are beyond
the control of an equipment manufacturer.
The equipment shall be so designed that the loss of
site air-conditioning or heating will not cause a catastrophic
failure within 15 minutes after the loss.
4.1 D̲E̲F̲I̲N̲I̲T̲I̲O̲N̲S̲
* OPERATING: These limites apply to equipment
installed as specified and operating
in a normal office or computer
room environment.
* STORAGE: These limits apply to equipment
properly packed and protected
against dust, moisture, condensed
water, etc.
* TRANSPORTATION: These limits apply to equipment
properly packed for shipment.
4.2 A̲L̲T̲I̲T̲U̲D̲E̲
* OPERATING: 0 to 2000 m.
* STORAGE
/TRANSPORTATION 0 to 10000 m.
4.3 T̲E̲M̲P̲E̲R̲A̲T̲U̲R̲E̲
* OPERATING: 10 to 40 deg. C. Maximum rate
of change 10 deg. C per hour.
* STORAGE/
TRANSPORTATION - 40 to 70 deg. C.
4.4 H̲U̲M̲I̲D̲I̲T̲Y̲
* OPERATING: 20 per cent RH to 80 per cent
RH non-condensing. Maximum rate
of change 10 per cent RH per
hour.
Absolute water contend in the
room air shall be limited to
22g water per cubic meter of
air.
* STORAGE/
TRANSPORTATION: 10 per cent RH to 90 per cent
non-condensing
4.5 V̲I̲B̲R̲A̲T̲I̲O̲N̲
* OPERATING/STORAGE 5 Hz to 50 Hz constant displacement
of 0,02 mm. 50 Hz smooth crossover.
50 Hz to 350 Hz constant acceleration
0,2 g.
* TRANSPORTATION: 5 Hz to 350 Hz constant acceleration
1,5 g.
4.6 S̲H̲O̲C̲K̲
* OPERATING/STORAGE: 1g, half sine wave, 10 ms duration.
Not to be repeated more often
than one per 10 seconds.
* TRANSPORTATION: 25g, half sine wave, 10 ms duration.
4.7 D̲U̲S̲T̲,̲ ̲F̲U̲M̲E̲S̲
The equipment shall be able to operate continously
and with normal scheduled preventive maintenance in
the following air-environment:
a) A̲i̲r̲ ̲C̲l̲e̲a̲n̲n̲e̲s̲s̲
Particle size Max. allowable no.
(microns) (particles/cubicmeter)
̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲ ̲
Greater than 5 4 * (10…0e…5…0f…)
Greater than 1,5 4 * (10…0e…6…0f…)
Greater than 1 4 * (10…0e…7…0f…)
b) F̲u̲m̲e̲s̲
Sulphur dioxide max. 14 ppm.
4.8 S̲U̲N̲S̲H̲I̲N̲E̲,̲ ̲R̲A̲I̲N̲,̲ ̲F̲U̲N̲G̲U̲S̲,̲ ̲S̲A̲L̲T̲F̲O̲G̲
* STORAGE/
TRANSPORTATION According to the special transportation
environments, it shall be ensured
that the equipment is maximum
protected during packaging against
sunshine, rain, fungus, and
saltfog.
4.9 E̲L̲E̲C̲T̲R̲I̲C̲A̲L̲ ̲E̲M̲M̲I̲S̲S̲I̲O̲N̲
RADIATED: Conforming to VDE 871 class
C and VDE 875 class G.
CONDUCTED: Conforming to VDE 875 class
G.
4.10 E̲L̲E̲C̲T̲R̲I̲C̲A̲L̲ ̲S̲U̲S̲C̲E̲P̲T̲I̲B̲I̲L̲I̲T̲Y̲
RADIATED: Electromagnetic Field Strength
less than IV/m with frequencies
from 30 MHz to 500 MHz induced
from distance of 3 m.
CONDUCTED: Noise pulses on main wires with
amplitude less than 1000 V and
risetime longer than 35 ns.
Pulse duration 0,1 micro seconds
to 10 micro seconds. Repetition
rate not more than one per second.
4.11 B̲E̲N̲C̲H̲ ̲H̲A̲N̲D̲L̲I̲N̲G̲
Smaller assemblies and sub-assemblies normally subject
to bench repair shall be cabable of withstanding being
dropped onto a hard surface on all faces from a 30
degrees angle using any one edge of the unit as a pivot,
without any physical, electrical or electronic damage.
4.12 V̲E̲N̲T̲I̲L̲A̲T̲I̲O̲N̲ ̲A̲N̲D̲ ̲C̲O̲O̲L̲I̲N̲G̲
a) Intake cooling air, if considered necessary, shall
be filtered such that the pressure within the associated
cabinet is higher than the ambient pressure outside.
The cooling air should preferably be exhausted
to the atmosphere at the top of the cabinet.
b) Resonance effects and vibrations because of the
ventilation and cooling shall not cause any deterioration
of equipment performance.
4.13 A̲C̲O̲U̲S̲T̲I̲C̲ ̲N̲O̲I̲S̲E̲
The maximum sound level due to noise emitted from the
equipment shall be less than 70 dB (A) when measured
under free field conditions by a precision sound level
meter located at a point 2 meters distant from the
noise source, and at the height at which the maximum
reading of the meter is obtained. The measuring instrument
shall be in accordance with IEC publication 179 second
edition 1973.
