Data items shall be submitted in accordance with the requirements of Attachment 1, A1.2.4.9 of this volume.
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13.9.1. Data to verify compliance with the design and test requirements of this volume shall be submitted to the PSWG for PSWG and Range Safety review and approval before the arrival of ordnance at the payload processing facility and launch site area.
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13.9.2. All schematics and functional diagrams shall have well defined, standard Institute of Electrical and Electronics Engineers (IEEE) Std 315-1975 (ANSI Y32.2-1975) terminology and symbols.
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ELECTRICAL AND ELECTRONIC EQUIPMENT |
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Electrical and Electronic Ground Support Equipment and Flight Hardware General Design Requirements and Standards |
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14.1.1. Equipment shall be designed, fabricated, inspected, and tested in accordance with NFPA 70 and MIL-HDBK-454, Standard General Requirements for Electrical Equipment.
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14.1.2. All wiring shall be copper and contact with dissimilar metals shall be avoided. Aluminum wire shall not be used.
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14.1.3. At a minimum, electrical equipment shall be designed to operate within the voltage ratings of ANSI C84.1, Electric Power Systems and Equipment - Voltage Ratings (60 Hz).
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14.1.4. Electrical and Electronic Ground Support Equipment and Flight Hardware Power Cutoff. All electrical and electronic ground support equipment (EGSE) and flight hardware shall have a means to cut off power before installing, replacing, or interchanging units, assemblies, or portions thereof.
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14.1.5. EGSE and Flight Hardware Power Transient. Safety critical systems shall be protected against power transients and power outages.
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14.1.6. EGSE and Flight Hardware Connectors. Connector design shall avoid the generation of a hazardous condition that could lead to a hazardous event. A hazardous condition is where there is a possibility for the inadvertent connection of an electrical circuit to cause unintentional current to flow where it would cause a short, spark, energize equipment, or initiate ordnance that would create a hazardous event.
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14.1.6.1. If a hazardous condition can be created by mismating or reverse polarity, a positive means of preventing connector mismating shall be provided.
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Mismating includes improper installation as well as connecting wrong connectors. Prevention of connector mismating includes alignment pins and key-way arrangements or other possible means to make it impossible to incorrectly mismate. Color coding may be used in addition to, but not in lieu of, the more positive means of connector mismate prevention.
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14.1.6.2. If a hazardous event can occur, the following precautions shall be taken:
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14.1.6.2.1. Power and signal leads shall not be terminated on adjacent pins of a connector.
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14.1.6.2.2. Wiring shall be isolated so that a single short circuit occurring in a connector cannot affect other components.
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14.1.6.2.3. Pin locations shall be assigned to prevent inadvertent pin-to-pin and pin-to-case shorts.
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14.1.6.2.4. Spare pins shall not be used in connectors controlling hazardous operations or safety critical functions.
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14.1.6.2.5. The payload project shall provide a bent pin analysis to the PSWG for PSWG and Range Safety review on all safety critical and/or hazardous system connectors.
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14.1.6.3. Connectors used in safety critical or hazardous systems shall be of the locking type.
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14.1.6.4. Connectors relying solely on springs to maintain an electrical contact shall not be used in safety critical or hazardous systems. Connectors for safety critical or hazardous systems shall have a positive locking mechanism to prevent inadvertent, momentary electrical disruption or disconnection of the circuit
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14.1.6.5. Plug and socket type connectors shall be used in safety critical or hazardous systems.
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14.1.6.6. Connectors shall be of a scoop-proof design” that will prevent a partial inadvertent mismate or shell-to-pin contact.
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14.1.7. EGSE and Flight Hardware Grounding, Bonding, and Shielding
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14.1.7.1. Equipment shall be designed and constructed to ensure that all external parts, shields and surfaces, exclusive of radiating antennas and transmission line terminals, are at ground potential.
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14.1.7.2. Shields shall not be used as current carrying ground connections, except for coaxial cables.
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14.1.7.3. Circuits that operate safety critical or hazardous functions shall be protected from the electromagnetic environment to preclude inadvertent operation.
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14.1.8. EGSE and Flight Hardware Cables
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14.1.8.1. Cables shall be supported and protected against abrasion or crimping.
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14.1.8.2. Cables shall be located or protected so as not to present a tripping hazard.
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14.1.8.3. Cables in hazardous areas shall be designed so that they do not, in and of themselves, create a hazard.
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14.1.8.4. Cables shall be selected to include factors such as toxicity, combustibility and smoke production, off-gassing, and compatibility with liquids in the area and environmental exposure.
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14.1.9. EGSE and Flight Hardware Batteries
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14.1.9.1. EGSE and Fight Hardware Battery General Design Requirements
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14.1.9.1.1. All batteries shall be capable of being readily accessible for electrical disconnection and/or removal.
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14.1.9.1.2. Battery connectors shall be designed to prevent reverse polarity.
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14.1.9.1.3. The capability for reverse current to cause a hazardous condition shall be prevented.
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Diodes may be used to prevent reverse current. Diodes may be placed in the battery or in external circuitry.
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14.1.9.1.4. If a battery is not connected to the system, the battery terminals or connector plug shall be given positive protection against shorting.
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Protection against shorting of connector terminals may be accomplished by taping or guarding with a suitable temporary connector.
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14.1.9.1.5. Identification. Each battery shall be permanently identified with the following appropriate information:
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14.1.9.1.5.1. Component name.
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14.1.9.1.5.2. Type of construction; for example lead-acid or nickel-cadmium.
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14.1.9.1.5.3. Manufacturer identification.
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14.1.9.1.5.4. Part number.
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14.1.9.1.5.5. Lot and serial number.
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14.1.9.1.5.6. Date of manufacture.
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14.1.9.2. EGSE and Flight Hardware Lithium Primary Batteries. The following requirements are applicable to lithium batteries used in flight hardware and EGSE.
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Batteries that have a UL listing and are intended for public use are exempt from these requirements.
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14.1.9.2.1. All lithium battery designs shall be reviewed and approved by the PSWG and Range Safety before arrival, usage, packing, storage, transportation, or disposal at the payload processing facility and launch site area.
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14.1.9.2.2. Safety devices shall be incorporated into the lithium battery design.
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Safety devices include fuses, overpressure relief devices, over temperature cutoff, reverse current blocking diode, current limiting resistor, or other device determined to be acceptable by the PSWG and Range Safety. The following are examples of safety devices that should be incorporated into the lithium battery design:
(1) The use of thermistors or fuses for each battery output;
(2) Placement of internal diodes between each cell, unless proven by test that any single cell cannot be driven into reversal by the remaining cells;
(3) The use of shunt diode protection for cells in series;
(4) The use of blocking diodes for parallel rows of cells.
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14.1.9.2.3. Each electrical safety device shall have a specific quality control program approved by the PSWG and Range Safety.
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14.1.9.2.4. Safety critical steps and processes shall be identified during development for the manufacturing process. These points in manufacturing shall be reviewed by the appropriate local safety authorities identified by the PSWG and Range Safety and a determination made of what points require approval before change and what points the payload project can approve with just notification after the fact.
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14.1.9.2.5. Batteries shall be designed not to create a catastrophic hazard even when the safety tests described in 14.3.4 are performed.
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14.1.9.3. EGSE and Flight Hardware Lithium-ion Batteries. In addition to the other design and operational requirements of this publication, the following requirements are applicable to lithium-ion batteries used in flight hardware and EGSE.
Note: The following Lithium-ion (Li-Ion) battery system safety requirements are not applicable to Li Ion batteries used in UL or MSA-approved appliances that have Li Ion batteries as part of the certification. Examples include batteries that are in cell phones and computers.
Note: The following Li-Ion system safety requirements are applicable to any flight hardware or aerospace ground support equipment (GSE) without UL or MSA approval for the cells, batteries, and battery chargers approved specifically for the cell pack used.
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14.1.9.3.1. Charging and Discharging
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14.1.9.3.1.1. GSE used for charging and discharging shall prevent each cell from exceeding 4.4 volts or driving cells to less than 0 volts.
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14.1.9.3.1.2. The GSE used for charging and discharging shall be dual failure tolerant.
Note: The requirements for charging and discharging are also applicable to any charging, power, or battery management activities such as current compensation, topping charge, constant current, constant voltage (CCCV) charging, etc. where a battery is in the same circuit as the external voltage and/or current source.
Note: Individual cells that have an internal design which provides high rate discharge protection, (e.g., Positive Temperature Coefficient Devices and Internal Fuses) may be considered to already have one inhibit.
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14.1.9.3.1.3. Individual cell monitoring and recording of voltage, current and temperature is required during charging and discharging to preclude the inadvertent venting of cells.
(1) Cell voltages shall be recorded at least every minute. For charge rates that exceed the battery capacity (i.e., if capacity is 1 Amp-Hour and charger is supplying greater than 1 Amp of current), record voltages every 10 seconds for charge rates between 1 and 2 times battery capacity and every second for charge rates that exceed 2 times battery capacity.
(2) Data shall be reviewed for anomalies and verification of voltage limits real-time throughout charging or discharging activities.
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14.1.9.3.1.4. Charging, monitoring, and recording EGSE shall be intrinsically safe if used within the Class I Division I or Division II areas and shall prevent high heat, sparking, and high charge/ discharge current rates.
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14.1.9.3. 1.5. Discharge shall not take place below -20C or above 60C.
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14.1.9.3.2. Battery and Cell Case Design
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14.1.9.3.2.1. High pressure protection for cells is required.
Note: Examples include burst disks and heat-sealed pouches.
(1) Battery and cell case design shall have a 3:1 burst pressure based on vent device operating pressure with individual cells capable of surviving a short circuit current with a vent opening to release products.
(2) Cell pressure relief devices shall be demonstrated by test to show that the vent operates as intended and that the vent is adequate to prevent cell fragmentation.
Note: Recommended test is NAVSEA 9310 High Temperature Test.
(3) Battery case design shall not impede cell vent operation. Battery design shall accommodate all cells within the battery venting at the same time. This shall be demonstrated by test.
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14.1.9.3.2.2. Battery and cells shall be treated as always having a voltage potential, therefore, connection or disconnection of battery shall be considered an electrical personnel hazard and a ”spark” potential.
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14.1.9.3.2.3. Batteries/cells shall be evaluated for toxic, reactive, flammable, and combustion materials. This evaluation shall include the products if the cell case vents. Fratricide of all cells in a pack will be assumed in this evaluation unless the design incorporates mechanical and thermal barriers between cells that are proven by test to prevent fratricide.
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14.1.9.3.2.4. Support equipment (ground or airborne) shall be verified to operate correctly prior to first operational use, including all failure tolerant devices or subsystems, prior to connecting battery. Verification shall include inducing overvoltage/under-voltage/temperature extremes to the monitoring devices as intended when in use prior to connecting of the battery.
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14.1.9.3.2.5. Storage of the batteries (when not installed in GSE or Airborne hardware) shall be in approved battery storage locations.
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14.1.9.3.2.6. Transportation to the launch site shall meet DOT requirements. When batteries are not incorporated into flight hardware, they shall meet the following:
(1) Transported on publicly-accessed roadways, they shall not exceed 50 percent of rated charge.
(2) When lithium content exceeds 8.0 grams per battery, transportation packaging of individual batteries shall have caution labels in accordance with 49 CFR 173.185.
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14.1.9.3.2.7. Batteries that are transported incorporated into flight hardware shall be approved on a case-by-case basis.
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