En 50155 (2017)
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BS EN 50155:2017
BSI Standards Publication
Railway applications - Rolling stock - Electronic equipment
BRITISH STANDARD
BS EN 50155:2017
National foreword This British B ritish Standard is the UK U K implementat implementation ion of EN 50155:2017 50155:2017.. It supersedes BS EN 50155:2007, which 50155:2007, which is withdrawn. The UK participation in its preparation was entrusted to Technical Committee GEL/9/2, Railway Electrotechnical Applications Rolling stock. A list of organizations represented on this committee can be obtained on request to its secretary. secretar y. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. © The British Standards Institution 2017 Published by BSI Standards Limited 2017 ISBN 978 0 580 82911 6 ICS 45.060.10; 45.060.01 Compliance with a British Standard cannot confer immunity from legal obligations. obligations. This British Standard was published under the authority of the Standards Policy and Strategy Committee on 31 October 2017. Amendments/corrigenda issued since si nce publication Date
Tex t af fected
BS EN 50155:2017
EUROPEAN STANDARD
EN 50155 50155
NORME EUROPÉENNE EUROPÄISCHE NORM
October 2017
ICS 45.060.01
Supersedes EN 50155:2007
English Version
Railway applications - Rolling stock - Electronic equipment Applications ferroviaires ferroviaires - Équipements Équipements électroniques utilisés sur le matériel roulant
Bahnanwendungen - Elektronische Einrichtungen auf Schienenfahrzeugen
This European Standard was approved by CENELEC on 2017-05-08. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CENELEC member. This European Standard exists in three official off icial versions (English, French, German). A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions. CENELEC members are the national electrotechnical committees committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung
CEN-CENELEC Management Centre: Centre: Avenue Marnix 17, B-1000 Brussels
© 2017 CENELEC All rights of exploitation in any form form and by any means reserved worldwi worldwide de for CENELEC Members. Ref. No. EN 50155:2017 E
BS EN 50155:2017
EN 50155:2017 (E)
Contents
Page
European foreword............................................................................................................................... 9 Introduction......................................................................................................................................... 11 1
Scope ............................................................................................................................................ 12
3
Terms, definitions and abbreviations abbreviations ....................................................................................... 14
2
4
Normative references.................................................................................................................. 12
3.1
Terms and definitions ............................................................................................................. 14
3.2
Abbreviations Abbreviation s ......................................................................................................................... 19
General requirements ................................................................................................................. 20 4.1
Performance requirements .................................................................................................... 20
4.2
Performance criteria ............................................................................................................... 20
4.2.1
General ........................................................................................................................... 20
4.2.2
Performance criterion A .................................................................................................. 20
4.2.3
Performance criterion B .................................................................................................. 20
4.2.4
Performance criterion C .................................................................................................. 21
4.3
4.3.1
Altitude ............................................................................................................................ 21
4.3.2
Operating temperature t emperature.................................................................................................... 21
4.3.3
Switch-on extended operating temperature .................................................................... 22
4.3.4
Rapid temperature variations .......................................................................................... 23
4.3.5
Shock and vibration ........................................................................................................ 23
4.3.6
Electromagnetic Electromagn etic compatibility ......................................................................................... 23
4.3.7
Relative humidity............................................................................................................. 23
4.4
5
Special service s ervice conditions...................................................................................................... 24
4.4.1
General ........................................................................................................................... 24
4.4.2
Atmospheric pollutants pollutants ................................................................................................... 24
Electrical service conditions...................................................................................................... 24 5.1
Power supply.......................................................................................................................... 24
5.1.1
DC Supply ....................................................................................................................... 24
5.1.2
Supply by a specified source s ource other than the main power source ................................... 28
5.1.3
Supply change-over ........................................................................................................ 28
5.1.4
Supply with overhead line or third rail ............................................................................. 28
5.2
2
Environmental service conditions .......................................................................................... 21
Installation requirements requirements ........................................................................................................ 29
5.2.1
Power supply .................................................................................................................. 29
5.2.2
Thermal compatibility c ompatibility ...................................................................................................... 29
5.2.3
Electromagnetic Electromagn etic compatibility ......................................................................................... 29
5.2.4
Cabling ............................................................................................................................ 29
5.2.5
Installation instruction ..................................................................................................... 29
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5.2.6 6
Reliability, maintainability and expected useful life ................................................................ 29 6.1
7
Equipment reliability ............................................................................................................... 29
6.1.1
Predicted reliability .......................................................................................................... 29
6.1.2
Proof of reliability ............................................................................................................ 31
6.2
Useful life ............................................................................................................................... 32
6.3
Maintainability Maintainabili ty ........................................................................................................................ 33
6.3.1
General ........................................................................................................................... 33
6.3.2
Preventive Maintenance ................................................................................................. 33
6.3.3
Corrective Maintenance .................................................................................................. 33
6.4
Built-in diagnostics ................................................................................................................. 34
6.5
Automatic test equipment....................................................................................................... equipment....................................................................................................... 34 34
6.6
Purpose built test equipment and special tools ..................................................................... 34
Design........................................................................................................................................... 34 7.1
General................................................................................................................................... 34
7.1.1
Equipment....................................................................................................................... 34
7.1.2
Quality management....................................................................................................... 34
7.1.3
System Life-cycle ............................................................................................................ 34
7.2
Detailed practices - Hardware................................................................................................ 35
7.2.1
Insulation coordination .................................................................................................... 35
7.2.2
Interfacing ....................................................................................................................... 35
7.2.3
Fault protection ............................................................................................................... 37
7.2.4
Referencing power supplies ........................................................................................... 37
7.2.5
Interchangeability Interchangea bility ............................................................................................................ 37
7.2.6
Reduction of supply voltage and ON/OFF phases ......................................................... 37
7.2.7
Polarity reversal .............................................................................................................. 37
7.2.8
Inrush currents ................................................................................................................ 37
7.2.9
Energetic transient pulses .............................................................................................. 37
7.2.10
Capacitance to ground/earth .......................................................................................... 38
7.2.11
Spare capacity ................................................................................................................ 38
7.2.12
Programmable Programmab le Component............................................................................................. 38
7.3
Detailed practices - Software ................................................................................................. 38
7.3.1
General ........................................................................................................................... 38
7.3.2
Life-cycle ......................................................................................................................... 38
7.4
8
Insulation......................................................................................................................... 29
Features of software controlled equipment ............................................................................ 38
7.4.1
General ........................................................................................................................... 38
7.4.2
Self-test ........................................................................................................................... ........................................................................................................................... 38
7.4.3
Watchdog ........................................................................................................................ 38
7.4.4
Failure indication ............................................................................................................. 38
7.4.5
Recovery ......................................................................................................................... 38
Non-railway designed electronic equipment ............................................................................ 39
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Components ................................................................................................................................ 39 9.1
General................................................................................................................................... 39
9.2
Procurement........................................................................................................................... 39
9.3
Application.............................................................................................................................. 39
10
Construction Construct ion ............................................................................................................................ 40
10.1
Equipment construction ...................................................................................................... 40
10.1.1
General ........................................................................................................................... 40
10.1.3
Polarization or coding ..................................................................................................... 40
10.1.4
Dimensional requirements .............................................................................................. 40
10.1.5
Sockets and edge connectors ........................................................................................ 40
10.1.6
Cabling inside cubicles ................................................................................................... 40
10.1.2
10.2
Component mounting ......................................................................................................... 41
10.2.1
General ........................................................................................................................... 41
10.2.2
Layout ............................................................................................................................. 41
10.2.3
Fixing .............................................................................................................................. 41
10.2.4
Componentt lead terminations......................................................................................... 41 Componen
10.2.5
Pre-set control................................................................................................................. 41
10.2.6
Select on test components ............................................................................................. 41
10.3
4
Mechanical protection ..................................................................................................... 40
Electrical connections......................................................................................................... 41
10.3.1
General ........................................................................................................................... 41
10.3.2
Soldered connections ..................................................................................................... 41
10.3.3
Crimped connections ...................................................................................................... 42
10.3.4
Wire wrap connections ................................................................................................... 42
10.3.5
Other connections........................................................................................................... 42
10.4
Internal flexible wiring (electrical and optical)..................................................................... 42
10.5
Flexible printed wiring ......................................................................................................... 42
10.6
Printed boards - flexible and rigid ....................................................................................... 43
10.6.1
Printed board .................................................................................................................. 43
10.6.2
PCB acceptability............................................................................................................ 43
10.6.3
Layout ............................................................................................................................. 43
10.6.4
Materials ......................................................................................................................... 43
10.7
Protective coatings for printed board assemblies .............................................................. 43
10.8
Identification ....................................................................................................................... 44
10.8.1
Bare PCB identification ................................................................................................... 44
10.8.2
Identification of subracks s ubracks and printed board assemblies ................................................ 44
10.8.3
Mounting position of subracks and printed board assemblies........................................ 44
10.8.4
Fuse and battery identification ........................................................................................ 44
10.9
Mounting ............................................................................................................................. 44
10.10
Cooling and ventilation ....................................................................................................... 45
10.11
Materials and finishes ......................................................................................................... 45
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10.12 11
Reworking, modification and repair of electronic assemblies ............................................ 45
Safety ........................................................................................................................................ 45
11.1
General ............................................................................................................................... 45
11.2
Requirements ..................................................................................................................... 45
11.3
Fire behaviour requirements .............................................................................................. 45
11.4
Functional safety ................................................................................................................ 46
11.5
Personnel safety ................................................................................................................. 46
12.1
General ............................................................................................................................... 46
12.2
Supply and storage of documentation documentation ................................................................................ 46
12.3
Datasheet ........................................................................................................................... 46
12.4
User manual m anual ....................................................................................................................... ....................................................................................................................... 49
12.5
Equipment integration/installation integration/installation documentation.............................................................. 49
12.6
Commissioning documentation .......................................................................................... 50
12.7
Design documentation documentation ........................................................................................................ 50
12
13
Documentation Documenta tion ......................................................................................................................... 46
12.7.1
General ........................................................................................................................... 50
12.7.2
Block diagrams ............................................................................................................... 51
12.7.3
Wiring diagrams .............................................................................................................. 51
12.7.4
Interface specification ..................................................................................................... 51
12.7.5
Internal interface specification ........................................................................................ 51
12.7.6
Equipment drawings ....................................................................................................... 51
12.7.7
Documentation – Hardware ............................................................................................ 51
12.7.8
Non repairable items list ................................................................................................. 52
12.7.9
Repair and Maintenance Documentation ....................................................................... 52
12.7.10
Documentation – Software .......................................................................................... 53
12.7.11
Documentation – System ............................................................................................ 54
Testing ...................................................................................................................................... 54
13.1
General ............................................................................................................................... 54
13.2
Categories of tests.............................................................................................................. 54
13.2.1
General ........................................................................................................................... 54
13.2.2
Type tests ....................................................................................................................... 55
13.2.3
Routine tests ................................................................................................................... 55
13.2.4
Investigation tests ........................................................................................................... 55
13.3
Tests summary ................................................................................................................... 55
13.4
Test specification................................................................................................................ 56
13.4.1
Visual inspection ............................................................................................................. 56
13.4.2
Performance test............................................................................................................. 56
13.4.3
Power supply test............................................................................................................ 57
13.4.4
Low temperature start-up test ......................................................................................... 60
13.4.5
Dry heat test t est.................................................................................................................... 61
13.4.6
Low temperature storage test ......................................................................................... 64
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13.4.7
Cyclic damp heat test ..................................................................................................... 65
13.4.8
Electromagnetic Electromagn etic compatibility test .................................................................................. 67
13.4.9
Insulation test .................................................................................................................. 67
13.4.10
Salt mist test ................................................................................................................ 68
13.4.11
Vibration and shock test .............................................................................................. 69
13.4.12
Enclosure protection test (IP code) ............................................................................. 69
13.4.13
Stress screening s creening test ................................................................................................... 70
13.4.14
Rapid Temperature variation test ................................................................................ 70
Annex A (informative) (informative) List of default default requirements requirements of EN 50155 and 50155 and related clauses ................ 71 Annex B (informative) (informative) Testing approach approach .......................................................................................... 72 B.1
General................................................................................................................................... 72
B.2
Situation of applicability.......................................................................................................... 72
B.3
General methodology............................................................................................................. 72
B.4
Equipment Specific Methodology........................................................................................... 74
B.5
Equipment integration design review ..................................................................................... 74
B.6
Equipment integration type test ............................................................................................. 74
B.7
Equipment installation design review ..................................................................................... 74
B.8
Equipment installation type test ............................................................................................. 75
B.9
Equipment installation routine test ......................................................................................... 75
B.10
Equipment periodic re-verification ...................................................................................... 75
B.11
Replacement of items and ancillary componen c omponents ts ............................................................... 75
Annex C (informative) (informative) Severity of the service conditions in different different rolling stock locations ... 76 C.1
General................................................................................................................................... 76
C.2
Severity of service conditions in different rolling stock types ................................................. 76
C.3
Intended use of rolling stock .................................................................................................. 76
C.4
Location of equipment on board rolling stock ........................................................................ 76
C.5
Severity of the service conditions in different rolling stock locations ..................................... 78
Annex D (informative) (informative) Example of test report compliance summary ............................................ 80 Annex E (informative) (informative) Life cyc cycle le model examples — Programmable component life cycle cycle example ............................................................................................................................................... 82 Annex F (informative) (informative) Design guidelines for electronic hardware used on board of rolling stock .............................................................................................................................................................. 83
6
F.1
Purpose of this annex ............................................................................................................ 83
F.2
Design Rules .......................................................................................................................... 83
F.2.1
Pollutants ........................................................................................................................ 83
F.2.2
Methods against ageing regarding energetic transient pulses ....................................... 83
F.2.3
Capacitor to ground/earth ground/earth ............................................................................................... 84
F.2.4
Inside cabling for equipment ........................................................................................... 84
F.2.5
Earthing configuration ..................................................................................................... 84
F.2.6 F.2.7
Prototype testing ............................................................................................................. 85 Interfacing ....................................................................................................................... 85
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F.2.8
Solder joint on PBA ......................................................................................................... 85
F.2.9
Derating .......................................................................................................................... 85
Annex G (informative) (informative) Non-railway designed designed electronic equipment ............................................. 96 Annex H (informative) (informative) Paragraphs with Agreements Agreements between the involved Partie Parties s ................... 98 Annex ZZ (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC ..................................................................................... 102 Bibliography...................................................................................................................................... 104 Tables Table 1 — Operating temperature temperature classes....................................................................................... 22 Table 2 — Switch-on extended Operating temperature temperature classes ................................................... 22 Table 3 — Temperatu T emperature re variation classes........................................................................................ 23 Table 4 — Continuous Voltage range ............................................................................................... 25 Table 5 — Fluctuation Voltage ranges ............................................................................................. 25 Table 6 — Interruption voltage supply classes ............................................................................... 27 Table 7 — Maximum M aximum Peak to Peak Voltages with a DC Ripple Factor of 5 % .............................. 28 Table 8 — Supply change-over classes ........................................................................................... 28 Table 9 — Useful life classes ............................................................................................................ 32 Table 10 — Protective coating classes ............................................................................................ 43
Table 11 — List of required documentation according according to the class ............................................. 52 Table 12 — List of tests ..................................................................................................................... 56 Table 13 — Interruptions of voltage supply classes ...................................................................... 59 Table 14 — Test voltages of voltage withstand test ....................................................................... 68 Table A.1 — Default requirements .................................................................................................... 71 Table C.1 — Example of typical equipment locations on board rolling stock ............................. 7 77 7 Table C.2 — Minimum severity of service conditions in different rolling stock locations ......... 78 Table D.1 — Test report compliance summary ............................................................................... 80 Table F.1 — Type and concentration of pollutants ......................................................................... 83 Table F.2 — Derating factor ............................................................................................................... 86 Table ZZ.1 — Correspondence between this European Standard, the TSI “Locomotives and Passenger Rolling Stock” (REGULATION (EU) No 1302/201 1302/2014 4 of 18 November 2014) and Directive 2008/57/EC ........................................................................................................................ 102 Table ZZ.2 — Correspondence between this European Standard, the CCS TSI (COMMISSION REGULATION (EU) 2016/919 of 27 May 2016) and Directive 2008/57/EC.................................... 103 Figures Figure 1 — Roles and relationship of user and/or supplier ........................................................... 11 11 Figure 2 — DC Power supply voltage range .................................................................................... 25 Figure 3 — Temporary DC power supply voltage fluctuation requirements requirements ................................ 26 Figure 4 — Styles of Test Plans ........................................................................................................ 31 Figure 5 — System interfacing with the typical EMC-areas A, B and C ....................................... 36 Figure 6 — Temporary supply overvoltages (a) .............................................................................. 57
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Figure 7 — Temporary supply overvoltages (b) .............................................................................. 58 Figure 8 — Temporary supply dips .................................................................................................. 58 Figure 9 — Interruption of supply voltage ....................................................................................... 59 Figure 10 — Supply change-over Class C1 ..................................................................................... 60 Figure 11 — Supply change-over Class C2 ..................................................................................... 60 Figure 12 — Low temperature temperature start-up test ..................................................................................... 61 Figure 13 — Dry heat thermal test — Cycle A ................................................................................. 62 Figure 14 — Dry heat thermal test — Cycle B ................................................................................. 63 Figure 15 — Dry heat thermal test — Cycle C ................................................................................. 64 Figure 16 — Cyclic damp heat test: Description of the first 24-h cycle ....................................... 65 Figure 17 — Cyclic damp heat test: Recovery period .................................................................... 66 66 Figure B.1 — Testing stages ............................................................................................................. 74 Figure C.1 — Typical equipment locations on board rolling stock ............................................... 76 Figure C.2 — Integration of the equipment into the vehicle cabinet ............................................ 79 Figure E.1 — Programmable component life cycle example ......................................................... 82
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European foreword This document (EN 50155:2017) has been prepared by CLC/SC 9XB, “Electrical, electronic and electromechanical electromechan ical material on board rolling stock, including associated software”. The following dates are fixed:
latest date by which this document has to be implemented at national level by publication of an identical national standard or by endorsement
(dop)
2018-04-13
latest date by which the national standards conflicting with this document have to be withdrawn
(dow)
2020-10-13
•
•
This document supersed s upersedes es EN 50155:2007. 50155:2007. EN 50155:2017 includes the following significant technical changes with respect to EN 50155:2007: 50155:2007: a)
revision of Clause 1, Scope;
b)
revision of Clause 2, Normative references;
c)
revision of Clause 3, Terms, Terms, definitio definitions ns and abbreviations, with reorganisation reorganisation of subclauses; subclauses;
d)
improvement of Clau Clause se 4, General requ requirements, irements, in terms of better wo wording, rding, requirement requirement expansion and reorganisation of subclauses;
e)
revision of Clause 5, Electrical service conditions, conditions, with with reorganisation reorganisation of subclauses; subclauses;
f)
improvement of Clause Clause 6, Reliability, maintainability and e expected xpected useful life, with reorganizatio reorganization n of subclauses and introduction of explicative figures; f igures;
g)
revision of Clause 7, Design;
h)
introduction of a new Clause Clause 8, Non-railway designed electronic equipment;
i)
renumbering renumbering of previous Clause 8 to Clause 9, Components, and revision;
j)
renumbering renumbering of previous Clause 9 to Clause 10, Construction, and introduction of new requirements;
k)
renumberin renumbering g of previous previous Clause 10 to Cl Clause ause 11, Safety, and improving of the wording; wording;
l)
renumberin renumbering g of previous Clause Clause 11 to Clause 12, Documentation, Documentation, and introduction of new requirements requiremen ts also considering new technologies;
m) renumberin renumbering g of previous Clause 12 to Clause 13, Testing, text impro improvement vement with a pa particular rticular attention to table “List of tests” and introduction introduction of explainin explaining g figures; n)
introduction of the following informative Annexes: 1)
Annex A - List of default requirements requirements o off EN 50155 and 50155 and related clauses;
2)
Annex B - Testing approach;
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o)
3)
Annex C - Severity Severity of the service service conditions conditions in different rolling stock locations; locations;
4)
Annex D - Example of test report compliance summary;
5)
Annex E - Life cycle model examples;
6)
Annex F - Design guidelines for electronic hardware used on board of rolling stock;
7)
Annex G - Non-railway designed electronic equipment;
Bibliography (extended and corrected).
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CENELEC shall not be held responsible for identifying any or all such patent rights. This document has been prepared under a mandate given to CENELEC by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). For the relationship with EU Directive 2008/57/EC amended by Commission Directive 2011/18/EU, see informative Annex ZZ, which is an integral part of this document.
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Introduction This standard is applied in the design, manufacturing, manufacturing, testing of any electronic equipment installed on board rolling stock. It also describes the electrical and environmental operati operating ng conditions. There are not correlations between the operating temperature classes listed in Table 1 and the air temperature classes listed in EN 50125-1:2014, 50125-1:2014, Table 2. The aim of this standard is not to be a detailed guideline for the design of the electronic equipment; the design is made under the responsibility of the supplier. The supplier should take into account the requirements requireme nts resulting from the specific location of the on board installation (see Annex C). This standard contains the design, the documentation and the testing requirements. The roles of user and/or supplier are shown in Figure 1 below. SUPPLIER Manufacturer
USER Railway undertaking
Integrator
Train staff
Purchaser Maintainer
Figure 1 — Roles and relationship of user and/or supplier
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1
Scope
This European Standard applies to all electronic equipment for control, regulation, protection, diagnostic, energy supply, etc. installed on rail vehicles. For the purpose of this European Standard, electronic equipment is defined as equipment mainly composed of semiconductor devices and recognized associated components. These components will mainly be mounted on printed boards. Sensors (current, voltage, speed, etc.) and Semiconductor drive unit (SDU) for power electronic devices are covered by this standard. Complete Semiconductor drive unit (SDU) and power converters are covered by EN 61287-1. 61287-1. This European Standard covers the conditions of operation, operation, design requirements, documentation, and testing of electronic equipment, as well as basic hardware and software requirements considered necessary for compliant and reliable equipment. Specific requirements related to practices necessary to ensure defined levels of functional safety will be determined in accordance with relevant railway safety standards. st andards. The software requirements for on board railway equipment are specified by EN 50657.
2
Normative references
The following documents, in whole or in part, are normatively referenced in this document and are indispensable its edition application. dated references, only thegedition cited applies. For undated references, thefor latest of theFor referenced document (includin (including any amendments) applies. EN 45545 (all parts), Railway applications — Fire protection on railway vehicles v ehicles EN 45545-2:2013+A1:2015, 45545-2:2013+A1:2015, Railway applications — Fire protection on railway vehicles — Part 2: Requirements for fire behaviour of materials and components components EN 50121-3-2:2016, Railway applications — Electromagnetic compatibility — Part 3-2: Rolling stock Apparatus Apparatus EN 50124-1:2017, Railway applications — Insulation coordination — Part 1: Basic requirements Clearances and creepage distances for all electrical and electronic equipment EN 50125-1:2014, 50125-1:2014, Railway applications — Environmental conditions for equipment — Part 1: Rolling stock and on-board equipment EN 50126-1:2017, Railway Applications — The Specification and Demonstration of Reliability, Availability, Maintainability Maintainability and Safety (RAM (RAMS) S) — Part 1: Generic Generic RAMS Process Process EN 50153:2014, 50153:2014, Railway applications — Rolling stock — Protective provisions relating to electrical hazards hazards EN 50163:2004, 50163:2004, Railway applications — Supply voltages of traction systems (IEC 60850:2000, not equivalent) equivalent) EN 50657:2017, Railway applications applications — Rolling stock application applications s — Software onboard of rolling stock EN 60068-2-1:2007, 60068-2-1:2007, Environmenta Environmentall testing — Part 2-1: Tests — Test A: Cold ( IIEC EC 60068-2-1:2007 60068-2-1:2007 ) ) EN 60068-2-2:2007, 60068-2-2:2007, Environmental testing — Part 2-2: Tests — Test B: Dry heat (IEC 60068-22:2007) 2:2007)
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EN 50155:2017 (E)
EN 60068-2-11:1999, 60068-2-11:1999, Environmental testing — Part 2: Tests — Test Ka: Salt mist (IEC 60068-211:1981) 11:1981) EN 60068-2-30:2005, 60068-2-30:2005, Environmenta Environmentall testing — Part 2-30: Tests — Test Db: Damp heat, cyc cyclic lic (12 h + 12 h cycle) ( IIEC EC 60068-2-30:2005 60068-2-30:2005 ) ) EN 60297 (all parts), Mechanical structures for electrical and electronic equipment — Dimensions of mechanical structures of the 482,6 mm (19 in) series (IEC 60297 series) series) EN 60352-1:1997, 60352-1:1997, Solderless connections — Part 1: Wrapped connections — General requiremen requirements, ts, test methods and practical guidance ( IIEC EC 60352-1:1997 60352-1:1997 ) ) EN 60352-2:2006, 60352-2:2006, Solderless connections — Part 2: Crimped connections — General requirements, test methods and practical guidance (IEC 60352-2:2004) 60352-2:2004) EN 60529:1991, 60529:1991, Degrees of protection provided by enclosures (IP Code) (IEC 60529:1989) 60529:1989) EN 61249-2-7:2001, Materials for printed boards and other interconnecting structures — Part 2-7: Reinforced base materials, clad and unclad — Epoxide woven E-glass laminated sheet of defined flammability (vertical burning test), copper-clad ( IEC IEC 61249-2-7:2002 ) ) EN 61249-2-22:2005, 61249-2-22:2005, Materials for printed boards and other interconnecting structures — Part 2-22: Reinforced base materials, clad c lad and unclad — Modified non-halogenated epoxide woven E-glass laminated sheets of defined flammability (vertical burning test), copper-clad (IEC 61249-2-22:2003) 61249-2-22:2003) EN 61373:2010, 61373:2010, Railway applications applications — Rolling stock equipment equipment — Shock and vibration tests ( IIEC EC 61373:2010 ) ) EN 62326 (all parts), Printed boards (IEC 62326 series) series) EN ISO 13732-1:2 13732-1:2008, 008, Ergonomics of the thermal environment — Methods for the assessment of human responses responses to contact with surfaces s urfaces — Part 1: Hot s surfaces urfaces ( ISO ISO 13732-1:2006 ) ISO/IEC 90003, 90003, Software engineering — Guidelines for the application of ISO 9001:2008 to to computer software software ISO/IEC/IEEE 15289:2017, Systems and software engineering — Content of life-cycle information items (documentation) (documentation) IPC-A-600 (H):2010, Acceptability of Printed Boards IPC-A-610 (E):2010, Acceptability of Electronic Assemblies IPC-2220:2010 IPC-2220:20 10 series, Family of Design Documents IPC-2221 (B):2012, Generic Standard on Printed Board Design IPC-2222 (A):2010, Sectional Design Standard for Rigid Organic Printed Boards IPC-2223 (C):2011, Sectional Design Standard for Flexible Printed Boards IPC-2581 (B):2013, Generic Requirements for Printed Board Assembly Products Manufacturing Description Data and Transfer Methodology IPC-4101 (D):2014, Specification for Base Materials for Rigid and Multilayer Printed Boards IPC-6013 (C):2013, Qualification and Performance Specification for Flexible Printed Boards
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IPC-7711B/7721B:2007, IPC-7711B/772 1B:2007, Rework, Modification and Repair of Electronic Assemblies
3 3.1
Terms, definitions and abbreviations Terms and definitions
For the purposes of this document, the following terms and definitions apply. 3.1.1 printed boards base materials which are cut to size containing all required holes and bearing at least one conductive pattern, and which are typically subdivided according to: •
their structure (e.g. single and double sided, multilayers);
•
the nature of the base material (e.g. rigid, flexible)
[SOURCE: IEV ref.541-01-03, modified — The definition was grammatically modified.] 3.1.2 printed board assembly printed board with electrical and mechanical components and/or other printed boards attached to it with all manufacturing processes, soldering, coating, etc., completed 3.1.3 operating temperature temperature range in which the electronic equipment will operate (e.g. cubicle temperature, rack temperature, roof box temperature) in full conformity with his performance criteria, and outside which there can be temporary or permanent degradation of the equipment performances 3.1.4 plug-in unit unit which plugs into a subrack and is supported by guides Note 1 to entry: Plug-in units can be of various types, types, ranging from a printed board with with components inserted, to a frame or box-type unit designed d esigned with a plug-in connection.
[SOURCE: IEV ref 581-25-0 581-25-04] 4] 3.1.5 subrack structural unit for housing printed boards with components inserted, and plug-in units [SOURCE: IEV ref 581-25-0 581-25-01] 1] 3.1.6 rack free-standing free-standin g or fixed f ixed structure for housing electrical and electronic equipment [SOURCE: IEV ref 581-25-0 581-25-03] 3] 3.1.7 cubicle enclosure for housing electrical and/or electronic equipment 3.1.8 line replaceable unit modular component that is designed to be removed and replaced at the field level to restore the system to an operational ready condition
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3.1.9 performance test test in which the equipment is stimulated and measured to verify the conformance to the specified functional requirements, requirements, and which will verify all functionalities Note 1 to entry: The performance test is carried out according to the Performance test specification and Performance test procedure provided by the supplier.
3.1.10 operational check tailored performance test which is carried out during and/or after environmental tests or stress screening sufficient to prove that the equipment is within its operational limits, and that it has survived the environmental/stress screening test Note 1 to entry: entry:
Every environmental test or stress stress screening can use a different operational check.
Note 2 to entry: Operational checks are carried out according to Operational check specifications and Operational check procedures provided by the supplier.
3.1.11 system voltage supply voltage supply used to power the electronic equipment 3.1.12 vehicle wiring all wiring which can be connected to the system s ystem voltage supply, wherever located, and all other wiring external to the electronic equipment under consideration 3.1.13 supply overvoltage electrical disturbance to the control system voltage supply (e.g. caused by equipment controlling that supply, load drop) Note 1 to entry: entry:
A supply ov overvoltage ervoltage will occur as an increase in the level of the control sys system tem voltage supply supply..
3.1.14 energetic transient pulses non-periodic and relatively short positive or negative (or both) rapid change(s) of voltage and/or current between two steady states 3.1.15 failure termination of the ability of an item to perform a required function Note 1 to entry:
“Failure” is an event, as distin distinguished guished from “fault”, which is a state.
Note 2 to entry: Attention is drawn to the possibility of a consequential failure of a second item of equipment resulting from a temporary malfunction of an item i tem of equipment connected to it. Note 3 to entry: A temporary malfunction will not be considered as a failure provided that the equipment recovers normal operation automatically following malfunction.
3.1.16 damage change in visual appearance or alteration of electrical or mechanical integrity
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3.1.17 useful life useful life, time interval, from first use until user requirements are no longer met, due to economics of operation and maintenance, or obsolescence Note 1 to entry:
In this context, “first use” excludes testing testing activities prior to hand-over of the item to the end-
user.
[SOURCE: IEV 192-02-27] Note 2 to entry: For a repairable item the individual useful life may be ended by a ffailure ailure which is not considered as repairable for any reason.
3.1.18 fault state of an item characterized by its inability to perform a required required function Note 1 to entry: A fault is often the result of a failure of the item itself, but may ex exist ist without prior failure (e.g. in the case of a design fault).
3.1.19 performance criteria performance specification for the operation of the electronic equipment throughout the environmental test conditions stated in this standard 3.1.20 minimum performance level defined level of deviation from normal opera operation tion 3.1.21 user person or organization that receives and specifies equipment or software for further use, and that can be: •
a system integrator in relationship to the manufacturer;
•
a purchaser purchaser;;
•
a maintainer;
•
a railway undertaking
3.1.22 manufacturer party who develops and manufactures the electronic equipment 3.1.23 system integrator party who is responsible for the specification and/or the integration of the electronic equipment into the railway vehicle or vehicle component
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3.1.24 system set of interrelated elements considered in a defined context as a whole and separated from their environment [SOURCE: IEV ref.351-42-08, modified — The original Notes to the definition have not been reproduced reprodu ced here.] 3.1.25 equipment single apparatus or set of devices or apparatuses, or the set of main devices of an installation, or all devices necessary to perform a specific task [SOURCE: IEV ref.151-11-25, modified — The original Note to the definition has not been reproduced here.] 3.1.26 apparatus device or assembly of devices which can be used as an independent independent unit for specific functions f unctions Note 1 to entry: purposes.
In English, the term “apparatus” sometimes implies use by skilled pe persons rsons for professional
[SOURCE: IEV ref.151-11-22] ref.151-11-22] 3.1.27 component constituent part of a device which cannot be physically divided into smaller parts without losing its particular function [SOURCE: IEV ref.151-11-21] ref.151-11-21] 3.1.28 device material element or assembly of such elements intended to perform a required function Note 1 to entry:
A device may form part of a larger device.
[SOURCE: IEV ref.151-11-20] ref.151-11-20] 3.1.29 item part, component, device, subsystem, functional unit, equipment or system that can be individually considered Note 1 to entry: people.
An item may consist of hardware, software or both, and may also in particular cases, include
[SOURCE: IEV ref.192-01-01, modified — The definition itself and the Note have been made more precise and the other Notes in the original definition have not been reproduced here.] 3.1.30 event something that occurs in a certain place during a particular interval of time
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3.1.31 supplier organization which has the responsibility for the supply of individual item of equipment or groups of the equipment to the user, and which can be: •
a manufacturer;
•
a system integrator in relation to railway undertaking or maintainer
3.1.32 performance classes classification applied to an electronic equipment and specifying different performance levels for a performance requirement requirement 3.1.33 commercial off-the-shelf equipment/co equipment/components mponents item purchased from a supplier’s catalogue, available on the domestic and foreign market, according to a supplier reference, and for which the user has no control over the design definition or on the production Note 1 to entry: This item may be modified; the manufacturing discontinued or may no longer be maintained without the user being notified and has no right to be so. A single supplier or multiple suppliers may exist for the same item.
3.1.34 equipotentiall area equipotentia area of electronic components/equipment and electric connections referenced to the same potential and without insulation between the components 3.1.35 performance performan ce specification document that specifies the functions that a system or component is to perform (often part of a requirements requiremen ts specification) 3.1.36 DC ripple factor ratio of half the difference between the maximum and minimum value of a pulsating direct current to the mean value of this current Note 1 to entry: With low values of the DC ripple factor this quantity is approximately equal to the ratio of the difference to the sum of the maximum and the minimum values.
[SOURCE: IEV 551-17-29] 3.1.37 Extra Low Voltage (ELV) circuit secondary circuit with voltages between any two conductors of the circuit, and between any one such conductor and earth, not exceeding 25 V AC or 60 V DC, under normal operating conditions, which is separated from hazardous hazardous voltage by basic insulation Note 1 to entry: entry:
18
The values 25 V AC and 60 V D DC C are taken from band I of EN 50153 50153..
BS EN 50155:2017
EN 50155:2017 (E)
3.2
Abbreviations
For the purposes of this document, the following abbreviations apply. AC
Alternating Current Current
ASIC
Application Specific Specific Integrated Circui Circuit, t,
ATE
Automatic Test Equipment Equipment
CAN
Controller Area Network bus
CMRR
Common Mode Rejection Ratio
CPLD
Complex Programmab Programmable le Logic Device
CPU
Central Processing Unit
CTR
Current Transfer Ratio
DC
Direct Current
ELV
Extra Low Voltage
EMC
Electromagne Electromagnetic tic compatibility
EN
European Standard (Norm)
ESD
Electrostatic discharge
FPGA GBWP
Field Programmable Programmable Gate Array Gain–bandwidth Gain–bandwidth product
HR
Relative Humidity
IEC
International Electrotechnical Commission
IEEE
Institute of Electrical and Electronics Engineers
IEV
International Electrotechnical Vocabulary
I/O
Input Output
IP code
International Protection Code
IPC
Association Connecting Electronics Industries
LED
Light Emitting Diode
LRU
Line Replaceable Unit
MTBF
Mean Time Between Failures
MTTR
Mean Time To Repair
MVB
Multifunction Vehicle Bus
NA
Not Applicable
PBA
Printed Board Assembly
PCB
Printed Circuit Board
PLD
Programmable Programmable Logic Device
PoE
Power over Ethernet
PPS
Polyphenylene sulfide
PTE
Portable Test Equipment
RAMS
Reliability Availability Maintainability Safety
REACH
Registration, Evaluation, Authorization and Restriction of Chemicals
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RF
Radio Frequen Frequency cy
rms
Root Mean Square (value of a quantity)
RoHS
Restriction of the Use of Hazardous Substances
SOT
Select On Test
TCMS
Train Control and Monitoring System
TFT TTL
Thin-Film-Transistor Transistor-Transistor Transistor-Transistor Logic
TVS
Transient Voltage Suppressor
UV
Ultraviolet
4
General requirements
4.1
Performance requirements
The electronic equipment performance requirements (e.g. functional, electrical, mechanical, appearance, appearan ce, interfaces) shall be defined. The standard specifies a set of default performance performance classes of requirements; requirements; different classes may be requested at tender stage.
4.2 4.2.1
Performance criteria General
The normal performance level of the electronic equipment may be replaced by a permissible loss of performance. In the text below if performance criteria A, B or C are used in Clauses 4 to 12 the word “test” shall be replaced by “event”. “ event”. The minimum performance level shall be defined. If the minimum performance level or the permissible loss of performance is not specified by the supplier, either of these may be derived from the product description and documentation and what the user may reasonably expect from the apparatus apparatus if used as intended. No damage to any connected equipment is allowed when the electronic equipment does not operate as intended during or after the test. Possible causes of failure are incorrect timing of output signals, overvoltage outside specifications, etc. 4.2.2
Performance criterion A
The apparatus shall continue to operate as intended during and after the test/event. No degradation of performance or loss of function is allowed. Changes of actual operating state or stored data are not allowed. If agreed between the involved parties, the normal performance level (all functions are working as specified) can be replaced by a minimum performance level. 4.2.3
Performance criterion B
The apparatus shall continue to operate as intended after the test/event. During the test/event, degradation of performance is however allowed. Changes of actual operating state or stored data are not allowed.
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4.2.4
Performance criterion C
During the test/event temporary loss of function is allowed. The equipment could: •
automatically restart. The normal performan performance ce sh shall all be obtained within a maximum maximum defined time. After this time the equipment shall retain retain the previous operating operating state and shall work as intended. The loss of significant data is not allowed; or
manuallyand/or restartclearly or process controlled restart. In this this this the shall shalluser be agreed user and supplier defined in the user manual. In case this case manualbetween shall be available to the user at the tender stage.
•
NOTE
4.3
Significant stored data are application dependent and stated into the Performance specifications.
Environmental service conditions
4.3.1
Altitude
The altitude at which the equipment is normally to function does not exceed the values called for in EN 50125-1:2014, 50125-1:2014, Table T able 1 “Classes of altitude range”. In case of required required altitude above the EN 50125-1:2014, 50125-1:2014, Table 1 class A1, compliance with the requirements shall be agreed between the involved parties. Unless otherwise specified, the requirements of EN 50125-1:2014 50125-1:2014,, Table 1 class A1 apply. 4.3.2
Operating temperature
Electronic equipment shall be designed and manufactured to meet the full performance specification requirementt for the selected temperature classes as stated in Table 1. requiremen The supplier of the electronic equipment shall specify its power dissipation and the thermal integration constraints (e.g. natural convection cooling, forced air cooling, cooled plate, mounting position, free space inside integration volume, preheating, air outlet) to respect a correct integration of this electronic equipment into their operating environment. The user of the electronic equipment shall respect the thermal integration constraints specified by the supplier and shall design the integration environment in order to ensure an operational temperature compliant with the operational temperature class of the integrated electroni electronic c equipment. The requirements for active or assisted cooling system shall be described according to Subclause 12.5 Equipment integration/installation documentation “Electronic equipment” and “Integration environment” are generic designations applicable to several levels; some examples are listed below: •
an “Enclosed” or “Open frame” complex component integrated on a PCB;
•
a “Single electronic board” or a “Plug-In unit” integrated into a “Sub-rack”;
•
a “Single electronic board” integrated into an “Enclosure”;
•
a “Sub-rack” integrated into a “Cubicle” or “Cabinet” or “Case”;
•
a “Rack” or a “Case” integrated into a “Vehicle”.
The ambient temperatures outside vehicle are defined into the EN 50125-1:2014 50125-1:2014, Table 2, column 1.
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Table 1 — Operating temperature classes Class
Equipment operating temperature range (°C) temperature
OT1
–25 to +55
OT2
–40 to +55
OT3 OT4
–25 to +70 –40 to +70
OT5
–25 to +85
OT6
–40 to +85
Class OT5 and OT6 cannot be used as a general specification for temperature in vehicle require requirement ment (e.g. can be used for f or Semiconductor Drive Unit (SDU), combustion engine control unit). Temperature classes OT1 and OT2 should be used for passenger compartments and driver’s cab with a reference permanent temperature of 25 °C for which the effects on the material ageing are equivalent to those of the climatic temperature during lifetime. OT3 and OT4 should be used for equipment in technical cabinet with a reference permanent temperature of 45 °C for which the effects on the material ageing are equivalent to those of the cl climatic imatic temperature during lifetime. Unless otherwise specified, the requirements of category OT3 apply. 4.3.3 Switch-on extended extended operating temperat temperature ure The design shall take into account temperature rises within cubicles to ensure that the components do not exceed their specified temperature ratings. For example, it is expected, that the air temperature surrounding surrounding the individual printed boards rises about 15 °C (this temperature temperature rise depends significantly on the power dissipation of the board itself and on the power dissipation of other boards in the vicinity of it, on the natural or forced air flow, etc.). This shall be taken into account for the design of the PBA, particularly when individual PBA’s are intended to be horizontally or vertically juxtaposed or when when sub-racks containing containing the PBAs are superposed. superposed. The supplier should take into account the requirements resulting from the specific on board installation (see Annex C). In some special cases (e.g. cubicle, effect of sun, assisting cooling system shutdown) an extra operational check at the equipment switched on at short-term thermal conditions is carried out according to the classes ST1 or ST2 of Table T able 2. Table 2 — Switch-on extended Operating temperature classes
Class
Switch-on extended operating temperature temperature
Thermal test cycle cycle
(duration: 10 min)
See 13.4.5
ST0
No switch-on extended operating temperatur temperature e
Test cycle A
ST1
OTx +15 °C
Test cycle B
ST2
OTx +15 °C
Test cycle C
NOTE “OTx +15 °C” corresponds to (maximum temperature of “OTx” operating tem temperature perature range of Table 1) + (15 °C) and only for “OTx” with "x" = 1, 2, 3 or 4.
Class ST1 and ST2 do not apply to classes OT5 and OT6. Unless otherwise specified, the requirements of class ST1 apply.
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4.3.4
Rapid temperatur temperature e variations
Special operation conditions as rapid temperature variations during train running through tunnels shall s hall be taken into account. The temperature variation seen by the equipment depends on installation location (see Table C.1; locations 4, 5, 6, 7 are particularly expose exposed). d). The following classes are defined for the equipment and they define the requirements that the equipment shall fulfil: Table 3 — Temperature variation classes
Class
H1
Column 1
Column 2
Column 3
Cold air temperature surrounding the equipment
Hot air temperature surrounding the equipment
Temperature gradient gradient °C/s
No requirements requirements
No requirements requirements
No requirements requirements
−25 25 °C °C
15 °C / 95 %RH
±3
10 10 °C °C
40 40 °C °C / / 60 %RH
±3
H2
NOTE The H2 class take into account the situation of a vehicle entering into a tunnel from low temperature environment (from −25°C to 15°C) or exiting from a tunnel into a hot and wet environment (from 10°C to 40°C). Condensation phenomena occur in both cases.
The values given in Table 3, Class H2 are worst case values which will typically not occur regularly throughout the year. Both directions of the rapid temperature change shall be taken into account. Class H2 cannot be used as a general specification for temperature and humidity change in vehicle requirements requireme nts (e.g. can be used for equipment mounted outside vehicle body). If class H2 is specified the duration of column 1 and column 2 shall be specified (typical and worst case). Furthermore,, the frequency of occurrence of the rapid temperature change shall be specified. Furthermore Unless otherwise specified, the requirements of class H1 apply. 4.3.5
Shock and vibration
The equipment shall be able to withstand, without deterioration or malfunction, vibrations and shocks that occur in service. The level of shock and vibration that the equipment can withstand in normal operation shall be specified. This shall be done using the Categories and Classes as specified by EN 61373. 61373. The supplier shall specify the permitted orientation for mounting the equipment on the vehicle according to the definitions of EN 61373. 61373. Unless otherwise specified, the requirements of EN 61373 61373 category category 1 class B apply. 4.3.6
Electromagnetic Electromagnetic compatibility
All electronic equipment equipment shall comply with with EN 50121-3-2 50121-3-2.. 4.3.7
Relative humidity
Electronic equipment shall be designed for the humidity conditions described in EN 50125-1. 50125-1. The external humidity levels and time periods to consider are specified by the EN 50125-1 50125-1..
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NOTE The temperature class to apply, in relation with the psychometric charts of EN 50125–1, is the class of air temperatures as defined in EN 50125–1:2014, Table 2.
The service condition (e.g. pollution degree of EN 50124-1 50124-1)) shall be taken into account in order to avoid malfunction or failure due to condensation c ondensation (see Annex C).
4.4
Special service conditions
4.4.1
General
Special arrangements shall be agreed between the appropriate parties involved when service conditions can be proved to be different from those mentioned in Subclause 4.3 (e.g. electronic equipment mounted on the bogie or integrated within a power converter, etc.). Checks for the effectiveness of such arrangements can, if required, form the subject of optional type tests which can be carried out on the vehicle itself in accordance with methods to be agreed between the involved parties. 4.4.2
Atmospheric Atmospheric pollutants
The equipment may be expected to be exposed throughout its life to various pollutants (e.g. oil mist, salt spray, conductive dust, sulfur dioxide.). The types of pollutants, their concentration, test procedures procedure s and test specifications should be defined in the tender documents.
5
Electrical service conditions
5.1
Power supply
5.1.1 5.1.1.1
DC Supply General
The nominal voltage of equipment ( U n) shall be selected from amongst the following values: 24 V, 28 V, 36 V, 48 V, 72 V, 96 V, 110 V The recommended values are the following: 24 V, 72 V, 110 V. These nominal voltage values are given only as standardizing values for the design of equipment. They should not be considered as the off load battery voltages since these are determined by the types of battery, the number of cells and the operating conditions. The supply may be derived from a vehicle battery. The battery may be charged from battery chargers, auxiliary inverters and motor-alternator or motor-generator sets with associated electronic regulations. The grouping of power supply nominal voltage ranges is allowed for equipment designed to be compliant with a wide input voltage range. In this case, the principle (for performance and power supply type test compliance) is to consider the most stringent values in the voltage range; it means that the minimum continuous voltage shall be 0,7 U n the lowest nominal power supply voltage and that the maximum continuous voltage shall be 1,25 U n the highest nominal power supply voltage (i.e. an equipment can be designed to be compliant with the nominal power supply voltages of 24 V up to 48 V; the minimum continuous voltage to consider is 0,7 × 24V and the maximum continuous voltages to consider (1,25 × 48) V). See Figure 2 for other example of “DC Power supply voltage range”. For thermal compliance and EMC tests, the most stringent values in the voltage range shall be considered. For DC voltage supply fluctuation tests, the most stringent values in the voltage range shall be considered (see Figure 3 for other example of “DC Power supply voltage fluctuation requirements”). For the interruption of voltage supply the equipment shall be validated for the minimum nominal power supply voltage for which he is designed for operation (i.e. for equipment designed to be
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operated with minimum power supply voltages of 24 V, 48 V, 72 V or 110 V the interruption of voltage supply compliance test shall be performed at 24 V). The grouping is not relevant for vibration and shock tests. All requirements requirements related to power supply (with possible exception for Subclause 5.1.1.4 5.1.1.4 and Subclause 5.1.3) shall be applied to all I/O ports referenced to the power supply line. 5.1.1.2
DC power supply range
Electronic equipment shall operate satisfactorily for all the values of the DC power supply voltage within the range defined in Table 4 measured at the terminals of the equipment, see also Figure 2. In case of variation of the power supply voltage from zero to the maximum (e.g. intervention of circuit breaker) the equipment shall neither fail, nor be the cause of failure of other equipment. The equipment shall restart in normal operating mode when the power supply voltage is within the continuous voltage range. Table 4 — Continuous Voltage range Nominal voltage U n
Limits
Minimum continuous voltage:
0,7 U n
Maximum continuous voltage:
1,25
U n
Figure 2 — DC Power supply voltage range It is permitted to group different DC power supply voltages. 5.1.1.3
Temporary DC power supply fluctuation
Electronic equipment shall operate for the values of the DC power supply voltage within the fluctuation range defined in Table 5 measured at the terminals of the equipment, see also Figure 3. Table 5 — Fluctuation Voltage ranges Nominal voltage U n
Limits
Minimum fluctuation voltage
0,6 U n
Maximum fluctuation voltage
1,4 U n
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Figure 3 — Temporary DC power supply voltage fluctuation requirements requirements Voltage fluctuation can be either positive (overvoltage) or negative (dips). Temporary supply overvoltages lying between U n and 1,4 deviation of function (performance criterion A). Temporary supply overvoltages lying between 1,25 performance criterion B.
U n and
U n and
Temporary supply dips lying between U n down to 0,6 deviation of function (performance criterion A).
1,4
U n and
not exceeding 0,1 s shall not cause
U n and
not exceeding 1 s shall fulfil
not exceeding 0,1 s shall not cause
Temporary supply overvoltages shall be assumed to be generated with respect to the control system voltage supply return potential and to be present only as an increase to the level of the control system voltage, which shall be assumed to be present before and after the application of the overvoltage. Overvoltage of opposite polarity to the control c ontrol system voltage supply need not be considered. Overvoltage exceeding in duration or amplitude the specified voltage fluctuation shall be assumed to occur only in the case of a failure in the control system voltage supply. Voltage dips are mainly caused by faults in the DC distribution system, or by sudden large changes of load. In the case of combustion engines, see also 5.1.1.5. 5.1.1.4
Interruptions of voltage supply
Due to a short circuit on a DC supply distribution line and subsequent operation of fuse/circuit breakers, input voltage may reduce to 0 V for a short period. The classes of interruptions on supply voltage, are listed in Table 6: During a short interruption, the DC distribution system presents a “low impedance” (short circuit) condition due to the clearing of an overload or fault condition on the supply bus. This condition can cause reverse current (negative peak inrush current) from the load. Regarding interruptions interruptions on supply voltage, there are three classes of interruptio interruption: n:
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Table 6 — Interruption voltage supply classes Class
Requirements In case of voltage interruption, no performance criterion is requested but the equipment shall continue to operate as specified after the voltage interruption.
S1
In case of voltage volt age interruptio interruption n up to 10 ms the equipment shall behave according to performance criterion A.
S2
In case of voltage volt age interruptio interruption n up to 20 ms the equipment shall behave according to performance criterion A.
S3
For a voltage interruption longer than specified in Table 6, the behaviour of the equipment shall be agreed between the involved parties. This classification is valid for nominal voltage. The choice of class should be defined by the system integrator; unless otherwise specified, the requirements requireme nts of class S2 apply. Unless otherwise specified, the requirements for interruption of voltage supply apply to the power supply input ports only; the behaviour of the I/O ports, not functionally associated to the power supply of the equipment, but referenced to the same supply distribution line, shall be handled as described in the specification of the equipment. 5.1.1.5
Variations of voltage supply for rolling stock powered by combustion engine
At start-up of combustion engines the voltage supply system shall be designed to guarantee the supply to the essential electronic equipment during the whole starting sequence. 5.1.1.6
DC ripple factor
The DC ripple voltage, and frequency, on a DC supply s upply is dependent on the type of power generator or converter that produces the controlled DC supply. The DC ripple normally consists of a small AC waveform superimposed on the DC supply once the generator or converter output has been rectified and filtered. In practise there are three common ways to produce a stable DC supply as follows: f ollows: •
rectified single phase AC (50 Hz or 60 Hz) that p produces roduces a DC ripple at at frequencies of 100 Hz and 120 Hz;
•
rectified 3 phase AC (50 Hz or 60 Hz) that p produces roduces a DC ripple at frequencies frequencies of 300 300 Hz and 360 Hz;
•
rectified inverter produced single phase AC (1 kHz and higher) that produces produces a DC ripple of twice the inverter switching frequency, i.e. 2 kHz and higher.
A peak to peak ripple voltage that gives a DC ripple factor no greater than 5 % is shown in Table 7. The formula to calculate the DC ripple factor is given below where U max max is the maximum voltage peak at the nominal voltage (U n) and U m m inimum voltage peak at U n. min in is the minimum U
DC Ripple Factor (%) =
m ax
U
–
min
2U
n
U
×100 approximately
2U
m ax
– U
max
+
min
U
U
m in
×100
n
The equipment shall be able to work properly when its DC power supply has a periodic function ripple with a peak to peak value stated in Table 7. The supplier shall specify in the documentation the limits of the ripple with which the equipment will operate normally.
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Table 7 — Maximum Peak to Peak Voltages with a DC Ripple Factor of 5 %
5.1.2
Nominal Voltage (U n)
Maximum Peak to Peak ripple allowed (V)
Umax (V)
Umin (V)
DC Ripple factor (%)
24
2,4
25,2
22,8
5%
36
3,6
37,8
34,2
5%
48
4,8
50,4
45,6
5%
72
7,2
75,6
68,4
5%
96
9,6
100,8
91,2 91,2
5%
110
11
115,5
104,5
5%
Supply by a specified source other than the main power source
In the case of equipment supplied by a specified source, not directly connected to the vehicles power supply (e.g. stabilized DC-DC-converter, PoE) the specification of this local source (e.g. voltages, currents, tolerances) shall be met. Characteristics (e.g. range, fluctuation, ripple factor) of the output voltage of the stabilized supply and input voltage of the equipment shall fit together. The specification shall be agreed between the involved parties. 5.1.3
Supply change-over
When the equipment supply is switched between different sources (e.g. redundancy switching), the equipment shall operate satisfactorily s atisfactorily under the conditions stated in Subclauses 5.1.1.1, 5.1.1.2, 5.1.1.3, 5.1.1.6. Table 8 — Supply change-over classe classes s Class
Requirements
C1
at 0,6 U n duration 100 ms (without interruption interruptions). s). Performance criterion A
C2
during a supply break of 30 ms starting at
U n.
Performance criterion B
The supply break is an open circuit and not a short circuit. c ircuit. Unless otherwise specified, the requirements of class C1 apply. Unless otherwise specified, the requirements for interruption of voltage supply apply to the power supply input ports only; the behaviour of the I/O ports, not functionally associated to the power supply of the equipment, but referenced to the same supply distribution line, shall be handled as described in the specification of the equipment. 5.1.4
Supply with overhead line or third rail
In the case of electronic equipment with a supply derived directly from the overhead line or third rail (e.g. control electronics of a self-starting static converter), the equipment shall operate satisfactorily (Performance Criterion Criterion A) for f or values of contact line voltage as described in EN 50163 50163..
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5.2
Installation requirements
5.2.1
Power supply
The power supply to the electronic equipment should be provided by a separate conductor connected as directly as possible to the source or the main battery line. The separated conductor should be used only for the supply to electronic circuits. Calculations for inrush the battery and protection take intoIntegration account the power consumption and currentcabling specified by current the datasheet or by shall the Equipment Manual. If one pole of the battery of the vehicle is connected to the vehicle body, this s shall hall be specified. 5.2.2
Thermal compatibility
The integration of the electronic equipment into its operational environment shall respect the thermal integration constraints specified by the datasheet or by the Equipment Integration Manual and the integration environment shall be designed in order to ensure an operational temperature compliant with the operational temperature class of the integrated i ntegrated electronic equip equipment. ment. 5.2.3
Electromagnetic Electromagnetic compatibility
The installation of the electronic equipment shall be arranged to reduce, as far as possible, the effects of electrical disturbances to the electronic equipment and as far as possible the effect of emissions by the equipment to the electrical/electronic system of the rolling stock according to EN 50121-3-2. 50121-3-2. The assembly of the equipment into the complete vehicle will give adequate immunity, provided that an EMC plan has been prepare prepared d and implemented, taking into account the limits in EN 50121-3-2. 50121-3-2. 5.2.4
Cabling
The cabling to connect the equipment on the vehicle should be done according to EN 50343. 50343. 5.2.5
Installation instruction
The equipment integration/installation instruction shall contain the specific installation requirements, (e.g. thermal requirements, handling, cable length). 5.2.6
Insulation
The insulation coordination requirements are defined in EN 50124-1. 50124-1. For voltage withstand test, the minimum value of the test voltage shall be selected from Table 14.
6
Reliability, maintainability and expected useful life
6.1
Equipment reliability
6.1.1
Predicted reliability
Failure rate data of components are published in several well-known reliability handbooks. Usually the data published are obtained from equipment in specific applications e.g. telephone exchanges. In some cases the source of the data are unspecified and is not principally obtained from field data. Due to this reason failure rate predictions often differ significantly from field observations and can often lead to false consequen c onsequences. ces. Failure rate predictions are based on the following assumptions (the list could be not fully comprehensive): •
The prediction model uses a simple simple reliability reliability series system of all components, in other other words, words, a failure of any component is assumed to lead to a system failure.
•
Component failure rates needed for the prediction predicti on are assumed to be constant for the time period considered.. This is known to be realistic for electronic components after burn-in. considered
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•
Componen Componentt failures are independe independent. nt.
•
No distinction is made between complete failures and drift failures.
•
Componen Components ts are faultless and are used within their specifications.
•
Design and manufacturing processes of the item under consideration are faultless.
•
Process weaknesses have been eliminated, or if not, screened by burn-in.
Limitations of failure rate predictions are: a)
Provide only in information formation whether reliability goals can be reached.
b)
Results are dependent on the trustworthiness of failure failure rrate ate data.
c)
The assu assumption mption of constant co component mponent failure ra rates tes may not always be true. In such cases cases this method can lead to pessimistic results.
d)
Failure rate data may not not exist for new new component component types.
e)
In general redundancies redundancies cannot be modelled.
f)
Other stresses can predomina predominate te and influence the reliability.
g)
Improper design and process w weaknesses eaknesses can cause ma major jor deviations. deviations.
h)
Different re reliability liability cal calculation culation metho methods ds appl applied ied to the same circuit, although although based based on well-known reliability handbooks, (e.g. IEC/TR 62380 62380)) can lead to completely different results.
However reliability prediction methods can be useful at design stage to compare different designs in order to choose the design that probably will have the lowest failure rate. The user can require from the supplier a reliability prediction calculation. The user may require the manufacturer to predict his reliability figure or meet the user's reliability target. The method of calculation shall be agreed at the time of tendering between the manufacturer and the user, and shall be in accordance with a recognized standard. Failure rates used in the calculation can be either the failure rate from a supplier database or the failure rate from a well-known reliability handbo handbook. ok. The supplier shall provide to the user a reference mission profile and the information needed to understand and to verify calculations. The following list is an example of a reference mission profile: i)
environmen environment: t: ground mobile;
j)
average op operating erating temperature: temperature: 45 °C; NOTE For reliability calculation, the yearly average temperature is conventionally taken as 45 °C for all classes (EN 50125–1).
k)
average operating hours per day: 18 h;
l)
ON/OFF cycles per day: 16;
m) average operating days per year: 350 d;
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n)
stress de derating rating design rules ap applied plied to the compo component nent types (se (see e Annex F).
Reliability prediction results are never directly comparable with actual failure rates and cannot be used to predict field failure rates. 6.1.2
Proof of reliability
The user may require the supplier to reach a target level for field reliability. Demonstrations which are required to establish whether one or more reliability characteristic of the equipment is better, or not, than a specified level, with some stated degree of confidence are conducted on a sample of the series of a given system or type of equipment. The pass/fail criteria for statistical tests are generally known as plans. Two styles of plans can be applied: •
fixed time/failure test;
•
sequential test.
Figure 4 — Styles of Test Plans The Reliability Demonstration Plan shall be agreed between supplier and user. The Reliability Demonstration Plan shall specify the following: a)
the reference mission profile;
b)
the target reliability and availability;
c)
monitoring and recording criteria;
d)
acceptance-r acceptance-rejection ejection criteria;
e)
the maximum duration time;
f)
the cumulative test duration;
g)
numerosity of the specimen;
h)
specimen insertion/cancellation insertion/cancellation criteria;
i)
failure analysis criteria.
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The IEC 60605 series, Equipment reliability testing , can be used as a guide: •
IEC 60605-2 60605-2,, Part 2: Design of test cycles; cycles;
•
IEC 60605-4 60605-4,, Part 4: Statistical procedures for exponential distribution — Point estimates, confidence intervals, prediction intervals and tolerance intervals; intervals ;
•
IEC 60605-6 60605-6,, Part 6: Tests for the validity and estimation of the constant failure rate and constant failure intensity .
To perform accelerated ageing test, EN 62506 62506 can can be used as a guide. Example of implemented plans can be found in: •
MIL-HDBK-781A MIL-HDBK-781A.. dated dated 1 April April – 1996 - US Department of Defence: Defence: Handbook Handbook for Reliability Test Methods, Plans, and Environments for Engineering Development Qualification and Production.
Other relevant standards: •
EN 61014 61014;;
•
IEC 61070 61070;;
•
IEC 61123 61123;;
•
EN 61124 61124;;
•
IEC/TR 62380 62380..
Of greater importance is the assessment of RAMS data from the field (RAMS testing during operation),, e.g.: operation) •
EN 60300-3-2 60300-3-2;;
•
IEC 60300-3-5 60300-3-5;;
•
IEC 60319 60319..
The detailed reliability evaluation procedure procedure shall be stated in the reliability evaluation plan.
6.2
Useful life
The useful life of the electronic equipment shall be specified according to one of the following classes: Table 9 — Useful life classes
32
Life Class
Useful Life (years)
L1
5
L2
10
L3
15
L4
20
LX
As agreed by the involved parties
BS EN 50155:2017
EN 50155:2017 (E)
Unless otherwise specified, the life class L4 applies. When the supplier intends to use items with a known life shorter than the useful life of the electronic equipment, this shall be declared by the supplier at the time of tendering and specified by the documentation of the equipment.
6.3
Maintainability
6.3.1
General
Unless otherwise agreed the equipment should be designed such that regular periodic maintenance is not necessary. The presence of any non-repairable items in the equipment shall be declared in the equipment documentation. The supplier shall provide the maintenance requirements requirements and the information on the life-cycle costs to the user at the tender stage. Printed board assemblies, and/or subracks and/or line replaceable units shall be capable of being individually tested. NOTE Maintenance processes such as ultrasonic cleaning, connecting of diagnostic test equipment, electrical insulation testing, and transportation packaging arrangements, can reduce the equipment reliability level, through additional stressing of the assembly and components.
6.3.2
Preventive Maintenance
Equipment should be designed such that regular periodic maintenance should not be necessary. If this is not possible, then maintenance requirements shall be specified in the datasheet of the equipment 6.3.3 6.3.3.1
Corrective Maintenance Maintenance On-vehicle diagnosis and repair
The user and the supplier shall agree on the line replaceable units (LRU). These units shall be designed to be easily exchanged. Equipment shall be designed such that a failed line replaceable unit can be identified by the use of either suitable portable test equipment or built-in diagnostics, both with associated test instructions. The supplier shall declare in the documentation of the equipment the necessary information to be exchanged to allow the identification of the LRU as a result of on-vehicle fault diagnosis. The supplier shall also declare in the documentation if any specialized tools are required in this maintenance procedure. Maintenance or diagnostic procedures at this level shall not require the removal or replacement of any component of the Line Replaceable Unit. 6.3.3.2
Off-vehicle diagnosis and repair
Equipment shall be designed such that test equipment with associated test instructions shall enable the full diagnosis and validation of performance of train-borne equipment in repair centres by qualified personnel. Repairable Equipment shall be constructed such that access necessary for diagnosis and repair can be achieved without damage or undue disturbance to the components or wiring. Repairable printed board assemblies shall have test facilities (e.g. test plugs, test pads, etc.) to aid the diagnosis and repair process.
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6.4
Built-in diagnostics
Communication interface or indicators to assist diagnostic maintenance should be used where appropriate, in order to provide status of input data, output data, main control functions, power supplies, etc. Self-test routines shall be capable of providing a clear indication of the operational status of the equipment. Any built-in diagnostic facilities capable of exercising rather than monitoring the equipment shall be suitably interlocked to prevent interruption of the normal operation of the equipment other than under test conditions. The use of extra components for built-in diagnostic facility shall be taken into account in the calculation of the reliability prediction of the equipment.
6.5
Automatic test equipment
The user may require the use of a specific type of automatic test equipment for fault location either on or off vehicle. It is permitted to remove plug-in units which do not contribute to the function of the equipment to facilitate the connection of Automatic Test T est Equipment. If it is required, details of such test equipment and its interfacing with train-borne equipment or equipment connector shall be provided by the user at the time of tendering.
6.6
Purpose built test equipment and special tools
The prior approval of the user shall be obtained regarding the use of items requiring tools other than readily available industrial tools. Where purpose built test equipment and/or special tools are required to carry out the user's formal maintenance procedures, this equipment, or alternatively the manufacturing and procurement details for it, shall be offered for sale by b y the manufacturer to the user. Test equipment does not necessarily have to comply with this standard.
7
Design
7.1 7.1.1
General Equipment
As electronic equipment can vary in dimension and complexity to perform a specific task, the supplier shall ensure during the integration stages the requirements are fulfilled. 7.1.2
Quality managemen managementt
The design shall follow a quality management system. NOTE
The quality management system could follow EN ISO 9001 9001..
The design process shall be visible and auditable. If the user requires details of this process for tender evaluation, it shall be defined in the tender documents. Particular attention is drawn to the implicit need for the use of quality management system for all system, hardware, and software design to proceed according to clearly laid down functional and interface specifications. 7.1.3
System Life-cycle
The design process shall follow a tailored life cycle model of EN 50126-1, which shall be laid down in the quality plan, e.g. in Annex E.
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7.2
Detailed practices - Hardware
7.2.1
Insulation coordination
The user shall define the EN 50124-1 50124-1 requirements requirements at tender time. Unless otherwise specified the pollution degree PD2 of the EN 50124-1 applies. 50124-1 applies. Unless otherwise specified by the user, only the tests in this standard are applied. 7.2.2
Interfacing
All interfaces shall be so implemente im plemented d as to allow the equipment to meet its requirements requirements in respect of: a)
personnel safety;
b)
potential differences;
c)
electromagn electromagnetic etic compatibility.
and to control propagation of damage arising from external faults/failures. The user may require galvanic isolation to meet m eet the above. In this case the requirement and particular areas for its application shall be declared at the tender stage. An example of system system interfacing with various various EMC areas is given in in Figure 5.
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BS EN 50155:2017
s t u p n i y r a n i B
s t u p t u o y r a n i B
s t u p t u o y r a n i B s u b e l c i h e V
s t u p n i y r a n i B
s t u p t u O g o l a n A
C a e r A
e d c e n t e ) c r e f e k t c o r a r e r p t b n i a u e M S r . a g l E . a t e s ( n i n g a i S g a
s t u p n I i / g U o l a n A
) E ( 7 1 0 2 : 5 5 1 0 5 N E
r o t i c t u n d U s e n e l s o v u c i i r p m D e S
r o t i c t u n s d U u n e t a o v t c i i r s m D e S
e i n c d c i s ) e n l n t s r a c e o e r l e e n t t g b r i c o f e e r t s a B l p e n , c e l e d i i y M a l r e a l c t A r e r b n a E t u e h p r p a s c e i n . r e i . c s e r a g . P a g e a (
y r e t t a B
t t a B U
n o i s s e r p p u n s o e i t c a n l o e s r i e r c f i e n t n a i v l a M g E h h t i i t w w r r e e m m r r o o f f s s n n a a r r t t l l a a n n g g i i S S
A a e r A
d r e o e s p n S e s
/ r o ) e M t s l r t E c n i r e e v h j n m e o v a o t r a e m c . p h f g t o . m e e ( d s e e o i c s c r r c o n u i n t e c s o r a s f e a e h r t n r t e o A i w t n c i
C d n a B , A s a e r a C M E l a c i p y t e h t h t i w g n i c a f r e t n i m e t s y S — 5 e r u g i F
6 3
BS EN 50155:2017
EN 50155:2017 (E)
7.2.3
Fault protection
Outgoing cables shall be rated to at least the current limit value of the protective device for that circuit. Equipment shall be protected against external faults/failures (e.g. short circuit or open circuit conditions) as appropriate. appropriate. Regulated power supply units for electronic equipment shall incorporate current limiting to minimize the use of fuse elements. If the equipment uses electromechanical relays and the contacts are provided as potential free and not short-circuit protected; an external device to limit the current or an overcurrent protection should be installed by the system integrator. Where protective devices of the tripping type are incorporated in the output circuits, the available current under short circuit/overload conditions shall be sufficient to operate them. In addition, devices with manual resetting shall be easily accessible. Any protective devices used shall be so arranged that the risk of fire within the equipment is minimized. 7.2.4
Referencing power supplies
The output of galvanically isolated power supply units should not be allowed to float for EMC reasons. When the outputs are not connected to the battery supply, then one of the supply rails should be connected to the vehicle frame or a defined earth point. The voltage bands of EN 50153 shall 50153 shall be taken into account. This reference and the means of connection should be defined by the s system ystem integrator. 7.2.5
Interchangeability
Unless otherwise agreed, all individual printed board assemblies or LRU forming part of a system shall be functionally complete and fully interchangeable with any other unit of the same functional type without the need for any recalibration of the hardware after the board or LRU has been inserted in the system. 7.2.6
Reduction of supply voltage and ON/OFF phases
The equipment shall not suffer damage, when the supply is, or falls, below the lowest limit of its specified source voltage, irrespective of the rate at which the voltage changes. In addition, the equipment shall not generate any spurious output which could lead to consequential failure of any other equipment under these conditions including during power on/off phases. 7.2.7
Polarity reversal
To prevent any damage to the equipment, electrical or mechanical means shall be provided to ensure protection against polarity reversal of the incoming power supply. 7.2.8
Inrush currents
The design of the equipment shall take account of inrush currents which may occur at the time of switch-on, so that protective devices do not trip and no damage occurs. The inrush current of the equipment shall be within the limits of the main circuit breaker according to the nominal current. 7.2.9
Energetic transient pulses
Experience shows that battery supply energetic transient pulses can occur that might cause ageing of the components. A guideline how to cope is given in Annex F, F.2.2.
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7.2.10 Capacitance to ground/earth To avoid failure or to avoid tripping of earth fault detection systems the total value of the capacitance to earth shall be limited. A guideline how to cope is given in Annex F, F.2.3. 7.2.11 Spare capacity If the user requires spare capacity (e.g. spare inputs, spare outputs, CPU loading, etc.) for system expansion or changes during the equipment life-cycle, they shall specify this at the tender stage. Compliance with these requirements shall be included in the design process. Customer may request spare capacity for system expansion only when this capability has a high probability to be used during the life of rolling stock (e.g. TCMS) and not when such expansion is improbable improbabl e (e.g. Battery charger computational power). 7.2.12 Programmable Component The design development process of a programmable component shall follow a tailored life cycle model of EN 50126-1, which shall be laid down in the quality plan, e.g. in Annex E.
7.3 7.3.1
Detailed practices - Software General
The design process shall be visible and auditable according to EN 50657. If the user requires details of this process for tender evaluation, he shall define this in the tender documents. 7.3.2 Life-cycle Software design shall proceed according to a tailored life cycle model according to EN 50657 under consideration of ISO/IEC 90003. 90003. The tailored life cycle model shall be laid down iin n the quality plan.
7.4 7.4.1
Features of software controlled equipment General
Software controlled equipment, unless very simple, shall be constructed with the following features, intended to provide operation under all conditions. 7.4.2
Self-test
The equipment should include a self-test function which verifies that the system is operational operational at each initialization (e.g. memory checking, I/Odiagnostic test, configuration test, communication interfaces). As farthe as possible in the event of self-test failing, information shall be made available to indicate area of the fault. Where possible the system shall enter the recovery state. 7.4.3
Watchdog
The equipment/system shall include a watchdog function, to cause it to enter a recovery state in the case of failure of the operational software (e.g. software entering an unintended loop due to abnormal transient disturbances). 7.4.4
Failure indication
As far as possible, on detection detection of failure the processor shall record record or indicate that that such an event has occurred. It shall then enter a recovery state. 7.4.5
Recovery
The equipment as far as possible, from anyrecovery fault or may errorrequire state, into it may be forced, with the shall, minimum disruption to itsrecover functions. This the which processor to reinitialize. Where it is not safe or practicable to recover from this state, the supplier shall declare the effect on the equipment.
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EN 50155:2017 (E)
8
Non-railway designed electronic equipment
In some special cases (e.g. passenger entertainment, new technologie technologies), s), it might be necessary to use equipment that is not fully compliant with the requirements of this standard. In such case, an agreement is necessary between the involved parties and Annex G provides a guideline to handle the process of proof of applicability.
9
Components
9.1
General
The component documentation is delivered only under specific request of the user and is subject to a contract agreement between supplier and user regarding the confidentiality and the rights of use of those documents.
9.2
Procurement
All components shall comply with detailed specifications which define the component or functional and physical parameters. All components components used shall have been been manufactured manufactured according to a q quality uality system. NOTE
The quality system might be compliant with the requirements of EN ISO 9001 9001 or or an equivalent quality
system.
The component specifications referenced above shall be in accordance with one of the standards or documents listed below: •
EN or IEC specifications;
•
other national or international standards or specifications;
•
specification of the component manufacturer;
•
specification of the equipment supplier;
•
the components referenced above shall be in accordance with this standard.
Components with a multiple source of supply should be used. For the purpose of this standard, “multiple sourcing” shall imply complete interchangeability in respect of fit and function according to the specification. Components to be used should be chosen on the basis of a high probability that further supplies will be available for a time equivalent to the life of equipment. If, despite this precaution, certain components componen ts should become unavailable during the period covered by the equipment supply contract, the supplier of the electronic equipment shall provide an alternative solution. Specialized components such as custom hybrid circuits and application specific integrated circuits (ASIC), programmable components components (FPGA, CPLD, etc.) refer to 12.7.7.3.
9.3
Application
All selected components shall be of such a grade as to be appropriate for use in the application, and subject to the requirements (e.g. environment, quality, life expectancy, etc.) described in this standard. All components components shall be used: a)
In accordance with the component manufacturer’s basic specifications;
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b)
In such a mann manner er as not to compromise compromise the equipment equipment life or performance; for this reason, tolerances and ageing of components shall be taken in due consideration during the design process and the decision shall be properly documented (varistors, transient voltage suppressor diodes, fuses, electrolytic capacitors, relays, mechanical components, optocouplers, connectors, etc.) and components shall not be used outside the recommended operating conditions stated by their manufacture m anufacturer; r;
c)
In such a w way ay that a percentage of of logic ga gates tes inside of programmabl programmable e components components shall be available for any future use.
The choice of temperature range, derating, packaging and screening, etc. of components is the complete responsibility of the supplier. If required by the user, the supplier shall demonstrate (e.g. by calculations or other applications), at the time of tendering, that the equipment fulfils all the requirements given in this standard with particular reference to reliability and the life of components as described in Clause 6. The life expectancy of components shall not be less than the useful life of the equipment except for components with a known life as defined in 6.2.
10 Construction 10.1 Equipment construction 10.1.1 General Equipment shall comply with the constructional requirements requirements specified by the following subclauses. 10.1.2 Mechanical protection It shall be possible to lay on a flat surface all LRUs on any of their faces without causing mechanical damage to any component. Where necessary, mechanical guards shall be fitted. 10.1.3 Polarization or coding Where required by the user, all LRUs shall incorporate mechanical means of polarization or coding to prevent incorrect insertion. 10.1.4 Dimensional requirements The mechanical dimensions shall be stated in the documentation. The dimensional requirements for racks, subracks, and plug-in units should comply with the dimensional requirements requirements of EN 60297-3-100; 60297-3-100; in such cases board sizes of 3U or 6U, and 160 mm or 220 mm length are preferred. 10.1.5 Sockets and edge connectors There are two classes: —
Class K1: integrated circuit sockets and/or edge connectors connectors a are re allowed allowed
—
Class K2: integrated circuit sockets and edge connectors ar are e not not allowed
Unless otherwise specified, the class K2 applies. 10.1.6 Cabling inside cubicles The cabling inside cubicles should be done according EN 50343 50343 as as far as possible. Useful hints are also available in Annex F.
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10.2 Component mounting 10.2.1 General Electronic assembly (PBA) acceptability shall comply with IPC-A-610 class 2 minimum and shall comply with constructional requirements from 10.2.2 to 10.2.6. 10.2.2 Layout Components and parts of repairable equipment shall be located, secured and placed with respect to each other and the structural items in order to be inspected, removed and replaced without damage to other parts or wiring. Wherever possible, the marking on the fitted component shall be visible. Equipment shall not be designed to have components attached to wiring terminal blocks unless adequate clamping or an auxiliary printed board assembly is provided and component identification is preserved. Heat dissipating components shall be mounted so that they will not cause damage to printed boards or any other components. 10.2.3 Fixing Components which do not have specific mechanical fixings, whose weight can through vibration during the life of the equipment cause stress or damage to the soldered connections, shall be secured to the printed board. The method of securing shall be such that they can be replaced without damage to the printed board board.. All components shall be mounted in accordance with the component manufacturer's recommendations or, in the absence of such recommendations, in such a way that the method of fixing has no adverse effect eff ect on the performance of the component, including the soldered joints. 10.2.4 Component lead terminations Lead terminations to components shall be made such that no mechanical or thermal stress exceeds the limits specified for the component. Bending of component leads shall not cause damage or permanent stress to the component body/lead junction. 10.2.5 Pre-set control Where pre-set controls have been deemed necessary for operating adjustments (i.e. not internal calibration), they shall be accessible with the complete equipment and adjacent equipment in operation. Such controls shall retain their settings in normal operation and shall be protected against accidental adjustment. 10.2.6 Select on test components Where selected on test components are used they shall be soldered to component mounting posts to facilitate removal.
10.3 Electrical connections 10.3.1 General Connections shall be of the following types. 10.3.2 Soldered connections Soldered connections shall be made only to components specially designed for that purpose. Flexible/stranded Flexible/strand ed conductors and metallic m etallic braiding designed for flexing shall not be soldered but fitted with crimped tags or ferrules f errules and strain relieved before the electrical connections.
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EN 50155:2017 (E)
Silver or gold plated wires or components should not be soldered, unless the plating is thin enough to avoid any adverse effect on the joints. Soldered wires and components shall, as far as possible, be capable of disconnection without damaging to the other connections. Solder fluxes shall be non-corrosive. 10.3.3 Crimped connections connections Crimped connections shall be in accordance with EN 60352-2 60352-2.. 10.3.4 Wire wrap connections All wire wrap connections shall, as a minimum, comply with EN 60352-1 60352-1 modified wrapped connection. Soldered and wrapped wire connections on the same post are not allowed. The wire used shall be suitable for the chosen wrapping process, and at least three turns of the wire shall be in close contact to the post. 10.3.5 Other connections connections Other methods of connection e.g. insulation displacement, press-fit, etc. can be used. If required by the user, the supplier shall justify which ones are appropriate for use in the application, and subject to the requirements (e.g. environment, quality, life expectancy, etc.) described in this t his standard.
10.4 Internal flexible wiring (electrical and optical) optical) Wiring which could be subjected to flexing shall s hall be provided with suitable clamps, sheaths or supports s upports adjacent to the terminations and at suitable locations along its route. Wiring shall be so arranged that its performance shall not be affected aff ected by extremes of temperature. temperature. Wiring shall not be bent to a radius less than the minimum permissible value specified by its manufacturer. Where a minimum radius is not specified, for electrical cable, the inside radius of the bend shall not be less than the overall diameter of the wire including its insulation. Grommets, bushes or edge protections shall be fitted f itted where wiring passes through any material likely l ikely to cause abrasion damage. Internal wiring shall be adequately supported by clamping, looming, troughing, or similar means. Wiring shall be clamped into plugs and sockets in such a way that the connections inside the connector cannot be subjected to detrimental tensile or torsional stress by normal operation and handling. Where practical, sufficient wire shall be provided to enable a re-connection to be made at each end of the wire. All wiring shall be readily traceable to a point-to-poin point-to-pointt wiring diagra diagram m or list.
10.5 Flexible printed printed wiring The base material shall have suitable temperature ranges and mechanical properties to suit the application. Wherever possible, sharp bends shall be avoided. The T he minimum bending radius shall not be so small that it results in cracking or deterioration of the base material or the overlay. Adequate support support to any transition termination shall be p provided rovided to ensure that separ separation ation of the base material or underlay does not occur. Any termination using this technique shall be capable of re-connection without damage to the wiring system.
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10.6 Printed boards - flexible and rigid 10.6.1 Printed board All the holes used for soldered con connections nections shall be plated plated through, with p pads ads on both sides. sides. 10.6.2 PCB acceptability PCB acceptability shall comply with IPC-A-600 class 2 as a minimum. Alternative standards of equivalent scope may be used with prior approval of the user. For specific customized electronic products, alternative standards of equivalent scope may be used with prior approval of the user. 10.6.3 Layout Board layout shall be carried out according to EN 62326 (all parts), IPC-2220:2010 series, IPC-2221 (B):2012, IPC-2222 (A):2010 or IPC-2223 (C):2011 as appropriate with due regard to the service conditions of this standard. 10.6.4 Materials The base material shall be an epoxy woven glass fabric laminated sheet of defined flammability (vertical burning test) for rigid printed boards and for use in the fabrication of multilayer printed boards, according to EN 61249-2-7 61249-2-7,, EN 61249-2-22, 61249-2-22, EN 62326 (all parts) or IPC-4101 Specification for Base Materials for Rigid and Multilayer Printed Boards, as appropriate. For flexible printed boards the base material shall be a flexible copper-clad polyimide film of defined flammability (vertical burning test), according to IPC-6013. Other materials may be used providing they meet or exceed the performance of the base material specified above.
10.7 Protective coatings for printed board assemblies The following classes are defined for the protective coatings and they define the requirements that the equipment shall fulfil: Table 10 — Protective coating classes Class PC1
Protective coatings requirement No protective coatings. In this case Temperature variation class requirement for the electronic equipment shall be H1, see 4.3.4. (e.g.TFT display, camera, hard disk, RF modules)
PC2
All printed board assemblies shall be protected on both sides with a protective transparent fluorescent pigment coating, in order to prevent deterioration or damage due to such causes as moisture and atmospheric contaminants. The coating shall not have any adverse reaction with any other materials or components used. The protective coating shall not be applied to integrated circuit sockets, test points or to connector contact mating surfaces, etc.
PCX
As agreed between user and supplier
Unless otherwise specified, class PC2 applies. When the board is considered c onsidered not repairable, repairable, the coating c oating could be opaque.
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When the board is considered repairable, it shall be possible to repair it without the need for complete removal of the coating. After repairing, repairing, the board shall shall be locally recoated recoated.. Coating types and thickness shall be according IPC-A-610.
10.8 Identification 10.8.1 Bare PCB identification identification The artwork shall reproduce sufficient information to enable its correct identification including its revision. 10.8.2 Identification Identification of s subracks ubracks and and printe printed d board assemblies Labelling of subracks and printed board assemblies shall be adequate to enable their correct identification including serial number and revision. All labels shall be clear, bold, concise and durable. Labelling of line replaceable unit (LRU) shall also include its identification name, manufacturer's manufacturer's name or trade mark, and serial number. Means shall be provided on the subracks and printed board assemblies to record any change to fit, form or function. Where possible the identification label shall be placed on the front panel of plug-in units. For maintenance purposes it is also desirable that the modification status label be fitted to this front panel. 10.8.3 Mounting position position of subracks subracks and printed b board oard ass assemblies emblies Each mounting position should be marked to indicate the type of subrack, printed board assembly or cable connectors to be located in that position. 10.8.4 Fuse and battery identification All fuse ratings should should be indicated adjacent to the fuse. Where batteries are used, the front panel of the plug-in unit or LRU in which they are placed should be marked to indicate their presence and to show the recommended recommended date of replacement. replacement.
10.9 Mounting The equipment shall be mounted in some way to ensure its ability to operate in the specified service conditions. Such mounting may comprise: for major equipment: equipment: a cubicle, a number of rracks, acks, sub subracks racks and printed board assemblies; •
•
for smaller, localized equipment: individual sealed enclosures.
In each case, the enclosure shall provide the necessary protection (IP code according to EN 60529) 60529) from the service conditions, and permit dismantling and repair of the contained equipment. Potting (the covering of, for example, a printed board assembly with silicone rubber, resin or other material) to provide additional protection is not preferred and shall only be used where (for example in the case of a remotely mounted transducer) special environmental environmental conditions dictate it. If the supplier intends to use encapsulation, it shall advise the user at the t he earliest possible stage. NOTE The requirements of this clause do not apply to individual components such as hybrid circuits, ASICs, etc.
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10.10 Cooling and ventilation Cooling shall not be achieved by the forced induction of air into the equipment enclosure, unless precautions agreed between involved parties are taken to ensure that the life of the equipment is not thereby adversely affected by the introduction of contaminants. When an assisting cooling system is used (e.g. fan, pump), the equipment shall be protected so that no damage can occur due to the failure of the cooling system. The full performance shall be maintained until the related protective device operates. NOTE Damage in this context includes effects on the equipment life due to the operation of any component beyond its maximum specified ratings.
10.11 Materials and finishes Materials and finishes shall be suitable for the conditions of use, and shall be chosen with respect to the environmental, environmental, wear and ageing factors, as well as to the risk of toxic influences on persons. All materials shall be be dimensional dimensionally ly stable, non-hygr non-hygroscopic, oscopic, resistant to fung fungal al growth and either either nonignitable or resistant to flame propagation. propagation. The user shall provide a list of materials which are controlled by national law. In addition, the supplier shall specify the method of disposal of any component which contains toxic material.
10.12 Reworking, modification and repair of electronic electronic assemblies assemblies Reworking, modification and repair of electronic assemblies are allowed and shall be executed according to IPC-A-610 and IPC-7711B/7721 IPC-7711B/7721B. B.
11 Safety 11.1 General These provisions relate to both the main equipment and any maintenance equipment, tools or procedures.
11.2 Requirements The safety requirements for rolling stock equipment applied in design, manufacturing and installation are as follows: a)
personnel safety against against electric electric sho shock ck shall be in accordance with EN 50153; 50153;
b)
insulation coordination shall be in accordance with EN 50124-1 50124-1;;
c)
personne personnell safety against effects of of excessive temperature temperature shall be be in accordance accordance with EN ISO 13732-1. 13732-1.
11.3 Fire behaviour behaviour requirements requirements Guidelines of the EN 45545 series for protection against spread of fire shall be used. Equipment shall be designed, manufactured and installed (as relevant to the contract), in full accordance with the respective Safety legislation of the country or countries of use. Fire behaviour testing shall be according to EN 45545-2 45545-2.. In respect of printed boards (EL9 according to EN 45545-2:2013+A1:2015, Table 2) it shall be noted that only the printed boards without any attached components have to meet the requirements. The attached components will be accepted without any testing because of their functional necessity as stated in EN 45545-2:2013+A1:2015 45545-2:2013+A1:2015,, 4.7.
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11.4 Functional safety The safety related functions for the equipment or system are not covered by this standard, nevertheless this standard applies to the hardware of all rolling stock safety related equipment and systems.
11.5 Personnel safety The user shall identify any special requirements related to personnel safety, in respect of equipment, construction and use of materials, at the time of tendering tendering..
12 Documentation 12.1 General As referenced in Clause 7, the equipment equipment design shall shall be documented documented.. NOTE
This might be done according to the provisions of EN ISO 9001:2015.
12.2 Supply and storage storage of documentation As a minimum the datasheet datasheet and u user’s ser’s manual of the e equipment quipment shall shall be given to the user. user. For any additional documentation the supplier and user shall agree in writing: a)
the quantity, scop scope, e, content, presen presentation, tation, medium and and updating p process rocess of documentation documentation required by the user;
b)
the scope scope,, conditions conditions and dur duration ation applying applying to the storage of documentation documentation by the supplier. supplier.
12.3 Datasheet The datasheet is a document that describes the electronic equipment. This document shall contain all information useful for the user in order to evaluate the technical compliance of the product with the following expectations: a)
equipment identification: 1)
manufacturer's manufacturer's name or trade mark;
2)
equipment name and type;
3)
equipment version (if any);
b)
table of contents;
c)
definitions or acronyms used in the document;
d)
general description:
46
1)
pictures (If any);
2)
hardware architecture;
3)
functional purpose and principle of op operation eration of the equipment;
4)
optional parts available, available, with their d description escription and fun functionalities ctionalities (if (if any);
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e)
f)
g)
electrical features: 1)
nominal supply voltage: U n = Volts DC (see 5.1.1 or 5.1.2);
2)
nominal power consumption: [Watts] (Min., Max., powe powerr consumption consumption ifif appropriate); appropriate);
3)
inrush current characteristics: [I2t];
4)
DC power supply fluctuation range (see 5.1.1.3);
5)
interruptions interruptions on power power supply voltage Cla Class ss (No, 1 10 0 ms or 20 ms) (see 5.1.1.4); 5.1.1.4);
6)
supply change-over class (if appropri appropriate): ate): (see 5.1.3);
7)
earth potential reference;
mechanical features: 1)
overall dimensions [mm, or “U” / TE for EN 60297 60297 ((all all parts) racks];
2)
mechanical drawings;
3)
weight [g, or kg];
4)
IP code [see EN 60529 60529]; ];
environmen environmental tal features: 1)
operating temperature range:[see Table 1 - Operating Operating temperature temperature classes classes (°C)];
2)
switch-on extended operating temperature class: see Table 2 - Switch-on extended operating temperature class;
3)
natural cooling or forced ventilation constraints for the equipment;
4)
storage temperature range: [min. max. °C];
5)
relative humidity compliance: [% max];
6)
altitude class: [1000, 1200, 1400, . . metres max.];
7)
pollution degree conformance: [PD1, PD2 ...];
8)
shock and and vibration vibration “categories & classes” [as specified specified by EN 61373]; 61373];
9)
rapid temperatur temperature e variation class: [see Table 3];
10) conformal coating type; 11) information relating relating to any hazardous materials materials that are present in the equip equipment ment (if any); 12) RoHS, compliance if applicable applicable [see European Directive 2011/65/EU]; 2011/65/EU]; 13) REACH compliance [see European Regulation Regulation No 1907/2006+168 1907/2006+1688/2016]; 8/2016]; 14) fire behaviour behaviour compliance; compliance;
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h)
RAMS features: 1)
useful life class: [Years] [see Table Table 9 - Use Useful ful life classes];
2)
[repairable, [repairable, not repairable], equipment or pa parts rts of the equipment equipment (if (if any);
3)
identification of the the LRU parts of of the electronic equipment;
4)
MTTR: [Min, Hours] (if any);
5)
list of limited life components (if any);
6)
storage precautions (if any);
7)
identification of commercial commercial off-the-shelf equip equipment/componen ment/components ts inside the electronic equipment (if any);
8)
periodic maintenance instructions (if any);
9)
reliability [MTBF Hours] [Predicted or Measured from the field with all information about applied methodology, methodology, applied mission profile, Reliability handbook or standard used];
10) functional safety reference if ap applicable; plicable; 11) information relating to any implosion or explosion hazards which may exist within the equipment or which may occur in use or in handling; i)
functional description and interfaces: 1)
functional block diagram, diagram, including hardware and software;
2)
central processing unit and peripherals peripherals (if (if relevant); relevant);
3)
memory (if relevant);
4)
input-Output input-Output ports description (at equ equipment ipment iinterface nterface le level vel – connectors level);
5)
signal name, pin-out, function, function, electrical fea features, tures, with descrip description tion of circuit operation, operation, including voltage, current, impedance, DC or AC, frequency, isolated signal, overcurrent/overvoltage overcurre nt/overvoltage protections, min. max loads characteristics, etc. where appropriate; appropriate;
6)
communication ports and proto protocols cols descri descriptions ptions (i (iff any at equipment equipment interface interface level); level);
7)
RS-232; RS-485; CAN; MVB MVB;; Ethernet, Ethernet, Other, etc. (if any); any);
8)
with all protocol protocol features: features: Baud rate, Par Parity, ity, Drivers standards, standards, Master-Slave, Master-Slave, Ports Ports address, etc.;
9)
cabling recommendations; recommendations;
10) visual interfaces interfaces (if any); any); 11) display description description (if any); 12) lamps or LED (or (or other visual signals) signals) description (i (iff any);
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j)
k)
l)
equipment labelling labelling description: description: 1)
Product (LRU) Part number identification;
2)
Product (LRU) Serial number identification;
3)
Product (LRU) Revision index identification;
4)
connectors identification;
5)
other labels (fuses, battery, etc.) (if any);
routine and type test test compliance compliance summary: (see Annex Annex D): 1)
list of performed test (ro (routine utine and type) on the the equipment; equipment;
2)
summary of the test methods, methods, reference reference stan standard dard an and d criteria criteria applied; applied;
ordering or commercial references: 1)
reference of Commissioning Manual (if any);
2)
reference of User Manual (if any);
3)
reference of Application Notes (if any);
4)
reference of Equipment Integration manual (if any);
5)
reference of optional optional par partt for the electronic electronic equipment. equipment. (if any any); );
6)
reference of accessories accessories associa associated ted to the electronic electronic equipment. equipment. (if (if any);
7)
reference of special special tools for mounting, mounting, dismou dismounting nting the equipment equipment (if any);
8)
reference (commercial) of rep replaceable laceable components (Fuses, B Battery, attery, etc.) (if any);
9)
reference of replaceable replaceable boards (if any);
10) reference of PTE associated associated to the electronic equipmen equipment. t. (if any); 11) reference of ATE associated to the electronic equipment. equipment. (if any); 12) reference of programming programming tools to use for uploading uploading software (if any); 13) reference of standard standard software to upload on the ele electronic ctronic equipment (if any); m) datasheet document history with rrevision evision index. index.
12.4 User manual This document shall contain all relevant information for the user of the electronic equipment. For basic electronic products with limited human interfaces, this content may be integrated into the datasheet.
12.5 Equipment integration/installation integration/installation documenta documentation tion This document shall contain all relevant information for system integrato integratorr of the electronic equipment. If appropriate for basic electronic products with limited mechanical and electrical interfaces, this content may be integrated into the datasheet.
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The following items provide a check c heck list for Equipment Integration constraints constraints (not exhaustive): —
type of mechanica mechanicall frame need needed ed for mounting the electronic equi equipment: pment: mounting frame, frame, mounting plate, rack, subrack, case, etc. (with references and characteristics);
—
mechanical drawing (dimension, (dimension, fixing, mounting points);
—
orientation constraints for mounting the equipment;
—
natural cooling or or forced ventilation constraints for the equipment; equipment;
—
required free spa space ce inside integration volume for natural cooling;
—
need of preheating or air outlet;
—
need o off free spa space ce for access access to p parts, arts, or for mounting mounting – dismounting; dismounting;
—
mechanical protection constraints, screening;
—
earth terminals location;
—
shielding requirements for input input or or output output wir wired ed sign signals; als;
—
possible recommenda recommendation tion for wire gauges;
—
mechanical polarization or coding where applicable;
—
external filters to add for EMC compliance;
—
external overcurrent protections to add: fuse fuses, s, micro circuit circuit breakers, etc., on power supply supply circuit or output circuits. (If any, with references);
—
external overvoltage protections to add: TVS, ESD p protection, rotection, etc. (If any, with with references); references);
—
interconne interconnection ction diagrams and charts;
—
hardware and software Interface information. information.
12.6 Commissioning documentation This document shall provide all relevant information and instructions for the person in charge of the commissioning of the electronic equipment. If appropriate for basic electronic products with limited human interfaces, this content may be integrated into the datasheet document: 1)
commissioning instructions and pre-setting data;
2)
test points;
3)
on/off vehicle diagnostic procedures procedures and and test equipment equipment required.
12.7 Design documentation 12.7.1 General The design documentation describes the detailed design of the electronic equipment and all detailed information regarding the internal functionalities of this electronic equipment. The design documentation is delivered only as a specific request of the user and is subject to a contractual agreement between the involved parties.
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12.7.2 Block diagrams Block diagrams shall show the flow of information between the identifiable parts of a system and should have symbols conforming to the IEC I EC 60617 database and EN 61082-1. 61082-1. 12.7.3 Wiring diagrams Wiring diagrams and charts shall show the inter-unit wiring within equipment enclosures and, in addition, the services provided (i.e. supplies, distribution, alarms, etc.). 12.7.4 Interface specification specification Interface design specification carrying all the necessary information to permit replacement of the equipment with another functionally equivalent. 12.7.5 Internal interface specification Internal interface design specification carrying all the necessary information to permit replacement of the equipment with another functionally f unctionally equivalent. 12.7.6 Equipment drawings Equipment drawings drawings shall show s how the layout of equipment mounted in racks or subracks, the distribution of units and sub-units within an enclosure, and the essential mechanical features of all cubicles, racks, subracks, plug-in units, and printed board assemblies. 12.7.7 Documentation Documentation – Hardware 12.7.7.1
General
The following items provide a check list for hardware documentation: 12.7.7.2
Manufacturing Manufacturing data
The manufacturing data are all necessary information for the manufacturing and the assembly of the PBA or electronic equipment. The manufacturing data are delivered only under specific request of the user and are subject to a contractual agreement between supplier and user regarding the confidentiality and the rights of use of those documents. The generic requirements for PBA product manufacturing description data and the transfer methodology,, IPC-2581 (B), shall be applied. methodology 1)
bill of materials (PCB, electronic electronic parts, mechanical parts, parts, etc.) with component component specifications specifications and sourcing (i.e. manufacture m anufacturer) r) information;
2)
manufacturing documents (circuit diagrams, wiring diagrams, etc.);
3)
bit stream co codes des for programmabl programmable e compon components ents - e e.g. .g. CPLD, FPGA, FPGA, etc. With programming programming instructions, documentation, references of programming tools, etc.);
4)
drawings, mounting instructions and specifications;
5)
in situ testing
12.7.7.3
specifications, test programs (boundary (boundary scan programs, where appropriated). appropriated).
Programmable component (FPGA, PLD, ASIC, etc.)
The list of documents required for a programmable component, shall be defined according to class M0 or M1:
•
Class M0: Th The e documents documents listed in the column “Class M0” M0” of Table 11 shall be available available according to the contractual agreement between the involved parties. These documents shall be sufficiently precise to allow subsequent redesign of a ‘functionally equivalent component at interface level’.
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•
Class M1: The documents documents listed in the col column umn “Cla “Class ss M1” of Table Table 11 shall be available available according to the contractual agreement between the involved parties. These documents shall be sufficiently precise to allow a modification of the design. For this purpose, the supplier shall demonstrate that the delivered source code (with design constraints and procedure) allows the correct generation of the programming file. If the generated and original files are not totally identical, the functionality of the component using the generated file shall be validated. Table 11 — List of required documentation according according to the class Documentation Documentation
Class M0
Class M1
Architecture and and interface specification specification
X
X
Requirement specification
X
X
Development tools specification (simulation, generation…e generation…etc.) tc.)
X
X
Device programming procedure
X
X
Device programming file
X
X
Quality management plan
X
X
Programming file generation procedure
X
Detailed design specification
X
Test bench files
X
Simulation report
X
Test and validation report
X
Source code, design constraint file, project file
X
Unless otherwise specified the requirements of class M0 apply. 12.7.8 Non repairable items list The manufacturer/integrator manufacturer/integrator shall provide the list of all the declared non repairable items. 12.7.9 Repair and Maintenance Documenta Documentation tion 12.7.9.1
General
All documents submitted to the user shall bear an appropriate appropriate drawing number, date, version/release and title indicating the particular item shown and the type of drawing. All documents and components lists shall have an issue or revision index and a record of modification. The Repair and Maintenance documents are delivered only under specific request of the user and are subject to a contractual agreement between supplier and user regarding the confidentiality and the rights of use of those documents.
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12.7.9.2
Circuit diagrams
Circuit diagrams shall be generated for each printed board assembly, and plug-in unit of the complete equipment. Where practicable, all circuit diagrams shall be drawn so that the main sequence of events on the signal path is from f rom left to right (and where necessary for arrangement purposes, from top to bottom). Wherever practical, the circuit diagram for any one unit shall be completely self-contained, selfexplanatory, readily related to other circuit diagrams and shall show: —
supply voltage levels and interconnections, interconnections,
—
connections between the low voltage circuits,
—
connections b between etween these circuits, the ele electronic ctronic equipme equipment, nt, the transducers transducers and the controlled controlled or monitored devices,
—
earth connections of the metallic parts,
—
connections between the electronic zero volt lines, lines,
—
casings and their connections,
—
screened or twisted cables.
Discrete components external to a printed board assembly or plug-in unit but essential to its operation shall be shown in dotted outline on the circuit diagram and be appropriately identified. All component symbols shall be marked with their circuit references and the nominal value of components shall be marked on the circuit diagram where the component list is not included on the same diagram. Components with three or more connections shall have the connection points identified or marked. The function of all controls, switches and indicating devices shall be indicated in accordance with the inscriptions marked on the equipment. The symbols for rotary controls shall be marked with an arrow indicating clockwise rotation of the spindle s pindle when viewed from the operating end. Relays shall always be shown in the de-energize de-energized d position. 12.7.9.3
Component lists
Component lists shall uniquely identify for each component its circuit reference number and the specification or part number/manufacturer indication of that component. 12.7.9.4
Component layout
Component layout drawings shall show the location of each individual component used in a printed board assembly or plug-in unit, marked with its circuit reference number, outline and polarizing details where used. 12.7.9.5
Special maintenance tool
The list, the description and references of special tools (Hardware and/or Software) associated to the electronic equipment shall be provided. 12.7.10 Documentation – Software
According the chosen software documents, life cycle model of 7.3.2, deliverable, the supplier or shall determine andand list what what informationtoitems are deliverable intermediate non-deliverable; information items are to be archived. The list shall be laid down in the quality plan. All identified information information items (documentation) (documentation) shal shalll be according to E EN N 50657.
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At least the highly recommended (HR) documents in EN 50657:2017, 50657:2017, Table A.1 column basic integrity shall be provided for non safety safet y related on board equipment. 12.7.11 Documentation – System All identified information items (documenta (documentation) tion) shall be according to ISO/IEC/IEEE 15289:2017, 15289:2017, Clauses 7 and 10. For each identified information item, the generic contents as specified in ISO/IEC/IEEE 15289:2017, 15289:2017, Clause 7 shall be part of the required item content. At least the following identified information item according to the ISO/IEC/IEEE 15289:2017, 15289:2017, Clause 10 shall be available: 10.83
System architecture description
10.84
System element description
10.85
System requirement requirement specification
10.88
User documentation documentation
10.92
Validation report
10.95
Verification report
13 Testing 13.1 General A test plan listing all the tests to be performed on the Electronic equipment equipment and their procedure procedures s shall be written by the supplier. All items forming a specific specific equipment type shall have passed the appropriate appropriate device level conformity. conformity. The system integrator shall give the evidence to ensure all requirements are addressed providing: a)
A Type Test Re Report port or an an integration Type Test Rep Report ort according to the type Test Procedure Procedure to show that all the items forming a specific equipment when integrated together are operating according to the specified functional requirements, see 4.1.
b)
A Routine Test Report or or an integration integration Routine Test Report acco according rding to the routine Test Procedure confirming that the installed equipment is ready to be brought into use.
During the type tests and routine tests, the item shall not malfunction or produce a performance which is its i.e. specification. equipment should be tested in the the equipment manner in which they are expected to outside be used, protective The covers should be in position and arranged, as nearly as possible, in the position it will occupy in actual use. The requirements not associated with a test procedure shall be verified at the design review level. Additional requirements, requirements, acceptance criteria and the related verification/test shall be agreed between the involved parties at the tender stage. Since some of the tests subject to agreement may be costly, it is advisable to carry out only those tests which are necessary. The user may require to witness and check the results of any tests. Arrangements Arrangemen ts for this shall be contained contained in the contract. contract.
13.2 Categories of tests tests 13.2.1 General There are three categories of tests: —
type tests;
—
routine tests;
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—
investigation tests.
At the time of tendering, tendering, the user shall identify any tests subject to agreement (see Table 12 12 - List of tests). 13.2.2 Type tests Type tests shall be carried out to verify that a product will meet the specified requirements. Type tests shall be performed on a single equipment of a given design and manufacturing procedure procedure.. Equipment used for type test should be equipment already submitted to routine test procedure. procedure. If an equipment is not identical to one tested previously the supplier shall provide documents justifying that the change does not alter the validity of existing previous report; otherwise a complete re-test or a subset of type tests shall be performed. The Type Test sequence starts with visual inspection and a performance test. After all Type Tests have been performed the visual inspection and performance test shall be repeated. Some or all of the type tests may be repeated from time to time on samples drawn from current production or deliveries, according to an agreement between the user and the supplier, so as to confirm that the quality of the product still meets the specified requirements. requirements. In addition, the user may request the supplier to repeat a type test either totally or in part following: —
modification of equipment equipment likely to affect its function function or method method of operation operation;;
—
failure or variations variations established during type or routine tests;
—
resumption of production production after an interruption interruption of more tha than n five ye years; ars;
—
change of manufacturing site.
The type test reports shall be produced and managed according to the implemented quality system. Equipment used for type test shall not be delivered to the user. 13.2.3 Routine tests Routine tests shall be performed by the supplier on each manufactured equipment. Routine tests shall be carried out to verify that the properties of a product meet the specification after the manufacturing process and correspond to those measured during the type tests. A complete routine test report shall be generated for each equipment and managed according to the implemented quality system. 13.2.4 Investigation tests Investigation tests are intended to obtain additional information by means of reports regarding the performance of the electronic equipment outside its specified requirements. They shall be specially requested by the supplier or by the t he user and subjected to contract agreement. The results of investigation tests may not be used as grounds for refusing acceptance of the equipment or to invoke penalties. These tests are not described in this standard.
13.3 Tests summary Table 12 lists the type t ype and routine tests for electronic equipment; the test sequence is not mandatory. The test plan shall indicate the tests to be performed and the test sequence to be followed. The complete test is carried out according to the test specification and the test procedure written by the supplier either for type test and for routine test.
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Table 12 — List of tests Test
Type
Routine
Test Subclause
Requirement Subclause
1
Visual inspection
M
M
13.4.1
4.1
2
Performance test
M
M
13.4.2
4.1
3 4
Power supply test Insulation test
M M
O M
13.4.3 13.4.9
5.1 5.2.6
5
Low temperature storage test
O
NA
13.4.6
4.1
6
Low temperature start-up test
M
O
13.4.4
4.3.2
7
Dry heat test
M
O
13.4.5
4.3.2 and 4.3.3
8
Cyclic damp heat test (see NOTE 2)
M
O
13.4.7
4.3.2 and 4.3.7
9
Salt mist test
O
NA
13.4.10
4.4.2
10
Enclosure protection test (IP code)
O
O
13.4.12
4.1
11
EMC test
M
O
13.4.8
4.3.6
12
Vibration and shock test
M
NA
13.4.11
4.3.5
13 14
Equipment stress screening test Rapid Temperature variation test
O O
O NA
13.4.13 13.4.14
4.3.4
For the purpose of these tests ambient temperature shall be defined as 25 °C ± 10 °C. Test specification shall define performance criteria for each test. NOTE 1
Tests marked “M” are mandatory. Tests marked “O” are subject to contract agreement between the user and the supplier. Tests marked “NA” are not applicable.
NOTE 2
For class PC1 and class PCX without coating, the cyclic damp heat test is not applicable (see 10.7, Table 10).
13.4 Test specification 13.4.1 Visual inspection The Visual inspection test verifies the mechanical, dimensional and appearance conformance of the Electronic Equipment; see 4.1. The Visual inspection shall be carried out before and after tests to check whether any damage or deterioration deterioratio n has occurred resulting from the tests. 13.4.2 Performance test The performance test verifies the functional requirements of the Electronic Equipment, see 4.1. The performance test is carried out according to the Performance test specification and Performance test procedure written by the supplier either for type test or for routine test. The performance test shall be carried out at the ambient temperature. The performance test shall consist of a comprehensive series of measurements of the characteristics of the equipment to check that its performance is in accordance with the functional requirements of the particular equipment concerned, including any special requirements of its individual specification, and general requirements of this standard.
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Performance test during type test could be different from performance test during routine test. 13.4.3 Power supply test 13.4.3.1
General
The test verifies the functionality of the Electronic Equipment in all the conditions foreseen for the power supply, see 5.1. To carry out the power supply tests, EN 61000-4-29 may 61000-4-29 may be used as a guide. If the electronic equipment has a large number of similar power supply ports, which are electrically identical, then a sufficient number shall be selected to simulate actual operating conditions and to ensure that all the different types of termination are covered (e.g. 20 % of the ports or at least four ports). Electronic equipment shall be tested, for each selected combination of test level and duration, with a sequence of 10 dips/interruptions and overvoltage with intervals of 10 s minimum and 1 min maximum (between each test event). In all cases, the voltage levels and time durations of the test waveform shall be measured with the test generator disconnected from the equipment. 13.4.3.2
Supply variations
Tests shall be performed to prove correct functioning at nominal supply voltage and at the specified upper and lower limits (see 5.1.1.2). —
DC power supply range: Tests shall be performed to prove correct functioning for the voltage range (see 5.1.1.3).
—
DC power supply fluctuation: The rise/fall waveforms of the diagrams are purely indicative.
Temporary supply overvoltages shall be assumed to be generated with respect to the control system voltage supply return potential and to be present only as an increase to the level of the control system voltage, which shall be assumed to be present before and after the application of the overvoltage. Overvoltage of opposite polarity to the control of the system voltage supply need not be considered. Overvoltage exceeding in duration or amplitude the specified voltage fluctuation shall be assumed to occur only in the case of a failure in the control system voltage supply. Temporary supply overvoltages up to 1,4 function (performance criterion A). A).
U n lasting
no more than 0,1 s shall not cause deviation of
Voltage V DC 1,4 Un
Un Time < 10 ms
100 ms
< 10 ms
Figure 6 — Temporary supply overvoltages (a)
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For temporary supply overvoltages up to 1,4 performance performanc e criterion B. B.
U n lasting
no more than 1 s the equipment shall fulfil
Voltage V DC 1,4 Un
Un Time 1s
< 100 ms
< 100 ms
Figure 7 — Temporary supply overvoltages (b) 13.4.3.3
Temporary supply dips
Voltage dips are mainly caused by faults in the DC distribution system, or by sudden large changes of load (low impedance condition). Temporary supply dips down to 0,6 (performance criterion A). A).
U n not
exceeding 0,1 s shall not cause deviation of function
Voltage V DC Un
0,6 Un Time < 10 ms
100 ms
< 10 ms
Figure 8 — Temporary supply dips 13.4.3.4
Interruptions Interruptions of voltage supply
During a short interruption, the DC distribution system presents a “low impedance” (short circuit) condition due to the clearing of an overload or fault condition on the supply bus. This condition can cause reverse current (negative peak inrush current) from the load. Regarding interruptions interruptions on supply voltage, there are three classes of equipment:
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Table 13 — Interruptions of voltage supply classes Class
Requirements Requirements
Duration of the interruption time Tint Tint (See Figure 9) 9)
No performance criterion is requested but the equipment shall continue to operate as
S1
NOTE As defined in 5.1.1.4, this test is not required.
specified after the voltage interruption. S2
The equipment shall performance criterion A.
behave
according
10 ms
S3
The equipment shall performance criterion A.
behave
according
20 ms
For voltage interruption longer than specified within the class, equipment shall behave at minimum according performance criterion C. Tests shall be carried out at nominal voltage.
Voltage V DC Un
0V Time < 50 µs
10 ms or 2 20 0 ms
< 50 µs
Figure 9 — Interruption of supply voltage 13.4.3.5
Supply change-over
In the case of equipment supplied with power alternatively from an accumulator battery and a DC stabilized source, the DC distribution system presents a “high impedance” condition due to switching from one source to another. The equipment shall operate satisfactorily under the conditions stated in Subclauses 5.1.1, 5.1.1.2, 5.1.1.6 and 5.1.3. —
Class C1: at 0,6 U n during 100 ms (without interruption interruptions). s).
Performance criterion criterion A;
—
Class C2 C2:: during a supply supply break of 30 ms starting at U n
Performance criterion B. B.
The supply break is an open circuit and not a short circuit (“high impedance” impedance” condition). Unless otherwise specified, the requirements of class C1 apply to power supply only.
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Voltage V DC Un
0,6 Un Time < 10 ms
100 ms
< 10 ms
Figure 10 — Supply change-over Class C1
Voltage V DC Un
0V Time < 50 µs
30 ms
< 50 µs
Figure 11 — Supply change-over Class C2 13.4.4 Low temperature start-up test This test is carried out in accordance with EN 60068-2-1 60068-2-1 (test (test Ad), using natural ventilation. Equipment shall be tested according to its operating temperature class; low operating temperature (TTEST) shall be taken from Table 1 of this standard. Equipment is placed, without any voltage applied, in a test chamber. The equipment shall be first conditioned by leaving it, after thermal stabilization of the chamber, for a sufficient period of time in which to achieve thermal stabilization. In any case, the stabilization time period shall not be less than 2 h, see Figure 12. At the end of this period the equipment shall be switched s witched on and a performance test shall be carried out, keeping the equipment at the low temperature. After recovery, this this operational che check ck shall be repeated repeated at normal roo room m temperature. temperature. Test acceptance requirements:
During and after the test, the equipment shall work as intended and within its specified limits (performance criterion A). A).
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Temperature
+25 C °
1 C / min °
≥
1 hour
Stabilisation time
TTEST
ON
Performance test
time
OFF
Equipment switched ON
ON Continuous Operational checks
O FF
ON
Operational check
Equipment switched OFF
Figure 12 — Low temperature start-up test 13.4.5 Dry heat test 13.4.5.1
General
This test is carried out in accordance with EN 60068-2-2 (test 60068-2-2 (test Be), using natural ventilation unless a different type of cooling is normally used by or provided to the equipment. In that case, the normal configuration of the equipment shall be replicated. The temperature value for this test is dependent of the temperature class and the switch-on extended operating temperature temperature class of equipment equipment under test (see Table 1 and Table T able 2 for details). Equipment shall be tested according to its operating temperature class; high operating temperature shall be taken from Table 1 and Table 2.
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13.4.5.2
Dry heat thermal test — Cycle A
Temperature
TTEST 1 C/min °
1 C/min °
Stabilization time
+ 25 C °
6h
≥1 h
Time ON
OFF
ON
Continuous Operational checks
Performance test
OFF
ON
Performance test
Equipment switched ON Equipment switched OFF
Figure 13 — Dry heat thermal test — Cycle A The switched off equipment is placed in a chamber where the temperature is progressively raised to the maximum operating temperature (T TEST) (see Figure 13). Once the temperature of the whole equipment (internal and external) has stabilized, in any case the stabilization time shall not be less than 2 h, then the equipment is switched on and left for a time period of 6 h with continuous operational checks carried out at the maximum operating temperature (TTEST). The equipment is then allowed to cool to ambient temperature and a further performance test is carried out after the stabilization time. tim e. Test acceptance requirements:
During and after the test, the equipment shall work as intended and within its specified limits (performance criterion A). A).
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13.4.5.3
Dry heat thermal test — Cycle B
Temperature 1 C/min °
T TEST +15 C °
TTEST 1 C/min °
1 C/min °
Stabilization time
+ 25 C °
6h
10 min
≥1 h
Time ON
OFF
ON
Continuous Operational checks
Performance test
ON
OFF
Continuous Operational checks
ON
Performance test
Equipment switched ON Equipment switched OFF
Figure 14 — Dry heat thermal test — Cycle B The switched off equipment is placed in a chamber where the temperature is progressively raised to the maximum operating temperature (T TEST) (see Figure 14). Once the temperature of the whole equipment (internal and external) has stabilized, in any case the stabilization time shall not be less than 2 h, then the equipment is switched on and left for a time period of 6 6 h with continuous operational checks carried out at the maximum operating temperature (TTEST). Once this test is complete, a continuous operational check is carried out with the 10 min overtemperature value (see Figure 14 for details). The equipment is then allowed to cool to ambient temperature and a further performance test is carried out after the stabilization time. tim e. Test acceptance requirements:
During and after the test, the equipment shall work as intended and within its specified limits (performance criterion A). A).
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13.4.5.4
Dry heat thermal test - Cycle C
Temperature 1 C/min °
T TEST +15 C °
TTEST 1 C/min °
1 C/min °
Stabilization time
+ 25 C °
10 min
6h
≥1 h
Time ON
OFF
Performance test
ON
Continuous Operational checks
OF F
ON
Performance test
Equipment switched ON Equipment switched OFF
Figure 15 — Dry heat thermal test — Cycle C The switched off equipment is placed in a chamber where the temperature is progressively raised to the extended operating temperature (T TEST + 15 °C) according to the selected temperature class (see Figure 15). Once the temperature of the whole equipment (internal and external) has stabilized, in any case the stabilization time shall not be less than 2 h, then the equipment is switched on and continuous operationall checks are carried out at this extended operating temperature operationa temperature value for 10 min. The equipment is then allowed to cool to the maximum operating temperature (T TEST) and the continuous operational operational checks last for a time period of 6 h. The equipment is then allowed to cool to ambient temperature and a further performance test is carried out after the stabilization time. tim e. Test acceptance requirements:
During and after the test, the equipment shall work as intended and within its specified limits (performance criterion A). A). 13.4.6 Low temperature storage test Where the equipment is to be subjected to temperatures less than its minimum operating temperature, then a low temperature storage test may be carried out. This test shall be carried out in accordance with EN 60068-2-1 (test 60068-2-1 (test Ab). Equipment without packaging is placed, without any voltage applied, in a test chamber. The temperature value for the test shall be −40 °C and the time period after stabilization shall be 16 h minimum.
After recovery, a performance performance te test st shall be carried out at the ambient ambient reference temperature. temperature. Test acceptance requirements:
After recovery, the equipment shall work as intended and within its specified limits (performance criterion A). A).
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13.4.7 Cyclic damp heat test This test is carried out in accordance with EN 60068-2-30 60068-2-30,, test Db variant 2. The equipment under test shall not be powered except during the operational check. Temperatures:: Temperatures
+ 55 °C and + 25 °C
Number of cycles:
2 (breathing effect)
Time:
(2 × 24) h
If condensation has not occurred by the beginning of the second cycle, (low thermal inertia of test piece), speed of temperature tem perature variati variation on can be increased (but not exceed 1 °C/min, and with wit h a maintained relative humidity). (HR) Relative Humidity % ≥
93
60
95 3
96 %
±
≥
80
±
15
90 %
≥
80 %
0 Equipment switched ON Operational check
Temperature C °
+55
±
2
+25
±
3
time
0 time
1h 3h±½ 12 h ±½
3 h–6 h
24 h cycle
3 h ±½
Equipment Switched OFF
Figure 16 — Cyclic damp heat test: Description of the first 24-h cycle
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HR % ≥
95 Laboratory humidity
75
±
2
0 time
Temperature Laboratory temperature 15 C – 35 C
C
°
Recovery period
°
+25
±
°
3 0 End of 2
nd 24
h cycle
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