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RTCA DO-160: “Environmental Conditions and Test Procedures for Airborne Equipment”
RTCA DO-160 is critical for qualifying electronics modules for use on aircraft.
RTCA DO-160 is key for getting electronics modules tested in order to ensure proper operation and support certification of aircraft. The current Rev is G and can be purchased here. Its history traces back to 1958, about the same time the precursors to MIL-STD-461 were coming into existence. It follows the same general principles as many MIL-STD-461-derived standards: test individual units very thoroughly, and when you integrate them into a larger system you have a good chance that will operate together successfully. In DO-160, EMC-related topics are a subset of a larger realm of environmental testing, including thermal, humidity, shock & vibe, sand & dust, salt spray, etc. Sections 16 - 23, plus 25, are the ones with the most EMC/E3 impact.
Section 16 specifies “Power Input” and can be thought of as a power quality spec. It controls things like normal operating voltages, both AC and DC, normal transients, ripple voltages, phase imbalance for AC power, and abnormal conditions as well. It has more in common with MIL-STD-704 than 461 or 464. This section assumes the equipment under test (EUT) is getting power in one of the following forms: 14, 28, or 270 Vdc, or 115 or 230 Vrms AC at 400 Hz.
Section 17 is for “Voltage Spike” testing. This is most similar to MIL-STD-461 CS06/CS106 testing, which was removed from the latest 461 Rev G. It can be found in the older versions of 461, as well as in GSFC-STD-7000.
Section 18, “Audio Frequency Conducted Susceptibility”. This is closely related to MIL-STD-461 CS101, which can be a tricky test to execute.
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Figure 18-1 of DO-160G shows an optional current monitor as part of the test setup. Always use this if you have the equipment–it gives you a lot of additional information for not a lot of extra effort. In particular it gives you the ability to calculate how the input impedance of the EUT is changing over frequency.
Section 19 covers “Induced Signal Susceptibility”. This doesn’t have a direct MIL-STD-461 analogue, but in general it is looking for susceptibility to low frequency stimulus induced in signal lines, as opposed to Section 18 focusing on power lines.
Section 20, “RF Susceptibility (Radiated and Conducted)” covers similar test methods to MIL-STD-461 CS114 and RS103. The radiated test includes both semi-anechoic and reverb methods.
Section 21, “Emission of RF Energy”, covers similar test methods to MIL-STD-461 CE102 and RE102. As in Section 20, the radiated test includes both ALSE and reverb methods.
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Use reverb testing whenever possible to save time. DO-160G Section 20 has excellent information about the mathematical and statistical techniques needed to ensure a chamber is set up correctly. The math is scarier, but there’s a significant savings in terms of testing time-in-chamber.
Sections 22 and 23 cover lightning testing (“Lightning Induced Transient Susceptibility” and “Lightning Direct Effects”). These share a lot of heritage with MIL-STD-464 as electromagnetic environmental effects tests. Section 25 covers ESD, and like most ESD specs basically follows IEC 61000-4-2.
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One of the things that separates DO-160 from other standards is the use of alphanumeric codes to describe the EUT and the applicable tests. Whenever you pin down a letter/number designation that applies to your EUT, write it down somewhere. Otherwise you’ll spend a lot of time flipping back and forth across many pages trying to find the right code again.
AIAA-S-121: “Electromagnetic Compatibility Requirements for Space Equipment and Systems”
AIAA-S-121 adapts MIL-STDs 464 and 461 specifically for space missions, including ground handling and launch vehicles.
AIAA-S-121 is an interesting beast. It is a tailoring of the combination of both MIL-STD-464 (system level) and -461 (equipment/module level) with an eye to making them specifically applicable to space systems. It can be purchased from the AIAA. It was reaffirmed in 2023, and there’s an effort underway to make it a joint standard with the IEEE. It’s something that the EMC Society standards committee and also Technical Committee 8 (Aerospace EMC) have been involved in, so if that’s of interest to you, please get in touch (standards@emcunited.com).
AIAA-S-121 draws from MIL-STD-1541 and SMC-S-008 (both freely available), and has similarities with GSFC-STD-7000. However it is very much its own document and should be read independently. Generally speaking, Section 6 follows MIL-STD-464, Section 7 follows MIL-STD-461 Section 4, and Section 8 follows MIL-STD-461 Section 5. Section 7 starts with a helpful table that explains many of its deviations from MIL-STD-461. Like MIL-STDs 464 and 461, it has appendices with excellent additional information that reward the thorough reader.
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Just because a unit is compliant to MIL-STD-464 and -461 does not guarantee that it will be successful in meeting AIAA-S-121. At a minimum, the radiated susceptibility levels are different. MIL-STD-461 RS103 for space systems specifies a threat level of 20 V/m, where AIAA-S-121 requires levels up to 50 or 100 V/m depending on frequency range and mission phase.
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For those concerned about Multipaction in space RF systems, MIL-STD-464 requires verification by test but does not specify or even recommend or reference a specific test method. AIAA-S-121 helps us out by pointing to “ECSS-E-20-01A, Space Engineering – Multipaction and Test, European Space Agency (ESA) for the European Cooperation for Space Standardization (ECSS), 5 May 2003.”
MIL-STD-464: “Electromagnetic Environmental Effects Requirements for Systems”
MIL-STD-464 is the main aerospace/defense document that applies E3 requirements to full systems and platforms.
MIL-STD-464 is an interesting beast, less well known than its counterpart MIL-STD-461. MIL-STD-464 is currently on Rev D and can be officially downloaded for free.
This document is concerned with making sure full systems (aircraft, tanks, etc.) are able to operate safely in regards to all the potential threats from the electromagnetic environment. Testing to MIL-STD-461 is part of making sure that a given component will integrate safely with the larger platform, ensuring electromagnetic compatibility. However, the broader MIL-STD-464 standard has many additional concerns: making sure aircraft are safe when hit by lightning; making sure space RF systems don’t suffer from multipaction; controlling intermodulation products from RF systems installed on naval vessels; making sure that personnel and ordnance isn’t affected by the excess charge picked up by aircraft in flight, and much more. It includes sections on lightning, EMP, RADHAZ, TEMPEST, ESD and several others. So while it is one of the primary sources of EMC requirements on defense and aerospace projects, it encompasses a much broader universe of E3 (electromagnetic environmental effects).
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As with MIL-STD-461, anyone who takes the extra time to read the appendices will be amply rewarded with context, lessons learned, and additional technical details.
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It was frustrating to me for a long time that MIL-STD-464 requires testing as verification for Multipaction (relevant to space RF systems), but did not give any hints or pointers to a test standard. AIAA-S-121 does include such a reference, to ECSS-E-20-01A, Space Engineering – Multipaction and Test, European Space Agency (ESA) for the European Cooperation for Space Standardization (ECSS), 5 May 2003.”