2. About Hursley EMC
• UKAS Accredited
• Established 1997
• Notified body for EMC Directive
• International Compliance
Military EMC Commercial EMC
DEFSTAN 59-411
MIL 461
DO160
FCC Listed (USA)
VCCI Listed (Japan)
ICES Listed (Canada)
KCC Listed (South Korea)
BSMI Listed (Taiwan)
We are an Independent EMC Test Laboratory based on the South Coast
3. About Me!
• Background summary:
• Product development & EMC Engineer for IBM
• Present Role:
• Director of Hursley EMC Services
• EMC testing, developing new test area
• Chairman EMC Test Labs Association (Working Group A)
• Education and quality of EMC Test Labs
• Writing Technical Guidance Notes for DEFSTAN 59-411
4. • Defining COTS and MOTS
• Pros and Cons
• Audience Participation
• Comparison of COTS and MOTS environments
• COTS into MOTS problems and possible solutions
• MOTS into COTS process
• Worked example of MOTS to COTS
• Summary
• Q & A
Presentation Overview
Look out for Top Tips
6. COTS = Commercial Off The Shelf
MOTS = Military Off The Shelf
What it is
7. Low Cost
Quick to Develop
Fast Deployment
Technically advanced
Pros of COTS
8. Not Certified for Military
No build standard control
Not robust
Can disappear without trace
Obsolescence management
Cons of COTS
9. Low Cost
Quick to Develop
Fast Deployment
Technically advanced
Best and Worst
Not Certified for Military
No build standard control
Not robust
Can disappear without trace
Obsolescence management
10. MIL461F COTS to MOTS Statement
Simply put in Section 4.2.2 of MIL 461F:2007
14. • System Requirement Document
• Test Plan
• Product Specification
• Usage Environment
Defining the Environment
15. Evaluating COTS Performance
Collect evidence of existing performance
CE Report (Accredited ?)
Country of origin (pedigree)
Product exerciser details
Frequency ranges
Test levels
Create gap analysis (wary of different standards)
16. Military Commercial Origin
Radiated E Field DRE01 EN55022 Generics
Radiated E Field AVG DRE03 None -
Radiated H Field DRE02 Annex A of EN55103-1 Pro AV
Conducted Power Port DCE01 EN60945 Marine
Conducted Signal Port DCE02 EN55022 ITE
Exported Transients DCE03 None -
Emissions Comparisons
17. Military Commercial Origin
Radiated E Field DRS02 EN61000-4-3 Railway
Radiated H Field DRS01 EN55103-2 ProAV
Magnetic DC Field DRS03 EN61000-4-8 Railway
Conducted AF Power port DCS01 EN61000-4-16 Railway
Conducted AF Signal Port DCS03 None -
BCI DCS02 EN61000-4-6 Alarm
Immunity Comparisons
18. Military Commercial Origin
Externally Generated DCS05 None -
Imported Long DCS06 EN61000-4-12 Railway
ESD DCS10 EN61000-4-2 Generic
Imported Low Frequency DCS12 None -
Transients Comparisons
19. Functional Criticality / Risk Rating
Critical Function needs:
• High Immunity performance
• Low Emissions performance
Gap Analysis tools are UNavailable
If unsure get your EMC lab to do it
20. Mitigation of Risk
Post Functional criticality review: two options
1. Identify additional works to improve EMC performance
(Resultant engineering changes may invalidate CE
Marking, unless just a new simple chassis/barrier)
2. Fully test product to relevant military standard
21. CE
Reality of success for unmodified COTS
More chance of Aston Villa topping the Premier Division
23. • Radiated Emissions
• Conducted Emissions
• Radiated Immunity
• Conducted Immunity
• Transients (brief statement only)
• Keeping it simple with Sea and Land Class C & D.
DEFSTAN 59-411 vs CE standards
26. 20
30
40
50
60
70
80
90
100
0.01 0.1 1 10 100 1000 10000
Below Deck Above Deck 60945 RE QP Land Class D Land Class C
Sea Limits + Land Class B & C + EN60945
27. 20
30
40
50
60
70
80
90
100
0.01 0.1 1 10 100 1000 10000
Below Deck Above Deck 60945 RE QP Cispr A QP Cispr B QP Cispr B Ave Land Class D Land Class C Class A Avg
Sea Limits + Land Class B & C + EN60945 + EN55022 Class A
33. Radiated Magnetic Emissions Sea Limits + EN55103-1
50
70
90
110
130
150
170
10 100 1000 10000 100000 1000000
DRE02.B-Limits for Air Land and Sea Service use
DRE02 55103
35. • No easy comparison to commercial
• EN61000-4-33 Measurement Methods for High Powered Transients
• Different injection methods
• Different output impedances
• DCS05 switching levels OK, NEMP and Land need specials
• DCS06 usually OK
• DCS12 is ‘Brutal’
Transient Immunity
36. MIL 461F statement
Most Commercial Mains filters are designed from 150kHz to 30MHz.
Issues will be at the low frequency end, typically 10kHz to 100kHz.
Additional power filtering needed likely to be 2 or 3 stages. (Ringing risk with
existing filtering)
Likely Outcomes – Conducted Emissions & Immunity
37. • Additional power filtering
• Additional shielding (external chassis or cabinet)
• Double screened interface cables
• Perfect 360° screening at connector shell
• Braided and foiled cable screen terminations
• LCD overlay screen or ITO coating
Likely Outcomes – Radiated Emissions & Immunity
Ensure modifications do not compromise air-flow,
causing unreliability
38. • Additional power filtering
• Additional Transorbs, MOV, surge arrestors & VDR
• Possible MOV on output of filter for DCS12 only
• Double screened interface cables
• Perfect 360° screening at connector shell
• Braided and foiled cable screen terminations
Likely Outcomes – Transient Immunity
Ensure modifications do not compromise product
electrical safety
42. • Section 1 Scope
• Section 2 Directives for Conformity
• Section 3 Application of the EMC directive for military equipment
• Annex A Defence Procurement Directive
• Annex B Article 346 Treaty of Lisbon
• Annex C List of exempt items
• Annex D Environments
• Annex E Decision diagram for apparatus
• Annex F Decision diagram for fixed installations
• Annex G Read Across Tables for Military and harmonised stds
• Annex H Comparison of EMC test methods
• Annex I Example of Gap Analysis
• Annex J Example Case Studies
TR 50538 Contents
43. • Harmonised standards appear in Official Journal (OJ)
• How many Military stds are in OJ ?
• Apparatus not in Annex C require a CE mark
• Applicable to Apparatus and ‘Fixed Installations’
• Anything portable or mobile is Apparatus
= None
Issues
45. Consider the intended environment of Apparatus
• Ships above and below decks
• Aircraft internal and external
• Land Service
• Connection to existing commercial infrastructure
• Choose most suitable standard from the OJ
• Use these for your Declaration of Conformity
Annex D
47. • Use of Harmonised Standards
• Mixed EMC Assessment
• Detailed Technical EMC Assessment
Full Testing = minimal risk (££££)
Tricky to be confident of result will
need some testing for Fast Transient
Bursts, Surge, Harmonics & Flicker
(£££)
Section 3 – Conformity Assessment
Theoretical exercise (££)
48. Review existing Reports
Computer modelling
Design evidence (best practice examples)
Similarity to existing Apparatus
Limitations of use (certain modes only)
Gap Analysis (Annex I)
Not difficult to create, but needs careful
analysis for the correct result
Ratified by Notified Body (optional)
Beware concessions
Detailed Technical Assessment
49. Commercial Test DEFSTAN Test Notes Decision
EN55022 Radiated
Emissions
DRE01.B Most DEFSTAN should
be ok but >1GHz
unknown for Ships
Accept with checking
report profile
EN60945 Radiated
Emissions
DRE01.B Sea Below Decks
easier. Notch BW
Unlikely to comply
but check profile
EN60945 Radiated
Emissions
DRE01.B Sea Above Decks
mainly tighter
Accept with checking
report profile
EN55022 Conducted
Emissions Class A
DCE01.B Class A is easiest to
meet
Accept with checking
report profile
EN60945 Conducted
Emissions
DCE01.B Very tight limit for its
freq’ range
Sea above decks
possibly
DEFSTAN to COTS Emissions
50. Radiated Emissions considerations
• Military Ground Plane a huge factor in emissions performance
• Shouldn’t assume 20dB / decade rule will be true from 1m to 3m (9.5dB) or 10m (20dB)
• Consider broadband and narrowband differences
51. Commercial Test DEFSTAN Test Notes Decision
EN61000-4-3 Radiated
Immunity
DRS02.B DEFSTAN is more
severe
Accept
EN61000-4-6 Conducted
Immunity
DCS02.B DEFSTAN is more
severe except
below 1MHz
Check if 3V or 10V
requirement
DEFSTAN to COTS Immunity
52. Commercial Test DEFSTAN Test Notes Decision
EN61000-4-2 ESD DCS10.B Above & Below ok Accept
EN61000-4-4 Fast burst No equivalent Needs testing Test
EN61000-4-5 Surges No equivalent Needs testing Test
EN61000-3-2 Harmonics No equivalent Needs testing Test
EN61000-3-3 Flicker No equivalent Needs testing Test
EN61000-4-11 Dips No equivalent Should pass Accept
DEFSTAN to COTS Transients & Power
53. CE Mark product
- it is ok to affix to the packaging or manual
Perform a complete CE test to
harmonised standards if possible, not
so expensive or time consuming, and
reduces the risk.
CE Mark Apparatus
54. Sea Below Decks to EN60945 example
Radiated Emissions
20
30
40
50
60
70
80
90
100
0.01 0.1 1 10 100 1000
DRE01.B -Limits for All Platforms
Below Deck Above Deck 60945 RE QP Cispr A QP Cispr B QP
Cispr A Av Cispr B Ave D C
55. Sea Below Decks to EN60945 example
Radiated Emissions Gap Analysis combination
20
30
40
50
60
70
80
90
100
0.01 0.1 1 10 100 1000
DRE01.B -Gap analysis Sea above Decks & EN60945
Gap Analysis test Limits
56. Sea Above Decks to EN60945 example
Conducted Emissions
-20
0
20
40
60
80
100
120
140
0.0001 0.001 0.01 0.1 1 10 100
DCE01 Limits for all platforms
DCE01.B SAD DCE01.B SBD CISPR A QP (dBuA) CISPR B QP
57. Sea Above Decks to EN60945 example
Conducted Emissions Gap Analysis combination
-20
0
20
40
60
80
100
120
140
0.0001 0.001 0.01 0.1 1 10 100
DCE01 Gap Analysis
Gap Analysis Test Limits
58. Sea Above Decks to EN60945 example
Immunity shortfall testing
EN61000-4-4 as no direct equivalent
EN61000-4-5 as no direct equivalent
EN61000-4-6 as only 4V and needs to be 10V
59. COTS to MOTS isn’t possible
Modified COTS to MOTS is possible
No definite worst case Commercial or Military Standard
Worst case Emissions and Immunity levels for both
MOTS to COTS needs careful gap analysis
Gap Analysis tools unavailable
EMC Test Lab experience and support very important
If in doubt or Risk Averse – Just Test !
Summing Up
Editor's Notes
Operating for nearly 20 years
Started out as commercial EMC moved into Military about 7 years ago
Was a customer of EMC dept
Moved into EMC dept by accident, but I really enjoy it, working with customers and finding solutions to problems.
I have 30+ years of working in EMC.
I perform these tests I will be describing today and the gap analysis exercises as well.
I am an engineer and not a salesman / presenter, I have like you all have I am sure sat through countless power points, but this is my first presentation and if it goes badly
my last !
Ive spent sometime thinking how to put this subject down simply and make it memorable for everyone.
This is the plan for today.
Quite a bit to get through
Look at the issues with putting COTS kit into Military environment
Comparing Limits of both environments via a short game, nothing to onerous but hopefully fun!!
and then using our simplified Gap analysis tool compare COTS to MOTS Limits to see visually differences. Focussing on DEFSTAN and sea and Land Class C & D limits.
Then Looking at the process for MOTS kit into the CE environment.
Just so everyone is in the right room
COTS and MOTS isn’t this !
It’s the need to place your industry standard kit into service as Military equipment.
There is a 3rd one, which is GOTS, which would apply to Urgent Operational Requirement, where you get what you get! But we are focusing on certified routes so this GOTS doesn’t apply.
The advantages of COTS kit are clear
With everyone looking at cost and time to get it into service COTS makes a lot of sense
Someone else has spent time and money creating it. But just not for the military en
vironment.
But it does give access to the lastest leading edge technology
But on the other hand
The cons are the RISKS
Its
Unknown
Untested
Uncontrolled
How long will the motherboard or LCD be around ? Mention banks a good choice for this as they have long supply needs
One current issue we are seeing is touch sensitive buttons failing transients but you cant modify it to suit you as you don’t control it.
Although I’ve listed 5 Cons, this is sort of a balancing point.
We will look at how factors affect the decision making process
This balancing act is neatly summed up my the Americans in
MIL Standard 461
Cheap, quick and high tech !
But keep the standard still
So as its my first presentation I thought we’d play a short game, just 8 quick questions, if you don’t know guess.
to see what we know and also some differences between the CE and Military EMC specs
PRESS
I have no glamorous assistant like Brucie sadly.
So From that short quiz, I think it is clear that perhaps the expectation that all Military EMC is tougher than the world of CE isn’t true.
So how do we bridge the gap to a MOTS environment ?
This is the flow chart from 59-411 part 1
The blue boxes show you what to do
And the yellow balloons suggest how you go about it.
It looks very simple, but it isn’t !
We will run through these stages now
Ideally your customer will have a test plan that your product is going to have to meet this would define the environment and test levels and frequency ranges
How it is going to be exercised and monitored during testing. Monitoring is
key.
Automotive products tend to do well in MOTS environment as their reports are very highly detailed with regard to testing and monitoring. Unlike some generic CE which can be a bit lax
Ideally you will have a full CE report. But given that the CE process is a bit lax, this may not be the case. If you are lucky to have a report, where has it come from EU ? USA, Far East ?
How was it exercised ?
PC with 16 RS232 port story
Any testing > 1GHz
We will look at some simple examples in the next few slides on gap analysis
The military column is showing the tests we need to cover and the Commercial one the possibilities from different standards that are the closest
ITE products are often tested to FCC specs for USA and this can go up to 40GHzdepending on product spec
There are a couple of gaps you can see
It’s the same here, showing that Rail spec are the best match for Military specs
For DCS03, we could argue that EN61000-4-6 is close
Transients are harder to analyse
Only the ESD is very close marked in red
This is always going to be difficult
The higher the risk environment and function the less any gaps can be tolerated.
The MOD do have a Gap analysis tool, but it is not yet in the market place. It is currently being updated to add new specs, and this might change in 2016.
EMC labs all have their own. I would strongly advise to consult your EMC Test Lab, but I would wouldn’t I ? !!!
Its then down to how you reduce the risk of putting COTS kit into MOTS service
PRESS
It may be the COTS kit can be put into a 19 inch rack with its own built in filters which wont require any mods so the CE marking is still valid.
PRESS
But if not then it will be a question of full testing.
DON’T PRESS KEYS YET UNTIL YOU SPEAK
Experience has shown that putting COTS kit into MOTS without any modifications isn’t going to work.
It is effectively – hit button to bring in slide 1
And there is more chance of Aston Villa being on top of the Premier League today.
Like the reality of unmodified COTS success here is the real Villa position -
So our reality is that COTS is going to be modified COTS, with a power filter, possibly in a chassis with additional signal port filters depending on which environment its going in.
So I’d like to run through in a bit more detail and compare the test levels and frequency range differences between CE and DEFSTAN.
Ive just chosen a few as on the first trials the graphs were just too busy and too hard to understand.
There are the limits at Hursley EMC we work most commonly with.
Sea Above Decks quite rightly being tougher, but note both stop at 1GHz
Adding in the Land C & D limits they are similar to the Sea, but extend to 18GHz.
I haven’t shown the Land A & B, but these are an order lower.
Land Class A & B equipment will need a customer enclosure to meet limits.
The Commercial Marine standard EN60945 is a good comparison.
As you can see it crosses over the Above decks limits in a few places but you can see where it is tighter in the VHF band 156 to 165 MHz.
60945 also stops at 2GHz.
Then bringing in the generic Class A & B limits you can see these are better than Sea Above decks where they share the same frequency range.
But there are huge gaps.
Here we have the Sea conducted limits
Military world is in dBuA ( except MIL 461 CE102) and the Commercial world in dBuV, so there is some converting, and allowance for LISN impedances etc.
Ive kept is all in the military world as this is what we are focussing on.
Again you can see the 60945 limit is a good starting point. But the commercial world stops at 30MHz.
The Sea specs start at 500Hz, but the Land classes at 20Hz.
If a product met 60945, there would be a good chance of a pass to Sea Above Decks unaltered.
Adding the Generic Class A & B limits their 150kHz starting frequency means more testing will be needed.
No commercial EMC will have testing below 150kHz ( except 60945)
This is how I think we all expect it to look
Military way above commercial for radiated immunity.
But you can see that over the same frequency range there is correlation.
For Conducted Immunity you can see that the heavy industrial limit is in fact higher than the Sea limits below 1MHz and higher above 30MHz,
but the light industrial at 3V is consistently lower across the range.
This is one that usually never has any comparisons as the professional AV spec is not widely used. But you can see there are some similarities and areas where you would need to retest ie 10khz to 100khz
Likewise just to show the gap, the H field immunity from 55103-2 is below the military and will need full testing.
We’ve tested a few hailing devices which started out as Pro AV kit.
Transient comparisons are hardest to do
61000-4-33 shows a methodology to do this, but this is a presentation all in its self.
If you want to know more, download a copy.
PRESS
We don’t get too many modified commercial items failing DCS05 switching levels, but NEMP is a different matter !
Likewise DCS06 is a pass first time 9 times out of 10.
DCS12 though is the killer. Luckily it only applies to Sea Systems. Extra work is usually needed on power filters.
Roughly 30mins!
So a quick look at some potential requirements due to shortfalls in Commercial filters frequency range and attenuation performance.
We’ve worked with a filter manufacturer now for about 5 years to develop a solution up to 6Amps. It has worked on virtually everything for sea below decks and Land Class C & D since then.
PRESS
Sea systems earth leakage is a big issue and MIL 461 again has some wise words on limiting capacitance values and hence leakage.
PRESS
As we never know what goes into high current filters, I am not sure this is always adhered to !
You can see here the typical measures needed for COTS to MOTS
The LCD would only be needed for a very low emissions environment like Land Class A
Press button for top tip then
It is important to focus on the potential over heating risks that all this shielding could bring
Similar in a way, more protection as we mentioned before for DCS12 if its Sea systems you are designing for.
Its important to check cables terminations are as per drawing and not as its easiest to make it with a pig tail instead.
Double screening although expensive is usually more than twice as effective.
Press for top tip.
Finally
PRESS
Please check all the filtering add-ons and ground changes don’t affect the basic product safety.
We’ve covered the COTS to MOTS now and will move on to the reverse
Certifying a Military product for commercial use.
This is a bit shorter as we wont need to revisit the gap analysis graphs.
When doing MOTS to COTS it’s a question of picking the Product Specific Standard or Product Family Standard that you need to certify to.
There are some examples here.
Luckily there is a useful guide for this purpose.
PRESS
It isn’t a standard itself but a Technical Report
It has a defined methodology and process to follow for CE marking, but it still needs experience and knowledge to use it successfully.
Section 1 – defines applicability to military equipment not exempted by Annex C
Section 2 – directives to use, EMC, R&TTE, automotive, Maritime
Section 3 – application of the EMC directive to military equipment
Annex A refers to setting up a European Defence equipment market legislative framework
Annex B refers to protecting essential security issues
Annex C – listing what you can ignore for CE Marking
Annex D – Military standards DEFSTAN MIL , etc
Annex E – flow diagram for Apparatus
Annex F – flow diagram for fixed installations
We will look at the relevant ones in more detail shortly. Its going to be too big cover in 15 minutes.
And focus mainly on the annexes highlighted in red for this presentation
PRESS
The Official Journal is published usually twice a year.
PRESS
PRESS
Everything Military based which isn’t excluded needs to be CE marked
PRESSA fixed installation would be dockyard
A Comms rack would be apparatus
PRESS
An aircraft carrier is a portable apparatus.
This is fairly obvious one but each MOTS item will need to be declared to a Directive.
The oddity is that military radios do not need to meet the R&TTE directive or soon to be RED Directive but the EMC Directive.
But a radio used on site by contractors would
Consider where it has been Certified for
DEFSTAN Land
MIL 461 Ships
For examples
Then also look at how it is going to interface to the infrastructure in its CE environment, this will help you to select the most appropriate standard from the OJ.
Annex E shows us how to get that elusive CE mark.
It is a simple flow chart with options, one to study over a coffee maybe ?
These are our three choices
PRESSHarmonised standards and testing reduces the risk but obviously has a cost involved.
PRESS
Mixed EMC assessment needs experience to interpret GAP analysis and there will be the need to do some testing as highlighted – lower costs than above
Detailed Technical assessment
PRESS
ignores harmonised standards and use experience and a lot of work to analyse and make a decision – brings the highest risk. – this may be the only way for some apparatus, no testing costs, but consider consultant costs.
These are the suggested methods from within
TR50538.
PRESS - check for concessions don’t assume full pass
PRESS
Experience and skill needed for Gap analysis
Notified body can be used for additional confidence. (we have done this twice only for military equipment).
Example tables of MOTS to COTS for the detailed technical assessment
This is part of our in house gap analysis.
Such difference in the set up mean nothing is guaranteed as a read across.
Peak for Military and quasi peak for commercial have potential differences for broadband and narrow band signals
45 mins
Less risk here as military levels are high and the frequency range wide
Most products would pass EN61000-4-11 PLD specs.
ESD is the same-ish
But no easy read across for the transients
So we’ve finally got round to our CE marking after one of these routes
PRESS
To avoid label confusion on approved MOTS kit there is no need to fix the CE sticker onto the apparatus the packaging or manual is fine.
Press for top tip
Then say
I would recommend the testing route if you can.
So we’ve finally got round to our CE marking after one of these routes
PRESS
To avoid label confusion on approved MOTS kit there is no need to fix the CE sticker onto the apparatus the packaging or manual is fine.
Press for top tip
Then say
I would recommend the testing route if you can.
So we’ve finally got round to our CE marking after one of these routes
PRESS
To avoid label confusion on approved MOTS kit there is no need to fix the CE sticker onto the apparatus the packaging or manual is fine.
Press for top tip
Then say
I would recommend the testing route if you can.
So we’ve finally got round to our CE marking after one of these routes
PRESS
To avoid label confusion on approved MOTS kit there is no need to fix the CE sticker onto the apparatus the packaging or manual is fine.
Press for top tip
Then say
I would recommend the testing route if you can.
So we’ve finally got round to our CE marking after one of these routes
PRESS
To avoid label confusion on approved MOTS kit there is no need to fix the CE sticker onto the apparatus the packaging or manual is fine.
Press for top tip
Then say
I would recommend the testing route if you can.
So we’ve finally got round to our CE marking after one of these routes
PRESS
To avoid label confusion on approved MOTS kit there is no need to fix the CE sticker onto the apparatus the packaging or manual is fine.
Press for top tip
Then say
I would recommend the testing route if you can.
We’ve seen that COTS to MOTS is a non starter unless its something like a battery lamp
Military specs aren’t always tough than commercial ones
Gap analysis tools don’t exist
EMC lab experience and support is going to be essential for COTS to MOTS or MOTS to COTS exercises
Finally I would like to thank Pete Dorey, Tim Williams and Ken Summerbell for help and support with material for this presentation.