Appendix 1 DO-160 Sections Changes from DO-160C to DO-160D1 Changes from DO-160D1 to DO-160E Changes from DO-160E to DO-160F Changes from DO-160F to DO-160G Category Q definition. Inserted two new Figures for Category Q, Fig.
21-4 and Fig. 21-5. Renumbered remaining figures as required.
Added Section 21 User Guide to Section 21.
Section 22: DO-160D Change No. 3, The DO-160E cable bundle test Section 22 was restructured The most significant change to Lightning published December 2002, section was modified to include with additional test Section 22 in DO-160G is the Induced added additional waveform a new section providing requirements moved from addition of a User’s Guide (UG) as Transient sets, cable bundle test levels, guidance for performing cable notes under figures to the main an appendix to Section 22. This Susceptibility and the procedures for performing indirect lightning multiple stroke and multiple burst tests using the existing defined test waveforms. The category designations were modified to allow users to designate categories that indicated that these additional tests had been performed.
New Waveform Set designators, G through K, were added to cover the Multiple Burst and Multiple Stroke tests.
Another significant addition to Change 3 was setup information on performing pin injection tests with power applied. Several different setup diagrams were added to assist users in performing these tests properly.
Improperly connecting the lightning generator to a pin with power applied could result in insufficient stress on the pin.
bundle tests on bundles that normally contain shields, with the shields removed. This guidance allowed testing of a cable bundle at test levels currently defined in DO-160, but intended to demonstrate compliance to aircraft installation threats that are higher than these standardized levels. It explicitly stated that the test generator used for cable bundle testing does not need to be capable of producing the voltage or current limit level, provided that the current or voltage test level can be achieved on the cable under test.
body of the document, and paragraphs were numbered to provide easy reference to the requirements contained in each paragraph. In the waveform set tables and the test level tables, both the voltage and the current waveform number are now shown to eliminate any ambiguities with how waveforms are related to each other.
This section was modified to clarify when a test was successfully completed and when, in the case of reaching a limiting level before a test level, another waveform test was needed. The cable bundle section now contains a path to follow for every waveform set and criteria for acceptable and unacceptable test limit waveforms that leads the user to successful test completion regardless of the configuration of the cable under test.
appendix removes guidance material from the requirements portion of the section. This allows for an in-depth discussion on relevant topics without “muddying” the procedures and test level definitions contained in the requirements portion of Section 22. The UG format is a paragraph by paragraph match with the requirements section for easy references to guidance on specific topics. Where no guidance material was added, the UG paragraph is not populated. It is expected that the UG will assist equipment designers with design and test considerations as well as improve standardization of testing between test facilities.
For example, by providing a detailed discussion on dealing with noise during waveform measurements, labs are more likely to use the same methodology for making measurements, resulting in much more consistency across the industry.
The DO-160G Section 22 A-9
Appendix 1 DO-160 Sections Changes from DO-160C to DO-160D1 Changes from DO-160D1 to DO-160E Changes from DO-160E to DO-160F Changes from DO-160F to DO-160G requirements portion adds the test methods and test levels for performing Waveform 6 Multiple Burst testing. Voltage limits for Waveform 6 are based on the open circuit voltage level from Waveform 3 Pin Injection, as Waveform 6, by definition, does not have a voltage limit. The Waveform 6 Multiple Burst test resulted in the addition of another waveform set character to identify the waveform used for Multiple Burst testing. Waveform set ‘L’ is used to identify Waveform 3 Multiple Burst and waveform set ‘M’ identifies Waveform 6 Multiple Burst.
Due to potential inconsistencies between the two Pin Injection test calibration methods, the resistor method was removed. The open circuit voltage/short circuit current method is considered the preferred method. As a result of the method elimination, several test setup diagrams were updated to reflect the change.
Clarification was added for the use of the ‘Z’ designator when the waveform generator is switched because the generator used did not produce a compliant ‘limit’ waveform. It is now specified that switching generators requires that the waveform set designation be a ‘Z’, the only exception being where A-10
Appendix 1 DO-160 Sections Changes from DO-160C to DO-160D1 Changes from DO-160D1 to DO-160E Changes from DO-160E to DO-160F Changes from DO-160F to DO-160G this is done for power line testing only. Testing of the power line separate from a standard interconnect bundle is the most common way of testing, therefore the exception is allowed providing better representation of the waveform set used for testing on the EUT interconnect bundle.
Section 23:
Lightning Direct Effects Additional procedure with associated electrode was provided for producing flashover when flashover is not produced during the normal procedure and it is desired that flashovers occur.
No significant changes were made.
Clarification of test waveforms and methods has been added throughout the section. Category designations have been added to separate voltage and current tests. Category designations have been clarified, and Category F was deleted.
No changes were made.
Section 24:
Icing Editorial and clarifications changes only.
No changes were made. No major changes were made.
Clarification of type of ice was incorporated.
No changes were made.
Section 25: A new section was added to No significant changes were No significant changes were Added note that ESD connection Electrostatic address device level made. made, except correcting point is not applicable to connector Discharge susceptibility issues for ESD. typographical errors in the figures.
pins. Added expansion of type and of the list of test points to be considered. Address case of no discharge.
Section 26: Section 26 was introduced in No changes were made. Categories A and B minor wording Fire, DO-160E. changes, test method remained the Flammability same. Category C: Flammability Entire section removed and replaced with FAA accepted methods verbatim from FAA Fire Test Handbook. Added configurations exempt from testing. Added definitions for “small parts exemption”. Added user guide A-11
Appendix 1 DO-160 Sections Changes from DO-160C to DO-160D1 Changes from DO-160D1 to DO-160E Changes from DO-160E to DO-160F Changes from DO-160F to DO-160G addressing all three categories.
Appendix A Abandon the use of nameplate marking for equipment environmental qualification category declaration.
A-12