Packaging Development Guide PRO-0149-00 - F5 Networks

Packaging Development Guide PRO-0149-00

Thursday, June 20, 2019

Authored By: James Parker

F5 Networks, Inc.

Platform Technology Liberty Lake, WA

Packaging Development Guide

F5 Company Confidential/Proprietary PRO-0149-00 REV F

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File Revision History Log

Reviewers:

Reviewers Date Reviewed

Bret Britz

Alan Petri

Chris Lambiotte

Bud Gothmann

Larry MacDonald

Teng Moua

John Harris

Jim Cronin

Date Author Revisi

on Comments

9/17/08 J.Parker A Original

6/21/11 J.Parker B Updated – ECO-3476

J.Parker C Updated & added Palletized PKA test requirements - ECO-XXXX

12/3/12 L.MacDonald D Add 3.1.12 stitching specifications

7/12/2013 L.MacDonald E Update test procedure to better conform to industry standards. Add section for testing unitized loads

5/28/19 L.MacDonald F

Correct page numbering add clarification to package test criteria, limit testing explanation, add packaging requirement doc and test plan summary reference, add design step clarification, add variants testing section, add packaging design preferences and requirements based on F5 process changes since previous revision.



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Table of Contents

1 INTRODUCTION ................................................................................................................................... 5

2 DESIGN STEPS .................................................................................................................................... 6

3 PACKAGING PREFERENCES ............................................................................................................. 8

4 PACKAGING REQUIREMENTS ......................................................................................................... 12

5 QUOTING REQUIREMENTS ..……………………………………………………………………………...14

6 TESTS FOR NON-NEBS NON-PALLETIZED PACKAGING SYSTEMS INCLUDING FRUS ......... .15

7 TESTS FOR NEBS NON-PALLETIZED PACKAGING SYSTEMS INCLUDING FRUS....................26

9 TESTS FOR NEBS PALLETIZED PACKAGING SYSTEMS ............................................................. 32

10 TESTS FOR UNITIZED LOADS ......................................................................................................... 36



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Acronyms:

CoC: Certificate of Conformance

CRU: Customer Replaceable Unit

DUT: Design Under Test

ECO: Engineering Change Order

EUD: End user device

FRU: Field replaceable unit

GRMS: Root-mean-square accelleration

HDD: High density drive

LCD: Liquid crystal diode

LDPE: Low Density Polyethylene

PD: Product Development

PS: Power supply

RH: Relative humidity

SSD: Solid state drive

U: Standard equipment rack height unit = 1.75"



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1 Introduction

1.1 Purpose

This document is an engineering template for designing and testing F5 product packaging to meet or exceed customer expectations and the environmental standards for shipping product to customers. This guide is designed to assist packaging designers in their effort to create packaging solutions for F5 Networks, Inc. by defining our general preferences and requirements.

1.2 Design Steps

The design steps section of this document describes the general steps and order of operations performed during packaging design.

1.3 Preferences

The preferences section of this document outlines a list of design features preferred by F5 Networks, Inc. When possible, we expect these preferences to be followed and used as an

effective guide in development of a packaging solution.

1.4 Requirements

The requirements section of this document outlines a list of items or features that are required for any packaging to be approved by F5 Networks, Inc. These items or features are not negotiable and must be included in all packaging solutions.

1.5 Quoting Expectations

The quoting expectations section of this document outlines all expectations dealing with price quoting of packaging under development.

1.6 Testing

The Testing portion of this document outlines the required tests all packaging solutions must pass

in order to be approved by F5 Networks, Inc. Destructive limit testing as defined in the test plan

summary may be conducted to validate PD fragility test results, for example will be ‘for

information purposes’ and pass/fail criteria may not apply.



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2 Design Steps

2.1 For every new product design, the mechanical engineer will provide a packaging requirements doc (PSD-xxxx-00) to the packaging designer. This document will specify (as best as possible at this early stage): project parameters and schedule, physical parameters, shipping configurations, expected variants, accessory packaging contents, FRUs/ CRUs (provided by Product Marketing), any other requirements or areas of concern. This document will be rev controlled and updated by the mechanical engineer as the product matures through the prototype phases.

2.2 In the first step of the design process, F5 Networks will provide solid models and a mechanical sample if available, and accessories to the packaging designer. The solid model and mechanical sample must represent the dimensions, weight and features of the final design. Specific requirements must be known prior to the start of packaging design (ex. fixed rack ears shipped mounted on chassis or in separate box as defined in the Packaging Requirements Document

2.3 The next step is for the package design team to design a prototype packaging solution. A packaging rendering will be produced and sent to the F5 responsible engineer for F5 team review. Upon approval, a package test sample will be provided for preliminary drop testing per the test directions in the appropriate section of this document. At this stage, a preliminary quote (requirements listed in section 5) should be requested to make sure the packaging solution is within the price point requirements set by F5 Purchasing.

2.4 After a prototype packaging solution has been designed and passed a preliminary drop test, it should be sent to the mechanical team at F5 Networks in Liberty Lake for review. After reviewing it locally it may be sent to our manufacturing team for a second review. As an alternative, a detailed test presentation with photos can serve as a review. At this point, F5 will send a summary with any concerns or modification requests. Depending on the significance of the changes, a new sample may be requested for review and testing. This determination will be made on a case by case basis. Interim prototype samples will often be required in small quantities during multiple development stages for use as F5 prototype system shipping. It is understood that there may be some assumed risk of shipping with prototype packaging.

2.5 If modifications are requested for enhancement or necessity due to product design changes, updated solid models should be sent to the packaging designer and an updated rendering should be generated and sent back to F5 for review. The packaging should be re-quoted to determine cost impact. A cost-benefit analysis will be made on ‘nice to have’ changes and if the determination is to proceed, An updated test sample will be provided for drop testing.

2.6 When no further modifications are required, F5 will submit one working unit (two if there are plans for both domestic and overseas chassis production) for full conditioned packaging test. The test unit(s) will be inspected and tested for functionality once returned to the F5 packaging team. A final test report should be supplied to the F5 mechanical team from the packaging team.

2.7 When the unit is submitted for final review by the F5 packaging team, a final test report will be attached to the manufacturing tab on Agile upon ECO release.



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2.8 Any/All approved designs will need drawings and print plate proofs submitted to F5 so they can be reviewed and entered into our Agile system.

2.9 Tooling will then be purchased for the approved final submission and a final tooled and fully conditioned drop test will be performed. A final report will be supplied by the packaging test team.



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3 Packaging Preferences

3.1 Non-Palletized Unit Packaging (<100lb)

3.1.1 Packaging volume, weight, and material use should be the minimum amount required to maintain necessary levels of safety for the packed product.

3.1.2 A top and bottom cap design is preferred for ease of packaging of potentially heavy systems. Systems that are too heavy for two-person lift (100lb or more) should be palletized. This is a guideline only. Packaged units <100 can be palletized if it is deemed sensitive to damage, awkward to lift, etc.

3.1.3 All corrugated/foam packaging assemblies should have handles located in the center of the

short edges or for heavier ‘two-person lift’ packages two set per side if located on the long edges. Handles should be hinged on the upper side as to provide cushion when being held. If more than one handle is used per side, they should be ergonomically and conveniently located Handle location should be sufficiently away from the top edge and reinforced to prevent tearing during lifting. Also, the handles need to be positioned so that there is clearance internally to ensure ease of use.

3.1.4 Any accessories that are not attached to the unit should be packed inside a cavity or in an

accessory box inside the outer shipping container.

3.1.5 Any accessory boxes located inside the outer shipper should have handles, finger holes, or recesses for easy removal if they are in locations that would make them hard to remove.

3.1.6 Accessory packaging should be multi-purpose when possible to fit multiple accessories using fewer packaging part numbers. For example: two accessory cables can use the same outer shipper as one power supply cable.

3.1.7 For heavier (>1U) corrugated/foam solutions the package should be designed for easy, single person, top loading using a vacuum system. The unit should not have to be inserted at extreme angles or maneuvered strategically to be inserted.

3.1.8 When possible the F5 logo ball, all keys, power supply handles, ports, or any other delicate protruding parts on the unit should not be in contact with the foam portion of the package. Ideally, packaging should be designed so delicate parts are removed and packaged separately (Product Marketing should be consulted for approval).

3.1.9 All systems should be shipped to customers in a single container.

3.1.10 The unit should include some form of protection against cosmetic damage of the surface finish. This may include a plastic wrap (for 2U appliances) or bag (for 1U appliances) to eliminate the chafing between the foam and the powder coated system.



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3.1.11 The unit should be secured in the package as to permit little to no movement to prevent cosmetic damage of the surface finish.

3.1.12 The manufacturers seam of the outer shipper can be glued or stitched at the discretion of the F5 packaging team, but if stitched, staples must be no more than 1” apart with the top and bottom staples no more than ½” from the flap bends. In general, glued seams are preferred from a cost standpoint but heavier chassis (>1U) may require stitching if the glued seam does not hold up to drop testing. A good compromise may be an extended glue tab which is 2” wide and extends 2” onto shipper top flap although there is an additional cost associated with this to be considered.



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3.2 Palletized Unit Packaging (100lb or greater)

3.2.1 Palletized loads and chassis on custom designed pallets must be compatible with standard forklifts, pallet jacks and lifters. Palletized packages should not have handles that allow it to be lifted by hand.

3.2.2 The packaging should be easily opened and closed for inspection at customs facilities.

3.2.3 Packaging volume, weight, and material use should be the minimum amount required to maintain necessary levels of safety for the packed product.

3.2.4 Any accessories that are not attached to the unit should be packed in an accessory box or cavity inside the outer shipping container.

3.2.5 Any accessory boxes located inside the outer shipper should have handles, finger holes, or recesses for easy removal if they are in locations that would make them hard to remove.

3.2.6 Accessory packaging should be multi-purpose when possible to fit multiple accessories using fewer packaging part numbers. For example: two accessory cables can use the same outer shipper as one power supply cable.

3.2.7 When possible the F5 logo ball, all keys, power supply handles, ports, or any other delicate protruding parts on the unit should not be in contact with the foam portion of the package. Ideally, packaging should be designed so delicate parts are removed and packaged separately (Product Marketing should be consulted for approval).

3.2.8 All systems should be shipped to customers in a single container.

3.2.9 The unit should include some form of protection against cosmetic damage of the surface finish. Typically, this will be a gusseted bag for ease of pack out and to eliminate the chafing between the foam and the powder coated system

3.2.10 The unit should be secured in the package as to permit little to no movement to prevent cosmetic damage of the surface finish.



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3.3 CRU (customer replaceable unit)/FRU (field replaceable unit) Packaging

3.3.1 It is preferred that one package is developed to fit many different parts (ex. the same packaging fits HDD, LCD, PS, and fan trays). This is for both cost reduction and so one part number can be used for multiple parts to save storage space.

3.3.2 Packaging volume, weight, and material use should be the minimum amount to maintain necessary levels of safety for the packed product.

3.3.3 CRU/FRU packaging should be large enough for a small FedEx shipping label (~4”x6”).

3.3.4 CRU/FRU packaging should be large enough for all part related documentation.

3.3.5 CRU/FRU packaging should be large enough for all related accessories (ex. Power cords, hardware, and/or interconnect cables). The internal accessory packaging is not required to fit all parts into one package. Multiple (ideally identical) boxes may be used.

3.3.6 The CRU/FRU should be secured in the package as to permit little to no movement to prevent cosmetic damage of the surface finish.



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4 Packaging Requirements

4.1 All Packages Must:

4.1.1 All packaging designed and tested for F5 Networks must have all test documentation reviewed and approved by the responsible Mechanical Engineer before it can be released.

4.1.2 All packaging designed for F5 Networks must abide by all Compliance labeling listed in PRO-0186-XX; PRODUCT AND PACKAGING LABEL GUIDE. Where possible these should be part of the shipper or accessory pack artwork.

4.1.3 All packages designed for F5 Networks must be RoHS compliant. The supplier must submit a Certificate of Compliance (CoC) without exemption. The CoC may be a blanket certificate rather than piece by piece.

4.1.4 All packaging for F5 Networks must be recyclable. Some materials will require labeling of their recyclability. For example, plastics have a set of standard recyclability labels that give their information specifically for recycling. LDPE foam is shown below. Labels must maintain adhesion under normal shipping and handling. Digital printed symbols are preferred over labels if the supplier has the capability.

4.1.5 All packaging must be able to ship a system without requiring accessory packaging for support structure. Warranty equipment often ships alone.

4.1.6 All packages designed to be shipped as outer packages must have the printed graphics as specified in PRO-0197-0X, Guidelines, Packaging Boxes on the outer corrugated.

4.1.7 All corrugated parts must have the part number (‘PKG’, not ‘PKA’ assembly part number) printed on the bottom-outside. The font, color, size will be provided.

4.1.8 All packaging must have a convenient location to place documentation kits for the customer.

4.1.9 All packaging designed for F5 Networks must pass the minimum testing procedures listed in sections 6 through 10 of this document.

4.1.10 Handles should be designed to adequately handle full package weight. This should include fiber reinforced tear tape in all handles for heavier packages (>1U).

4.1.11 All accessory packaging may contain the printed contents description. The customer should be able to read the contents when the main shipping container is opened.



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4.2 Variant Products and ECOs:

4.2.1 For variant products (FIPS, SSL, configuration modules, extra PSU, DC), packaging testing may not always be required. The mechanical engineering team and the packaging design/test team will meet and perform a risk assessment and will plan accordingly (and define in the Packaging Requirements doc)

4.2.2 Any major ECO will also be evaluated as to whether packaging testing will be required (switching to SSD’s, changing a mechanical feature) – Will be discussed, similar to 4.2.1



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5 Quoting Requirements

5.1 Non-recurring engineering costs should be quoted (or an accurate estimate provided) upon receiving product from F5.

5.2 Pricing Quotes should be delivered with all packaging designs submitted to F5 for final approval. The quotes should be for quantities of 50 (prototype), 100, 250 and 500 or higher if estimated annual volumes warrant. This is preferred so the F5 Networks Purchasing can account for long term costs of all packaging. All quoting exercises to be managed through F5 supply chain and then reviewed with MFG/Mechanical Engineering for any possible concerns.

5.3 Quotes for all tooling should be delivered with all packaging designs submitted for F5 final approval. Approximate turnaround time for tooling should also be provided at the same time.

5.4 Approximate lead times for initial and long-term delivery of packaging should be delivered with all packaging designs submitted for F5 for approval. All possible shipping difficulties should be disclosed at this time as well.



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6 Tests for Non-NEBs Non-Palletized Packaging Systems Including FRUS

The following tests shall be performed on all non-NEBS packaging to qualify for production release. Tests not completed / passed should be reported to the F5 Networks Packaging Team. The test procedures are based on NEBS and ISTA 2A, requirements. Tests should be performed on multiple samples when possible (N=3 to 5) and should be completed sequentially on each sample as listed below. NEBS products will be tested per NEBS GR-63-CORE specification. If the packaging that passed ISTA 2A testing fails NEBS testing, a decision will be made to modify the packaging to pass NEBS or design separate NEBS packaging. Cost will be the primary driver for this decision.

6.1 Environmental Conditioning (Profile per ISTA 2A)

• Atmospheric Preconditioning: Packaged product should be stored prior to climate conditioning at laboratory ambient temperature and humidity for a minimum of 6 hours.

• Extreme cold uncontrolled RH: 72 hours, -29C (-20F), uncontrolled RH.

• Hot, Humid: 72 hours, 38C (100F), 85% RH (+/-5%).

• Extreme Heat, Moderate RH: 6 hours, 60C (140F) 30% RH (+/-5%).

The equipment should be tested for functionality before and after each test when possible. The operational state of the equipment shall simulate the configuration for actual service conditions. The most stable/current version of functional test should be used. All environmental tests shall be conducted in a thermal chamber capable of producing the temperature and humidity conditions given in the test procedure. Unless otherwise specified, the temperature shall be maintained within +/-3°C. Packages must be loaded in the environmental chamber flat on side 5 (bottom). They must not be stacked. Placing them on bread racks is acceptable as long as they do not overhang.

Temperature and humidity sensors shall be calibrated for the ranges of temperature and humidity expected during the test and shall be capable of measuring with enough accuracy to ensure the tolerances in the procedure are satisfied. Unless otherwise specified, ambient temperature is defined as a temperature between 20C (68F) and 30C (86F) and the ambient relative humidity is within 5% - 85%.

Pass condition:

- Equipment or packaging shall not sustain any physical damage or deteriorate in functional performance

6.2 Transportational Vibration (based on NEBS GR-63-CORE)

- Package the equipment as intended for shipment to a customer - Setup per table 6.2.1 for 30 minutes per axis. - Test the DUT for function - Proceed to the next test step

Pass condition:



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- Equipment shall not sustain any physical damage or deteriorate in functional performance - Minor cosmetic damage, such as scratches, dings, and nicks, do not constitute

nonconformance - Shipping container damage is considered cosmetic provided it does not transmit damage to

the equipment packaged inside - Visible shipping container damage and/or loose component sounds, inspect EUT immediately

Frequency Range (Hz) Test Severity - PSD Level

5-20 0.01g2/Hz

20-200 -3dB/octave

Table 6.2.1: Transportation Random Vibration Stimulation

6.3 Packaged Drop Testing

- Attach the accelerometer at the same location where the F5 responsible engineer used for fragility testing. If that location cannot be determined, select a solid surface where the system structure is rigid to reduce noise in the acceleration data. Generally near screws or edges are best. If there are questions about the best location, please refer them to the responsible F5 engineer.

- Package the equipment as intended for shipment to a customer - Ensure unit has completed prior tests (unconditioned packaging that is drop tested should be

noted preliminary or prototype in the results) - For conditioning drop procedure, “condition” the manufacturer’s edge by drop sequence is

C1, E1, E2, and E3 following heights listed in table 6.3.3. Allow 1 minute between drops



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- Gathering accelerometer data, drop the package per sequence S1, S2, S3, S4, S5, and S6 Allow 1 minute between drops

Figure 6.3.1: Package Edge, Surface and Corner Marking

- Test the DUT for function - Proceed to the next test step

Pass condition:

- The goal is 50-60Gs on all surface drops after filtering per table 6.3.4. Pulses higher than 60Gs must be compared with unpackaged drop data performed by the responsible design engineer fragility test data (supplied as part of the packaging handoff document) to determine if it was caused by the accelerometer placement or if packaging modifications are needed. Small packages such as FRUs and some designs will tend to yield high Gs in some axes. In these cases, if the graphs show short durations, the pulses are considered noisy and are not damaging.

- Inspect packaging / unit for items per table 6.4 - Visible shipping container damage and / or loose component sounds, inspect DUT immediately - Package contents to be secure and undamaged

- If the packaging is damaged per 6.4 criteria, it may be replaced to finish the testing but the replacement must be noted in the report.

-

Drop Height Requirements

Mass of Product

kilograms [lbs]

Drop Height Required

Mm [in]

0-9 (0-20) 970 (38)

E3 C1 (on Manufacturers Edge)

S 1

S3

E2

E1

S 5 (Bottom)

S 2(Side)

S 6

S 4 (Back)



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10-18 (21-40) 810 (32)

19-27 (41-60) 660 (26)

28-44 (61-99) 510 (20)

45-67 (100-149) 310 (12)

Table 6.3.3: Packaged Drop test vs. weight

Table 6.3.4: Filtering frequency table



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6.4 Packaging Pass/Fail Criteria

SHIPPING DAMAGE UNACCEPTABLE ACCEPTABLE

UNIT TYPE

LOCATION PACKAGE DAMAGE EXAMPLE PACKAGE DAMAGE

EXAMPLE

Type 1

(Small boxed

Product) Two

person lift or less

Container

(External)

- Any rupture to the extent that it can no

longer contain or support the product.

- Compression damage from a

palletized load that creates unstable

pallet loads.

- Failure of closure such that one or

more flaps are free to open or cannot

support the weight of the product.

- Serious cosmetic or aesthetic

deterioration.

- Carton carrying device failure that creates a safety

hazard.

- Glue joint breaks open and exposes internal contents.

- Crushed cartons leading to an

unstable pallet load which creates

a safety issue during storage or

handling.

- Tape, snap-lock, or fastener failure

compromising containment.

- Delamination, discoloration, or illegible product

graphics.

- Hand hole or handle failure.

- Localized ruptures of edges

from impacted corners.

- Compression damage from a palletized load,

but the pallet load remains stable.

- Localized failures in closure in area of impact

(carton is still effectively closed.).

- Dents, dirt, small punctures from

handling impacts.

- Carton carrying device which

tears or cracks, but maintains

structural integrity.

- Edges or corners have small localized

cracks/ruptures.

- Minor compression which is supported by internal package or product support, or

corner pads and stretch wrap.

- The tape splits across bottom edge.

- Dented corners, dirty flat panels, small

partial carton punctures.

- Handle corner tearing.

Cushioning

(Internal)

- Failure of bonded joints or surfaces which results in

internal packaging to lose original

configuration.

- Fractured or deformed material which no longer

maintains product position.

- Product contamination or

abrasion from cushioning resulting

- Laminated material

separation.

- Cushioning deteriorated to a

point that the product is no

longer held in its intended position

or it cannot continue its

protective function.

- Top case texture worn and

contaminated with foam powder.

- Fracture or permanent

deformation that still permits

internal packaging to maintain

product position.

- Product contamination

from cushioning not resulting in

cosmetic or functional defects.

- Cracked and crushed ribbing.

- Loose foam beads or pulp fiber on the

product.



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in cosmetic or functional defects.



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7 Tests for NEBs Non-palletized Packaging Systems Including FRUs

The following tests shall be performed on all NEBS products to qualify for production release. Tests not completed / passed should be reported to the F5 Networks Packaging Team. The test procedures are based on NEBS GR-63-CORE requirements. Tests should be performed on multiple samples when possible (N=3 to 5) and should be completed sequentially on each sample as listed below. If the packaging that passed ISTA 2A testing fails NEBS testing, a decision will be made to modify the packaging to pass NEBS or design separate NEBS packaging. Cost will be the primary driver for this decision.

• Storage High, Low Temperature and Humidity Test (profile per NEBS GR-63-CORE).

• Transportational Vibration Testing (profile per NEBS GR-63-CORE).

• Packaged Drop Test (drop height related to NEBS GR-63-CORE). The equipment should be tested for functionality before and after each test when possible. The operational state of the equipment shall simulate the configuration for actual service conditions. The most current version of the EUD test should be used for verification of the operational state of each sample. All environmental tests shall be conducted in a thermal chamber capable of producing the temperature and humidity conditions given in the test procedure. Unless otherwise specified, the temperature shall be maintained within+/-3°C. Packages must be loaded in the environmental chamber flat on side 5 (bottom). They must not be stacked. Placing them on bread racks is acceptable as long as they do not overhang.


7.1 Storage High, Low Temperature and Humidity Test (profile per NEBS GR-63-Core)

This is a non-operational test, but when possible, prior to and immediately following the storage conditioning each tested unit should be checked for proper operation. - Test the DUT for function - Package the equipment as intended for shipment to a customer - Place it into the temperature/humidity chamber - Subject to the profiles below. These are to be done sequentially. - The unit may need a short low humidity/warm soak to dry the system out before the

functionality test is performed to ensure the assembly is dry. - Test the DUT for function. - Proceed to the next test step.

Pass condition:

- Equipment shall pass functional test not sustain any physical damage.



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-

Figure 7.1.1: Low Temperature Exposure and Shock

-

Figure 7.1.2: High Temperature Exposure and Thermal Shock

-50

-40

-30

-20

-10

0

10

20

30

0 10 20 30 40 50 60 70 80

Te

mp

era

ture

Deg

ree

s C

Time - Hours

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80

Te

mp

era

ture

De

gre

es

C

Time - Hours

70

-40°C, any RH, 72 hours

70°C, Any RH, 72 hours



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Figure 7.1.3: High Relative Humidity – ETSI/NEBS Humidity Slow Temp Change


- Package the equipment as intended for shipment to a customer - Setup per table 7.2.1 for 30 minutes per axis. - Test the DUT for function - Proceed to the next test step Pass condition:


nonconformance


5-20 0.01g2/Hz

20-200 -3dB/octave


0

5

10

15

20

25

30

35

40

45

0 10 20 30 40 50 60 70 80 90 100

Te

mp

era

ture

Deg

ree

s C

Time - Hours

40°C, 90%-95% RH, 96 hours

Transition, 30°C/Hr



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- Package the equipment as intended for shipment to a customer - Ensure unit has completed prior tests - The packaging is dropped on each of the following using the drop heights listed in table 7.3.2

• Surface S1, S2, S3, S4, S5, S6 (every surface).

• Edge E2-3, E2-5, E5-3

• Corner C1-2-6, C1-4-5, C2-3-5, C3-4-5 - Allow 1 minute between drops

C1-4-5 C1-2-6

Figure 7.3.1: Package Edge, Surface and Corner Marking

- Test the DUT for function - Proceed to the next test step

E5-3 C2-3-5 (on Manufacturers Edge)

S 2

S5

E2-5 S 3 (Bottom)

S 4(Side)

S 1

S 6 (Back)

E2-3

C3-4-5



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Pass condition:

- Inspect unit for damage - Check for loose component sounds and inspect EUD immediately - Package contents to be secure and undamaged - If the packaging is damaged, it may be replaced to finish the testing.


Mass of Product

kilograms [lbs]


Mm [in]

< 15 (<31.1) 1000 (39.4)

<20 (<44.1) 800 (31.5)

<30 (66.2) 600 (23.6)

<40 (<88.2) 500 (19.7)

<50 (<110.3) 400 (15.7)




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8 Tests for Non-NEBS Palletized Packaging Systems

The following tests shall be performed on all palletized packaging to qualify for production release. Tests not completed / passed must be reported to the responsible F5 Networks employee. The test procedures are performed based on NEBS, ISTA 2A, ISTA 1E and ISTA 1G (packaged products 150 lbs. or less), requirements. Tests should be performed on multiple samples when possible (N=3 to 5) and should be completed sequentially on each sample as listed below.

8.1 Environmental Conditioning (Profile per ISTA 2A)




• Extreme Heat, Moderate RH: 6 hours, 60C (140F) 30% RH (+/-5%).

The equipment should be tested for functionality before and after each test when possible. The operational state of the equipment shall simulate the configuration for actual service conditions. The most current version of the EUD test should be used for verification of the operational state of each sample. All environmental tests shall be conducted in a thermal chamber capable of producing the temperature and humidity conditions given in the test procedure. Unless otherwise specified, the

temperature shall be maintained within 3°C. Packages must be loaded in the environmental chamber flat on side 3 (bottom). They must not be stacked. Placing them on bread racks is acceptable if they do not overhang.

Temperature and humidity sensors shall be calibrated for the ranges of temperature and humidity expected during the test and shall be capable of measuring with enough accuracy to ensure the tolerances in the procedure are satisfied.

Unless otherwise specified, ambient temperature is defined as a temperature between 20C

(68F) and 30C (86F) and the ambient relative humidity is within 5% - 85%.

Pass condition:

- Equipment or packaging shall not sustain any physical damage or deteriorate in functional performance


- Package the equipment as intended for shipment to a customer - Setup per table 8.2.1 for 30 minutes per axis. - Test the DUT for function - Proceed to the next test step



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Pass condition:


nonconformance - Shipping container damage is considered cosmetic provided it does not transmit damage to

the equipment packaged inside - Visible shipping container damage and / or loose component sounds, inspect EUD immediately


5-20 0.01g2/Hz

20-200 -3dB/octave



- Attach the accelerometer at the same location where the F5 responsible engineer used for fragility testing, if known. If that location cannot be determined, select a solid surface where the system structure is rigid to reduce noise in the acceleration data. Generally near screws or edges are best. If there are questions about the best location, please refer them to the responsible F5 engineer.

- Package the equipment as intended for shipment to a customer

- Ensure unit has completed prior tests (unconditioned packaging that is drop tested should be noted preliminary or prototype in the results)



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- Gathering accelerometer data drop the package on S3 (bottom) following height listed in table 8.3.2 one time.

Figure 8.3.1: Package Surface Marking

- Test the DUT for function - Proceed to the next test step Pass condition:

- The goal is 50-60Gs after filtering per table 8.3.3. Pulses higher than 60Gs must be compared with unpackaged drop data performed by the responsible design engineer fragility test data (supplied as part of the packaging handoff document) to determine if it was caused by the accelerometer placement or if packaging modifications are needed. Small packages such as FRUs and some designs will tend to yield high Gs in some axes. In these cases, if the graphs show short durations, the pulses are considered noisy and are not damaging.

- Inspect packaging / unit for items per table 8.6 - Visible shipping container damage and / or loose component sounds, inspect EUD immediately - Package contents to be secure and undamaged

- If the packaging is damaged per 8.6 criteria, it may be replaced to finish the testing, but the replacement must be noted in the report.


Mass of Product

kilograms [lbs]


Mm [in]

28-44 (61-99) 310 (12)

45-67 (100-149) 200 (8)


S 3 (Bottom)



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Table 8.3.3: Filtering frequency table

8.4 Packaging Incline Test Procedure

- Package the equipment as intended for shipment to a customer - Perform the incline test by sliding the assembly on its base into a non-flexing and flat

structure at a rate of >69 in/second. The test should be done on the smallest sides first ending in the largest sides. All four sides should be tested. (based on ISTA 1E 2005)

- Test the DUT for function - Proceed to the next test step Pass condition:

- Inspect packaging / unit for items per table 8.6 - Visible shipping container damage and / or loose component sounds, inspect EUD immediately - Package contents to be secure and undamaged - If the packaging is damaged per 8.6 criteria, it may be replaced to finish the testing, but the

replacement must be noted in the report.



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8.5 Packaging Tip Over Test

- Package the equipment as intended for shipment to a customer - Tip the palletized assembly slowly until it begins to tip on its own and let it come to a rest

without interruption. - Slowly tip the assembly back until it returns to a resting position on the bottom of the pallet. - Repeat tip over test on all sides. - Test the DUT for function - Proceed to the next test step

Pass condition:

- Inspect packaging / unit for items per table 8.6 - Visible shipping container damage and / or loose component sounds, inspect DUT immediately - Package contents to be secure and undamaged - If the packaging is damaged per 8.6 criteria, it may be replaced to finish the testing, but the

replacement must be noted in the report.



UNIT

TYPE

LOCATION PACKAGE

DAMAGE

EXAMPLE PACKAGE

DAMAGE

EXAMPLE

Type 2

(Large

Single

Product

Palletized)

Larger than

two person

lift-

palletized

External - Non-functional

pallet.

- Ruptured wraps,

bands, clips, or

strapping.

- Fractured bolts,

fastening systems, or

other hardware used

in pallet construction

which are beyond

their usable function

or create a human

hazard.

- Protruding

nails or bolts, or

sharp wood

sections.

- Splits, cracks or

breaks in wood

members that do

not degrade its

function.

- Loose stretch

wrap, banding, or

fasteners.

- Cracked stringers or

blocks.

Cushioning

(Internal)

- Failure of bonded

joints or surfaces

which results in

internal packaging to

lose original

configuration.

- Fractured or

deformed material

- Laminated

material

separation.

- Cushioning

deteriorated to a

point that the

product is no

longer held in

- Fracture or

permanent

deformation that

still permits

internal

packaging to

maintain product

position.

- Cracked and crushed

ribbing.

- Loose foam beads or

pulp fiber on the

product.



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which no longer

maintains product

position.

- Product

contamination or

abrasion from

cushioning resulting

in cosmetic or

functional defects.

its intended

position or it

cannot continue

its protective

function.

- Top case

texture worn

and

contaminated

with foam

powder.

- Product

contamination

from cushioning

not resulting in

cosmetic or

functional

defects.



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9 Tests for NEBS Palletized Packaging Systems

The following tests shall be performed on all palletized NEBS products to qualify for production release. Tests not completed / passed should be reported to the responsible F5 Networks employee. The test procedures are based on NEBS GR-63-CORE requirements. Tests should be performed on multiple samples when possible (N=3 to 5) and should be completed sequentially on each sample as listed below. If the packaging that passed ISTA 2A testing fails NEBS testing, a decision will be made to modify the packaging to pass NEBS or design separate NEBS packaging. Cost will be the primary driver for this decision.

• Storage High, Low Temperature and Humidity Test (profile per NEBS GR-63-CORE).

• Transportational Vibration Testing (profile per NEBS GR-63-CORE).

• Packaged Drop Test (drop height related to NEBS GR-63-CORE). The equipment should be tested for functionality before and after each test when possible. The operational state of the equipment shall simulate the configuration for actual service conditions. The most current version of the EUD test should be used for verification of the operational state of each sample. All environmental tests shall be conducted in a thermal chamber capable of producing the temperature and humidity conditions given in the test procedure. Unless otherwise specified, the temperature shall be maintained within+/-3°C.


9.1 Storage High, Low Temperature and Humidity Test (profile per NEBS GR-63-Core)

This is a non-operational test, but when possible, prior to and immediately following the storage conditioning each tested unit should be checked for proper operation. - Test the DUT for function - Package the equipment as intended for shipment to a customer - Place it into the temperature/humidity chamber - Subject to the profiles below. These are to be done sequentially. - The unit may need a short low humidity/warm soak to dry the system out before the

functionality test is performed to ensure the assembly is dry. - Test the DUT for function. - Proceed to the next test step.

Pass condition:

- Equipment shall pass functional test not sustain any physical damage



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-

Figure 9.1.1: Low Temperature Exposure and Shock

-

Figure 9.1.2: High Temperature Exposure and Thermal Shock

-50

-40

-30

-20

-10

0

10

20

30

0 10 20 30 40 50 60 70 80

Te

mp

era

ture

Deg

ree

s C

Time - Hours

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80

Te

mp

era

ture

De

gre

es

C

Time - Hours

70

-40°C, any RH, 72 hours

70°C, Any RH, 72 hours



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Figure 9.1.3: High Relative Humidity – ETSI/NEBS Humidity Slow Temp Change


- Package the equipment as intended for shipment to a customer - Setup per table 9.2.1 for 30 minutes per axis. - Test the DUT for function - Proceed to the next test step Pass condition:


nonconformance


5-20 0.01g2/Hz

20-200 -3dB/octave


0

5

10

15

20

25

30

35

40

45

0 10 20 30 40 50 60 70 80 90 100

Te

mp

era

ture

Deg

ree

s C

Time - Hours

40°C, 90%-95% RH, 96 hours

Transition, 30°C/Hr



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- Package the equipment as intended for shipment to a customer - Ensure unit has completed prior tests - Place the palletized chassis on a smooth, level concrete (or similarly unyielding surface) test

area sufficiently large so the DUT is not precluded from toppling over. - Raise the DUT to the prescribed height of 100mm (3.9 in.). - The DUT is subjected to 2 drops to the normal rest surface.

Pass condition:

- Inspect sample for physical damage - Test the DUT for functionality



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10 Tests for Unitized Loads

The following tests shall be performed on unitized loads, made up as single or multiple products or packages of the same products. Tests not completed / passed must be reported to the responsible F5 Networks employee. The test procedures are performed based on ISTA 3E, requirements. F5 does not typically ship to customers in this configuration; this test procedure is geared to suppliers (ex: chassis enclosure manufacturers and contract manufacturers shipping in bulk.

10.1 Environmental Conditioning




• Extreme Heat, Moderate RH: 6 hours, 60C (140F) 30% RH (+/-5%). All environmental tests shall be conducted in a thermal chamber capable of producing the temperature and humidity conditions given in the test procedure. Unless otherwise specified, the

temperature shall be maintained within 3°C.

Temperature and humidity sensors shall be calibrated for the ranges of temperature and humidity expected during the test and shall be capable of measuring with enough accuracy to ensure the tolerances in the procedure are satisfied.

Unless otherwise specified, ambient temperature is defined as a temperature between 20C

(68F) and 30C (86F) and the ambient relative humidity is within 5% - 85%.

10.2 Unitized Load Incline Test Procedure

- Perform the incline test by centering the unitized load on a carriage with the pallet edge against the backstop and parallel to the leading edge of the carriage. If the packaged products overhang the pallet see ISTA 3E for special instructions.

- Test the unitized load at a rate of 42 in/second (1.1m/sec). The test should be done on the smallest sides first ending in the largest sides. All four sides should be tested. (based on ISTA 3E 2005)

- Proceed to the next test step

10.3 Unitized Load Rotational Edge Drop Test Procedure

- Perform the rotational edge drop by placing the unitized load onto a flat rigid surface such as steel or concrete.

- Support one of the shortest face 3 (bottom of pallet) edges with a timber or support 3.5 to 4.0 inches (90 to 100 mm) in height and width.

- Lift the opposite face 3 edge to 8 inches (200 mm) off the surface. - Release the edge so it falls freely onto the flat, rigid surface. - Repeat on one of the face 3 edges radiating 90 degrees from the edge just tested. - Proceed to the next step.



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10.4 Unitized Load Compression Test Procedure

- Calculate the test load using the formula: WT x F x 9.8 x 1.4 where: Wt = gross weight of the unitized load (lbs. or kg.) F = Compensating factor which is used for affects that may not be simulated in a warehouse environment. We will use 1.5. 9.8 = Metric conversion factor. 1.4 = factor to account for time of compression.

- Using a compression test system center the packaged product with face 3 (bottom of pallet) resting on the lower platen of the compression tester.

- Start the test machine and bring the platens together at a rate of .5 in. (13mm) per minute. - Increase the force until it reaches the test force determined from the calculated test load. - Release the force.

Pass condition:

- Inspect packaging / unit for items per table 10.5 - Visible shipping container damage and / or loose component sounds, inspect DUT immediately - Package contents to be secure and undamaged



UNIT TYPE LOCATION PACKAGE DAMAGE EXAMPLE PACKAGE

DAMAGE

EXAMPLE

Type 2

(Large Single

Product

Palletized)

Larger than

two person

lift-

palletized

External - Non-functional pallet.

- Ruptured wraps, bands,

clips, or strapping.

- Fractured bolts,

fastening systems, or

other hardware used in

pallet construction which

are beyond their usable

function or create a

human hazard.

- Protruding nails

or bolts, or sharp

wood sections.

- Splits, cracks or

breaks in wood

members that do

not degrade its

function.

- Loose stretch

wrap, banding, or

fasteners.

- Cracked stringers or

blocks.

Cushioning

(Internal)

- Failure of bonded joints

or surfaces which results

in internal packaging to

lose original

configuration.

- Fractured or deformed

material which no longer

maintains product

position.

- Laminated

material

separation.

- Cushioning

deteriorated to a

point that the

product is no

longer held in its

intended position

or it cannot

- Fracture or

permanent

deformation that

still permits

internal packaging

to maintain product

position.

- Product

contamination from

cushioning not

- Cracked and crushed

ribbing.

- Loose foam beads or

pulp fiber on the

product.



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- Product contamination

or abrasion from

cushioning resulting in

cosmetic or functional

defects.

continue its

protective

function.

- Top case texture

worn and

contaminated with

foam powder.

resulting in

cosmetic or

functional defects.

10.6 Random Vibration Test

- Place the packaged product on the vibration table so that face 3 (bottom of pallet) rests on the platform.

- The following breakpoints shall be programed into the vibration controller to produce the acceleration vs. frequency profile (spectrum) below with an overall Grms level of 0.54. The theoretical stroke required to run this vibration profile is 45.13 mm (1.777 inch peak to peak.

- 180 minute test duration.

10.7 Unitized Load Rotational Edge Drop Test Procedure

- Repeat rotational edge drop test sequence in section 10.3 - Testing is now complete. Inspect for pass/fail criteria per table 10.5.

Frequency,

Hz

PSD Level,

g2/Hz

1.0 0.00072

3.0 0.018

4.0 0.018

6.0 0.00072

12.0 0.00072

16.0 0.0036

25.0 0.0036

30.0 0.00072

40.0 0.0036

80.0 0.0036

100.0 0.00036

200.0 0.000018

Overall Grms: 0.54

Packaging Development Guide PRO-0149-00 - F5 Networks

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