CSS 06-2176C Jan 2023.pdf

CALIBRATION STANDARDS SPECIFICATION

PROCUREMENT PACKAGE

AUTOMATED

DEADWEIGHT PISTON GAUGE

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

CSS 06-2176C

CALIBRATION STANDARDS SPECIFICATION

PROCUREMENT PACKAGE

AUTOMATED

DEADWEIGHT PISTON GAUGE

Prepared by:

Physical/Mechanical Standards (MS 33)

Measurement Science Department

Naval Surface Warfare Center, Corona Division

P.O. Box 5000

Corona, CA 91718-5000

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

ADPG SPECIFICATION CSS 06-2176C

Table of Contents

1.0 SCOPE

1.1 General

1.2 Usage

1.3 Classification

1.3.1 Class

1.3.2 Enclosure

1.3.3 Color

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents

2.2 Order of precedence

3.0 REQUIREMENTS

3.1 Safety

3.2 Equipment components

3.2.1 Interchangeability

3.2.2 Restricted materials

3.2.2.1 Material restricted for Navy use

3.2.2.2 Other restricted materials and gases

3.2.2.2.1 Organic materials

3.2.2.2.2 Flammable materials

3.2.2.2.3 Explosive materials

3.2.2.2.4 Carcinogens

3.2.2.2.5 Helium

3.2.2.3 Combination of materials

3.3 Design and construction

3.3.1 Operator adjustments and controls

3.3.1.1 Operator adjustments

3.3.1.2 Operator controls

3.3.2 Connectors, electric

3.3.3 Wiring, internal

3.3.4 Internal cooling

3.3.4.1 Cooling devices

3.3.5 Front panel display indicators

3.3.6 Self-test capability

3.4 Digital interface

3.4.1 Digital interface requirements

3.5 Electrical power sources and connections

3.5.1 Electrical power source

3.5.1.1 Power consumption

3.5.1.2 Nominal and alternate power source

3.5.1.2.1 Interruption of power source

3.5.1.2.2 Battery restrictions

3.5.1.2.2.1 Lithium batteries

3.5.2 Electrical power connections

3.5.2.1 Input power cable

3.5.2.2 Input power switch

3.5.2.3 Excessive current drain protection

3.5.2.4 Indicators

3.6 Enclosure physical characteristics

3.6.1 Dimensions

3.6.2 Weight

3.6.3 Enclosure requirements

3.6.3.1 Accessory stowage

3.6.3.2 Corners

3.7 Marking and identification

3.7.1 Marking

3.7.1.1 Reference designations

3.7.1.2 Warning markings

3.7.1.3 Battery warning label

3.7.1.4 Panel markings and processes

3.7.2 Equipment identification

3.7.2.1 Identification plate

3.7.2.1.1 Identification plate

3.7.2.1.2 Identification plate, supplemental

3.7.2.1.3 Identification plate, material

3.7.2.1.4 Identification plate, marking

3.7.2.2 Reusable pouch or container

3.7.2.3 Item unique identification (IUID)

3.8 Environmental requirements

3.8.1 Warm-up

3.8.2 Temperature and humidity

3.8.2.1 Temperature not operating

3.8.2.2 Temperature operating

3.8.2.3 Humidity operating

3.8.3 Altitude

3.8.4 Fungus resistance

3.8.5 Acoustic noise

3.9 Performance requirements

3.9.1 Pneumatic range and uncertainty

3.9.2 Hydraulic range and uncertainty

3.9.4 Resolution

3.9.5 Contamination prevention

3.9.6 TI pressure media

3.9.7 Units of measure

3.9.8 Operating components and characteristics

3.9.8.1 Base

3.9.8.1.1 Automated piston rotation

3.9.8.3.3 Pressure control valves

3.9.8.3.4 Over-pressure protection

3.9.8.3.5 Pressure indicator

3.9.8.4 Environmental sensors

3.9.8.5 Vacuum sensor (removable)

3.9.8.6 Vacuum pumps

3.9.8.7 Mass Set(s)

3.9.8.8 Automated mass handler(s)

3.9.8.9 Plumbing

3.9.8.9.1 Pneumatic plumbing

3.9.8.9.2 Hydraulic plumbing

3.9.8.9.3 Labeling

3.9.8.9.4 Output pressure ports (pneumatic

3.9.8.9.5 Output pressure port (hydraulic)

3.9.8.9.6 Accessories

3.9.8.9.7 Accessory case

3.9.8.9.8 Pressure hoses ................................................ Error! Bookmark not defined.

3.9.8.9.9 Pneumatic pressure fitting adapters (range 2 to 1,000 psi)

3.9.8.9.10 Pneumatic pressure fitting adapters (1,000 to 15,000 psi)

3.9.8.9.11 Hydraulic pressure fitting adapters

3.10 Maintainability

3.10.1 Fault isolation

3.10.2 Preventive maintenance

3.10.3 Maintenance provisions

3.10.4 Repair

3.11 Calibration

3.11.1 Calibration certificate

3.11.2 Calibration interval

3.11.3 Calibration procedure

3.12 Reliability

3.12.1 Warranty label

3.13 Technical manuals

4.0 VERIFICATION

4.1 Equipment sample requirements

4.2 First Article

4.2.1 First Article inspection and tests, Group A

4.2.1.1 First Article preoperational inspection

4.2.1.2 First Article Level A performance tests

4.2.1.3 First Article Level B performance tests

4.2.2 First Article tests, Group C

4.2.3 First Article tests, Group D

4.2.4 First Article tests, Group E

4.2.5 First Article tests, Group F

4.2.6 Letter of Compliance

4.3 Examinations and test methods

4.3.1 Failure criteria

4.3.2 Test sequence

4.3.3 Test conditions

4.3.3.1 Measurements of test conditions

4.3.3.1.1 Accuracy of test instruments

4.3.3.1.2 Tolerance of test conditions

4.3.4 Test plan

4.3.5 Test equipment

4.3.6 Performance of test

4.3.7 Test item installation

4.3.7.1 Government Facility Verification Testing

ADPG CALIBRATION STANDARD SPECIFICATION CSS 06-2176C

1.0 SCOPE

1.1 General. This document specifies the minimum requirements for an Automated Deadweight Piston Gauge pressure calibration system. This equipment is intended for use by Navy personnel in shore-based laboratories.

The equipment will be used to calibrate precision analog and digital pressure measuring and calibration equipment that utilize both pneumatic and hydraulic pressure media. For the purpose of this calibration standards specification (CSS), the Automated Deadweight Piston Gauge shall be referred to as the

ADPG.

1.2 Usage. Equipment covered by this CSS is intended for testing equipment and systems in controlled environments in Navy shore-based laboratories. The requirements of this CSS are tailored for the intended use of the equipment.

Specific requirements of MIL-PRF-28800G, identified and or modified in this CSS, are invoked according to the class of equipment.

1.3 Classification. Test equipment specified herein is categorized by class, (requirements arising from the intended operational environment), as specified below in 1.3.1 Class through 1.3.3 Color. The class is assigned by the most severe environmental condition expected for the equipment

1.3.1 Class. The ADPG shall conform to Class 4 requirements in accordance with MIL-PRF-28800G for Navy shore-based laboratory use as specified in this

CSS.

1.3.2 Enclosure. For the purpose of this CSS, the enclosure refers to the rack/bench required as a foundation and work space for the ADPG and drawer space required for the storage of all accessories delivered with the

ADPG.

1.3.3 Color. The color of the equipment and transit cases shall be the color normally provided by the manufacturer.

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issues of these documents shall be those in effect on the date of this solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-28800G - Test Equipment for use with Electrical and Electronic Equipment, General Specification for

MIL-PRF-38793 Manuals, Technical: Calibration Procedures Preparation of.

(Copies of DoD specifications are available online at http://quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 - Standard Practice of Identification Marking of U.S. Military Property

MIL-H-19457 Phosphate Ester Base Hydraulic Fluid

MIL-PRF-23699 Steam Turbine and Gear Lube Oil

MIL-F-16884 Distillate Fuel

MIL-DTL-5624 JP-4/JP-5/JP-8 Fuel

MIL-PRF-17331 Steam Turbine Lube Oil, 2190

MIL-PRF-17672 Hydraulic Fluid, 2075, 2110, 2135

MIL-PRF-8188 Aircraft Turbine Engine Oil, Synthetic Base

MIL-PRF-83282 Hydraulic Fluid, Synthetic Hydrocarbon Base

MIL-H-81019 Hydraulic Fluid, Petroleum Base

MIL-H-46170 Hydraulic Fluid, Synthetic Hydrocarbon Base

A-A-59290 Arresting Gear Fluid, Ethylene Glycol / water mix

(Copies of DoD Standards are available online at http://quicksearch.dla.mil/or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

NIST Special Publication 811 - Guide for the Use of the International System of Units (SI)

(Copies of NIST documents are available online at http://physics.nist.gov/cuu/pdf/sp811.pdf or Standards Information Center, 100 Bureau Drive, Stop 2100 Gaithersburg, MD 20899-2100 or Email: ncsci@nist.gov Phone: (301) 975-4040.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI-Y32.2 - Graphic Symbols For Electrical and Electronic Diagrams

ANSI-Y32.16 - Standard Reference Designations for Electrical and Electronics Parts and Equipment

(Copies of ANSI documents are available from http://webstore.ansi.org/ or ANSI Attn:

Customer Service Department, 25 W 43rd Street, 4th Floor, New York, NY, 10036

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.20.1 - Pipe Threads, General Purpose, Inch

(Copies of ASME documents are available from www.asme.org or ASME Information Central Orders/Inquiries, P.O. Box 2300, Fairfield, NJ 07007-2300.)

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 260.1 - IEEE Standard Letter Symbols for Units of Measurement (SI Units, Customary Inch- Pound Units, and Certain Other Units)

(Copies of IEEE documents are available from http://www.ieee.org or IEEE Service Center, 445 Hoes Lane, Piscataway, NJ 08854-1331.)

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60488-2 - Standard Digital Interface for Programmable Instrumentation

IEC 61010-1 - Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use (General Requirements)

(Copies of IEC documents are available online at http://www.iec.ch/ or EC publications are available in the US from the Sales Department. American National Standards Institute, 11 West 42nd Street,113 Floor, New York, NY 10036, USA.)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 7779 - Measurement of Airborne Noise Emitted by Information Technology and Telecommunications Equipment

(Copies of ISO documents are available online at http://www.iso.org/iso/home.html or International Organization for Standardization (ISO) 1, ch. de la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland) http://webstore.ansi.org/ http://www.iec.ch/ http://www.iso.org/iso/home.html

JOINT COMMITTEE FOR GUIDES IN METROLOGY (JCGM)

JCGM 100:2008 - Evaluation of Measurement Data – Guide for the Expression of Uncertainty in Measurement

(Copies of JCGM documents are available online at http://www.bipm.org/en/home/ or Bureau International des Poids et Mesures, Pavillon de Breteuil, F-92312 Sèvres Cedex, France)

STANDARD COMMANDS FOR PROGRAMMABLE INSTRUMENTS (SCPI)

CONSORTIUM

SCPI Volume I -1999 - Standard Commands for Programmable Instruments (SCPI)

(Copies of SCPI documents are available online at http://www.ivifoundation.org or IVI Foundation Corporate Office, PO Box 1016, Niwot, CO 80544-1016.)

TELECOMMUNICATIONS INDUSTRY ALLIANCE

TIA 232-F – 1997 - Interface Between Data Terminal Equipment and Data Circuit Termination Equipment Employing Serial Binary Data Interchange

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE AS4841 - Fittings, 37 Degree Flared, Fluid Connection

(Copies of SAE documents are available at http://www.sae.org/technical/standards/AS484 1 or SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096- 0001.)

WORLD WIDE WEB (W3C) CONSORTIUM

SVG Specification 1.1 - 2003 - Scalar Vector Graphics (SVG) 1.1 Specification

(Copies of W3C documents are available online at http://www.w3.org)

2.2 Order of precedence. In the event of conflict between the text of this CSS and the references cited herein, the text of this specification shall take precedence. Nothing in this CSS, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

http://www.ivifoundation.org/ http://www.sae.org/technical/standards/AS4841 http://www.sae.org/technical/standards/AS4841 http://www.w3.org/

3.1 Safety. The equipment shall comply with the safety requirements of IEC 61010-1. For safety ground all accessible surfaces of the equipment shall be at ground potential. Power cables shall include a safety ground conductor.

This is also true of drawer assemblies; disconnecting the safety ground shall also disconnect the power conductors.

3.2 Equipment components. Parts, materials, and process shall be as specified below in 3.2.1 Interchangeability through 3.2.2.3 Combination of materials and shall permit the equipment to comply with the requirements of this CSS.

3.2.1 Interchangeability. A model number shall be designated for all units provided.

All units and the replaceable assemblies, subassemblies, and parts comprising the unit shall be interchangeable on a noninterference basis.

3.2.2 Restricted materials. Restricted materials shall be as specified below in

3.2.2.1 Material restricted for Navy use through 3.2.2.3 Combination of materials.

3.2.2.1 Material restricted for Navy use. The materials and parts specified in a through c shall not be used in equipment for the Navy unless otherwise specified. An exception is made for small lithium batteries used for memory backup as specified below in 3.5.1.2.2.1 Lithium batteries for lithium battery types approved for use.

a. Mercury, including mercury batteries

b. Radioactive material

c. Lithium electrochemical cells .

3.2.2.2 Other restricted materials and gases. Test equipment shall not contain materials that promote the premature failure of the equipment or that present a health hazard under normal use or storage conditions as specified below in

3.2.2.2.1 Organic materials through 3.2.2.2.5 Helium.

3.2.2.2.1 Organic materials. Test equipment shall not contain materials prone to organic decay or that act as a nutrient for the growth of multicelled organisms.

3.2.2.2.2 Flammable materials. Test equipment component/s shall not contain materials that ignite into flames at operating or storage temperatures.

3.2.2.2.3 Explosive materials. Test equipment shall not contain materials that explode at operating or storage temperatures.

3.2.2.2.4 Carcinogens. Certain chemicals have been identified in the Occupational Safety and Health Act (OSHA) as cancer-producing substances (carcinogens). Before using any materials that might contain these chemicals, the materials shall be evaluated in accordance with 3.1 Safety.

3.2.2.2.5 Helium. Helium shall not be used as pressurizing gas in sealed units containing electron tubes. When necessary to use helium for leak detection purposes, exposure shall be limited to the time necessary for the test, followed by thorough purging.

3.2.2.3 Combination of materials. The equipment shall contain no combination of materials that cause deterioration of any material contained in the equipment due to the effects of outgassing.

3.3 Design and construction. The test equipment shall be designed and constructed to permit compliance with all applicable requirements of its class as defined in this CSS, as well as the performance, measurement uncertainty, and other requirements in this CSS.

3.3.1 Operator adjustments and controls. Operator adjustments and controls shall be as specified below in 3.3.1.1 Operator adjustments and 3.3.1.2 Operator controls.

3.3.1.1 Operator adjustments. The equipment shall include built-in adjustments or compensating devices for any function or parameter that would exceed the specified tolerance within the calibration interval defined in 3.11.2 Calibration interval. Under all specified service conditions the variation of any adjustment or control shall produce the desired control action to bring the equipment within tolerance.

3.3.1.2 Operator controls. Operating controls and indicators shall be readily accessible to the operator. The readings presented on the controls and indicators shall be available to the operator without the need for operator conversion or calculation.

3.3.2 Connectors, electric. Provision shall be made to ensure that connectors will be mated only with the appropriate counterparts. Where design considerations require close proximity of connectors of similar configuration, the mating connectors shall be suitably coded or marked. The live or hot side of unmated connectors shall be protected against shorting.

3.3.3 Wiring, internal. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance and calibration.

3.3.4 Internal cooling. The equipment shall be capable of operating without interruption for at least 24 hours at the maximum operating temperature as specified in this CSS without overheating, losing power or otherwise exhibiting failure.

3.3.4.1 Cooling devices. Cooling devices used in the equipment shall be an integral part of the equipment and not degrade any aspect of performance or safety.

3.3.5 Front panel display indicators. Front panel/control panel display indicators designed to present change-of-state information to the operator shall be distinguishable at a distance of 1 meter. All display indicators shall be discernible at viewing angles from 0 degrees to 45 degrees in all directions.

3.3.6 Self-test capability. The ADPG shall perform an automatic diagnostic self-test at startup. The self-test shall determine operational readiness and isolate faulty component(s). The information provided by the self-test shall indicate operational readiness. If failure occurs, the associated lowest replaceable unit (LRU) causing the malfunction shall be identified.

3.4 Digital interface. A digital interface shall be provided and shall meet the requirements as specified below in 3.4.1 Digital interface requirements. The digital interface shall include an IEEE 488.2 General Purpose Interface Bus conforming to IEC 60488-2:2004 and an RS-232 serial port conforming to TIA- 232-F.

3.4.1 Digital interface requirements. The digital interface shall have the programmable capability to control the various ADPG functions including all ranges, modes, and levels. The hardware protocol and programming command sets shall be documented and provided via electronic media.

Primary power control and other non-measurement functions need not be controllable through the digital interface. The digital interface shall also support printing of test results.

3.5 Electrical power sources and connections. The electrical power sources and connections shall be as specified below in 3.5.1 Electrical power source and

3.5.2 Electrical power connections.

3.5.1 Electrical power source. The equipment requiring electrical power shall operate from the input power conditions specified in 3.5.1.1 Power consumption through 3.5.1.2.1 Interruption of power source.

3.5.1.1 Power consumption. The maximum power for operation of an ADPG system component that requires an external single phase 120 Vrms power source shall not exceed 1500 watts.

3.5.1.2 Nominal and alternate power source. The equipment shall operate at the nominal values for voltage and frequency as specified in a and b below. An alternate power source is not required.

a. The nominal voltage shall be 120 Vrms (±10%).

b. The nominal frequencies shall be single phase 50 Hz and 60 Hz (±5%).

3.5.1.2.1 Interruption of power source. Voltage or frequency interruptions shall not cause damage to the equipment. A power source interruption is when the voltage falls in the range of 0 to 70% of nominal or frequency falls in the range of 0 to 90% of nominal. Equipment performance is not required during interruption of the power source. After power interruptions of any duration, the equipment shall automatically resume operation at either the last operating condition before interruption, or a default power-up condition.

3.5.1.2.2 Battery restrictions. For Navy applications, the use of lithium and mercury batteries is restricted and shall not be used in equipment unless specifically required and approved by the procuring Navy activity. If a restricted type of battery is approved, technical manuals shall reference substitute battery types, and all necessary modifications to use the substitute batteries. An exception is made for small lithium batteries used for memory backup as specified below in 3.5.1.2.2.1 Lithium batteries. A label containing the following caution and information shall be affixed to the outside of the unit, as applicable for either lithium or mercury batteries:

3.5.1.2.2.1 Lithium batteries. Commercial UL approved equipment that contains lithium batteries (size double A or button cell type) used for memory backup are approved for use under a general blanket approval waiver. Lithium or re-chargeable batteries larger than the type specified above requires a separate approval. Tadiran liquid cathode batteries, SO2 (sulfur dioxide) batteries or lithium vinyl chloride “liquid cathode” batteries are strictly prohibited. For the purpose of this specification, a lithium (size double A or button cell type) battery as described above is approved.

3.5.2 Electrical power connections. The requirements specified in 3.5.2.1 Input power cable through 3.5.2.4 Indicators shall apply to the equipment. The equipment shall operate with a ground at the primary power.

3.5.2.1 Input power cable. The input power cable shall be a detachable power cable provided by the manufacturer.

3.5.2.2 Input power switch. The operator shall be able to energize the equipment via an input power switch. A standby capability may be incorporated to activate and deactivate the equipment. If such a capability is provided, suitable warnings shall be placed in the operating and service manuals and on the equipment to warn the operator of possible shock hazards during servicing, due to partially activated power supplies.

THIS UNIT CONTAINS MERCURY BATTERIES

Battery Manufacturer:

Battery Part Number:

THIS UNIT CONTAINS LITHIUM BATTERIES

Battery Manufacturer:

Battery Part Number:

3.5.2.3 Excessive current drain protection. An automated safety mechanism (circuit breaker/fuse) shall be incorporated to automatically disconnect the equipment in the event of current being drawn that is in excess of the equipment rating.

The mechanism shall be readily available to the operator. Safety breaker or fuse shall be implemented on the input power line side (minimum) with external access to the breaker or fuse.

3.5.2.4 Indicators. Visual indication shall be provided on the front panel to indicate when the equipment is energized.

3.6 Enclosure physical characteristics. The physical characteristics of the equipment shall be as specified in 3.6.1 Dimensions through 3.6.3.4 Enclosure, Work surfaces.

3.6.1 Dimensions. The dimensions and arrangement of each piston gauge, enclosure/components and workspace as shown in the figure below is desirable, but need not be exact.

3.6.2 Weight. The weight of any ADPG main component including the enclosure that exceeds 100 pounds shall have provisions for attaching weight handling equipment.

3.6.3 Enclosure requirements. The ADPG enclosure shall be as specified in 3.6.3.1 Accessory stowage through 3.6.3.4 Work surfaces console cabinet.

3.6.3.1 Accessory stowage. The enclosure shall have provisions for stowage of accessories and shall not adversely affect the stability of the equipment. The accessories shall be contained in a manner that prevents damage to the accessories or equipment during use and storage.

3.6.3.2 Corners. All corners shall be designed to preclude injury to personnel or damage to material. All corners shall be adequately reinforced to protect the instrument from damage during shipping, handling and storage.

3.6.3.3 Enclosure, console cabinet. The enclosure shall have accommodations to securely mount/rack and stack the pressure generation and control equipment to minimize overall footprint.

3.6.3.4 Enclosure, work surfaces. The enclosure shall provide a suitable work surface to accommodate and support the mounting of units under test. The work surface shall be able to support units weighing up to 75 lbs.

3.7 Marking and identification. Marking and identification of test equipment shall be as specified below in 3.7.1 Marking through 3.7.2 Equipment identification.

3.7.1 Marking. Test equipment shall be marked in a manner that does not adversely affect safety or performance.

3.7.1.1 Reference designations. Reference designations shall be used to identify each part for its particular circuit application. Subminiaturized and non-repairable assemblies need not be marked with reference designations.

Reference designator usage shall be in accordance with ANSI Y32.2 and

ANSI Y32.16.

3.7.1.2 Warning markings. Warning markings shall warn of the location, the nature, and the extent of a hazard. Letters of warning markings shall be of clearly legible gothic capitals. Warning markings shall have high contrast between the letter and background colors. The markings shall be as permanent as normal life expectancy of the test equipment, and located as close as possible to the point of danger. Warning markings indicating circuits of more than 500 Vdc or Vrms shall read:

DANGER HIGH VOLTAGE (maximum applicable voltage) VOLTS

3.7.1.3 Battery warning label. Equipment containing batteries shall be provided with a battery warning label attached to the equipment. Battery warning labels shall be as specified below:

3.7.1.4 Panel markings and processes. Panel markings shall enable the operator to identify the functions and use of all items requiring operator intervention

3.7.2 Equipment identification. All equipment, excluding small accessory items contained within a reusable pouch or container, shall be identified with the items specified in a through d.

a. Manufacturer name

WARNING

REMOVE BATTERIES BEFORE SHIPMENT OR INACTIVE

STORAGE OF 30 DAYS OR MORE.

NOTE: DO NOT REMOVE INTERNAL MEMORY BACKUP

BATTERIES.

b. Equipment model number with installed options

c. Equipment nomenclature

d. Serial number

3.7.2.1 Identification plate. An equipment identification plate shall be affixed to the test equipment enclosure when the enclosure also serves as the transit case.

The identification plate shall contain the information provided below in

3.7.2.1.1 Identification plate. The identification plate shall be permanently affixed.

3.7.2.1.1 Identification plate. The identification plate shall contain the information provided in a through f.

a. Configuration model number

b. Configuration nomenclature

c. Configuration CAGE

d. Component nomenclature

e. Component part number

f. Component serial number

3.7.2.1.2 Identification plate, supplemental. When accessories are required to meet the requirements of the CSS and the combination is given a part or model number designation that differs from that of the main unit, there shall be a supplemental identification plate containing the information in a and b. The plate shall be placed on the accessory container, as applicable. Whether or not a configuration model designation is assigned to the accessory or group of accessories, all major accessories shall be marked as in c:

a. Model configuration number: (Model number assigned to the equipment configuration).

b. Consists of: [part number of all components (excluding cables and adapters) comprising the equipment configuration].

c. Part of (or p/o): (Model number assigned to the equipment configuration, or main unit model number, as applicable), s/n: (serial number assigned to the equipment comprising the set or the serial number of the primary instrument if a separate s/n is not assigned to the set).

3.7.2.1.3 Identification plate, material. The following materials with minimum thickness of 1/32 inch are recommended.

a. Brass

b. Corrosion resistant steel

c. Aluminum alloy

3.7.2.1.4 Identification plate, marking. The plate background color shall be black. It shall have a minimum character size of 1/8 inch. All characters shall be permanent using best commercial practices for laser engraving, etching, or photosensitive marking of material.

3.7.2.2 Reusable pouch or container. If a reusable pouch or container is provided, containers shall be marked "accessories for use with" (test equipment nomenclature or model number), or, "maintenance aids for use with" (test equipment nomenclature or model number), as applicable.

3.7.2.3 Item unique identification (IUID). A two dimensional Unique Identification (IUID) data matrix conforming to MIL-STD-130 shall be included on the Identification Plate.

UID Data Elements. The following is required per DFARS clause 252.211- 7003, Paragraph 4(e):

• UID Type

• Issuing Agency Code

• UID Data Element

• Enterprise ID

• Original Part Number

• Serial Number

• Quantity Shipped

• Unit of Measure

• Description

• Unit Acquisition Cost

• Current Part Number Effective Date

• Current Part Number

3.8 Environmental requirements. The ADPG environmental performance requirements shall be as specified below in 3.8.1 Warm-up through 3.8.5 Acoustic noise. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.8.1 Warm-up. The ADPG shall comply with the specified performance requirements after a 60-minute warm-up period preceded by a 24-hour not operating temperature stabilization period. The temperature and humidity during the stabilization period shall be within the specified operating conditions of 3.8.2.2. Temperature operating and 3.8.2.3 Humidity operating.

3.8.2 Temperature and humidity. The temperature ranges and humidity limits for both operating and not operating conditions shall be as specified in 3.8.2.1 Temperature not operating through 3.8.2.3 Humidity operating.

3.8.2.1 Temperature not operating. The ADPG shall conform to the specified performance and accuracy requirements after being stored in a dry condition at temperatures ranging from -30 ºC to 70 ºC.

3.8.2.2 Temperature operating. The ADPG shall conform to the specified performance and accuracy while being operated in ambient temperatures over the range of 64 ºF to 82 ºF inclusive.

3.8.2.3 Humidity operating. The ADPG shall conform to the specified performance and accuracy for conditions where the relative humidity is 20 to 60±5 percent in the temperature range of 64 ºF to 82 ºF inclusive.

3.8.3 Altitude. The ADPG components shall conform to the specified performance and accuracy requirements after being subjected to an altitude of 15,000 feet for 1 hour with equipment not operating.

3.8.4 Fungus resistance. Equipment shall not contain materials that provide nutrients for the growth of fungus.

3.8.5 Acoustic noise. The ADPG shall not generate acoustic noise in excess of 80 dBA sound pressure level (SPL) when measured at the operator position, in accordance with ISO 7779.

3.9 Performance requirements. The ADPG system shall include all necessary components and accessories to automatically generate, control, measure and record pressure measurements over the range and within the uncertainty specified in 3.9.1 Pneumatic range and uncertainty through 3.9.1.1 Hydraulic range and uncertainty. The system shall include automated mass handling for pressure measurements including absolute pressure measurements below atmospheric pressure.

The ADPG system may consist of more than one deadweight piston gauge and/or multiple piston cylinders to meet all performance requirements.

The ADPG shall be capable of operating in both a semi-automated mode and a fully automatic mode. In both modes the ADPG shall receive all necessary inputs from the operator; measure environmental conditions, perform all calculations, automatically generate and control pressure, load and float the mass required, settle at the test point(s), record and display test results. The semi-automated mode shall require the operator to input the test instrument (TI) data at each test point and then command the ADPG to proceed to the next test point. In the fully automatic mode the ADPG shall be able to communicate with the TI, obtain TI data, and then automatically proceed to the next test point. For the purpose of this CSS, TI is equivalent to Unit Under Test (UUT).

3.9.1 Pneumatic range and uncertainty. The ADPG system shall be capable of generating, controlling and measuring pressure over the range and within the uncertainty specified in a and b below.

a. Pneumatic absolute and gauge pressure range: 2.0 psi to 1,000 psi;

uncertainty: ±35 ppm

b. Pneumatic absolute and gauge pressure range: 1000 psi to 15,000 psi;

uncertainty: ±50 ppm

3.9.1.1 Pneumatic unique range coverage. The pneumatic piston cylinders shall cover the discrete ranges listed below in a thru c. That is, there shall be at least one piston cylinder that covers the entirety of each of the following ranges in a through c:

a) 10 to 100 psig

b) 100 to 2,000 psig

c) 1,000 to 15,000 psig

3.9.2 Hydraulic range and uncertainty. The ADPG system shall be capable of generating, controlling and measuring hydraulic pressure over the range and within the uncertainty specified in a below.

c. Hydraulic gauge pressure range: 1000 psig to 50,000 psig; uncertainty:

±50 ppm

3.9.3 Uncertainty. The measurement uncertainty of the ADPG system/s shall be provided. It shall be expressed as a percent of indicated value (iv) or as a parts per million (ppm) value. The uncertainty shall be calculated using the methods described in JCGM 100:2008 Guide for the Expression of Uncertainty in Measurement. The uncertainty shall include, in tabular form, the standard uncertainties of all the error contributors to the measurement system and processes, with an expanded coverage factor of 2 (K=2).

3.9.4 Resolution. The control unit resolution shall be capable of displaying a minimum of 7 digits.

3.9.5 Contamination prevention. The ADPG system shall maintain system cleanliness and prevent contamination of TI’s as specified in a thru c below.

The ADPG system may require the TI to be cleaned prior to calibration, if necessary. However, it shall not contaminate a cleaned gauge in any capacity.

a) Pneumatic systems which utilize a liquid lubricated piston/cylinder design shall be configured for unidirectional flow of the pressure media to prevent cross contamination of the ADPG components and the TI’s under test

b) A four port test manifold mounted on the enclosure with isolation valve shall be provided with each pneumatic system to attach pneumatic TI’s.

The manifold shall be marked “Pneumatic” and include the pressure range of the system.

c) A single port test manifold mounted on the enclosure with isolation valve shall be provided with each hydraulic system to attach hydraulic TI’s. The manifold shall be marked “Hydraulic” and include the pressure range of the system.

3.9.6 TI pressure media. The ADPG system shall be able to calibrate TIs that are exposed to the pressure media specified in the table below

Clean, dry Nitrogen

Clean, dry air

Potable water

Sea Water

MIL-H-19457 (Phosphate Ester Base Hydraulic Fluid)

MIL-PRF-23699 (Steam Turbine and Gear Lube Oil)

MIL-F-16884 (Distillate Fuel)

MIL-DTL-5624 (JP-4/JP-5/JP-8 Fuel)

MIL-PRF-17331 (Steam Turbine Lube Oil, 2190)

MIL-PRF-17672 (Hydraulic Fluid, 2075, 2110, 2135)

MIL-PRF-8188 (Aircraft Turbine Engine Oil, Synthetic Base)

MIL-PRF-83282 (Hydraulic Fluid, Synthetic Hydrocarbon Base))

MIL-H-81019 (Hydraulic Fluid, Petroleum Base)

MIL-H-46170 (Hydraulic Fluid), Synthetic Hydrocarbon Base

A-A-59290 (Arresting Gear Fluid, Ethylene Glycol / water mix)

3.9.7 Units of measure. The ADPG system shall, at a minimum, be capable of operating/displaying pressure in the vacuum, absolute and gauge modes. It shall be capable of displaying the pressure measurement units in the table below which are appropriate for the pressure range. Example, altitude units applicable to equipment capable of sub-atmospheric pressure measurements.

Software shall allow dynamic conversion of pressure units displayed. Unit conversion shall be in accordance with NIST Special Publication 811.

Symbols shall be in accordance with IEEE 260.1.

Imperial Units SI Units inH2O (@ 4°C, 20°C, & 60°F) Pa, kPa, MPa inHg (@ 0°C) bar, mbar psia,psig, Torr, mTorr

Altitude (ft)

3.9.8 Operating components and characteristics. The ADPG components and operating characteristics shall be as specified in 3.9.8.1 Base through

3.9.8.1.4 Interchangeability.

3.9.8.1 Base. The ADPG system base(s) shall be the housing for piston cylinder assemblies. The base(s) shall be equipped with all necessary components to meet the requirements specified in 3.9.8.1.1 Automated piston rotation through 3.9.8.1.4 interchangeability.

3.9.8.1.1 Automated piston rotation. The base(s) shall be able to maintain automated piston rotation throughout the measurement process.

3.9.8.1.2 Piston displacement/position monitoring. The base(s) shall monitor the vertical position of the piston throughout the measurement process. Piston position data shall be communicated to the controller such that the controller can float the piston without overshoot at the test points.

3.9.8.1.3 Piston cylinder orientation. The base(s) shall contain a means for monitoring and correcting the vertical orientation of the piston cylinder. This correction shall ensure that the piston cylinder is sufficiently vertically aligned to achieve the uncertainty as specified in 3.9.3 Uncertainty.

3.9.8.1.4 Interchangeability. The ADPG piston cylinders shall be able to be removed from the base and replaced in no more than 15 minutes. This time includes the removal of the masses, disconnection and reconnection of any pressure lines.

3.9.8.2 Controllers. The ADPG system shall have controllers for both pneumatic and hydraulic pressure control. The controllers shall conform to the requirements in 3.9.8.2.1 Digital TI communication through 3.9.8.2.4 Operator alerts. A system dedicated Portable Computer with software may be utilized if it is necessary to meet any one of the following requirements, however it shall also meet all other requirements specified for the controllers.

3.9.8.2.1 Digital TI communication. The ADPG system shall have the capability to communicate with TI’s via IEEE 488, and RS-232 in order to automate the TI calibration process. Communication shall include sending and receiving of data, specifically the receiving of TI indication data and printing of test results. The pneumatic system(s) shall be programmed to communicate with and perform an automated calibration of the TI model in a below. The barometric pressure range transducer is excluded.

a) King Nutronics precision pressure standard model 3689A

3.9.8.2.2 Memory. The ADPG shall be capable of saving and recalling test programs, test data, and all parameters required for pressure calculation (environmental temperature/pressure, local gravity, actual mass values, piston effective area, etc.).

3.9.8.2.3 Safety. The controllers shall have an abort feature where the operator can easily and safely abort a test without damage to the ADPG unit or TI. The controller shall be capable of limiting the maximum allowable pressure available for testing a TI, based on the TI full-scale range plus 10 percent.

The system shall automatically control/relieve excess pressure. The equipment shall have pressure relief protection to prevent over-pressurization of the equipment. It shall also have provisions to protect test instruments connected to the equipment from over pressurization.

3.9.8.2.4 Operator alerts. The ADPG shall alert the operator in the event of abnormal operating conditions, such as environmental conditions outside the operating specifications stated in 3.8 Environmental requirements. The ADPG shall alert the operator in the event of a communication loss with system components or the TI. The ADPG shall alert the operator in the event of a system or component malfunction. During an alert the ADPG shall give the option to safely abort the current action and relieve pressure from the test setup.

3.9.8.3 Pressure intensifier. There shall be a minimum of two pressure intensifiers, one for pneumatic pressure media and one for hydraulic pressure media.

They shall be capable of boosting the pressure of the calibration medium and supplying it to the controllers upon demand. The intensifiers shall conform to the requirements in 3.9.8.3.1 Intensifier range through 3.9.8.3.5 Pressure indicator.

3.9.8.3.1 Intensifier range pneumatic. The pneumatic pressure intensifier shall have an input pressure range of 0 to 3,000 psig and an output range of 0 to 15,000 psig. It shall be capable of intensifying gas pressure from a minimum input pressure source of 500 psig or lower to an output pressure of 16,000 psig.

3.9.8.3.2 Intensifier range hydraulic. The hydraulic pressure intensifier shall have the capability to increase the pressure of a hydraulic media from 0 psig to an output pressure of 55,000 psig.

3.9.8.3.3 Pressure control valves. The intensifier output pressure circuit shall have an inline control valve to isolate intensifier output pressure from the ADPG.

The intensifier shall also have a means to vent/relieve accumulator pressure.

3.9.8.3.4 Over-pressure protection. The pressure intensifiers shall have an integral pressure relief valve to provide over-pressure protection.

3.9.8.3.5 Pressure indicator. The intensifiers shall have a pressure indicator to display accumulator pressure.

3.9.8.4 Environmental sensors. The ADPG system shall contain the environmental sensors necessary to correctly calculate the pressure it generates. All environmental sensors shall be accessible (or removable) for troubleshooting and calibration.

3.9.8.5 Vacuum sensor (removable). The ADPG system shall include an auxiliary/removable vacuum sensor to support absolute pressure measurements below atmospheric pressure. A dedicated storage and shipping container shall be provided to protect the vacuum sensor in storage and shipping.

3.9.8.6 Vacuum pumps. The ADPG system shall include both a reference pressure vacuum pump and control pressure vacuum pump to support absolute pressure measurements below atmospheric pressure.

3.9.8.7 Mass Set(s). The ADPG masses shall be of sufficient size and tolerance to allow the system to meet the range and uncertainty requirements as specified in sections 3.9.1 pneumatic range and uncertainty thru 3.9.3 Uncertainty. A trim mass set shall be included with the ADPG mass set.

3.9.8.8 Automated mass handler(s). The automated mass handler(s) shall be able to load masses onto the piston without manual assistance from the operator.

The automated mass handler(s) shall receive commands from the controller in order to load the appropriate masses for the required test point. If necessary in order to generate exact pressures, the mass handler shall be capable of supporting trim masses.

3.9.8.9 Plumbing. The ADPG system plumbing shall be suitable for a calibration standard that is intended to remain in a single location for the entirety of its service life. The plumbing shall be contained in the enclosure as much as possible such that, in the rare case that the ADPG system is moved, the enclosure may be moved with the plumbing in place. The plumbing shall be accessible and able to be safely disconnected for ADPG system or component maintenance. The plumbing shall conform to 3.9.8.9.1 Pneumatic plumbing or 3.9.8.9.2 Hydraulic plumbing.

3.9.8.9.1 Pneumatic plumbing. Pneumatic plumbing shall have a minimum rated operating pressure that is equal to or greater than the maximum attainable pressure for which the system is designed. It shall have a proof pressure of

1.5 times the maximum operating pressure.

3.9.8.9.2 Hydraulic plumbing. Hydraulic plumbing shall have a minimum rated operating pressure that is equal to or greater than the maximum attainable pressure for which the system is designed. It shall have a proof pressure of

1.5 times the maximum operating pressure.

3.9.8.9.3 Labeling. All components that will be visible during operation of the ADPG system (pipes, hoses, valves, etc.) shall have the working pressure labeled on them. Depending on the component, they shall be either permanently tagged or laser etched.

3.9.8.9.4 Output pressure ports (pneumatic). The pneumatic ADPG system/s output pressure port shall connect to a four port manifold, mounted on the enclosure. Two manifolds shall be provided, one for each of the pressure ranges listed below in a and b. Manifold ports shall be compatible with the adapters required in 3.9.8.9.9 Pressure fitting adapters (pneumatic). All output pressure ports shall have tethered caps/plugs to prevent contamination and/or damage during non-use or storage.

a. Low Pressure range 2-1,000 psi

b. High Pressure range 1,000-15,000 psi

3.9.8.9.5 Output pressure port (hydraulic). The hydraulic ADPG system output pressure port/test port, mounted on the enclosure, shall be an industry standard high pressure port compatible with the adapters required in

3.9.8.9.10 Pressure fitting adapters (hydraulic). All output pressure ports shall have tethered caps/plugs to prevent contamination and/or damage during non-use or storage.

3.9.8.9.6 Accessories. The ADPG shall, at a minimum, have the accessories below in 3.9.8.9.7 Accessory case through 3.9.8.9.10 Pressure fitting adapters

(hydraulic) as well as any other accessory required for the ADPG to meet the requirements of this CSS.

3.9.8.9.7 Accessory case. The accessory case shall also serve as the storage location. Internal foam/packing material shall be impervious to water and hydrocarbon base fluids. It shall contain accessories and maintenance aids for the ADPG system i.e., pressure fittings and adapters. Accessories shall be contained in foam/packing material cutouts to prevent damage when the accessories are removed for use and returned after use.

3.9.8.9.8 Pneumatic pressure fitting adapters (2 to 1,000 psi) . The pressure fittings/adapters listed in a through d below shall be provided to mate with the pneumatic manifold for the pressure range of 2 to 1,000 psi. Pressure fittings/adapters shall be labeled (laser etched) with their maximum working pressure; example “MWP X,XXX psi”. The pressure fittings/adapters shall have a working pressure that is equal to or greater than the maximum working pressure of the system. To the maximum extent possible, the adapters shall be of one piece design and construction. They shall be contained in a separate reusable case. The adapters shall be of corrosion resistant steel. The rated working pressure shall be as listed. The proof pressure shall be 1.5 times the working. Pipe threads shall be in accordance with ASME B1.20.1. Flare fittings shall be in accordance with

SAE AS4841.

a. Pneumatic low pressure port to male (NPT) taper pipe; size 1/8”, 1/4”, 3/8”, 1/2”, working pressure; equal to or greater than maximum system working pressure.

b. Pneumatic low pressure port to female (NPT) taper pipe; size 1/8”, 1/4”, 3/8”, 1/2”, working pressure; equal to or greater than maximum system working pressure.

c. Pneumatic low pressure port to male (37° flare); size #4, #6, working pressure; equal to or greater than maximum system working pressure.

d. Pneumatic low pressure port to female (37° flare); size #4, #6, working pressure; equal to or greater than maximum system working pressure.

3.9.8.9.9 Pneumatic pressure fitting adapters (1,000 to 15,000 psi). The pressure fittings/adapters listed in a through d below shall be provided to mate with the pneumatic manifold for the pressure range of 1,000 to 15,000 psi.

Pressure fittings/adapters shall be labeled (laser etched) with their maximum working pressure; example “MWP XX,XXX psi”. To the maximum extent possible, the adapters shall be of one piece design and construction.

They shall be contained in a separate reusable case. The adapters shall be of corrosion resistant steel. The rated working pressure shall be as listed. The proof pressure shall be 1.5 times the working pressure. Pipe threads shall be in accordance with ASME B1.20.1.

a. Pneumatic high pressure port to male high pressure cone/gland collar fitting; size 1/4”,3/8”, 9/16”,, working pressure; pneumatic 15,000 psig.

b. Pneumatic high pressure port to female high pressure cone/gland collar fitting; size 1/4”,3/8”, 9/16”,, working pressure; pneumatic 15,000 psig.

c. Pneumatic high pressure port to male (NPT) taper pipe; size ⅛”, ¼”,3/8”, 1/2”, working pressure; pneumatic 15,000 psig.

d. Pneumatic high pressure port to female (NPT) taper pipe; size ⅛”, ¼”,3/8”, 1/2”, working pressure; pneumatic 15,000 psig.

3.9.8.9.10 Hydraulic pressure fitting adapters . The pressure fittings/adapters listed in a through d below shall be provided to mate with the high pressure hydraulic output port. Pressure fittings/adapters shall be labeled (laser etched) with their maximum working pressure; example “MWP XX,XXX psi”. The adapters shall have caps to protect the threads and sealing surface. They shall be contained in a separate reusable case. The adapters shall be of corrosion resistant steel construction. The rated working pressure shall be as listed. The proof pressure shall be 1.5 times the working pressure. Pipe threads shall be in accordance with ASME B1.20.1

a. Hydraulic high pressure port to male high pressure cone/gland collar fitting; size 1/4”,3/8”, 9/16”, working pressure; hydraulic 50,000 psig.

b. Hydraulic high pressure port to female high pressure cone/gland collar fitting; size 1/4”,3/8”, 9/16”, working pressure; hydraulic 50,000 psig.

c. Hydraulic high pressure port to male taper pipe; size ⅛”, ¼”, 3/8”, 1/2”, working pressure; hydraulic 15,000 psig.

d. Hydraulic high pressure port to female taper pipe; size ⅛”, ¼”, 3/8”, 1/2”, working pressure; hydraulic 15,000 psig.

3.10 Maintainability. Maintainability shall be as specified below in 3.10 Fault isolation through 3.10.2 Maintenance provisions.

3.10.1 Fault isolation. The design of the equipment shall permit isolation of faults, and repair down to the component item or lowest replaceable unit (LRU) with the maintenance provisions furnished. Refer to MIL-PRF-28800G paragraph

6.6.17 for a definition of a nonrepairable subassembly.

3.10.2 Preventive maintenance. Preventive maintenance, excluding piston/cylinder cleaning and system calibration, shall not require more than 60 minutes per

30-day period. Preventive maintenance shall not require breaking of the equipment seams where calibration seals would normally be placed.

3.10.3 Maintenance provisions. Equipment shall be as specified in a through d to facilitate maintenance:

a. Accessibility for maintenance. The equipment shall be designed to ensure that any necessary maintenance access can be accomplished utilizing ordinary tools.