PD08WRGBGBEA10_REV_B.doc

PD08WRGBGBEA10

REV B

CAGE 98752

14 April 2009

PD08WRGBGBEA10

PURCHASE DESCRIPTION

TEST SET, FLIGHT CONTROL SYSTEMS

1. SCOPE

This purchase description establishes the minimum design performances and test requirements for a portable pitot and static tester (test set) to be used for the inspection and acceptance of pitot and static systems including altimeters, vertical velocity indicators, air speed indicators, and air data computer systems.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are for guidance and information.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this document to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C/26173

Ocean Gray, NAVSEA

MILITARY SPECIFICATIONS

MIL-PRF-28800F

Test Equipment for Use with Electrical and Electronic Equipment, General Specifications for

MILITARY STANDARDS

MIL-STD-130N

Identification Marking of US Military Property

MIL-STD-461F

Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-810G

Environmental Engineering Considerations and Laboratory Tests

MIL-STD-859A

Standard Calibration Table for Aeronautical Pressure Measuring Equipment

MIL-STD-1472F

Human Engineering

MIL-STD-1472F

Human Engineering

MILITARY HANDBOOKS

MIL-HDBK-454B

General Guidelines for Electronic Equipment

MIL-HDBK-781A

Reliability Test Methods, Plans, and Environments for Engineering, Development Qualification, and Production

MIL-HDBK-470A

Designing and Developing Maintainable Products and Systems

2.3 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications of the exact revision level shown form a part of this document to the extent specified herein.

DI-SAFT-80101B

System Safety Hazard Analysis Report

DI-SAFT-81626

System Safety Program Plan

MIL-A-81852A

Altitude-Encoder AAU-32/A

NASA TN D-822

Tables of Airspeed, Altitude, and Mach Number Based on Latest International Values for Atmospheric Properties and Physical Constants

2.4 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DoDISS are the issues of the documents cited in the solicitation.

SK-ED-0017

Flush Static Port Adaptor (Cage Code 81996)

US Standard Atmosphere, IEEE-STD-488.1-1987

2.5 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 PERFORMANCE

Range Altitude -1,500 to +80,000 ft

(32 to 0.8 inches Hg) approximately

Altitude Slew Rate 0 to 50,000 feet per minute

Airspeed, Indicated 20 to 1,000 knots (0.02 to 73.5 inches Hg differential)

Airspeed Slew Rate 0 to 800 knots per minute.

Mach Limit Setting 0 to 4.9 Mach

Static Load Range 5 to 250 cubic inches*(Volume reduced at higher slew rates)

Pitot Load Range 5 to 250 cubic inches

Accuracy

Altitude 10 feet or ±0.1% of setting (whichever is greater) - Across the entire operating temperature range

Altitude Slew Rate ±10 feet per minute or 3% of setting

Airspeed ±0.5 knots from 20-200 knots

±0.1 knots from 200-1000 knots

Airspeed Slew Rate ±2 knots per minute or 3% setting

Mach Limit Setting

0.05 Mach

Pressure Modulation

Frequency 0.05, 0.25 and 0.50 Hz

Amplitude Variable

Temperature

Operating -40°C to +60°C (-40°F to +140°F)

Non-operating -51°C to +71°C (-59.8°F to +159.8°F)

Altitude

Operating -1,000 to +20,000 feet

Non-operating -1,000 to +50,000 feet

Weight Shall not exceed 87 pounds (39.46kg)

Power

AC

115 V, 400 Hz, single phase

DC

28VDC

3.2 Safety. The equipment shall comply with the Class II safety requirements specified in MIL-PRF-28800F.

3.2.1 RVSM Compliant. Reduced Vertical Separation Minimum (RVSM) reduces the vertical separation between flight level (FL) 290–410 from 2000 ft to 1000 ft and makes six additional FL’s available for operation. The equipment shall be fully compliant to this standard.

3.2.2 Personnel Hazards. Personnel hazards shall be kept to a minimum. The safety criteria of MIL-PRF-28800F shall be made applicable for tasks and efforts such as the part selection, manufacturing and assembly process and any product baseline configuration changes that may be implemented during the contract. Compliance with this requirement shall be determined by visual inspection and operation.

3.2.3 Exposed—Edge Rounding. Exposed edges and corners shall be rounded sufficiently to minimize laceration and puncture hazards. The suggested design goal is a minimum radius of 1 mm for edges and a minimum radius of 12.7 mm for corners.

3.2.4 Radioactive Materials. Radioactive materials shall not be used.

3.3 Design and construction. Unless otherwise specified herein, the equipment shall consist of all new and unused components and shall comply with Class II equipment design and construction requirements of MIL-PRF-28800F and shall be a modified commercial-off-the-shelf (COTS) tester. The exterior finish color of the tester shall be Ocean Gray, NAVSEA, Color Number 26173 of FED-STD-595.

3.3.1 Weight. The equipment and accessories (including the remote unit and excluding manuals) shall not exceed 87 pounds. The weight of the remote unit shall not exceed 10 pounds.

3.3.2 Dimensions. The equipment shall not exceed 4.5 cubic feet in volume, when housed in the combination case with the cover closed. No external dimension of the case shall exceed 30 inches. The remote unit dimensions shall be compatible with cockpit use, and the maximum length and width dimensions of the remote unit shall be no greater than 10 inches by 16 inches.

3.3.3 Handles and Grasp Areas. The equipment shall have handles and grasp areas that comply with MIL-STD-1472F, Section 5.9.11.5 requirements.

3.3.4 Maneuverability. The equipment shall be wheeled to allow one person transport.

3.3.5 Human Factors. Equipment shall comply with paragraph 4.4P of MIL-STD-1472F.

3.3.6 Displays, Indicators, and Controls. The test set and remote unit shall provide displays, controls, and status indicators to the user. Adjustable illumination shall be provided for visual displays (including display and control labels) that must be read under darkened conditions. The test set and remote unit shall have as a minimum, but not limited to the following indicators, displays, and controls:

Elapsed time indicator

Power on indication and switch

Self test fault indication, selector

Simulated altitude display, selector, indicator

Test set ready indication

Decoded altitude display

Altitude code bit display

Leakage test mode indication, selector

Altitude slew rate display, selector, indicator

Ambient barometric pressure indication, vent switch

Indicated/true airspeed display

3.3.7 Accessibility. The equipment shall be constructed so that:

3.3.7.1 Subassemblies and chassis components can be removed without removing any other hard wired printed circuit card, subassembly, or component.

3.3.7.2 Adjustments can be made without removing any component, printed circuit card, or subassembly. The use of extender cards or cables are permitted.

3.3.7.3 Printed circuit cards can be removed without the need to unsolder cables and interconnecting wiring. Printed circuit cards (mother boards) designed primarily to distribute power and signals to other printed cards (daughter boards) are excluded from this requirement. When such mother boards are used, they shall be readily accessible.

3.3.8 Encapsulation and Embedment. Encapsulation and Embedment (potting) of subassemblies, if used, shall be readily accessible.

3.3.9 Attitude. The test set shall operate in a horizontal or vertical position and shall be self supported on either position.

3.3.10 Altitude Encoder Connection. The test set shall have a connector for connecting the encoder output of encoding altimeters to the test set. An adapter cable for connecting the AAU-32.-encoder (MIL-A-81852A) output to the test set shall be provided.

3.3.11 Elapsed Time Indicator. The elapsed time indicator shall indicate the total accumulated time in hours that the pump has been operating.

3.3.12 Test Set Ready Indication. The test set shall indicate when the test set is ready to accept an input from the user.

3.3.13 Remote Unit. A hand held remote unit shall provide the primary means of controlling the test set. The remote unit shall be compact, lightweight, and portable. It shall be housed in a case to protect it from the environmental and EMI conditions. The environmental requirements for the remote control units are the same requirements that apply to the test set. The connection between the remote unit and the main unit shall be a single 20 foot long electrical cable assembly. A 50 foot long electrical cable assembly shall be available between the remote unit and the main unit for use as an option for use with larger aircraft. As a minimum, the remote must be capable of displaying two separate indications simultaneously, such as altitude, airspeed, or rate of climb. The remote shall have the capability to stop all functions of the test set. Adjustable illumination shall be provided on the remote unit for visual displays (including display and control labels) that must be read under darkened conditions.

3.3.14 IEEE-488 Operation and ethernet bus. The IEEE-488 control bus shall operate with the remote unit connected or disconnected. An Ethernet bus shall also be included on the test set.

3.3.15 Keyboard. A general numeric keyboard shall be provided as the primary input device for the operators to enter test points, rates of change, etc.

3.3.16 Pressure—Vacuum Pump. The pressure-vacuum pump shall be a motor driven dry type pump.

3.3.17 Internal Pneumatic Tubing. The internal tubing of the test set shall be designed for ease of maintenance.

3.3.18 Protection to the Unit Under Test. The test set shall provide protection to the unit under test and to the test set. The test set shall prevent pressure surges, pressure transients, over-pressure, and under-pressure in both, the test set and the unit under test (UUT). This protection shall have visual and/or audio warning systems. The test set shall provide pressure balance protection to the altimeter and airspeed indicator.

3.3.19 Negative Differential Pressure. The test set shall limit the negative differential pressure from exceeding 0.5 inches Hg.

3.3.20 Static Pressure Limiting. The test shall maintain the static pressure between a maximum of 32 inches Hg and a minimum of 3.343 inches Hg.

3.3.21 Total Pressure Limiting. The test shall not permit the total pressure to exceed the static pressure by more than 8.866 inches Hg.

3.3.22 Pneumatic Filtering. The test set shall provide pneumatic filtering to preclude the transmission of foreign matter to the unit under test and to provide protection to the test set.

3.3.23 Water Extraction. The test set shall extract the water that may accumulate in the internal pneumatic system of the test set. Water shall be extracted when the test set is operated on either a horizontal or a vertical attitude and removal of the unit from its enclosure shall not be required. Water extraction shall be an automatic function of the test set.

3.3.24 Human Error Design Protection. Front panel control functions shall be designed such that neither incorrect adjustment nor random sequencing of functions cause damage to the test set or the unit under test.

3.3.25 Pneumatic Output Venting. The ambient barometric pressure indication shall indicate when the pneumatic outputs of the test set are at the ambient barometric pressure. When the ambient vent switch is activated the test set shall automatically vent the pneumatic outputs to the ambient barometric pressure at a controlled rate. The ambient vent condition may be considered as a “reset function.

3.3.26 Pressure Limiters and Relief Valves. Pressure and Relief Valves shall be supplied, located, and have limits such that the pressure transducers are adequately protected from potentially damaging overpressures and negative pressures.

3.3.27 Warm-up. Warm-up shall be as specified in MIL-PRF-28800F, except that the warm-up and auto exercise time shall not exceed 15 minutes.

3.3.28 Workmanship. The workmanship shall be as specified in MIL-HDBK-454B, Guideline 9.

3.4 Parts, Materials and Processes. Unless otherwise specified herein, the equipment shall comply with parts, materials, and processes’ requirements of MIL-PRF-28800F.

3.4.1 Restricted Material. The equipment shall comply with the restricted material requirements of MIL-PRF-28800F, including the requirement for mercury and radioactive materials and shall contain no combination of materials that cause deterioration of any material contained in the equipment.

3.4.2 Interchangeable. Unless otherwise specified herein, the equipment shall comply with the interchangeable requirements of MIL-PRF-28800F.

3.5 Marking and Identification. Unless otherwise specified herein, the equipment shall comply with the marking and identification requirements of MIL-PRF-28800F.

3.5.1 CAGE Code. All replaceable assemblies, subassemblies, modules and printed circuit card assemblies shall be individually marked with the Contractor and Government Entity (CAGE) Code and the contractor’s part number.

3.5.2 Supplemental Identification Plate. The supplemental identification plate specified in MIL-PRF-28800F shall contain the following information:

a.

Nomenclature and Type Designator b.

Contract Number c.

Serial Number d.

National Stock Number “U.S.”

f.

Date of Manufacture g.

Unique Identification Number as defined by MIL-STD-130N

3.5.3 Battery Warning Label. If a battery is used in the equipment, the equipment shall provide a battery warning label according to MIL-PRF-28800F.

3.5.4 Warranty Plate. An information plate containing the warranty termination date shall be affixed to each instrument.

3.6 Transportability. The equipment must be capable of being transported within its own case and transportable in either a general purpose commercially available TMDE transit case or in mobile maintenance shelters (tied down).

3.7 Equipment Power. The test set shall operate from any of the following power sources:

DC POWER:

28 volts, +8 to -12 volts

AC POWER: 110—240 volts 50 to 400 Hertz single-phase

3.7.1 Input Power Switch. The input power switch shall be as specified in MIL-PRF-28800F. The power switch shall function as an emergency power turn-off. Turning the switch to the off position at any moment during operation of the test set shall not damage the test set and the unit under test. After turn-off the test shall automatically vent all pneumatic outputs to the ambient barometric pressure at a controlled rate. A power on indicator shall indicate whenever power is applied to the test set. An input power switch shall be located on the front panel of the set and/or on the remote control unit.

3.7.2 Fuses and Circuit Breakers. Adequate instrument protection is required. Fuses, fuseholders, circuit breakers, and associated hardware shall be in accordance with MIL-HDBK-454B, Requirement 39. Common or separate fuse holders may be provided. Fuses and circuit breakers required for equipment operation shall be according to MIL-HDBK-454B. These fuses shall be standard available commercial fuses and shall be easily accessible to the operator without the use of tools or disassembly. Refer to paragraph 4.2.2 in MIL-HDBK-454 for spare fuses.

3.7.3 External Ground. The test set shall have an external ground connection.

3.8 Accessories. All accessories necessary for proper operation and maintenance of the test set shall be provided with each instrument.

3.8.1 Hoses and Connections. Hoses, clamps, couplings, sleeves, and reducers, as applicable shall connect the tester to points in the aircraft plumbing, to the pitot pressure port located in the aircraft pitot head, and to the static pressure port which may protrude, or be flush located on the outer surface of the aircraft. Adapters shall also be provided to connect the tester directly to the instrument cases. For bench—testing uninstalled instruments, valves shall be provided with the accessory hose connections to isolate the instruments being tested for leakage.

3.8.2 Power Cables. Power cables, extensions, and adapters shall conveniently connect the tester to any of the power sources listed in section 3.7 of the purchase description. The removable 115 V power cable shall be furnished with a non-removable, three prong, grounding connector molded to the cable jacket at the power source end. The cable assembly shall be at least 25 feet in length and meet the requirements of MIL-PRF-28800F.

3.8.3 Commercial Accessories. Standard accessories furnished with the commercial instrument shall be included.

3.8.4 Batteries. If batteries are provided for memory backup they will be batteries that are in the Government inventory. Batteries requiring replacement more frequently than annually shall be replaceable by the operator and accessible without subjecting the operator to any electrical hazard.

3.9 Environment. Except for the temperature requirements, the equipment shall comply with the Type II, class 2, Style C, environmental requirements specified in MIL-PRF-28800F. Temperature requirements shall meet Class 1 temperature requirements listed in 3.9.1.

3.9.1 Temperature. The equipment shall perform all of its electrical requirements as specified herein in the operating temperature range of -40 degrees Celsius to +60 degrees Celsius.

3.9.2 Electromagnetic Interference (EMI). The equipment shall comply with the Army aircraft flight line equipment EMI requirements of MIL-STD-461F.

3.9.3 Altitude. The test set shall meet the performance and accuracy requirements specified herein when operated in altitudes from -1000 to 20,000 feet. Changes in the ambient -barometric pressure shall not affect the performance and accuracy requirements of the test set.

3.9.4 Precipitation.

3.9.4.1 Rain. The tester shall be capable of storage and operation during rainfall of five inches per hour for three consecutive hours and ten inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with six inches of rain per hour impinging on the tester at angles from vertical to 45°.

3.9.4.2 Snow and ice. The tester shall be capable of storage and operation during snow accretion up to two inches per hour for at least 12 hours and up to 1.5-inches of ice.

3.9.4.3 Solar radiation. The tester shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments.

3.9.4.4 Fungus. All materials used in the tester shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The tester shall be suitable for operation and storage in conditions encountered in a tropical environment.

3.9.4.5 Salt fog. The tester shall be capable of storage and operation in high temperature, high humidity, salt laden, and sea coast environments without damage or deterioration of performance.

3.9.4.6 Sand and dust. The tester shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance.

3.10 Reliability, Availability, and Maintainability (RAM).

3.10.1 Reliability. The equipment shall comply with the Type II Reliability Requirements of MIL-PRF-28800F.

3.10.2 Calibration. The calibration interval shall meet or exceed 360 days with 85% of instruments (which have not failed) still within tolerance.

3.10.2.1 Any special software required for calibration or alignment must be provided with the unit, and must be Microsoft Windows compatible.

3.10.2.2 Special cables required for calibration or alignment shall be kept to a minimum and must be provided with the unit.

3.10.2.3 Both calibration and alignment shall not require disassembly or modification to the unit and can be accomplished at the front panel, using the remote, or via an IEEE bus, at the calibrator’s discretion.

3.10.2.4 All calibration check points must be easily accessible.

3.10.2.5 All calibrated parameters shall have the capability to be set to their nominal value.

3.10.2.6 Calibration adjustments will be such that they cannot be inadvertently changed during routine use.

3.10.2.7 New calibration standards shall not be required for calibration of the test set. Calibration standards shall be selected from equipment in the government inventory for this purpose.

3.10.2.8 Calibration Time. Calibration time shall not exceed 3 hours and shall include all time required to check the equipment parameters on all range and function settings and all input and outputs. Calibration time does not include the time to repair and readjust the equipment because of malfunction.

3.10.2.9 A complete record of calibration shall be stored on-board in non volatile memory. This shall include date of calibration and any offsets applied.

3.10.3 Maintenance Provisions. The equipment shall meet the maintenance provisions of MIL-PRF-28800F except the accessibility of accessories does not apply. Peculiar support equipment shall not be required for maintenance of the test set. Support equipment selection shall be based on equipment already existing in the Government inventory, such as general purpose electronic test equipment.

3.11 Performance.

3.11.1 Altitude and Airspeed Simulation. As a minimum, the test set shall simulate and display any selected altitude (feet or meters) and airspeed (knots or kilometers per hour) condition continuously, based on selection, within the limits specified herein. The pressure regulation system of the test set shall not be affected by changes in the ambient barometric pressure. The altitude pressure output shall be based on a fixed barometric pressure reference of 29.9213 inches Hg, and shall be calibrated to the standard atmosphere as listed in MIL-STD-859A and in the U.S. Standard Atmosphere, 1976. The airspeed pressure output shall be calibrated to NASA TN D-822. The altitude and airspeed displays shall provide for both commanded and measured values. All other commanded and displayed values shall be displayed whenever selected by the operator. The altitude display shall show commanded values and an indicator/display shall be provided to let the operator know when the measured rate is equal to the commanded rate within specified tolerances.

3.11.2 Ranges, Resolution and Accuracies. The test set shall simulate pressure/vacuums in accordance with the ranges, resolution, units, and accuracies listed on page 2. The test set shall have the capability to display in Psi pressure units.

3.11.3 Simulated, True Airspeed Control. The test set shall simulate indicated airspeed and true airspeed. A control shall be provided to select the desired kind.

3.11.4 Display Characteristics All displays shall be digital and direct sunlight readable. The displays shall have a minimum contrast ratio of 6 over a field of view of ± 45 degree cone with a target contrast ratio of 45 over a ± 60 degree cone. Displays shall be as follows:

NUMBER OF DIGITS

CHARACTER HEIGHT

(minimum) (minimum)

Altitude 0.187 inches

Airspeed 0.187 inches

Altitude Rate 0.187 inches

3.11.5 Decoded Altitude. The test set shall display the output of altitude reporting encoders of altimeters or equipment which incorporates encoders for automatic altitude reporting. The display shall be in feet of altitude and 100 foot steps.

3.11.6 Code Bit Displays. A 10-bit minimum display shall be available to indicate the status of each bit of an altitude reporting encoder. The display shall be for trouble shooting those units that have an erroneous digital reading to determine which code bits are missing.

3.11.7 Leakage Test Mode. On this mode the test set shall measure the leakage on the static and dynamic pneumatic outputs and display the corresponding leakage on the simulated altitude and airspeed displays. The test set shall be capable of performing individual and simultaneous pneumatic channel leak tests. The test set shall perform this test regardless of the starting conditions of simulated altitude and airspeed with an accuracy of 50 feet per minute on the altitude channel and one knot per minute on the airspeed channel. The leakage test mode indicator shall indicate that the test set is in this mode of operation until the mode is deactivated by the user.

3.11.8 Self Test. The test set shall execute the self test routine when power to the test set (turn-on) is applied or by front panel controls. The self test routine shall also be executable through the IEEE-488 control bus. Adequate status information or flags shall be available through the bus in case a malfunction condition exists. If a lamp test is initiated, all lamps and other indicating devices shall illuminate. The lamp test shall include the testing of the numeric displays. A malfunction in the self test circuits shall not impair the operation of the test set. If a malfunction is detected by the self test, the test set shall vent the pneumatic outputs to the atmospheric pressure at a controlled rate. The self test sequence shall not require intervention of the user for its completion. The self test routine shall, as a minimum, test the following functions;

a.

The static and dynamic pressure sensors.

b.

The pressure generating system.

c.

The pressure controlling system.

d.

Lamp test (if applicable).

e.

Numeric displays.

3.11.9 IEEE-488 Bus and RS-232 interface. The test set shall be capable of interfacing an IEEE-488 control bus in accordance with IEEE-STD-488.1-1987 and as specified in MIL-PRF-28800F and with a RS-232 Interface. The test set shall be controlled through the IEEE-488 control bus by using an external bus controller. All functions, indications and readings on the test set shall be available through the control bus. It is acceptable to operate the remote unit from the IEEE-488 bus.

3.11.10 External Volume Range. The test set shall operate and perform as specified herein with any combination of external volumes connected to the pneumatic outputs. The external volume range is:

a.

Connected to the static output, from 5 to 250 cubic inches.

b.

Connected to the dynamic output, from 5 to 250 cubic inches.

3.11.11 Stability. The test set shall maintain stable pressure control and regulation of simulated altitude and airspeed, while operating into any combination of external volumes as specified herein.

3.11.11.1 Altitude Stability. The maximum allowable altitude variation of simulated altitude shall be ± 3 feet or ± 0.02% of simulated altitude, whichever is greater.

3.11.11.2 Airspeed Stability. The maximum allowable variation of simulated airspeed shall be ± 1 knot throughout the entire simulated airspeed range.

3.11.11.3 Oscillations Within Stability Limits. The test set shall not produce rapid oscillations, surges, or transients within the stability limits specified herein. Any oscillations shall be exhibited as a slow drift. The duration of a drift from a maximum to a minimum stability limit shall not exceed one minute.

3.11.11.4 Stability of Pressure Interaction. The test set shall have minimum interaction between the simulated altitude output and the simulated airspeed output as follows:

a.

At indicator readings of 5,000 feet altitude and 50 knots airspeed, an increase in airspeed to 300 knots shall not produce an altitude change in excess of ± 50 feet.

b.

At indicator readings of 2000 feet altitude and 50 knots airspeed, an increase in altitude to 35,000 feet shall not produce an air speed change in excess of ± 2 knots.

3.11.12 Overshoot. Overshoot regulation shall be accomplished by automatically reducing the commanded slew rate (altitude or airspeed) when the simulated pressure at the output approaches the pressure equivalent to the commanded altitude or airspeed.

3.11.13 Test Set Leakage. The test set’s leakage shall not exceed 50 feet per minute and one knot per minute on the static and dynamic outputs under the conditions of 35,000 feet and 400 knots simulated altitude and airspeed.

4. VERIFICATION

Responsibility for Inspection. Unless otherwise specified in the contract, the contractor is responsible for the performance of all inspection requirements as specified herein. Unless otherwise specified in the contract, any facility suitable for the performance of all inspection requirements specified herein may be used by the contractor unless disapproved by the Government. The Government reserves the right to perform or witness any of the inspections as stated in the specification. Random samples shall be selected by a government representative. The contractor shall notify the Government before inspection of the production lot size. Bid sample testing will be performed by the Government.

4.1 System Safety Engineering Inspection. A visual inspection shall be performed in the presence of a U. S. Government Representative to determine that all requirements of section 3.2 Safety and its subparagraphs have been met. Inability to meet these requirements shall constitute a failure of the test. The contractor shall submit and receive approval of a Systems Safety Program Plan per DI-SAFT-81626 requirements and a System Safety Hazard Analysis Report per DI-SAFT-80101B requirements.

4.2 Quality Conformance Inspection. Unless otherwise required herein, the test methods, procedures, and conditions used for quality conformance inspection shall be as specified in MIL-PRF-28800. Equipment shall be subjected to burn-in before productions inspection.

4.2.1 Preconditioning Requirement (Burn-In). Each deliverable piece of equipment shall be subject to burn-in as follows:

4.2.1.1 All equipment shall be subject to a minimum 10 hours on-time burn-in period before acceptance testing. During the last 3 hours of on-time burn-in, the equipment must operate failure free. Until this time, the equipment will be allowed to accumulate failures. Each equipment that fails during the final 3-hour period shall be repaired and returned to test until it successfully survives a 3-hour period without failure. Failures that occur during the burn-in test shall be noted and reported, but shall not count toward the establishment of equipment mean-time-between-failure (MTBF). Before burn-in, the satisfactory operation test (SOT) shall be conducted. Daily satisfactory operation checks (SOC) shall be conducted. For the last 3.25-hour failure free period, a complete SOT shall be conducted before and after the period. Satisfactory Operation Test (SOT) employs the necessary external input and evaluation equipment to determine if the equipment conforms to all the requirements of the associated detail specification. Satisfactory Operation Check (SOC) employs a maximum number of active circuits of the equipment with a minimum requirement for external input or evaluation equipment to ensure that all functions of the equipment are operational. If the equipment fails during the SOT, the entire 10 hour burn-in period must be repeated. While under burn-in, the equipment shall be subjected to the following conditions:

a.

Ambient Temperature: 40°C +5°C -0°C (104°F +9°F -0°F) b.

Input Voltage: 115 Volts, +5%, -2%.

c.

Equipment On-Off Cycling: The equipment power shall be cycled (on for 2 hours and off for 15 minutes, repeat), until a minimum of 3 full cycles have been completed. Immediately following the power cycling, the equipment shall remain on for a minimum of at least 3.25 hours, during which time the unit will operate without failure.

4.2.2 Production Inspection. Each equipment shall be subjected to the inspection tests of Table 1 to ensure qualitatively the proper functioning of the equipment, including all operating controls and conformance with safety requirements.

4.2.3 Production Control.

4.2.3.1 Tests. After passing inspection tests, the instruments shall be tested to show conformance with the performance parameters of Table 2.

4.2.3.2 Sampling Plan. From each lot a random sample of instruments shall be selected and tested to show conformance with the performance parameters of Table 2. Sampling shall be according to Table AA. Lots in which samples exhibit any failure shall be screened for that failure before being subjected to environmental tests of Table 3.

4.2.4 Environmental

4.2.4.1Tests. The tests of Table 3 shall be performed on instruments that have passed the required parameters of Table 2. The tests shall be performed according to MIL-PRF-28800 or MIL-STD-810 except as specified in the following subparagraphs.

4.2.4.1.1 Vibration. The equipment shall conform to the specified performance and accuracy requirements during the vibration conditions specified for class 2 in MIL-PRF-28800.

4.2.4.1.2 Electromagnetic Interference. The equipment shall be tested for compliance with the requirements of paragraph 3.9.2. Test procedures shall be according to the test methods of MIL-STD-461 as implemented by a contractor- prepared, government approved test plan. Accordingly, the emission and susceptibility requirements of CE1O2, CS1O1, CS114, RE1O2, and RS1O3 must be complied with, and shall be met by the procedures in MIL-STD-461, as outlined in the approved EMI test plan.

4.2.4.1.3 Total Temperature Simulation. The equipment shall incorporate a precision resistance assembly and connector, wired in accordance with Figure 1, which shall be used to simulate the resistance of a total temperature probe of an aircraft at any combination of altitude and airspeed within the ranges and limits previously specified. The resistance range shall be from 30 to 130 ohms. The total temperature simulation capability shall be fully compatible with aircraft air data computing systems utilizing the three-wire automatic compensation temperature sensing system which enables automatic compensation for the resistance of the cable connecting the test set or temperature sensor to the computer. The precise resistance value set on the test set control dial or indicator must appear at test set connector terminals C and D. If the test set is used with a two-wire non-compensated temperature sensing system, the operator must add the resistance of the connecting cable to the value set on the test set control dial or indicator to obtain the correct total resistance .

Figure 1

4.2.4.1.4 Sampling Plan. From first production lot only, a random sample of three instruments shall be selected and two instruments shall be subjected to all Environmental Tests in Table 3 except EMI. If a sample exhibits any failure, the entire lot shall be screened for that failure. The third instrument shall be subjected to the specified EMI tests of paragraph 3.9.2, following the successful completion of other environmental testing. The EMI test failures shall not require retesting of other environmental tests unless an instrument modification is necessary. If modifications were made to the other units during any other environmental testing, they shall be incorporated into the EMI unit before EMI testing.

4.2.1.4.1 High temperature operation test. The first article testers shall be tested in accordance with MIL-STD-810G, Method 501.5, Procedures I and II, to demonstrate compliance with the high temperature operating requirements of 3.9.1. Test duration shall be one 24-hour cycle for each procedure.

4.2.1.4.2 Low temperature operation test. The first article testers shall be tested in accordance with MIL-STD-810G, Method 502.5, Procedures I and II, to demonstrate compliance with the low temperature operating requirements of 3.9.1. Test duration shall be one 24-hour cycle for each procedure.

4.2.1.4.3 Rain test. The first article testers shall be tested in accordance with MIL-STD-810G, Method 506.5, Procedure I, to demonstrate compliance with 3.9.4.1.

4.2.1.4.4 Ice accretion test. The first article testers shall be tested in accordance with MIL-STD-810G, Method 521.3, with an ice thickness of 1.5-inches to demonstrate compliance with the ice accretion requirement of 3.9.4.2.

4.2.1.4.5 Solar radiation. Contractor certification to demonstrate compliance with 3.9.4.3.

4.2.1.4.6 Fungus. Contractor certification to demonstrate compliance with 3.9.4.4.

4.2.1.4.7 Salt fog test. The first article testers shall be tested in accordance with MIL-STD-810G, Method 509.5, to demonstrate compliance with 3.9.4.5. Test duration shall be alternating 24-hour periods of salt fog exposure and drying conditions for 24-hour periods (two wet and two dry).

4.2.1.4.8 Sand and dust test. The first article testers shall be tested in accordance with MIL-STD-810G, Method 512.5, Procedures I (12 hours) and II (90 minutes per side), to demonstrate compliance with 3.9.4.6.

4.2.5 Reliability.

4.2.5.1 Tests. After showing conformance with all safety requirements of section 3.2 of the purchase description and its subparagraphs, the instruments shall be tested to show conformance with all RAM requirements of Table 4. Test Plan IVD of MIL-HDBK-781 shall apply. The contractor shall demonstrate the equipment MTBF (O0) as stated in the bid— data submission. The stated value shall be equal to or greater than an upper test MTBF (00) of 500 hours. Reliability tests shall be performed on the first production lot only.

4.2.5.1.1 Sampling Plan. From the first production lot only, a random sample of ten instruments shall be selected and tested to show conformance with all RAM requirements of Table 4. If the sample size, selected from Table AA, from the first production lot is not of sufficient size to allow ten dedicated instruments for Ram Requirements Reliability testing, then the sample size shall be increased to a quantity sufficient to accommodate this requirement.

4.2.5.1.2 Test Length. Testing shall continue until the total units’ hours, with the total count of relevant equipment failures, permit an accept or reject decision. Only equipment “ON” time may be used in MTBF determinations. Testing shall be monitored so the time to failure may be estimated with reasonable accuracy. No single equipment “ON” time shall be less than one-half the average operating time of all equipment “ON” time.

4.2.5.1.3 Examination and Test Method. The satisfactory operation test (SOT) and the satisfactory operation check (SOC) shall be used to verify equipment operation during reliability testing. The SOT shall be used to confirm proper equipment operation before and following reliability testing. The SOT also shall be performed weekly to verify proper equipment operation. The SOC shall be used to monitor proper operation of the equipment daily.

4.2.5.1.4 Calibration. Acceptance Testing will include calibration. Calibration acceptance testing will be accomplished at the Air Force Primary Standards Laboratory (AFPSL). Equipment shall also be tested to ensure compliance with paragraph 3.10.2 and its subparagraphs.

4.2.6 Maintainability. The contractor shall demonstrate the equipment Mean-Time-To-Repair (MTTR) (H0 as described in MIL-HDBK-470) and stated in the bid-data submission. The stated value shall be less than or equal to a MTTR (H0) of 90 minutes. The maximum tolerable MTTR (Hi of MIL-HDBK-470) shall be 120 minutes. MTTR shall include all the time required to troubleshoot, fault isolate, repair, and test the equipment. It shall follow the Government approved maintenance concepts for any malfunction down to the lowest circuit card or module level of the equipment without including calibration time. Equipment that does not use the modular concept shall include all the time required to troubleshoot, fault isolate, repair, and test the equipment for any malfunction down to the lowest discrete component in calculating the MTTR. The calculation of the MTTR does not include the calibration time.

4.2.6.1 Scheduled Maintenance. The test set shall not require scheduled maintenance more frequently than every 1500 hours.

4.2.6.2 Tests. The maintainability test of Table 4 shall be performed on an instrument that has passed the required tests according to Section B, Quality Assurance Provisions, paragraph 2.2, and shall be conducted according to MIL-PRF-28800.

4.2.6.3 Sampling Plan. Testing shall be performed on one dedicated random sample. The producer’s risk is 0.20 and the consumer’s risk is 0.10 (MIL-HDBK-470).

4.2.7 Design.

4.2.7.1 Tests. The design tests of Table 5 shall be performed on instruments that have passed the required inspection tests of Table 1 according to Section B, Quality Assurance Provisions, paragraph 2.2.

4.2.7.2 Sampling Plan. From the first production lot only one instrument shall be randomly selected and subjected to the design tests of Table 5.

TABLE AA

PRODUCTION CONTROL SAMPLING

Lot Size Sample Size

2to8

9to90

91 to 150

151 to 280

281 to 500

501 to 1200

1201 to 3200

3201 to 10,000

10,001 to 35,000

35,001 to 150,000 over 150,001

NOTES:

1.

*Indicates entire lot must be inspected

2.

Acceptance number (failures) in all cases is zero

5. PACKAGING

5.1 Spare Fuses. Two of each fuse that is required for complete operation, besides that provided in paragraph 3.7.2, will be packed with the meter.

6. NOTES

None

TABLE 1

INSPECTION TESTS

Description Section A. Requirements Safety

3.2 Personnel Hazards

3.2.2 Exposed-Edge Rounding

3.2.3 System Safety Engineering Inspection

3.2.4 Remote Unit

3.3.13 Restricted Materials

3.4.1 Marking and Identification

3.5 CAGE Code

3.5.1 Supplemental Identification Plate

3.5.2 Warranty Plate

3.5.4 Equipment Power

3.7 Fuses and Circuit Breakers

3.7.2 Accessories

3.8 Power Cables

3.8.2

TABLE 2

PERFORMANCE PARAMETERS

Parameter

Section A. Requirements

Altitude

3.11.2 Altitude Rate

3.11.2 Decoded Altitude

3.11.2 Airspeed

3.11.2 Simulated True Airspeed Control

3.11.3 Decoded Altitude

3.11.5 Leakage Test Mode

3.11.7 Stability

3.11.11 UUT Protection

3.11.12-3.11.13 Test Set Leakage

3.11.13

TABLE 3

ENVIRONMENTAL TESTS

Parameter

Requirement Temperature 3.9.1 Electromagnetic Interference (EMI) 3.9.2

Altitude 3.9.3 Precipitation 3.9.4 *A certificate of conformance may be provided in lieu of actual testing

TABLE 4

RAM REQUIREMENTS

Parameter Section A. Requirements

Reliability, Availability, and Maintainability

3.10 Reliability

3.10.1 Calibration

3.10.2 Maintainability

4.2.6 Calibration Time

3.10.2.8 Maintenance Provisions

3.10.3

TABLE 5

DESIGN TESTS

Parameter Section A. Requirements Radioactive Materials

3.2.4 Design and Construction

3.3 Weight

3.3.1 Dimensions

3.3.2 Parts, Materials and Processes

3.4 Restricted Material

3.4.1 Interchangeable

3.4.2 Equipment Power

3.7 Fuses and Circuit Breakers 3.7.2 Beneficial comments, recommendations, additions, deletions, clarifications, etc. and any data that may improve this document should be sent to WR-ALC/642 CBSG/GBEA, Robins AFB, GA 31098-1611

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