PD08WRGBGBEA10 - TRB Approved.doc

PD08WRGBGBEA10

REV C

CAGE 98752

17 May 2010

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 specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

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

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-A-81852A

Altitude-Encoder AAU-32/A

MIL-PRF-28800F

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

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD 882D

Standard Practice for System Safety

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

DEPARTMENT OF DEFENSE 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

MIL-HDBK-217

Reliability Prediction of Electronic Equipment

2.2.2 Other Government documents.

NASA TN D-822

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

2.3 Non-Government publications.

The following documents of the exact revision listed below form a part of this document to the extent specified herein.

SK-ED-0017

Flush Static Port Adaptor (Cage Code 81996)

US Standard Atmosphere, 1976 Defines US Standard Atmosphere Institute of Electrical and Electronics Engineers

STD-488.1-1987

Standard for Higher Performance Protocol for the Standard Digital Interface for Programmable Instrumentation (Application for copies should be addressed to IEEE Publications Office, 10662 Los Vaqueros Circle, P.O. Box 3014, Los Alamitos, CA 90720-1264.)

Society of Automotive Engineers

ARP 1199

Selection, Application, and Inspection of Electric Overcurrent Protective Devices (Application for copies should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale PA 15096.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), one sample shall be subjected to first article inspection in accordance with 4.2

3.2 Safety. The equipment shall comply with the Class II safety requirements specified in MIL-STD 882D. The design of the equipment shall not contain any system safety mishap risk categories greater than low as defined in Table A-IV of MIL-STD-882.

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. The safety criteria of MIL-STD 882D shall be made applicable for tasks and efforts such as the part selection, manufacturing and assembly process and any product baseline configuration. 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 design requirement is a radius of 0.0394 inches for edges and a minimum radius of 0.5 inches 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-28800 and shall be a modified commercial-off-the-shelf (COTS) tester. The exterior finish color of the tester shall be Ocean Gray, NAVSEA, and 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 100 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 5.9.11.5 of MIL-STD-1472.

3.3.4 Maneuverability. The equipment shall have wheels to allow one person transport, and shall be maneuverable over various terrain.

3.3.5 Human factors. Equipment shall be in accordance with 4.4P of MIL-STD-1472.

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 shall be read under darkened conditions and direct sunlight. 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

Leakage test mode indication, selector

Altitude slew rate display, selector, indicator

Ambient barometric pressure indication, vent switch

Indicated/true airspeed display

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

3.3.6.2 Test set ready indication. The test set shall indicate when the test set is ready to accept an input from the user.

3.3.6.3 Independent display and control. The test set shall include two independent display and control units: the main unit and the hand held remote unit. Operators shall have the capability to select the main unit or remote unit as the primary controlling unit. Failure of the hand held remote unit shall not prohibit the operator from operating the test set main unit controls and display.

3.3.6.4 Keyboard. A general numeric keyboard/keypad shall be provided as the primary input device for the operators to enter test points, rates of change, etc., and needs to be usable for operators wearing MOPP IV gear or Arctic mittens.

3.3.6.5 Human error design protection. Front panel control functions shall be designed such that neither incorrect adjustment nor random sequencing of functions causes damage to the test set or the unit under test.

3.3.6.6 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 listed in TABLE I.

TABLE I. Display characteristics

3.3.7 Accessibility. The equipment shall be constructed as follows:

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

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

3.3.7.3 Printed circuit cards. Printed circuit cards shall be removable 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 in either position.

3.3.10 Remote unit. 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 and selectable indications which shall be fully and instantaneously selectable for all available display outputs, per requirement. 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.

3.3.11 IEEE-488, RS-232, USB and ethernet bus. The IEEE-488 control bus shall operate with the remote unit connected or disconnected. An Ethernet Bus, RS-232, and Universal Serial Bus (USB) shall also be included on the test set. For more on how these connections are used see3.11.7.

3.3.12 Pressure—vacuum pump. The pressure-vacuum pump shall be a motor driven dry type pump.

3.3.13 Internal pneumatic tubing. The internal tubing system of the test set shall be designed for ease of maintenance.

3.3.14 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.

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

3.3.16 Static pressure limiting. The test set shall not permit the static pressure to exceed 32.2 +/- 0.2 inches Hg.

3.3.17 Total pressure limiting. The test set shall not permit the total pressure to exceed 106.0 +/- 0.2 inches Hg.

3.3.18 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.

3.3.19 Water extraction. The test set shall extract any water accumulation 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.

3.3.20 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 used during the “reset function” to speed up venting.

3.3.21 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.

3.3.22 Warm-up. Warm-up shall be in accordance with 3.8.1.1 of MIL-PRF-28800, except that the warm-up and auto exercise time shall function as follows:

a. Operation temperature -40 deg C to +10 deg C warm up time should not exceed 60 minutes.

b. Operation temperature +0 deg C to +10 deg C warm up time should not exceed 30minutes.

c. Operation temperature +10 deg C to +55 deg C warm up time should not exceed 15 minutes.

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

3.4.1 Restricted material. The equipment shall comply with the restricted material requirements of MIL-PRF-28800, 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-28800.

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

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-28800 shall contain the following information:

a. Nomenclature and Type Designator

b. Contract Number

c. Serial Number

d. National Stock Number “U.S.”

e. Date of Manufacture g.

Unique Identification Number as defined by MIL-STD-130

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-28800.

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 Test Measurement Diagnostic Equipment (TMDE) transit case or in mobile maintenance shelters (tied down). The tester shall be capable of withstanding mechanical shock and vibration characteristics with all forms of transportation.

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

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

3.7.1 Power cables. Power cables, extensions, and adapters shall conveniently connect the tester to the power source. 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-28800.

3.7.2 Input power switch. The input power switch shall be as specified in MIL-PRF-28800. 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 or 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, or the remote control unit, or both.

3.7.3 Fuses and circuit breakers. Adequate instrument protection is required. Fuses, fuseholders, circuit breakers, and associated hardware shall be in accordance with MIL-HDBK-454, Requirement 39. Fuses, fuseholders, and associated hardware should be selected from SAE-ARP 1199. The load should be connected to the fuseholder terminal that terminates in the removable cap assembly. MIL-HDBK-217 provides reliability prediction models for fuses. Fusing should be so applied that fuses in branch circuits will open before the fuses in the main circuit. Common or separate fuse holders shall be provided. Fuses and circuit breakers required for equipment operation shall be according to MIL-HDBK-454. 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 section 4.2.2 in MIL-HDBK-454 for spare fuses.

3.7.4 External ground. The test set shall have an external ground connection.

3.7.5 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.

3.8 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 and to the static pressure port. The fittings shall meet the requirements of SAE AS4841, 37 degree flare, Unified Standard Class 3B thread. The material shall be corrosion resistant. The static port hose fitting shall be size no. 6 (AN Size 6), and the pitot port hose fitting shall be size no. 4 (AN Size 4). The fittings shall also be used to attach the hoses to the individual adapters used on the different airframes.

a. Pitot Static Adapter Connection Points

b. Pitot Port: SAE AS4841, 37 degree flare, Unified Standard Class 3A thread, AN Size 4

c. Static Port: SAE AS4841, 37 degree flare, Unified Standard Class 3A thread, AN Size 6

The Static Hose shall be color coded red and the Pitot Hose shall be color coded blue. Each hose shall be a minimum 40 +/- 2 feet in length. Local manufacture for replacement hoses shall be specified in vendor data package. 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 Commercial accessories. In addition to specified items, other standard accessories furnished with or typical of the commercial instrument shall be included with each unit upon delivery.

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

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 +55 degrees Celsius. The storage temperature range shall be -51 degrees Celsius to +71 degrees Celsius.

3.9.2 Electromagnetic interference (EMI).

The test set shall be in accordance with the following radiated emission and susceptibility requirements of MIL‑STD‑461: RE102 and RS103.

3.9.3 Operating and non-operating altitude. The test set shall meet the performance and accuracy requirements specified herein when operated in altitudes from -1000 to 15,000 feet. Changes in the ambient -barometric pressure shall not affect the performance and accuracy requirements of the test set. The non-operating altitude shall range -1000 to 50,000 feet.

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 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.

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

3.9.6 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.

3.9.7 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-28800.

3.10.2 Calibration. The calibration interval shall meet or exceed 365 days with 85% of instruments (which have not failed) still within tolerance.

3.10.2.1 Special software. Any special software required for calibration or alignment must be provided with each unit on a CD or DVD, and must be Microsoft Windows compatible.

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

3.10.2.3 Disassembly or modification. 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 Check points. All calibration check points shall be easily accessible.

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

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

3.10.2.7 Calibration standards. 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 Calibration record. A complete record of calibration shall be stored on-board in non volatile memory. This shall include date of calibration and any offsets applied. The tester shall be shipped with NIST traceable calibration certificates to prevent it from being calibrated as soon as it gets to the base that ordered it.

3.10.3 Maintenance provisions. The equipment shall meet the maintenance provisions of MIL-PRF-28800 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.

3.10.4 Scheduled maintenance. The time between the scheduled maintenances of the test set shall be no less than 1500 hours. .

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 not exceeding 4.9 Mach 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-859 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 in TABLE II and TABLE III. The test set shall have the capability to display in Psi pressure units.

TABLE II. Ranges

TABLE III. Accuracies

±1.5 knots from50-80 knots ±1 knots from 80-150 knots ±0.5 knots from 150-400 knots ±0.2 knots from 400-1000 knots

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. By simulating True Airspeed it will not need to be calculated using Indicated Airspeed.

3.11.4 Pressure modulation. The test set shall provide a control mode for cycling altitude or airspeed pressure above and below the command set point value. The pressure shall cycle within user specified limits under a controlled rate condition. This mode shall have adjustable settings for range and rate as follows:

The test set shall cycle altitude pressure at a user specified range not to exceed +/-5000 feet above and below the set point command value at a rate no greater than 6000 feet per minute. The test set shall cycle airspeed pressure at a user specified range not to exceed ± 100 knots above or below the set point command at an airspeed rate not exceeding 100 knots per minute.

3.11.5 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.

3.11.6 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 (IEEE-488 referenced in Section 3.3.14). 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.

3.11.7 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-28800 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.

3.11.8 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.

3.11.9 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.

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

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

3.11.9.3 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.

3.11.9.4 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.

3.11.10 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.

3.11.11 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.

3.12 Workmanship. 3. The unit, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.12.1 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.12.2 Cleaning. The unit shall be thoroughly cleaned. Loose, spattered, or excess solder; welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION 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 Classification of inspections

a. First article inspection (see 4.2)

b. Conformance inspection (see 4.3)

4.2 First article inspection. The first article test set shall be subjected to the examinations, tests, and analyses described in 4.5.1 through 4.5.6.3. The contractor shall provide or arrange for all test equipment and facilities.

4.3 Conformance inspection. Each production test set shall be subjected to the examination and tests described in 4.5.1, and burn-in described in 4.5.2.

4.4 Inspection requirements.

4.4.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

4.4.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data and/or shorter intervals shall be provided as appropriate for any specific test.

a.

Date.

c. Time started.

d. Time finished.

c. Ambient temperature.

4.4.3 Test rejection criteria. Throughout all tests specified herein, the test set shall be closely observed for the following conditions, which shall be cause for rejection:

a. Failure to conform to design or performance requirements specified herein or in the contractor’s technical proposal.

b. Any spillage or leakage of any liquid except as allowed herein.

c. Structural failure of any component, including permanent deformation, or evidence of impending failure.

d. Evidence of excessive wear.

e. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

f. Evidence of corrosion or deterioration.

4.5 Test Methods.

4.5.1 Examination of product. Each test set shall be examined to verify compliance with the requirements herein, and prior to accomplishing any tests listed in section 4.5. A contractor-generated, Government-approved checklist shall be used to identify each relevant requirement not verified by a test or analysis, and to document the inspection results. Particular attention shall be given to materials, workmanship, dimensions, surface finishes, protective coatings and sealants and their application, welding, fastening, and markings. Proper operation of each test set function shall be verified. Each production test set shall be inspected to a Government-approved reduced version of the checklist, and shall include the following requirements of Table IV to ensure qualitatively the proper functioning of the equipment, including all operating controls. Certifications shall be provided in accordance with Table V. From each lot a random sample of instruments shall be selected and tested to show conformance with the performance parameters of TABLE VI. Sampling shall be according to TABLE VII. Lots in which samples exhibit any failure shall be screened for that failure before being subjected to environmental tests of TABLE VIII.

TABLE IV. Requirements

TABLE V. Required certifications

TABLE VI. Performance parameters

TABLE VII. Production control sampling

NOTES:

1.

*Indicates entire lot must be inspected

2.

Acceptance number (failures) in all cases is zero

4.5.2 Burn-In. All units used for random sampling testing shall be subject to a minimum 10 hours on-time burn-in period before acceptance inspection/testing. During the last 3 hours of on-time burn-in, the units must operate failure free. Until this time, the units will be allowed to accumulate failures. Each unit 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-hour failure free period, a complete SOT shall be conducted before and after the period. SOT employs the necessary external input and evaluation equipment to determine if the units conform to all the requirements of the associated detail specification. SOC employs a maximum number of active circuits of the units with a minimum requirement for external input or evaluation equipment to ensure that all functions of the units are operational. If the units fail during the SOT, the entire 10 hour burn-in period must be repeated. While under burn-in, the units 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.

4.5.3 System safety hazard analysis. A system safety hazard analysis of the unit shall be conducted in accordance with 4.2 through 4.8 of MIL-STD-882 to demonstrate compliance with the mishap risk requirement of section 3.2.

4.5.4 Environmental

4.5.4.1 Tests. 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.

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

4.5.4.1.2 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.

4.5.4.1.3 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 IX 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.

TABLE VIII. Environmental testing

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

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

4.5.4.1.6 Precipitation test.

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

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

4.5.4.1.6.3 Salt fog test. The first article testers shall be tested in accordance with MIL-STD-810, Method 509.5, to demonstrate compliance with 3.9.4.3. Test duration shall be alternating 24-hour periods of salt fog exposure and drying conditions for 24-hour periods (two wet and two dry).

4.5.4.1.7 Solar radiation. Contractor shall provide certification to demonstrate compliance with 3.9.5.

4.5.4.1.8 Fungus. Contractor shall provide certification to demonstrate compliance with 3.9.6.

4.5.4.1.9 Sand and dust test. The first article testers shall be tested in accordance with MIL-STD-810, Method 510.5, Procedures I (12 hours) and II (90 minutes per side), to demonstrate compliance with 3.9.7.

4.5.5 Reliability.

4.5.5.1 Tests. After showing conformance with all safety requirements of section 3.2 , the instruments shall be tested to show conformance with all RAM requirements of TABLE IX Test Plan IVD of MIL-HDBK-781 shall apply. The contractor shall demonstrate the equipment MTBF (00) 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.

TABLE IX. RAM tests

4.5.5.1.1 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 VIII, 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.

4.5.5.1.2 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 shall be used in MTBF determinations. No single equipment “ON” time shall be less than one-half the average operating time of all equipment “ON” time.

4.5.5.1.3 Examination and test method. The SOT and the 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.

4.5.5.1.4 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 3.10.2 and its subparagraphs.

4.5.6 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.

4.5.6.2 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.

4.5.6.3 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).

5. PACKAGING

5.1 Packaging requirements. For acquisition purposes, the packaging requirements shall be as specified in the contract or order. When actual packaging of materiel is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point's packaging activity within the Military Department or Defense Agency, or within the Military Department's System Command. Packaging data retrieval is available from the managing Military Department's or Defense Agency's automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. NOTES

6.1 Intended use. The Flight Control System Test Set will replace the TTU-205J Pitot/Static Test Set. It is intended to be used on all types of US Air Force aircraft. The Flight Control System Test Set tests the operability of the pitot/static system and the accuracy of the system. It also checks for leaks. It accomplishes these tasks by simulating altitude, airspeed, and pressure. The test set will be used in war zones and non-war zones. There are commercial counterparts to the Flight Control System Test Set. The Air Force’s version of the commercial test set will be more rugged and will interface with all types of airframes through the use of adapters.

6.2 Acquisition requirements. Acquisition documents must specify the following:

a. Title, number, and date of this purchase description.

b. If first article inspection is required (see 3.1).

Comments, suggestions, or questions on this document should be addressed to: WR‑ALC/GRVEC, Robins AFB GA 31098-1813.

AMSC N/A

FSC 4920

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

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