TCSH_System_Performance_Spec_ver_1-0_20151008.docx

Performance Specification

For the

M1A1

Tank Commander’s Single Handle

Version 1.0

Product Manager, Tank Systems Armor and Fire Support Systems Marine Corps Systems Command

8 October 2015

RECORD OF REVIEW/APPROVAL OF THE

PERFORMANCE SPECIFICATION

FOR THE

TANK COMMANDER’S SINGLE HANDLE

PREPARED BY:

MARCORSYSCOM

Armor and Fire Support Systems

Project Officer, TCSH

CONCURRENCE:

MARCORSYSCOM

Armor and Fire Support Systems

Lead Engineer, PdM Tanks

MARCORSYSCOM

Armor and Fire Support Systems

APPROVAL:

MARCORSYSCOM

Armor and Fire Support Systems Assistant Program Manager, Engineering

Record of Changes

Refer questions concerning this Performance Specification to Mr. Michael Kreiner, TCSH Project Officer, PdM Tank Systems, Marine Corps Systems Command, Quantico, VA (703) 432-5744, michael.l.kreiner@usmc.mil.

Distribution Statement A. Approved for public release; distribution is unlimited.

ii

INTRODUCTION

1.1 Scope. This specification establishes the performance, test, manufacture and acceptance requirements for the Tank Commander’s Single Handle (TCSH).

APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. While every effort has been made to ensure the completeness of this list, document users are cautioned that they shall 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 form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

SPECIFICATIONS

FEDERAL

A-A-59133B Cleaning Compound High Pressure Steam Cleaner

MILITARY

STANDARDS

HANDBOOKS

MIL-HDBK-454B General Guidelines for Electronic Equipment

Unless otherwise indicated, copies of federal and military specifications, standards, and handbooks are available from the Navy Publications and Forms Center (Attn: NPODS), Standardization Documents Order Desk, 700 Robbins Avenue, Philadelphia, PA 19111-5094.

2.2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract

DRAWINGS

OTHER PUBLICATIONS

ATPD-2167 Environmental Test Methods, M1 Tank Program

2.3 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, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

REQUIREMENTS

3.1 Item Definition

The Tank Commander Single Handle (TCSH) shall have the capability of the Commander’s Control Handle (CCH) part number 12283114 and the Stabilized Commander’s weapon Station (SCWS) Grip Assembly part number 12521315 (excluding the intercom function). The new part number is 13060585.

0. Characteristics

3.2.1 Performance

General.

a. AC input power: 26 + 0.1 Vrms. 400 + 8.0 Hertz (Hz) sine wave between J1-A to J1-B.

b. Load: 10,000 + 10 ohms between J1-C to J1-D and J1-E to J1-F.

Circuit Continuity The resistance between circuits defined in Table I shall not exceed 1.0 ohm.

Table I Circuit Continuity

3.2.1.3 Circuit Isolation

Equipment power returns (primary and secondary) shall be electrically isolated from equipment chassis by a resistance of 1 Mohms or greater, and primary power returns isolated from secondary power returns by a resistance of 1 Mohms or greater. A two wire power distribution system shall be used. Equipment signal returns shall be electrically isolated from the equipment chassis by a resistance of 100 Kohm DC or greater at the vehicle/equipment connector interface.

The chassis shall not be used for power current return. The resistance between the pins specified in Table II shall be a minimum of 10 Mohms at 30.0 + 3.0 VDC.

0. Dielectric Withstanding Voltage

a. The following requirements shall be met with the TCSH in the SCWS mode and the track/slew switch in the track position. The leakage current shall not exceed 500 micro amperes during an application of 45 + 5 V rms electrical potential between isolated circuits, and between each isolated circuit and case (indicated wires listed in Table II). The voltage shall be applied for a period of 5.0 (+5,-0) seconds.

Table II Circuit Isolation

b. When 500 VAC electrical potential is applied between isolated circuits and between each isolated circuit and case for a period of 5 seconds, the leakage current shall be no more than 500 microamperes in any rotated position (clockwise (CW), counterclockwise (CCW), elevate or depress).

3.2.1.5 Insulation Resistance

a. The resistance shall not be less than 10 Mohms during an application of 100 + 10VDC electrical potential between isolated circuits and between each isolated circuit and case (indicted wires as listed in Table II).

b. The insulation resistance of the assembly shall be not less than 10 Mohms at 500 volts DC, measured between each terminal and case at any rotated position (CW, CCW, elevate or depress).

3.2.1.6 Voltage Transients and Protection Circuits

The TCSH shall meet the requirements of 3.2 after being subjected to the transients, abnormal voltages and ripple and noise as specified in 12347457.

3.2.1.7 Palm Switch

When the TCSH is in the SCWS mode and the palm is fully depressed, the resistance between J2-F and J2-G and J2-E and J2-H shall be less than 1.0 ohms. When the TCSH is in either Turret or SCWS mode and the palm is released, the resistance between J2-F and J2-G and between J2-E and J2-H shall be greater than 1 Mohms.

3.2.1.8 Trigger

When the TCSH is in the SCWS mode and the trigger is fully depressed, the resistance between J2-J and J2-K shall be less than 2.5 ohms. When the TCSH is in either Turret or SCWS mode and the trigger is released, the resistance between J2-J and J2-K shall be greater than 1 Mohms.

3.2.1.9 Track/Slew Switch

When the TCSH is in the SCWS or turret mode the track/slew switch is in the up position, slew mode, the resistance between J2-P and J2-R shall be less than 2.5 ohms. When the track/slew switch is in the down position, track mode, the resistance between J2-P and J2-R shall be greater than 1 Mohms.

3.2.1.10 Turret/SCWS Switch

When the turret/SCWS switch is in the up position, SCWS mode, the resistance between J2-L and J2-M shall be less than 2.5 ohms and J2-M and J2-N shall be greater than 1 Mohms. When the turret/SCWS switch is in the down position, turret mode, the resistance between J2-N and J2-M shall be less than 2.5 ohms and J2-M and J2-L shall be greater than 1 Mohms.

3.2.1.11 Cursor Control

When the TCSH is in the SCWS mode the cursor control provides linear output voltage which is proportional to the force and voltage applied directionally. With +5.0 VDC + 0.5 VDC applied to J2-A and -5.0 VDC + 0.5 VDC applied to J2-D the cursor shall function as described throughout 3.2.1.11.1 and 3.2.1.11.2.

3.2.1.11.1 Null Voltage

When the cursor control is powered as specified in 3.2.1.11, the cursor control shall have continuous null output of + 125 mVDC Azimuth is measured across J2-C and RTN. Elevation is measured across J2-B and RTN.

3.2.1.11.2 Cursor Control Output

When the cursor control is powered as specified in 3.2.1.11, the full scale output shall be defined as follows: With the cursor in the maximum positive azimuth position (right), the output of J2-C shall be 1.0 (+0.3, -0.2) VDC. With the cursor in the maximum negative azimuth position (left), the output of J2-C shall be -1.0 (+0.2, -0.3) VDC. With the cursor in the maximum positive elevation position (forward), the output of J2-B shall be 1.0 (+0.3, -0.2) VDC. With the cursor in the maximum negative elevation position (back), the output of J2-B shall be -1.0 (+0.2, -0.3) VDC.

3.2.1.12 Palm switch Actuation

The handle shall include a grip safety (palm) switch. This switch shall be a momentary, normally open positioned such that it is depressed when griping the handle. The palm switch shall be a discrete output. Actuation force shall be 18 + 5 ounces (at switch) with a pre-travel of 0.060 inches maximum and an over-travel of 0.156 inches minimum.

3.2.1.13 Weapon Trigger Actuation

The handle shall include a trigger. This switch shall be a momentary, normally open button with actuator. Actuation force shall be 4.0 + 1.0 pounds (at switch) with a resistive force of 1.0 pound minimum and total travel of 0.085 + 0.015 inches.

3.2.1.14 Turret/SCWS Switch Actuation

The handle shall include a turret/SCWS switch. The turret/SCWS switch shall be a two position low profile rocker switch. When in the “UP” position, the system shall control the SCWS. When in the “DOWN” position, the system shall control the turret.

3.2.1.15 Track/Slew Switch Actuation

The handle shall include a track/slew switch. The track/slew switch shall be a two position toggle switch. Actuation force shall be 16.0 + 6.0 ounces and a total travel of + 14.0 degrees (+ 2.0 degrees) from center to each position. When in the “UP” position, the system shall function in SLEW mode. When in the “DOWN” position, the system shall function in the TRACK mode.

3.2.1.16 Range/STC Actuation

The handle shall include a range/STC switch. Actuation force shall be 3.5 + 1.0 pounds (at switch) with a resistive force of 1.0 pound minimum. The range switch shall actuate .04 to .01 inches before full travel

3.2.1.17 Cursor Control Switch Actuation

The cursor control is a two axis force operated control device to control SCWS movement in azimuth and elevation. Azimuth movement is signaled by cursor movement to the left or right. Elevation movement is signaled by cursor movement forward and back. Actuation force shall be 1.1 pound-force minimum and no more than 22.5 pound-force with a total travel of + 10.0 degrees (+ 2.0 degrees) from center. The cursor shall return to null position with no mechanical input applied.

3.2.1.18 Torque

The torque required to obtain maximum handle travel shall be:

25 + 10 /-15 in-lb

3.2.1.19 Switch Logic and Continuity

When the TCSH is in the turret mode, the switch and continuity requirement shall be:

The assembly shall conform to the above values in any rotated position (CW, CCW, elevate or depress).

3.2.1.20 Self-Test Circuit

The continuity from J1-L to J1-S shall be less than 0.25 ohms.

3.2.1.21 Null

3.2.1.21.1 Neutral Position

With the TCSH in the turret mode, with the conditions of 3.2.1.1 and the assembly at neutral position, the output signals shall be as stated below.

VRMS Max

When the TCSH is in the SCWS mode there shall be no output signals from J1-C to J1-D or J1-E to J1-F at any operating temperature.

3.2.1.21.2 Hysteresis

With the TCSH in the turret mode, the output signal at neutral position measured between J1-C and J1-D after rotating the handle to full elevate or depress shall be a maximum of + 0.030 VAC in phase to + 0.030 VAC out of phase. The output signal at neutral position measured between J1-E and J1-F after rotating the handle to full CW or CCW shall be a maximum of + 0.030 VAC in phase to + 0.030 VAC out of phase. (Phase is with respect to J1-A and J1-B).

3.2.1.22 Threshold and Mechanical Dead Band

3.2.1.22.1 Elevation

With the TCSH in the turret mode the phase sensitive Vrms at J1-C to J1-D for a handle displacement of 1.5 degrees elevate and depress shall be the null voltage plus .01 Vrms minimum. The phase sensitive Vrms at J1-C to J1-D for a handle displacement of 2 degrees elevate and depress shall be 0.285 to 0.560 Vrms. The handle displacement is defined as degrees rotation from neutral-center position.

3.2.1.22.2 Traverse

With the TCSH in the turret mode the phase sensitive Vrms at J1-E to J1-F for a handle displacement of 2 degrees CW and CCW shall be the null voltage plus .01 Vrms minimum. The phase sensitive Vrms at J1-E to J1-F for a handle displacement of 4 degrees CW and CCW shall be 0.225 to 0.360 Vrms. The handle displacement is defined as degrees rotation from neutral-center position.

3.2.1.23 Scale Factor

With the TCSH in the turret mode and with conditions of 3.2.1.1, scale factor shall be as specified below.

0.24 to 0.35 phase sensitive volt per deg at -25 deg F and +140 deg F

0.078 to 0.100 phase sensitive volt per deg at -25 deg F and +140 deg F

The output from + 22 degrees elevation and + 60 degrees traverse to each extreme position shall be measured.

3.2.1.24 Output Phasing

With the TCSH in the turret mode and with the conditions of 3.2.1.1, the output phasing with the input voltage in each handle direction shall be as specified below.

Physical Characteristics

Weight The total weight of the TCSH shall not exceed 11.0 pounds maximum.

Environmental Conditions The TCSH shall operate under the environmental conditions specified herein. The conditions may occur singly or in any natural combination thereof. The TCSH shall meet the performance characteristics of this document during exposure to those environments designated as operating. The TCSH shall not be damaged nor its performance impaired after exposure to those environments designated as non-operating.

Temperature Operating Temperature The TSCH shall meet the requirements of 3.2.1 during and after exposure to temperatures in the range of -25°F to +140°F.

Storage Temperature The TSCH shall meet the requirements of 3.2.1 before and after being stored to temperatures in the range of -60°F to +160°F.

Vibration The TCSH, when mounted as in its intended application, shall meet the requirements of 3.2.1 during and after exposure to sinusoidal vibration applied in accordance with Table 3 for 180 minutes in each of the three mutually perpendicular axes as shown in Figure 2. The vibration shall consist of a 15 minute logarithmic sweep from 5 to 500 to 5 Hz applied at the assembly mounting base.

Figure 2: TSCH Axes

Table 3: Sinusoidal Vibration Inputs

Note: Null Voltage (3.2.1.11.1) is not checked during vibration, only after.

Shock Null voltage 3.2.1.11.1 is not checked during shock only after.

Basic Shock The TCSH shall meet the requirements of 3.2.1 during and after exposure to 3 shock impulses of 30 ± 3g with 11.0±1.1 milliseconds (ms) half-sine wave applied in each direction of three mutually perpendicular axes for a total of 18 impulses.

Gun Firing Shock The TCSH shall meet the requirements of 3.2.1 during and after to exposure to shock impulses of 100 + 10g’s, 1.0 + 0.2 ms half sine wave applied in each direction of the 3 mutually perpendicular axes for a total of 18 impulses.

Ballistic Shock The TCSH shall meet the requirements of 3.2.1 during and after to exposure to shock impulses of 200 + 20g’s, 0.5 + 0.1 ms half sine wave applied in each direction of the 3 mutually perpendicular axes for a total of 18 impulses.

High Intensity Shock The TCSH and parts thereof, shall remain intact and shall not become secondary projectiles when subjected to high intensity shock levels of 980 + 98g’s, 0.5 + 0.1 ms half sine wave applied in each direction of the 3 mutually perpendicular axes for a total of 18 impulses.

Cleaning Spray The TCSH shall not be damaged by, and shall meet the requirements of 3.2.1 after exposure to a tap water jet or steam spray using agents conforming to A-A-59113 immediately followed by a cold water rise. The jet shall be applied perpendicular to and at a distance of 1.0 + 0.5 feet (ft) from the component surface at a cleaning rate of 1.0 + 0.5 square foot per minute (ft2/min) for at least 10 minutes. The water jet shall be derived from a nozzle having an orifice diameter of 0.25 to 0.30 inch and a nozzle pressure of 25 + 5 pounds per square inch gauge (psig).

Humidity The TSCH shall meet the requirements of 3.2.1 during and after exposure to a relative humidity of up to 95% for five continuous 48 hour cycles as defined in ATPD-2167.

3.4.6 Salt Fog

The TSCH shall meet the requirements of 3.2.1 after exposure to a salt fog atmosphere for 48 hours. The salt fog atmosphere shall be defined as:

· 5% by weight NaCl, and 95% by weight distilled water,

· Fog density shall be approximately 3 quarts solution per 10 ft3 per 24 hours, and

· Ambient temperatures between 90.0 degrees F and 95.0 degrees F.

3.4.7 Chemicals

The TCSH shall meet the requirements of 3.2.1 after exposure to vapors on and in direct contact with the following materials:

a. Hydraulic fluid per MIL-PRF-46170E

b. Cleaning fluid per A-A-59133B

3.4.8 Submergence

The TCSH shall meet the requirements of 3.2.1 after the assembly is submerged to a depth of 1 inch for 30 minutes minimum. Submergence depth shall be measured between the water surface and the top of the assembly. A 30 minute drip-dry period is permissible prior to performance check. Installation of standard connector caps is required during submergence.

3.4.9 Fungus

The TCSH shall not support fungus growth.

Electromagnetic Radiation

3.5.1 Electromagnetic Interference (EMI)

The TSCH shall meet the requirements of MIL-STD-461F specifically CE102, CS101, CS114, CS115, CS116, RE102 and RS103.

0. Bonds and Grounds The TCSH shall provide electrical continuity across the following interfaces. The bonding resistance limits shall apply over the life of the TSCH:

a. 2.5 milliohms or less across the individual faying interfaces of the TSCH enclosure;

b. 2.5 milliohms or less from the handle body to the outer cable shield.

c. 2.5 milliohms or less from the outer cable shield to the connector backshell.

3.5.3 Electrostatic Discharge

In the installed, operating conditions, electrical equipment and subsystems shall be protected from upset and damage due to personnel electrostatic air discharge of +/-15 kV from a 150 picofarad capacitor source through a 330 ohm resistor applied to the TCSH (IAW IEC 61000-4-2).

The electrical equipment and subsystems including electrical connectors, pins, sockets and jacks, for both operating and maintenance conditions, shall be protected from damage due to personnel electrostatic air discharge of +/-15 kV from a 150 picofarad capacitor source through a 330 ohm resistor applied to the TCSH (IAW IEC 61000-4-2).

3.6 Design and Construction

3.6.1 Production Drawing

The TCSH shall conform to the requirements of Drawing 13060585.

3.6.2 Identification and Marking

The TCSH shall be identified and marked in accordance with MIL-STD-130N.

3.6.3 Workmanship

Workmanship shall be such that the TCSH shall be free of burrs, chips, scratches, sharp edges, cracks, surfaces out of alignment, or out of contour (visually apparent). There shall be no evidence of conditions that could present a safety hazard to operating or maintenance personnel. The TCSH shall contain no loose foreign material. Workmanship shall be in accordance with MIL-HDBK-454B, Guideline 9, or best commercial practices.

3.6.4 Corrosion

There shall be no evidence of corrosion on the TCSH.

3.6.5 Magnesium and Magnesium Alloys

Magnesium and magnesium alloys shall not be used.

3.7 Standards of Manufacture

3.7.1 Crimp Contacts

Crimp type connector contacts shall be crimped using tools and procedures defined in MIL-C-22520.

3.7.2 Heat Shrinking

Rubber tubing per MIL-R-46846D shall be uniformly heat shrunk until the tubing configuration reflects the contour of the surface it is intended to insulate.

3.7.3 Wire Marking

All wires shall be marked with the applicable circuit number identified on the wiring diagram. Individual wires shall be marked at three inch intervals except individual wires which are within multicolor cables may be marked only within three inches of the wire termination. Marking shall be in accordance with MIL-M-81594A.

3.7.4 Optional Wire

A mixture of optional wire types shall not be used within any single TCSH.

3.7.5 Wire Stripping

Thermal stripping is mandatory for the removal of the outer jacket insulation of the shielded cables and wires of the No. 12 AWG and smaller diameters.

3.8 Switch Reliability

The TCSH shall contain switches/buttons to meet the function requirements and each switch shall have an endurance of 200,000 cycles.

3.9 Chemical, Biological, Radiological and Nuclear (CBRN)

3.9.1 Nuclear Survivability and Hardening

The TCSH shall meet the performance requirements of 3.2.1 after exposure to initial nuclear radiation, which includes neutron fluence, gamma peak dose rate, and total radiation dose as specified in LS199500011841.

3.9.2 Decontamination

The system shall be able to be decontaminated as identified in Appendix A – Nuclear, Biological, and Chemical (NBC) Contamination Survivability Criteria.

Quality Assurance Provisions

Responsibility for Inspection Unless otherwise specified in the contract, the contractor is responsible for the performance of all inspection requirements (examination and test) as specific herein. Except as otherwise specified in the contract, the contractor may use his own or any other facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness or perform any of the inspections set forth in this specification.

Responsibility for Compliance All items shall meet all requirements of Sections 3 and 5. The inspection set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of ensuring that all products submitted to the Government for acceptance comply with all requirements of this specification and contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

Inspection Equipment Unless otherwise specified in the contract, the contractor is responsible for the provision and maintenance of all inspection and test equipment necessary to ensure that supplies and services conform to contract requirements. The contractor may utilize equipment or methods equal to or exceeding the accuracy and precision requirements of any equipment that may be specified herein. Under any circumstance, measurements shall be made to an accuracy of 10 percent of the component tolerance. Calibration of inspection and test equipment shall be in accordance with ANSI/NCSL-Z450-1.

4.1.3 Classification of Inspections

The inspection requirements specified herein and identified in the category of inspections of Table 4 are classified as follows:

a. First Article

b. Quality Conformance

c. Control Tests

4.1.4 Inspections Condition

Unless otherwise specified, all inspections, demonstrations, and testing shall be performed under the following conditions:

· Air temperature 73 + 10 degrees F

· Barometric pressure 28.5 (+2.0, -3.0) in Hg

· Relative humidity 50 + 30 percent

4.1.5 Requirement Verification

Table 4 provides the cross reference between system requirements in section 3 and the verification methods in section 4. The test classifications are: First Article (FAT), and Quality Conformance Inspection (QCI).

Table 4. Requirement Verification Cross Reference

4.4.8

4.4.9

4.6.5

4.1.6 Quality Conformance Inspection (QCI). Each inspection shall be performed in accordance with Table 4. QCI shall be performed on 100% on the units. Any assembly that fails to conform to any examination/test shall be rejected. The rejected assembly may be repaired or corrected, and resubmitted for inspection.

Performance Testing Methods

System Performance Tests General Unless otherwise specified, the inspection herein shall be performed with the AC input power and loads as specified in 3.2.1.1 applied to the respective connections specified in 3.2.1.1.

Circuit Continuity With no input voltage applied, the resistance between each pin of each Group specified in Table 1 shall not exceed 1.0 ohm.

Circuit Isolation With no input voltage applied, and chassis disconnected, the resistance from each pin defined in Table 2 to chassis shall be a minimum of 10 Mohms at 30.0 + 3.0 VDC.

Dielectric Withstanding Voltage

· With no input voltage (4.2.1.1) applied and using a megger, apply a 500 + 50 VAC electrical potential for a period of 5 seconds minimum between circuits and between circuits and assembly case as specified below.

· J1-A to C, E, G, L, P, R, T and case

· J1-C to E, G, L, P, R, T and case

· J1-E to G, L, P, R, T and case

· J1-G to L, P, R, T and case

· J1-L to P, R, T and case

· J1-P to R, T and case

· J1-R to T and case

· J1-T to case

Using the megger microammeter, measure the current leakage between all above circuits. Values shall be in accordance with 3.2.1.2. The assembly may be static, rotated, elevated, or depressed when performing this test.

· With no input voltage applied, verify the leakage current shall not exceed 500 micro amperes during an application of 45 + 5 Vrms electrical potential between isolated circuits, and between each isolated circuit and case (indicated wires in Table 2). The voltage shall be applied for a period of 5.0 (+5, -0) seconds. The track/slew switch shall be in the track position. The turret/SCWS switch shall be in the SCWS position.

4.2.1.5 Insulation Resistance

· With no input voltage (4.2.1.1) applied and using a megger, measure the insulation resistance between assembly pins and between pins and case as specified below 500 + 50 VDC, except m, which will have 50 VDC + 10 VDC applied.

· J1-A to C, E, G, L, P, R, T and case

· J1-C to E, G, L, P, R, T and case

· J1-E to G, L, P, R, T and case

· J1-G to L, P, R, T and case

· J1-L to P, R, T and case

· J1-P to R, T and case

· J1-R to T and case

· J1-T to case

Values shall be in accordance with 3.2.1.3. The assembly may be static, rotated, elevated, or depressed when performing this test.

· With no input voltage applied, verify the resistance shall not be less than 10 Mohms during an application of 100 + 10 VDC electrical potential between isolated circuit and between each isolated circuit and case (indicated wires as listed in Table 2).

1. Voltage Transients and Protection Circuits After being subjected to the transients, abnormal voltages and ripple and noise as specified in 12347457 the TCSH shall meet the requirements of 3.2.1.

1. Palm Switch With the turret/SCWS switch in the SCWS mode, fully depress the palm switch. Monitor the resistance between J2-F and J2-G and between J2-E and J2-H. Verify the resistance between each set of pins shall be less than 1.0 ohms. Release the palm switch. Monitor the resistance between J2-F and J2-G and between J2-E and J2-H. Verify the resistance between each set of pins shall be greater than 1.0 Mohm.

1. Trigger With the turret/SCWS switch in the SCWS mode, fully depress the trigger switch. Monitor the resistance between J2-J and J2-K. Verify the resistance between the pins shall be less than 2.5 ohms. Release the trigger switch. Monitor the resistance between J2-J and J2-K. Verify the resistance between the pins shall be greater than 1.0 Mohm.

1. Track/Slew Switch With the turret/SCWS switch in the SCWS mode, and the track/slew switch in the up position (slew mode), monitor the resistance between J2-P and J2-R. Verify the resistance between the pins shall be less than 2.5 ohms. With track/slew switch in the down position (track mode), monitor the resistance between J2-P and J2-R. Verify the resistance between the pins shall be greater than 1.0 Mohm.

1. Turret/SCWS Switch With the turret/SCWS switch in the up position (turret mode), monitor the resistance between J2-L and J2-M shall be less than 2.5 ohms and J2-M and J2-N shall be greater than1 Mohms. With the turret/SCWS switch in the down position (SCWS mode), monitor the resistance between J2-N and J2-M shall be less than 2.5 ohms and J2-M and J2-L shall be greater than1 Mohms.

1. Cursor Control The reference voltage between J2-A to J2-D is ½ half the difference. With +5.0 (+ 0.25) VDC applied to J2-A and -5.0 (+ 0.25) VDC applied to J2-D, the cursor shall function as described throughout 4.2.1.11.

Null Voltage Apply +5.0 VDC to J2-A and -5.0 VDC to J2-D. Verify the cursor control for azimuth shall have continuous null output of + 125 mVDC maximum measured across J2-C and RTN. Verify the cursor control for elevation shall continuous null output of + 125 mVDC maximum measured across J2-B and RTN.

Cursor Control Output Apply +5.0 VDC to J2-A and -5.0 VDC to J2-D. Verify with the cursor moved to the maximum left position, the output of J2-C shall be 1.0 (+0.3, -0.2) VDC. Verify with the cursor moved to the maximum right position, the output of J2-C shall be -1.0 (+0.3, -0.2) VDC. Verify with the cursor moved to the maximum forward position, the output of J2-B shall be 1.0 (+0.3, -0.2) VDC. Verify with the cursor moved to the maximum back position, the output of J2-B shall be -1.0 (+0.3, -0.2) VDC.

4.2.1.12 Palm Switch

Using a volt-ohm meter between pins J1-G to J1-P, the resistance shall decrease from greater than 5 megohms to less than 0.5 ohms when the palm switch actuator is depressed .10 to .22 inches from the free position. Switch actuation travel shall be measured at the farthest point from switch actuator fulcrum. Depress the palm switch and verify the force to actuate shall be 18 + 5 ounces (at switch). Measure the distance to actuate the palm switch, verify the pre-travel shall be 0.060 inches maximum and an over travel shall be 0.156 inches minimum.

4.2.1.13 Trigger Switch

With the palm and trigger switch fully depressed and a volt-ohm meter attached between pins J2-G and J2-T, slowly release the trigger switch. The resistance shall increase from less than 0.5 ohms to greater than 5 megohms when the trigger switch actuator is depressed .04 to .01 inches from the fully depressed position. Switch actuation travel shall be measured at the farthest point from the switch actuator fu1crum. Depress the trigger switch and verify the force to actuate shall be 4.0 + 1.0 pounds (at switch). After actuation, verify there shall be a resistive force of 1.0 pound minimum.

4.2.1.14 Turret/SCWS Switch

Verify that the force to toggle the track/slew switch shall be 16.0 + 6.0 ounces. Verify there shall be a total travel of + 14.0 degrees (+ 2.0 degrees) from center.

4.2.1.15 Track/Slew Switch

Verify that the force to toggle the track/slew switch shall be 16.0 + 6.0 ounces. Verify there shall be a total travel of + 14.0 degrees (+ 2.0 degrees) from center.

4.2.1.16 Range/STC Switch.

With the turret/SCWS switch in the turret mode and the palm and range switch fully depressed and a volt-ohm meter attached between pins J1-G and J1-R, slowly re1ease the range switch. The resistance shall increase from less than 0.5 ohms to greater than 5 megohms when the range switch actuator is depressed .04 to .0l inches from the fully depressed position. Switch actuation travel shall be measured at the farthest point from the switch actuator fulcrum. Depress the range/STC switch and verify the force to actuate shall be 4.0 + 1.0 pounds (at switch). After actuation, verify there shall be a resistive force of 1.0 pound minimum.

4.2.1.17 Cursor Control

The cursor control is a two axis force operated control device to control SCWS movement in azimuth an elevation. Verify the force to actuate the cursor control switch in the left and right directions (azimuth) shall be 1.1 pounds-force minimum and no more than 22.5 pounds-force. Verify the force to actuate the cursor control switch in the forward and back directions (elevation) shall be 1.1 pounds-force minimum and no more than 22.5 pounds-force. Verify there shall be left and right direction (azimuth) total travel of + 10.0 degrees (+ 2.0 degrees) from center. Verify there shall be forward and back direction (elevation) total travel of + 10.0 degrees (+ 2.0 degrees) from center.

4.2.1.18 Torque

Mount a torque sensor to measure CW and CCW torque values. Measure torque at each CW and CCW extreme handle positions. Values shall be in accordance with 3.2.1.18. Remount torque sensor to measure elevate and depress torque values. Measure torque at each elevate and depress extreme handle positions. Values shall be in accordance with 3.2.1.18.

4.2.1.19 Switch logic and continuity.

With a volt-ohm meter measure each of the circuits with the conditions specified in 3.2.1.19. All values shall be in accordance with 3.2.1.19. The assembly may be static, rotated, elevated or depressed when performing this test

4.2.1.20 Self-test circuit.

With a volt-ohm meter, measure the resistance between J1-L to J1-S. The value shall be in accordance with 3.2.1.20.

4.2.1.21 Null

4.2.1.21.1 Neutral position.

Using a phase angle voltmeter, measure the phase sensitive and maximum Vrms outputs between Jl-C to Jl-D and J1-E to JI-F with the handle assembly at neutral position. Values shall be in accordance with 3.2.1.21.1.

4.2.1.21.2 Hysteresis.

Using a phase angle voltmeter between pins J1-C and J1-D, the maximum phase sensitive voltage measured after each of 3 full elevate and full depress back to neutral position shal1 be in accordance with 3.2.1 .21.2. Using a phase ang1e voltmeter between pins J1-E and J1-F, the maximum phase sensitive voltage measured after each of 3 full CW and CCW back to neutral position shall be in accordance with 3.2.1.21.2.

4.2.1.22 Thresho1d and Mechanical Deadband

4.2.1.22.1 Elevation.

With a phase angle voltmeter connected between J1-C and J1-D and an angular measuring device mounted to indicate elevate and depress degrees, the phase sensitive output measured at 1.5 and 2.0 elevate and depress shall be in accordance with 3.2.1.22.1.

4.2.1.22.2 Traverse.

With a phase angle voltmeter connected between J1-E and J1-F and a rotational measuring device mounted to indicate CW and CCW degrees of rotation, the phase sensitive output measured at 2 and 4 CW and CCW shall be in accordance with 3.2.1.22.2.

4.2.1.23 Scale factor.

With a phase angle voltmeter connected between J 1-C and J1-D and an angular measuring device mounted to indicate elevate and depress degrees, the output measured per degree of movement shall be in accordance with 3.2.1.23. With a phase angle voltmeter connected between J1-E to J1-F and a rotational measuring device mounted to indicate CW and CCW degrees of rotation, the output measured per degree of rotation shall be in accordance with 3.2.1.23. The elevation scale factor shall be calculated using the least squares fit method starting at the positive threshold using a minimum of 4 equally spaced measurements up to +22°, and then calculating the depression scale factor using the least squares fit method starting at the negative threshold using a minimum of 4 equally spaced measurements down to -22°. The CW scale factor shall be calculated using the least squares fit method starting at the positive threshold using a minimum of 4 equally spaced measurements through +60°, and then calculating the CCW scale factor using the least squares fit method starting at the negative threshold using a minimum of 4 equally spaced measurements through -60°.

1. Output Phasing With the phase angle voltmeter connected between J1-C and J1-D, depress the handle assembly. Phasing shall be in accordance with 3.2.1.24. Elevate the handle assembly. Phasing shall be in accordance with 3.2.1.24. With a phase angle voltmeter connected between J1-E and J1-F, rotate the handle assembly CW. Phasing shall be in accordance with 3.2.1.24. Rotate the handle assembly CCW. Phasing shall be in accordance with 3.2.1.24.

4.3 Physical Characteristics

4.3.1 Weight

The assembly shall be weighed to verify conformance to the weight requirements of 3.3.1.

4.4 Environmental Conditions

4.4.1 Temperature

4.4.1.1 Operating Temperature

The assembly shall be subjected to the operating temperature test of ATPD-2167 to verify conformance to 3.4.1.1. The assembly shall be subjected to the tests of 4.2.1 both during and after exposure.

4.4.1.2 Storage Temperature

The assembly shall be subjected to the storage temperature test of ATPD-2167 to verify conformance to 3.4.1.2. The assembly shall be subjected to the tests of 4.2.1 after exposure.

4.4.2 Vibration

The assembly shall be mounted using its mounting hardware, or equivalent, and subjected to the vibration test of ATPD-2167 to verify conformance to 3.4.2. During exposure, the assembly shall be subjected to the tests of 4.2.1.7 through 4.2.1.11 once in each axis. At the conclusion of the test, the assembly shall be examined for damage and subjected to the performance tests of 4.2.1.

4.4.3 Shock

4.4.3.1 Basic Shock

The assembly shall be mounted using its mounting hardware, or equivalent, and subjected to the shock test of ATPD-2167 to verify conformance to 3.4.3.1. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.3.2 Gun Firing Shock

The assembly shall be mounted using its mounting hardware, or equivalent, and subjected to the shock test of ATPD-2167 to verify conformance to 3.4.3.2. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.3.3 Ballistic Shock

The assembly shall be mounted using its mounting hardware, or equivalent, and subjected to the shock test of ATPD-2167 to verify conformance to 3.4.3.3. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.3.4 High Intensity Shock

The assembly shall be mounted using its mounting hardware, or equivalent, and subjected to the shock test of ATPD-2167 to verify conformance to 3.4.3.4. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.4 Cleaning Spray

The assembly shall be subjected to the cleaning spray test of ATPD-2167 to verify conformance to 3.4.4. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.5 Humidity

The assembly shall be subjected to the humidity test of ATPD-2167 to verify conformance to 3.4.5. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.6 Salt Fog

The assembly shall be subjected to the salt fog test of ATPD-2167 to verify conformance to 3.4.6. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.7 Chemicals

The assembly shall be subjected to the chemicals test of ATPD-2167 for a minimum of 48 hours to verify conformance to 3.4.7. After exposure, the assembly shall be subjected to the tests of 4.2.1.

4.4.8 Submergence

The assembly shall be submerged in clean water to a depth of 1 inch, measured between the surface and the top surface of the assembly, for a period of 30 minutes minimum to verify conformance to 3.4.8. Installation of standard connector caps is permissible. After exposure, the assembly shall be subjected to the tests of 4.2.1. A 30 minute drip dry period is permissible prior to performing the tests of 4.2.1.

4.4.9 Fungus

Compliance shall be verified through analysis that the system meets the requirements outlined in Mil-Std-810G Method 508.6.

4.5 Electromagnetic Radiation

4.5.1 Electromagnetic Interference

The TSCH shall be tested for compliance with the EMI requirements (3.5.1) using the methods described in MIL-STD-461F. Compliance may also be established through analysis if approved by the procuring activity.

4.5.2 Bonds and Grounds

Measure the DC resistance of each bond in accordance with MIL-STD-202H, method 3. Verify that the DC resistance is as specified in 3.7.1

4.5.3 Electrostatic Discharge

Test the assembly in accordance with the methods of IEC 61000-4-2 to verify conformance to 3.7.2

4.6 Design and Construction

4.6.1 Production Drawing

Visual examination shall be performed during fabrication and assembly to verify conformance to drawing 13060585.

4.6.2 Identification and Marking

Visual inspect the assembly to verify conformance to 3.6.2.

4.6.3 Workmanship

Visual inspection shall be performed on each assembly and at all phases of fabrication, assembly, and test to verify conformance to 3.6.3.

4.6.4 Corrosion

Visual inspection shall be performed on each assembly to verify conformance to 3.6.4.

4.6.5 Magnesium and Magnesium Alloys

A review of the documentation which describes the materials used in manufacturing and assembly shall be performed to verify the materials are free of magnesium and magnesium alloys in accordance with 4.6.5.

4.7 Standards of Manufacture

4.7.1 Crimp Contacts

The assembly shall be inspected for crimp type connector contacts, that they are crimped using tools and procedures defined in MIL-C-22520.

4.7.2 Heat Shrinking

Rubber tubing per MIL-R-46846D shall be inspected for uniform heat shrink until the tubing configuration reflects the contour of the surface it is intended to insulate.

4.7.3 Wire Marking

All wiring shall be inspected for marking with the applicable circuit number identified on the wiring diagram. Individual wires shall be marked at three inch intervals except individual wires which are within multiconductor cables may be marked only within three inches of the wire terminal. Marking shall be in accordance with MIL-M-81594A.

4.7.4 Optional Wire

The assembly shall be inspected to assure that a mixture of optional wire type are not used within any single assembly.

4.7.5 Wire Stripping

The assembly shall be inspected for mandatory thermal stripping, for the removal of outer jacket insulation of shield cables and wires of No. 12 AWG and smaller diameters.

4.8 Switch Reliability

Monitor the appropriate pins of the TSCH for each switch test. For each switch (palm, trigger, track/slew, turret/SCWS, range/STC, cursor) verify that the switch meets the requirement of 3.7. Each switch shall be subjected to 200,000 cycles and checked at the end to see that it is still operational. One cycle consist of an open and closed or going from position to the other position and then back to the original positon.

4.9 Chemical, Biological, Radiological and Nuclear

4.9.1 Nuclear Survivability and Hardening

The assembly shall meet the requirements 3.8.1 on the basis of circuit analysis, electronic piece part component test data, and testing. Each electronic piece part component shall be analyzed to determine the radiation survivability design margin. The design margin is the radiation level at which electronic piece part circuit parameter failure occurs compared to the specified radiation criteria. When the generic part design margins are less than 10, statistical analysis providing a probability of survival in the circuit application of 99 percent at 90 percent confidence of the actual electronic device test data shall be performed.

4.9.2 Decontamination

Verification of conformance to 3.8.2 shall be accomplished by inspection, analysis, certification or test, as required.

Section 5: Packaging

5.1 Preservation, Packaging, and Packing

Materials and methods for packaging, packing, and preserving the assembly shall be as specified in MIL-STD-2073.

5.2 Marking for Shipment and Storage

Interior packages and exterior shipping containers shall be marked according to MIL-STD-129R.

Appendix A – Nuclear, Biological, and Chemical (NBC) Contamination Survivability Criteria

A.1 Scope This annex establishes quantitative NBC contamination survivability criteria for material. Quantitative criteria, expressed in terms of decontaminability, hardness, and compatibility, are designed to ensure that all materiel systems developed can be used by personnel who are wearing protective clothing and equipment.

A.2 Criteria

A.2.1 Decontaminability Criteria

A.2.2.1 Contaminants The exterior and interior surfaces of materiel developed shall be designed such that NBC contamination remaining on, or desorbed or reaerosolized from, the surface following decontamination shall not result in more than a negligible risk (as defined in Table A-1) to unprotected personnel working inside, on, or 1 meter from the item. The following (worst case) conditions apply:

Exterior surfaces initially are uniformly and separately contaminated with:

a. 10g/m2 of thickened droplets of GD having a mass median diameter (MMD) of 2-5mm.

b. 10g/m2 of unthickened VX

c. 10g/m2 of unthickened HD

d. 105 spores/m2 of biological agent 1-5 micrometers in size.

e. 4 g/m2 of insoluble radioactive contaminants 37-200 micrometers in size and 185 Gbq/m2 gamma activity.

Initial contamination levels on interior surfaces subject to contamination are a factor of 10 lower than on exterior surfaces in the absence of evidence to the contrary.

A.2.2.2 Decontamination begins 1 hour after contamination using standard field decontaminants or simulants, equipment and procedures; and the decontamination process, excluding monitoring, lasts no longer than 75 minutes. Suitable stimulants may be used.

A.2.2.3 Exposure of unprotected personnel to the decontaminated material is not to exceed 12 hours. Surface temperature is 30 C average and exterior wind speed no greater than one m/s (3.6km/h).

A.2.2.4 Induced Activity Materiel developed shall be designated such that, when exposed to a neutron fluence from a nuclear detonation that results in a total dose of 3,000 cGy (rad) to the crew of the equipment, the neutron induced activity in the item will result in no more than a negligible risk (as defined in Table A 1.) to unprotected personnel arriving at H+2 and remaining inside, on, or 1 meter from the item, not to exceed 12 hours.

Table A 1: Negligible Risk Values for NBC…