Attachment_J.4__System_Specification.pdf
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- M67854-17-R-7823
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United States Marine Corps
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For Official Use Only
(FOUO)
SYSTEM SPECIFICATION
FOR
SUPPORTING ARMS VIRTUAL TRAINER (SAVT)
TASK ORDER 2 – SYSTEM MODIFICATIONS
PROGRAM MANAGER TRAINING
SYSTEM TRAINING SYSTEMS DIVISION
12211 SCIENCE DRIVE
ORLANDO, FL 32826
DISTRIBUTION B. This protection covers publications required solely for official use or strictly for administrative or operational purposes. Further dissemination only as directed by PROGRAM MANAGER, TRAINING SYSTEMS, MARINE CORPS
SYSTEMS COMMAND (SAVT), 12211 SCIENCE DRIVE, ORLANDO, FLORIDA
32826-3224.., (29 March 2017) or higher DoD authority.
M67854-17-R-7823 08/25/2017
Attachment J.4 ii
FOR OFFICIAL USE ONLY
Table of Contents
Para. /Section Title Page
1. SCOPE
1.1 Identification
2. APPLICABLE DOCUMENTS
2.1 General
2.1.1 Government documents
2.1.2 Non-Government publications
2.2 Order of precedence
3. REQUIREMENTS
3.1 Performance and functional requirements
3.1.1 Student Component Input/Output System
3.1.2 Lensatic Compass
3.1.3 Windows/Red Hat Operating System Upgrades
3.1.4 Cybersecurity
3.1.4.1.1 Software and Operating System updates
3.1.4.1.2 Security Technical Implementation Guides
3.2 Reliability
3.3 Maintainability
3.3.1 Mean-Time-To-Repair (MTTR)
3.3.2 Maximum-repair-time (Mmax)
3.4 Environmental conditions
3.4.1 Operating temperature
3.4.2 Non-operating temperature
3.4.3 Operating relative humidity
3.4.4 Non-operating relative humidity
3.5 Materials and processes
3.5.1 Parts
3.5.1.1 Custom designed microelectronic devices
3.5.1.2 Power supplies
3.5.2 Materials
3.5.2.1 TPE reparability
3.5.2.2 Flammable materials
3.5.2.3 Fire retardant additives
3.5.2.4 Fungus-inert materials
3.5.2.5 Hazardous materials
3.5.2.5.1 Use of hazardous materials
3.5.2.5.2 Marking of hazardous items
3.5.2.5.3 Precautions
3.5.2.6 Metals
3.5.2.7 Wood products
3.5.2.7.1 Preservation
Table of Contents
Para. /Section Title Page iii
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3.5.2.7.2 Fire retardant
3.5.2.7.3 Termite protection
3.5.2.7.4 Grade
3.5.2.8 Radioactive material
3.5.3 Manufacturing processes
3.5.3.1 Painting, and preparation for painting
3.5.3.2 Corrosion prevention
3.5.4 Electromagnetic Environmental Effects (E3)
3.6 Nameplates and product markings
3.6.1 Lettering, permanency, and legibility
3.6.2 Initial Support Kit (ISK) bar code
3.6.3 Marking of units, assemblies, subassemblies, and parts
3.6.3.1 Units
3.6.3.2 Location of ID plates
3.6.3.3 ID plate information
3.7 Plug-in assemblies
3.7.1.1 Assembly chart
3.8 Fuse holders
3.8.1 Fuse rating
3.8.2 Spare fuses
3.9 Controls and indicating devices
3.9.1 Function and operation marking
3.9.2 Function and operation marking location
3.9.3 Sockets
3.9.3.1 Identification and marking of sockets
3.9.3.2 Chassis marking of sockets
3.9.3.3 Chassis marking of sockets, reverse side
3.9.3.4 Location chart for sockets
3.9.3.5 Location chart markings
3.9.4 Printed wiring boards
3.9.4.1 Electrical operation interference
3.9.4.2 Ink type
3.9.4.3 Marking considerations
3.9.5 Terminals, terminal blocks, and strips
3.9.5.1 Marking of terminals, terminal blocks, and strips
3.9.6 Marking for limited space areas
3.9.6.1 ESD marking
3.9.6.1.1 ESD symbols
3.9.6.1.2 ESD symbol location for assemblies
3.9.6.2 ESD sensitive equipment
3.9.6.3 ESD symbol location for equipment
3.9.6.4 ESD symbol visibility
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3.9.6.5 ESD caution statement location for equipment
3.9.6.6 External equipment terminals
3.9.6.7 Reference designators
3.9.6.7.1 Replaced units
3.9.6.7.2 Reference designators for new equipment
3.9.6.7.2.1 Assignment of reference designators
3.9.6.7.2.2 Identification of unmodified GFE
3.9.6.7.2.3 Marking and location of reference designators
3.9.6.8 Cable and wire markings
3.9.6.8.1 Damage due to markings
3.9.6.8.2 Cable and wire marking location
3.9.6.8.3 Cable marking method
3.9.6.8.4 Cable marking information
3.9.6.8.4.1 “W” and “P” cable designations
3.9.6.8.4.1.1 “W” cable designations
3.9.6.8.4.1.2 Numerical portion of “W” designations
3.9.6.8.4.1.3 “P” cable designations
3.9.6.8.4.1.4 Numerical portion of “P” designations
3.9.6.8.4.2 To-from designators
3.9.6.8.4.3 Assembly and part number
3.9.6.8.4.3.1 Assembly and part number marking location
3.9.6.9 CaNDI marking
3.9.6.9.1 Plug-in modules charts for CaNDI
3.9.6.9.2 CaNDI identification, nameplates, and labels
3.9.6.10 Warning marking for simulated and modified equipment
3.9.6.10.1 Trainer-use-only identification
3.9.6.10.1.1 Visibility of other markings
3.9.6.11 Safety markings
3.9.6.11.1 Safety marking of guards, barriers, and access doors, covers, and plates
3.9.6.11.2 Safety marking location
3.9.6.11.3 Marking of safety hazards
3.9.6.11.4 Marking of internal safety hazards
3.9.6.11.5 Equipment energized from multiple power sources
3.9.6.11.5.1 Multiple power sources marking location
3.9.7 Interchangeability
3.9.8 Safety
3.9.8.1 Emergency equipment power disconnect
3.9.8.1.1 Equipment power removal
3.9.9 Human engineering
3.9.9.1 Human engineering performance
3.9.10 Security
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3.9.10.1 Cabinet door locks
3.9.11 Computational system requirements
3.9.11.1 Cybersecurity verifications
3.9.12 Computational system
3.9.12.1 Spare resources
3.9.12.1.1 Spare processing capacity
3.9.12.1.2 Spare memory
3.9.12.1.3 Spare mass storage
3.9.13 Logistics
3.9.13.1 Maintenance
3.9.13.1.1 Maintenance concept
3.9.13.2 Qualitative maintainability requirements
3.9.13.2.1 Special tools
3.9.13.2.1.1 Special tools holders
3.9.13.2.2 Lamps
3.9.13.2.3 Blown fuse indicator lights
3.9.13.2.3.1 Visibility of CaNDI and GFE blown fuse indicator lights
3.9.13.2.4 Utility receptacles
3.9.13.2.4.1 Equipment racks in row configurations
3.9.13.2.4.2 Standalone equipment racks
3.9.13.2.5 Accessibility
3.9.13.2.5.1 Non-repairable assemblies
3.9.13.2.5.2 Routine servicing and maintenance
3.9.13.2.5.3 Cable slack
3.9.13.2.5.3.1 Cables slack behind equipment panels
3.9.13.2.5.3.2 Equipment connection and disconnection
3.9.13.2.5.4 Parts
3.9.13.2.5.4.1 Front panel and sub-chassis removal
3.9.13.2.5.5 Assemblies
3.9.13.2.5.5.1 Units, assemblies, subassemblies, and parts accessibility
3.9.13.2.5.5.2 Locking devices
3.9.13.2.5.5.3 Interior components and parts accessibility
3.9.13.2.5.5.4 Mounting screws, test points, adjustment points, lubricating points accessibility
3.9.13.2.5.5.5 Access panels
3.9.13.2.5.5.6 Accessibility for test probes and maintenance tools
3.9.13.2.5.5.7 Mounting of replaceable assemblies
3.9.13.2.5.6 Covers, panels, and doors
3.9.13.2.5.6.1 Equipment balance
3.9.13.2.5.6.2 Removable covers
3.9.13.2.5.6.3 Hinged front panels
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3.9.13.2.5.6.4 Grounding of parts and assemblies mounted on hinged doors, panels, and covers
3.9.13.2.5.6.5 Opening of hinged panels
3.9.13.2.5.7 Handles
3.9.13.2.5.7.1 Enclosure handles
3.9.13.2.5.8 Modular assemblies
3.9.13.2.5.8.1 Keying of modular assemblies
3.9.13.2.5.8.2 Assembly sockets
3.9.13.2.5.8.3 Grouping of modular assemblies
3.9.13.2.6 Circuit cards
3.9.13.2.6.1 Circuit card connectors
3.9.13.2.6.2 Circuit card connectors, power and ground
3.9.13.2.6.3 Wiring board extender cards
3.9.13.2.6.3.1 Indexing system for extender cards
3.9.13.2.6.3.2 Conducting surfaces of extender cards
3.9.14 Facilities and facility equipment
3.10 Fabrication
3.10.1 Workmanship
3.10.1.1 Cleaning
3.10.1.2 Threaded fasteners
3.10.1.3 Wiring
3.10.1.3.1 Harnesses and cable form containment
3.10.1.3.2 Insulation deformation
3.10.1.3.3 Burns, abrading, and pinch marks
3.10.1.3.4 Wires and cables clearance
3.10.1.4 Shielding
3.10.1.4.1 Fraying
4. VERIFICATION
4.1 Methods of verification
4.2 Classification of verifications
4.3 Inspections and tests
4.3.1 Training scenarios
4.3.2 Stress tests
4.3.3 Training system performance verifications
4.3.4 Reliability verification
4.3.4.1 Assessment duration
4.3.4.2 Data collection and tracking
4.3.4.3 Failure criteria
4.3.4.3.1 Relevant failure classification
4.3.4.3.2 Failures applicable to MTBF determination
4.3.4.4 Reliability assessment conditions
4.3.4.4.1 Environmental conditions during reliability assessment vii
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4.3.4.4.2 Electrical stresses during reliability assessment
4.3.5 Spare resource testing
4.3.5.1.1 Delivered spare mass storage
4.3.5.1.2 Operational spare mass storage
4.3.5.2 Computational network spare capacity
4.3.5.3 I/O subsystem spare capacity
4.3.6 Training device software
4.3.6.1 Cold Start & Installation and Configuration Procedures testing
4.3.6.1.1 Cold Start & Installation and Configuration Procedures initial conditions
4.3.6.1.2 Cold Start results
4.3.6.1.3 Installation and Configuration results
4.3.6.2 Cybersecurity requirements for cold start
4.3.6.3 Media requirements
4.3.7 Maintainability verifications
4.3.7.1 MTTR elements subject to tracking
4.3.8 E3 verifications
5. PACKAGING
6. NOTES
6.1 Definitions
6.1.1 Commercially available off-the-shelf (COTS) item
6.1.2 Commercial Item
6.1.3 Control Drawing
6.1.4 Failure definitions and criteria
6.1.4.1 Chargeable failures
6.1.4.2 Non-chargeable failures
6.1.4.3 Non-relevant failures
6.1.4.4 Relevant failures
6.1.5 Cybersecurity-Enabled Operating System
6.1.6 Initial Support Kit (ISK)
6.1.7 Interchangeable item
6.1.8 Non-Developmental Item (NDI)
6.1.9 Scheduled Maintenance
6.1.10 Trainer Peculiar Equipment (TPE)
6.1.11 Unscheduled On-site Maintenance
6.1.12 User Interface
6.1.13 Verification methods
6.1.13.1 Analysis
6.1.13.2 Demonstration
6.1.13.3 Examination
6.1.13.4 Test
6.2 Changes from previous issue
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ix
TABLES
Table Title Page TABLE I. Requirement/Verification Cross-Reference Matrix
FIGURES
Fig. No. Title Page FIGURE 1. Unit ID Plate FIGURE 2. ESD Symbols FIGURE 3. ESD Caution Label FIGURE 4. Examples of Cable Markings FIGURE 5. Trainer Use Only Identification FIGURE 6. Multiple Power Source Label
FOR OFFICIAL USE ONLY
System Specification For
Supporting Arms Virtual Trainer Task Order 2 – SYSTEM MODIFICATIONS
1. SCOPE
This specification establishes the performance requirements for the SAVT Task Order 2. These requirements include development, fabrication, production, testing, and installation of the Lensatic Compass, STIM box replacement, Windows/Red Hat Operating System upgrade and cybersecurity updates at the following SAVT system locations:
a. Marine Corps Base, Camp Pendleton, California
b. Marine Corps Air-Ground Combat Center, Twenty-Nine Palms, California
c. Marine Corps Base, Camp Lejeune, North Carolina
d. Marine Corps Base, Kaneohe Bay, Hawaii
e. Marine Corps Base, Camp Hansen, Okinawa, Japan
f. SAVT Test Berth currently NAWCTSD, WSIL, Orlando, FL. (to be relocated)
1.1 Identification
For the purposes of this specification, the terms SAVT, trainer, training system, and training device are equivalent.
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 the specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.
2.1.1 Government documents
The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent referenced herein.
MIL-STD-130N - Identification Marking of U.S. Military Property
MIL-HDBK-454B - General Guidelines For Electronic Equipment
DODI 8510.01
Risk Management Framework (RMF) for DoD Information Technology
Appendix C
29 CFR 1910 - Occupational Safety and Health Standards
MIL-STD-1472G - Human Engineering
2.1.2 Non-Government publications
The following documents of the exact revision listed below form a part of this document to the extent specified herein.
ANSI Z535.1-2006 (R 2011) - Safety Colors
ANSI Z535.2-2011
Environmental and Facility Safety Signs
ANSI Z535.3-2011
Criteria for Safety Symbols
ANSI Z535.4-2011
Product Safety Signs and Labels
ANSI Z535.5-2011
Safety Tags and Barricade Tapes (for Temporary Hazards)
EIA RS-471 - Symbol and Label for Electrostatic Sensitive Devices
ASME Y14.44-2008 - Reference Designations for Electrical and Electronics
Parts and Equipment
2.2 Order of precedence
In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this specification, however, supersedes applicable laws and regulations, unless a specific exemption has been obtained.
3. REQUIREMENTS
3.1 Performance and functional requirements
The modified trainer performance baseline shall:
a. Be defined by the results from the Pre-Modification Inspection (PMI) of the existing trainer, as specified in the contract, to describe the simulation characteristics and trainer performance prior to contractor modifications.
b. Include the added functionality and performance requirements defined in section 3.
c. Not introduce new deficiencies to the PMI results.
3.1.1 Student Component Input/Output System.
The SAVT Student Toolset Interface Module (STIM) shall be replaced with a COTS system (per Performance Work Statement (PWS) 3.2). The STIM is the interface between the Image Generator, the Mission computer and student components. The replacement shall ensure there is no loss of student component functionality or performance. The COTS solution shall leave no less than twenty percent spare I/O channels. The spare I/O channels shall be for each individual type of I/O channel supported by the equipment.
3.1.2 Lensatic Compass.
The SAVT shall be modified to incorporate a stimulated military lensatic compass (per PWS 3.2) for student training during scenarios. The compass shall be of fit, function and appearance to the current military lensatic compass used in the field. A replica of a standard military lensatic compass is acceptable. The simulated lensatic compass shall function in both day and night scenarios. The compass shall integrate with the SAVT such that the magnetic North indication displayed by the compass shall match with the magnetic North of the database used during training. The compass shall provide students the capability to determine relative bearing based on the magnetic North indications. The compass shall use a physical wired connection.
3.1.3 Windows/Red Hat Operating System Upgrades
Currently installed operating systems shall be upgraded to newer versions (per PWS 3.2).
Operating systems (OS) such as Windows 7, Windows 7 embedded, Microsoft Server 2008, and Red Hat Linux 4.4 shall be upgraded to Windows 10, Windows 10 embedded, Microsoft Server 2016, and the latest version of Red Hat Linux, respectively. OS upgrades shall not result in loss of current SAVT performance.
Current SAVT spare processing (See 3.9.12.1.1) and spare memory requirements (See 3.9.12.1.2) shall be maintained.
3.1.4 Cybersecurity
The SAVT shall be updated (per PWS 3.2) to meet Risk Management Framework (RMF) requirements for DoD Information Technology compliance per DODI 8510.01.
3.1.4.1.1 Software and Operating System updates
All software applications and operating systems shall be updated with the latest software updates and patches.
3.1.4.1.2 Security Technical Implementation Guides.
All SAVT component IT hardware and software design shall implement all applicable security configurations, policies, options, and settings throughout the development and fielding processes.
3.1.4.1.3 Licenses, Keys, and Passwords.
All software and firmware licenses, keys, and passwords (including patches, updates and upgrades) required for operation of all Cybersecurity-enabled devices, accessories, and ancillary devices shall be provided with the products. Such licenses, keys, and passwords shall enable the Cybersecurity-enabled devices, accessories, and ancillary devices to be used for their intended purpose, and shall be provided to the Government at the time of product delivery. Each license shall be valid over the entire contract life and shall be useable at any SAVT location worldwide.
All software and firmware licenses, keys, and passwords shall be transferrable between hardware to support hardware or software replacement in case of failure. All licenses shall be transferred to the Government upon modification acceptance.
3.1.4.1.4 Other Cybersecurity Requirements.
All Cybersecurity-enabled devices, accessories, and ancillary devices shall be able to implement all applicable control measures, Security Technical Information Guidelines (STIGs), and be able to receive and implement the following
• new software versions/releases/upgrades
• software patches
• anti-virus updates
3.2 Reliability
The minimum acceptable Mean-Time-Between-Failures (MTBF) for the SAVT, as a result of equipment added or modified as a result of the required modifications, shall remain 265 hours.
3.3 Maintainability
3.3.1 Mean-Time-To-Repair (MTTR)
The equipment added or modified as a result of the required modifications shall have a Mean- Time-To-Repair (MTTR) of not greater than 15 minutes for Unscheduled On-site Maintenance (see 6.1.11).
3.3.2 Maximum-repair-time (Mmax)
The equipment added or modified as a result of the required modifications shall have a Maximum-repair-time (MMAX) of 60 minutes to the 90th percentile for Unscheduled On-site Maintenance.
3.4 Environmental conditions
3.4.1 Operating temperature
The equipment added or modified as a result of the required modifications shall meet the specified performance requirements without deterioration when operating in ambient temperatures from 60 degrees Fahrenheit (deg. F) to 80 deg. F.
3.4.2 Non-operating temperature
The equipment added or modified as a result of the required modifications shall not be damaged by non-operating storage in temperatures ranging from 65 degrees Fahrenheit (deg. F) to 160 deg. F.
3.4.3 Operating relative humidity
The equipment added or modified as a result of the required modifications shall meet the specified performance requirements without deterioration when operating in relative humidity range from 50 percent to 75 percent, non-condensing.
3.4.4 Non-operating relative humidity
The equipment added or modified as a result of the required modifications shall not be damaged by non-operating storage in relative humidity range from zero (0) percent to 95 percent, non-condensing.
3.5 Materials and processes
3.5.1 Parts
The equipment added or modified as a result of the required modifications shall consist of Commercial Items (see 6.1.2), Commercially available off-the-shelf (COTS) items (see 6.1.1), and Non-Developmental Items (NDI - see 6.1.8) to the maximum extent practicable. Trainer Peculiar Equipment (TPE - see 6.1.10) shall be kept to a minimum.
3.5.1.1 Custom designed microelectronic devices
The use of custom designed microelectronic devices shall be avoided unless no reasonable alternative exists. Commercial Items, COTS items, NDI, and GFE are exempt.
3.5.1.2 Power supplies
All power supplies to be used in the required trainer modifications shall be COTS or Commercial Items.
3.5.2 Materials
3.5.2.1 TPE reparability
Materials selected for Trainer Peculiar Equipment (TPE) shall ensure that the TPE can be repaired.
3.5.2.2 Flammable materials
Materials shall be noncombustible or fire retardant when exposed to the operating and non-operating environmental conditions specified in 3.4.
3.5.2.3 Fire retardant additives
Only permanent fire retardant additives shall be used.
3.5.2.4 Fungus-inert materials
When the environmental conditions specified in 3.4 are conducive to fungus growth, the equipment shall be fabricated using fungus-inert materials. Guideline 4 of MIL-HDBK-454B may be used for guidance for the selection of fungus-inert materials.
3.5.2.5 Hazardous materials
The equipment shall not expose personnel or the environment to hazardous levels of toxic, carcinogenic, teratogenic, and otherwise hazardous materials as defined by 29 CFR 1910.
3.5.2.5.1 Use of hazardous materials
If hazardous materials are needed in order to meet the performance requirements of this specification, only Government-authorized materials shall be used.
3.5.2.5.2 Marking of hazardous items
The hazardous items shall be marked.
3.5.2.5.3 Precautions
Precautions shall be taken IAW the handling standards for the hazardous materials.
3.5.2.6 Metals
Metals shall be corrosion-resistant, or shall be coated or metallurgical processed to resist corrosion.
3.5.2.7 Wood products
3.5.2.7.1 Preservation
Wood products shall be treated for preservation.
3.5.2.7.2 Fire retardant
Wood products shall be treated for fire retardant.
3.5.2.7.3 Termite protection
Wood products shall be treated for termite protection.
3.5.2.7.4 Grade
Wood products shall conform to commercial Grade B or better.
3.5.2.8 Radioactive material
Radioactive materials shall not be used.
3.5.3 Manufacturing processes
Manufacturing processes shall be IAW established industry standards, such as American Society for Testing and Materials (ASTM), ANSI, and IEEE standards.
3.5.3.1 Painting, and preparation for painting
Painted surfaces shall be prepared and painted IAW the paint manufacturer’s specifications.
3.5.3.2 Corrosion prevention
The equipment added or modified as a result of the required modifications shall resist corrosion when exposed to the operating and non-operating environmental conditions specified in 3.4.
3.5.4 Electromagnetic Environmental Effects (E3)
The equipment added or modified as a result of the required modifications shall comply with all applicable US commercial standards concerning the emission and susceptibility of Electromagnetic Radiation.
3.6 Nameplates and product markings
3.6.1 Lettering, permanency, and legibility
Methods of applying, type of lettering, permanency, and legibility of markings shall be IAW
MIL-STD-130N.
3.6.2 Initial Support Kit (ISK) bar code
The ISK bar code shall contain the contractor-provided ISK (see 6.1.6) IUID number.
Instructions in obtaining the IUID and other information can be found at http://www.acq.osd.mil/dpap/pdi/uid/index.html. A sample IUID number format is: IUID = IAC + EI + PN + SN = LD61340XXXXX0001, where:
a. LD is the Issuing Agency Code (IAC) for DoD
b. 61340 is the Department of Defense Activity Address Code (DoDAAC) No./Enterprise
Identifier (EI)
c. XXXXX is Original Part No. or Training Device No.
d. 0001 is the Serial No.
3.6.3 Marking of units, assemblies, subassemblies, and parts
3.6.3.1 Units
Each unit shall be marked with contractor-supplied identification (ID) plates as shown on FIGURE 1. Unmodified GFE is exempt from the marking requirements of this section.
UNIT 1
XXXXXASSYXXXXX-XXX
Part of Mfg. Part No. XXXXXXX
Part of IUID No. XXXXXXXXXX
Trainer Mfg. Unit Serial No.
Trainer Mfg. Unit Part No.
Trainer Mfg. CAGE No.
Trainer Part No.
Trainer IUID No.
FIGURE 1. Unit ID Plate
3.6.3.2 Location of ID plates
The ID plates shall be:
a. Located in the front and back of the units, at the top center location,
b. Installed so that they are not obscured by other parts.
http://www.acq.osd.mil/dpap/pdi/uid/index.html
3.6.3.3 ID plate information
Information on the ID plates shall include the unit reference designator, assigned IAW this specification, the assembly information, and the trainer Part Number and IUID information, as shown on FIGURE 1.
3.7 Plug-in assemblies
Plug-in assemblies and subassemblies shall be keyed or permanently color-coded.
3.7.1.1 Assembly chart
Where keying or color-coding is impractical, a permanent, legible directory or chart shall be posted conspicuously on the equipment, showing location and orientation of such assemblies and subassemblies.
3.8 Fuse holders
3.8.1 Fuse rating
The current rating of fuses shall be marked adjacent to the fuse holder on TPE, and Commercial Items and NDI (CaNDI) that are procured using Control Drawings (CDs - see 6.1.3). COTS items, unmodified Commercial Items, GFE, and Contractor-Acquired Operational Equipment (CAOE) are exempt.
3.8.2 Spare fuses
“SPARE” shall be marked adjacent to each spare fuse holder on TPE, and CaNDI that are procured using CDs. COTS items, Unmodified Commercial Items, GFE, and Contractor- Acquired Operational Equipment (CAOE) are exempt.
3.9 Controls and indicating devices
3.9.1 Function and operation marking
For TPE, and CaNDI that are procured using CDs, markings shall be provided on the front of each exterior and interior panel, panel door, control mounting surfaces of each chassis and sub-panel to clearly (though necessarily briefly) designate the functions and operations of controls, fuses, and indicating devices mounted thereon, protruding through, or available through access holes therein. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.2 Function and operation marking location
For TPE, and CaNDI that are procured using CDs, function and operation markings shall be located on the panel or chassis in correct relationship to the respective designated items. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.3 Sockets
3.9.3.1 Identification and marking of sockets
For TPE, and CaNDI that are procured using CDs, the chassis shall be marked to identify sockets and parts, modules, or assemblies to be plugged into the sockets. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.3.2 Chassis marking of sockets
For TPE and CaNDI that are procured using CDs, the side of the chassis upon which items are plugged into sockets shall be marked, adjacent to each socket, with the reference designation for the item. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.3.3 Chassis marking of sockets, reverse side
For TPE, and CaNDI that are procured using CDs, the reverse side of the chassis shall be marked, adjacent to each socket, with the reference designation used in the circuit diagram and table of parts to identify the socket itself. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.3.4 Location chart for sockets
For TPE, and CaNDI that are procured using CDs, if there is no space to mark reference designations on sockets and parts, modules, or assemblies mounted in sockets, a location chart shall be placed where it is visible when viewing the chassis. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.3.5 Location chart markings
The location chart shall display the markings described in 3.9.3.1 through 3.9.3.3.
3.9.4 Printed wiring boards
3.9.4.1 Electrical operation interference
Markings on TPE printed wiring boards shall not interfere with electrical operation. COTS items, CaNDI, GFE, and CAOE are exempt.
3.9.4.2 Ink type
When ink is used for marking of TPE printed wiring boards, the ink shall be non-conductive.
COTS items, CaNDI, GFE, and CAOE are exempt.
3.9.4.3 Marking considerations
Markings shall be considered when leakage (creepage) distances are determined on TPE printed wiring boards. COTS items, CaNDI, GFE, and CAOE are exempt.
3.9.5 Terminals, terminal blocks, and strips
3.9.5.1 Marking of terminals, terminal blocks, and strips
Terminals, terminal blocks, and terminal strips on TPE, and CaNDI that are procured using CDs, shall be identified and marked to facilitate replacement of connections. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.6 Marking for limited space areas
Where space limitations prohibit marking on the terminal, terminal block, or terminal strip on TPE, and CaNDI that are procured using CDs, the marking shall be on the chassis adjacent to the terminal, terminal block, or terminal strip. COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.6.1 ESD marking
3.9.6.1.1 ESD symbols
ESD sensitive TPE assemblies, and ESD sensitive CaNDI assemblies that are procured using CDs, shall be marked with the EIA RS-471 or the military symbol as shown on FIGURE 2.
COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
(RS-471)
FIGURE 2. ESD Symbols
3.9.6.1.2 ESD symbol location for assemblies
The symbol shall be located in a position readily visible to personnel when the TPE and CaNDI assembly is incorporated in its next higher assembly. Unmodified COTS items, Unmodified Commercial Items, GFE, and CAOE are exempt.
3.9.6.2 ESD sensitive equipment
Equipment containing ESD sensitive TPE parts and assemblies, and equipment containing ESD sensitive CaNDI parts and assemblies, shall be marked with the EIA RS-471 or military symbol as shown on FIGURE 2 and the ESD caution statement shown on FIGURE 3. Unmodified GFE is exempt.
FIGURE 3. ESD Caution Label
3.9.6.3 ESD symbol location for equipment
The symbol shall be located on the exterior surface of the equipment.
3.9.6.4 ESD symbol visibility
The symbol shall be readily visible to personnel prior to gaining access to ESD sensitive parts and assemblies within the equipment.
3.9.6.5 ESD caution statement location for equipment
The ESD caution statement shall be placed adjacent to the ESD sensitive symbol.
3.9.6.6 External equipment terminals
The EIA RS-471 or military symbol shall be applied on the exterior of the equipment cabinet adjacent to external terminals connected internally to ESD sensitive TPE parts and assemblies and ESD sensitive CaNDI parts and assemblies. Unmodified GFE is exempt.
3.9.6.7 Reference designators
The existing SAVT reference designator system that is already in place in the trainer, shall be continued, avoiding duplication of existing unit and cable numbers.
3.9.6.7.1 Replaced units
All replacement units shall retain existing unit numbers.
3.9.6.7.2 Reference designators for new equipment
Reference designators IAW the unit numbering method of ASME Y14.44-2008 shall be employed to identify and mark the location of electrical and electronic parts and equipment added as a result of the required modifications.
3.9.6.7.2.1 Assignment of reference designators
The assignment of reference designators shall:
a. Begin at the unit level of assembly, and
b. Continue down to the basic part level of assembly as defined in ASME Y14.44-2008.
3.9.6.7.2.2 Identification of unmodified GFE
Unmodified GFE shall be identified on related system or assembly drawings and schematics with assigned unit or assembly level reference designators.
3.9.6.7.2.3 Marking and location of reference designators
Marking and location of reference designators shall be IAW ASME Y14.44-2008.
3.9.6.8 Cable and wire markings
For TPE, GFE, CaNDI, and CAOE, disconnectable or detachable cables and wires shall be permanently and legibly marked. Types of disconnectable or detachable cables and wires include plugs, jacks, lugged terminals, and push-on captivated wires. Jumpers or links located on terminal boards, jacks, or plugs are exempt from such marking. Soldered or wire wrap connections are also exempt from such marking.
3.9.6.8.1 Damage due to markings
Markings shall not damage the wires or cables attached.
3.9.6.8.2 Cable and wire marking location
Markings shall be located within approximately eight centimeters from the back of the connector, terminal, or plug, oriented in such a manner as to be readable without removal of the wire or cable or support clamps.
3.9.6.8.3 Cable marking method
The following methods shall be used to mark disconnectable or detachable cables and wires:
a. Molded on the cable
b. Stamped on the cable
c. Securely attached, marked plastic bands (No less than .25 mm thickness)
d. Bands of marked heat shrinkable tubing
3.9.6.8.4 Cable marking information
3.9.6.8.4.1 “W” and “P” cable designations Disconnectable cables shall be marked with “W” and “P” designations IAW FIGURE 4.
Daisy chain, continuous ribbon cable with clamp on connectors:
UNIT 6
W1P1 6A1J1
W1P2 6A2J1
NOTE (1) PREFIX MAY BE OMITTED FOR WIRES OR CABLES LOCATED ENTIRELY WITHIN THE
SAME CABINET.
NOTE (2) FOR PURPOSES OF THESE MARKING REQUIREMENTS, UNITS COMPRISED OF MULTIPLE
CABINETS OR BAYS PERMANENTLY WELDED OR BOLTED TOGETHER SHALL BE
CONSIDERED AS HAVING SEPARATE CABINETS.
NOTE (3) THE UNDERLYING CRITERIA FOR WIRE AND CABLE MARKING SHALL BE EASE OF
MAINTENANCE AND REDUCTION OF CHANCES FOR MISCONNECTION.
W2P2 4A1J1/5A2J2
W2P1 4A1J1/5A2J2
P/N 927D1057
W3P1 6A1J1/7A1J3/8A5J4
P/N 927D1058
A1CB1-1/A2TB3-10 A1CB1-1/A2TB3-10
W3P2 6A1J1/7A1J3
W3P3 6A1J1/8A5J4
Terminal wire marking:
Multiple destination cable:
W1P3 6A3J1/8A2J1
Basic inter-cabinet cable:
W1P4 6A3J1/8A2J1
W1P5 8A1J1
UNIT 8
FIGURE 4. Examples of Cable Markings
3.9.6.8.4.1.1 “W” cable designations A “W” designation, such as W1, W2, W3, and so on, shall be assigned to uniquely identify cables and wires.
3.9.6.8.4.1.2 Numerical portion of “W” designations
The numerical portion of the “W” designations shall be consecutive throughout the trainer.
3.9.6.8.4.1.3 “P” cable designations Each connector within the same cable shall be identified with a “P” designation, such as P1, P2, P3, and so on.
3.9.6.8.4.1.4 Numerical portion of “P” designations
The numerical portion of the “P” designations shall be consecutive for a given cable.
3.9.6.8.4.2 To-from designators
In addition to the “W” and “P” designations, markings on disconnectable cables and wires shall include “to-from” reference designators, IAW FIGURE 4, to identify the locations where the cables are connected. The “from” designator requirement is not applicable to cables and wires internal to subassemblies.
3.9.6.8.4.3 Assembly and part number
Disconnectable trainer-peculiar wires, cables, and harnesses shall be marked with the applicable assembly or part number.
3.9.6.8.4.3.1 Assembly and part number marking location
The number may be included with other required cable markings where space permits.
Otherwise, a separate marking shall be made adjacent to the “W”, “P”, and “to-from” designator markings IAW FIGURE 4.
3.9.6.9 CaNDI marking
Where CaNDI external marking or identification of controls, fuses, or connectors is absent, such equipment shall be marked with function or rating.
3.9.6.9.1 Plug-in modules charts for CaNDI
Where the equipment contains plug-in modules that are not keyed to prevent incorrect connection or insertion, a permanent legible directory or chart showing identification number, location, or orientation of such modules, shall be provided and posted conspicuously on the equipment.
3.9.6.9.2 CaNDI identification, nameplates, and labels
All nameplates, instruction labels, and equipment identification furnished with CaNDI shall be written in the English language and numbering system.
3.9.6.10 Warning marking for simulated and modified equipment The following types of trainer equipment shall be identified and marked IAW this specification below:
a. GFE or CAOE that has been modified for use in the trainer modifications.
b. Unmodified CAOE that has not been fully tested and certified for military use
c. Simulated equipment which has overall outward appearance which is substantially identical to the operational-tactical equipment for which it could be mistaken
3.9.6.10.1 Trainer-use-only identification
The trainer-use-only identification shall consist of a sticker or nameplate with yellow background and the legend shown on FIGURE 5 in black.
FIGURE 5. Trainer Use Only Identification
3.9.6.10.1.1 Visibility of other markings
The trainer-use-only sticker or nameplate shall not obscure other identification or labeling.
3.9.6.11 Safety markings
Danger, caution, and warning signs, labels, and markings shall be used to warn of specific hazards such as voltage, current, thermal, and physical.
3.9.6.11.1 Safety marking of guards, barriers, and access doors, covers, and plates Guards, barriers, and access doors, covers, and plates shall be marked to indicate the hazard that may be present upon removal of such devices.
3.9.6.11.2 Safety marking location
When practicable, the marking shall be located such that the marking is not removed when the barrier or access door is removed.
3.9.6.11.3 Marking of safety hazards
Hazards shall be marked IAW ANSI Z535.1-2006 (R 2011), ANSI Z535.2-2011, ANSI Z535.3-2011, ANSI Z535.4-2011, and
ANSI Z535.5-2011.
3.9.6.11.4 Marking of internal safety hazards
Hazards internal to units shall be marked adjacent to hazards if they are significantly different from those surrounding items.
3.9.6.11.5 Equipment energized from multiple power sources
A warning label IAW FIGURE 6 shall be affixed to electrical and electronic units that have more than one source of electrical power.
WARNING
THIS EQUIPMENT ENERGIZED FROM MULTIPLE SOURCES.
TURN OFF THE FOLOWING TO FULLY DEENERGIZE THIS UNIT.
SWITCH
LOCATION
SWITCH
IDENTIFICATION CIRCUIT
FIGURE 6. Multiple Power Source Label
3.9.6.11.5.1 Multiple power sources marking location
The warning label shall be affixed in a location where operation and maintenance personnel can identify the circuits providing electrical power, and the location and designation of the de-energizing switches.
3.9.7 Interchangeability
Where practicable, TPE parts shall be made identical and Interchangeable (see 6.1.7). For example, circuit card types should be kept to as few as practicable so that a large inventory of spare circuit cards is unnecessary.
3.9.8 Safety
3.9.8.1 Emergency equipment power disconnect
Equipment added to the trainer, as a result of the required modifications, shall be connected to the existing power disconnect system.
3.9.8.1.1 Equipment power removal
When an Emergency Power Off (EPO) control device is activated, power to the training equipment, including utility power, shall be automatically removed.
3.9.9 Human engineering
Except where operational systems are being replicated, the design, selection, and arrangement of modified equipment shall be IAW MIL-STD-1472G.
3.9.9.1 Human engineering performance
The design, selection, and arrangement of modified equipment shall ensure ease, efficiency, and safety of operation in the performance of necessary functions by instructional, maintenance, and trainee personnel in fulfilling the intended use of the trainer.
3.9.10 Security
3.9.10.1 Cabinet door locks
When equipment cabinets are added as a result of the required trainer modifications, the equipment cabinet doors shall be equipped with key operated locks that are keyed alike.
3.9.11 Computational system requirements
3.9.11.1 Cybersecurity verifications
The Cybersecurity verifications shall consist of executing a set of test procedures and tools, such as DoD approved vulnerability scanners, which validate compliance with DOD approved Security Technical Implementation Guides (STIGs) and the Government provided Cybersecurity controls.
3.9.12 Computational system
Computational system tests shall consist of power-up sequencing, on-line readiness, verification of commercial computer vendor documentation including the computer operator’s manual, and the following:
3.9.12.1 Spare resources
3.9.12.1.1 Spare processing capacity
During execution of the worst-case training scenario(s), as specified in the Government accepted Test Procedure, at least fifty percent of processing capacity of each processing core shall be unused while concurrently not degrading trainer performance. Spare processing capacity shall be measured and applied using the smallest execution time increment (frame time) implemented on each CPU core. Spare processing capacity shall be measured concurrently with spare memory capacity. At no time during execution of the worst-case training scenario(s) shall a frame over-run occur. At no time during execution of the worst-case training scenario(s) shall processing tasks be dropped or delayed from executing during their anticipated or assigned time slot.
3.9.12.1.2 Spare memory
Computational subsystem spare memory requirements shall be determined such that error free operation of the subsystem software shall occur when fifty percent of the installed memory is made unavailable for data and software execution. The physical removal of memory or disabling of memory through BIOS settings shall not be used to accomplish spare testing. Spare memory testing shall be accomplished through test.
3.9.12.1.3 Spare mass storage
Total installed mass storage capacity shall be sufficient to store all required program software, including executable code, databases, and other machine-readable software with a spare storage drive capacity of no less than fifty (50) percent.
3.9.13 Logistics
3.9.13.1 Maintenance
3.9.13.1.1 Maintenance concept
The Navy's objective in training device maintenance is to become independent of the Original Equipment Manufacturer (OEM)/vendor. Initially maintenance shall be accomplished by/through Interim Contractor Support (ICS) Program with follow on support via the Contractor Operation and Maintenance of Simulators (COMS) program. The levels of maintenance for this trainer are on site organizational maintenance (on line and off line) and off site depot maintenance. The on line organizational level of maintenance consists of scheduled maintenance and corrective maintenance (remove and replace), which are performed on site. The off line level of maintenance consists of repair of faulty/inoperable items (on site and off site). The trainer equipment (Commercial Items and TPE) shall be included in each level of maintenance as follows:
a. On-line maintenance: on line organizational maintenance shall emphasize "remove and replace" procedures rather than "repair at point of failure." Corrective maintenance shall be accomplished by module replacement by the ICS contractor or the COMS. Module replacement refers to the smallest unit, assembly, subassembly, and part in which a malfunction can be quickly identified, the unit can be replaced, and the replacement spare can be timely and economically provided and stored. On line organizational maintenance activities shall include the following:
(1) Verify that the trainer is ready for training by performing daily readiness tests and inspections.
(2) Isolate trainer malfunctions to lowest repairable component through the use of standard test equipment, test procedures, computer based diagnostics and by substitution when an ambiguity group is identifiable.
(3) Remove and replace faulty component in a manner that minimizes trainer downtime with verification of the repair using the trainer as a test bed. For example, if the faulty component is a repairable item, replace the component with a spare and arrange for repair of the component at the off line level of maintenance and verify that the substitution returns the trainer to an operable state.
(4) Perform scheduled maintenance and inspections during non-training hours as required.
(5) Isolate and document software related failures.
(6) Alignment and calibration of training system equipment. Procedures to recalibrate all station and console equipment shall take no greater than five minutes and shall be automated to the max extent practical.
b. The off-line level of maintenance shall consist of fault isolation and repair of failed components. The COMS maintains an off line repair capability on site or returns the failed components to the OEM/vendor to accomplish the following:
(1) Overhaul/rebuild modules
(2) Weight Test
(3) Perform piece part repairs
(4) Return defective component to operable condition
(5) Provide replacement components that are fully compatible with the trainer configuration.
(6) Emphasis shall be placed on providing the spare parts, technical documentation, diagnostics, standard Tools and Test Equipment (T&TE) to fully support on site piece part repair. The need for, and use of special T&TE shall be minimized.
c. Offsite maintenance shall consist of commercial repair of failed components that are beyond the capability of onsite repair.
3.9.13.2 Qualitative maintainability requirements
3.9.13.2.1 Special tools
There shall be no need to use special tools for equipment maintenance unless common tools are inadequate. This requirement is applicable to equipment added to the trainer as a result of the required trainer modifications.
3.9.13.2.1.1 Special tools holders
Special tools shall be retained in holders provided inside of the equipment near where the tools are normally used. This requirement is applicable to equipment added to the trainer as a result of the required trainer modifications.
3.9.13.2.2 Lamps
Lamps used in TPE shall be replaceable from the front. COTS items, CaNDI, GFE, and CAOE are exempt from this requirement.
3.9.13.2.3 Blown fuse indicator lights
Blown fuse indicator lights shall be provided and visible on the outside of TPE racks when doors are closed and when standing in front of the racks.
3.9.13.2.3.1 Visibility of CaNDI and GFE blown fuse indicator lights CaNDI, GFE, and CAOE are exempt from the blown fuse indicator lights requirements specified above; however, CaNDI and GFE having blown fuse indicator lights shall be installed so that the indicator lights are not hidden by other equipment installed in the same area.
3.9.13.2.4 Utility receptacles
3.9.13.2.4.1 Equipment racks in row configurations
To facilitate maintenance and to ensure maintenance personnel safety, 60 Hz, 120-Volt, grounding type utility duplex receptacles with ground fault circuit interrupting (GFCI) shall be installed at the bottom of every other newly added equipment rack positioned in row configurations and within six feet of areas where maintenance is to be performed.
3.9.13.2.4.2 Standalone equipment racks
Each newly added, individually located, equipment rack shall be equipped with a 60 Hz, 120- Volt, grounding type utility duplex receptacle with GFCI, externally mounted at the bottom of the rack.
3.9.13.2.5 Accessibility
Trainer modification equipment shall provide access to internal parts, terminals, and wiring, for adjustments, required circuit checking, and the removal and replacement of maintenance parts.
3.9.13.2.5.1 Non-repairable assemblies
Accessibility for testing shall not apply to parts located in non-repairable assemblies.
3.9.13.2.5.2 Routine servicing and maintenance
For routine servicing and maintenance, unsoldering of wires, wire harnesses, parts, or subassemblies shall not be required in order to gain access to terminals, soldered connections, mounting screws, and the like.
3.9.13.2.5.3 Cable slack
The trainer modification equipment shall have sufficient cable slack and cable-bending features to assure full extension access to multiple equipment extensions during maintenance without stressing the cables and associated connectors.
3.9.13.2.5.3.1 Cables slack behind equipment panels
There shall be sufficient slack in the cables behind equipment panels to remove each instrument, display, or control panel and to disconnect them from associated cables in one maintenance operation from the front of the equipment without stressing the cables and associated connectors.
3.9.13.2.5.3.2 Equipment connection and disconnection
The need for rear access to disconnect or reconnect the equipment from associated mounting shall be prevented.
3.9.13.2.5.4 Parts
Replaceable parts shall be readily removable and not be permanently mounted.
3.9.13.2.5.4.1 Front panel and sub-chassis removal
No unsoldering of connections shall be necessary in order to remove front panels and sub-chassis for maintenance purposes.
3.9.13.2.5.5 Assemblies
Parts shall be readily accessible for maintenance.
3.9.13.2.5.5.1 Units, assemblies, subassemblies, and parts accessibility Tracks, rollers, hinges, pivots, or a combination thereof shall provide accessibility to units, assemblies, subassemblies, and parts.
3.9.13.2.5.5.2 Locking devices
Locking devices shall be provided to lock the chassis in the servicing position and in the fully opened and fully closed positions.
3.9.13.2.5.5.3 Interior components and parts accessibility
Each major assembly, subassembly, and unit shall provide access to its interior components and parts for maintenance.
3.9.13.2.5.5.4 Mounting screws, test points, adjustment points, lubricating points accessibility It shall not be necessary to displace or remove wires, cables, subassemblies, or assemblies in order to gain access to mounting screws, test points, adjustment points, lubricating points, and the like.
3.9.13.2.5.5.5 Access panels
Where visual inspection is necessary, and open access is not feasible, transparent access panels shall be used.
3.9.13.2.5.5.6 Accessibility for test probes and maintenance tools The placement of parts shall provide space for the use of test probes and maintenance tools.
3.9.13.2.5.5.7 Mounting of replaceable assemblies
Assemblies subject to replacement or service shall not be permanently fastened.
3.9.13.2.5.6 Covers, panels, and doors
Hinged covers and doors shall be equipped with a mechanism to retain them in their open positions.
3.9.13.2.5.6.1 Equipment balance
When opened, hinged covers and doors shall not cause the equipment to become unbalanced.
3.9.13.2.5.6.2 Removable covers
Removable covers for which no convenient location is available during maintenance shall be equipped with a chain or lanyard fastened to the equipment.
3.9.13.2.5.6.3 Hinged front panels
Front panels containing parts that require maintenance, such as instruments, switches, potentiometers, and the like, shall be hinged.
3.9.13.2.5.6.4 Grounding of parts and assemblies mounted on hinged doors, panels, and covers Where parts or assemblies are mounted on hinged doors, on panels, and on covers, the electrical ground return shall not depend on the hinge contact for electrical continuity.
3.9.13.2.5.6.5 Opening of hinged panels
Hinged panels shall be equipped with a mechanism to retain the panels in the open position to access parts mounted on the panels, to prevent damage to the panels, and to prevent injury to personnel performing maintenance.
3.9.13.2.5.7 Handles
Handles and handgrips shall be provided for removing units or chassis from enclosures.
3.9.13.2.5.7.1 Enclosure handles
Handles on enclosures shall be recessed.
3.9.13.2.5.8 Modular assemblies
Modular assemblies such as circuit boards shall be equipped with connectors so that they may be removed without de-soldering.
3.9.13.2.5.8.1 Keying of modular assemblies
Modular assemblies shall be designed so that they can be inserted into the equipment in one position only.
3.9.13.2.5.8.2 Assembly sockets
Sockets within each assembly shall be oriented in the same direction and positioned so that they are visible.
3.9.13.2.5.8.3 Grouping of modular assemblies
Modular circuits shall be grouped in functional units.
3.9.13.2.6 Circuit cards
Where practicable, functions shall be apportioned to circuit cards to take advantage of standardization and commonality of components, such that the need for spare parts inventory is minimized.
3.9…
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