g_SAVT_TO2_SPEC_DRAFT__18_April_17.pdf

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 F. 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 04/14/2017

Attachment XXXX ii

FOR OFFICIAL USE ONLY

Table of Contents

Para./Section Title Page

1. SCOPE

1.1 Identification

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 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

3.1.5 SAVT Test Berth relocation

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

Table of Contents

Para./Section Title Page iii

FOR OFFICIAL USE ONLY

3.5.2.6 Metals

3.5.2.7 Wood products

3.5.2.7.1 Preservation

3.5.2.7.2 Fire retardancy

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

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3.9.6.2 ESD sensitive equipment

3.9.6.3 ESD symbol location for equipment

3.9.6.4 ESD symbol visibility

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

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3.9.9 Human engineering

3.9.9.1 Human engineering performance

3.9.10 Security

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

3.9.13.2.4.3 Other trainer areas

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

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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

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

3.9.14.1 Trainer power requirements

3.9.14.1.1 Monitors and indicators

3.9.14.1.2 Under and overvoltage

3.9.14.1.3 Multiphase power line protection

3.9.14.1.4 Visual indication

3.9.14.1.5 Voltage transients

3.9.14.1.6 Phase rotation

3.9.14.1.7 Phase sequence

3.9.14.1.8 Under-frequency

3.9.14.1.9 Automatic shutdown

3.9.14.1.10 Frequency transients

3.9.14.1.11 Frequency variations

3.9.14.1.12 Power interruption

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

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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

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

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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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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

Attachment XXXX

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. * Marine Corps Air Station, Yuma, Arizona (Not included in this Task Order)

g. SAVT Test Berth currently NAWCTSD, WSIL, Orlando, FL. (to be relocated)

*MCAS Yuma SAVT system is not included in this Task Order. Future Task Order option may be requested at a later date specific to this site.

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.

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

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

Department of Defense (DoD) Standard Practices

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

Attachment XXXX Appendix C

(Copies of these documents are also available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other Government documents, drawings, and publications

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

DoD Handbooks

MIL-HDBK-454B - General Guidelines For Electronic Equipment (Copies of these documents are also available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

DOD 5000.2 - Defense Acquisition System

DoD Security Documents DODI 8510.01 - Risk Management Framework (RMF) for DoD

Information Technology

Federal Regulations

29 CFR 1910 - Occupational Safety and Health Standards (Copies of these regulations are downloadable from http://www.gpo.gov/fdsys/browse/collectionCfr.action?collectionCode=CFR)

MIL-STD-1472F - Human Engineering

Institute Of Electrical And Electronics Engineers (IEEE)

IEEE 200-1975 Rev. 1988 - Standard Reference Designations for Electrical and Electronics Parts and Equipment (ANSI/IEEE Y32.16)

2.3 Non-Government publications

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

American National Standards Institute (ANSI)

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 http://www.gpo.gov/fdsys/browse/collectionCfr.action?collectionCode=CFR

ANSI Z535.5-2011 - Safety Tags and Barricade Tapes (for Temporary Hazards)

(Copies of these documents are available from www.ansi.org, http://global.ihs.com/, or Global Engineering Documents, 15 Inverness Way, East Englewood, CO 80112.)

Electronic Industries Alliance (EIA) EIA RS-471 - Symbol and Label for Electrostatic Sensitive Devices (Copies of this document are available from www.eia.org, http://global.ihs.com/, or Global Engineering Documents, 15 Inverness Way, East Englewood, CO 80155-6800

American Society of Mechanical Engineers (ASME) ASME Y14.44-2008 - Reference Designations for Electrical and Electronics

Parts and Equipment (Copies of this document are available from http://www.asme.org, http://global.ihs.com, or Global Engineering Documents, 15 Inverness Way, East Englewood, CO 80155-6800)

2.4 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 Baseline Configuration Audit (BCA) and 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 BCA and PMI results.

3.1.1 Student Component Input/Output System.

The SAVT Student Toolset Interface Module (STIM) shall be replaced with a COTS system that is commercially supportable. 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 simulated military lensatic compass for student training during scenarios. The compass shall be identical in form, fit, and function to the current military lensatic compass used in the field. The visual appearance, weight, and balance of the simulated lensatic compass shall be identical to the actual and shall function in both day and http://www.ansi.org/ http://global.ihs.com/ http://www.eia.org/ http://global.ihs.com/ http://www.asme.org/ http://global.ihs.com/ night scenarios. The compass shall integrate with the SAVT such that the magnetic North indication displayed by the compass shall match what is the magnetic North for each database used during any training sessions. The compass shall provide the appropriate hardware to allow students 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. 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 to meet Risk Management Framework (RMF) requirements for DoD Information Technology compliance.

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.

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

3.1.5 SAVT Test Berth relocation

The contractor shall relocate the SAVT test berth from the Navy’s Weapons Simulation & Integration Laboratory (WSIL), currently located in Naval Air Warfare Center Training Systems Division (NAWCTSD) Orlando, to the PDSS/Non-PDSS contractor site. The Test Berth shall remain at this location for the remainder of the contract. The Test Berth shall be moved and installed with no detriment to the system. The contractor shall provide the personnel, tools, facilities and other resources necessary in order to accomplish the relocation. Confirmation of functionality shall be the responsibility of the contractor. Backup, shutdown, removal, movement, installation, testing and running the system after relocation are the responsibility of the contractor.

The Test Berth shall remain fully accessible and fully functional throughout the contract and until directed otherwise by the Government.

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 65 degrees Fahrenheit (deg. F) to 75 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 75 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 20 percent to 80 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 within a humidity range of fifty (50) percent plus or minus five (5) 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 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 metallurgically 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 retardancy

Wood products shall be treated for fire-retardancy.

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 http://www.acq.osd.mil/dpap/pdi/uid/index.html

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.

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 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-1472F.

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, that validate compliance with DOD approved Security Technical Implementation Guides (STIGs) and the specified trainer 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), 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. Off site 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.

3.9.13.2.4.3 Other trainer areas

One utility duplex receptacle shall be provided on each side of the selected equipment racks where access doors or panels are provided, and at convenient locations at other maintenance areas such as outside each cockpit, hydraulic and pneumatic equipment, and pump facilities, and where electrical tools, utility lamps, or test equipment will be required for servicing and repair work.

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…