Attachment_4_PHTC.pdf

Purchase Description Portable High Temperature Calibrator (PHTC)

1.0 SCOPE:

General: Ruggedized Portable High Temperature Calibrator (PHTC) solution that is capable of generating and controlling stable and accurate temperatures from 100°F (38°C) to 1220°F (660°C) at the accuracy ranges specified in the draft specification listed below. The PHTC will be used to calibrate items such as bi-metal & digital thermometers, temperature switches with bulb or coil probes (Detroit Switch model 222 types being the most prevalent within the Navy), various process control or monitoring temperature instrumentation and temperature reading instruments.

The PHTC will be used on shipboard and shore-based facilities and must conform to CLASS 3 requirements as listed in MIL-PRF-28800. Equipment will also be subjected to operational conditions aboard both military and commercial land, sea and air vehicles during periods of operation, transportation and storage. The PHTC shall weigh no more than 40 pounds and be no larger than 14” high x 11” deep x 16” wide with cover for storage configuration. Operation orientation is not critical as long as the PLTC can tolerate shock and vibration as called for in paragraphs 3.34 and 3.35.

1.1 Classification: The PHTC shall meet the following requirements contained in this purchase description, and be subject to the verification and inspection methods of MIL-PRF- 28800F, Class 3 for Navy applications.

2.0 APPLICABLE DOCUMENTS:

2.1 General: The documents listed in this section are referenced in this Purchase Description PHTC document. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in this purchase description, or as applicable in MIL-PRF-28800F, whether or not they are listed.

2.2 Government Documents: Specifications and standards: The following specifications and standards form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplemented there.

MIL-PRF-28800F Test Equipment for Use with Electrical and Electronic Equipment.

MIL-PRF-38793C Technical Manuals: Calibration Procedures – Preparation.

DI-MGMT-81772 Data Item Description: Lead-Free Control Plan (LFCP).

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

MIL-HDBK-781 Reliability Test Methods, Plans, and environments for Engineering

Development, Qualification and Production.

Unless otherwise indicated, copies of Federal and military specifications and standards are available from the Department of Defense Single Source Stock Point, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094 [Telephone 215-697-2179]. They are also available at www.everyspec.com.

3.0 Requirements:

3.1 Safety: The equipment shall comply with the safety requirements of IEC 61010-1. For safety ground all accessible surfaces of the equipment shall be at ground potential. The power cable shall include a safety ground conductor. This is also true of drawer assemblies; disconnecting the safety ground shall also disconnect the power conductors. It shall also indicate on the screen or via a light on the instrument panel a caution to the operator when the well, insert, and unit under test are too hot or cold to touch (defined in Heating and Cooling times in section 3.45). If a standoff screen or grate is utilized, it shall have enough well access as to provide for testing of direct connect bulb type switches (i.e. the screen or grate hole should be at least 1 & 5/8 inch diameter to accommodate the mounting nut and flange of the temperature switch).

3.2 Color: The color of the equipment and the transit cases shall be the color normally provided by the manufacturer; however, they must NOT be green, magenta, or red.

3.3 Restricted Material: Mercury, including mercury batteries, radioactive material, Lithium electrochemical cells, organic material, explosive material, flammable material and carcinogens are not to be utilized. No combination of materials shall be used that cause deterioration of any material contained in the equipment due to the effects of outgassing. See 3.16 for additional information for batteries.

3.4 Well and Inserts Material: Well and inserts material, dimensions, and dimension tolerances shall be such that they maximize thermal characteristics while ensuring ease and speed of removal over repeated long term use. Insert configurations are described in section 3.53.

3.5 Operator adjustments: The PHTC shall be capable, if needed, to automatically adjust without operator interaction. The equipment shall include built-in adjustments or compensating devices for any function or parameter that would exceed the specified tolerance within the calibration interval.

3.6 Operator Controls: Operating controls and indicators shall be readily accessible to the operator from the control panel of the equipment. The readings presented on the controls and indicators shall be available to the operator without conversion or calculation.

3.7 Cooling or Heating Devices: Cooling or heating devices used in the equipment shall be an integral part of the equipment and not degrade any aspect of performance or safety.

3.8 Front panel display indicators: Front control and panel display indicators designed to present change-of-state information to the operator shall be distinguishable at a distance of 1 meter with provisions to be distinguishable outdoors in direct sunlight and in a minimum light level of 1 foot-candles (fc). All display indicators shall be discernible at viewing angles from 0 degrees to 45 degrees.

3.9 Digital interface: A digital interface shall be provided and shall meet the requirements as specified below in Digital interface requirements. The digital interface shall include an IEEE 488.2 General Purpose Interface Bus conforming to IEC 60488-2:2004 /IEEE 488.2-1992; at least two USB connections conforming to the Universal Serial Bus Specification (USB) Revision 2.0 or higher and a RS-232 interface. Two USB’s are called for with the intent that one could be used to control the instrument. The second USB would be used as a printer port. Also, one of the USB ports should support USB flash drive for firmware updates, firmware updates from a laptop and/or CD (i.e. CD firmware updates to laptop to instrument or USB CD drive to instrument), and file transfer (see screen capture discussed in paragraph 3.46).

3.10 Digital interface requirements: The digital interface shall have the programmable capability to control each device function including all ranges, modes, and levels. The digital interface shall support control of the device without the need for any proprietary drivers or software. The syntax and style of programming commands shall conform to the Standard Commands for Programmable Instruments (SCPI). Primary power control and other non-measurement functions need not be controllable through the digital interface.

3.11 Power consumption: The maximum power for operation from a single phase 120 Vrms power source shall not exceed 1500 watts.

3.12 Nominal and alternate power source: The equipment shall operate at the nominal values for voltage and frequency as specified in (a) and (b) below. An alternate power source is not required. (a) The nominal voltage shall be 120 Vrms, (b) The nominal frequencies shall be single phase 50 Hz and 60 Hz. The PHTC shall be capable of using both 50 Hz and 60 Hz.

3.13 Steady-state conditions: The performance and accuracy of the equipment shall not be adversely affected when operated under any combination of conditions 1 through 3. Tolerance values are derived from, and referenced to, the nominal values stated above. For definitions of voltage waveform factor and harmonics, see MIL-PRF-28800F paragraph 6.5.1a Voltage waveform deviation factor and 6.5.1b Harmonics.

1. The steady-state voltage-tolerance shall be 115Vrms ±10%.

2. The steady-state frequency-tolerance shall be ±5%.

3. The deviations in waveform characteristics shall be as in (a) through (d)

a) Waveform deviation factor of ±10 percent or less

b) Total harmonics of ±10 percent or less

c) Individual harmonics of ±5 percent or less

d) Crest factor of 1.27 to 1.56

3.14 Transient-state conditions: Operation of the equipment during voltage and frequency transients shall be as specified below for transients that recover to within the steady-state tolerance band within 500 ms. The equipment performance may be impaired during the transient. Transient values are derived from, and referenced to, the nominal values specified for voltage and frequency.

Voltage transients within the range of ±10 percent to ±30 percent shall not cause the operation of the equipment to be impaired for longer than 30 seconds following the transient and not cause loss of information stored in a volatile memory. Frequency transients within the range of ±5 percent to ±10 percent shall not cause the operation of the equipment to be impaired for longer than 30 seconds following the transient and not cause loss of information stored in a volatile memory. The 30 second recovery time does not include the well temperature times.

3.15 Interruption of power source: Voltage or frequency interruptions shall not cause damage to the equipment. A power source interruption is when the voltage falls in the range of 0 to 70% of nominal or frequency falls in the range of 0 to 90% of nominal. Equipment performance is not required during interruption of the power source. After power interruptions of any duration, the equipment shall automatically resume operation at either the last operating condition before interruption, or a default power-up condition.

3.16 Battery restrictions: The use of lithium and mercury batteries is restricted and shall not be used in the equipment. The Equipment shall incorporate safety precautions of UL1950 and appropriate warning labels as specified. Commercial UL approved equipment that contains lithium batteries (size double A or button cell type) used for memory backup are approved for use. Lithium or re-chargeable batteries larger than the type specified above are not approved for use. Tadiran liquid cathode batteries, SO2 (sulfur dioxide) batteries or lithium vinyl chloride “liquid cathode” batteries are strictly prohibited. For the purpose of this specification, a lithium (size double A or button cell type) battery as described above is approved. The self-test shall identify a failing battery.

3.17 Input power switch: The operator shall be able to energize the equipment from the front panel. A standby capability may be incorporated.

3.18 Excessive current drain protection: An automated safety mechanism (ex. circuit breaker/fuse) shall be incorporated to automatically disconnect the equipment in the event of current being drawn that is in excess of the equipment rating. The mechanism shall be available from the control panel.

3.19 Indicators: Visual indication shall be provided on the front panel to indicate when the equipment is energized (ex. LED light or screen on).

3.20 Overall Dimensions and Weight: The PHTC shall be no larger than 14” high x 11” deep x 16” wide with cover for storage configuration. Operation orientation is not critical as long as the PLTC can tolerate shock and vibration as called for in paragraphs 3.34 and 3.35. The PLTC shall weigh no more than 40 pounds. This shall include the cover, power cord, caliper, insert removal tool, the multi holed insert, and at least 3 other inserts. Extra inserts, manuals, other accessories, etc. can be provided in an accessory case which is not included in the PHTC 40 pound limit. The accessory case shall be no more than 11” in any direction, preferably smaller in one or more directions and can be stored in any direction without contents becoming jumbled. These dimensions and weight are absolute maximums.

3.21 Mechanical stability: The equipment shall be designed to preclude tipping during normal handling and operation.

3.22 Cover: The enclosure shall have a cover. The enclosure and cover interface shall have a gasket or offset lap seam to prevent entry of dirt or spray-type moisture or contaminates during shipping, storage, or transit to on site location.

3.23 Latches: Latches and hinges shall be incorporated for cover opening and removal. The latches shall incorporate a quick-opening mechanism. . If utilized, slip joint type hinges shall allow easy cover removal. Latches should be either recessed or rugged to withstand loose cargo bounce test of paragraph 3.33.

3.24 Stacking provisions: Equipment enclosures shall have a geometric configuration that permits stacking without harm to the enclosure or its contents. The stacking height shall be 4 units.

3.25 Handles: The enclosure(s) shall have three handles. A handle shall be located above the equipment center of gravity (top center of covers) to ensure carrying stability. The enclosure(s) shall also have a handle on both the left and right sides (either relative to operation or storage orientation as the bidder deems appropriate) of the enclosure(s). Each handle by itself shall support the full weight of the enclosure. Handles should be either recessed or rugged to withstand loose cargo bounce test of paragraph 3.33. Also note if the bidder decides the PHTC should be transported (re: loose cargo bounce test) in an orientation different from the storage orientation this will need to be clearly stated on the outside of the PHTC.

3.26 Connections and controls: All external electrical connections (including power connections) and operating controls shall be on the control panel.

3.27 Pressure equalizing valve: A mechanism for equalizing air pressure within the enclosure with the external ambient pressure, when the enclosure is sealed, shall be provided. The mechanism provided shall not protrude beyond the enclosure.

3.28 Temperature and humidity not operating: The PHTC shall conform to specified performance and accuracy requirements after being stored or shipped from -22 ºF (-30 ºC) to 160 ºF (71 ºC) and 0% to 100% relative humidity. Storage in conditions of greater than 90% humidity or at low temperature before bringing the PHTC into operating conditions so that condensation is likely may require that the PHTC is allowed a 2 hour dry-out period prior to operation.

3.29 Temperature operating: The PHTC shall conform to the specified accuracy, performance, and full ranges while being operated at temperatures over the range of 55°F (13ºC) to 91°F (33ºC).

For operation from 32°F (0ºC) to 55°F (13ºC) and 91°F (33ºC) to 122°F (50ºC), minimum specifications for accuracy, stability, hysteresis, and uniformity are double (as shown at the bottom of the table in section 3.44).

3.30 Humidity operating: The PHTC shall conform to the specified performance and accuracy for conditions where the relative humidity is 0 to 90% RH non-condensing in the temperature range of 50 °F to 122 °F (10 ºC to 50 ºC). At temperatures below 50 °F (10 ºC) down to 32°F (0ºC), the equipment shall conform to the specified performance at relative humidity from 25% to 90% RH non-condensing.

3.31 Warm-up: If the PHTC is stored or shipped for an extended period before turn on in very cold (below freezing) conditions, the warm-up period may be preceded by a 1-hour non energized soaking (hardware temperature stabilization) period.

In normal operations where the calibrator has been stored for at least one hour in 50°F to 122°F:

1) For operation in 50°F to 122°F, the required warm-up period shall be no more than 5 minutes.

2) For operation in environments below 50°F down to freezing the required warm-up period shall be no more than 10 minutes.

3.32 Altitude: The PHTC components shall conform to the specified performance and accuracy requirements after being subjected to an altitude of 15,000 feet for 1 hour with equipment not operating.

3.33 Bounce, loose cargo: The PHTC shall conform to the specified performance and accuracy requirements after being tested in accordance with MIL-PRF-28800F paragraph 4.5.5.3.3 loose cargo bounce test with the exception that the shaker can be operated at 240 rpm. Also, for clarity of the test setup described in MIL-PRF-28800F 4.5.5.3.3 Step 2, the test setup is three fences rather than four.

3.34 Bench handling: The PHTC shall conform to the specified performance and accuracy requirements and there shall be no damage to any controls, indicators, or fuse holders, after being tested in accordance with MIL-PRF-28800F paragraph 4.5.5.4.3 Bench handling test.

3.35 Water resistance: The enclosure and cover shall provide a water resistant barrier to protect the internal components when exposed to rain or condensation in high humidity.

3.36 Fungus resistance: Equipment shall not contain materials that provide nutrients fungus growth.

3.37 Salt atmosphere: Equipment component surfaces exposed to atmosphere shall have an anti-corrosion treatment to provide corrosion protection.

3.38 Dust exposure: Equipment enclosure with cover shall provide protection for the PHTC from dust exposure.

3.39 Acoustic noise: The PHTC shall not generate acoustic noise in excess of 80 dBA sound pressure level (SPL) when measured at the operator position, in accordance with ISO 7779.

3.40 Primary requirement: The PHTC shall be a ruggedized temperature drywell portable automated temperature calibration system with user-friendly controls and intuitive menus for sailors (typically Petty Officers E-4, 5, & 6) trained via the Shipboard Gauge Calibration Program (SGCP). It shall be capable of generating and controlling stable accurate temperatures from 100°F (38°C) to 1220°F (660°C) at the accuracies and ranges specified in section 3.45.

3.41 Well sizes: The low temperature well shall be minimum 1 inch diameter by 6 inches deep.

Because of the temperature ranges called for, tolerances, and materials shall be such as to minimize inserts getting stuck or worn/damaged.

3.42 Resolution: For normal use the PHTC display resolution shall be 0.01°F/C. When the PHTC is itself being calibrated or aligned a display resolution of 0.001°F/C is desired (but not required).

3.43 Units of measure & display: Switchable between degrees Celsius (°C) and Fahrenheit (°F).

3.44 Range, accuracy, stability, and hysteresis: The PHTC shall be capable of generating, and controlling temperature over the range and within the uncertainty specified below. The uncertainty shall have a level of confidence of 95 percent. The uncertainty shall be calculated as a root-sum of squares (RSS) of the standard uncertainties of all the error contributors to the measurement system and processes, with an expanded coverage factor of 2 (K=2). All parameters specifications from bottom to 3” from top of well.

Ambient 55°F (12.8°C) to 91°F (32.8°C)

Well Range Accuracy 1

100°F (38°C)2 to 580°F (305°C) ±0.5°F (0.28°C)

580.01°F (305°C) to 900°F (482.2°C) ±0.75°F (0.42°C)

900.01°F (482.2°C) to 1220°F (660°C) ±1.0°F (0.56°C)

Stability ±0.09°F (0.05°C) 3

Hysteresis 0.126°F (0.07°C) 3

Uniformity ±0.27°F (0.15°C) to 580°F, ±0.5°F (0.28°C) to 900°F, ±0.72°F (0.4°C) to 1220°F 3

Ambient below 55°F (12.8°C) or above 91°F (32.8°C)

Well Range Accuracy

100°F (38°C)2 to 580°F (305°C) ±1.0°F (0.56°C)

580.01°F (305°C) to 900°F (482.2°C) ±1.5°F (0.83°C)

900.01°F (482.2°C) to 1220°F (660°C) ±2.0°F (1.11°C)

Stability ±0.18°F (0.1°C) 3

1 Accuracy verified in calibration procedure at full depth and 3 inch depth in Navy depot laboratories (i.e. ambient 60°F to 85°F). More detail on calibration in sections 3.45 through 3.49.

2 When ambient is above 85°F, lowest range point is no more than ambient plus 15°F (i.e. if ambient is 86°F lowest range point is no more than 101°F) 3 Stability, hysteresis, and uniformity included in overall accuracies. Uniformity is for both vertical and radial.

Hysteresis 0.252°F (0.14°C) 3

Uniformity ±0.54°F (0.3°C) to 580°F, ±1.0°F (0.56°C) to 900°F, ±0.1.44°F (0.8°C) to 1220°F 3

3.45 Heating and Cooling times: The PHTC shall take no longer than the times specified below to heat or cool to the desired stable (±1°F) test points. To achieve the best accuracy (±0.5°F) and stability, up to 10 minutes may be added to these times.4 These times are absolute maximums.

The times below are for the wells with an insert and unit under test (UUT). Safe removal of the insert with the insert removal tool is considered to be 200°F or less. Safe human handling of the insert or UUT is considered to be 120°F or less. The PHTC shall indicate when the well and insert is above 200°F and is not safe to remove (i.e. a red light on the screen), when the insert is safe to remove with the insert removal tool (i.e. 200°F or less a yellow light on the screen), and when the insert is safe to touch (i.e. 120°F or less a green light on the screen).

Heat up from room temperature (70°F):

70°F to 100°F no more than (NMT) 3 minutes 70°F to 200°F NMT 5 minutes 70°F to 400°F NMT 10 minutes 70°F to 600°F NMT 15 minutes 70°F to 1220°F NMT 22 minutes

Cool down from hot4:

400°F to 200°F NMT 25 minutes 600°F to 200°F NMT 45 minutes 800°F to 200°F NMT 65 minutes 1000°F to 200°F NMT 100 minutes 1220°F to 200°F NMT 120 minutes

200°F to 120°F NMT 15 minutes (room NMT 70°F) 20 minutes (room NMT 75°F) 25 minutes (room NMT 80°F)

3.46 User interface: A color screen is not required. If a color screen is utilized the screen pages shall be of simple design and maximum contrast.5 A touchscreen is not required. If a touchscreen is utilized, it shall meet IP67 requirements and it shall not be the sole user interface meaning all user input/control shall also be available via hard buttons, dials, etc. Given the long intended service life, and tough usage, proper selections of screen, buttons, keys, dials, etc. is necessary.

Printing of screens, data, etc. shall be provided via USB connection (i.e. USB printer connected to PLTC USB). Digital images (ex. png files) of screens, and data (ex. cvs or excel files) transfers to PCs, and/or external drives, etc. shall be available via USB connection. The main intent of the

4 10 minute add on not applicable for insert removal purposes, ambient is 70°F for these times unless otherwise noted 5 http://www.usability.gov/articles/newsletter/pubs/022010new.html#ColorsthatWorktheBest screen captures is to facilitate Navy calibration procedure writing (ex. get a copy of a PLTC screen and paste it into a Navy calibration procedure).

3.47 Temperature control: The temperature control shall provide precision automated control and display of temperature with user-friendly controls and intuitive menus for minimally trained operators. The control unit shall be capable of performing UUT calibrations using automatic or manual control as specified in 1 through 3 below.

1) The control unit shall be capable of notifying the operator when the well, insert and UUT have reached the test point and is stable.

2) The control unit shall have an abort feature where the operator can easily and safely abort a test without damage to the control unit or UUT. Also see Safety in section 3.1.

3) In manual mode the PHTC shall be capable of both coarse and fine adjustment control of temperature at each test point. If adjustment control is via a keypad only, adjustment via + and

– keys is required.

a) Course adjustment mode shall be capable of increments of 1°F.

b) Fine adjustment mode shall be capable of increments of 0.1°F.

c) In addition to the above course and fine modes, for calibration of the PHTC an extra fine mode shall be provided of 0.01°F.

3.48 Excess temperature control: The PHTC shall be capable of automatically limiting the maximum allowable temperature available for testing a TI, based on the TI full-scale range plus 10 percent.

3.49 Temperature switches testing: Using a built-in continuity6 checker the PHTC shall have the capability to test unpowered temperature switches either manually or via a built-in automated mode. The automated mode shall only require the operator to enter the nominal switch temperature and then the unit will run the test automatically. The PHTC shall control temperature, display switch activation temperature; display switch reset temperature, and record values. Three foot test leads for bench top testing and 15 foot leads for shipboard installed switches shall be provided with the PHTC.

3.50 TI test setups: The control unit shall be user programmable via the control panel/user interface.

1) The software shall interact with the operator via intuitive menu selections and data input requests. It shall guide the user in the development of generic UUT test setups and implementation of tests. It shall guide the experienced user with minimal instruction (i.e.

‘advanced’ mode) and the novice user with expanded instructions/interactions (i.e. ‘normal’ mode), in the development of TI test setups and implementation of tests. It shall be capable of saving and recalling test setups. .

a. Example of generic test setups:

6 Good continuity is considered to be nominally 2Ω or less.

i. For bi-metal temperature dial gages, the user inputs the gage range & accuracy.

The PHTC then generates the test points and tolerances for those test points.

ii. For temperature switches, the user inputs the switch set point, accuracy, & activation (i.e. opens above X, closes above X, etc.). The PHTC then generates the test point(s) and tolerance(s) for those test point(s).

2) Software shall utilize intelligent intuitive naming convention for storage and recall of test setups with minimal input from the operator. Intelligent naming convention shall utilize information gathered during test setups; UUT type, range, accuracy etc. to create an intuitive standard naming convention with an option for additional operator input.

3) Subsequent test setups shall have an option to select previously stored test setups that match information in data input fields on a progressive basis. As menu options and data input fields are filled in, similar test setups shall appear on the screen that may be selected once the operator is confident the available test setup will meet the requirement.

4) Software shall display pass or fail information at each test point including the deviation between the PHTC and the UUT in percentage and in °F or °C units.

5) Completed test data shall be recorded and the operator shall have the option to repeat same test or create new test setup.

3.51 Accessories: The PHTC shall, at a minimum, have the accessories listed below as well as any other accessory required for the PHTC to meet the requirements laid out in this document.

3.52 Accessory case: The accessory case shall also serve as the transit case for the accessories.

Transit case and internal compartments, strapping, etc. shall be impervious to water and hydrocarbon base fluids. It shall contain accessories, maintenance aids for the PHTC, the insert extraction tool, any extra rarely used inserts, power cord, etc. Accessories shall be contained in compartments and strappings to prevent damage during transit. Four inserts, AC power cable, continuity test leads, and the insert extraction tool, shall be able to be stored in the PHTC cover as well (and included in the 40lb. weight limit). The remaining accessories shall be stored in the accessory case. The following accessories shall be provided with each PHTC:

3.53 Inserts: All inserts shall have surface finish of AA 125u inch, Ra 3.2um (i.e. ream finish) or better. Multi-holed inserts shall not degrade the accuracy specifications. Typical hole dimensions will be oversized by 1/64 inch (ex. hole for ¼ inch probes will be 17/64 inch) with a tolerance of ±0.002”. Thermal conductive liquid or grease shall not be used as a thermal transfer material. The inserts will be Aluminum-Bronze with nominal outer dimensions of 1” dia. by 6” deep. Because of the temperature ranges called for tolerances shall be such as to minimize inserts getting stuck or worn/damaged.

The following 10 inserts shall be provided with each PHTC:

1) Multi hole insert (see illustration on right)

2) 3/8” hole (this one can do small bulb temperature switches)

3) 11/16” hole (this one can do big bulb temperature switches)

4) 7/16” hole

5) 9/16” hole

5/16 1/8

PRT

.219

1/4 3/16

6) Calibration insert with two 0.219” holes, one with 3” depth and one full depth to accommodate Rosemount 162CE PRT probe

7) Blank insert for future requirements

8) Three different depths 11/16” nominal counter sunk 3/8” hole inserts to accommodate MIL-

T-17244 and MIL-T-19646 thermometers (sample inserts from Navy’s legacy inserts can be provided after contract award)

3.54 Inserts inscriptions: Each insert shall be appropriately inscribed as illustrated above. In addition, inscriptions on the sides of the inserts shall be done as necessary (ex. “PHTC Cal” inscribed on the side of the Calibration insert).

3.55 Caliper: One heavy duty stainless steel 4 inch dial caliper (for measuring TI probe, bulb, etc. diameters) ±0.001” accuracy and resolution.

3.56 Maintainability: Maintainability shall be as specified below.

3.57 Fault isolation: The design of the equipment shall permit isolation of faults, and repair down to the component item or lowest replaceable unit (LRU) with the maintenance provisions furnished. Also see Self-test capability below.

3.58 Self-test capability: The PHTC shall perform an automatic diagnostic self-test at startup.

The self-test shall determine operational readiness and isolate any faulty sub system(s). If a failure occurs, the associated lowest replaceable unit (LRU) causing the malfunction shall be identified via the self-test and/or applicable documentation (i.e. service and/or user manual). The self-test shall at minimum define faults down to the sub system level. Critical components, defined by manufacturer (i.e. temperature sensor(s) used in the control of the well), failures shall also be identified by the self-test. Where practical and useful (again, as defined by the manufacturer), daughter card failures within sub systems shall be identified by the self-test. If the PHTC utilizes a battery (i.e. for clock or memory) the self-test shall identify a failing battery.

3.59 Preventive maintenance: Preventive maintenance shall not require more than 15 minutes per a 30-day period. Preventive maintenance shall not require breaking of the equipment seams where calibration seals would normally be placed.

3.60 Maintenance provisions: Equipment shall be as specified in a. through d. to facilitate maintenance:

a. Accessibility for maintenance: The equipment shall be designed to ensure that any necessary maintenance access can be accomplished utilizing ordinary tools. The equipment shall be constructed so that no damage to any component shall occur and no permanent distortion to any structural member shall be caused during maintenance and calibration.

b. Maintenance and calibration aids: Special adapters, special tools, circuit board extenders, and patch or interface cables required for maintenance or calibration shall be provided. They shall be identified as a set with a unique part number. Stowage shall be in a reusable pouch or container.

c. Accessibility for repair: The equipment shall be designed so that LRU’s can be removed without removing other hardwired subassemblies or components. There shall be no need to unsolder cables or interconnecting wiring to remove printed circuit cards. Assemblies designed primarily to distribute power and signals to other components are excluded from this requirement. When troubleshooting or repair information is provided and access to both sides of a repairable assembly is necessary, the design of the equipment shall facilitate this directly or through extender cards.

d. Calibration and alignment of the PHTC: The PHTC shall be capable of manual calibration and alignment via onboard intuitive screens and menus. Automated control by the PHTC of the PHTC and external Navy standards (3458A Agilent DMM with Rosemount 162CE PRT) for calibration and alignment is not required but is desired. The PHTC shall be provided with all necessary instructions and firmware needed to calibrate and align the equipment so that the equipment meets its performance specifications after repair or due to the equipment failing calibration.

1. Calibration and alignment software and instructions: The calibration and alignment software and instructions (for manual and/or automated control) shall be embedded in the PHTC firmware.

i. If automated control for calibration and alignment is implemented (again, automated control for calibration and alignment of the PHTC is not a requirement but is desired), the PHTC shall be capable of automated calibration and alignment utilizing the digital interface to control and read the Navy’s external precision temperature reference standards. Current Navy standards to calibrate the PHTC are an Agilent 3458A 8.5 digit DMM with a Rosemount 162CE PRT. Since the DMM has no capability to convert ohms to temperature, the PHTC will need the capability to accept ITS-90 coefficients from the report of calibration of the PRT and convert the ohms reading from the DMM to temperature. The PHTC shall perform as an automated controller to generate, control, measure, and display the temperature at each calibration test point and shall initiate and control communication with the external precision temperature reference standard (DMM & PRT) to validate the measured value at each test point. The PHTC values and the actual values from the external precision temperature reference standard shall be stored in memory for future recall, display and printing via the digital interface.

2. PHTC accuracies will be verified at full depth and 3 inch depths (re. calibration inserts in section 3.53). Calibration verification points to be 100°F, 340°F, 579°F, 700°F, 899°F, 1020°F, and 1220°F. Alignment points may be different than the verification calibration points above.

3. Navy calibration standards: The PHTC shall be able to utilize existing Navy calibration standards (Agilent 3458A 8.5 digit DMM and Rosemount 162CE PRT) that meet all necessary minimum performance requirements to satisfy an adequate traceable calibration.

4. Alignment data: If the equipment has alignment data stored in memory (e.g.:

EEPROM, data files, DACs, etc.) that is necessary for the equipment to meet its performance specification and modification of this alignment data is necessary after repair or a calibration failure, the equipment shall be designed and information provided so that the alignment can be performed by the Navy.

5. The Calibration and Alignment routines shall be available to authorized users via password protection.

6. The calibration and alignment algorithms, associated SCPI commands, configuration information, and example programs shall be provided for using an external PC with GPIB to run the calibration and alignment and read/write alignment data to/from the PHTC. These non-proprietary algorithms shall be accessible and executable by Navy calibration and maintenance personal.

3.61 Repair: Maintenance instructions shall be furnished to facilitate the replacement of Lowest Replaceable Units (LRUs) and subsequent testing procedures to ensure the performance of the equipment or the repair action taken.

3.62 Firmware updates: The equipment shall be designed to allow for the Navy to update the equipment firmware. For the length of the contract and any subsequent warranty period beyond the length of the contract, the manufacturer shall provide to the Navy notification of any firmware updates, instructions on how to perform the update, and free access via appropriate media transfer method supported by the Navy (e.g. ROM disc, Website, email) to firmware updates that fix bugs relating to any of the performance requirements cited in this specification. For the same time period, the manufacturer shall provide to the Navy notification of any improvements relating to any performance requirements cited in this specification. The firmware update process shall use any common interface path supported by the equipment (e.g. the USB DVD-ROM drive plug and play with the calibrator, USB flash drive, and/or PC with web downloaded firmware update files).

3.63 Calibration: Calibration refers to the process of comparing a test instrument with a calibration standard to determine the indicated error at specified test points. Alignment refers to the process of characterizing and adjusting a test instrument to cause it to indicate within its specified accuracy limits.

3.64 Calibration certificate: The equipment provided shall have a current calibration certificate, with a calibration data sheet, calibration sticker with date calibration was done and next due date, which is traceable to the National Institute of Standards and Technology (NIST).

3.65 Calibration interval: The minimum interval between calibrations shall be at least 12 months. At the end of this interval, 85 percent or more of the units shall remain in tolerance.

3.66 Calibration procedure: A manual calibration procedure in accordance with MIL-PRF- 38793 shall be provided.

3.67 Reliability: The design of the equipment shall be such that under normal use and operation the equipment does not fail within 1500 hours of operation with a statistical certainty of 95%. The manufacturer shall provide a summary of maintenance or warranty records to establish the validity of the statistical assertion. If records of the actual equipment model offered are not available, records from a similar model may be substituted. The manufacturer shall be able to reasonably establish the claim that the offered equipment shall provide reliability similar to the model used to provide substitute records. Note: roughly 75% of the Navy’s workload for its portable drywells will be across the Navy’s Portable Low Temperature Calibrator (PLTC) and 25% across the PHTC.

3.68 Warranty: Standard commercial warranty.

3.69 Warranty label: The equipment shall have a warranty label that reflects the start and end dates of the warranty.

3.70 Service Life: The expected service life of the PHTC shall be at least 15 years which includes parts availability. The Navy desires offerer’s provide Objective Quality Evidence (OQE) that the PHTC proposed (or similar item) has reached a comparable service life in a heavy industrial environment such as a Navy Ship. In the absence of OQE a discussion of offerer’s expected service life is desired.

3.71 Calibration Traceability: Traceability to the National Institute of Standards and Technology (either ANSI Z-540 or 17025).

3.72 Solder: The DoD is exempted from the requirement for lead free solder. Because of reliability issues in harsh environments, the Navy prefers the PHTC be manufactured using only eutectic solder (tin/lead 63/37%). If this is not to be the case and lead free solder is utilized, a Lead-Free Control Plan (LFCP) which describes how the PHTC supplier plans to manage the risk of lead-free solders or finishes used in the PHTC during the PHTC's 15 year lifecycle shall be provided. Format and required content for this LFCP is given in DI-MGMT-81772 Data Item Description: Lead-Free Control Plan (LFCP).

3.73 Identification Plate: An equipment identification plate shall be permanently affixed to both the PHTC and the accessory case. Each identification plate shall contain the following information; model number, CAGE, serial number, case X of Y, nomenclature, part number, and a two dimensional barcode as defined below. Minimum thickness of the plate is 1/32 inch and the recommended material is aluminum alloy. The plate background color shall be black. It shall have a minimum character size of 1/8 inch. All characters shall be permanent using best commercial practices for laser engraving, etching, or photosensitive marking of material.

3.74 Item unique identification (IUID): DFARS clause 252-211.7003 is invoked. A two dimensional Unique Identification (IUID) data matrix conforming to MIL-STD-130 shall be included on the Identification Plate.

UID Data Elements: The following is required per DFARS clause 252.211-7003, Paragraph 4(e):

• UID Type

• Issuing Agency Code

• UID Data Element

• Enterprise ID

• Original Part Number

• Serial Number

• Quantity Shipped

• Unit of Measure

• Description

• Unit Acquisition Cost

• Current Part Number Effective Date

• Current Part Number

3.75 Technical manuals: Two copies of an operation and maintenance manual shall be provided with each unit. Technical manuals shall be updated per government requirements and require approval for the final release. The technical manuals shall be provided with each PHTC in electronic format (ex. CD). A printed condensed ‘Quick Start’ guide shall also be provided with each PHTC. The electronic copies shall be in a Portable Document Format (PDF) and shall conform to ISO/IEC 32000-1:2008.

The contents of the technical manuals shall include sections addressing safety, general information, use and installation, maintenance and service, storage, and symbols. Drawings of the device with sufficient detail to identify all controls and connections shall be supplied in scalar vector graphics format (SVG) and shall conform to the W3C Scalar Vector Graphics 1.1 Specification. Anotated photographs may also be utilized. The manual shall contain warnings, cautions and notes to prevent injury to personnel and damage to equipment. The warnings shall contain safety precautions where hazards such as high voltage, ESD, high temperature, etc. may be present during installation, operation, or maintenance. The manual shall contain the following: purpose and functions, capabilities, performance characteristics, description (model number, dimensions, and weight), power information, operational environment, list of items furnished, list of items required for operation and maintenance but not supplied, tools and test equipment, warranty information, shipping and handling precautions.

A use and installation section shall provide any instructions that may be required for unpacking, assembly, and procedures to pursue in the case of the equipment found damaged during shipping.

This section shall also minimally contain information on the following: operating instructions (illustrations and explanations of the uses and functions of all controls and indicators), initial adjustments and control settings, startup procedures, system reset procedures, ventilation clearances required, illustrations of equipment connections to external units under test, external memory storage device instructions and precautions, and reprogramming of reprogrammable memory including program setup, check-out and illustrations.

The level of maintenance philosophy shall be unit operational verification, module level, and component level. Information on performance verification shall include: instructions to verify equipment is performing accurate measurements, list of test equipment required to perform the verification tests, step-by-step instructions for test connections, signal levels expected, calibration/alignment procedure information, and self-test routines.

Module and component level maintenance shall require information on troubleshooting, disassembly, reassembly, and test. The manual shall include step-by-step instructions for troubleshooting and fault isolation, signal levels expected, list of required test equipment and connection diagrams, and block and schematic diagrams. Parts lists shall be shown on illustrations or a separate listing that includes an index or reference to other illustrations. Parts lists shall include part number and generic description. Sequential instructions for disassembly, repair, replacement, and reassembly shall be provided. As required, the instructions will define localizing a defective circuit card or component. Test data sheets shall also be included.

If batteries are used in the equipment, instructions shall be included that describe the procedure for battery replacement – part number and description. Proper disposal procedures shall be contained in the manual.

The maintenance and servicing section of the technical manual shall contain instructions on equipment return procedures for equipment failure occurring during the period the manufacturer’s warranty is in effect.

Common commercial parts such as hardware items shall be identified by part number and description to facilitate substitutions of parts from other sources.

Manuals shall contain instructions for repackaging of unit or assembly including electrostatic sensitive devices information.

The technical manual shall include information on storage. Information required shall include environmental conditions, battery removal if required, and any specific requirements.

Cleaning information covering intervals, types of solvents, and materials used shall be listed in the maintenance and servicing section of the technical manual.

3.76 Training materials: Computer based training material that is designed to train a high school graduate with very little or no experience with temperature devices and instrumentation in the Normal (beginner) mode through advanced (experienced) mode of operation of the PHTC shall be provided. This computer based training material shall be compatible with operation on Navy Marine Corps Intranet (NMCI) Windows 7 computers. NMCI is limited in regards to running or installing software, hence it is recommended that this training material be compatible with Microsoft Office, Explorer 8, and/or Adobe Reader. .mp4 file format is recommended for any video content.

3.77 Copyright release: A statement of copyright release for reproduction of technical manuals for government use shall be printed in the first two pages of each technical manual. If an existing manual is provided, the statement of copyright release for reproduction shall be permanently affixed/marked in the manual. A statement of copyright release for reproduction of the technical manual CD for government use shall be printed on each CD.