CSS_06-2175_Force_Calibration_Press_02242016_-_MD.docx

FCP CALIBRATION STANDARD SPECIFICATION CSS 06-2175

CSS 06-2175

CALIBRATION STANDARDS SPECIFICATION PROCUREMENT PACKAGE

Force Calibration Press

DISTRIBUTION STATEMENT A. APPROVED FOR PUBLIC RELEASE

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

24 FEbruary 2016

CALIBRATION STANDARDS SPECIFICATION PROCUREMENT PACKAGE

Force Calibration Press

Physical/Mechanical Standards (MS 33) Measurement Science Department Naval Surface Warfare Center, Corona Division P.O. Box 5000 Corona, CA 91718-5000

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

Table of Contents

FCP CALIBRATION STANDARD SPECIFICATION CSS 06-2175

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1.0 SCOPE

1.1 General. This document specifies the minimum requirements for a Force Calibration Press. This equipment may be of commercial design. It is intended to be used by Navy personnel in shore-based calibration laboratories. This equipment will be used with existing Navy load cell calibration standards to test the accuracy of aircraft weight and balance instruments, including platform scales and compression load cells. For the purpose of this calibration standards specification (CSS), the Force Calibration Press shall be referred to as the FCP.

1.2 Usage. Equipment covered by this CSS is intended for use in testing equipment and systems in the worldwide natural and controlled environments in which Military equipment is operated. Equipment will also be subjected to environments aboard land, sea and air vehicles, both military and commercial during periods of transportation and storage. The requirements of this CSS are tailored to the intended use of the equipment.

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issues of these documents shall be those in effect on the date of this solicitation.

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 - Standard Practice of Identification Marking of U.S. Military Property (Copies of DoD Standards are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

American National Standards Institute (ANSI)

(Copies of ANSI documents are available from http://webstore.ansi.org/ or ANSI Attn: Customer Service Department, 25 W 43rd Street, 4th Floor, New York, NY, 10036

2.2 Order of precedence. In the event of conflict between the text of this CSS and the references cited herein, the text of this specification shall take precedence. Nothing in this CSS, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 Safety. 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.

3.2 Interchangeability. A model number shall be designated for all units provided. All units and the replaceable assemblies, subassemblies, and parts comprising the units shall be interchangeable on a noninterference basis and shall cause no degradation of performance, unless alignment in-situ is required for the replaced components as part of the repair process and such alignment meets all maintainability requirements

3.3 Equipment components. Parts, materials, and process shall be as specified below in 3.3.1 Finish through 3.3.2.2 Combination of materials.

3.3.1 Finish. Unless otherwise specified the equipment shall be the finish normally provided by the manufacturer.

3.3.2 Restricted materials. Restricted materials shall be as specified below in 3.3.2.1 Other restricted materials and gases through 3.3.2.2 Combination of materials.

3.3.2.1 Other restricted materials and gases. Test equipment shall not contain materials that promote the premature failure of the equipment or that present a health hazard under normal use or storage conditions as specified below in 3.3.2.1.1 Organic materials through 3.3.2.1.5 Helium.

3.3.2.1.1 Organic materials. Test equipment shall not contain materials prone to organic decay or that act as a nutrient for the growth of multicelled organisms.

3.3.2.1.2 Flammable materials. Test equipment shall not contain materials that ignite into flames at operating or storage temperatures.

3.3.2.1.3 Explosive materials. Test equipment shall not contain materials that explode at operating or storage temperatures.

3.3.2.1.4 Carcinogens. Certain chemicals have been identified in the Occupational Safety And Health Act (OSHA) as cancer-producing substances (carcinogens). Materials that might contain these chemicals shall not be used unless specifically required and approved by the procuring Navy activity.

3.3.2.1.5 Helium. Helium shall not be used as pressurizing gas in sealed units containing electron tubes. When necessary to use helium for leak detection purposes, exposure shall be limited to the time necessary for the test, followed by thorough purging.

3.3.2.2 Combination of materials. The equipment shall contain no combination of materials that cause deterioration of any material contained in the equipment due to the effects of outgassing.

3.4 Design and construction. The test equipment shall be designed and constructed to permit compliance with all applicable requirements as defined in this CSS, as well as the performance, accuracy, and other requirements in this CSS.

3.4.1 Operator controls. Operating controls and indicators shall be readily accessible to the operator from the front of the equipment. The readings presented on the controls and indicators shall be available to the operator without conversion or calculation.

3.4.2 Connectors, electric. Provision shall be made to ensure that connectors will be mated only with the appropriate counterparts. Where design considerations require close proximity of connectors of similar configuration, the mating connectors shall be suitably coded or marked. The live or hot side of unmated connectors shall be protected against shorting.

3.4.3 Wiring, internal. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance.

3.5 Electrical power sources and connections. If the FCP uses electrical power, the electrical power sources and connections shall be as specified below in 3.5.1 Electrical power source and 3.5.2.2 Indicators.

3.5.1 Electrical power source. The equipment shall operate from the input power conditions specified in 3.5.1.1 Power consumption through 3.5.1.2 Nominal power source.

3.5.1.1 Power consumption. The maximum power for operation of a FCP component that requires an external single phase 120 Vrms power source shall not exceed 1500 watts.

3.5.1.2 Nominal power source. The equipment shall operate at 120 Vrms single-phase 50 Hz and 60 Hz source.

3.5.1.2.1 Steady-state conditions. The performance and accuracy of the equipment shall not be adversely affected when operated under any combination of conditions a through c. Tolerance values are derived from, and referenced to, the nominal values specified for voltage and frequency in 3.5.1.2 Nominal power source above.

a. The steady-state voltage-tolerance shall be ±10%.

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

c. The deviations in waveform characteristics shall be as in 1 through 4.

1. Waveform deviation factor of ±10 percent or less

2. Total harmonics of ±10 percent or less

3. Individual harmonics of ±5 percent or less

4. Crest factor of 1.27 to 1.56

3.5.1.2.2 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

3.5.2 Electrical power connections. The requirements specified in 3.5.2.1 Input Excessive current drain protection through 3.5.2.2 Indicators shall apply to equipment rated at 10A rms, or less. Power connectors and connections for equipment rated above 10A rms shall be as specified in the purchase description. When single-phase operation is specified, the equipment shall operate with a ground at the primary power source on either or neither side of the single phase input power line.

3.5.2.1 Excessive current drain protection. An automated safety mechanism (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.

3.5.2.2 Indicators. Visual indication shall be provided on the front panel to indicate when the equipment is energized.

3.6 Enclosure physical characteristics. The physical characteristics of the equipment shall be as specified in 3.6.1 Dimensions through 3.6.6 Case insert, transit case.

3.6.1 Dimensions. Maximum dimensions of the FCP shall not exceed 70 inches in height, inches in 60 width and 48 inches in depth.

3.6.2 Weight. The weight of the FCP including all covers and accessories shall not exceed 3000 pounds.

3.6.3 Enclosure requirements. The FCP enclosure shall be as specified in 3.6.3.1 Corners through 3.6.3.2 Connections and controls.

3.6.3.1 Corners. All corners shall be designed to preclude injury to personnel or damage to material. All corners shall be adequately reinforced to protect the instrument from damage during shipping, handling and storage.

3.6.3.2 Connections and controls. All external electrical connections (except power connections) and operating controls shall be on the control panel. Electrical power connections shall be on the rear.

3.6.4 Accessory stowage, transit case. The transit case shall have provisions for the stowage of accessories, operating instructions, removable power cables, signal leads, and designated spares. Stowage shall not adversely affect the carrying stability of the equipment and shall be contained in a manner that prevents damage to the accessories or equipment during transit.

3.6.5 Corners, transit case. All hard edged corners shall be designed to preclude injury to personnel or damage to material. All corners shall be adequately reinforced to protect the accessories or equipment from damage during shipping, handling and storage.

3.6.6 Case insert, transit case. A custom cut, high density, polyethylene black polyplank foam case insert shall be provided to organize and provide robust protection of the FCP accessories while stored in the transit case.

3.7 Marking and identification. Marking and identification of test equipment shall be as specified below in 3.7.1 Marking through 3.7.2 Equipment identification.

3.7.1 Marking. Test equipment shall be marked in a manner that does not adversely affect safety or performance.

3.7.1.1 Reference designations. Reference designations shall be used to identify each part for its particular circuit application. Subminiaturized and nonrepairable assemblies need not be marked with reference designations. Reference designator usage shall be in accordance with ANSI Y32.2 and ANSI Y32.16.

3.7.1.2 Warning markings. Warning markings shall warn of the location, the nature, and the extent of a hazard. Letters of warning markings shall be of clearly legible gothic capitals. Warning markings shall have high contrast between the letter and background colors. The markings shall be as permanent as normal life expectancy of the test equipment, and located as close as possible to the point of danger.

3.7.1.3 Panel markings and processes. Panel markings shall enable the operator to identify the functions and use of all items requiring operator intervention.

3.7.2 Equipment identification. All equipment, excluding small accessory items contained within a reusable pouch or container, shall be identified with the items specified in a through d.

1. Manufacture name Equipment model number with installed options Equipment nomenclature Serial number

3.7.2.1 Identification plate. An equipment identification plate shall be affixed to the test equipment enclosure when the enclosure also serves as the transit case. The identification plate shall contain the information provided below in 3.7.2.1.1 Identification plate, multiple cases through 3.7.2.1.5 Identification plate, marking. The identification plate shall be permanently affixed.

3.7.2.1.1 Identification plate, multiple case. When multiple cases are required, the identification plate shall contain the information provided in a through e.

d. Configuration model number or equipment model number with installed options

e. Configuration or equipment nomenclature

f. Configuration or manufacturer CAGE

g. Configuration serial number

h. Case X of Y

3.7.2.1.2 Identification plate, supplemental. When accessories are required to meet the requirements of the CSS and the combination is given a part or model number designation that differs from that of the main unit, there shall be a supplemental identification plate containing the information in a and b. The plate shall be placed on the accessory container, as applicable. Whether or not a configuration model designation is assigned to the accessory or group of accessories, all major accessories shall be marked as in c:

i. Model configuration number: (Model number assigned to the equipment configuration).

j. Consists of: [part number of all components (excluding cables and adapters) comprising the equipment configuration].

k. Part of (or p/o): (Model number assigned to the equipment configuration, or main unit model number, as applicable), s/n: (serial number assigned to the equipment comprising the set or the serial number of the primary instrument if a separate s/n is not assigned to the set).

3.7.2.1.3 Identification plate, transit case. The equipment transit cases for accessory stowage, shall be provided with an identification plate that is permanently affixed. An acceptable method of attachment is to use 1/8” diameter solid or semi-tubular rivets and backup washers. The identification plate shall be as specified below in 3.7.2.1.4 Identification plate, material through 3.7.2.1.5 Identification plate, marking.

3.7.2.1.4 Identification plate, material. The following materials with minimum thickness of 1/32 inch are recommended.

l. Brass

m. Corrosion resistant steel

n. Aluminum alloy

3.7.2.1.5 Identification plate, marking. 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.

3.7.2.2 Reusable pouch or container. If a reusable pouch or container is provided, containers shall be marked "accessories for use with" (test equipment nomenclature or model number), or, "maintenance aids for use with" (test equipment nomenclature or model number), as applicable.

3.7.2.3 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.

3.8 Environmental requirements. The FCP environmental performance requirements shall be as specified below in 3.8.1 Warm-up through 3.8.3 Salt atmosphere. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.8.1 Warm-up. The FCP shall comply with the specified performance requirements after a 10-minute warm-up period preceded by a 1-hour not operating temperature stabilization period.

3.8.2 Temperature and humidity. The temperature ranges and humidity limits for both operating and not operating conditions shall be as specified below in 3.7.2.1 Temperature not operating through 3.7.2.3 Humidity. A RH of 95 percent (with the applicable tolerance) does not include conditions of precipitation.

3.8.2.1 Temperature not operating. The FCP shall conform to the specified performance requirements after being stored at temperatures ranging from -40 ºC to 70 ºC (-40 ºF to 158 ºF).

3.8.2.2 Temperature operating. The FCP shall conform to the specified performance while being operated at temperatures over the range of 19.4 ºC to 26.1 ºC (67 ºF to 79 ºF).

3.8.2.3 Humidity. The FCP shall be subjected to conditions where the relative humidity is 20 to 60 percent in the temperature range of 19.4 ºC to 26.1 ºC (67 ºF to 79 ºF).

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

Figure 1 Example Force Calibration Press

3.9 Performance requirements.

3.9.1 Frame. The FCP frame shall perform to the specifications described in 3.9.1.1 Capacity through 3.9.1.6 Vertical adjustment. Figure 1 above is provided as an example to illustrate frame components and terminology, and to aid communication of the performance requirements. The FCP frame does not need replicate Figure 1 example exactly.

3.9.1.1 Capacity. The FCP frame shall have a capacity of 100,000 lbf (50 short tons) minimum. Working capacity shall be 80,000 lbf (40 short tons). The frame shall be labeled with “CAPACITY 80,000 LBF”.

3.9.1.2 Design analysis. A design analysis report shall be provided with calculations, test data, and/or computer simulation models proving the FCP is safe to use at 100,000 lbf. The report shall identify yield and failure forces. The design model shall account for point load in the center of the test surface.

3.9.1.3 Mobility. The frame shall allow for lifting and transport via fork lift and/or pallet truck, without damage to the frame assembly. The pallet jack will have a 48 inch fork length, a 27 inch outside fork spread, and 15 inch inside fork spread. Fork minimum height will be 3 inches, with a maximum lifting height of 7.75 inches. The bottom surface of the frame shall be approximately 4 inches above the ground, allowing for fork lift and/or pallet truck fork insertion and lifting.

3.9.1.4 Leveling feet. Leveling feet shall be provided to allow adjustment for stability and test surface levelness.

3.9.1.5 Test surface. The FCP test surface shall support platform scales and compression load cells. The test surface, free from obstructions, shall be 52 inches in width and 42 inches in depth minimum. The top of the test surface shall be between 28 to 35 inches from the ground. The test surface shall not exceed the dimension specified in 3.6.1 Dimensions.

3.9.1.6 Hydraulic cylinder mounting. The FCP frame shall support the 3.9.2.1 Hydraulic cylinder with the plunger perpendicular to the test surface, allowing the application of compressive force between the plunger and test surface. The plunger center shall be aligned with the center of the test surface.

3.9.1.7 Vertical adjustment. The vertical distance between the test surface and the 3.9.2.1 Hydraulic cylinder plunger shall be adjustable from 1 inch to 18 inches. This adjustment allows for various height dimensions of the unit under test, load cell, adapters and loading blocks. Adjustment may be accomplished by using an adjustable height cross beam, using a long stroke 3.9.2.1 Hydraulic cylinder, or a combination of these two methods. Electric motor assist shall be provided for quick adjustment, with a low speed setting for fine adjustment.

3.9.2 Hydraulic system. The FCP hydraulic system shall be capable of producing 100,000 lbf (50 short tons) minimum.

3.9.2.1 Hydraulic cylinder. The hydraulic cylinder shall be capable of producing 100,000 lbf minimum. The hydraulic cylinder shall be single-action, spring return type. Maximum operating pressure shall be 10,000 psi. The FCS shall be designed to use 80% or less of the total stoke for the hydraulic cylinder.

3.9.2.2 Hydraulic pump. The hydraulic pump shall provide fluid flow to the 3.9.2.1 Hydraulic cylinder. Maximum operating pressure shall be 10,000 psi. The hydraulic pump shall be manually operated. The hydraulic pump reservoir capability shall be appropriately sized to accommodate the hydraulic cylinder force capacity and stroke. The hydraulic pump shall have two speeds, minimum, allowing for course and fine force application control. Manual operation, motor assisted operation, or combination of operation methods is acceptable.

3.9.2.3 Fine control pump. A fine control pump shall be provided for fine force adjustment to a resolution of 0.1 lbs or smaller, as measured by the load cell standard. The fine control pump shall be manually operated. Maximum operating pressure shall be 10,000 psi.

3.9.2.4 Load cell mounting. The 3.9.2.1 Hydraulic cylinder plunger shall be the mounting point for Navy load cell calibration standards. Only one load cell will be mounted to the plunger at a time; mounting multiple load cells at the same time is not required. The plunger will interface with the load cell at the bottom threaded hole. The plunger will hold the load cell weight. The following table provides the capacities, dimensions, and weights of the load cell expected to mount to the plunger.

3.9.3 Accessories. The following accessories specified in 3.9.3.1 Load cell adapters through 3.9.3.10 Aluminum round plate shall be provided with each FCP.

3.9.3.1 Load cell adapters. The load cell adapters shall be provided to mount the load cell calibration standards to the hydraulic cylinder plunger, as described in 3.9.2.4 Load cell mounting. An adapter will be provided for each load cell.

3.9.3.2 Large aluminum loading block. The large aluminum load block shall be 17 inch (±0.25) in width, 10 inch (±0.25) in depth, and 1.75 inch (minimum) in height. The block shall be made of 6061-T6 aluminum.

3.9.3.3 Large rubber loading pad. The large rubber loading pad shall be 17 inch (±0.25) in width, 10 inch (±0.25) in depth, and 0.5 inch (±0.125) in height. The rubber loading pad material shall have a 40 to 70 Shore A rating.

3.9.3.4 Small aluminum loading block. The small aluminum load plate shall be 8 inch (±0.25) in width, 8 inch (±0.25) in depth, and 1.75 inch (minimum) in height. The block shall be made of 6061-T6 aluminum.

3.9.3.5 Small rubber loading pad. The small rubber loading pad shall be 8 inch (±0.25) in width, 8 inch (±0.25) in depth, and 0.5 inch (±0.125) in height. The rubber loading pad material shall have a 40 to 70 Shore A rating.

3.9.3.6 Aluminum distribution plate. The aluminum distribution plate shall be 20 inch (±0.25) in width, 14 inch (±0.25) in depth, and 1.5 inch (minimum) in height. The plate shall be made of T6061-T6 aluminum with Brinell harness of 95.

3.9.3.7 Square aluminum distribution plate. The square aluminum distribution plate shall be 12 inch (±0.25) in width, 12 inch (±0.25) in depth, and 1.5 inch (minimum) in height. The plate shall be made of T6061-T6 aluminum with Brinell harness of 95.

3.9.3.8 Hardened steel plate. The hardened steel plate shall be 4 inch (±0.25) in width, 4 inch (±0.25) in depth, and 0.5 inch (minimum) in height. The plate shall be made of 4340 steel hardened to Rockwell C 47/48, ground flat within .001 TIR and parallel to .002.

3.9.3.9 Aluminum round spacer. The aluminum round spacer shall be 8 inches in diameter x 3 inches in height. The spacer shall be made of T6061-T6 aluminum with Brinell harness of 95.

3.9.3.10 Aluminum round plate. The aluminum round spacers shall be 5 inches in diameter x 5.25 inches in height. The plate shall be made of T6061-T6 aluminum with Brinell harness of 95.

3.10 Maintainability. Maintainability shall be as specified below in 3.10.1 Preventive maintenance isolation through 3.10.5 Washability.

3.10.1 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.

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

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.

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

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

3.10.3 Repair. Maintenance instructions shall be furnished to facilitate the replacement of repairable assemblies and subsequent testing procedures to ensure the performance of the repairable assemblies or the repair action taken.

3.10.4 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 CNCS (e.g. the USB DVD-ROM drive available with the device).

3.10.5 Washability. The equipment shall conform to all requirements after being washed, and there shall be no evidence of deterioration.

3.11 Workmanship. The manufacture, assembly and packaging of the items covered by this CSS shall be representative of the best commercial practices and shall conform to the requirements of this CSS. All items will remain securely held in place during normal transit. Adequate protection will be afforded for the equipment on all sides to avoid transient damage.

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