CSS_06-0179_FCA_Force_System_-_Final_(1).docx

Load cell and indicator kit CALIBRATION STANDARD SPECIFICATION CSS 06-0179

CSS 06-0179

CALIBRATION STANDARDS SPECIFICATION PROCUREMENT PACKAGE

Load Cell AND Indicator Kit

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

JULY 2016

CALIBRATION STANDARDS SPECIFICATION PROCUREMENT PACKAGE

Load Cell AND Indicator KIT

Prepared by:

Physical / Mechanical Standards (MS 33) Measurement Science Department Naval Surface Warfare Center, Corona Division

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

Table of Contents

LOAD CELL AND INDICATOR KIT CALIBRATION STANDARD SPECIFICATION CSS 06-0179

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1.0 SCOPE

1.1 General. This document specifies the minimum requirements for a Load Cell and Indicator Kit. This equipment may be of commercial design. It is intended to be used by Navy and Marine Corps personnel in shore-based laboratories and for on-site, in-place calibration. The indicator will be used with the load cell specified as well as with various other load cells to verify the measurement performance of testing equipment and systems. For the purpose of this calibration standards specification (CSS), the Load Cell and Indicator Kit shall be referred to as the Kit.

KEY POINTS:

The load cell will utilize IEEE 1451 plug and play capability to store calibration data within the load cell itself; preventing incorrect data entry and accidental overload.

The indicator will be capable of:

1) Identifying load cell and reading load cell data/coefficients.

2) Writing new calibration data/coefficients to load cells.

3) Storing load cell information and calibration data/coefficients for use with load cells not specified in this CSS that do not utilize IEEE 1451 EEPROMs.

System range: 0 to 20,000 lbf tension System accuracy: +/- 4 lbf from 1,000 to 20,000 lbf

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

International Electrotechnical Commission (IEC) IEC 61010-1 - Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use (General Requirements) (Copies of IEC documents are available online at http://www.iec.ch/ or EC publications are available in the US from the Sales Department. American National Standards Institute, 11 West 42nd Street,113 Floor, New York, NY 10036, USA.)

InSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE) IEEE STD 1451.4 - Mixed-mode Communication Protocols and Transducer Electonic Data Sheet (TEDS) Formats (Copies of IEEE documents are available from http://www.ieee.org or IEEE Service Center, 445 Hoes Lane, Piscataway, NJ 08854-1331.)

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. 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.

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

3.2.1 Operator adjustments. The equipment shall include built-in adjustments or compensating devices for any function or parameter that would exceed the specified tolerance. Under all specified service conditions the variation of any adjustment or control shall produce the desired control action to bring the equipment within tolerance.

3.2.2 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.

3.2.3 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.

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

3.2.5 Internal cooling. The equipment shall be capable of operating without interruption for at least 24 hours at the maximum operating temperature as specified in this CSS without overheating, losing power or otherwise exhibiting failure.

3.3 Electrical power sources and connections. The electrical power sources and connections shall be as specified below in 3.3.1 Electrical power source and 3.3.2 Input power cable.

3.3.1 Electrical power source. The equipment shall operate from the input power conditions specified in 3.3.1.1 Nominal power source through 3.3.1.3 Excessive current drain protection.

3.3.1.1 Nominal power source. The equipment shall operate using a 120 Vrms (±10%), single phase 50 Hz and 60 Hz (±5%) receptacle power source.

3.3.1.2 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.

3.3.1.3 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. The mechanism shall be available from an exterior panel of the 3.8.4 Digital indicator.

3.3.2 Input power cable. The input power cable shall be a detachable power cable normally provided by the manufacturer.

3.4 Enclosure physical characteristics. The physical characteristics of the equipment shall be as specified in 3.4.1 Dimensions through 3.4.2 Weight.

3.4.1 Dimensions. Maximum dimensions of the Kit components including handles and covers, if any, shall be sized to allow the Kit components to be stored and protected in the 3.5 Transit cases.

3.4.2 Weight. The weight of the Kit including transit cases and all accessories shall not exceed 88 pounds. The weight of each transit case and its contents shall not exceed 44 pounds.

3.5 Transit cases. Hard transit cases shall be provided to protect the contained test equipment and accessories during shipping and storage. Each case shall have a gasket to prevent entry of dirt or spray-type moisture or contaminates during shipping or storage. The transit cases are not an integral part of the test equipment. It need not provide for operational capability of the equipment when enclosed. The physical characteristics of the transit case shall be as specified in 3.5.1 Dimensions, transit case through 3.5.6 Case insert, transit case.

3.5.1 Dimensions, transit case. The exterior dimensions of each transit case shall not exceed 10 inches in height, 24 inches in width and 18 inches in depth. Alternative dimensions are all acceptable if the exterior volume is 4320 cubic inches or less.

3.5.2 Cover, transit case. The transit case shall have a cover that can to be closed and fastened. Fasteners shall allow for quick opening. If the cover is removable, fasteners shall not interfere with cover removal. The cover and main body of the transit case shall utilize a tongue-in-groove gasket to provide a watertight seal.

3.5.3 Handles, transit case. One or more handles shall be provided.

3.5.3.1 Handles, hard transit case. Handles shall stop open at 90 degrees, and shall be returned to a closed position by a spring-loaded or retaining mechanism when not in use. Handles shall be recessed or protected.

3.5.4 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 instrument from damage during shipping, handling and storage.

3.5.5 Pressure equalizing valve, transit case. Air tight transit cases shall have a mechanism for equalizing air pressure within the enclosure, when the enclosure is sealed. The mechanism provided shall not protrude beyond the transit case enclosure.

3.5.6 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 Kit while stored in the transit case.

3.6 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

a. Manufacture name

b. Equipment model number with installed options

c. Equipment nomenclature

d. Serial number

3.7 Environmental requirements. The Kit environmental performance requirements shall be as specified below in 3.7.1 Warm-up through 3.7.2 Temperature and humidity. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.7.1 Warm-up. The Kit shall comply with the specified performance requirements after a 2 hour warm-up period preceded by a 1-hour not operating temperature stabilization period.

3.7.2 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.

3.7.2.1 Temperature not operating. The Kit shall conform to the specified performance and accuracy requirements after being stored in the transit case at temperatures ranging from -10 ºC to 60 ºC (14 ºF to 140 ºF).

3.7.2.2 Temperature operating. The Kit shall conform to the specified performance and accuracy while being operated at temperatures over the range of 0 ºC to 50 ºC (32 ºF to 122 ºF).

3.7.2.3 Humidity. The Kit shall conform to the specified performance and accuracy for conditions where the relative humidity is 5 to 75±5 percent in the temperature range of 30 ºC to 40 ºC (86 ºF to 104 ºF), and where the relative humidity is 5 to 45±5 percent at temperatures above 40 ºC (104 ºF).

3.8 Performance requirements. The Kit shall perform as specified in 3.8.1 Measurement requirements through 3.8.4 Digital indicator.

3.8.1 System interface. The Kit shall utilize IEEE 1451.4 smart technology to enable the digital indicator to recognize load cell range and calibration/characterization data stored on board the load cell. The system shall utilize plug and play technology to facilitate the discovery of a new or replacement load cell without the need for physical device configuration.

3.8.2 System accuracy. System accuracy shall be ±0.02% of full scale (±4 lbf) from 1,000 to 20,000 lbf or better.

3.8.3 Load cell. The load cell shall perform as specified in 3.8.3.1 Measurement range through 3.8.3.11 Dimensions.

3.8.3.1 Measurement range. The load cell measurement range of 0 to 20,000 lbf.

3.8.3.2 Safe overload rating. The load cell shall be capable of being loaded up to 150% of rated load capacity, without producing a permanent shift in performance.

3.8.3.3 Tension loading. The load cell shall be capable of being loaded and making measurements in the tension direction.

3.8.3.4 Type. The load cell shall be strain gage based, utilizing a full strain gage bridge circuit. Nominal bridge resistance shall be 350 ohm. A single bridge is required.

3.8.3.5 Sensitivity. The nominal load cell sensitivity shall be 2, 3 or 4 mV/V. 4 mV/V is preferred.

3.8.3.6 Excitation voltage. The nominal load cell excitation voltage 10 VDC.

3.8.3.7 Wiring configuration. The load cell shall use the 6 wire/conductor configuration to connect the strain gage bridge to the digital indicator.

3.8.3.8 Cable. The load cell shall use a shielded cable having 8 wires/conductors with 22 AMG size. The cable shall be detachable. Cable length shall be 15 feet minimum.

3.8.3.9 Cable connector. The load cell cable shall use a D subminiature 9 pin connector (DE-9,DB-9) plug. This cable connector will used to interface with the digital indicator.

3.8.3.9.1 Hood. The cable connector hood (backshell) shall be easily assembled and disassembled to facilitate maintenance.

3.8.3.9.2 Contacts. The cable connector shall use male solder pin contacts.

3.8.3.9.3 Pin assignments. The cable wires/conductors shall be soldered to the contact pins according to the following table.

3.8.3.10 EEPROM. A 1 wire EEPROM shall be used to store load cell identification and calibration data using the Transducer Electronic Data Sheet (TEDS) template and table formats recommended in IEEE 1451.4. The EEPROM data pin shall be soldered to cable connector Pin 7. The EEPROM ground pin shall be soldered to cable connector Pin 8. The EEPROM shall be housed in the load cell. Maxim IntegratedTM DS2431 and DS2433 are examples of EEPROMs that may be used for this application.

3.8.3.10.1 Template 40. Calibration table template ID=40 can be used to store multiple mV/V and lbf calibration data points to characterize the load cell.

3.8.3.10.2 Template 41. Calibration table template ID=41 can be used to store polynomial curve coefficients to characterize the force (lbf) versus defection (mV/V) load cell response.

3.8.3.11 Dimensions. The load cell maximum height shall be 213 mm (8.38 inches), with 1 1/2-12UNF-2B x 1.31 inch deep tapped holes on the top and bottom of the load cell. Maximum diameter shall be 127 mm (5 inches).

3.8.4 Digital indicator. The digital indicator shall perform to the parameters specified in 3.8.4.1 Accuracy and 3.8.4.10 Load cell channel connectors.

3.8.4.1 Accuracy. The digital indicator shall be accurate to ±0.01% of indicated value or better.

3.8.4.2 Display resolution. The digital indicator display resolution shall be 6 digits, ranging from positive (+) 999,999 to negative (-) 999,999. The decimal point placement shall be adjustable as shown in the following table.

999999.

99999.9

9999.99

999.999

99.9999

9.99999

3.8.4.3 Display units. The digital indicator shall display measurement unit of lb, kN, and mV/V minimum.

3.8.4.4 Display lines. The digital indicator shall have a two line/row digital display; top row for the first channel and bottom row for the second channel.

3.8.4.5 Load cell type. The digital indicator shall be compatible with 350Ω full-bridge strain gage load cells.

3.8.4.6 Load cell sensitivity. The digital indicator shall accommodate load cell full scale sensitivity values between 1 to 4.5 mV/V.

3.8.4.7 Load cell excitation. The digital indicator shall provide 5 and 10 VDC load cell excitation.

3.8.4.8 Load cell calibration data. The digital indicator shall be programmable for mating load cells as specified in 3.8.4.8.1 Load cell calibration curve through 3.8.4.8.4 Calibration curve adjustment.

3.8.4.8.1 Load cell calibration curve. The load cell calibration curve stored in the digital indicator shall be adjustable using 10 points from zero load to full scale. For load cells used in the tension and compression, the tension curve shall be adjustable using 10 points from zero load to full scale and the compression curve shall be adjustable using 10 points from zero load to full scale.

3.8.4.8.2 Number of load cell calibration curves. The digital indicator shall store up to 20 load cell calibration curves for use with load cells that do not have EEPROMs to store calibration curves internally. The calibration curves shall be selectable using the front panel controls and display.

3.8.4.8.3 EEPROM stored calibration curve. The digital indicator shall be capable of facilitating plug and play automatic setup with the 3.8.3 Load cell. The digital indicator shall upload load cell identification and calibration data from the load cell 3.8.3.10 EEPROM when connected. The digital indicator shall use the EEPROM calibration curve to convert the load cell mV/V output to a force indication in lbf.

3.8.4.8.4 Calibration curve adjustment. The calibration curve shall be adjustable using physical load on the load cell and electrical load cell signal simulation. The digital indicator shall be capable of adjusting or editing the calibration curve stored in the load cell EEPROM.

3.8.4.9 Load cell channels. The digital indicator shall have two channels, allowing connection to two load cells simultaneously.

3.8.4.10 Load cell channel connectors. The digital indicator shall have two connectors, allowing connection to two load cells simultaneously. These connectors shall be D subminiature 9 pin (DE-9,DB-9) receptacles. The receptacle pins shall be wired as described in the following table.

3.9 Maintainability. Maintainability shall be as specified below in 3.9.1 Preventive maintenance through 3.9.4 Firmware updates.

9. 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.

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

1. 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 (performance verification and adjustment/alignment).

1. Maintenance and calibration aids. If required, circuit board extenders, special adapters, special tools, 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.

1. Accessibility for repair. The equipment shall be designed for easy access to repairable assemblies without removing other hardwired subassemblies or components. 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 a replaceable assembly is necessary, the design of the equipment shall facilitate this directly or through extender cards.

1. Adjustment/Alignment. The equipment shall be provided with any necessary instructions/software (to include programming commands, if not explicitly company proprietary and non-releasable to the Navy or any other commercial customer) needed to adjust/align the equipment so that the equipment meets its performance specifications after repair or due to the equipment failing performance verification.

8. Accessibility for adjustment. The equipment design shall permit adjustments of components that are changeable without removing any component, printed circuit cards, or subassembly. The use of extender cards is permitted. (Example: Access will be provided to potentiometers that control the accuracy of specified parameters.)

8. Alignment instructions/software. If the equipment has alignment data stored in memory (example: 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. The alignment process shall be able to use existing Navy calibration standards that meet all necessary minimum performance requirements to satisfy a traceable calibration.

This alignment information provided shall include any necessary software (preferably software commands) usable via any allowable communications interface specified in this document, e.g. IEEE-488 data bus, and usage instructions required to perform an alignment (to include any necessary setup instructions/software commands to put the equipment into the alignment mode, instructions/software commands necessary to gather new alignment data, along with any software algorithms required to format the alignment data into the appropriate data required by the equipment, and any instructions/software commands necessary to reprogram the equipment with the new alignment data).

If software is required for the alignment process, preference will be given to software that uses current Navy calibration standards without modification (or the modification must be able to be performed by the Navy). Alternatively, if the software will not use Navy calibration standards without modification and modification by the Navy is not possible, preference will be given if the manufacturer supplies the explicit instructions/software commands and any necessary algorithms for the Navy to develop its own organic alignment support using existing Navy calibration standards.

9. Repair. Maintenance instructions shall be furnished to facilitate the replacement of repairable assemblies and subsequent testing procedures to ensure the proper performance of the repaired assembly.

9. 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. Calibration. The Kit shall meet the calibration requirements as specified below in 3.10.1 Calibration certificate through 3.10.3 Calibration procedure. For the purpose of this CSS, 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.

10. Calibration certificate. The equipment provided under this CSS shall have a current calibration certificate, with a calibration data sheet, traceable to the National Institute of Standards and Technology (NIST).

10. Calibration interval. The minimum interval between calibrations shall be 12 months. At the end of this interval, a minimum of 85 percent of the units shall remain in tolerance.

10. Calibration procedure. A calibration procedure in accordance with best commercial practices shall be provided.

3. Warranty label. The equipment shall have a warranty label that reflects the start and end dates of the warranty image1.jpeg