CSS 06-3235 Automatic Pressure Controller_ver4.pdf

CSS 06-3235

MAY 2025

CALIBRATION STANDARDS SPECIFICATION

PROCUREMENT PACKAGE

AUTOMATIC PRESSURE CONTROLLER

Prepared By

MEASUREMENT SCIENCE AND ENGINEERING DEPARTMENT

NAVAL SURFACE WARFARE CENTER

CORONA, CA 92878–5000

PUBLISHED BY DIRECTION OF COMMANDING OFFICER, NAVAL SURFACE WARFARE CENTER, CORONA DIVISION

APC CALIBRATION STANDARD SPECIFICATION CSS 06-3235

CSS 06-3235 Automatic Pressure Controller_ver4 A

RECORD OF CHANGES

Date Revision Author Pages Description of Change

10/21/2024 Original N. Adame 26

CSS 06-3235 Automatic Pressure Controller_ver4 i

Table of Contents

1.0 SCOPE

1.1 General

1.2 Usage

1.3 Classification

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents

2.1.1 Government documents

2.1.2 Non-Government publications

2.2 Order of precedence

3.0 REQUIREMENTS

3.1 Performance requirements

3.1.1 APC general requirement

3.1.1.1 Pressure media requirement

3.1.1.2 Pressure rating

3.1.1.3 Excess pressure relief

3.1.1.4 Contamination prevention

3.1.1.5 Pressure transducers

3.1.1.6 Units of measure

3.1.1.7 APC Range and Accuracy

3.1.1.8 Resolution

3.1.2 Accessories

3.1.2.1 Vacuum Pump

3.1.2.2 Accessory case

3.1.2.3 Pressure hoses

3.1.2.3.1 Supply pressure hose

3.1.2.3.2 Test Pressure hoses

3.1.2.4 Pressure fitting adapters

3.1.2.5 Contamination prevention system

3.2 Equipment components

3.2.1 Finish

3.2.2 Color

3.2.3 Interchangeability

3.2.4 Restricted materials

3.2.4.1 Material restricted for Navy use

3.2.4.2 Other restricted materials and gases

CSS 06-3235 Automatic Pressure Controller_ver4 ii

3.2.4.2.1 Organic materials

3.2.4.2.2 Flammable materials

3.2.4.2.3 Explosive materials

3.2.4.2.4 Carcinogens

3.2.4.2.5 Helium

3.2.4.3 Combination of materials

3.3 Design and construction

3.3.1 Operator adjustments

3.3.2 Operator controls

3.3.3 Electric connectors

3.3.4 Internal wiring

3.3.5 Internal cooling

3.3.6 Front panel display indicators

3.3.7 Self-test capability

3.4 Digital control interface

3.4.1 IEEE 802.3 ethernet interface requirements

3.5 Electrical power sources and connections

3.5.1 Electrical power source

3.5.1.1 Power consumption

3.5.1.2 Nominal and alternate power source

3.5.1.2.1 Steady-state conditions

3.5.1.2.2 Transient-state conditions

3.5.1.2.3 Interruption of power source

3.5.2 Electrical power connections

3.5.2.1 Input power cable

3.5.2.2 Input power switch

3.5.2.3 Excessive current drain protection

3.5.2.4 Indicators

3.6 Enclosure physical characteristics

3.6.1 Dimensions

3.6.1 Weight

3.6.2 Mechanical Stability

3.6.3 Enclosure requirements

3.6.3.1 Cover

3.6.3.2 Component protection

3.6.3.3 Chassis fasteners

3.7 Transit case

3.7.1 Transit case cover

CSS 06-3235 Automatic Pressure Controller_ver4 iii

3.7.2 Transit case handles

3.7.2.1 Hard transit case handles

3.7.3 Transit case accessory stowage

3.7.4 Transit case insert

3.8 Marking and identification

3.8.1 Marking

3.8.1.1 Reference designations

3.8.1.2 Warning markings

3.8.1.3 Panel markings and processes

3.8.2 Equipment identification

3.8.2.1 Identification plate

3.8.2.1.1 Single case identification plate

3.8.2.1.2 Multiple cases identification plate

3.8.2.2 Identification plate supplemental information

3.8.3 Transit case identification plate

3.8.4 Reusable pouch or container

3.8.5 Item unique identification (IUID)

3.9 Environmental requirements

3.9.1 Environmental conditions

3.9.2 Temperature and humidity (T/H)

3.9.2.1 Temperature, not operating

3.9.2.2 Temperature, operating

3.9.2.3 Humidity

3.9.3 Mechanical shock

3.9.3.1 Bench handling

3.9.4 Fungus resistance

3.9.5 Dust exposure

3.10 Safety

3.11 Warranty label

3.12 Calibration

3.12.1 Calibration interval

3.12.2 Calibration procedure

3.13 Reliability

3.14 Maintainability

3.14.1 Fault isolation

3.14.2 Preventive maintenance

3.14.3 Maintenance provisions

3.15 Copyright release

CSS 06-3235 Automatic Pressure Controller_ver4 iv

3.16 Workmanship

CSS 06-3235 Automatic Pressure Controller_ver4 1

1.0 SCOPE

1.1 General. This document specifies the minimum requirements for an Automatic Pressure Controller. This equipment may be of commercial design or modified commercial design. It is intended to be used by Navy personnel in shore-based laboratories. The equipment will be used by Navy personnel for calibration of a wide variety of pressure transducers, gauges, and indicators using pneumatic or hydraulic fluid media. For the purpose of this calibration standards specification (CSS), the Automatic Pressure Controller shall be referred to as the APC.

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 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. Specific requirements of MIL- PRF-28800G, as identified in this CSS, are invoked according to the class of equipment.

1.3 Classification. Equipment specified herein is categorized by class, (requirements arising from the intended operational environment). The class is assigned by the most severe environmental condition expected for the equipment. The equipment shall conform to the following class requirements in accordance with MIL-PRF- 28800G for Navy shore-based laboratory use as specified in this CSS.

a. Class 3 – Equipment is designed for operational environments where conditions are routinely encountered in a diverse, controlled climate.

Examples include test equipment for bench-top, rack-mount, or occasional portable use in diverse and environmentally controlled locations.

b. Class 4 – Equipment is designed for benign operational environments where the environmental conditions are controlled and protected. Examples include test equipment for use in a fully protected and environmentally controlled service area such as a laboratory.

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.

2.1.1 Government documents.

DEPARTMENT OF DEFENSE specifications MIL-PRF-28800G – Test Equipment for use with Electrical and

Electronic Equipment

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

CSS 06-3235 Automatic Pressure Controller_ver4 2

(Copies of DoD specifications are available online at http://assist.dla.mil.)

DEPARTMENT OF DEFENSE STANDARDS

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

(Copies of DoD standards are available online at http://assist.dla.mil.)

DEPARTMENT OF DEFENSE handbookS MIL-HDBK-781A – Reliability Test Methods, Plans, and

Environments for Engineering Development, Qualification, and Production

(Copies of DoD handbooks are available online at http://assist.dla.mil.)

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

NIST Special Publication 811 – Guide for the Use of the International

System of Units (SI)

NIST Technical Note 1297 – Guidelines for Evaluating and Expressing the Uncertainty of NIST Measurement Results

(Copies of NIST documents are available online at http://www.nist.gov/pml/productsservices /special-publications-tutorials.)

2.1.2 Non-Government publications.

American society of mechanical engineers (asme) ASME Y14.44 (2014) – Reference Designations for Electrical and

Electronics Parts and Equipment

ASME B1.20.1 (2013) – Pipe Threads, General Purpose, Inch

(Copies of ASME documents are available from www.asme.org or ASME Information Central Orders/Inquiries, P.O. Box 2300, Fairfield, NJ 07007-2300.)

Institute of electrical and electronics engineers (ieee) IEEE 260.1 (2004) – IEEE Standard Letter Symbols for Units of

Measurement (SI Customary Inch-Pound Units, and Certain Other Units)

IEEE 315 – Graphic Symbols for Electrical and Electronic Diagrams (Including Reference Designation Letters)

(Copies of IEEE documents are available from http://www.ieee.org or IEEE Service Center, 445 Hoes Lane, Piscataway, NJ 08854-1331.)

International Electrotechnical Commission (IEC) IEC/IEEE 60488-1 – Standard for Higher Performance Protocol for the

Standard Digital Interface for Programmable Instrumentation http://www.nist.gov/pml/productsservices

CSS 06-3235 Automatic Pressure Controller_ver4 3

IEC/IEEE 60488-2 – Standard Digital Interface for Programmable Instrumentation

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.)

STANDARD COMMANDS FOR PROGRAMMABLE INSTRUMENTS (SCPI)

CONSORTIUM

SCPI Volume I -1999 – Standard Commands for Programmable Instruments (SCPI)

(Copies of SCPI documents are available online at http://www.ivifoundation.org or IVI Foundation Corporate Office, PO Box 1016, Niwot, CO 80544-1016.)

Society of automotive engineers (sae) SAE AS4841D – Fittings, 37 Degree Internal Flare, Fluid

Connection

(Copies of SAE documents are available at http://www.sae.org/technical/standards/AS4841 or SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001.)

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 Performance requirements.

3.1.1 APC general requirement. The APC system shall be a pneumatic and/or hydraulic pressure calibration system with user-friendly controls and intuitive menus for both experienced and novice operators. The APC shall have an option for manual and automatic operation to control and monitor pressure output in static and dynamic modes within the specified ranges and accuracies outlined in 3.1.1.7. The PGC shall have the capability of automated leak testing and pressure head correction. The PGC shall include an automated self purging liquid trap and have the capability of calibrating both pneumatic and hydraulic pressure indicating Test Instruments (TI’s) with minimal need for prior cleaning of TI’s. The input, output, and exhaust pressure ports of the APC shall be designed to mate with industry standard fittings or quick disconnects. All ports shall have a tethered cap/plug to prevent contamination and/or damage during non-use or storage.

CSS 06-3235 Automatic Pressure Controller_ver4 4

3.1.1.1 Pressure media requirement. Pneumatic media shall be clean, dry nitrogen as well as clean, filtered, and dry ambient air. If the APC is capable of using hydraulic media, it shall be clean, filtered water. Pressure media shall travel from the pressure source one way through the system pressure controller out to the TI. The pressure media circuit shall prevent media from traveling in reverse direction, and have a separate circuit for returning media from the TI where potentially contaminated media may be processed, collected, and safely disposed of. In the same direction flow of the pressure media, the circuit shall apply for vacuum operation.

3.1.1.2 Pressure rating. All internal tubing, fittings, and adapters shall have a proof pressure of 1.5 times the maximum pressure to which they are exposed. They shall have a burst pressure of 4 times the maximum possible pressure.

3.1.1.3 Excess pressure relief. The APC shall be capable of limiting the maximum allowable pressure available for the testing a TI, based on the TI full scale range plus 10 percent. It shall automatically relieve excess pressure through the exhaust pressure circuitry.

3.1.1.4 Contamination prevention. The APC shall maintain system cleanliness and prevent cross contamination of TI’s. There shall be minimum cleaning required for either pneumatic or hydraulic system TI’s prior to calibration and no cleaning required for after calibration to prevent cross contamination of the TI’s and/or the APC. There shall be an automated self purging liquid trap contamination prevention system (CPS) that meets the requirements listed in 3.1.2.5, with two sets of contamination traps, lines, and associated fittings for processing contaminated media returning from the TI. One set shall be designed and designated (reference color blue) for use with clean pneumatic media and one set designed and designated (reference color orange) for use with pneumatic media contaminated with one or more of the following fluids listed.

Water

Sea Water

MIL-H-19457 (Phosphate Ester Base Hydraulic Fluid)

MIL-PRF-23699 (Steam Turbine and Gear Lube Oil)

MIL-F-16884 (Distillate Fuel)

MIL-DTL-5624 (JP-4/JP-5/JP-8 Fuel)

MIL-PRF-17331 (Steam Turbine Lube Oil, 2190)

MIL-PRF-17672 (Hydraulic Fluid, 2075, 2110, 2135)

MIL-PRF-8188 (Aircraft Turbine Engine Oil, Synthetic Base)

MIL-PRF-83282 (Hydraulic Fluid, Synthetic Hydrocarbon Base))

MIL-H-81019 (Hydraulic Fluid, Petroleum Base)

MIL-H-46170 (Hydraulic Fluid), Synthetic Hydrocarbon Base

A-A-59290 (Arresting Gear Fluid, Ethylene Glycol / water mix)

CSS 06-3235 Automatic Pressure Controller_ver4 5

3.1.1.5 Pressure transducers. The APC shall utilize smart transducer technology to enable recognition of pressure transducer range, accuracy, and calibration/characterization data stored on board the transducer or the APC system. The system shall utilize plug and play technology to facilitate the discovery of new or replacement transducer without the need for physical device configuration. The system shall conform to requirements a through f, listed below.

a. There shall be a maximum of 10 calibration/sensitivity data points and stored onboard the transducer

b. There shall be a maximum of five transducers to cover the pressure range with minimum specifications listed in 3.1.1.7 for the APC. Interchanging transducers to achieve minimum specifications may be allowed to meet the minimum specifications.

c. Transducer operation/utilization shall be indicated to the user. It shall be a seamless operation throughout the pressure range from vacuum through 10,000 psig.

d. Pressure limiting device shall be utilized to protect transducers from over-pressurization. Pressure relief shall not allow backflow of contaminated gas to the transducer.

e. Transducers shall be easily removable from the system.

f. Transducers shall be easily cleanable using non-ozone depleting solvents.

3.1.1.6 Units of measure. The APC shall, at a minimum, be capable of operating/displaying the pressure measurement units in the table below.

Software shall allow dynamic conversion of pressure units displayed. Unit conversion shall be in accordance with NIST Special Publication 811.

Symbols shall be in accordance with IEEE 260.1.

Absolute ± Gauge Vacuum psi psi psi kPa kPa kPa bar bar bar mbar mbar mbar inHg1 inHg1 inHg1 mmHg1 mmHg1 mmHg1 inH2O2,3,4 inH2O2,3,4 inH2O2,3,4 ft-H2O2,3,4 ft-H2O2,3,4 ft-H2O2,3,4 ft-seaH2O2,3,4 ft-seaH2O2,3,4 ft-seaH2O2,3,4

1 Reference Temperature: 32°F (0°C) 2 Reference Temperature: 39°F (4°C) 3 Reference Temperature: 60°F 4 Reference Temperature: 68°F (20°C)

CSS 06-3235 Automatic Pressure Controller_ver4 6

3.1.1.7 APC Range and Accuracy. The APC system shall be capable of controlling, and measuring either hydraulic and/or pneumatic pressure over the range and within a minimum accuracy detailed in the following table. The uncertainty shall be expressed in terms of percent of indicated value (% IV), with floor value. The uncertainty shall have a level of confidence of 95% and 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).

Pressure Mode Range Accuracy

Absolute 1 to 10,000 psia ±(0.1% IV or 0.005 psia whichever is greater)

Gauge -14 to 10,000 psig ±(0.1% IV or 0.005 psig whichever is greater)

Vacuum 0 to 28 inHg ±0.1% IV or ±0.01 inHg, whichever is greater

3.1.1.8 Resolution. The display resolution of the APC shall be at least a 5½ digit display.

3.1.2 Accessories. Each APC shall be provided with a minimum of the accessories specified herein. Any other accessories required for the APC to meet the requirements of this CSS shall also be provided.

3.1.2.1 Vacuum Pump. The APC shall include a vacuum pump to support the APC range specified in 3.1.1.7.

3.1.2.2 Accessory case. The accessory case shall also serve as the transit case.

Transit case and internal foam/packing material shall be impervious to water and hydrocarbon base fluids. It shall contain accessories and maintenance aids for the APC system i.e., pressure hoses, pressure fittings and adapters.

Accessories shall be contained in foam/packing material cutouts to prevent damage during transit. Small accessories shall be contained within reusable containers and contained within a cutout. The following accessories specified in 3.1.2.3 through 3.1.2.5 as well as any other accessory required to meet the requirements of this CSS shall be provided with each APC.

3.1.2.3 Pressure hoses. The pressure hoses provided with the APC shall have a rated operating pressure of 10,000 psig, a proof pressure of 15,000 psig, and a minimum burst pressure of 40,000 psig. They shall have the working pressure and burst pressure clearly marked on a metal tag and permanently attached to the hoses. The hoses shall be designed with a protective outer covering that shall resist damage from crimping or abrasion. The hoses shall be flexible and capable of being in a radius 2.5 inches at maximum working pressure. In addition, hose ends shall have sufficient strain relief to prevent damage to the hose/fitting interface. All hoses shall have a tethered quick disconnect caps/plugs for each end to prevent contamination and/or damage during non-use or storage.

CSS 06-3235 Automatic Pressure Controller_ver4 7

3.1.2.3.1 Supply pressure hose. There shall be a minimum of one supply hose 5 feet long. Hoses shall terminate with industry standard fitting that meets the pressure requirements listed in 3.1.2.2. They shall also include required adapters and quick disconnect fittings to connect to a pressure regulator outlet port to the inlet port of the APC. Hoses shall have tethered caps on each end.

3.1.2.3.2 Test Pressure hoses. There shall be a minimum of two test pressure hoses 10 feet long. Hoses shall terminate with industry standard fitting that meets the pressure requirements listed in 3.1.2.2. Hose assemblies shall also include quick disconnect fittings with required adapters to connect to the hose termination fitting. One end of the each hose shall have an adapter and male quick disconnect fitting, and the opposite end of each hose shall have an adapter and female quick disconnect fitting. Hoses shall connect to the output of the APC to the TI utilizing pressure fittings and adapters listed in 3.1.2.4. Hoses shall have tethered caps on each end.

3.1.2.4 Pressure fitting adapters. The Pressure fittings and adapters listed below with quick disconnect probes shall be provided. To the maximum extent possible the adapters shall be of one piece design and constructed with the quick disconnect male probe as an integral part of the adapter. They shall be contained in a separate reusable case that can be stored in the case of the APC. The adapters shall be of stainless steel construction and rated for working pressure. The rated working pressure shall be as listed. The proof pressure shall be 1.5 times the working pressure and the minimum burst pressure shall be 4 times the working pressure. Pipe threads shall be in accordance with ASME B1.20.1. Flare Fittings shall be in accordance with

SAE AS4841.

Description Size Working Pressure

Male probe quick disconnect to male super pressure fitting

1/4"

10,000 psig

Male probe quick disconnect to female super pressure fitting

1/4"

Male probe quick disconnect to male national pipe thread

1/8", 1/4",3/8", 1/2"

Male probe quick disconnect to female national pipe thread

1/8", 1/4",3/8", 1/2"

Male probe quick disconnect to male 37° flared fitting

#4, #6

Male probe quick disconnect to female 37° flared fitting

#4, #6

Male probe quick disconnect to male barb hose fitting

1/8", 1/4" 100 psig

3.1.2.5 Contamination prevention system. The contamination prevention system (CPS) shall be provided with the APC to protect the equipment from

CSS 06-3235 Automatic Pressure Controller_ver4 8 contaminated pressure media returning from the TI. CPS shall be operated automatically by the APC with an option to manually relieve the pressure within the pressure circuit. The internal plumbing of the CPS shall have a rated working pressure of 10,000 psig, a proof pressure of 15,000 psig, and a minimum burst pressure of 40,000 psig. Contaminated fluid shall be collected in an accessible reservoir to be discarded appropriately.

3.2 Equipment components. Parts, materials, and process shall be as specified herein and shall permit the equipment to meet all applicable requirements of its class.

3.2.1 Finish. The equipment shall be the finish normally provided by the manufacturer.

3.2.2 Color. The color of the equipment and the transit cases shall be the color normally provided by the manufacturer.

3.2.3 Interchangeability. A model number shall be designated for all units provided.

All units and the replaceable assemblies, subassemblies, and parts comprising the unit shall be interchangeable on a noninterference basis with all such designated models provided.

3.2.4 Restricted materials. Restricted materials shall be as specified herein.

3.2.4.1 Material restricted for Navy use. The materials and parts specified in a through e shall not be used except as specified in this CSS. An exception is made for small lithium batteries used for memory backup as specified in 3.6.1.2.5.1 Battery restrictions of MIL-PRF-28800G.

a. Mercury, including mercury batteries

b. Radioactive material

c. Lithium electrochemical cells

d. Helium-3

e. Cadmium, except batteries

3.2.4.2 Other restricted materials and gases. 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 herein.

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

3.2.4.2.2 Flammable materials. Equipment shall not contain materials that ignite into flames at operating or storage temperatures.

3.2.4.2.3 Explosive materials. Equipment shall not contain materials that explode at operating or storage temperatures.

CSS 06-3235 Automatic Pressure Controller_ver4 9

3.2.4.2.4 Carcinogens. Equipment shall not contain materials identified by Occupational Safety and Health Administration (OSHA) in CFR Title 29 Part 1910 as cancer-producing substances (carcinogens).

3.2.4.2.5 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. Helium-3 shall not be used due to limited availability.

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

3.3 Design and construction.

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

3.3.2 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.

3.3.3 Electric connectors. Provision shall be made to ensure that connectors can only be mated 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.

3.3.4 Internal wiring. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance, filter service, and calibration.

3.3.5 Internal cooling. Equipment shall be capable of operating without interruption for at least 24 hours (or maximum battery life) at the maximum operating temperature, as specified in this CSS, without overheating, losing power or otherwise exhibiting failure. Cooling devices used in the equipment shall be an integral part of the equipment and shall not degrade any aspect of performance or safety.

3.3.6 Front panel display indicators. Front panel display indicators designed to present change-of-state information to the operator shall be distinguishable at a distance of 1 m in a maximum ambient light level of 100 foot-candles (fc) and a minimum light level of 1 fc. All display indicators shall be discernible at viewing angles from 0 degrees to 45 degrees.

CSS 06-3235 Automatic Pressure Controller_ver4 10

3.3.7 Self-test capability. The equipment shall perform an automatic diagnostic self-test at startup. The self-test shall determine operational readiness and isolate faulty modules. At a minimum, the information provided shall indicate whether the equipment is functional or identify malfunctions. If failure occurs, the associated lowest replaceable unit (LRU) causing the malfunction shall be identified.

3.4 Digital control interface. A digital control interface shall be provided and shall meet the requirements as specified herein. 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). The unit shall be capable of functioning as a controller to perform self-calibration utilizing the digital interface to communicate with an external calibration reference standard. Primary power control and other non-measurement functions need not be controllable through the digital interface.

The digital control interface shall include one, at a minimum, of the following:

a. IEEE 488.2 General Purpose Interface Bus conforming to IEC 60488-

2:2004 /IEEE 488.2-1992

b. IEEE 802.3 Ethernet connection (using an RJ-45 connector) conforming to LAN Extensions for Instrumentation (LXI) Standard

c. USB connection conforming to the Universal Serial Bus Specification (USB) Revision 2.0.

3.4.1 IEEE 802.3 ethernet interface requirements. An IEEE 802.3 digital control interface that complies with the 10/100/1000 Base-T communications sections of IEEE 802.3 shall be provided.

3.5 Electrical power sources and connections.

3.5.1 Electrical power source. The equipment shall operate from the input power conditions specified herein.

3.5.1.1 Power consumption. The maximum power for operation of an APC unit that requires an external single phase 120 Vrms power source shall not exceed 1200 watts.

3.5.1.2 Nominal and alternate power source. The equipment shall operate at 120 volts root mean square (Vrms), single-phase, 50 hertz (Hz) and 60 Hz source (see MIL-PRF-28800G Table 1. Power source.). Equipment designed to operate from both external and internal power sources shall conform to specified performance and accuracy requirements when operated from the external source with the internal battery removed. There shall be an indication of the selected power source.

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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. (See MIL-PRF-28800G paragraph 6.6.12 for definitions of terms used).

a. The steady-state voltage variation shall be ±10 percent (%) of the nominal power source voltage as specified in MIL-PRF-28800G Table 1.

b. The steady-state frequency variation shall be ±5% of the nominal power source frequency as specified in MIL-PRF-28800G Table 1.

c. The deviations in waveform characteristics shall be as follows: .

1. Waveform deviation factor of ±10% or less

2. Total harmonics of ±10% or less

3. Individual harmonics of ±5% or less

4. Crest factor of 1.27 to 1.56

3.5.1.2.2 Transient-state conditions. For transients that do not exceed the nominal steady-state band specified in MIL-PRF-28800G Table 1, the transient recovery time of the equipment shall not exceed 500 milliseconds (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. Operation of the equipment during voltage and frequency transients that exceed the allowable nominal steady-state bands specified in Table 1 shall be in accordance with the following:

a. The maximum transient amplitude of voltage transients within the range of ±10% to ±30% 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 volatile memory.

b. The maximum transient amplitude of 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 volatile memory. .

3.5.1.2.3 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 herein shall apply to equipment rated at 10 amperes (A) rms, or less. Power connectors and

CSS 06-3235 Automatic Pressure Controller_ver4 12 connections for equipment rated above 10A rms shall be specified in the purchase description. When single-phase operation is specified, the equipment shall operate with a ground at the primary power source whether from an ashore site that has “grounded circuitry” or afloat where the ship has “ungrounded circuitry."

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

3.5.2.2 Input power switch. For bench top equipment, the operator shall be able to energize the equipment from the front panel. A standby capability may be incorporated to activate and deactivate the equipment. If such a capability is provided, warnings shall be placed in the Use and Installation Manual and on the equipment to warn the operator of possible shock hazards during servicing, due to partially activated power supplies.

3.5.2.3 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 in in an exterior panel.

3.5.2.4 Indicators. The front panel shall include visual indicators that indicate when the equipment is energized.

3.6 Enclosure physical characteristics. A commercial-off-the-shelf (COTS) enclosure normally provided by the manufacturer that meets the requirements specified herein shall be provided. For the purpose of this CSS, the enclosure refers to the case for the APC. The enclosure provides protection for the individual system components during storage, handling, and use.

3.6.1 Dimensions. Maximum dimensions of the equipment shall not exceed 12 inches in height with feet, 18 inches in width and 20 inches in depth.

3.6.1 Weight. The maximum weight of the equipment including all covers and accessories shall not exceed 45 pounds (lbs).

3.6.2 Mechanical Stability. The APC shall be designed for benchtop use to preclude tipping during normal handling and operation.

3.6.3 Enclosure requirements. The degree of protection provided by the enclosure shall allow the equipment to pass the environmental tests applicable to the class as specified herein.

3.6.3.1 Cover. The enclosure shall have a cover to protect the front panel during shipping or while in storage.

3.6.3.2 Component protection. Panels shall be designed to conform to the bench handling requirement of 3.9.3.1 Bench handling.

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3.6.3.3 Chassis fasteners. The chassis shall be securely fastened within the enclosure conforming to the maintainability requirements of 3.14.3 Maintenance provisions.

3.7 Transit case. A transit case shall be provided to protect the contained equipment and accessories during shipping and storage. The transit case is not an integral part of the equipment. It need not provide for operational capability of the equipment when enclosed. The physical characteristics of the transit case shall be as specified herein.

3.7.1 Transit case cover. The transit case shall have a cover that can be closed and fastened. Fasteners shall allow for quick opening. If the cover is removable, fasteners shall not interfere with cover removal.

3.7.2 Transit case handles. One or more handles shall be provided. The number and location of handles shall be such that the load distribution per handle shall not exceed 20 kg (44 lbs). Handles shall be located above the equipment center of gravity to ensure carrying stability.

3.7.2.1 Hard transit case handles. The transit case shall include hinged handles with sufficient internal clearance to allow a block 44 mm (1.75 inches) by 106 mm (4.17 inches) in cross section with edges rounded to a 25 mm (1 inch) radius to pass through them. The grip portion of the handles shall be of a nonmetallic material at least 89 mm (3.5 inches) in length with a 19 mm (¾ inch) diameter or other approved cross section that is shaped to fit the hand comfortably.

Handles shall stop open at 90 degrees and have a retaining mechanism to keep them in the closed 90 degree position. Handles shall be recessed or protected. A handle located on the top of the enclosure shall be recessed to facilitate stacking.

3.7.3 Transit case accessory stowage. The transit case shall allow 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.

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

3.8 Marking and identification.

3.8.1 Marking. Equipment shall be marked in a manner that does not adversely affect safety or performance.

3.8.1.1 Reference designations. Reference designations shall identify each part for its particular circuit application. Subminiaturized and non-repairable

CSS 06-3235 Automatic Pressure Controller_ver4 14 assemblies need not be marked with reference designations. Reference designator usage shall be in accordance with IEEE 315.

3.8.1.2 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 equipment, and located as close as possible to the point of danger. Warning markings indicating circuits of more than 500 VDC or Vrms shall read as follows:

a. The precautionary signal word shall be at least 2.5 mm high.

b. The text shall be at least 1.5 mm high and contrasting in color to background.

c. If molded or stamped in a material, text shall be at least 2.0 mm high and, if not contrasting in color, a depth or raised height of at least 0.5 mm.

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

3.8.2 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.

a. Manufacturer name

b. Equipment model number with installed options

c. Equipment nomenclature

d. Serial number

3.8.2.1 Identification plate. An equipment identification plate shall be permanently affixed to the equipment enclosure when the enclosure also serves as the transit case. The identification plate shall contain the information provided below in 3.8.2.1.1 Single case identification plate, if the equipment is contained within a single case or 3.8.2.1.2 Multiple case identification plate, if the equipment is contained within multiple cases.

3.8.2.1.1 Single case identification plate. The identification for a single case shall contain the information provided in a through d.

a. Equipment model number with installed options

DANGER HIGH VOLTAGE (maximum applicable voltage) VOLTS

Markings shall be in accordance with IEC 61010-031, which requires the following for warning and caution markings:

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b. Equipment nomenclature

c. Manufacturer Commercial and Government Entity (CAGE) code

d. Serial number

3.8.2.1.2 Multiple cases identification plate. When multiple cases are required, the identification plate shall contain the information proved in a through g.

a. Configuration model number

b. Configuration nomenclature

c. Configuration CAGE

d. Configuration serial number

e. Case X of Y

f. Component nomenclature

g. Component part number

3.8.2.2 Identification plate supplemental information. When accessories are required to meet the requirements of the CSS and the combination has a part or model number designation that differs from that of the main unit, there shall be a supplemental identification plate containing the following:

a. Part number of main unit and all accessories (excluding cables and adapters) comprising the equipment configuration.

b. Model configuration number.

c. Whether a configuration model designation is assigned or not assigned, all major accessories shall be marked as follows:

d. Part of number (p/o): Model number assigned to the equipment configuration or main unit model number, as applicable.

e. Serial number (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.

3.8.3 Transit case identification plate. The equipment transit case shall include a permanently affixed identification plate that contains the information specified in

3.8.2.1 Identification plate. An acceptable method of attachment is to use 1/8” diameter solid or semi-tubular rivets and backup washers.

3.8.4 Reusable pouch or container. If a reusable pouch or container is provided, containers shall be marked "accessories for use with" (equipment nomenclature or model number), or, "maintenance aids for use with" (equipment nomenclature or model number), as applicable. If assigned, the equipment nomenclature shall be used in lieu of the model number.

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3.8.5 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.

3.9 Environmental requirements. Environmental performance requirements shall be as specified herein.

3.9.1 Environmental conditions. The equipment shall conform to the specified performance requirements, when subjected to the environmental conditions of this specification, after a 30-minute warm-up period preceded by a 2-hour not operating temperature stabilization period or when tested in accordance with the applicable test method.

3.9.2 Temperature and humidity (T/H). The temperature ranges and humidity limits for both operating and not operating conditions shall be as specified herein. A relative humidity (RH) of 95 percent (with the applicable tolerance) shall be achieved in a non-condensing condition.

3.9.2.1 Temperature, not operating. The equipment shall conform to the specified performance and accuracy requirements after being subjected to not operating temperatures in the range of -51 to 71 ºC.

3.9.2.2 Temperature, operating. The equipment shall conform to the specified performance and accuracy requirements while operating at temperatures ranging from 0 to 50 ºC for Class 3 equipment, and from 10 to 40 ºC for Class 4 equipment.

3.9.2.3 Humidity. The equipment shall conform to the specified performance and accuracy requirements for conditions where the relative humidity is 5 to 95±5 percent in the temperature range of 10 to 30 ºC. At temperatures below 10 ºC, the humidity is uncontrolled, but the equipment shall conform to the specified performance requirements (after the specified warm-up period) and shall withstand the effects of humidity up to 100 percent. The equipment shall also be subjected to conditions where the relative humidity is 5 to 75±5 percent in the temperature range of 30 to 40 ºC, and where the relative humidity is 5 to 45±5 percent in the temperature range above 40 ºC (as appropriate for the specified class).

3.9.3 Mechanical shock.

3.9.3.1 Bench handling. The equipment shall conform to the specified performance and accuracy requirements and there shall be no damage to any controls, indicators, or fuseholders when subjected to the MIL-PRF-28800G paragraph

4.5.5.4.3 Bench handling test.

3.9.4 Fungus resistance. Equipment shall not contain materials that provide nutrients for the growth of fungus. When a transit case is specified, it shall not contain materials that provide nutrients for the growth of fungus.

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3.9.5 Dust exposure. Equipment enclosure with cover shall provide protection for the APC from dust exposure. Equipment in hard transit cases shall conform to all requirements after exposure to dust when tested in accordance with MIL-PRF- 28800G paragraph 4.5.6.4 Dust resistance test (Class 1 and hard transit cases).

3.10 Safety. The equipment shall meet the safety requirements of IEC 61010-1. For safety, all accessible surfaces of the equipment shall be at ground potential. The power cable shall include a safety ground conductor. Disconnecting the safety ground shall also disconnect the power conductors for drawer assemblies.

3.11 Warranty label. Each APC shall have a warranty label that specifies the model number, nomenclature, manufacturer, CAGE number, contract number, and warranty expiration date.

3.12 Calibration. The APC shall meet the calibration requirements as specified herein.

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.

3.12.1 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. The vendor shall substantiate that the APC will meet the desired minimum interval or any interval beyond that by providing the statistical data used to derive the interval.

3.12.2 Calibration procedure. The methodology to support calibration of the APC and development of a Navy calibration procedure in accordance with MIL-PRF- 38793 shall be provided.

3.13 Reliability. The APC shall have a statistical certainty of 95 percent. (This allows for infant mortality, random variation, and spurious failures.) The following minimum equipment reliability requirements shall be met:

a. Handheld equipment. The design of the equipment, except for COTS non-rechargeable batteries, shall be such that under normal use and operation, the equipment does not fail within 2,500 hours of operation.

b. Bench top equipment. The design of the equipment shall be such that, under normal use and operation, the equipment does not fail within 10,000 hours of operation (2,000 power on hours [POH] for 5 years or a 23 percent duty cycle).

3.14 Maintainability.

3.14.1 Fault isolation. The design of the equipment shall permit isolation of faults and repair down to the component item or lowest replaceable unit with the maintenance provisions furnished.

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

3.14.3 Maintenance provisions. Equipment shall be as specified herein to facilitate maintenance:

c. Accessibility for maintenance. Equipment shall be designed to ensure that 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, calibration, and adjustment/alignment).

d. 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 and national stock number (NSN).

Stowage shall be in a reusable pouch or container.

e. Accessibility for repair. Equipment shall be designed so that subassemblies and chassis components can be removed without removing other hardwired subassemblies or components. Printed circuit cards shall be removable without the need to unsolder cables or interconnecting wiring. Printed circuit cards designed primarily to distribute power and signals to other printed cards are excluded from this requirement. When motherboards are used, they shall be accessible from both sides to facilitate troubleshooting or repair.

f. 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.

1. Accessibility for adjustment. Equipment design shall permit adjustments to be made without removing any component, printed circuit cards, or subassembly. The use of extender cards is permitted.

2. Alignment instructions/software. 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 as specified herein.

a) The equipment shall be designed and information provided so that the alignment can be performed by the Navy.

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b) The alignment process shall be able to use existing Navy calibration standards that meet all necessary minimum performance requirements to satisfy a traceable calibration.

c) The 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)

d) The alignment information shall include usage instructions required to perform an alignment. The instructions shall include any necessary setup instructions/software commands to put the equipment into the alignment mode; instructions/software commands necessary to gather new alignment data; 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.

3.15 Copyright release. A statement of copyright release for reproduction of any portion of the technical manual for 'government use only' shall be provided in writing. The intent of this release is to allow for the production of additional copies as required, the ability to post the manual on government restricted websites, and the ability to provide information to the user on operation, service, and maintenance of the equipment.

3.16 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.