Environmental_Test_Requirements.pdf

UNCLASSIFIED

ATSO First Article Environmental Test Requirements

Airborne Threat Simulation Organization NAWCWD Code 534100E

Point Mugu, CA 93042‐5049

Prepared by: Brian Bati

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only because of critical technology (02/10/14). Other requests shall be referred to the Commander, Naval Air Warfare Center, Point Mugu, CA 93042‐5001.

Unclassified/Limited Distribution documents shall be handled using the same standard as "For Official Use Only (FOUO)" material, and will be destroyed by any method that will prevent disclosure of contents or reconstruction of the document.

When local circumstances or experience indicates that this destruction method is not sufficiently protective of unclassified limited information, local authorities may prescribe other methods but must give due consideration to the additional expense balanced against the degree of sensitivity.

WARNING ‐ This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq), as amended. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

Revision Brief Description Date Approved

A See Detailed Revision History 4/17/2014 initiator:matthew.jue@navy.mil;wfState:distributed;wfType:email;workflowId:4bab2f48fcbe0d42a29954013b7b801f

ATSO UNCLASSIFIED Page 2

ATSO First Article Environmental Test Requirements Revision A

ATSO Signing Authority Date

Division Head: 4/17/2014 Emery Kujiraoka

Branch Head: 4/17/2014 Jacqueline Garcia

Chief Engineer: 4/17/2014 John Ota

Engineering Lead: 4/17/2014 David Omoto

Mechanical Lead: 4/17/2014 Nathan Alday

Environmental Lead: 4/17/2014 Josh Galbraith

Creator/Reviser: 4/17/2014 Brian Bati

ATSO UNCLASSIFIED Page 3

ATSO First Article Environmental Test Requirements Revision A

Table of Contents

1.0 Scope

2.0 Reference Documents

3.0 Order of Precedence

4.0 Test Failure

5.0 Order of Testing

6.0 Environmental Tolerances and Limits

7.0 Description of Environmental Tests

7.1 High Operating Temperature

7.1.1 General Instructions

7.1.2 ATSO Deviations from the MIL‐STD

7.2 Low Operating Temperature

7.2.1 General Instructions

7.2.2 ATSO Deviations from the MIL‐STD

7.3 Thermal Shock

7.3.1 General Instructions

7.3.2 ATSO Deviations from the MIL‐STD

7.4 Aggravated Humidity

7.4.1 General Instructions

7.4.2 ATSO Deviations from the MIL‐STD

7.5 Random Vibration

7.5.1 General Instructions

7.5.2 ATSO Deviations from the MIL‐STD

7.6 Mechanical Shock

7.6.1 General Instructions

7.6.2 ATSO Deviations from the MIL‐STD

7.7 Pyroshock

7.7.1 General Instructions

7.7.2 ATSO Deviations from the MIL‐STD

7.8 Temperature‐Altitude

7.8.1 General Instructions

7.8.2 ATSO Deviations from the MIL‐STD

7.9 Immersion

7.9.1 General Instructions

7.9.2 ATSO Deviations from the MIL‐STD

8.0 Detailed Revision History

Table of Figures Figure 7.1 Random Vibration Profile Figure 7.2 SRS Shock Profile Figure 7.3 Temperature‐Altitude Profile

ATSO UNCLASSIFIED Page 4

ATSO First Article Environmental Test Requirements Revision A

Table of Tables Table 6.1 Test Tolerances and Limits Table 7.1 Individual Aggravated Humidity Cycle Table 7.2 Frequency vs. PSD Table 7.3 Frequency vs. Acceleration Table 7.4 Temperature vs. Altitude Table 8.1 Detailed Revision History

ATSO UNCLASSIFIED Page 5

ATSO First Article Environmental Test Requirements Revision A

1.0 Scope

The purpose of this document is to define the required First Article Environmental Test Requirements for the Airborne Threat Simulation Organization (ATSO) assemblies, subassemblies, hardware, and components herein referred to as Unit Under Test (UUT). MIL‐ STD‐810 shall be followed unless deviated from as outlined below. The UUT shall not exhibit any temporary or permanent degradation as the result of exposure to the environments required in this document. Any deviations from this procedure must have written approval from the procuring activity.

2.0 Reference Documents

MIL‐STD‐810G Department of Defense Test Method Standard

“Environmental Considerations and Laboratory Tests”

3.0 Order of Precedence

In the event of a conflict between the contract, the specification, this environmental specification and any applicable subsidiary specifications, the following precedence shall apply:

a. Contract. The contract shall have precedence over any specification.

b. Specification. The specification shall have precedence over the environmental specification and all applicable subsidiary specifications. Any deviation from the specification or from subsidiary specifications, where applicable, shall be specifically approved in writing by the procuring activity.

c. Environmental Specification. This environmental specification shall have precedence over all applicable subsidiary specifications. Any deviation from this specification, or from subsidiary specifications, where applicable, shall be specifically approved in writing by the procuring activity.

d. Referenced specifications. Any referenced specification shall have precedence over all applicable subsidiary specifications referenced therein.

In the event of a conflict between reference specifications or subsidiary specifications cited herein, guidance shall be obtained from the procuring activity. Nothing in this specification, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

ATSO UNCLASSIFIED Page 6

ATSO First Article Environmental Test Requirements Revision A

4.0 Test Failure

Should a test failure be encountered, ATSO shall be contacted within one working day. A detailed failure analysis report shall be available upon request.

5.0 Order of Testing

The UUT specification shall define the required environmental tests. The required tests must be completed per the following sequence below. Procuring activity must provide written approval of any deviations from this test sequence. If an environmental test is not required per the UUT specification, the test sequence shall skip that test and continue with the next required test.

Functional test requirements (Full‐Functional Tests and Limited Functional Tests) and testing conditions (Monitoring Conditions, Operating Conditions, Powered‐On Conditions and Non‐ Operating or Powered‐Off Conditions) shall be defined in the UUT specification.

1. Full Functional

2. High Operating Temperature

3. Low Operating Temperature

4. Thermal Shock

5. Aggravated Humidity (Any Sequence)

6. Random Vibration (Any Sequence)

7. Mechanical Shock (Any Sequence)

8. Pyroshock (Any Sequence)

9. Temperature‐Altitude

10. Immersion

11. Full Functional

Note: Test 5 – 8 can be conducted in any sequence after test 4 has been completed.

ATSO UNCLASSIFIED Page 7

ATSO First Article Environmental Test Requirements Revision A

6.0 Environmental Tolerances and Limits

Table 6.1 Test Tolerances and Limits

Description Tolerance/Limit Altitude Change Rate ± 10 m / s (32.8 ft / s) maximum

Altitude Extremes ± 5 %

High Temperature Extreme ± 2 o C

Low Temperature Extreme ± 2 o C

Stabilization Temperature Longest thermal lag changing at a rate of less than 2 o C / hour*

Temperature Shock Transfer Time 1 minute maximum

Temperature Transition Rate (not including Temperature Shock Transitions)

± 3 o C / minute maximum

Dwell Times ± 1%**

Relative Humidity Extremes ± 5 %

Vibration Measurement System Resolution ± 0.5 dB

Vibration Abort Levels ± 6 dB

Vibration Grms Level ± 10 %

Vibration Out of Axis Abort Levels ‐ 3 dB of input vibration profile PSD (maximum)

Shock Abort levels ‐ 3 dB; + 6 dB

* A temperature change rate of less than 2 o C / hour or equivalent (i.e. 1 o C / 30 minutes) shall be used. If the internal temperature stabilization of the UUT cannot be measured a minimum 4 hour dwell time is acceptable. The 4 hours shall include stabilization and dwell times.

** Dwell times during climatic tests can be extended with procuring activities approval.

7.0 Description of Environmental Tests

7.1 High Operating Temperature

7.1.1 General Instructions

Testing shall be in accordance with MIL‐STD‐810 High Temperature Method

501.5

Constant temperature exposure

Unsheltered exposure

Test tolerances and limits shall be in accordance with Section 6.0

ATSO UNCLASSIFIED Page 8

ATSO First Article Environmental Test Requirements Revision A

7.1.2 ATSO Deviations from the MIL‐STD

24 hour pre‐soak at +71˚C “Non‐Operating Conditions” followed by 2 hours at

+71˚C while the UUT is in “Operating Conditions”.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

(Note: Post “Limited Functional Tests” can be waived if the next test in the test sequence is a “Full Functional Test”.)

7.2 Low Operating Temperature

7.2.1 General Instructions

Testing shall be in accordance with MIL‐STD‐810 Low Temperature Method

502.5.

Constant temperature exposure.

Unsheltered exposure.

Test tolerances and limits shall be in accordance with Section 6.0.

7.2.2 ATSO Deviations from the MIL‐STD

24 hour pre‐soak at –54˚C “Non‐Operating Conditions” followed by 2 hours at

(‐40˚C) while the UUT is in “Operating Conditions”.

o Two hour operating dwell shall start after the UUT reaches temperature stabilization.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

7.3 Thermal Shock

7.3.1 General Instructions

Testing shall be per MIL‐STD‐810 Temperature Shock Method 503.5 Procedure I‐ C Multi‐cycle shocks with constant extreme temperature.

Use MIL‐STD‐810, Figure 503.5‐3: Multi‐Cycle Shocks as shock profile reference.

7.3.2 ATSO Deviations from the MIL‐STD

Temperature extremes shall be –40˚C and +71 ˚C.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

ATSO UNCLASSIFIED Page 9

ATSO First Article Environmental Test Requirements Revision A

7.4 Aggravated Humidity

7.4.1 General Instructions

Testing shall be per MIL‐STD‐810 Humidity Method 507.3 Procedure II‐

Aggravated

Use MIL‐STD‐810, Figure 507.5‐7: Aggravated Temperature‐Humidity Cycle as a temperature profile reference with temperature changes in compliance with Table 7.1 below

Test tolerances and limits shall be in accordance with Section 6.0

7.4.2 ATSO Deviations from the MIL‐STD

Post‐conditioning shall be eliminated

Perform “Limited Functional Tests” checks of the fifth and tenth cycles at both temperature conditions.

UUT shall be oriented in its operational upright state. (Note: No additional protection shall be used. It is permitted to connect non‐operating ports in a normal mating fashion.)

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

Table 7.1 Individual Aggravated Humidity Cycle Time Temperature (˚C) Temperature (˚F) Relative Humidity (%)

00:00 28 82 85 minimum

02:00 71 160 95

08:00 71 160 95

16:00 28 82 85 minimum

24:00 28 82 85 minimum

7.5 Random Vibration

7.5.1 General Instructions

Testing shall be per MIL‐STD‐810 Vibration Method 514.6 Procedure I ‐ General

Vibration.

7.5.2 ATSO Deviations from the MIL‐STD

The vibration profile shall be per Figure 7.1 and Table 7.2.

The vibration duration shall be 1 hour minimum in each of the three orthogonal axes (lateral, longitudinal and vertical) .

No vibration isolators shall be used.

UUT shall be in “Monitoring Conditions” during vibration exposure.

ATSO UNCLASSIFIED Page 10

ATSO First Article Environmental Test Requirements Revision A

A response accelerometer attached to or near the UUT is required (tri‐axial accelerometer recommended for best practice) .

o Out of axis response warning levels are set at ‐3 dB input vibration profile PSD.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

Figure 7.1 Random Vibration Profile

Table 7.2 Frequency vs. PSD

Frequency (Hz) PSD (g2/Hz)

10 0.06

1000 0.06

2000 0.015

GRMS = 9.46

ATSO UNCLASSIFIED Page 11

ATSO First Article Environmental Test Requirements Revision A

7.6 Mechanical Shock

7.6.1 General Instructions

Testing shall be per MIL‐STD‐810 Shock Method 516.6 Procedure I – Functional

Shock.

7.6.2 ATSO Deviations from the MIL‐STD

Three 12 g 11 ms half sine shocks in each +/‐ direction in all three orthogonal axes (lateral, longitudinal and vertical) for a total of 18 shocks.

UUT shall be in “Monitoring Conditions” during shock exposure.

No vibration isolators shall be used.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

7.7 Pyroshock

7.7.1 General Instructions

Testing shall be per MIL‐STD‐810 Pyroshock Method 517.1.

7.7.2 ATSO Deviations from the MIL‐STD

UUT shall be in “Monitoring Conditions” during shock exposure.

Three shocks applied in each +/‐ direction in all three orthogonal axes (lateral, longitudinal and vertical).

If no platform‐specific shock profile is available use Figure 7.2 and Table 7.3.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

ATSO UNCLASSIFIED Page 12

ATSO First Article Environmental Test Requirements Revision A

Figure 7.2 SRS Shock Profile

Table 7.3 Frequency vs. Acceleration Frequency (Hz) Acceleration (g)

20 10

100 100

2000 1400

10000 1400

Q=10

7.8 Temperature‐Altitude

7.8.1 General Instructions

Testing shall be per MIL‐STD‐810 Temperature, Humidity, Vibration and Altitude

Method 520.3 Procedure III – Qualification.

7.8.2 ATSO Deviations from the MIL‐STD

Humidity and Vibration are excluded.

Altitude and Temperature conditions per Figure 7.3 and Table 7.4.

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

ATSO UNCLASSIFIED Page 13

ATSO First Article Environmental Test Requirements Revision A

Figure 7.3 Temperature‐Altitude Profile

Table 7.4 Temperature vs. Altitude Elapsed Time (Minutes)

Temperature (˚C) Altitude (Ft)

UUT

On**/Off***

0 ‐40 Ambient Off

60 ‐40 Ambient Off

60* ‐40 40,000 On

90 ‐40 40,000 On

90* +71 Ambient Off

150 +71 Ambient Off

150* +40 40,000 On

180 +40 40,000 On

* Chamber transition times not included ** UUT On is defined as “Operating Conditions” *** UUT Off is defined as “Non‐Operating Conditions”

ATSO UNCLASSIFIED Page 14

ATSO First Article Environmental Test Requirements Revision A

7.9 Immersion

7.9.1 General Instructions

Testing shall be per MIL‐STD‐810 Immersion Humidity Method 512.5 Procedure

I – Immersion.

7.9.2 ATSO Deviations from the MIL‐STD

If no test plan procedure is provided for immersion time and depth use:

o Immersion time = 48 hour minimum o Immersion depth = 1 meter minimum in salt water

After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions.

8.0 Detailed Revision History

Table 8.1 Detailed Revision History

Revision Date Creator/ Reviser

Paragraph Effected

Documentation of Changes

‐ 2/10/14 Brian Bati NA Released

A 4/17/14 Brian Bati Entire

Document

1. Correlated Operating, Monitored, Full, Limited, Non‐operating conditions throughout the document as defined in the specification.

2. Fixed minor formatting.

3. Moved the location of the Limited

Functional Test call out and by adding Limited Functional Tests to every test

4. Removed MIL‐STD‐810G from every test since it is called out at the beginning of the document.

5. Defined “UUT On” and “UUT Off” on Table

7.4 Temperature vs. Altitude.

6. Added current “Distribution Statement”.

7. Added “Table of Figures” and “Table of

Tables”

8. Changed “will” to “shall”.