ACPRS_Environmental_Test_Report_10120-6487-3.pdf

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Test Report 10120-6487-3 Rev. -

REVISION SUMMARY

Revision Date Affected Page (s) Affected Paragraph (s)

Initial Release 1 April 2011 N/A N/A

Note: Paragraphs affected by revisions are indicated by a superscript of the revision number appearing just after the paragraph title in the body of the report. Due to the revisions, some items may change pages.

Altitude Test Summary and Results

Specification / Reference: MIL-STD-810G Method 500.5

Date Started: 10 March 2011 Date Completed: 10 March 2011

Test Assembly & Procedure:

One (1) U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0009, was subjected to Altitude testing per MIL-STD-810G Method 500.5, The non-operating altitude was specified as 45,000 feet by the U.S. Army PM FSS.

Functional tests were performed by the U.S. Army PM FSS representative. Data collected by U.S. Army PM FSS was retained by them and is not part of this report.

The ACPRS was placed in an altitude chamber. The chamber controls were programmed to provide the pressure equivalent of an altitude of 45,000 feet for a minimum of one (1) hour at laboratory ambient temperature, with an altitude ramp rate of 2000 feet/minute (10 m/sec).

The chamber door was closed and sealed. The chamber controls were enabled and the chamber began a ramp from site ambient pressure to the pressure equivalent of 45,000 feet altitude at a rate of 10 m/sec. Upon reaching the required pressure conditions, the ACPRS began a one (1) hour soak. Upon completion of the one (1) hour soak, the chamber was ramped to site ambient pressure with an altitude ramp rate of 10 m/sec.

Upon reaching ambient conditions, the chamber was opened, and the ACPRS was removed from the chamber and visually examined for any anomalies. No anomalies were noted.

The U.S. Army PM FSS representative performed a functional check on the unit. No anomalies were noted.

Test Results:

Inspection of the ACPRS after the Altitude testing showed no physical anomalies.

Photographs, test equipment list, test logs, and plots are attached.

Rapid Decompression Test Summary and Results

Specification / Reference: MIL-STD-810G Method 500.5, Procedure III

Date Started: 11 March 2011 Date Completed: 11 March 2011

Test Assembly & Procedure:

One (1) U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0009, was subjected to Rapid Decompression testing per MIL- STD-810G Method 500.5, Procedure III - Rapid Decompression. The altitude was specified as 40,000 feet.

Functional tests were performed by the U.S. Army PM FSS representative. Data collected by U.S. Army PM FSS was retained by them and is not part of this report.

The ACPRS was installed in the altitude chamber. The chamber door was closed and sealed. The chamber and unit were allowed to stabilize at ambient temperature and pressure. Then the chamber began a ramp to the atmospheric pressure equivalent of 8,000 feet altitude. The unit was allowed to stabilize at this pressure. Then the chamber pressure was reduced to the equivalent of 40,000 feet altitude within fifteen (15) seconds, as required by MIL-STD-810G. This pressure was maintained for at least ten (10) minutes, as required by MIL-STD-810G. Upon completion of the ten (10) minute dwell at the 40,000 foot level, the chamber was allowed to ramp back to laboratory ambient atmospheric pressure.

When the chamber had returned to ambient conditions, the ACPRS was removed from the chamber.

The U.S. Army PM FSS representative performed a functional check on the unit. No anomalies were noted.

Test Results:

Inspection of the ACPRS after the Rapid Decompression testing showed no physical anomalies.

Explosive Atmosphere Test Summary and Results

Specification / Reference: MIL-STD-810F Method 511.4, Procedure I

Date Started: 11 March 2011 Date Completed: 11 March 2011

Test Assembly & Procedure:

Two (2) U.S. Army PM FSS ACPRS units, P/N WA-25000, S/N 0009 and 0006, were subjected to Explosive Atmosphere testing per MIL-STD-810F Method 511.4, Procedure I – Explosive Atmosphere. The test was performed at a test altitude of 40,000 feet and an ambient temperature of +62.8°C (+145°F) within the chamber. Functional tests were performed by the U.S. Army PM FSS representative. Data collected by U.S. Army PM FSS was retained by them and is not part of this report.

The ACPRS units were placed in the explosive atmosphere chamber. Connections were completed to allow operation and monitoring of the units. One (1) thermocouple was placed in the chamber to monitor air temperature. One (1) thermocouple was placed at the chamber wall to monitor the wall temperature. One (1) thermocouple was placed on the ACPRS Unit 1 to monitor the unit temperature. One (1) thermocouple was placed on the ACPRS Unit 2 to monitor the unit temperature.

The chamber door was closed. Checks were made to ensure that the ACPRS units were configured properly and that the thermocouples functioned as expected. Upon confirming functionality, the chamber door was locked and sealed. The chamber temperature was ramped up to +62.8°C. After allowing time for stabilization, the chamber air temperature was recorded as +63.1°C, the chamber wall temperature as +58.3°C, the ACPRS Unit 1 temperature as +65.7°C, and the ACPRS Unit 2 temperature as +62.5°C.

The chamber air pressure was reduced to the pressure equivalent of an altitude of 2,000 meters above the selected test altitude of 40,000 feet. Upon stabilizing at this altitude equivalent, n-Hexane was introduced into the chamber. The volume of fuel to be used at 40,000 feet simulated altitude was calculated using the net chamber volume (73.5 ft3), the fuel temperature (+62.8°C), the chamber pressure, and the specific gravity of n-Hexane as inputs to the formula in MIL- STD-810F. Accordingly, 56.0 mL of n-Hexane was added and mixed with the air within the chamber. The chamber began a three (3) minute dwell to allow the fuel vapors to mix with the air and become a homogenous mixture. During this dwell, the equivalent altitude was ramped down to 1,000 meters above the 40,000 feet test altitude. The operational test period began. At this altitude equivalent, a sample of the chamber atmosphere was isolated. The isolated sample was subjected to an ignition test to confirm the proper Hexane mixture was present. The ignition of the sample was successful, indicating the chamber atmosphere was volatile. Then, with the chamber pressure at approximately 40,000 feet altitude equivalent, the U.S. Army PM FSS representative activated Unit 1. Unit activation was achieved and no anomalies were noted.

The chamber pressure continued to ramp down to 1,000 meters below the selected test altitude of 40,000 feet. There were no indications of any explosive events during the operation of the unit by the U.S. Army PM FSS representative. At this altitude equivalent, a sample of the chamber atmosphere was isolated. The isolated sample was subjected to an ignition test to confirm that the proper hexane mixture was present. The ignition of the sample was successful, indicating the chamber atmosphere was volatile.

Explosive Atmosphere Test (continued)

Next, the chamber pressure was ramped to an altitude equivalent of 2,000 meters above site pressure. Hexane was introduced into the chamber. The volume of fuel to be used at site pressure was calculated using the net chamber volume (73.5 ft3), the fuel temperature (+62.8°C), the chamber pressure, and the specific gravity of n-Hexane as inputs to the formula in MIL-STD-810F. Accordingly, 280 mL of n-Hexane was added and mixed with the air within the chamber.

The chamber began a three (3) minute dwell to allow the fuel vapors to mix with the air and become a homogenous mixture. During this dwell, the equivalent altitude was ramped down to 1,000 meters above site pressure. At this altitude equivalent, a sample of the chamber atmosphere was isolated. The isolated sample was subjected to an ignition test to confirm that the proper hexane mixture was present. The ignition of the sample was successful, indicating the chamber atmosphere was volatile. The operational test period began.

The chamber pressure was ramped to site pressure. Then, with the chamber at site pressure, the U.S. Army PM FSS representative activated Unit 2. Unit activation was achieved and no anomalies were noted. There were no indications of any explosive events during the operation of the unit by the U.S. Army PM FSS representative. A sample of the chamber atmosphere was isolated. The isolated sample was subjected to an ignition test to confirm that the proper hexane mixture was present. The ignition of the sample was successful, indicating the chamber atmosphere was volatile.

Upon completion of the sample ignition test, the exposure requirement was complete. Heat was turned off to the chamber. The chamber door was opened, and the chamber was vented of hexane. The ACPRS units were removed from the chamber and examined for any anomalies. No anomalies were noted.

Test Results:

Inspection of the ACPRS units after the Explosive Atmosphere testing showed no physical anomalies.

Vibration (CH-47) Test Summary and Results

Specification / Reference: MIL-STD-810F Method 514.5, Procedure I

Date Started: 10 March 2011 Date Completed: 10 March 2011

Test Assembly & Procedure:

Two (2) U.S. Army PM FSS ACPRS units, P/N WA-25000, S/N 0025 and 0027, were subjected to Vibration (CH-47) testing per MIL-STD-810F Method 514.5, Procedure I, Category 9. The vibration profile was set in accordance with Figure 514.5C-10 of MIL-STD-810F, summarized in Table 1 which follows.

Random Sine Frequency Bandwidth

(Hz)

P.S.D.

Level (g2/Hz)

Roll Up (dB / oct) Roll – Off (dB / oct)

Acceleration Level

(g RMS) Frequency

(Hz) Acceleration

(g) Axis Duration (minutes)

3.75 – 100 +3 2.76

3.75 0.1 Lateral, Longitudinal, Vertical 60 100 – 300 0.001 11.25 1.125

300 - 500 -9 22.5 1.125

33.75 2.5

Table 1. Sine on Random Vibration Parameters (CH-47)

The ACPRS units were mounted on a fixture plate, and the fixture plate was mounted on a vibration exciter, oriented for testing in each axis noted in the following paragraphs. One (1) accelerometer was mounted on the fixture for control of vibration input.

Longitudinal Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Longitudinal Axis. The units were exposed to one (1) hour of sine on random vibration per the parameters in Table 1. No anomalies were noted.

Lateral Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Lateral Axis. The units were exposed to one (1) hour of sine on random vibration per the parameters in Table 1. No anomalies were noted.

Vertical Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Vertical Axis. The units were exposed to one (1) hour of sine on random vibration per the parameters in Table 1. No anomalies were noted. This completed vibration testing in all three (3) axes. A post-test visual inspection of the units revealed no damage or anomalies.

Test Results:

Inspection of the ACPRS units after the Vibration (CH-47) testing showed no physical anomalies.

Vibration (Propeller Aircraft) Test Summary and Results

Date Started: 11 March 2011 Date Completed: 11 March 2011

Test Assembly & Procedure:

Two (2) U.S. Army PM FSS ACPRS units, P/N WA-25000, S/N 0025 and 0027, were subjected to Vibration (Propeller Aircraft) testing per MIL-STD-810F Method 514.5, Procedure I – General vibration, using Table 514.5C-II and Figure 514.5C-9 General Exposure for Propeller aircraft vibration exposure. The parameters are summarized in Table 2 which follows.

Broadband Random Narrowband Random Duration (hr:min) Axis TemperatureFrequency

(Hz)

PSD

(g2/Hz) Frequency

(Hz)

PSD

(g2/Hz) 15 to 2000 0.01 68 0.030

1:00 Lateral, Longitudinal, Vertical

Ambient 136 Roll-off −6 dB / octave

Overall 4.577 gRMS

Table 2. Random Vibration Parameters (Propeller Aircraft)

The ACPRS units were mounted on a fixture plate, and the fixture plate was mounted on a vibration exciter, oriented for testing in each axis noted in the following paragraphs. One (1) accelerometer was mounted on the fixture for control of vibration input.

Lateral Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Lateral Axis. The units were exposed to one (1) hour of random vibration per the parameters in Table 2. No anomalies were noted.

Longitudinal Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Longitudinal Axis. The units were exposed to one (1) hour of random vibration per the parameters in Table 2. No anomalies were noted.

Vertical Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Vertical Axis. The units were exposed to one (1) hour of random vibration per the parameters in Table 2. No anomalies were noted. This completed vibration testing in all three (3) axes. A post-test visual inspection of the units revealed no damage or anomalies.

Vibration (Propeller Aircraft) Test (continued)

Test Results:

Inspection of the ACPRS units after the Vibration (Propeller Aircraft) testing showed no physical anomalies.

Vibration (Jet Aircraft) Test Summary and Results

Date Started: 11 March 2011 Date Completed: 11 March 2011

Test Assembly & Procedure:

Two (2) U.S. Army PM FSS ACPRS units, P/N WA-25000, S/N 0025 and 0027, were subjected to Vibration (Jet Aircraft) testing per MIL-STD-810F Method 514.5, Procedure I – General vibration, using Table 514.5C-III and Figure 514.5C-6 General Exposure for Jet aircraft vibration exposure. The Vibration (Jet Aircraft) parameters are summarized in Table 3 which follows.

Frequency Bandwidth

(Hz)

P.S.D.

Level

(g2/Hz)

Roll - Up

(dB/oct)

Roll - Off

(dB/oct) Duration (hr:min) Axis Temperature

15 to 105.94 0.01 — —

0:30 Lateral, Longitudinal, Vertical

Ambient

105.94 to 150 — 6 —

150 to 500 0.02 — — 500 to 2000 — — 6

2000 0.0013 Overall 4.02 gRMS

Table 3. Random Vibration Parameters (Jet Aircraft)

The ACPRS units were mounted on a fixture plate, and the fixture plate was mounted on a vibration exciter, oriented for testing in each axis noted in the following paragraphs. One (1) accelerometer was mounted on the fixture for control of vibration input.

Vertical Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Vertical Axis. The units were exposed to thirty (30) minutes of random vibration per the parameters in Table 3. No anomalies were noted.

Lateral Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Lateral Axis. The units were exposed to thirty (30) minutes of random vibration per the parameters in Table 3. No anomalies were noted.

Longitudinal Axis Vibration

The ACPRS units were mounted on a fixture. The fixture was mounted on the vibration exciter, oriented to test the Longitudinal Axis. The units were exposed to thirty (30) minutes of random vibration per the parameters in Table 3. No anomalies were noted. This completed vibration testing in all three (3) axes. A post-test visual inspection of the units revealed no damage or anomalies.

Vibration (Jet Aircraft) Test (continued)

Test Results:

Inspection of the ACPRS units after the Vibration (Jet Aircraft) testing showed no physical anomalies.

Photographs

Job Number 10120-6487-3

U.S. Army PM FSS

ACPRS

P/N WA-25000

10 March 2011 – Altitude (Air Transport) Test Setup U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0009

11 March 2011 – Rapid Decompression Test Setup U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0009

11 March 2011 – Explosive Atmosphere Test Setup – Chamber U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0006 and 0009

11 March 2011 – Explosive Atmosphere Test Setup – Overall View U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0006 and 0009

10 March 2011 – Vibration Test Setup – Longitudinal Axis U.S. Army PM FSS ACPRS, P/N WA-25000, S/N 0025 and 0027

10 March 2011 – Vibration Test Setup – Lateral Axis

10 March 2011 – Vibration Test Setup – Vertical Axis

Test Equipment Used

10120-6487-3

U.S. Army PM FSS

ACPRS

MO: Maintenance Only NCR: No Calibration Required VAT: Verified at Test NPCR: No Periodic Calibration Required FIO: For Indication Only

Test Equipment Used NTS ID Description Last Cal Cal Due

ALTITUDE 10-Mar-11 TE0179 HP 11-Oct-10 31-Oct-11 (Old ID #) E5078T Data Acquisition System Model 34970A Serial No: us37002928 TE0192 Systron Donner MO NCR (Old ID #) E5099T Power Supply Model HB20-6 Serial No: 01004-9 TE0407 Omega Eng 24-Mar-10 30-Apr-11 (Old ID #) P5014T (-15 to 45) PSI Pressure Transducer Model PX203-30V45G5V Serial No: 298480 TE0535 Nor-Cal MO NCR (Old ID #) TE0535 Vacuum Chamber Model 970120-4 Serial No: 125797 TE0545 Watlow 21-Apr-10 31-May-11 (Old ID #) TE0545 Programmable Controller Model F4DH Serial No: 1596 TE1016 Dell MO NCR (Old ID #) TE1016 Desktop Personal Computer Model Dimension 3000 Serial No: serv tag 545W461 RAPID DECOMPRESSION 10-Mar-11 TE0179 HP 11-Oct-10 31-Oct-11 (Old ID #) E5078T Data Acquisition System Model 34970A Serial No: us37002928

MO: Maintenance Only NCR: No Calibration Required VAT: Verified at Test NPCR: No Periodic Calibration Required FIO: For Indication Only

Test Equipment Used (continued)

NTS ID Description Last Cal Cal Due RAPID DECOMPRESSION (continued) 10-Mar-11

TE0192 Systron Donner MO NCR (Old ID #) E5099T Power Supply Model HB20-6 Serial No: 01004-9 TE0407 Omega Eng 24-Mar-10 30-Apr-11 (Old ID #) P5014T (-15 to 45) PSI Pressure Transducer Model PX203-30V45G5V Serial No: 298480 TE0535 Nor-Cal MO NCR (Old ID #) TE0535 Vacuum Chamber Model 970120-4 Serial No: 125797 TE0545 Watlow 21-Apr-10 31-May-11 (Old ID #) TE0545 Programmable Controller Model F4DH Serial No: 1596 TE1016 Dell MO NCR (Old ID #) TE1016 Desktop Personal Computer Model Dimension 3000 Serial No: serv tag 545W461 VIBRATION 10-Mar-11 TE0014 Unholtz Dickie MO NCR (Old ID #) D5022T Amplifier Model T500 Serial No:

TE0014 Unholtz Dickie MO NCR (Old ID #) D5022T Exciter Model T500 Serial No: 225 TE0050 GenRad 01-Oct-10 31-Mar-11 (Old ID #) D6004T Vibration Control System Model 2552B Serial No: 7640

MO: Maintenance Only NCR: No Calibration Required VAT: Verified at Test NPCR: No Periodic Calibration Required FIO: For Indication Only

Test Equipment Used (continued)

NTS ID Description Last Cal Cal Due VIBRATION (continued) 10-Mar-11

TE0226 PCB 17-Jun-10 30-Jun-11 (Old ID #) E6109T Signal Conditioner Model 482A16 Serial No: 2204 TE0495 Ling MO NCR (Old ID #) TE0495 Vibration Exciter (Shaker) Model V860 Serial No: 361 TE0602 PCB 26-Oct-10 30-Apr-11 (Old ID #) D6102T Accelerometer Model 353B04 Serial No: 108631 EXPLOSIVE ATMOSPHERE 11-Mar-11 TE0441 Watlow 21-Apr-10 31-May-11 (Old ID #) ENV6067T Programmable Controller Model F4 Serial No: 008622 TE0480 Ultrak 15-Nov-10 30-Nov-11 (Old ID #) TE0480 Digital Stopwatch Model 340 Serial No:

TE0562 Omegadyne 07-May-10 31-May-11 (Old ID #) TE0562 Pressure transducer Model PX209-30VAC5V Serial No: 62723

TE0583 NTS MO NCR

(Old ID #) ENV36T Explosive Atmosphere Chamber Model Serial No:

TE0986 Graphtec 30-Apr-10 31-May-11 (Old ID #) TE0986 10 Channel Data Acquisition unit Model GL200A Serial No: H91215989

Test Data, Charts, Logs & Plots

10120-6487-3

U.S. Army PM FSS

ACPRS

Altitude Test

‐8

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PS

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10120‐6487 US Army PM FSS Air Transportation 3/10/11

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10120-6487-3

U.S. Army PM FSS

ACPRS

Rapid Decompression Test

10120‐6487 US Army Decompression from 40Kft to site 3/11/11

PSIG

‐2.00

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10120‐6487 US Army Decompression from 8 to 40K ft 3/11/11

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10120-6487-3

U.S. Army PM FSS

ACPRS

Explosive Atmosphere Test

Explosive Atmosphere 3/11/11

Air Unit 1 Wall Unit 2

Air Unit 1 Wall Unit 2

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10120-6487-3

U.S. Army PM FSS

ACPRS

Vibration (CH-47) Test

10120-6487-3

U.S. Army PM FSS

ACPRS

Vibration (Propeller Aircraft) Test

10120-6487-3

U.S. Army PM FSS

ACPRS

Vibration (Jet Aircraft) Test