BK_Draft__Attachment_B-1_PPD_Appliances_20160406.pdf

Attachment B-1

PPD for Modular Appliances

W911QY-16-R-0004

Performance Purchase Description

For the

Modular Appliances for Field Feeding

FSE-002

DRAFT

20160406

1. SCOPE. This document covers the physical, performance, interface, and acceptance requirements of the Modular Appliances for future Army field kitchens. These appliances will be used in Army field feeding kitchens as well as independent operation in buildings and forward field sites. This effort is in the developmental stage and as such, many characteristics are not yet fully defined. This document may be updated as detailed technical data for the Battlefield

Kitchen project matures. It is the intention of the government to replace or augment this document with a government owned and maintained technical data package. This document will cover the following field kitchen modular components:

1.1. Griddle

1.2. Stove Top

1.3. Tilt Skillet

1.4. Vent Hood

1.5. Convection Oven

1.6. Heater Tank

1.7. Refrigerator

1.8. Hand Wash Cabinet

1.9. Base

1.10. Cabinets

1.11. Caps

2. APPLICABLE DOCUMENTS

Human Factors Engineering, MIL-STD-1472

NSF/ANSI 2 – 2009, Food Equipment

System safety DA Pam 385-16

MIL-STD-882E for environmental safety and occupational Health

MIL-STD-810 Test Method Standard

Modular Burner Performance Purchase Description (FSE-001)

Appendix A, Test Methods for Appliance Efficiency

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2.1. GENERAL. The documents listed in this section are required to meet the requirements specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples.

While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

2.2. GOVERNMENT DOCUMENTS

2.2.1. Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense

Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation.

Human Factors Engineering, MIL-STD-1472

NSF/ANSI 2 – 2009, Food Equipment

System safety DA Pam 385-16

MIL-STD-882E for environmental safety and occupational Health.

OSHA standard 29

Modular Burner Performance Purchase Description (FSE-001)

MIL-STD-810, Test Method Standards

3. REQUIREMENTS

3.1. FIRST ARTICLE: First article requirements shall be specified in the contract.

3.2. GENERAL DESCRIPTION: The Modular Appliances are a family of components that can be assembled into various functional appliances and cabinets resulting in appliance suite tailored for specific applications. They are intended to be easily assembled using, at most, one hex key (ideally, without tools) into man-portable sections. The cabinetry is intended to be interchangeable to reduce logistics parts count, manufacturing costs, and ease of field repair and replacement. The appliances shall be designed around a standard footprint and interface so that it may be easily integrated into future field kitchens as well as current kitchens. The width was determined by the size of the oven and the width of a standard trailer. The 22 inch width is the narrowest that was practical for an oven that would fit a ½ sized commercial baking pan and also the widest that would allow for four appliances to be placed across an 8 foot platform with room for walls. All exhaust and ventilation is designed around the six inch flue. The entire suite is designed around the concept that the appliances and ventilation can be downloaded into a ground based structure and quickly made functional and safe with an operational ventilation system

3.3. GENERAL REQUIREMENTS. The following requirements apply to all modules and the completed appliance assembly.

3.3.1. NSF. All module components shall meet the requirements of NSF/ANSI 2 for Food

Equipment.

3.3.2. Inter-module Interface. All modules shall interface with each other using a standardized latching system. The latching system shall be easily operated. It shall securely hold

P a g e 3 | 35 the modules together during all modes of transportation and all operational conditions. As a minimum, the latching mechanism must be accessible from the outside of the cabinet to allow for easy assembly of appliances. See section 6.1.1.

3.3.3. Basic Footprint. The basic cabinet module shall be mountable on 22 inch centers resulting in a maximum cabinet width dimension of 21.88 inches wide. The depth (front to back) of the appliance shall not exceed 27 inches in transportation mode. There shall be no protrusions from the side or any vents as they may be blocked by a wall or adjoining appliance.

3.3.4. Pack-Out height limit. All modules shall be capable of being packed out within the envelope of the Battlefield Kitchen without hindering its ability to meet all transportability requirements.

3.3.5. Controls: The appliance shall have a heat control universal to all cooking appliances to minimize training and repair parts. There shall be two modes of operator control: Heat output

(either by duty cycle or variable firing rate) and thermostat controlled.

3.3.5.1. Duty Cycle Settings. For duty cycle burners there shall be a minimum of five heat output settings of 10%, 25%, 50%, 75%, and 100% duty cycle. The Burner off time shall be no greater than 40 seconds for all duty cycles except 100%. Note: It is desirable to minimize the burner off time.

3.3.5.2. Modulating Burner Range. For a modulating burner, the minimum heat output shall be no more than 20% of the maximum heat output.

3.3.5.3. Thermostatic Control. The thermostatic controlled appliances shall have a maximum temperature step of 25°F with a range minimum from 150°F to 400°F.

3.3.6. Thermostatic Control. The control shall automatically operate in this mode for appliances that require thermostatic control (e.g. Oven and Griddle). The thermostatic control shall have a maximum temperature step of 25°F with a range minimum from 150°F to 400°F.

3.4. INTERFACE REQUIREMENTS

3.4.1. Electrical Interface.

3.4.1.1. All modular appliance components that require electrical power shall be compatible with 120 VAC, single phase, and 50 or 60 Hertz input power.

3.4.1.2. Electrical cable. All modular appliance that require electrical power shall have a flexible cable that extends six feet from the appliance and terminates with a 15-5P connector.

The power cable shall exit the cabinet in such a way as to accommodate 1 inch of clearance from the back of the appliance to a solid surface without damage to the power cable. The cable shall be SJOOW type.

3.4.1.3. Burner electrical Interface. The appliance module shall have electrical connections of the proper type and location to interface with the modular burner in its normal operating position.

3.4.2. Burner mechanical interface. The modular appliances shall be capable of interfacing with the modular burner as the heat source. All cooking and heating requirements of the appliances shall be met when using the modular burner (See Performance Purchase Description

FSE-001).

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3.4.3. External Fuel Interface: The appliance assembly shall have a fuel system that provides the interface between the Battlefield Kitchen fuel system and the Modular Burner. Modules that require the use of the modular burner shall have a fuel connector capable of interfacing with the

Battlefield Kitchen fuel line without causing damage to the fuel line. The back of the modular appliances shall be located as close as 1 inch to a solid surface.

3.5. ENVIRONMENTAL REQUIREMENTS

3.5.1. Environmental temperature range. The Modular Appliance shall perform all functions without degradation when operated in basic and hot climate conditions.

3.5.1.1. Low temperature operation and storage. The appliances shall be fully operational in temperatures as low as -25°F and shall be capable of being stored without damage in temperatures as low as -60°F.

3.5.1.2. High temperature operation and storage. The appliances shall be fully operational in temperatures as high as +135°F and shall be capable of being stored without damage in temperatures as high as +160°F. Note: Although the requirement for the Battlefield Kitchen, which is the primary application of the Modular Appliances is +125°F. The Battlefield Kitchen interior can be expected to be 10°F higher than the ambient environment.

3.5.2. Wind. The appliances shall be capable of being exposed to and operating in wind up to

15 mph without damage or loss of capability.

3.5.3. Rain: Appliances shall be capable of being exposed to rain while in the non-operational condition without damage. Appliances may require service prior to being brought back into service after being exposed to rain; however, service shall be minimal and must be included as PMCS.

3.5.4. Blowing sand and dust. Appliances shall capable of being exposed to blowing sand and dust without damage. Appliances may require service prior to being brought back into service after being exposed to blowing sand and dust; however, service shall be minimal and must be included as part of PMCS.

3.5.5. Corrosion resistance. Appliances shall be resistant to corrosion caused by sea spray or other environments that will expose the appliance to salt.

3.5.6. Humidity. Appliances shall be capable of being exposed to and operating in humid environments as specified in AR-70-38 without damage or loss of capability.

3.6. LIFE CYCLE REQUIREMENTS

3.6.1. Maintainability. As much as practical, the appliances shall be maintainable and repairable by the operator. The Modular Appliances shall be the appliance suite for the

Battlefield Kitchen. The Maintenance Ratio of the appliances shall be evaluated as part of the

Battlefield Kitchen. A minimum number of tools shall be required to maintain and repair the appliances at the operator level.

3.6.2. Reliability.

3.6.2.1. Operational time and transit. The Battlefield Kitchen has a system requirement for reliability and transit. The Modular Appliances shall be evaluated for operational time and transit as a component of the Battlefield Kitchen.

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3.6.2.2. Cyclic failure. The mobile locking base shall be capable of a minimum of 100 cycles throughout its useful life without failure or degradation of performance.

3.7. SAFETY REQUIREMENTS

3.7.1. Health Hazards. The Modular Appliances shall be designed to meet the Health Hazard

Requirements specified in the contract.

3.7.2. Noise. An individual appliance shall produce no more than 73 decibels at the operator’s ear level while standing 1 foot from the front of the appliance with the burner firing and the vent hood drawing at 300 cfm.

3.7.3. Labeling. All controls shall be clearly labeled to indicate their function to the operator.

Safety hazards shall be appropriately labeled.

3.8. MODULE SPECIFIC REQUIREMENTS. The following requirements are specific to the module cited.

3.8.1. GRIDDLE

3.8.1.1. Capacity: The griddle cooking surface area shall maximized within the available footprint of the modular appliance and shall be no less than 500 square inches.

3.8.1.2. Grease Catcher. The griddle shall be equipped with grease catcher. The grease catcher shall be easily removable for emptying and cleaning. The capacity of the grease catcher shall be maximized within the constraints of the other requirements of the griddle.

3.8.1.3. Efficiency. Heat transfer efficiency of a pre-heated griddle shall be no less than

45%.

3.8.1.4. Cooking surface height: The Cooking surface shall be designed around the accepted standard height for cabinets. The griddle surface shall be a minimum of 36 inches and a maximum of 38 inches as measured from floor when assembled with a base module and a double height cabinet (or two single height cabinets).

3.8.1.5. Temperature control: The Griddle shall have thermostatic control capable of maintaining temperature at any set point between 150°F and 400°F. Maximum temperature range as measured between any two points on the cooking surface shall be within the range of ±

25ºF (measured to within 3 inches of the edge of the griddle surface).

3.8.1.6. Exhaust: The griddle shall interface with the vent hood to remove cooking and combustion effluent.

3.8.2. STOVE TOP

3.8.2.1. Compatibility: As a minimum, the Stove Top shall be capable of safely and effectively heating the following vessels:

3.8.2.1.1. 15 gallon stock pot: NSN: 7330-00-292-2307

3.8.2.1.2. 10 gallon stock pot: NSN: 7330-00292-2307

3.8.2.1.3. Baking and roasting pan: NSN: 7330-00-272-7876

3.8.2.1.4. Large Capacity Vessel: The Stove top shall be capable of effectively heating any vessel with a flat bottom and maximum size of at least 20 inches by 25 inches (from front to back) and up to 18 inches (vertical). The stove top shall be capable of supporting a

P a g e 6 | 35 cooking/heating vessel weighing up to 275 pounds with a safety factor of 2.5 (during stationary operation only, not during transportation).

3.8.2.2. Efficiency: The Stove Top shall have a minimum heating efficiency of 36% when heating the 15 gallon stock pot.

3.8.2.3. Working Height: The Surface that supports the cooking vessel shall be minimum of

34 and a maximum of 38 inches as measured from floor when assembled with a base module and a double height cabinet (or two single height cabinets).

3.8.3. TILT SKILLET

3.8.3.1. Capacity: The skillet shall have a capacity of no less than 12 gallons when filled to

80%.

3.8.3.2. Skillet height. The top front lip of skillet shall be no higher than 44 inches above the floor. The interior of the skillet shall be no lower than 32 inches above the floor when assembled to a base and double height cabinet (or two single height cabinet).

3.8.3.3. Tilting. The tilting skillet shall be easily and safely tilted using only one hand. The skillet shall stay in the fully tilted position without holding the handle or latching mechanism.

3.8.3.4. Cleaning. The skillet shall be designed to be easily removed for cleaning.

3.8.3.5. Efficiency: The tilt skillet shall demonstrate a heat transfer efficiency of no less than 38%.

3.8.4. CONVECTION OVEN

3.8.4.1. Capacity, baking sheets: The oven shall have a minimum capacity of 9 - ½ sized commercial sheet pans on a minimum of 3.25 inch centers.

3.8.4.2. Steam Table Pan Compatibility. The oven rack system shall be capable of supporting up to 4 each, six in deep, full sized steam table pans.

3.8.4.3. Oven Weight: The oven module with all racks shall weigh no more than 225 lbs.

3.8.4.4. Efficiency: The heat transfer efficiency (energy transferred to product divided by fuel energy input), shall be no less than 36%.

3.8.4.5. Pre-heat time: The oven shall be capable of reaching a temperature of 350ºF with

12 minutes from a cold state. A cold state shall be defined 70 ± 10 ºF.

3.8.4.6. Temperature accuracy. Thermostatic control capable of maintaining temperature at any set point between 150°F and 400°F. The average temperature within the cavity shall be no more than set point ± 20ºF from the set point.

3.8.5. HEATER TANK

3.8.5.1. Footprint. The steam stable shall have the footprint of three modules side by side.

3.8.5.2. Burner compatibility. The steam table shall require only one burner.

3.8.5.3. Efficiency. The Heater Tank shall have an efficiency of no less than 65%.

3.8.5.4. Serving line Capacity: The steam table shall have the minimum capacity of five standard full sized steam table pans and be compatible with standard full size steam table pans.

20 ¾ x 12 3/4 x 6 inches.

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3.8.5.5. Height: Top surface of steam table pans shall be no less than 38 inches no more than 40 inches above the level of the floor.

3.8.5.6. Sneeze Guard. When used as a serving line, the heater tank shall have a sneeze guard that is easily deployed for operation and removable or height reducible to meet the

Battlefield Kitchen transportability requirements.

3.8.5.7. Drain: The Heater Tank shall be equipped with a drain to allow the water to be drained from the tank.

3.8.5.8. Tray pack heating: The Heater Tank shall be capable of heating tray rations within the tank. There shall be a system of racks to keep the trays off the bottom of the tank to prevent the poly trays from melting to the bottom surface of the cavity. There shall be a means to cover the tank while heating tray packs. The racks shall maximize the tray ration capacity. The Heater

Tank shall be designed to minimize the heating time of the tray packs. The Heater Tank shall be capable of heating a minimum of 30 tray packs in a single batch.

3.8.5.9. Heat Control: The Heater Tank shall have a duty cycle controller.

3.8.6. REFRIGERATOR

3.8.6.1. Module Interface: Shall interface with the locking base and cabinet top

3.8.6.2. Module Assembly Height: The top surface shall be a minimum of 36 inches and a maximum of 39 inches measure normal to the floor.

3.8.6.3. Power Consumption. The steady state power consumptions shall be less than 125 watts.

3.8.7. HAND WASH CABINET

3.8.7.1. Height: 36 inches (not including faucet). The hand wash cabinet shall consist of only two modular components, the base and the cabinet. The total height of the hand wash cabinet shall not exceed the maximum required for transportation. See section 6.

3.8.7.2. Fixtures

3.8.7.2.1. Hand Wash: The hand wash sink shall have a faucet for hot and cold running water for hand washing purposes.

3.8.7.2.2. Prep Sink: The hand wash cabinet shall have as a minimum, a cold water faucet capable of extending a minimum of 11 inches to the left side of the hand wash cabinet a distance

6 inches from the rear of the hand wash cabinet. The outlet of the faucet shall be a minimum of

8 inches above the surface of the hand was cabinet and the water shall exit in a vertical downward direction. Note: This faucet will be used to provide water to the prep sink which will be located next to the Hand Wash Cabinet on the Battlefield Kitchen.

3.8.7.3. Sink size. The hand wash sink shall be no larger than 14 inches x 11 inches x 5 ½ inches deep.

3.8.7.4. Flow Rate. The Hand Wash Cabinet shall have an on-demand water pump capable of providing water at a flow rate of 0.75 gallons/minute at a supply pressure ranging from 6 feet of lift to 50 psi at the cabinet inlet.

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3.8.7.5. Water Heater. Must be capable of providing warm water for hand washing at a minimum temperature of 100°F and a maximum temperature of 110°F. The hand wash cabinet shall have the capability to heat water within the envelope of the cabinet.

3.8.7.6. Electric power: See paragraph 6.1.3.

3.8.7.7. Drain Interface. The Hand Wash cabinet shall have a quick disconnect drain connector to allow the hand wash cabinet to be connected to a drain hose.

3.8.7.8. Cold weather. During downtime (no power supplied to kitchen), the hand wash cabinet must be capable of withstanding freezing conditions. The downtime periods may exceed

8 hours.

3.8.8. MOBILE LOCKING BASE

3.8.8.1. Interface: The cabinet base shall incorporate a locking device that will interface with the floors of mobile field kitchens and the cabinet system on the modular appliance components. The locking base shall have a mechanism to lock the base to the hardware mounted in the floor without the use of tools.

3.8.8.2. Strength: This base module shall be of sufficient strength to safely restrain an appliance assembly weighing 400 pounds with a center of gravity 30 inches from the ground during all modes of transportation.

3.8.8.3. Height: The base shall be 4 inches high.

3.8.8.4. Toe kick: The base shall be sized such that it provided a 3 – 4 inch toe kick in the front of the appliances and an equal space in the rear of the appliance.

3.8.8.5. Mobility. The locking base shall have casters capable of allowing easy movement of the modular appliance on the floor of the BK or other had relatively smooth and hard surface.

The casters shall be fixed and allow movement in the direction of the 27 inch axis of the appliance only. At least one caster shall have a brake to prevent the appliance from moving during use when the appliance is not locked to the floor.

3.8.9. CABINETS

3.8.9.1. Cabinet, Single Height. The single height with door shall have a latched door capable of containing items held in the cabinet during transportation. The cabinet height shall be

10.3 inches.

3.8.9.2. Cabinet, Single Height, with Drawer. The single height cabinet with drawer shall have the same basic construction as the single height cabinet with the addition of a full extension drawer. The drawer slides shall be have a 175 pound capacity for operational use, 50 pound capacity during transportation. The drawer shall have a flush mounted drawer pull. The drawer shall have a latching mechanism that will be secure a fully loaded drawer during transportation.

3.8.9.3. Cabinet, Double Height. The double height cabinet shall have the same basic construction as the single height cabinet, maximizing commonality of parts. It shall have a latched door capable of containing items held in the cabinet during transportation. The cabinet height shall be 20.5 inches. The door shall have hinges that allow the door to be easily removed without tools.

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3.8.9.4. Cabinet, Triple Height. The full height cabinet shall have the same basic construction as the single height cabinet, maximizing commonality of parts. It shall have a door shall have a latched door capable of containing items held in the cabinet during transportation.

The cabinet height shall be 30.8 inches. The door shall have hinges that allow the door to be easily removed without tools.

3.8.10. CAPS

3.8.10.1. Vent Hood. The vent hood shall be compatible with the Griddle, Tilt skillet, and stove top modules. It shall capture burner combustion products as well as cooking effluent. It shall have an easily removed grease filter to remove grease from the cooking effluent. The grease filter shall be mounted in such a way that it will not fall out during transportation. It shall be easily cleaned using normal kitchen cleaning products. The vent hood shall not induce a draft on the burner combustion chamber. It shall have a grease catch capable of holding 4 ounces of liquid that is easily removable and cleanable.

3.8.10.1.1. Vent Hood Exhaust Port. The ventilation hood shall exhaust through a 6 inch outside diameter flange on the top of the vent hood. The center of the exhaust vent shall be six inches from the rear of the appliance envelope and centered from side to side. The flange shall be no less than 1.5 and no greater than 2 inches long.

3.8.11. Work surface. The work surface module shall interface with the cabinet modules. It shall meet NSF requirements for food surface contact and be made of Stainless Steel. The work surface thickness shall be 1 inch and shall attach to the cabinets using the standard latching mechanism. It will be used to create a flat top, work surface cabinet when used in conjunction with the cabinet modules.

4. VERIFICATION

4.1. VERIFICATION ALTERNATIVE. Alternative test methods, techniques, or equipment, including; application of statistical process control, tool control, or cost effective sampling procedures may be proposed by the contractor. Acceptable alternative verification approach, including the use of sample testing shall be identified in the contract.

4.2. VERIFICATION METHODS.

Table 1 Requirements and Verification Methods for Tests

Requirement

Paragraph

Requirement Verification

Paragraph

3.3 GENERAL REQUIREMENTS 4.3

3.3.1 NSF 4.3.1

3.3.2 Inter-module Interface 4.3.2

3.3.3 Basic Footprint 4.3.3

3.3.4 Pack out 4.3.4

3.3.5 Controls 4.3.5

3.3.5.1 Duty Cycle Settings 4.3.5.1

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3.3.5.2 Modulating Burner Range 4.3.5.2

3.3.5.3 Thermostatic Control 4.3.5.3

3.4 INTERFACE REQUIREMENTS 4.4

3.4.1 Electrical Interface 4.4.1.

3.4.1.1 Voltage Requirements 4.4.1.1

3.4.1.2 Electrical Cable 4.4.1.2

Length 4.4.1.2.1

Type 4.4.1.2.2

Connector 4.4.1.2.3

Clearance 4.4.1.2.4

3.4.1.3 Burner Electrical Interface 4.4.1.3

3.4.2 Burner Mechanical Interface 4.4.2

3.4.3 External Fuel Interface 4.4.3

3.5 ENVIRONMENTAL REQUIRMENTS 4.5

3.5.1 Environmental Temperature Range 4.5.1

3.5.1.1 Low Temperature Operation and Storage 4.5.1.1

3.5.1.2 High Temperature Operation and Storage 4.5.1.2

3.5.2 Wind 4.5.2

3.5.3 Rain 4.5.3

3.5.4 Blowing Sand and Dust 4.5.4

3.5.5 Corrosion Resistance 4.5.5

3.5.6 Humidity 4.5.6

3.6 LIFE CYCLE REQUIREMENTS 4.6

3.6.1 Maintainability 4.6.1

3.6.2. Reliability 4.6.2

3.6.2.1 Operational time and transit 4.6.2.1

3.6.2.2 Cyclic Failure 4.6.2.2

3.7 SAFETY REQURIEMENTS 4.7

3.7.1 Health Hazards 4.7.1

3.7.2 Noise 4.7.2

3.6.4 Labeling 4.7.3

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3.8 MODULE SPECIFIC REQUIREMENTS 4.8

3.8.1 GRIDDLE 4.8.1

3.8.1.1. Capacity 4.8.1.1

3.8.1.2 Grease Catcher 4.8.1.2

3.8.1.3 Efficiency 4.8.1.3

3.8.1.4 Cooking Surface Height 4.8.1.4

3.8.1.5 Temperature Control 4.8.1.5

3.8.1.6 Exhaust 4.8.1.6

3.8.2 STOVE TOP 4.8.2

3.8.2.1 Compatibility 4.8.2.1

3.8.2.2 Efficiency 4.8.2.2

3.8.2.3 Working Height 4.8.2.3

3.8.3 TILT SKILLET 4.8.3

3.8.3.1 Capacity 4.8.3.1

3.8.3.2 Skillet Height 4.8.3.2

3.8.3.3 Tilting 4.8.3.3

3.8.3.4 Cleaning 4.8.3.4

3.8.3.5 Efficiency 4.8.3.5

3.8.4 CONVECTION OVEN 4.8.4

3.8.4.1 Capacity, baking sheets 4.8.4.1

3.8.4.2 Steam Table Pan Compatibility 4.8.4.2

3.8.4.3 Oven Weight 4.8.4.3

3.8.4.4 Efficiency 4.8.4.4

3.8.4.5 Pre-Heat Time 4.8.4.5

3.8.4.6 Temperature Accuracy 4.8.4.6

3.8.5 HEATER TANK 4.8.5

3.8.5.1 Footprint 4.8.5.1

3.8.5.2 Burner Compatibility 4.8.5.2

3.8.5.3 Efficiency 4.8.5.3

3.8.5.4 Serving Line Capacity 4.8.5.4

3.8.5.5 Height 4.8.5.5

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3.8.5.6 Sneeze Guard 4.8.5.6

3.8.5.7 Drain 4.8.5.7

3.8.6 REFRIGERATOR 4.8.6

3.8.6.1 Module Interface 4.8.6.1

3.8.6.2 Modular Assembly Height 4.8.6.2

3.8.6.3 Power Consumption 4.8.6.3

3.8.7 HAND WASH CABINET 4.8.7

3.8.7.1 Height 4.8.7.1

3.8.7.2 Fixtures 4.8.7.2

3.8.7.2.1 Hand Wash Faucet 4.8.7.2.1

3.8.7.2.2 Prep Sink Faucet 4.8.7.2.2

3.8.7.3 Sink Size 4.8.7.3

3.8.7.4 Flow Rate 4.8.7.4

3.8.7.5 Water Heater 4.8.7.5

3.8.7.6 Electric Power 4.8.7.6

3.8.7.7 Drain Interface 4.8.7.7

3.8.7.8 Cold Weather 4.8.7.8

3.8.8 MOBILE LOCKING BASE 4.8.8

3.8.8.1 Interface 4.8.8.1

3.8.8.2 Strength 4.8.8.2

3.8.8.3 Height 4.8.8.3

3.8.8.4 Toe Kick 4.8.8.4

3.8.8.5 Mobility 4.8.8.5

3.8.9 CABINETS 4.8.9

3.8.9.1 Cabinet, Single Height 4.8.9.1

Cabinet Height 4.8.9.1.1

Latch Security 4.8.9.1.2

3.8.9.2 Cabinet, Single Height with Drawer 4.8.9.2

Commonality of Parts 4.8.9.2.1

Drawer Capacity 4.8.9.2.2

3.8.9.3 Cabinet, Double Height 4.8.9.3

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Cabinet Height 4.8.9.3.1

Latch Security 4.8.9.3.2

Commonality of Parts 4.8.9.3.3

3.8.9.4 Cabinet Triple Height 4.8.9.4

Cabinet Height 4.8.9.4.1

Latch Security 4.8.9.4.2

Commonality of Parts 4.8.9.4.3

3.8.10 CAPS 4.8.10

3.8.10.1 Vent Hood 4.8.10.1

Compatibility 4.8.10.1.1

Grease Filter and Grease Trap 4.8.10.1.2

Transportation 4.8.10.1.3

Operation 4.8.10.1.4

3.8.10.1.1 Vent Hood Exhaust Port 4.8.10.1.5

3.8.11 Work Surface 4.8.10.2

4.3. GENERAL REQUIREMENTS

4.3.1. NSF. Modules shall be inspected compliance to NSF requirements. Lack of NSF certification shall not be cause for failure; however, appliances and appliance components must meet the requirements of NSF 2.

4.3.2. Inter-module Interface. The latching system shall be engaged and disengaged to verify operation and accessibility. Latching mechanisms that are difficult to operate, engage, or align shall be cause for failure. Latching mechanisms that require access to the rear of the appliance to operate shall be cause for failure. Strength and durability shall be verified during transportability testing.

4.3.3. Basic Footprint. Verify that the appliances do not exceed 21.9 inches in width.

Exceeding this dimension is cause for failure. Verify the front to back dimension of the basic appliance cabinet does not exceed 27 inches. Components such as the oven handle, hinges, and latches may extend beyond the envelope. Components that extend beyond the envelope shall be protected from damage or designed to resists damage from contact during operation or transportation. Exceeding 27 inches shall be cause for failure. Verify that no vents or intakes are present on the sides of the appliances. Air intakes or exhausts located on the sides of the appliances shall be cause for failure.

4.3.4. Pack out. Verify that the appliances do not exceed the maximum height limitation in the pack out configuration. See 6.2.7. Exceeding the required dimension in any of the above condition shall constitute a failure.

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4.3.5. Controls

4.3.5.1. Duty Cycle Settings. Operate the appliance at the minimum setting (minimum duty cycle) as indicated on the controller for five complete cycles. Record the burner firing time and off time for each cycle. Calculate the ratio of burn time total cycle time. The cycle time shall be the average of times from one burner start to the next. Repeat this procedure for each heat setting on the controller. Operate the appliance at maximum duty cycle for a minimum of five minutes. Verify that the burner does not cycle off. Inability to operate at the minimum required discrete duty cycles shall constitute a failure. Inability to operate continuously at the maximum heat setting. A burner off time greater than 40 seconds in any duty cycle shall constitute a failure.

4.3.5.2. Modulating Burner Range. Operate the appliance at the minimum heat output setting for ten minutes using a fuel tank that can be weighed during operation. Record the fuel weight at zero, five, and ten minutes. Operate the appliance at the maximum heat output setting for ten minutes, again recording the fuel weight at zero, five and ten minutes. Calculate the average fuel consumed in pounds per hour at both minimum and maximum heat settings over the ten minute test. Divide the minimum by the maximum and verify that it is less 0.20 (20%).

Operate the appliance intermediate heat settings. Verify that there is a smooth transition from the lowest heat setting to the maximum. Calculate the average heat output in pounds per hour at low and high settings. Calculate the fuel consumption rate in pounds per hour at each of the five minute intervals. Verify that for a given setting, the variance between the two calculated firing rates (first five minutes and last five minutes) is not outside the range of the average over 10 minutes ± 5%. A minimum firing rate greater than 20% of the maximum firing rate shall constitute a failure. A heat output setting drift (first five minutes compared to last five minutes) outside the specified range shall constitute a failure. Inability to smoothly transition from minimum to maximum shall constitute a failure.

4.3.5.3. Thermostatic Control. Energize the oven controller. Verify that the thermostat can be set at 25°F increments from 150°F to 400°F. Inability to set temperature at 150°F, 400°F and all multiples of 25°F between (i.e. 200°F, 225°F, etc.) shall constitute a failure. Note: Oven operation will be evaluated separately.

4.4. INTERFACE REQUIREMENTS

4.4.1. Electrical Interface.

4.4.1.1. Supply Voltage. The appliances shall be operated from a power source of the required voltage at 50 and 60 Hertz. Failure to meet all operational requirements while operating on 120 VAC ± 12 volts, 60 Hertz power shall constitute a failure. Failure to operate without damage to components, even after long term use, on 120 VAC ± 12 volts, 50 Hertz power shall constitute a failure.

4.4.1.2. Electrical cable.

4.4.1.2.1. Length: Verify that each appliance has an electrical cable 6 feet ± 6 inches.

Measure the cable length from the rear plane of the appliance to the first contact with the connector. An out of specification length shall constitute a failure.

4.4.1.2.2. Type, verify that the electrical cable type SJOOW

4.4.1.2.3. Connector. Verify that the cable connector is a commercial grade 15-5P connector. An improper connector shall constitute a failure.

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4.4.1.2.4. Clearance. Verify that the cable is not damaged or placed in excessive strain under anticipated conditions. Place a flat surface within 1 inch of the rear of the appliance to simulate placing the appliance near a wall. Verify that the minimum bend radius of the cable is not less than the manufacturers’ minimum recommended bend radius. A cable bend less than the minimum recommended radius shall constitute a failure. Kinking of the cable shall constitute a failure.

4.4.1.3. Burner Electrical Interface. See paragraph 6.2.2.

4.4.2. Burner Mechanical Interface. Failure for a Modular Burner, NSN TBD, to physically fit the appliance shall be cause for failure. Failure to properly interface with the Modular Burner fuel and electrical systems shall be cause for failure. Failure to operate long term without damage to equipment or loss of capability shall be cause for failure. Evaluation of this requirement shall be in conjunction with the reliability testing.

4.4.3. External Fuel Interface: Verify that the fuel connectors are of the correct type to interface with the connectors on the Battlefield Kitchen. Incompatible connections shall be cause for failure. Place the appliance at a distance of 1 inch from a firm flat surface. Verify that the minimum bend radius of the fuel line is not less than the manufacturers minimum recommended bend radius. A bend radius less than the minimum recommended bend radius shall constitute a failure. Visible kinking of the fuel line shall constitute a failure.

4.5. ENVIRONMENTAL REQUIREMENTS

4.5.1. Environmental temperature range:

4.5.1.1. Low temperature operational test: Test the appliance in accordance with MIL-STD-

810G, method 502.5, and for operation and manipulation at a temperature of -25ºF. Failure to start and properly operate at the designated heat setting for three burner cycles shall constitute a failure. Operate according to the following set up.

4.5.1.1.1. Oven: no load, 350°F

4.5.1.1.2. Griddle: no load, 350ºF

4.5.1.1.3. Stove top, stock pot with 10 ± 1 gallon of water, medium setting

4.5.1.1.4. Tilt skillet: 5 ± ½ gallon, medium setting

4.5.1.1.5. Heater Tank: 10 ± 1 gallon, medium setting

4.5.1.2. High Temperature operational test: Test each appliance in accordance with ML-

STD-810G, method 501.5 and 4.8.1.3 for operation and manipulation at a temperature of

+135°F. Failure to start and properly operate at the designated heat setting for three burner cycles shall constitute a failure. Operate the appliances in accordance with the following set up:

4.5.1.2.1. Oven: no load, 350°F

4.5.1.2.2. Griddle: no load, 350ºF

4.5.1.2.3. Stove top, stock pot with 10 ± 1 gallon of water, medium setting

4.5.1.2.4. Tilt skillet: 5 ± ½ gallon, medium setting

4.5.1.2.5. Heater Tank: 10 ± 1 gallon, medium setting.

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4.5.2. Wind. The wind test shall be performed on normal to all four sides of the modular appliance with a constant wind speed of 15 mph. Operate the appliances in accordance with

4.8.1.2. Failure to start and properly operate at the designated heat setting for three burner cycles shall constitute a failure.

4.5.3. Rain: Expose appliances to rain IAW MIL-STD-810 method 506.5. After exposure to rain, prepare the appliance in accordance with the TM. Operate the appliance in accordance

4.8.1.2. Failure to start and properly operate at the designated heat setting for three burner cycles shall constitute a failure.

4.5.4. Blowing sand and dust. Test appliances in accordance with MIL-STD-810G, method

510.5. After exposure to sand, prepare the appliances for operation in accordance with the appliance TM. Operate the appliance in accordance 4.8.1.2. Failure to start and properly operate at the designated heat setting for three burner cycles shall constitute a failure.

4.5.5. Corrosion. Test appliance in accordance with MIL-STD-810G, method, 509.5.

Appliances shall be resistant to corrosion caused by sea spray or other environments that will expose the appliance to salt.

4.5.6. Humidity. Test appliance in accordance with MIL-STD-810G, method 507.5. Operate the appliance in accordance 4.8.1.2. Appliances shall be capable of being exposed to and operating in humid environments without damage or loss of capability.

4.6. LIFE CYCLE REQUIREMENTS

4.6.1. Maintainability. Maintainability shall be evaluated during reliability testing of the

Battlefield Kitchen. A failure of the Battlefield Kitchen to meet its Maintenance Ratio requirement that can be attributed to the Modular Appliances shall constitute a failure of the

Modular Appliances. The maximum number and type of tools required for operator maintenance shall be determined during the final development of the modular Appliances.

4.6.2. Reliability.

4.6.2.1. Reliability shall be evaluated during reliability testing of the Battlefield Kitchen. A failure of the Battlefield Kitchen to meet its operational time or transit requirement that can be attributed to the Modular Appliances shall constitute a failure of the Modular Appliances.

4.6.2.2. Cyclic failure. Four mobile locking bases shall be subject to a minimum of 100 cycles each with a total of 450 cycles for the four bases. A cycle shall consist of rolling the cabinet into position, engaging the locking mechanism, unlocking the mechanism then moving the appliance at least one foot out of position. Every 25 cycles, the appliances shall be rotated to a different appliance so that by the end of the test, each appliance has cycles 25 times on each base. There shall be no more than 1 failure of mobile locking base.

4.7. SAFETY REQUIREMENTS

4.7.1. Health Hazards. This evaluation shall be completed in conjunction with the reliability test of the Battlefield Kitchen. Verify that the Modular Appliances do not present any unacceptable hazards to the operators or equipment. Verify that damage to safeguards are easily noticeable by operators and maintainers. Health hazards in excess of requirement as specified in the Health Hazzard Assessment shall be cause for failure.

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4.7.2. Noise. This requirement shall be evaluated in conjunction with the testing of the

Battlefield Kitchen System. Operate each burner individually while mounted on the Battlefield

Kitchen in its normal operational configuration. For the Stove Top appliance, place a 15 gallon stock pot with 10 gallons of water in its normal cooking position. Operate each appliance individually. Verify that each individual appliance does not produce more than 73 decibels at the

5 foot 3 inches above the floor, 1 foot from the front of the appliance with the burner firing and the vent hood drawing at 300 cfm per appliance.

4.7.3. Labeling. Verify that all labels are present and meet the requirements of section 3.

Missing or damaged labels or labels with missing or incorrect markings shall be cause for failure.

4.8. MODULE SPECIFIC REQUIREMENTS. The following requirements are specific to the module cited.

4.8.1. GRIDDLE

4.8.1.1. Capacity: Measure the griddle cooking surface length and width in inches and calculate the griddle surface area in square inches. A griddle surface area less than 500 square inches shall constitute a failure.

4.8.1.2. Grease Catcher. Verify the location and ease of access of the grease catcher.

Inability to easily remove and clean the grease catcher shall constitute a failure.

4.8.1.3. Efficiency. Perform the heat transfer test for the griddle in accordance with

Appendix A, Method A. A heat transfer efficiency less than 45% shall constitute a failure.

4.8.1.4. Cooking surface height: Measure the distance normal to the floor to the cooking surface. A height outside the range of 36 to 38 inches shall constitute a failure.

4.8.1.5. Temperature control: Operate the griddle with a thermostatic setting of 200ºF for 3 burner cycles. After the burner cycles on the fourth time, measure the griddle surface at nine points. The outside points should form a box 3 inches from the outer edge of the griddle. The center point shall be centered in this box. Repeat this procedure for 300ºF and 400ºF. Verify that at any thermostat setting, the maximum variation between any two measurements is within the range of ± 25ºF of the set point.

4.8.1.6. Exhaust: Verify the vent hood interfaces and lock properly on the griddle module.

Failure of the vent hood to lock securely in place using and be removable from the griddle assembly with only the hex key shall constitute a failure.

4.8.2. STOVE TOP

4.8.2.1. Compatibility: This evaluation shall be conducted in conjunction with the reliability testing. Throughout the reliability testing the appliances shall be operated with various cooking vessels. Failure to safely and effectively operate with the 10 and 15 gallon stock pots and the baking and roasting pan as specified in section 3.8.2.1 shall constitute a failure.

4.8.2.1.1. Fabricate an open top vessel constructed of Aluminum with a minimum wall thickness of 0.13 inches that has a bottom surface 20 inches by 25 inches and 18 inch sides. Fill the vessel to a depth of between 14 and 15 inches. Operate the Stove top at 100% duty cycle for

30 minutes. Verify that there is no damage to the stove top as a result of the test. Place a static load of 500 pounds on the stove top evenly distributed. Verify that the Stove Top does not incur

P a g e 18 | 35 any damage as a result of the test. Damage to the stove as a result of the weight bearing or the heating of the vessels shall constitute a failure.

4.8.2.2. Efficiency: The Stove top shall be tested for efficiency in accordance with appendix

A, test method B. Failure to achieve a minimum efficiency of 36% shall constitute a failure.

4.8.2.3. Working Height: Measure the distance normal to the floor to the bottom surface of the stock pot when mounted on the Stove Top. A measurement outside the range of 36 to 38 inches shall constitute a failure.

4.8.3. TILT SKILLET

4.8.3.1. Capacity: Measure the capacity in gallons of the tilt skillet when filled to 80% of its total height. A capacity less than 12 gallons shall constitute a failure. As an alternative, this can be calculated. Calculate the volume of square inches at 80% of the total height of the skillet.

Convert the calculated volume to gallons. Verify that the volume is no less than 12 gallons. A measurement or calculated volume less than 12 gallons shall constitute a failure.

4.8.3.2. Skillet height. Measure the distance normal to the floor to the top of the skillet. A measurement in excess of 44 inches shall be cause for failure. Measure the distance normal to the floor to the bottom of the interior of the skillet, a measurement less than 32 inches shall constitute a failure.

4.8.3.3. Tilting. Operate the tilt feature with the vessel filled to 80% capacity of water.

Verify the force to operate the mechanism does not exceed the requirement of MIL-STD-1472.

Verify that the Skillet stays in the fully open position without user input. Verify that the tilt mechanism can smoothly and easily be operated to avoid spills and splashes.

4.8.3.4. Cleaning. Verify that the skillet can be easily removed (once cooled) by one person without the use of tools. Verify that the skillet can be easily installed by one person without the use of tools. Requiring a tool to remove or install the skillet shall be cause for failure. A skillet that requires more than 30 seconds to remove shall constitute a failure.

4.8.3.5. Efficiency: Test the heat transfer efficiency of the Tilt Skillet in accordance with appendix A, method C. A demonstrated efficiency of less than 38% shall constitute a failure.

4.8.4. OVEN, CONVECTION

4.8.4.1. Capacity: Baking Sheets: Verify the capacity of the oven. Failure to be capable of holding 9 half-sized commercial sheet pans on a minimum of 3.25 inch centers shall constitute a failure.

4.8.4.2. Steam table pans compatibility. Verify the oven rack system is can accommodate a minimum of four, six inch deep, full-sized steam table pans. Each pan shall be loaded to 40 lbs.

each. Failure to safely support a full size steam table pan shall constitute a failure.

4.8.4.3. Oven Weight: Weight the complete oven module. A weight of more than 225 pounds shall constitute a failure.

4.8.4.4. Heat Transfer Efficiency: Test the heat transfer efficiency of the oven in accordance with appendix A, test method D. A heat transfer efficiency of less than 36% shall constitute a failure.

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4.8.4.5. Pre-heat time. Initiate the pre-heat cycle with the oven in a cold (70 ± 10ºF) state and the thermostat set to 350ºF. Begin timing at the initiation of the pre-heat and stop timing when the thermostat is satisfied (burner cycles off for the first time), completing the pre-heat cycle. Inability to complete the pre-heat cycle in less than 12 minutes shall constitute a failure.

4.8.4.6. Thermostatic control: Measure the internal oven cavity in three locations with the oven cavity empty of baking pans. Operate the oven at 200ºF, 300 ºF and 400 ºF for 30 minutes at each temperature (not including any preheat time). Verify the average temperature of the three temperature reading does not exceed the range of ±20ºF of the set point. Failure to stay within the specified range shall constitute a failure.

4.8.5. HEATER TANK

4.8.5.1. Footprint. Measure the width of the Heater Tank. A width greater than 65.9 shall constitute a failure.

4.8.5.2. Burner compatibility. Verify that the Heater Tank requires only one burner for operation. Requiring more than one burner shall constitute a failure.

4.8.5.3. Efficiency. Test the efficiency in accordance with appendix A, test method E. An efficiency less than 65% shall constitute a failure.

4.8.5.4. Serving line Capacity: Verify the capacity of standard size steam table pans.

Failure to hold a minimum of five, 6 inch deep standard sized steam pans shall constitute a failure.

4.8.5.5. Height: Measure the normal distance from the floor to the top surface of a steam table pan inserted into the Heater Tank. A measurement less than 36 inches or greater than 38 inches shall constitute a failure.

4.8.5.6. Serving line control. The Heater Tank shall be capable of maintaining food in 5 full sized steam table pans at no less than 160°F indefinitely when the ambient (kitchen) temperature is 50°F and the steam table pans are covered.

4.8.5.7. Sneeze Guard. Verify presence of sneeze guard. Verify sneeze guard is designed and manufactured according design approved in the Critical Design Review. Transportability requirement will be verified during the verification of the Battlefield Kitchen to meet the air transit height requirement as a result of the height of the Heater Tank shall constitute a failure.

4.8.5.8. Drain. Verify the presence and operation of the Heater Tank drain. Missing or a non-functioning valve shall constitute a failure.

4.8.6. REFRIGERATOR:

4.8.6.1. Module Interface: Failure to properly interface with a within specification locking base and the flat surface top shall constitute a failure.

4.8.6.2. Assembly height: Measure the normal distance from the floor to the top surface of the refrigerator. A measurement of outside the range of 36 ± 0.25 inches shall constitute a failure.

4.8.6.3. Power Consumption. See section 6.1.3.

4.8.7. HAND WASH CABINET

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4.8.7.1. Height: The height of the hand wash cabinet assembly shall be measured normal to the floor to the top surface of the sink. A measurement outside the range of 36 to 36.5 inches shall constitute a failure. Configure the sink for transportation. Measure the normal distance from the floor to the highest point of the assembly. A measurement exceeding the required maximum (See section 6.2.7) shall constitute a failure.

4.8.7.2. Fixtures:

4.8.7.2.1. Hand Wash Faucet: Verify that the hand wash sink has a fixture capable of supplying both hot and cold water and a mixture of hot and cold water. Failure to have a fixture meeting this requirement shall constitute a failure.

4.8.7.2.2. Prep-Sink Faucet. Verify that the Hand Wash Cabinet has an auxiliary faucet than can be operated independently from the hand wash sink. Auxiliary faucet not being present shall constitute a failure. Measure the reach of the auxiliary faucet. Failure to reach a point 11 inches from the left edge of the hand wash cabinet (when measured at a point six inches from the rear plane of the hand wash cabinet) shall constitute a failure.

4.8.7.3. Sink size. Measure the hand wash sink dimensions. Width and length measurements shall be taken 1 inch from the top surface of the sink. The depth shall be measured from the deepest part of the sink to the top surface of the sink. Measurements in excess of 14.5 x 11.5 for length x width (order not important) shall constitute a failure. A measurement greater than 6 inches for the depth shall constitute a failure.

4.8.7.4. Flow rate. Connect the hand wash cabinet to a water supply that requires a six foot lift to the floor level of the cabinet. Draw water from the hand wash sink faucet for 60 seconds.

Measure the volume of water drawn. Connect the hand wash cabinet to a water supply to provided 50 psi at the pump inlet. Draw water from the hand wash sink faucet for 60 seconds.

Measure the volume of water drawn. Failure to draw at least 0.75 gallons in either test will constitute a failure.

4.8.7.5. Water heater. Allow water heater to run through a complete heating cycle. When the heater cycles off, draw water from the hand wash faucet for 60 seconds or 0.75 gallons, whichever comes first. Measure the quantity and temperature of the water. A measurement of less than 100°F shall constitute a failure. A measurement of greater than 110°F shall constitute a failure. A volume of water less than 0.75 gallons shall constitute a failure.

4.8.7.6. Electric power: See section 6.2.4.

4.8.7.7. Drain Interface. Verify by inspection that the hand was cabinet interfaces with the

Battlefield Kitchen drain hose. Failure to form a leak free seal without the use of tools shall constitute a failure.

4.8.7.8. Cold Weather. Prepare the hand wash cabinet for cold weather in accordance with the technical manual. Cold soak the hand wash cabinet for 8 hours at a temperature no greater than 25ºF.