Technical_Requirement_Document_(TRD)_Chamber_Controller.docx

TECHNICAL REQUIREMENTS DOCUMENT

FOR

300 SERIES CHAMBER CONTROLLER

WEST DESERT TEST CENTER

DUGWAY PROVING GROUND

DUGWAY, UTAH 84022

PREPARED BY:

JIM BARNETT

Chief, Physical & Environmental Branch MIL-STD-810 Test Section Test Support Division 21 March 2017

1. Background: Dugway Proving Ground (DPG) has ten (10) each 300 Series environmental conditioning chambers that are used to condition test items. The 300 Series chambers are located mostly in and round Carr Facility area. The chamber controllers and Human Interface (HMI) systems in the 300 Series chambers are over 12 years old and are not supported anymore, and the life cycle of most controllers is 5 to 6 years. The existing controllers are out dated. Over the past few years DPG has started upgrading most of its chamber controllers with the National Instruments cRIO-9068 controller with I/O modules additional temperature and humidity channels. The upgraded chamber controllers have been programed to operate the chambers using National Instruments Lab View system. However, in order for the controller to be able to control the chambers within the required ranges; execution codes had to be developed and proven for the cRIO-9068 controllers. The required execution codes were developed and proven out by Mallory Engineering Inc.

2. Description of Service/Supplies: The contractor shall provide new cRIO-9068 controller systems for each 300 Series environmental chamber. The new controllers to be installed shall be the same type as installed in the vibration environmental chambers at DPG. The controllers are a National Instruments cRIO-9068 controller with compatible I/O modules. The new controllers shall have a remote access capability and will be compatible with the Central Data Acquisition Control Center (CDACC) software on the central chamber system. The new controller shall provide a Human Machine Interface (HMI) in each 300 Series chamber to allow operators full capability of control in the chamber control room. Although the National Instruments cRIO-9068 is the controller that will be the physical hardware that is used to control the 300 Series environmental chambers, it is the computer program function codes and data logging software which is used to make the physical controller work and provides the HMI required to control the environmental chamber. The control and data logging software in use at DPG was developed by Mallory Engineering, Inc. using National Instrument’s Lab View and is proprietary. In order to accomplish the task of replacing ten (10) each chamber controllers, and the cost, this task will be conducted in 3 phases, with one phase per year subject to availability of funding.

3. General: This specification describes the cRIO-9068 environmental chamber controller and required data lines to support, control, function, and operate the 300 series environmental conditioning chambers, when conducting temperature and humidity testing in accordance with (IAW) MIL-STD-810G temperature and humidity limits. The controller shall have the capability to perform 810G Methods 501, 502, and 507 with control of the chamber temperature and humidity. The contractor’s proposal shall include sufficient conceptual equipment configuration drawings and schematics to permit technical evaluation of the proposed equipment. The environmental chamber controller requirements described below will be capable of controlling temperature and humidity and performing a number of data collection function at the same time. The controller and its saftware shall be required to operate, control, and collect the required data during a test operation in accordance with MIL-STD-810G, “Environmental Engineering Considerations and Laboratory Tests”, Methods 501, 502, and 507

3.1 In addition to meeting the 810G test profile requirements, the cRIO-9068 will be configured to meet the requirements in the following paragraphs governing test chamber functions and operation.

3.2 The contractor shall configure the cRIO-9068 controller and required I/O modules to perform chamber control and data collection. All chamber data shall be able to be downloaded to a chamber operator computer and saved into an Excel program.

3.3 The cRIO-9068 controller shall be configured to perform ramping and step profile control and save chamber operation profiles that are designed and programed into the controller by the chamber operator.

3.4 The controller must be configured to interface with each subsystem i.e. heaters, humidity and dehumidity, high temperature and low temperature, and all other systems. To provide a way to turn each system on and off, set min and max limits for each systems with time loops for setting off alarms. The controller must be able to shut down any system that goes into alarm and activate the chamber alarm system and to enter the type of alarm on to the alarm windo of the HMI.

3.5 There are between 100 to 120 different signals that would be involved in intergrating the required controller into the chamber system. A number of PID functions will be required in order to operate and control the chamber functions in order to meet the MIL-STD-810 requirements.

3.6 The contractor shall operate the 300 series chamber and verify that all equipment and subsystems are operational and report the results to the COR prior to conducting any other operations of this tasking. Upon completion and verification of system operational status the contractor will remove the existing chamber controller, failsafe controller, datalogger, and recorder from each 300 series chamber.

3.7 The contractor shall label all wiring, switches, controls, and any other item removed and/or replaced. The contractor shall remove and replace all wiring as needed or required to connect the required probes, sencers, and transducers as required.

3.8 The contractor will perform the required function and install work at his/her facility or on site at DPG. If the contractor performs the required work at his/her facility the contractor shall be required to transport the chambers to his/her facility and back to DPG.

4. Procurement of Controllers and Hardware (CLIN 0001)

4.1 The contractor shall procure the required number of cRIO-9068 units required to meet the requirements of this contract per year. The required number controllers per year are as follows: Base Period, four (4) each cRIO-9068 units, Ordering period 1, three (3) each cRIO-9068 units; and Ordering Period 2, three (3) each cRIO-9068 units.

4.2 Each cRIO-9068 will be configured to support the following channels for control and data collection:

a. Two (2) each RTD channels for temperature control that is equal to are greater than the temperature range of (+200oF to a -100oF) with an accuracy of +2oF

b. Two (2) each humidity channels for humidity control that is equal to are greater than the humidity range of (1% to 100%) and with an accuracy of +5% RH

c. Eight (8) each RTD channels for data collection that is equal to are greater than the temperature range of (+200oF to a -100oF) with an accuracy of +2oF

d. Eight (8) each k type thermocouple channels for data collection that is equal to are greater than the temperature range of (+200oF to a -100oF) with an accuracy of +2oF

e. Two (2) each humidity channels for humidity data collection that is equal to are greater than the humidity range of (1% to 100%) and with an accuracy of +5% RH

4.3 The contractor shall procure all hardware and materials required to make the required installation of the controllers and to make all connections to the subsystems in order to control the temperature and humidity operation of the 300 series chamber IAW the MIL-STD-810G requirements including but not limited to i.e. bolts, sheet metal, wiring, paint, probes, connectors, controllers, transducers, pressure gages, and sencers as required to be compatable with the cREO-9068 controller system.

4.4 The contractor shall provide a new Temperature Failsafe controller that is compatible with the cRIO-9068 controller.

4.5 The contractor shall provide a new panel face to support the cRIO-9068 controller, Failsafe, HMI, power switch, and any other system required.

4.6 The contract shall provide a 17-inch LCD tuch screen HMI for each 300 series chamber. The HMI shall be mounted in the face panel of the control cabnit.

4.7 The contractor shall provide and replace any required suction, discharge, and oil pressure transducers for all three (3) refrigeration systems that are not compatible with the cRIO-9068 controller and I/O modules system.

4.8 The contractor shall provide current transducers on the circulation fan, air heater, boiler, and dehumidifier, air cooled condenser, and all three refrigeration compressors, and interface with the cRIO-9068 controller and I/O modules as required.

4.9 The contractor shall provide Suction, Discharge and Oil pressure transducers on all three (3) refrigeration systems and interface with the cRIO-9068 controller and I/O modules as required.

4.10 The contractor shall provide Suction and Discharge temperature probes on all three refrigeration systems and interface with the cRIO-9068 controller and I/O modules as required.

4.11 The contractor shall provide a panel box with eight (8) each RTD connectors, eight (8) each K-type thermocouple connectors, and two (2) each humidity probe connectors. The panel box shall be connected to the cRIO-9068 controller for data collection.

4.12 The contractor shall provide 2 printed copies of the revised schematics, and 1 digital copy, a backup copy of the as deployed control application, and provide a standard warranty on all new components.

5. Installation and Delivery of Chamber Controllers (CLIN 0002)

5.1 The contractor shall install the required cRIO-9068 controllers and all required I/O modules in the chamber control room control cabinet and integrate each controller into the environmental chamber sub-systems.

5.2 The contractor shall install the two (2) RTD probes required for temperature control. The control probes shall have the capability to be located in the chamber head wall or to any location inside the chamber compartment in order to control the chamber temperature from any location within the chamber compartment. The control RTDs shall be able to pass through the pass through tubes of the chamber head wall.

5.3 The contractor shall install the two (2) humidity probes required for humidity control of the chamber. The humidity control probes shall have the capability to be located in the chamber head wall or to any location inside the chamber compartment in order to control chamber humidity from any location within the chamber compartment. The humidity control probes shall be able to pass through the pass through tubes of the chamber head wall.

5.4 The contractor shall install a new panel face to support the cRIO-9068 controller, Failsafe, HMI, power switch, and any other system required. The control cabinet panel shall have the required markings and equipment and connections.

5.5 The contractor shall install a panel box on the chamber head wall as required. The contractor shall install the required eight (8) each RTD connectors, eight (8) each K-type thermocouple connectors, and two (2) each humidity probe connectors into the panel box. The contractor shall install the required wiring from the connectors in the panel box to the cRIO-9068 controller and required I/O modules.

5.6 The contractor shall install the required Temperature Failsafe controller in to the chamber control panel. The temperature failsafe controller shall be compatible with the cRIO-9068 controller and intergraded into the chamber control system.

5.7 The contractor shall install a 17-inch LCD HMI for each 300 series chamber. The HMI shall be installed in the chamber control panel and connected to the cRIO-9068 controller as required.

5.8 The contractor shall install any required suction, discharge, and oil pressure transducers for all three (3) refrigeration systems that are not compatible with the cRIO-9068 controller and I/O modules system.

5.9 The contractor shall install the current transducers on the circulation fan, air heater, boiler, and dehumidifier, air cooled condenser, and all three refrigeration compressors, and interface with the cRIO-9068 and I/O modules as required.

5.10 The contractor shall install Suction, Discharge and Oil pressure transducers on all three refrigeration systems and interface with the cRIO-9068 controller and I/O modules as required.

5.11 The contractor shall install Suction and Discharge temperature probes on all three refrigeration systems and interface with the cRIO-9068 controller and I/O modules as required.

5.12 The contractor shall operate the new controller and verify that systems and installed items function as required. This is to be verified by the end user and COR.

6. Commercial Drawings/Models/Software and Associated List (CLIN 0003)

6.1 The contractor shall provide all documentation in both digital and hard copy for each of the following areas: operator instructions manuals, two sets of installation and equipment electrical/mechanical drawings and operator maintenance manuals, and suggested repair parts list to be maintained on hand. Contractor will provide a one year commercial warranty and technical support with price quote. Quote shall specify FOB Destination: US Army West Desert Test Center facility located at Dugway Proving Ground, Dugway Utah.

6.2 The contractor shall provide two (2) printed copies of the revised schematics, and one (1) digital copy, a backup copy of the as deployed control application, and provide a standard warranty on all new components

7. Acceptance Test Plan (CLIN 0004)

7.1 The Contractor will conduct a pre delivery test of the chamber at the contractor’s facility before delivery to DPG at no additional cost. The contractor shall conduct an acceptance test of each 300 series chamber with the new cRIO-9068 controllers after the completion of the installation. The acceptance test plan will be provided by the government. This testing will include demonstration of the cRIO-9068 controller ability to operate the 300 series chamber in accordance with the required MIL-STD 810G, Methods 501, 502, and 507 specifications. It will include demonstration of the cRIO-9068 controller and the required I/O modules can operation and control the temperature and humidity inside the chamber within the required limits, provide required data from each of the systems, and collect the required test data. The contractor shall perform both a ramping profile and a step profile for each of the three (3) different MIL-STD-810 Methods. Each profile will cover 24 hour. The contractor shall input the profiles provided by the government for each test. The contractor shall operate the chamber and collect the test data using the cRIO-9068 controller system and provide the test data to the COR for review. Government reserves the right to refuse acceptance of the equipment that does not meet performance specifications.

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