mil-std-810: l-3 gcs standard practices & · pdf filetesting issues/non-conformance...

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MIL-STD-810: L-3 GCS Standard Practices & Procedures

Part : 1000-0501-01 Rev: A

Author: M. Dombovy

Date: 12/2/2014 Sheet 1 of 28

MIL-STD-810: L-3 GCS Standard

Practices & Procedures

Revision History

Version Date Notes Author

A 12/2/2014 Initial release. M.Dombovy

This document is not to be shared on Internet

The information contained in this document is proprietary to L-3 Global Communications Solutions, Inc. (L-3 GCS). As such, said information may be used by the recipient solely for the purpose for which it was supplied by L-3 GCS. The recipient may not, under any circumstances, duplicate, use or disclose in any manner whatsoever, in whole or in part, the contents of this document to any other party without first securing the written permission of L-3 GCS.

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Table of Contents

Table of Figures ....................................................................................................................................................................... 4

1. Scope ............................................................................................................................................................................... 5

2. Order of Precedence ....................................................................................................................................................... 5

3. Equipment ....................................................................................................................................................................... 6

3.1. Equipment Orientation ............................................................................................................................................... 6

3.2. Equipment Replacement/Refurbishment/Cleaning ................................................................................................... 6

4. Standard Testing ............................................................................................................................................................. 8

4.1. MIL-STD-810 Test Confirmation .................................................................................................................................. 8

4.2. Standard Testing ......................................................................................................................................................... 8

4.2.1. Visual Test ............................................................................................................................................................... 8

4.2.2. Operational Test...................................................................................................................................................... 8

4.2.3. Testing Issues/Non-conformance (Failure) Reporting ............................................................................................ 8

4.3. Test Equipment Issues ................................................................................................................................................ 9

5. Environmental Tests ..................................................................................................................................................... 10

5.1. 500.5 Low Pressure ................................................................................................................................................... 10

5.1.1. Procedure I – Storage/Air Transport ..................................................................................................................... 10

5.1.2. Procedure II – Operation/Air Carriage .................................................................................................................. 10

5.2. 501.5 High Temperature ........................................................................................................................................... 11

5.2.1. Procedure I – Storage ............................................................................................................................................ 11

5.2.2. Procedure II - Operation ....................................................................................................................................... 11

5.3. 502.5 Low Temperature ............................................................................................................................................ 12

5.3.1. Procedure I – Storage ............................................................................................................................................ 12

5.3.2. Procedure II - Operation ....................................................................................................................................... 12

5.4. 505.5 Solar Radiation (Sunshine) .............................................................................................................................. 13

5.4.1. Procedure I – Cycling ............................................................................................................................................. 13

5.5. 506.5 Rain ................................................................................................................................................................. 14

5.5.1. Procedure I – Rain & Blowing Rain........................................................................................................................ 14

5.6. 507.5 Humidity .......................................................................................................................................................... 16

5.6.1. Procedure II – Aggravated ..................................................................................................................................... 16

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5.7. 509.5 Salt Fog ............................................................................................................................................................ 17

5.8. 510.5 Sand & Dust ..................................................................................................................................................... 18

5.8.1. Procedure I – Blowing Dust ................................................................................................................................... 18

5.8.2. Procedure II – Blowing Sand ................................................................................................................................. 19

6. Dynamic Tests ............................................................................................................................................................... 21

6.1. 514.6 Vibration.......................................................................................................................................................... 21

6.1.1. Procedure I – General Vibration ........................................................................................................................... 21

6.1.1.1. Category 4: Truck/Trailer/Tracked .................................................................................................................... 21

6.1.1.2. Category 7: Aircraft – Jet ................................................................................................................................... 21

6.1.1.3. Category 8: Aircraft – Propeller ........................................................................................................................ 22

6.1.1.4. Category 9: Aircraft – Helicopter ...................................................................................................................... 22

6.1.1.5. Category 10: Ship – Surface Ship ...................................................................................................................... 22

6.1.1.6. Category 11: Railroad – Train ............................................................................................................................ 22

6.1.2. Procedure II – Loose Cargo Transportation .......................................................................................................... 23

6.1.2.1. Category 5: Truck/Trailer .................................................................................................................................. 24

6.2. 516.6 Shock ............................................................................................................................................................... 25

6.2.1. Procedure II – Material to be Packaged ................................................................................................................ 25

6.2.2. Procedure IV – Transit Drop .................................................................................................................................. 27

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Table of Figures

Figure 1 - Default Equipment Orientations ............................................................................................................................. 6

Figure 2 - Category 5: Loose Cargo Typical Test Setup ......................................................................................................... 24

Figure 3 - Suggested Drop Height ......................................................................................................................................... 25

Figure 4 - Transit Drop Test Heights and Number of Drops Requirements .......................................................................... 28

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1. Scope

The objective of this document is to centrally locate the general practices used by L3 GCS to interpret and apply the

testing outlined in MIL-STD-810G. Given the variability in application of the specification it has been determined that a

document outlining L3 GCS’s general practices would be beneficial to the division.

This document is not meant to be used for scheduling purposes related to MIL-810G testing. Many tests require

ramp up/down times as well as variable conditioning periods that may increase the overall length of the test beyond

what is mentioned herein.

2. Order of Precedence

In the event of a conflict between the text of this document and the references cited herein, the text of this

document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a

specific exemption has been obtained.

All MIL-STD-810G variables, processes and test specifics not mentioned herein are to be as stated in MIL-STD-810G.

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3. Equipment

3.1. Equipment Orientation

For tests that require multiple orientations to be exposed, position the equipment as shown unless otherwise

directed. The front of the system is considered to be the front of the reflector.

Figure 1 - Default Equipment Orientations

3.2. Equipment Replacement/Refurbishment/Cleaning

Given the destructive nature of the tests it is permissible, and in some cases advisable, to clean up, replace, and

refurbish equipment between tests. Each test is designed to simulate a lifetime of abuse and can cause issues for

subsequent tests.

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4. Standard Testing

4.1. MIL-STD-810 Test Confirmation

Prior to the start of each test it is required to verify the test parameters with the test technician performing the test.

Given the variability in tests through customer driven requirements there is potential for discrepancy in test times,

temperatures, and other variables that could either over or under expose the items going through the intended test. It is

also advisable to ensure the test facility(s) and assigned test technician(s) have a copy of this document with the current

revision as of the testing start date (unless a required change causes a revision to this document).

4.2. Standard Testing

As an L-3 GCS standard all equipment shall pass a pre-test and post–test (visual, operational, or both). If the

equipment is in an operating mode it shall also be tested (if required per the test) while operating as indicated in each

test’s section. The test plan is to be approved prior to starting MIL-810 testing. It is applicable to use a post-test as a

pre-test when equipment is moving between MIL-STD-810G tests.

4.2.1. Visual Test

A visual test involves inspecting exposed equipment, case functionality, and equipment packed in cases as

applicable. Special care should be taken to observe and take note of damage or any change in the condition of the item

undergoing test. If any damage/change to the test item poses a safety hazard to operational use, discontinue future

testing and contact the responsible party or project lead.

4.2.2. Operational Test

In addition to the visual test we require an operational test. The approved test plan will outline the required tests for

the item or system undergoing test.

4.2.3. Testing Issues/Non-conformance (Failure) Reporting

In the event of complications with equipment the person conducting the pre/post test should contact the Project

Engineer in charge of the system in attempts to work through any issues that they may be experiencing. Before

contacting the Project Engineer to verify non-compliance (failure) there should be no communication of non-

conformance to the facility conducting the test. It is very important to fully verify non-conformance prior to disclosure.

Once a failure has been reported it cannot be reversed and the test will need to be repeated.

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4.3. Test Equipment Issues

Given the nature of L-3 GCS equipment setups there maybe components involved that are used to test the

equipment of interest. These other components shall be considered “test equipment” and are not part of the equipment

of interest undergoing test. In the event of an issue testing the equipment of interest due to a test equipment problem

or failure, all steps should be taken in attempts to continue the test and to prove out the equipment of interest per the

test plan. These steps usually involve other methods to communicate to or operate the equipment of interest that are

different from the initial test plan. Past issues have arisen from aged test equipment components that have passed

through MIL-STD-810G before that eventually fail.

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5. Environmental Tests

5.1. 500.5 Low Pressure

5.1.1. Procedure I – Storage/Air Transport

This test is designed to simulate low pressure scenarios in an as-packed configuration (i.e. air cargo

transport). Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 1 hour

Equipment Configuration: Packed in transit case(s)

Cabin Altitude (Pressure): 57.2 kPa (8.3 psi) simulating a height of 15,000 feet

Temperature: 25°C (77°F)

Required Testing: 1. Pre-test visual and operational

2. Post-test visual and operational

5.1.2. Procedure II – Operation/Air Carriage

This test is designed to simulate low pressure scenarios in an operational configuration (i.e. high altitude

deployment).

Test Duration: 1 hour

Equipment Configuration: Setup for operation (deployed) and running

Cabin Altitude (Pressure): 57.2 kPa (8.3 psi) simulating a height of 15,000 feet


Required Testing: 1. Pre-test visual and operational (deployed in chamber)

2. After 1 hour while at specified pressure and temperature conduct an

operational test

3. Post-test visual and operational (deployed in chamber)

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5.2. 501.5 High Temperature

5.2.1. Procedure I – Storage

This test is designed to simulate high temperature scenarios in an as-packed configuration (i.e. non-air-

conditioned transport). For this procedure temperature probes should be placed inside each case. Stabilization

occurs when all probes have reached the desired temperature. Unless otherwise specified the default L-3 GCS

test scenario is as follows:

Test Duration: 2 hours following temperature stabilization of the equipment via probes


Temperature: 72°C (161.6°F)



5.2.2. Procedure II - Operation

This test is designed to simulate high temperature scenarios in an as-packed configuration (i.e. desert

operation). Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 6 hours following temperature stabilization of the chamber




2. After 2 hours following temperature stabilization conduct an

operational test


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5.3. 502.5 Low Temperature

5.3.1. Procedure I – Storage

This test is designed to simulate low temperature scenarios in an as-packed configuration (i.e. non-

heated transport). For this procedure temperature probes should be placed inside each case. Stabilization

occurs when all probes have reached the desired temperature. Unless otherwise specified the default L-3 GCS


Test Duration: 2 hours following temperature stabilization of the equipment via probes


Temperature: -46°C (-50.8°F)



5.3.2. Procedure II - Operation

This test is designed to simulate high temperature scenarios in an as-packed configuration (i.e. arctic

operation). Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 6 hours following temperature stabilization of the chamber


Temperature: -32°C (-25.6°F)


2. After 2 hours following temperature stabilization conduct an

operational test


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5.4. 505.5 Solar Radiation (Sunshine)

5.4.1. Procedure I – Cycling

This test is designed to simulate high temperature scenarios during exposure to solar radiation.

Although our systems are often deployed in areas of high solar radiation it has been determined that the worst

case temperatures will be observed in an as-packed configuration (i.e. case on tarmac). Temperature probe(s)

are to be placed in the center most position in the case that’s accessible with-out modification to the case or

equipment. Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: Minimum of 3-7 cycles (1 cycle = 24 hours) until repeated peak

temperatures are reached (measured via probe(s))


Climatic Conditions: Worldwide Deployment (Cycle A1: peak loads of 1120 W/m2 and 49 C,

not concurrently)

Air Flow: 1.5 to 3.0 m/s (300 to 600 ft/min) across the test item(s)


2. Post-test visual1 and operational

Operational Testing: Given the specific nature and interpretation required, operational solar

tests should be configured for each project independently.

1 Make note of any changes to any item either internal or external (ex. deterioration of foam). Use the operational test to evaluate pass/fail criteria.

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5.5. 506.5 Rain

5.5.1. Procedure I – Rain & Blowing Rain

This test is designed to measure the effectiveness of our equipment in preventing the penetration of

water that negatively impacts the performance of our equipment (i.e. operation in precipitation). Unless

otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 30 minutes per exposed face

Equipment Configuration: Setup for operation2 (deployed) and not running

Orientation: See Figure 1 - Default Equipment Orientation

Rainfall Rate: 1.7 mm/min (4 in/hr)

Wind Velocity: 18 m/s (40 mph)




Transit Case Provision: It is required to test transit cases that have not yet gone through 506.5

Rain Procedure I – Rain & Blowing Rain during prior testing. The

objective of this test is to ensure the transit case and, if applicable,

internal equipment remains operational (i.e. no harmful deposit or

corrosion and the handles/wheels function as intended). The process

outline above remains the same however there are two scenarios

detailed below that are to be defined for each case:

Scenario A – Water ingress acceptable

Scenario B – Water ingress not-acceptable

2 If the test facility chamber is not big enough to have the test item deployed it is acceptable to test each major sub component individually.

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5.6. 507.5 Humidity

5.6.1. Procedure II – Aggravated

This test is designed to simulate the effects of a warm and humid environment (i.e. tropical operation).

This test does not simulate a naturally environment and is meant only as a way to accelerate the effects of

humidity. Given the 60 C temperature during the cycle equipment is set only to run during the operational tests

mentioned blow. It is not advisable to conduct humidity testing on equipment that has passed through or will

pass through salt fog, sand, and dust testing. If the operational check requires handling the chamber door can be

opened for up to 30 minutes. Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 10 cycles following 1 conditioning cycle (1 cycle = 24 hours)

Equipment Configuration: Setup for operation (deployed), only running to conduct tests

Temperature: Varies between 30-60°C (86-140°F)

Relative Humidity: Constant 95% (following conditioning cycle)


2. At the end of the 5th cycle conduct an operational test

3. At the end of the 10th cycle conduct an operational test



Humidity Procedure II – Aggravated during prior testing. The objective

of this test is to ensure the transit case and, if applicable, internal

equipment remains operational (i.e. no harmful deposit or corrosion

and the handles/wheels function as intended). The process outline

above remains the same however there are two scenarios detailed

below that are to be defined for each case:

Scenario A – Water ingress acceptable

Scenario B – Water ingress not-acceptable

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5.7. 509.5 Salt Fog

This test is designed to measure the effectiveness of protective coatings and finished on our equipment

and the effects of salt deposits that negatively impacts the performance of our equipment (i.e. operation in

maritime). Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 24-hour exposure, 24-hour dry, 24-hour exposure, 24-hour dry


Temperature: 35 ± 2°C (95 ± 4°F)



Rust/Corrosion: Rust is okay as long as it does not affect performance or function. An

action should be taken to record the affected areas.


Salt Fog during prior testing. The objective of this test is to ensure the

transit case and, if applicable, internal equipment remains operational

(i.e. no harmful deposit or corrosion and the handles/wheels function as

intended). The process outline above remains the same however there

are two scenarios detailed below that are to be defined for each case:

Scenario A – Water/Salt ingress acceptable

Scenario B – Water/Salt ingress not-acceptable


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5.8. 510.5 Sand & Dust

5.8.1. Procedure I – Blowing Dust

This test is designed to measure the effectiveness of our equipment to resist the effects of dust that

negatively impacts the performance of our equipment (i.e. long durations of operation). Unless otherwise

specified the default L-3 GCS test scenario is as follows:

Test Duration: 6-hour ambient, 6-hour elevated


Temperature: 25-55°C (77-131°F)


Our default orientation requires all four sides (not the top or bottom) to

be directed at the oncoming flow. This test will split up the each 6 hour

test (ambient and high temperature) into 4, 1.5 hour tests on each face

indicated, unless otherwise indicated.


2. Post-test visual and operational (deployed in chamber) (brushing,

shaking or wiping away of dust is acceptable)


Sand & Dust Procedure I – Blowing Dust during prior testing. The






Scenario A – Dust ingress acceptable

Scenario B – Dust ingress not-acceptable


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5.8.2. Procedure II – Blowing Sand

This test is designed to measure the effectiveness of our equipment to resist the effects of sand that

negatively impacts the performance of our equipment (i.e. desert operation). Unless otherwise specified the

default L-3 GCS test scenario is as follows:

Test Duration: 90 minutes per exposed face




Our default orientation requires all four sides (not the top or bottom) to

be directed at the oncoming flow. This test will consist of 4, 1.5 hour

tests on each face indicated, unless otherwise indicated.

Sand Concentration: 2.2 ± 0.5 g/m3 (Concentration “a”)


2. Post-test visual and operational (deployed in chamber) (brushing,

shaking or wiping away of sand is acceptable)


Sand & Dust Procedure II – Blowing Sand during prior testing. The






Scenario A – Sand ingress acceptable


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Scenario B – Sand ingress not-acceptable

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6. Dynamic Tests

6.1. 514.6 Vibration

6.1.1. Procedure I – General Vibration

This test is designed to measure the effectiveness of our packed transit cases to resist the effects

vibration damage and that negatively impacts the performance of our equipment (i.e. secured transportation).

Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: See each category below

Equipment Configuration: Packed in transit case(s), secured to vibration table, see below for

orientation(s)

Temperature: Ambient

Special Notes: 1. Multiple cases can be tested at the same time pending table size.

2. Case damage is to be expected and should not be considered a failure

if the equipment inside functions as intended.

3. Equipment damage does not necessarily indicate a failure. Consult

the responsible party or project lead for determination.


2. Post-test visual (note & photograph damage explicitly) and

operational

6.1.1.1. Category 4: Truck/Trailer/Tracked

Vibration Profile: Category 4: Truck/Trailer/Tracked, per MIL-STD-810G

Test Duration: 1 hour per axis (Simulation of 1000 miles)

Case Orientation: Perform vibrations in X, Y, and Z axes

6.1.1.2. Category 7: Aircraft – Jet

Vibration Profile: Category 7: Aircraft – Jet, per MIL-STD-810G

Test Duration: 1 hour per axis (1 minute per takeoff, 60 takeoffs assumed from LCEP)


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6.1.1.3. Category 8: Aircraft – Propeller

Vibration Profile: Category 8: Aircraft – Propeller, per MIL-STD-810G

Test Duration: 1 hour per axis (given)


6.1.1.4. Category 9: Aircraft – Helicopter

Vibration Profile: Category 9: Helicopter – Propeller, per MIL-STD-810G

Test Duration: 4 hours per axis (assumed from LCEP)


6.1.1.5. Category 10: Ship – Surface Ship

Vibration Profile: Category 10: Ship – Surface Ship, per MIL-STD-810G

Test Duration: 2 hours per axis (assumed from LCEP)


6.1.1.6. Category 11: Railroad – Train

Vibration Profile: Category 10: Railroad – Train, per MIL-STD-810G

Test Duration: 10 hours per axis (given)


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6.1.2. Procedure II – Loose Cargo Transportation

This test is designed to measure the effectiveness of our packed transit cases to resist the effects

damage and that negatively impacts the performance of our equipment (i.e. loose freight transportation).

Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: See each category below

Equipment Configuration: Packed in transit case(s), loose on package tester, contained by fencing


Special Notes: 1. Multiple cases can be tested at the same time pending table size

2. Case damage is to be expected and should not be considered a failure

if the equipment inside functions as intended


2. Optional mid-test (between each axis) visual and operational


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6.1.2.1. Category 5: Truck/Trailer

Vibration Profile: Category 5: Truck/Trailer – Loose Cargo, per MIL-STD-810G

Test Duration: 20 minutes per axis (given)

Case Orientation: Orient case in normal position, perform test in X and Y axes only

Special Notes: 1. Test bed should be made of cold rolled steel with no protrusions

2. Fencing should be at least 5 cm above the tops of the equipment

being tested and close enough to not allow the equipment to “walk

away” from each other

Figure 2 - Category 5: Loose Cargo Typical Test Setup

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prohibited without

written approval

from L-3 GCS.


Part : 1000-0501-01 Rev: A

Author: M. Dombovy

Date: 12/2/2014 Sheet 25 of 28

6.2. 516.6 Shock

6.2.1. Procedure II – Material to be Packaged

This test is designed to measure the effectiveness of our packed transit cases when placed in/on a

shipping container to resist the effects damage and that negatively impacts the performance of our equipment

(i.e. pallet transportation). Unless otherwise specified the default L-3 GCS test scenario is as follows:

Test Duration: 3 shocks in each direction along each of the X, Y, and Z axes

See Figure 3 below for drop heights

Equipment Configuration: Packed in transit case(s), secured to shock machine platform

Pulse (Shock) Type: Half Sine (the equipment required to conduct a trapezoidal pulse is

more expensive and rare, it has been determined that the half sine is an

appropriate substitute)


Special Notes: 1. Case damage is to be expected and should not be considered a failure





Figure 3 - Suggested Drop Height

7640 OMNITECH PLACE


PH: 585-742-9100

FX: 585-742-1914

Use or disclosure

of data contained

on this sheet is

prohibited without

written approval

from L-3 GCS.


Part : 1000-0501-01 Rev: A

Author: M. Dombovy

Date: 12/2/2014 Sheet 26 of 28

7640 OMNITECH PLACE


PH: 585-742-9100

FX: 585-742-1914

Use or disclosure

of data contained

on this sheet is

prohibited without

written approval

from L-3 GCS.


Part : 1000-0501-01 Rev: A

Author: M. Dombovy

Date: 12/2/2014 Sheet 27 of 28

6.2.2. Procedure IV – Transit Drop

This test is designed to measure the effectiveness of our packed transit cases subjected to shocks from

accidental drops or induced by loading and unloading to resist the effects of damage and that negatively impacts

the performance of our equipment (i.e. pallet transportation). Unless otherwise specified the default L-3 GCS


Test Duration: See Figure 4 below for number of drops and height requirements



Special Notes: 1. Case damage is to be expected and should not be considered a failure


2. Tests that require 26 drops can be divided among 5 test items

3. Operational tests can be administered after each drop or number of

drops if desired (this can help with when to substitute in new test items

or material)




(See next page for Figure 4 - Transit Drop Test Heights and Number of Drops Requirements)

7640 OMNITECH PLACE


PH: 585-742-9100

FX: 585-742-1914

Use or disclosure

of data contained

on this sheet is

prohibited without

written approval

from L-3 GCS.


Part : 1000-0501-01 Rev: A

Author: M. Dombovy

Date: 12/2/2014 Sheet 28 of 28

Figure 4 - Transit Drop Test Heights and Number of Drops Requirements

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