Attachment 0002 Purchase Description_PD Sheets 071524.pdf

PURCHASE DESCRIPTION

DEPLOYABLE POWER GENERATION & DISTRIBUTION

SYSTEM (DPGDS)

PRIME POWER DISTRIBUTION SYSTEMS (PPDS),

GENERAL SPECIFICATION FOR

15 July 2024

Prepared by:

Project Manager, Expeditionary Energy & Sustainment Systems Product Lead, Large Power Systems

ATTN: SFAE-CSS-E2-L

5850 Delafield Road, Building 324

Fort Belvoir, VA 22060-5863

DISTRIBUTION STATEMENT A. Distribution approved for public release: distribution is unlimited. 30 May 2024. Other requests for information per this document must be referred to PM E2S2/ PdL LPS, 5850 Delafield Road, Fort Belvoir, VA 22060.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

i

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: Project Manager, Expeditionary Energy & Sustainment Systems, Product Lead, Large Power Systems (PdL LPS), Attn: SFAE-CSS-E2-L, 5850 Delafield Road, Ft.

Belvoir, VA 22060-5809, or email albert.lyou.civ@army.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil/online/start/.

PD 6110-0136

PPDS PD

15 July 2024

PURCHASE DESCRIPTION

DEPLOYABLE POWER GENERATION & DISTRIBUTION SYSTEM (DPGDS)

PRIME POWER DISTRIBUTION SYSTEMS (PPDS)

GENERAL SPECIFICATION FOR

1. SCOPE.

1.1 Scope.

This Purchase Description (PD) covers the requirements for the Prime Power Distribution Systems (PPDS) for the Deployable Power Generation & Distribution System (DPGDS).

The PPDS enables the transformation and distribution of medium voltage power (4160 VAC or 13.8 kVAC), produced by the Deployable Power Generation & Distribution System (DPGDS) generator sets, to the 120/208V user loads. The PPDS end items include the improved Primary Switching Center (iPSC), improved Secondary Distribution Center Version 1 (iSDC-1), improved Secondary Distribution Center Version 2 (iSDC-2), and Tactical Prime Power Transformer (TPPT).

1.2 Classification.

PPDS end items will be of the following types, as specified in the applicable slash sheet.

o Type I – FSC 6110, Switching systems.

o Type II – FSC 6120, Distribution systems.

o Type III – FSC 6120, Transformer systems.

2. APPLICABLE DOCUMENTS.

General. The documents listed in this section are specified in section 3 and 4 of this PD.

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 of documents cited in section 3 and 4 of this PD.

2.1 Government Documents.

Specifications and 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 cited in the solicitation or contract.

SPECIFICATIONS

FEDERAL

A-A-55804 Rods, Ground (with Attachments).

FED-STD-H28 Screw-Thread Standards for Federal Services

PPDS PD

15 July 2024

MILITARY

MIL-DTL-53072

Chemical Agent Resistant Coating (CARC) System Application Procedures and Quality Control Inspection.

MIL-DTL-22992

Connectors, Plugs and Receptacles, Electrical, Waterproof, Quick Disconnect, Heavy Duty Type General Specification for.

MIL-DTL-53039

Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant.

MIL-DTL-64159

Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant.

MIL-L-85762

Lighting, Aircraft, Interior, Night Vision Imaging System (NVIS) Compatible.

MIL-PRF-32349

Performance Specification Container, Cargo Triple Container (Tricon) (Without Cabinets, Drawers, or Shelves)

MS90555

Connector, Receptacle, Electrical, Wall Mounting, Class L (Power Source Receptacle).

STANDARDS

MILITARY

MIL-STD-129 Military Marking for Shipment and Storage.

MIL-STD-130 Identification Marking of U.S. Military Property.

MIL-STD-209 Lifting and Tiedown Provisions.

MIL-STD-461

Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment.

MIL-STD-705 Mobile Electric Power Systems

MIL-STD-810

Environmental Engineering Considerations and Laboratory Tests.

MIL-STD-882 System Safety.

MIL-STD-889 Galvanic Compatibility of Electrically Conductive Materials MIL-STD-1366 Interface Standard for Transportability Criteria.

MIL-STD-1472

Department of Defense Design Criteria Standard: Human Engineering.

MIL-STD-1791 Designing for Internal Aerial Delivery in Fixed Wing Aircraft.

MIL-STD-2073-1 Standard Practice for Military Packaging.

MIL-STD-3056

Design Criteria for Chemical, Biological, And Radiological System Contamination Survivability.

MIL-STD-3071 Tactical Microgrid Communications and Control

HANDBOOKS

MILITARY

MIL-HDBK-784

Guidelines: Designs to Minimize Contamination and to Facilitate Decontamination of Military Vehicles and Other Equipment:

Interiors and Exteriors.

MIL-HDBK-831 Preparation of Test Reports.

MIL-HDBK-1857 Grounding, Bonding, and Shielding Design Practices.

MIL-HDBK-863 Wiring Data and System Schematic Diagrams Preparation Of

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the ASSIST Database located at https://quicksearch.dla.mil/qsSearch.aspx)

* (Application for copies of the above classified standard is available to personnel with the appropriate security clearance from the contracting activity or as directed by the Contracting Officer.)

2.2 Other Government Documents, Drawings, and Publications.

The following Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues shall be those in effect on the date of the solicitation.

AR 700-145 Item Unique Identification.

AR 750-1 Army Materiel Maintenance Policy.

AR 750-43 Army Test, Measurement and Diagnostic Equipment (TMDE) AR 750-59 Corrosion Prevention and Control for Army Materiel.

DoDI 4151.22 Condition-Based Maintenance Plus for Materiel Maintenance.

CATALOGS AND MANUALS

FM 3-11.4

Multiservice Tactics, Techniques, and Procedures for Nuclear, Biological and Chemical (NBC) Protection.

FM 3-11.5

CBRN Decontamination – Multiservice Tactics, Techniques and Procedures for Chemical, Biological, Radiological and Nuclear Decontamination.

SDDCTEA Modal Instruction 19 Rail (MI-19 Rail)

Tiedown Instructions for Rail Movements

SDDCTEA Modal Instruction 20 Truck (MI-20 Truck)

Tiedown Instructions for Truck Movements

SDDCTEA Modal Instruction 24 Airlift (MI-24 Airlift)

Vehicle Preparation Instructions for Airlift

SDDCTEA Transportability Instruction 70-47 (TI 70-47)

Engineering for Transportability Program

DRAWINGS

69-692 Terminal load 13229E6303 Data Plate Feeder Center 200AMP/PH 04-21023 Plate, Lifting and Tie down 04-21078 Plate, UID Identification 04-40160 Receptacle, Single Pole Male, w/Stud 04-40162 Receptacle, Single Pole Female, w/Stud 04-40164 Cover, Snap Back, Single Pole

(Copies of specifications, standards, handbooks, drawings, publications, and other Government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Officer).

2.3 Non-Government Publications.

The following documents form a part of this PD to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z535.2 Environmental and Facility Safety Signs.

ASQ/ANSI Z1.4 Sampling Procedures and Tables for Inspection by Attributes.

(Copies can be obtained at https://ansi.org)

ASSOCIATION OF AMERICAN RAILROADS (AAR)

AAR OTLR Sec 6 Open Top Loading Rules (OTLR) Manual Section 6 – Rules for Loading Military Equipment and Materiel

(Copies can be obtained at https://my.aar.org/OTLR)

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

IEEE C2 National Electrical Safety Code (NESC)

IEEE C37.74

Requirements for Subsurface, Vault, and Padmounted Load- Interrupter Switchgear and Fused Load-Interrupter Switchgear for Alternating Current Systems up to 38 kV.

IEEE C37.112

IEEE Standard Inverse-Time Characteristic Equations for Overcurrent Relays

IEEE C37.121

IEEE Guide for Switchgear – Unit Substation – Requirements and Underwriters Laboratories (UL) 1062; Standard for Safety – Unit Substations.

IEEE C57.12.90

Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers.

IEEE/ANSI 315 Graphic Symbols for Electrical and Electronics Diagrams.

IEEE/ANSI 315A

Supplement to Graphic Symbols for Electrical and Electronics Diagrams.

IEEE 386

Separable Insulated Connector Systems for Power Distribution Systems Rated 2.5 kV through 35 kV

(Copies can be obtained at https://www.ieee.org)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1496-1

Series 1 freight containers — Specification and testing —Part 1:

General cargo containers for general purposes

(Copies can be obtained at https://www.iso.org)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ST 20 Dry Type Transformers for General Applications (DoD adopted).

ANSI/NEMA WD 6 Wiring Devices – Dimensional Specifications

(Copies can be obtained at https://www.nema.org)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code (NEC) NFPA 70E Standard for Electrical Safety in the Workplace

(Copies can be obtained at https://www.nfpa.org)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) INTERNATIONAL

AMS-STD-595A Colors Used in Government Procurement

SAE AS12500

Corrosion Prevention and Deterioration Control in Electronics Components and Assemblies

(Copies can be obtained at https://www.sae.org)

UNDERWRITERS LABORATORIES (UL) STANDARDS & ENGAGEMENT

UL 67 Standard for Safety Panelboards

UL 94

Tests for Flammability of Plastic Materials for parts in Devices and Appliances

UL 1062 Standard for Unit Substations UL 1691 Single Pole Locking-Type Separable Connectors

UL 60950-1

Information Technology Equipment – Safety – Part 1: General Requirements

(Copies can be obtained at https://www.shopulstandards.com)

2.4 Order of Precedence.

Unless otherwise noted herein or in the contract, 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.

3. REQUIREMENTS.

3.1 PD Slash Sheets.

The individual set requirements shall be as specified herein and in accordance with (IAW) the applicable PD sheet. In the event of any conflict between the requirements of this PD and the PD sheets, the latter shall govern. The PPDS end item slash sheets are as follows:

PD 6110-0136/1

Improved Primary Switching Center (iPSC), 600A, 15.5kV;

Model #: MEPDS-1031

PD 6110-0136/2

Improved Secondary Distribution Center, 150 kilovolt-ampere (KVA), Reconnectable Voltage (4160 VAC and 13.8 KVAC);

Model #: MEPDS-3131

PD 6110-0136/3

Improved Secondary Distribution Center, 150 kilovolt-ampere Fixed Voltage (4160 VAC); Model #: MEPDS-3132

PD 6110-0136/4

Tactical Prime Power Transformer (TPPT) 500 kilovolt-ampere (KVA); Model #: MEPDS-2131

3.2 Reliability.

The minimum acceptable mean time between essential function failures (MTBEFF) for all PPDS end items shall be 3400 hours with an 80% lower confidence limit.

3.3 Test Models.

3.3.1 Preproduction Models.

When specified, the contractor shall furnish preproduction models of each end item specified in 3.1 and quantities specified by the contracting officer (see 6.2) for inspection/test in section 4.5.

3.3.2 First Article (Production Model).

When specified, the contractor shall furnish production first articles of each end item specified in 3.1 and quantities specified by the contracting officer (see 6.2) for inspection/test in sections 4.6, and 4.7.

3.4 General Design.

The PPDS end items shall be designed to transform and distribute electrical power as needed from the DPGDS and United States Air Force (USAF) Basic Expeditionary Airfield Resources (BEAR) generator sets operating individually or in parallel or utility power.

Each PPDS end items shall be designed in accordance with the applicable Purchase Description sheet as specified in the acquisition document. Each PPDS end item shall have the capability to interface and operate with one or multiple PPDS end items to provide power as a system. The PPDS panel design and component installation shall permit accessibility for maintenance and service in the field. The design shall be such as to prevent conditions that may be hazardous to personnel or deleterious to equipment.

The general panel assembly design shall be in accordance with UL 67 and NFPA 70. The PPDS design/fabrication shall minimize the collection and retention of fluids, contaminants, and decontaminants. The PPDS shall maximize the commonality of components/parts throughout all PPDS end items as described in the individual slash sheets.

3.4.1 Materials.

IAW AR 750-59 Corrosion Prevention and Control for Army Materiel, PPDS end items shall be fabricated from compatible metals and materials that are inherently corrosion resistant or are treated to prevent the various forms of corrosion and deterioration that may be encountered in the storage and operating environments specified herein.

Corrosion prevention methods are discussed in MIL-STD-2073-1 Standard Practice for Military Packaging. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion. Dissimilar metals and methods of protection are referenced and detailed in MIL-STD-889. Use of polyvinyl chloride (PVC) in non-ventilated areas is prohibited. Materials selected shall be free from perceptible odors and noxious fumes; fire retardant conforming to UL 94; and unaffected by battery electrolyte or petroleum (fuels, lubricants, and coolants) products specified herein. All rubber compositions shall be resistant to ozone deterioration and shall be formulated with an anti-ozone system. The use of ozone depleting chemicals (ODCs) or materials that produce ODCs during manufacture is prohibited.

3.4.2 Hardware.

The different sizes and types of hardware shall be kept to a minimum. All nuts, bolts, screws, and threaded parts shall have standard screw threads in accordance with FED- STD-H28. Fasteners with metric threads and heads shall not be used. All exterior threaded parts shall be made of stainless steel or plated brass. Sheet metal screws shall not be used.

3.4.3 Workmanship.

Workmanship shall be of a quality to assure delivery of PPDS end items that are free from defects (see 6.4.6) resulting from defective material and incorrect manufacturing or assembly practices.

3.4.4 Construction.

The PPDS end items shall be constructed to withstand the strains, vibrations, rough handling, and other conditions incident to shipping, storage, and service at military installations. The PPDS end items shall be fabricated with suitable integral structural members so that the components form a compact and stable unit, and so that adjustment, repairs, and replacement of parts can be easily made by military personnel in the field using the tools as specified herein.

3.4.5 Stability.

The PPDS shall be stable and not tip over when all cables are connected, and the skid base is sited on uneven surfaces or on slopes of as much as 15 degrees from the horizontal in any direction.

3.4.6 Enclosure.

The PPDS’s enclosures shall be designed to exclude wind-driven rain, snow sand and dust from the interior of the item to the extent necessary to meet all requirements specified herein. The enclosures shall be provided with adequate ventilation to afford satisfactory performance in all environments specified herein. Drain holes shall be provided in the lowest part of the enclosure to drain off any moisture that may accumulate inside the enclosure. The panels of the enclosures shall be removable to perform scheduled and unscheduled maintenance actions. The enclosures shall not be damaged by proper usage of the lifting and tiedown provisions (see 3.8). The enclosures shall have hinged doors for access to the interior of the item as necessary to perform all preventative and scheduled maintenance service actions. Hinged doors shall be self-supporting in the open position. The doors shall have lockable latches that can be operated by personnel wearing Mission Oriented Protective Posture (MOPP) IV or Artic clothing.

3.4.6.1 Skid Base.

The enclosure shall have a skid base capable of supporting the entire item. The skid base shall enable the PPDS items to meet all transportability requirements as specified in para 3.8. The skid base shall extend beyond all components of the item. The skid base shall be provided with a method to drain accumulated liquids from the interior of the set.

There shall be at least a 2-inch clearance between the lowest projection of the item and the bottom of the skid base. The PPDS items shall not move or "walk" when operating unrestrained, on a level concrete surface, under all operating conditions specified herein.

3.4.6.2 Hinges and Latches.

Hinges shall be removable. All hinge pins shall be removable unless a piano type of hinge is used and shall have means to prevent workout of the pins. The pins shall be captive. Latches shall require manual, not spring-action for closing. All parts of the latches having relative motion with each other shall be of corrosion-resistant metal.

3.4.6.3 Storage Box.

The PPDS enclosures shall be equipped with a drip proof storage box, located inside the housing assembly. The storage box shall be accessible without removal of any set component and may be integral with the item enclosure. The storage box shall:

(a) Have a hinged lid self-supportable in the open position.

(b) Provide space for secured storage of all set accessories, to include grounding components other than grounding rods, and Operator’s Technical Manual.

(c) Contain drain hole(s).

(d) Be permanently marked "STORAGE".

(e) Include lockable fastener(s) that will keep the lid closed under all transportability conditions (see 3.6) specified herein.

3.4.7 Illuminated Indicators.

All illuminated indicators shall meet the following secure lighting (blue/green) requirements:

(a) Light sources shall consist of light emitting diodes (LEDs).

(b) 95 percent of the light energy emitted by each light source shall be at wavelengths below 700 nanometers.

(c) All light sources shall be visible in bright sunlight.

(d) All light sources shall be compatible with Night Vision Imaging System (NVIS) Soldier equipment IAW MIL-L-85762.

3.4.8 Grounding.

All AC electrical components of the PPDS end item shall be isolated from ground, except as otherwise specified herein. The equipment ground terminal (GND) shall be connected by an accessible, visible, solid copper bar to the neutral output terminal "N”. Neutral connection of "WYE" connected current transformer secondary may be connected to circuits leading to the output terminal "N". Direct current components utilizing case grounding shall not be used. Equipment grounding and bonding shall comply with the requirements of NFPA 70, Article 250. Hinges and slides shall not be relied upon as the sole means of grounding or bonding. MIL-HDBK-1857 Grounding, Bonding and Shielding Design Practices provides design guidance for this requirement.

3.4.8.1 Grounding Lugs.

Ground lugs shall be provided to connect the PPDS item to earth ground. The ground lugs shall be 4/0 split-bolt copper lug in accordance with 30554-69-692. In addition, ground lugs shall be located in the area of the load break bushings. equipment ground terminals and marked "GND".

3.4.8.2 Ground Rods.

Ground Rods (with attachments), Type III, sectional rod, class B copper-clad steel, in accordance with A-A-55804 shall be provided. Proper storage of the ground rods shall be provided.

3.4.8.3 Grounding Conductor.

Each PPDS shall contain grounding conductors. Each PPDS shall have a 6-foot, non-insulated multi-stranded conductors. Each conductor shall be sized in accordance article

250.66 of NFPA 70. The ground conductor(s) specified in A-A-55804 shall be replaced by this grounding conductor.

3.4.8.4 Grounding Conductor Clamp.

Each grounding conductor shall have a grounding clamp IAW article 250.70 of NFPA 70.

The clamp shall have a one-piece assembly with a threaded hole and a hex-head cup set screw of 1/2-inch minimum diameter. The clamp shall be of sufficient size to allow it to be fitted over the ground rod. When mounted in place, it shall provide a positive electrical connection with the rod and grounding cable.

3.4.9 Electrical Parts, Components, Controls, and Instruments Identification.

All electrical parts, components, controls, and instruments shall be identified by a symbol and a number. Symbols shall be IAW those defined by IEEE STD 315 or 315A. The numbers shall be the same as used on the schematic diagram. This identification shall be permanently marked IAW MIL STD 130 in a visible location adjacent to the item on the mounting surface. Each terminal board lug shall be numbered, and the number permanently marked adjacent to the lug. All plugs and receptacles shall be identified by symbol and number (P, J) IAW the schematic diagram. Polarity of electrical components that are polarity-sensitive shall be permanently marked in an easily visible location on the mounting surface.

3.4.10 Wiring.

All wires shall be secured neatly into wire trays inside the PPDS and harnesses outside of the PPDS. Wires in all harnesses shall be of the proper length and shall be so run and secured (with insulated clamps) as to protect insulation against contact with sharp corners and edges, pinching, sharp bending and twisting, abrasion due to vibration. Where a cable or wire is run between parts that move relative to each other (as a result of vibration, adjustment, inspection, or as a matter of normal operation), sufficient slack shall be left in the harness to allow repeated movement to take place without bending or twisting to the point of damaging the wire in any manner. Wires shall not be spliced. All wiring harnesses shall terminate in connectors or terminal boards at each end or branch, except solder connections may be made to potentiometers, resistors, semiconductors, capacitors, and press-to-test indicator lights. A means shall be provided to prevent liquids from coming in contact with any electrical connection for all operating conditions specified herein. Not more than two terminal lugs shall be attached with any one screw on screw type terminal boards, and not more than four terminal lugs shall be attached to any one stud on stud-type terminal boards. Terminals on electrical components shall not have more than one wire attached.

3.4.11 Wire and Wire Marking.

All wires shall be multi-stranded conductor, flame retardant, moisture, heat, and oil resistant IAW the National Electric Code. Low voltage wires shall be numbered for easy identification. The markings shall be permanently applied to the wire to withstand all specified operating conditions herein throughout the life of the set. Markings shall be within three inches of each end and at intervals of 5 inches throughout the wire length.

The wire-numbering scheme shall be consistent with what is currently being employed by Industry Standards. All wires shall be marked using contrasting colors. The use of colored wire coating as a marking scheme is prohibited.

3.4.12 Ribbon Cable.

Ribbon cables, if used, shall use locking connectors. The ribbon cable assembly shall be considered a single component and shall be marked IAW paragraph 3.4.11.

3.4.13 Accessories.

The PPDS shall be provided with the following accessories and proper storage for them:

Quantity Description Reference

Rods, Ground (with attachments), Type III, sectional rod, class B copper-clad steel. (NSN 5795-00-878-3791) A-A-55804A

6 ft Properly sized grounding conductor 3.4.8.3

1 Grounding conductor clamp 3.4.8.4

3.5 Identification, Markings, and Information.

Safety markings and labels shall be provided identifying any potential hazards to personnel. Safety markings and labels shall comply with the requirements of ANSI Z535.2. Voltages exceeding 70 V shall use the signal word "WARNING". Voltages exceeding 500 V shall use the signal word "DANGER". Markings and labels shall be readily visible in accordance with ANSI Z535.2. They shall not be removed or obstructed when a barrier or access door is opened or removed. Marking for shipment and storage shall be in accordance with MIL-STD-129. Any special marking shall be as specified in contract.

3.5.1 Identification Plate.

Each PPDS item shall have an identification plate permanently affixed to the exterior of the item. Plates shall be photosensitive aluminum, 0.020-0.032 inches thick, impregnated with silver compound or coated with other than silver for one side printable area.

Photosensitive aluminum shall be capable of resolving not less than 25 lines per millimeter. Plates shall have natural aluminum copy on black background. The format of the plates shall be IAW Drawing 30554-13229E6303. Specific data elements on the plate shall be changed to reflect the data for each item.

3.5.2 Item Unique Identification (IUID) Plate.

All PPDS items shall have an IUID plate IAW MIL-STD-130 and AR 700-145 permanently affixed to the exterior of the item. The format of the plate shall be IAW 30554-04-21078.

This marking will provide improved part marking and data capturing with potential to improve life cycle management, logistics support, asset management, and asset accountability and valuation. In addition, all components or Line Replaceable Units (LRUs) which cost over $5,000.00, shall require IUID marking.

3.5.3 Operating Instructions.

A plate or plates containing operating instructions for each end item shall be mounted in a conspicuous location visible from the operator's position on each end item respectively.

Operating instructions shall comply with the labeling requirements of 3.10.3. The operating instructions shall:

(a) Be complete and brief.

(b) Describe procedures for operating in all environments as specified herein.

(c) Describe procedures for paralleling.

(d) State information on connecting the PPDS end item to earth ground with a warning that this should be done to avoid shock hazard.

3.5.4 Schematic, Plate, and Wiring Diagrams.

The plates depicting the schematic diagram and the wiring diagram shall be mounted in an easily visible location inside of the PPDS end item. If laminated cards depicting the schematic diagram and wiring diagram are used, the cards shall be contained in an easily accessible location inside of the PPDS end item and shall be held together by a ring tethered to the housing. The schematic diagram shall show the complete operational and functional sequence of the circuitry for analysis and maintenance of the PPDS end item.

The wiring diagram shall show the physical location of all wiring interconnections in the same relationship as when they are installed. Identification marking of instruments, control devices, and connections shall be shown on both diagrams and shall coincide with markings on all items being identified. Electrical symbols shall be IAW IEEE STD-315 & 315A. All symbols that are not defined in IEEE STD-315 & 315A shall be defined on the diagram. Guidance for schematic and wiring diagrams can be found in MIL-HDBK-863 Department of Defense Handbook for Wiring Data and System Schematic Diagrams Preparation Of.

3.5.5 Lifting and Tiedown Attachments Diagram Plate.

Each PPDS end item shall include a plate describing the lifting and tiedown procedures, permanently affixed to the exterior of the item. The plate shall include the size and weight of the item, and location of the center of gravity. The plate shall be formatted IAW 30554- 04-21023.

3.6 Safety.

The PPDS shall provide fail-safe features for safety of personnel during the installation, operation, maintenance and repair or interchange of a complete equipment assembly or component parts thereof. Equipment design for personnel safety shall be equal to or better than appropriate requirements of the Occupational Safety and Health Administration (OSHA) and shall meet the provisions of MIL-STD-882 and MIL-STD- 1472. Safety shall also be in accordance with IEEE C2 National Electric Safety Code

(NESC).

3.6.1 Fail-Safe.

The PPDS shall provide fail-safe (see 6.4.12) features for the safety of personnel during the installation, operation, maintenance, and repair or interchanging of a complete equipment assembly or component parts thereof.

3.6.2 Temperature.

Operator accessible components shall comply with the temperature limit requirements in UL-60950-1. At an ambient temperature of 77ºF (25°C), the operating temperature of control panels and operating controls shall not exceed 135ºF (57°C). Other exposed parts subject to contact by operating personnel shall not exceed 140ºF (60°C). Hot surfaces shall be clearly marked or labeled.

3.6.3 Electrical.

The PPDS end item’s design shall incorporate methods to protect personnel from inadvertent/accidental contact with voltages capable of producing shock hazards (voltages exceeding 30 volts rms or DC) during normal operation of equipment. The set shall have all external surfaces at the same potential. All non-current carrying metal parts shall be bonded to ground IAW the NFPA 70. All contacts, terminals and like devices having voltages between 50 and 500 volts rms or DC with respect to ground shall be guarded from accidental contact by personnel if such points are exposed to contact during direct support or operator maintenance. Guards or barriers IAW NFPA 70, shall be provided with test probe holes where maintenance testing is required IAW requirements in UL-60950-1.

3.6.4 Mechanical.

The design of the PPDS end item shall provide personnel maximum access and safety while installing, operating, and maintaining the equipment. Doors or hinged covers shall be rounded at the corners and provided with stops to hold them open. Fastening hardware shall not extend beyond the nut more than the nominal diameter of the fastener.

3.6.5 Insulation of Controls.

All control shafts and bushings thereof shall be grounded whenever practicable.

Alternatively, the control knobs or levers and all attachment screws that can be contacted during use shall be electrically insulated from the shaft.

3.6.6 High Voltage Access Restriction.

The PPDS end item shall deny operator access to bare conductors.

3.6.7 Arc Flash Hazards.

Each PPDS end items shall have an arc flash risk assessment study performed according to NFPA 70E, Section 130.5 and, where appropriate, shall include provisions to protect personnel from arc flash. Each PPDS end item and their components shall be tested to confirm the effectiveness of the insulation used in their design.

3.6.8 Electrical Shock Risk Reduction.

The PPDS shall be designed to reduce the risk of electrical shock at operator accessible external points of disconnection IAW UL 60950-1. Lock out tag out provisions shall be employed to prevent activation of all controls to include buttons, switches, circuit breakers, etc.

3.6.9 Disconnecting Devices.

The PPDS shall contain disconnecting devices IAW NFPA 70 and UL 60950-1.

3.6.10 Leakage Current.

The PPDS shall be designed and constructed such that neither touch current nor protective conductor current is likely to create an electric shock hazard in accordance with UL 60950-1 section 5.

3.6.11 Accidental Contact.

The PPDS switches and controls shall provide protection from accidental shut off which can interrupt power output or accidental actuation which can pose a hazard to operator or maintainers.

3.7 Human Engineering (HE).

The PPDS shall be designed to meet HE principles and design standards as defined in MIL-STD-1472. Observance of principles will allow for ease of use, reduced fatigue and errors, and ensure user capabilities and limitations are addressed. The PPDS end item shall be operable and maintainable during day and night by 5th percentile female through 95th percentile male soldiers when wearing the clothing that is appropriate to the environments specified herein.

3.8 Transportability.

The PPDS end items shall not be damaged by rough handling (see 6.4.3.2) which could be encountered during all land, sea, or air transportation as specified herein. The PPDS end items shall meet the transportability interface criteria defined in MIL-STD-1366. The Surface Deployment and Distribution Command – Transportation Engineering Agency (SDDCTEA) Transportability Instruction 70-47 (TI 70-47) Engineering for Transportability Program shall be used as a guide for design.

3.8.1 Lifting and Tiedown Provisions.

The PPDS end items shall have lifting and tiedown provisions IAW MIL-STD-209, including tiedowns for internal air transport. Special lifting slings/spreader bars or tiedown devices shall not be permitted. If possible, each PPDS end item shall be capable of being lifted by standard ISO 1496-1 shipping container material handling equipment (MHE).

Each PPDS end item shall be equipped with lifting and tiedown data plates (see 3.5.3).

3.8.2 Forklift Openings.

Each PPDS end item skid base shall include forklift openings to permit insertion of forklift tines. Each opening shall be not less than 12½ x 3¼ inches in size. The openings shall be located such that the center of gravity of the PPDS end item falls approximately midway between the centers of the forklift openings. The distance between forklift openings shall be a multiple of 2 inches but not less than 36 inches nor more than 60 inches. The openings shall be reinforced and equipped with guides such that the end items will not be damaged (see 6.4.3) when lifted by a forklift with tines that do not extend completely through the base. Each opening shall be marked "FORKLIFT HERE" in ¾ inch minimum letter height.

3.8.3 Air Transportability.

The PPDS end items shall be capable of being transported by aircraft without damage.

The PPDS end items and its components shall meet the internal air transport requirements of MIL-STD-1366 and MIL-STD-1791. The PPDS and components shall be designed for transport in C-5, C-17, C-130 and larger aircrafts while sitting upright. The SDDCTEA Modal Instruction 24 Airlift (MI-24 Airlift) Vehicle Preparation Instructions for Airlift shall be used as a guide for design.

3.8.4 Rail Transportability.

The PPDS end items shall be capable of being rail transported by a wood-decked, open top railcar equipped with a cushioned draft gear when tested IAW TM 40.5d of MIL-STD- 705.

3.8.4.1 Rail Tiedown Procedure.

The contractor shall provide a procedure for mounting the PPDS end items to a rail flat car for rail transportation. This procedure shall incorporate standard loading and bracing methods as show in section six (6) of the association of American Railroads (AAR) “General Rules Governing the loading of DoD Material on Open Top Cars”. Tiedown procedure shall be approved by the SDDCTEA. The SDDCTEA Modal Instruction 19 Rail (MI-19 Rail) Tiedown Instructions for Rail Movements shall be used as a guide for design.

3.8.5 Truck and Trailer Transportation.

The PPDS shall be capable of being transported by truck both on highway and off-road.

The SDDCTEA Modal Instruction 20 Truck (MI-20 Truck) Tiedown Instructions for Truck Movements, shall be used as a guide for design. Off-road is defined as the road test in TM 774.1 of MIL-STD-705.

3.9 Environmental Requirements.

The PPDS shall operate under each and any combination of the following Operational environmental requirements.

3.9.1 Operational Environmental Requirements:

(a) All possible relative humidity’s, with ambient temperatures ranging from -25°F (-32°C) with an objective of -50°F (-53°C) to 125°F (52°C) with an objective of 135°F (57°C).

(b) Altitudes up to and including 10,000 feet (3,048 m).

(c) With 127 millimeters (mm) (5 inches) of rain per hour impinging on the PPDS end items at angles from the vertical up to 45 degrees.

(d) With 355 British thermal units (BTUs) per square foot per hour of solar radiation.

(e) With sand and dust particle concentration of up to 1,400 milligrams per cubic meter (mg/m³). Particle sizes shall range from less than 74 micrometers in diameter to 1,000 micrometers with the bulk of the particles ranging in size from 74 to 350 micrometers.

(f) With a steady wind speed of 22 meters per second (m/s) (73 feet per second [ft/s]) and gusts up to 29 m/s (95 ft/s) at a height of 3 m (10 feet) above ground level.

(g) With accumulations of ice glaze, freezing rain and hoarfrost of up to 13 mm (0.5 inch) and up to a specific gravity of 0.9.

(h) In a salt fog or sea spray environment.

3.9.2 Storage.

The PPDS end items without packaging shall not be damaged (see 6.4.3) by exposure to:

(a) Storage at -60 F (151°C) to 160 F (71°C).

(b) Salt fog environment.

(c) All possible relative humid environment.

3.9.3 Preservation.

The PPDS end items shall withstand the effects of storage outdoors and onboard watercraft and shall be operational with minimal preparation after removal from storage consistent with standard DOD practice. PPDS end items shall withstand outside storage for up to 10 years or long-term facility storage for up to 20 years without damage or degradation of performance. Procedures for storage and preservation shall be developed as specified herein and incorporated into the technical manuals.

3.9.4 Fungus and Moisture Resistance.

Electrical circuitry, components and connections that are not inherently fungus and moisture resistant or hermetically sealed shall be protected from fungus growth and moisture by an overall coating treatment, appropriate to the component in accordance with SAE AS 12500 Corrosion Prevention and Deterioration Control in Electronics Components and Assemblies.

3.10 Electromagnetic Interference (EMI).

The PPDS end items shall comply with the EMI emission and susceptibility requirements of MIL-STD-461, for conducted emissions (CE102), conducted susceptibility (CS101, CS114, CS115 and CS116), radiated emissions (RE102), and radiated susceptibility (RS103). Grounding, bonding, and shielding design practices IAW MIL-HDBK-1857 shall be used as guidance for this requirement.

3.11 Chemical, Biological, Radiological and Nuclear (CBRN) Contamination Survivability.

PPDS end items shall meet CBRN requirements as specified in MIL-STD-3056 and shall have a Chemical Agent Resistant Coating (CARC) exterior coating as specified herein.

The PPDS shall be capable of being operated and maintained by personnel wearing Mission Oriented Protective Posture (MOPP) IV chemical, biological, and radiological clothing (see 6.4.19) without special tools or support equipment. The PPDS shall not be damaged and shall meet operational requirements specified herein, within 60 minutes after being decontaminated. Lenses or covers, gaskets, seals, marking, control knobs, and other devices on the control panel or display functions shall not be damaged by the hot, soapy water CBRN decontamination procedures described in FM 3-11.5. The PPDS shall be manufactured to minimize the collection and retention of agents and decontaminants. Design guidance is provided in MIL-HDBK-784. The PPDS shall meet operational requirements within 60 minutes after being decontaminated according to the procedure specified in APPENDIX A.

3.12 Treatment and Painting.

Treatment and painting shall be IAW MIL-DTL-53072. When referenced drawings are used, treatment and painting shall be as specified on the referenced drawing.

(a) All exterior surfaces of the PPDS, regardless of the material selected, shall have a finish coat of CARC paint IAW MIL-DTL-64159, MIL-DTL-53039, or MIL-DTL- 53072. Topcoat color shall be green 383, color number 34094 in accordance with AMS-

STD-595.

(b) Where the exterior surface material selected is not applicable to MIL-DTL-53072 (use of plastic or composites, as an example) the surface shall be treated using a non-hex chrome pretreatment, class N (non-chrome) primer and CARC topcoat as necessary for application of the finish coat of CARC as specified paint in paragraph a).

(c) The following items shall not be painted except where commercial treatment and painting have already been applied by the original equipment manufacturer: terminal wiring connections, instruction diagrams and plates, rectifiers, relays, switches, circuit interrupters, instrumentation, rubber, and all other parts whose operation or function would be adversely affected by paint. Insulation material shall be painted unless the sound absorbing characteristics of the material are compromised.

(d) After final assembly and all testing are completed, all exterior surfaces (except identification plates, markings, instruments, and rubber) shall be painted with a finish coat of CARC paint in accordance with MIL-DTL-53072. Color shall be Green 383, Tan 686 or a camouflage pattern, as specified (see 6.2) by the Contracting Officer. Application of the camouflage pattern shall be in accordance with MIL-DTL-53072.

(e) All exterior surface labels and markings specified in this PD shall be applied on camouflage painted PPDS using the coloration scheme in Table 1:

TABLE 1 – Camouflage Coloration Scheme

CAMOUFLAGE PATTERN

BACKGROUND

COLOR

LETTER COLOR

Standard 3-color Green 383 Black Brown 383 Black

Black Green 383

Winter Conditions White Brown 383

Brown 383 Black Black Green 383

Desert Conditions Tan 686 Black

(f) All specified identification plates (see 3.5) applied to exterior surfaces shall be installed following the final paint finish coat. Should a camouflage pattern be specified, when possible, placement of the plates should be on the black areas of the camouflage pattern.

(g) CARC paint shall not be applied to surfaces that will exceed temperatures of 400ºF (204ºC).

3.13 Servicing and Maintainability.

PPDS items shall be capable of being serviced and maintained IAW AR 750-1 two-level Maintenance Policy. All field-level service and maintenance tasks shall be capable of being accomplished by personnel wearing arctic clothing, MOPP IV chemical, biological and radiological clothing. The complete maintenance schedule, preventive and scheduled, shall be followed throughout all test phases, and demonstrated during the First Article testing. Where appropriate, Condition Based Maintenance principles IAW DoD 4151.22 shall be applied and used.

3.13.1 Servicing.

The design and construction of the PPDS items shall permit preventive maintenance checks and services (PMCS) under military field conditions.

3.13.2 PMCS.

Daily PMCS visual inspections shall be accomplished in 20 minutes or less, while the PPDS end items are energized. Daily PMCS actions shall include, but not be limited to the following:

(a) Visual inspection for loose hardware, cracks, moisture accumulation, corrosion, etc.

(b) Visual inspection for tripped breakers, blown fuses, inoperative phase lights, etc.

(c) Visual inspection of metering and monitoring devices, if equipped.

3.13.3 Minimum Scheduled Maintenance Interval.

If required, the minimum scheduled maintenance interval (hours of set operation) between scheduled maintenance service (repair, adjust, replace, etc.) shall not be less than 750 hours. Item design shall minimize the need and time to perform scheduled maintenance. Scheduled maintenance actions shall include but not be limited to the following:

(a) Monthly: In-service/energized visual inspection.

(b) Semi-Annual: In-service/energized inspection and service.

(c) Annual: Offline/de-energized inspection, service, and testing

3.13.4 Maintainability.

The PPDS items shall be designed to meet scheduled and unscheduled service and maintenance requirements with minimum removal of components. Scheduled maintenance shall not require removal of any other set component to perform the scheduled maintenance action. Maintainability requirements shall be applicable to the PPDS items while operating in the specified configuration (see 1.4). The following specific maintainability items shall be provided.

(a) If relays are used, a relay socket with a positive locking mechanism shall be provided for each relay.

(b) All modules/Line Replaceable Units (LRUs) shall interface with the wiring harness or other modules through quick disconnect plugs with a locking mechanism. The plugs used on wiring harnesses shall not be crimped and shall be easily repairable. Solder or crimp contacts may be used.

(c) Hardware that requires torquing shall be installed so that the nut, bolt, or screw head is accessible for torque wrench application. In assemblies where both a bolt and nut are used, the nut shall be accessible for torque wrench application.

(d) Test, measurement, and diagnostic equipment (TMDE) required for maintenance shall currently exist in the DoD supply system. If TMDE is required that is not in the DoD Supply System, selected TMDE shall be procurable by the Government. The contractor shall provide approved sources to the government to obtain selected TMDE. When TMDE is required, it shall be selected using criteria from AR 750-43, Army TMDE Program.

(e) All maintenance actions shall be accomplished using standard tools in the military inventory such as General Mechanic's Tool Kit (GMTK) (NSN 5180-01-548-7634), Standard Automotive Tool Set (SATS) (NSN 4910-01-490- 6453), Service Kit Power Plant (SKPP) (NSN 4940-01-682-2525), and Forward Repair System (FRS) (NSN 4940-01-463-7960).

3.13.5 Maintenance Ration (MR).

Field level MR (see 6.4.14) of the set shall not exceed 0.025.

3.13.6 Median Time to Repair (MTTR).

The MTTR (see 6.4.17) for all unscheduled maintenance actions at the field level shall not exceed 1.5 hours.

3.14 Maximum Time to Repair (MAXTTR).

The MAXTTR (see 6.4.15) for 90 percent of all essential unscheduled maintenance actions shall not exceed 4 hours.

4. VERIFICATION.

4.1 Classification of Inspection.

Inspections as specified herein, shall be classified as follows:

(a) Preproduction Inspection (see 4.5)

(b) First Article Production Qualification Inspection (see 4.6)

(c) First Article Production Verification Inspection (see 4.7)

(d) Individual Conformance Inspection (see 4.8).

(e) Lot Acceptance Inspection (see 4.9).

(f) Inspection Comparison (see 4.10).

4.2 Inspection Conditions.

Unless otherwise specified, all inspections shall be performed IAW the test conditions specified in applicable test method document or applicable paragraphs in the PD.

4.3 Inspection Reports.

Inspection reports shall be provided for each inspection listed in 4.1. The inspection reports shall contain all data, information, results, and conclusions obtained during the inspections. Reference MIL-HDBK-831 for an example of report format. The inspection reports shall also include the following:

(a) All test data obtained from applicable tests.

(b) Description of malfunction, damages, failures, and adjustments (other than adjustments permitted by this PD) that occur during inspection.

(c) Causes and analysis of malfunction, damages, or failures, and reasons for adjustments.

(d) Corrective actions taken or required.

4.4 Test Schedule.

The test schedules shall be as shown in Table II. Nonconformance to the applicable requirement paragraph shown in column 8 shall constitute failure of the test and shall be cause for rejection of the PPDS. The Government reserves the right to reject the equipment for not meeting any requirement herein, even though not performing a test directly related to the specific requirement. The requirements in section 3 shall apply to all tests performed as a part of another test. If a scheduled maintenance action is due after the beginning of any test, the shutdown shall be postponed until completion of the test or until completion of 100 hours of operation, whichever is lesser.

TABLE II- Test Schedule

1 2 3 4 5 6 7 8

Proto First Article Quality Control

P

P

T

SEE

4.3.2

P

Q

T

SEE

4.4.2

P

V

T

SEE

4.5

I

N

D

I

SEE

4.6.1

S

A

M

P

SEE

4.6.2

TEST TEST PARAGRAPH (See Note a)) AND

TEST METHOD (MIL-STD-705)

BASIC

REQUIREMENT

PARAGRAPH

X X Altitude

4.11.1; MIL-STD-810 TM 500.6

Low Pressure (Altitude) 3.9.1

X Chemical, Biological, Radiological, Nuclear

4.11.2; TOP 08-2-502 3.12

X X X Circuit Interrupter (Overload

Current)

4.11.3; TM 512.2e Circuit Interrupter Test (Overload

Current) 3.1

X X X Circuit Interrupter (Short

Circuit) 4.11.3; TM 512.2e Circuit

Interrupter Test (Short Circuit) 3.1

X X Cold Operation -25°F 4.11.4 3.9.1

X X Cold Operation -50°F 4.11.4 3.9.1

X X Cold Storage -60°F 4.11.5; TM 731.1 3.9.2

X X X Convenience Receptacle 4.11.6 3.1

X X Data Download To be conducted during

Maintainability Demo 3.1

X X X EMI 4.11.7 3.11

X X X Fungus and moisture resistance 4.11.8; TM 711.2c; MIL-STD-810, TM 507.5, Procedure I 3.9.4

X X X X High Temperature 125°F 4.11.10 3.9.1

X X X X High Temperature 135°F 4.11.10 3.9.1

X X X Hot Storage Test 160°F 4.11.11; TM 732.1 3.9.2

X X X Humidity 4.11.12; TM 711.1 3.9.1

X X X Human Engineering TM 803.1 3.7

X X Indicating Instruments TM 513.1 3.1

X X Interface 4.11.13 3.1

X X Ice Glaze and Wind TM 772.1 3.9.1

TABLE II- Test Schedule

1 2 3 4 5 6 7 8

Proto First Article Quality Control

P

P

T

SEE

4.3.2

P

Q

T

SEE

4.4.2

P

V

T

SEE

4.5

I

N

D

I

SEE

4.6.1

S

A

M

P

SEE

4.6.2

TEST TEST PARAGRAPH (See Note a)) AND

TEST METHOD (MIL-STD-705)

BASIC

REQUIREMENT

PARAGRAPH

X X X Lifting and Tiedown TM 740.4; MIL-STD-209 3.8.1

X X X X Operation in parallel

(See Note c)

4.11.14 3.1

X X X X Operational Performance 4.11.15 3.1

X X Phase Sequence TM 507.1 3.1

X X Physical Stability 4.11.16 3.4.5

X X Protective Devices 4.11.17 3.1

X X X Rain 4.11.18; MIL-STD-810, TM 506.5 3.9.1

X Reliability

(See Note b))

4.11.19 3.2

X X X Railroad Impact 4.11.20; MIL-STD-810, TM 526 3.8.4

X X X Road test 4.11.21 3..8.5

X X X Safety TM 802.1 3.12

X X X Salt Fog 4.11.22 3.9.1

X X X Sand and dust 4.11.23; MIL-STD-810, TM 510.5 3.9.1

X X Secure Lighting 4.11.24 3.4.7

X X X Size, Weight, and Center of

Gravity

4.11.25 3.1

X X Solar Radiation (See Note d))

4.11.26 3.9.1

X X Transformer Insulation

Resistance TM 301.d, 3.1

X X Transformer Turns Ratio

(TTR)

IEEE C57.12.90 3.1

NOTES:

(a) Tests shall be conducted with the 4160-volt…