Attachment 0005 Purchase Description.pdf

PD 6115-0133

Comments, suggestions, or questions on this document should be addressed to the Project Manager: Project Manager Expeditionary Energy & Sustainment Systems (PM E2S2), ATTN:

SFAE-CSS-E2, Fort Belvoir, VA 22060. Point of contact for this document is Michael I.

Segura at michael.i.segura.civ@army.mil.

AMSC N/A FSC 6115

Distribution Statement A. Approved for public release, distribution is unlimited.

PD Revision 1 1 2

Revision Date 3 09 May 2022 4

PURCHASE DESCRIPTION 6

ITEM SPECIFICATION 8

FOR THE 10

GENERATOR SET, SMALL TACTICAL ELECTRIC POWER: 3 < KILOWATTS < 5 12

Prepared for: 14

Project Manager Expeditionary Energy & Sustainment Systems (PM E2S2), 15 5850 Delafield Road, Building 324, Fort Belvoir, VA 22060 16

Prepared by: 18

Product Manager Mobile Electric Power Sources (PM MEPS), 19 5850 Delafield Road, Building 324, Fort Belvoir, VA 22060 20

1.0 SCOPE 23

1.1 Scope. This Purchase Description (PD) covers the greater than or equal to 3 24 kilowatt (kW) to less than 5kW Small Tactical Electric Power (STEP) generator set, hereinafter 25 referred to as "set" or "sets". This PD also covers any accessories that are used with the set(s). 26

1.2 Requirement levels. This PD lists two values for certain performance parameters. 27 The threshold (T) is the minimum acceptable level. The objective (O) is the desired level at 28 which performance results in an operationally significant increase in capabilities. When only one 29 requirement is stated, it is the threshold requirement. Within a single paragraph, if individual 30 sentences are marked, the T or O applies to the sentence preceding the marking. If an (O) 31 appears at the end of a paragraph, the entire paragraph is objective. 32

2.0 APPLICABLE DOCUMENTS 33

2.1 General. The documents listed in this section are specified in sections 3 or 4 of this 34 PD. This section does not include documents cited in other sections of this PD or recommended 35 for additional information or as examples. While every effort has been made to ensure the 36 completeness of this list, document users are cautioned that they must meet all specified 37 requirements of documents cited in sections 3 and 4 of this PD, whether or not they are listed. 38 mailto:michael.i.segura.civ@army.mil

2.2 Government Documents. 39

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, 40 and handbooks form a part of this document to the extent specified herein. Unless otherwise 41 specified, the issues of these documents are those cited in the solicitations or contract. 42

COMMERCIAL ITEM DESCRIPTIONS 43

A-A-52624 - Antifreeze, Multi Engine type 44

A-A-55804 - Rods, Ground (with Attachments) 45

A-A-59592 - Can, Fuel, Military: 20-Liter Capacity 46

DEPARTMENT OF DEFENSE SPECIFICATIONS 47

MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, 48 Combat/Tactical Service 49

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5 50

MIL-PRF-10924 - Grease, Automotive and Artillery 51

MIL-DTL-15024 - Plates and Tags for Identification of Equipment, General 52 Specification for 53

MIL-PRF-21260 - Lubricating Oil, Internal Combustion Engine, Preservative 54 Break-in 55

MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic 56

MIL-DTL-53072 - Chemical Agent Resistant Coating (CARC) System 57 Application Procedures and Quality Control Inspection 58

MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-59 34), NATO F-35, and JP-8+100 (NATO F-37) 60

MIL-L-85762 - Lighting, Aircraft, Interior, Night Vision Imaging System 61 (NVIS) Compatible 62

DEPARTMENT OF DEFENSE STANDARDS 63

MIL-STD-129 - Military Marking for Shipment and Storage 64

MIL-STD-130 - Identification Marking of U.S. Military Property 65

MIL-STD-188-125-2 - High-Altitude Electromagnetic Pulse (HEMP) 66 Protection for Ground-Based C4I Facilities Performing 67

Critical, Time-Urgent Missions - Part 2 - Transportable 68 Systems 69

MIL-STD-209 - Lifting and Tie-down Provisions 70

MIL-STD-461 - Requirements for the Control of Electromagnetic 71 Interference Characteristics of Subsystems and Equipment 72

MIL-STD-705 - Generator Sets, Engine Driven Methods of Tests and 73 Instructions 74

MIL-STD-810 - Environmental Engineering Considerations and Laboratory 75 Tests 76

MIL-STD-814 - Requirements for Tiedown, Suspension and Extraction 77 Provisions on Military Materiel for Airdrop 78

MIL-STD-882 - System Safety 79

MIL-STD-889 - Dissimilar Metals 80

MIL-STD-1275 - Characteristics of 28 Volt DC Input Power to Utilization 81 Equipment in Military Vehicles 82

MIL-STD-1332 - Definitions of Tactical, Prime, Precise, and Utility 83 Terminologies for Classification of the DoD Mobile 84 Electric Power Engine Generator Set Family 85

MIL-STD-1472 - Human Engineering 86

MIL-STD-1474 - Noise Limits 87

MIL-STD-1651 - Insert Arrangements for SAE-AS50151, MIL-DTL-22992 88 (Classes C, J, and R), MIL-DTL-83723 (Series II) and 89 SAE-AS95234 Circular Electrical Connectors 90

MIL-STD-2169 - High-Altitude Electromagnetic Pulse (HEMP) Environment 91 (Secret) 92

MIL-STD-3056 - Chemical, Biological, and Radiological System 93 Contamination Survivability Design Criteria for 94

MIL-STD-11991 - Parts, Materials, and Processes, General Standard for 95

MIL-STD-13231 - Marking of Electronic Items 96

MIL-D-16791 - Detergents, General Purpose (Liquid, Nonionic) 97

DEPARTMENT OF DEFENSE HANDBOOKS 98

MIL-HDBK-419 - Grounding, Bonding and Shielding for Electronic 99 Equipments and Facilities, (Handbook Contains both 100 Volume I Basic Theory, and Volume II Applications) 101

MIL-HDBK-454 - General Guidelines for Electronic Equipment 102

MIL-HDBK-831 - Preparation of Test Reports 103

MIL-HDBK-1857 - Grounding, Bonding and Shielding Design Practices 104

(Copies of these documents are available online at http://quicksearch.dla.mil/) 105

2.2.2 Other Government documents, drawings and publication. The following other 106 Government documents, drawings, and publications form a part of this document to the extent 107 specified herein. Unless otherwise specified, the issues of these documents are those cited in the 108 solicitation or contract. 109

ABERDEEN TEST CENTER (ATC) 110

TOP 01-1-011 - Test Operating Procedure: Vehicle Test Facilities at 111 Aberdeen Test Center and Yuma Test Center 112

(Copies of this documents are available online at http://quicksearch.dla.mil/) 113

ARMY PUBLISHING DIRECTORATE (APD) 114

AR 70-38 - Research, Development, Test and Evaluation of Materiel 115 for Extreme Climatic Conditions 116

AR 700-101 - Joint Operating Procedures Management and 117 Standardization of Mobile Electric Power Generating 118 Sources 119

AR 750-43 - Army Test, Measurement and Diagnostics Equipment 120 (TMDE) Program 121

ATP 3-11.32 - Multi-Service Tactics, Techniques, and Procedures for 122 Chemical, Biological, Radiological, and Nuclear Passive 123 Defense 124

TB 750-25 - Maintenance of Supplies and Equipment Army Test, 125 Measurement, and Diagnostic Equipment (TMDE) 126 Calibration and Repair Support (C&Rs) Program 127

(Copies of these documents are available from https://armypubs.army.mil/) 128

ENVIRONMENTAL PROTECTION AGENCY 129

http://quicksearch.dla.mil/ http://quicksearch.dla.mil/ https://armypubs.army.mil/

40 CFR 1068.225 - Title 40 - Protection of Environment: Chapter I - 130 Environmental Protection Agency: Subchapter U - Air 131 Pollution Controls: Part 1068 - General Compliance 132 Provisions For Highway, Stationary, and Nonroad 133 Programs: Subpart C - Exemptions and Exclusions: Section 134 § 1068.225 - Exempting engines/equipment for national 135 security 136

(Copies of this documents is available from https://www.govinfo.gov/ or https://www.ecfr.gov/) 137

PRODUCT MANAGER SET, OUTFITS, & TOOLS (PdM-SKOT) 138

SC 4910-95-A81 - SATS - Standard Automotive Tool Set (NSN 4910-01-490-139 6453) 140

SC 4940-95-B36 - SECM - Shop Equipment Contact Maintenance (NSN 141 4940-01-548-9064) 142

SC 4940-95-E42 - FRS - Forward Repair System (NSN 4940-01-533-1621) 143

SC 5180-95-B49 - GMTK - General Mechanics Tool Kit (NSN 5180-01-605-144 5146) 145

(Contents of these end items are available from https://www.peocscss.army.mil/pdmskot.html) 146

PROJECT MANAGER EXPEDITIONARY ENERGY & SUSTAINMENT SYSTEMS 147

(PM E2S2) 148

30554-69-692 - Terminal, Load 149

30554-69-668 - Line, Fuel, Auxiliary 150

30554-88-20063 - Plate, Identification 151

30554-95-8165 - Connector, Plug, Electrical, Intervehicle Power Cable 152

97403-13226E7032 - Cable Assembly, GRP E, 20 AMP 153

TM 10-1080-256-10 - Ultra Lightweight Camouflage Net System 154 (ULCANS) Increment I 155

TMS-TGP - Tactical Microgrid Standard–Tactical Ground Power 156

(Copies of these drawings and document required by contractors in connection with specific 157 acquisition functions should be obtained from the contracting activity or as directed by the 158 Contracting Officer.) 159 https://www.govinfo.gov/ https://www.ecfr.gov/ https://www.peocscss.army.mil/pdmskot.html

2.3 Non-Government publication. The following documents form a part of this 160 document to the extent specified herein. Unless otherwise indicated, the issues of these 161 documents are those cited in the solicitation or contract. 162

AMERICAN SOCIETY FOR QUALITY (ASQ) 163

ASQ/ANSI Z1.4 - Sampling Procedures and Tables for Inspections by 164 Attributes 165

(Copies of this document are available from https://www.asq.org/) 166

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) 167

ASTM D975 - Standard Specification for Diesel Fuel Oils 168

(Copies of this document are available from https://www.astm.org/) 169

ASSOCIATION OF AMERICAN RAILROADS (AAR) 170

AAR OTLR - Section 1 "General Rules for Loading All Commodities" 171

AAR OTLR - Section 6 "Rules for Loading Military Equipment and 172 Materiel" 173

(Copies of these documents are available from https://aarpublications.com/) 174

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE) 175

IEEE-315 - Graphic Symbols for Electrical and Electronics Diagrams 176

IEEE-519 - Recommended Practices and Requirements for Harmonic 177 Control in Electrical Power Systems 178

(Copies of these documents are available from https://www.ieee.org/) 179

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC) 180

IEC 61000-2-2 - Electromagnetic compatibility (EMC) – Part 2-2: 181 Environment – Compatibility levels for low frequency 182 conducted disturbances and signalling in public low-183 voltage power supply systems 184

IEC 61000-3-2 - Electromagnetic compatibility (EMC) – Part 3-2: Limits – 185 Limits for harmonic current emissions (equipment input 186 current ≤16 A per phase) 187

IEC 61000-3-4 - Electromagnetic compatibility (EMC) – Part 3-4: Limits – 188 Limitation of emission of harmonic currents in low-voltage 189 https://www.asq.org/ https://www.astm.org/ https://aarpublications.com/ https://www.ieee.org/ power supply systems for equipment with rated current 190 greater than 16 A 191

IEC 61000-3-12 - Electromagnetic compatibility (EMC) – Part 3-12: Limits – 192 Limits for harmonic currents produced by equipment 193 connected to public low-voltage systems with input current 194 >16 A and ≤ 75 A per phase 195

IEC 61000-4-5 - Electromagnetic compatibility (EMC) – Part 4-5: Testing 196 and measurement techniques – Surge immunity test 197

IEC 61000-4-7 - Electromagnetic compatibility (EMC) – Part 4-7: Testing 198 and measurement techniques – General guide on harmonics 199 and interharmonics measurements and instrumentation, for 200 power supply systems and equipment connected thereto 201

IEC 61000-4-30 - Electromagnetic compatibility (EMC) – Part 4-30: Testing 202 and measurement techniques – Power quality measurement 203 methods 204

IEC 61032 - Protection of persons and equipment by enclosures - Probes 205 for verification 206

(Copies of these documents are available from https://www.iec.ch/) 207

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) 208

ISO 7000 - DATABASE SNAPSHOT - Graphical symbols for use on 209 equipment 210

ISO 12103-1 - Road vehicles - Test contaminants for filter evaluation – 211 Part 1: Arizona test dust 212

ISO/IEC 15418 - Information technology - Automatic identification and data 213 capture techniques - GS1 Application Identifiers and ASC 214 MH10 Data Identifiers and Maintenance 215

ISO/IEC 15434 - Information technology - Automatic identification and data 216 capture techniques - Syntax for high capacity ADC media 217

ISO/IEC 16022 - Information technology - Automatic identification and data 218 capture techniques - Data Matrix bar code symbology 219 specification 220

ISO/IEC 16388 - Information technology — Automatic identification and 221 data capture techniques — Code 39 bar code symbology 222 specification 223 https://www.iec.ch/

(Copies of these documents are available from https://www.iso.org/) 224

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) 225

ANSI/NEMA WD 6 - Wiring Devices – Dimensional Specifications 226

NEMA MG 1 - Motors and Generators 227

NEMA MG 2 - Safety Standard for Construction and Guide for Selection, 228 Installation and Use of Electric Motors and Generators 229

(Copies of these documents are available from https://www.nema.org/) 230

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 231

NFPA 70 - National Electrical Code 232

NFPA 79 - Electrical Standard for Industrial Machinery 233

(Copies of these documents are available from https://www.nfpa.org/) 234

NORTH ATLANTIC TREATY ORGANIZATION (NATO) 235

NATO STANAG 3747 - Guide Specifications (Minimum Quality Standards) 236 for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, 237 F-40 and F-44) 238

(Copies of this document are available from https://nso.nato.int/nso/) 239

SOCIETY OF AUTOMOBILE ENGINEERS (SAE) 240

SAE AMS-STD-595 - (R) Colors Used in Government Procurement 241

SAE J514 - Hydraulic Tube Fittings 242

SAE J2360 - Automotive Gear Lubricants for Commercial and Military 243 Use 244

(Copies of these documents are available from https://www.sae.org/) 245

UNDERWRITERS LABORATORIES (UL) 246

UL 94 - UL Standard for Safety Tests for Flammability of Plastic 247 Materials for Parts in Devices and Appliances 248

UL 746C - UL Standard for Safety Polymeric Materials – Use in 249 Electrical Equipment Evaluations 250

UL 943 - UL Standard for Safety Ground-Fault Circuit-Interrupters 251 https://www.iso.org/ https://www.nema.org/ https://www.nfpa.org/ https://nso.nato.int/nso/ https://www.sae.org/

(Copies of these documents are available from https://ulstandards.ul.com/) 252

2.4 Order of Precedence. In the event of a conflict between the text of this document 253 and the references cited herein (except for related PD sheets), the text of this document takes 254 precedence. Nothing in this document, however, supersedes applicable laws and regulations 255 unless a specific exemption is obtained. 256

3.0 REQUIREMENTS 257

3.1 First article. When specified (6.2), the contractor shall furnish first article samples 258 as specified in 3.2 in the quantities specified by the contracting officer for inspection (6.4.15) as 259 specified in 4.1 for determination of conformance to this PD. 260

3.2 Description. The Tactical Microgrid Standard (TMS) compliant set (3.21) shall 261 consist of an engine that can operate on the fuels specified in 3.10.1, permanent magnet or 262 brushless generator, power converter (6.4.10) or excitation system if needed, governing system, 263 fuel system, Direct Current (DC) cranking system, control system, protection system, starting 264 battery, and other devices as required to achieve a complete set and to allow for the required 265 performance. In addition, all sets used for first article inspection (4.4) shall include any 266 accessories needed to meet required performance as stated herein. Sets used for production 267 quality inspection (4.5) and production sets shall have the required accessories specified in the 268 acquisition documentation (6.2). 269

3.2.1 Set rating. The set shall be rated at no less than 3kW, 0.8 Power Factor (PF) 270 lagging, 60 Hertz (Hz), Alternating Current (AC) continuous at the AC load terminals and shall 271 be reconnectable for the following voltages: 272

a. 1 Phase (PH), 2-wire, 120 Volts (V) (double the current of 3.2.1.b) (T). 273

b. 1PH, 3-wire, 120/240V (T). 274

c. 28VDC nominal, integral to the AC power source, adjustable 23-35VDC (O). 275

d. 1PH 50Hz, with the same reconnectability as 60Hz (O). 276

e. All in one power source selectable to 28VDC, 120VAC 1PH 50/60Hz 2-wire, or 277 120/240 VAC 1PH 50/60Hz 3-wire, where AC has selectable frequencies as well (O). 278

Additional capabilities shall be considered (i.e. leading 0.8PF) if feasible given other 279 performance constraints (O). Additional load terminals, circuit interrupters, and load receptacle 280 rearrangement as well as control devices and indicators shall be provided, if applicable (T). If 281 50Hz is provided, power rating shall be no less than five sixths (5/6) of 60Hz continuous at the 282 same PF (T). If DC is provided, current rating shall be no less than 64 Amperes (A) (T), 83A 283 (O). As applicable, power quality shall be no less than utility in accordance with MIL-STD-284 1332 and as described herein (T). 285 https://ulstandards.ul.com/

3.3 Reliability. The minimum acceptable Mean Time Between Failure (MTBF) for the 286 sets shall be 687 hours (T), 2290 hours (O) with a lower confidence of 80% under the conditions 287 specified in 4.8.9. 288

3.4 Audio noise. Audio noise sound pressure levels (SPL) emanating from the set shall 289 not exceed 72 dB(A) at 23.0 feet (7 meters) from the perimeter of the set when measured at 3.9 290 feet (1.2 meters) above the ground (T). In addition, audio noise SPL emanating from the set 291 shall be less than 85 dB(A) at the operator's station, with the control panel doors open if used, 292 defined to be a 2.3 feet (0.7 meters) hemisphere radiating outward from any point on the plane 293 defined by the front of the control panel (T). Audio noise SPL emanating from the set shall be 294 inaudible from the perimeter of the set 328 feet (100 meters) away (O). These requirements 295 apply under all operating conditions specified herein with the set operating at all loads from the 296 no-load to rated load (6.4.24) (T). 297

3.5 High-altitude electromagnetic pulse (HEMP). The sets and feeder boxes shall 298 withstand the HEMP (6.4.14) nuclear environment specified in MIL-STD-2169 in both operating 299 and non-operating conditions. The set and feeder box shall operate as specified herein after 300 being subjected to the applicable nuclear environments without damage (6.4.5). The set and 301 feeder box operating as a unit (not in parallel) shall meet operational requirements specified 302 herein within 5 minutes (recover) after being subjected to the specified HEMP environment. The 303 sets and feeder box operating in parallel (3 sets and one feeder box) shall meet operational 304 requirements specified herein within the same time it takes to start, parallel remotely, and 305 provide rated power at rated load (6.4.24) before and after being subjected to the specified 306 HEMP environment. The recovery for each may include manual or automatic correction of 307 HEMP induced changes in the set or feeder box, to include restart, but not the replacement of 308 piece parts or components. 309

3.6 Chemical, biological, radiological and nuclear (CBRN) contamination survivability. 310 The set and feeder box shall have a Chemical Agent Resistant Coating (CARC) painted as 311 specified in 3.36 and shall be so designed for contamination survivability in accordance with 312 MIL-STD-3056 Appendix A as applicable. The set and feeder box shall be capable of being 313 decontaminated (T), operated (T), and serviced (O) (3.16) by personnel wearing Mission 314 Oriented Protective Posture IV (MOPP IV) chemical, biological, and radiological clothing 315 (6.4.20) without special tools or support equipment. The set shall not be damaged (6.4.5) and 316 shall meet operational requirements specified herein within 60 minutes after being 317 decontaminated according to the procedure specified in APPENDIX A. 318

3.7 Electrical performance. Set electrical performance shall be as specified herein. Set 319 rating (3.2.1) shall be no less than 3kW at sea level (T), 1,000 feet (305 meters) (O) of altitude 320 and with an ambient temperature of +120°F (+49°C). Components of the set shall not be 321 damaged (6.4.5) when the set is operated continuously at all possible frequency and voltage 322 adjustments. The set shall provide the applicable load rating (3.8.2) at the output terminals under 323 all operating conditions specified herein. 324

3.8 Starting, operating, and stopping. The set, feeder box, and other accessories shall 325 perform in the various environments herein as required, where applicable, and with the 326 appropriate as applicable consumable (3.10), where each consumable is within their 327 recommended use conditions and shall provide the operator, while adorned in artic mittens or 328 MOPP IV clothing (6.4.20), the ability to control it. The planning guidance for realistic 329 consideration of climatic conditions in the Research, Development, Test, and Evaluation 330 (RDT&E) of material used in combat by the Army is described in AR 70-38. 331

3.8.1 Starting. The set shall start (6.4.32) within 5 minutes of the first user action in 332 accordance with the startup procedures with and without the battery under any combination of 333 the following conditions. The set shall start within 5 minutes of receipt of a remote signal, either 334 dry contact closure or via a TMS command, with NATO slave power or a set battery connected: 335

a. At ambient temperatures from –25°F (–32°C) to +120°F (+49°C) using the electric 336 start at any possible humidity; and from +20°F (–7°C) to +120°F (+49°C) using the manual start 337 at any possible humidity. 338

b. At altitudes up to and including 8,000 feet (2,438 meters) above sea level. 339

c. With the base of the set in planes from level up to 15 degrees (0.27 radians) from 340 level in any orientation. 341

d. With up to 5 inches (127 millimeters) of rain per hour impinging on the set at angles 342 ranging from the vertical up to and including 90 degrees (1.571 radians) from the vertical. 343

e. With up to 355 British Thermal Units (BTUs) per square foot per hour (1,120 watts 344 per square meter) of solar radiation. 345

f. With a sand/dust particle concentration of up to 1,400 mg per cubic meter. Particle 346 sizes shall range from less than 74 micrometers in diameter to 1,000 micrometers, with the bulk 347 of the particles ranging in size from 74 to 350 micrometers. 348

g. With a steady wind speed of up to 73 feet per second (22 meters per second) and 349 gusts up to 95 feet per second (29 meters per second) at a height of 10 feet (3 meters) above 350 ground level. 351

h. With accumulations of ice glaze, freezing rain and hoarfrost of up to 0.5 inch (13 352 millimeter) and up to a specific gravity of 0.9. 353

i. In a salt fog or sea-spray environment. 354

j. With fuels, lubricants, and coolants specified in 3.10. 355

3.8.2 Operating. Immediately after starting or with the remaining time left from startup 356 while at no load operation, the set, feeder box, and all other accessories shall operate without 357 damage (6.4.5 and 6.4.34) or failure (6.4.11) at all loads, continuous and intermittent, up to and 358 including rated load (6.4.24) under any of the conditions or combinations of the conditions 359 specified in 3.8.1, except that for the set rating as stated in 3.7: 360

a. At 4,000 feet (1,219 meters) altitude and +95°F (+35°C), set rated load (6.4.24) de-361 rating shall not exceed 10 percent (T), 5 percent (O). 362

b. At 8,000 feet (1,219 meters) altitude and +95°F (+35°C), set rated load de-rating shall 363 not exceed 30 percent (T), 23.3 percent (O). 364

3.8.3 Stopping. The set shall stop (6.4.33) within 60 seconds after activation of any 365 device intended to stop the set. Any cool down feature not requiring engine power can continue 366 to draw power from the set battery(ies) but not to a point where the set battery(ies) cannot start 367 the set (3.28.7.2.1). 368

3.8.4 Colder temperature. The set shall perform as prescribed in 3.8.1 through 3.8.3, 369 inherently, or with an accessory, at an ambient temperature of –65°F (–54°C) where the set is 370 electrically started and where the total time to start and operate is 10 minutes (O). If applicable 371 and if in parts, parts of the accessory that requires removal of set components (longer than 5 372 minutes each to remove) in order to install (i.e. engine, harness, etc.) or installation at ambient 373 conditions herein is impractical (i.e. adhesives used to attached the parts will not cure, etc.), 374 those accessory parts shall come with every set, making it inherent to the set, and as such, 375 included in the dry weigh of the set (T). 376

3.9 Endurance (life). The set shall operate for 2,150 hours without critical failure 377 (6.4.11.1) at all loads, continuous and intermittent, up to and including rated load (6.4.24) under 378 all of the conditions specified in 3.8.2. 379

3.10 Fuels, lubricants, and coolants. 380

3.10.1 Fuels. The set, while operating on F-24 fuel conforming to NATO STANAG 381 3747, Jet Propulsion (JP)-8 fuel conforming to MIL-DTL-83133, or diesel fuel conforming to 382 ASTM D975, shall meet all the requirements specified herein. Diesel fuel shall be of grades 383 very low or low sulfur (No. 1-D S15, No. 2-D S15 [also known as Ultra Low Sulfur Diesel 384 (ULSD)] or 1-D S500, No. 2-D S500). The set, while operating on JP-5 conforming to MIL-385 DTL-5624, shall meet all requirements herein, except rated load (6.4.24) may be reduced up to 386 20 percent and a maximum of 300 hours of operation on JP-5 per 2,150 hours of set operation 387 shall be required. Operation on JP-5 shall only be required at temperatures from 0°F (–18°C) to 388 +100°F (+38°C) and at altitudes up to 1,000 feet (305 meters). No manual adjustment is allowed 389 when changing between the above fuels. 390

3.10.2 Lubricants. The engine shall operate on lubricating oil conforming to MIL-391 PRF-2104 and MIL-PRF-46167, gear oil conforming to SAE J2360, grease conforming to MIL-392 PRF-10924, and preservative/break-in oils conforming to MIL-PRF-21260 as applicable. 393

3.10.3 Coolant. If a liquid cooled engine is used in the set, the engine shall be capable 394 of operating with coolants conforming to A-A-52624. 395

3.11 Other set requirements. 396

3.11.1 Overspeed. The set shall withstand engine operation at 110 percent of rated 397 speed (6.4.25) for 5 minutes without damage (6.4.5). 398

3.11.2 Flexural vibration and critical speeds. The set shall be free from dangerous 399 flexural vibrations (6.4.6) and dangerous torsional critical speeds (6.4.7) between the minimum 400 low idle speed and 115 percent of rated speed (6.4.25). 401

3.11.3 Vibration Stress. The set and feeder box shall be capable of withstanding 402 vibrational stresses without damage (6.4.5) during transportation and operational modes. 403

3.11.4 Maximum power. The minimum acceptable maximum power shall be 110 404 percent of rated real power under all operating conditions specified herein, except that at 405 altitudes above 1,000 feet (305 meters), the minimum maximum power shall be no less than the 406 de-rating allowed at altitudes and temperatures above 1,000 feet (305 meters) (3.8.2). 407 Production sets shall have a maximum power of not less than 2 percent below the average 408 maximum power measured for the First Article Test (FAT) sets when corrected for the same 409 conditions. 410

3.11.5 Fuel consumption. The set shall consume JP-8 fuel (6.56 pounds per gallon), F-411 24, and No, 2-D S15 at a rate less than 0.36 gallons per hour while operating at rated load 412 (6.4.24) in ambient conditions; less than 0.40 gallons per hour for JP-5 under the same conditions 413 except that load is at actual derated load if applicable. 414

3.12 Transportability. 415

3.12.1 Lifting and tiedown provisions. Mechanical lifting and tiedown provisions shall 416 be provided in accordance with MIL-STD-209, except as specified herein. Slinging and 417 multipurpose tiedown provisions shall have a minimum inside clearance of 1.969 inches, and a 418 maximum inside clearance of 2.169 inches. Slinging and multipurpose tiedown provisions shall 419 have a minimum clearance from the set surface to the farthest inside edge of 1.969 inches and a 420 maximum clearance from the set surface to the farthest inside edge of 3.969 inches. The 421 identification of slinging, tiedown, or multipurpose provisions shall be in letters not less than 422

0.375 inches in height. The set, with fuel tank 1/4 full to full, with or without the battery shall 423 remain within 15 degrees of level when lifted. Lifting provisions shall be marked "LIFT 424 HERE", and tiedown provisions shall be marked "TIE-DOWN". 425

3.12.2 Rail tiedown procedures. Procedures for mounting of the sets to a rail flat car 426 for shipment (transportation) shall be provided. Mounting of the sets shall be in accordance with 427 standard loading and bracing methods as shown in Section 1 “General Rules for Loading All 428 Commodities” and Section 6 "Rules for Loading Military Equipment and Materiel" of 429 Association of American Railroads (AAR) Open Top Loading Rules (OTRL) Manual. 430

3.12.3 Air transportability. The set and feeder box shall not be damaged (6.4.5) by 431 aircraft and helicopter transportation (6.4.2), and shall be transportable while facing forward, aft 432 and to either side. 433

3.12.3.1 Internal air transport. The lifting and tiedown provisions (3.12.1) shall meet the 434 requirements of MIL-STD-209. The set and feeder box shall be capable of being transported in a 435 C-130 or larger aircraft and inside utility rotary wing aircraft while facing forward, aft, or to 436 either side. 437

3.12.3.2 Military airdrop. The sets and feeder boxes shall be capable of being platform 438 mounted while facing forward, aft, or to either side. The set and feeder box shall meet the 439 requirements of MIL-STD-814 for Low Velocity Airdrop (LVAD). 440

3.12.4 Rail transport. The set and feeder box while facing forward, aft and to either 441 side shall be capable of being rail transported (6.4.23) on all open top railcars without damage 442 (6.4.5). 443

3.12.5 Utility vehicle and trailer transport. The set and feeder box shall be capable of 444 being transported by utility vehicle, truck, or trailer transportation (6.4.36) while facing forward, 445 aft, or to either side without damage (6.4.5). 446

3.12.6 Inclined transportation. The set and feeder box shall be capable of being 447 transported while in an operable condition but not operating, when inclined at any angle from 448 horizontal to 25 degrees from horizontal in any direction, and with the set fuel tank at any 449 possible level from empty to full, with no spillage or seepage from the set or any of its 450 components. 451

3.12.7 Forklift openings. Openings shall be provided in the skid base to permit 452 insertion of forklift tines. Each opening shall be not less than 8 inches long and 2.5 inches in 453 height and the openings shall be located such that the center of gravity of the set falls between 454 the centers of the forklift openings. The distance between the centers of the openings shall be a 455 multiple of 2 inches but not more than 28 inches nor less than 18 inches. The openings shall be 456 reinforced and equipped with guides such that the set will not be damaged (6.4.5) if it is lifted by 457 a forklift, with the tines not extended completely through the base. Each opening shall be 458 marked "FORKLIFT HERE" in 0.75 inch minimum letter height. 459

3.12.8 Handling. The set shall have provisions such that six soldiers can manually lift 460 and transport the set. These provisions shall be located below the centerline of the set, and shall 461 be suitable for use by personnel wearing arctic mittens and MOPP IV clothing (6.4.20). Handles 462 shall be located such that soldiers can lift and carry the set without interfering with one another. 463 The handling provisions shall be within the set maximum dimension (3.18) when not in use. If 464 non-fixed handles are used, the handles must have a stop position perpendicular to the surface on 465 which they are mounted, and be parallel to the ground when positioned for use. Any two 466 opposing handles shall be capable of supporting the weight of the set. 467

3.12.9 Wheel and handle. If the set weights more than 100 pounds (45 kg), the set 468 shall have a detachable wheel and handle accessory suitable for one solider to move (pull) the set 469 over paved and unpaved firm or gravel surfaces; and packed dirt or sand. The accessory shall 470 include any and all hardware required to install on the set. The force required to pull the set shall 471 not exceed 45 pounds (200 Newtons) in accordance with MIL-STD-1472 (TABLE XLVIII with 472 high traction) on a level surface. The set shall not be caused to have spilled liquids, fall over, or 473 damage (6.4.5) by the install or usage (movement and stationary) when all fluids are at their full 474 capacity. The accessory shall have the ability to prevent movement when the set is stationary on 475 a 15 degree incline when installed and while operating without the need for tools. The accessory 476 installation shall not require more than one solider to install properly. 477

3.13 Storage. The set and feeder box without packaging shall not be damaged (6.4.5 and 478 6.4.34) by exposure to: 479

a. Storage at –60°F (–51°C) to +160°F (+71°C). 480

b. Salt fog environment. 481

c. All possible relative humidities. 482

The set and feeder box shall be operational with minimal preparation after removal from storage 483 consistent with standard DoD practice. Procedures for storage and preservation shall be 484 incorporated in the technical manuals. 485

3.14 Safety. The set shall meet the provisions of MIL-STD-882, Warnings, hazards, and 486 safety of MIL-STD-1472 (as specified in 3.25), and should use the guidelines of MIL-HDBK-487 454 for guidance, specifically guideline 1. Exposed parts of such nature as to be a hazard to 488 personnel shall be insulated, enclosed or guarded without impairing the functioning of these 489 parts. 490

3.15 Electromagnetic interference (EMI). EMI and susceptibility characteristics shall 491 comply with the requirements of MIL-STD-461 for conducted emissions (CE102) (remote one 492 and three receptacles), conducted susceptibility (CS101, CS114, CS115, CS116, and CS118), 493 radiated emissions (RE102), and radiated susceptibility (RS103). A 5 meter (T), 3 meter (O) 494 standoff distance is allowable in order to meet this requirement. 495

3.16 Servicing, operation and maintenance. The design and construction of the set shall 496 permit routine service and maintenance under military field conditions. Any unscheduled 497 maintenance which requires the removal of the set housing shall be validated before the set 498 housing is replaced. The set shall be capable of being started and operated by one operator under 499 all conditions. Starting or stopping the set shall not require manipulation of more than one 500 control or switch, except for the activation of the engine starting aid control device (3.32.1.4). 501 Hardware which requires torqueing shall be installed such that the nut, bolt or screw head is 502 accessible for torque wrench application. In assemblies where both a bolt and nut are used, the 503 nut shall be accessible for torque wrench application. When Test, Measurement and Diagnostic 504 Equipment (TMDE) is required, TMDE shall be selected from the TMDE Preferred Items List 505 (PIL) (See Appendix B). Requirements for any new TMDE shall be developed in accordance 506 with AR 750-43, Army TMDE Program. The design shall maximize the use of existing tools 507 available in the following tool kits: the General Mechanic's Tool Kit (GMTK) NSN 5180-01-508 605-5146 (SC 5180 95-B49), the Standard Automotive Tool Set (SATS) NSN 4910-01-490-509 6453 (SC 4910-95-A81), the Forward Repair System (FRS) NSN 4940-01-533-1621 (SC 4940-510 95-E42), and the Shop Equipment Contact Maintenance (SECM) NSN 4940-01-548-9064 (SC 511 4940-95-B36) for all set maintenance and service actions if not already tethered to the set. The 512 design should avoid the need for a new special tool or new TMDE, and if required, the request 513 shall be made as soon as the need is recognized in the design. Servicing, operation and 514 maintenance requirements shall be met with the set on the ground. Design for maintainability 515 shall comply with 3.25. Particular design attention shall be given to paragraph 5.9 (especially 516

5.9.11.3 - Captive fasteners) of MIL-STD-1472 as specified in 3.25. Fasteners used for 517 scheduled maintenance shall be visible to the maintainer. Fluid indicators shall be easily and 518 readily accessible. 519

3.16.1 Alternate clothing servicing. Parts that require adjustment or servicing shall be 520 capable of being adjusted or serviced by personnel wearing arctic clothing, and/or MOPP IV 521 (6.4.20) chemical, biological and radiological clothing (O). 522

3.16.2 Fuses. If any non-resettable fuses are use, a spare fuse shall be stored and 523 properly marked close to the location of the fuse it is a spare for (T). Replacement of non-524 resettable fuses shall take no more than 5 minutes and not require tools (T). No non-resettable 525 fuses shall be used (O). 526

3.16.3 Maintainability requirements. Maintainability requirements shall be applicable 527 to the generator set while operating on the ground. The complete maintenance schedule, 528 preventive and scheduled, shall be followed throughout the first article inspection (4.4). 529

3.16.3.1 Preventive maintenance. The minimum interval (hours of set operation) 530 between scheduled preventive maintenance (checks, inspections, services), known as 531 Preventative Maintenance Checks and Services (PMCS), shall be 24 hours (T), 36 hours (O). 532 Preventive maintenance shall be simple enough for any Soldier (regardless of specialty) to 533 perform in less than 15 minutes (T), 5 minutes (O). Preventive maintenance actions shall include 534 but not be limited to the following: 535

a. Inspecting for loose connections, leaks, cracks, and making minor adjustments. 536

b. Checking and adding lubricating oil. 537

c. Draining of contaminants from fuel filters and water separators through drain valves. 538

d. Checking and servicing of the battery. 539

e. Checking and adding coolant if applicable. 540

f. Checking and servicing of air filters. 541

3.16.3.1.1 Oil level. The oil level shall be able to be checked while the set is in 542 operation without causing damage (6.4.5) (O). 543

3.16.3.2 Scheduled maintenance. The minimum interval (hours of set operation) 544 between scheduled maintenance services (adjustments, replacements, etc.) shall be not less than 545 100 hours (T), 150 hours (O). Scheduled maintenance service intervals for the set life (3.9) shall 546 be as recommended by the contractor. The maximum time for all scheduled maintenance actions 547 at each scheduled maintenance interval, performed at intervals less than 2,000 hours, shall be 2 548 hours when conducted by one person (MOS-91D). Without tools, one person shall be able to 549 change the oil and replace the oil filter, or replace or clean the fuel and air filters, within 20 550 minutes (T), 10 minutes (O). 551

3.16.3.3 Unscheduled maintenance. The Median Time to Repair (MTTR) (6.4.19) for all 552 unscheduled maintenance actions at the field level shall not exceed 1 hour (T), 0.5 hours (O). 553 The Maximum Time to Repair (MAXTTR) (6.4.18) for 90 percent of all unscheduled 554 maintenance actions shall not exceed 2 hours (T), 1 hour (O). 555

3.16.4 Maintenance Ratio. The maintenance ratio (6.4.17) of the set shall not exceed 556

0.028 (T), 0.020 (O) maintenance man-hours per operating hour for the combined organizational 557 and direct support maintenance levels. 558

3.16.5 Diagnostic test points. The set shall include diagnostic test points as necessary 559 to fully monitor and troubleshoot the set. All diagnostic test points shall be located in one easily 560 accessible area inside the control panel. All test points shall be labeled and identified 561 (3.38.3.1.10). 562

3.16.5.1 Self-diagnostics. In lieu of or in addition to the diagnostic test points, the set 563 shall conduct and display to the operator or maintainer a self-diagnosis of all Line Replaceable 564 Units (LRUs) during start-up and during operation to allow operators and maintainers to take 565 corrective actions and to enhance troubleshooting of the set (O). 566

3.16.5.2 Prognostics. If self-diagnostics capable, the set shall monitor the internal health 567 of the system and identify malfunctions and warn of performance anomalies before they become 568 failures. It shall also store warnings, faults, and maintenance actions, and set operational data 569 that may be displayed to the operator but shall be accessed through the remote one receptacle in 570 accordance with the Tactical Microgrid Standard–Tactical Ground Power (TMS-TGP). 571

3.16.6 Engine/generator lifting attachments. A single lifting attachment shall be 572 provided for removal of both the engine and generator. The lifting attachment shall withstand, 573 without damage (6.4.5), a minimum of 3.5 times the weight of the lifted assembly. The inside 574 dimensions of the lifting attachment shall permit passage of a 2-inch diameter lifting device. 575

3.16.7 Maintenance mode. The set shall have a mode for performing maintenance 576 which is entered into by actuating a separate control device located on the control panel or within 577 the set. The control device shall be protected from accidental actuation through code (i.e. actuate 578 for 10 seconds, etc.) or through mechanical means (i.e. a protective cover, etc.), or both. This 579 mode shall only be cancelled by the cycling (removal and reconnection) of DC control power. 580 While in maintenance mode (6.4.16) the set shall not open the AC circuit interrupter (or DC 581 circuit interrupter if equipped) in the event that the energized AC load terminals (or DC load 582 terminals if equipped) become exposed. The control system shall report through the remote one 583 receptacle the set state of this mode while in the remote TMS state (6.4.29). If a continuous 584 display is provided, then the continuous display shall indicate the same mode state. 585

3.17 Interchangeability. Future sets realized from this PD or specification, shall use the 586 same engine, governing system, skid base, housing, frame, wiring harness, mounts, battery, 587 battery charging system, fuel system, air filter, oil filter, fuel filter, muffler and as many other 588 common components as practical of sets initially realized from this PD unless otherwise stated 589 elsewhere. 590

3.18 Physical configuration. 591

3.18.1 Shape. The shape of the set shall be rectangular to optimize the storage volume 592 within tactical vehicles. The set housing shall inherently or with an ancillary accessory allow for 593 stackability to further optimize the storage volume within tactical vehicles. This capability shall 594 support at least the weight of the same set stacked on top. The set top shall also inherently have 595 features to enable nesting into matching features in the skid base to further enhance the 596 capability. (O) 597

3.18.2 Size. The maximum dimensions of the set shall be no more than (O): 598

a. Length – 34.75 inches (882.65 millimeters). 599

b. Width – 27.80 inches (706.12 millimeters). 600

c. Height – 26.50 inches (673.10 millimeters) 601

d. Control panel location as shown in FIGURE 1 (the actual side of the set). 602

3.18.3 Weight. The set dry weight (6.4.9) shall not weigh more than 308 pounds (140 603 kilograms). 604

3.18.4 Skid base. The set shall have a skid base that extends horizontally beyond all 605 components of the set. The skid base shall be provided with a method to drain spilled liquids 606 from the interior of the set. There shall be at least a 1-inch clearance between the lowest 607 projection of the set and the bottom of the skid base. The set shall not move or "walk" when 608 operating unrestrained, on a level concrete surface, under all operating conditions specified 609 herein. The skid base may be integral with the set housing. 610

3.18.4.1 Bolt pattern. A four (4) hole bolt pattern shall be provided in the skid base of 611 the set (T). The bolt pattern shall be located such that that the longitudinal and lateral center of 612 gravity of the set falls approximately between the centers of the bolt holes (T). The bolt holes 613 shall be large enough to accommodate a half inch diameter bolt (T). The skid base bolt pattern 614 shall match FIGURE 1 (O). 615

FIGURE 1. Objective skid base bolt pattern. 617

3.18.5 Housing. The set housing shall be removable to perform unscheduled 618 maintenance actions including removal of engine, generator or other components. The housing 619 shall provide for access to the interior of the set, without removal of panels, as necessary to 620 perform all preventative and scheduled maintenance service (3.16.3.2) actions and also permit 621 replacement of the set battery while setting on the ground. Hinged doors, if used, shall be self-622 supporting in the open position. The door swing for any hinged door shall not exceed 20 inches. 623 The housing shall be permanently marked with a CAUTION against standing or storage of heavy 624 objects on its top and/or specifics about its limits. The housing shall have drain holes to allow 625 liquids to drain from within the housing. The set housing shall not cause injury to personnel as a 626 result of increased temperatures from internal components. The set housing shall exclude wind-627 driven rain, snow and sand from the interior of the set to the extent necessary to meet all 628 requirements herein. If a gasket is used, it shall be mechanically fastened to the housing. 629

3.18.6 Hinges and latches. Hinges or hinge pins shall be peened at the ends, or other 630 means shall be provided to prevent workout of the pins. Hinges shall be removable. Latches 631 shall require manual, not spring action, for closing. All parts of the latches having relative 632 motion with each other shall be of corrosion-resistant metal. Access door latches (3.18.5) shall 633 be flush mounted, non-key locking, dead bolt, and shall not require the use of tools for operation 634 or require more than a half turn to latch or unlatch a door. 635

3.18.7 Grounding and Bonding. Grounding and bonding (6.4.13 and 6.4.3) of the set 636 and accessories shall be in accordance with article 250 of the NFPA70 National Electric Code. 637 The set shall be capable of being connected to earth to limit the affects imposed by HEMP, EMI, 638 lightning, and static charges. All non-current-carrying metal parts that are accessible to users 639 and are likely to become energized due to an electrical fault shall be bonded and grounded. 640 Panels and doors shall be attached or hinged in such a manner as to ensure that they are at the 641 same ground potential as the rest of the set in which they are mounted, whether in a closed or 642 open position. Hinges or slides shall not be used for grounding paths. Ground connections to 643 shields, hinges, and other mechanical parts shall not be used to complete electrical circuits. The 644 impedance between the set ground (3.19.1.2) and to any bonded non-current carrying metal part 645 shall be less than 0.1 ohms. 646

3.18.7.1 Set ground rod. A three-section ground rod and the ground rod accessories 647 (grounding conductor, grounding conductor clamp, and ground rod section interconnects) 648 conforming to A-A-55804-III-B shall be provided with each set (including both first article and 649 production). Provisions for storage of the ground rod sections and its accessories, internal to the 650 set, shall be provided, if the size of the set is large enough to allow for storage of ground rods 651 and its accessories. If the ground rods and its accessories are stored within the set, door(s) 652 through which ground rods are accessed shall be marked "GROUND ROD" on the outside. 653

3.18.8 Spacings. The minimum creepage and clearance (6.4.4) distances between 654 uninsulated live parts of opposite polarity and between uninsulated live parts and non-current-655 carrying metal parts shall be no less than the spacing distances in TABLE I. The shortest 656 distance between any output load terminals, including the ground terminal (3.19.1), shall be no 657 less than 1.25 inches (31.8 millimeters). 658

TABLE I. Spacings. 659

Potential involved, in volts, RMS AC or

DC

Minimum spacings, inch (millimeter)

0 – 30V 31 – 150V 151 – 300V

301 – 600V

Between any uninsulated live part and an uninsulated live part of opposite polarity, uninsulated grounded part other than the enclosure.

Creepage (Over surface)

0.0625 in (1.6mm)

0.125 in (3.2 mm)

0.25 in (6.4 mm)

0.375 in (9.5 mm)

Between any uninsulated live part and an uninsulated live part of opposite polarity, uninsulated grounded part other than the enclosure.

Clearance (Through air)

0.0625 in (1.6mm)

0.25 in (6.4 mm)

0.375 in (9.5 mm)

0.5 in (12.7 mm)

Between any uninsulated live part and any metal feature of a metal enclosure.

Shortest distance

0.25 in (6.4 mm)

0.5 in (12.7 mm)

0.5 in (12.7 mm)

0.5 in (12.7 mm)

3.19 Load terminals, load receptacles, and circuit interrupter. Load terminals, load 662 receptacles, and circuit interrupters shall be protected from accidental contact and shall be 663 protected from the environments while in use or not in use, attended or not attended, see section 664

406.9 “Receptacles in Damp or Wet Location” of NFPA 70 National Electrical Code. The AC 665 load terminals (and DC load terminals, if equipped) shall not be energized if a protective door, 666 lid, or cover has opened or has been removed.