Attachment 3 Perf Spec Rev 1 2025-04-02 for (PBC).pdf

DO NOT USE FOR PROCUREMENT

NOTE: This draft, dated 2 April 2025, has not been approved for procurement.

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

PERFORMANCE SPECIFICATION

FOR THE

PLATOON BATTERY CHARGER (PBC) & ACCESSORIES

PM-SWAR-SP-PBC-040225

Revision 1

April 2, 2025

Product Manager Soldier Warrior

Attn: SFAE-SDR-SWAR

10125 Kingman Road

Fort Belvoir, VA 22060 ii

PLATOON BATTERY CHARGER (PBC) & ACCESSORIES

PM-SWAR-SP-PBC-040225

Prepared and reviewed by:

Dan Milliken

Electronics Engineer

DEVCOM C5ISR Center

Date

Prepared and approved by:

Kevin Chu

Systems Engineer

Soldier Power

Product Manager Soldier Warrior

Date iii

PLATOON BATTERY CHARGER (PBC) & ACCESSORIES

PM-SWAR-SP-PBC-040225

REVISION

HISTORY

CHANGE RECORD

This sheet is a record of each issue of this document.

When the revised document is issued, the previous issue is automatically superseded.

VERSION DATE CONFIGURATION

MANAGEMENT

PAGES

CHANGED

REASON FOR

CHANGE

Initial Draft 4/2/2025 - -iv

Table of Contents

1 SCOPE

1.1 Scope

2 APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 Order of precedence

3 REQUIREMENTS

3.1 Reserved

3.2 Inspections

3.2.1 First article

3.2.2 Certification of conformity

3.3 Reserved

3.4 Physical characteristics

3.4.1 Dimensions

3.4.2 Weight

3.4.3 Color

3.4.4 Visual inspection

3.4.5 Stackable

3.4.6 Handles

3.4.7 Transport configuration

3.4.8 System connectors

3.4.9 Indicators

3.4.10 Chemical agents

3.4.11 Marking

3.5 Performance characteristics

3.5.1 Battery charging

3.5.2 USB ports

v

3.5.3 Operability

3.5.4 System characteristics

3.5.5 Electrical characteristics

3.6 Electrical conditions

3.6.1 Electromagnetic interference (EMI)

3.6.2 Reserved

3.6.3 AC spikes and surges

3.6.4 DC spikes and surges

3.7 Environmental conditions

3.7.1 Temperature

3.7.2 Humidity

3.7.3 Low pressure (altitude)

3.7.4 Salt fog

3.7.5 Solar radiation

3.7.6 Temperature shock

3.7.7 Transit

3.7.8 Crash hazard shock

3.7.9 Vibration

3.7.10 Immersion

3.7.11 Sand and dust

3.7.12 Rain

3.7.13 Fungus

3.7.14 Icing

3.7.15 Parachute landing fall impact

3.8 System safety

3.8.1 General safety

3.8.2 Electrical shock

3.8.3 Short circuit

3.8.4 Over/under-temperature

3.8.5 Safety features

3.9 Reliability

3.10 System accessories

3.10.1 Solar panel

vi

3.10.2 External AC to DC converter

3.10.3 Cables

3.10.4 Additional DC inputs

3.10.5 Hard cover

3.10.6 Soft cover

3.10.7 Transportation case

3.11 Repairability

4 VERIFICATION

4.1 Verifications of inspections

4.1.1 First article units

4.1.2 First article inspection

4.1.3 Classification of verification

4.1.4 Methods of verification

4.1.5 Basis for verification

4.2 Conformance inspection

4.2.1 Nonconformance

4.2.2 Sampling and order of inspection

4.3 Common procedures

4.3.1 Basic operational test (BOT)

4.3.2 Basic functional test (BFT)

4.4 Physical characteristics

4.4.1 Dimensions

4.4.2 Weight

4.4.3 Color

4.4.4 Visual inspection

4.4.5 Stackable

4.4.6 Handles

4.4.7 Transport configuration

4.4.8 System connectors

4.4.9 Indicators

4.4.10 Chemical agents

4.4.11 Marking

4.5 Performance characteristics

vii

4.5.1 Battery charging

4.5.2 USB ports

4.5.3 Operability

4.5.4 System characteristics

4.5.5 Electrical characteristics

4.6 Electrical conditions

4.6.1 Electromagnetic interference (EMI)

4.6.2 Reserved

4.6.3 AC spikes and surges

4.6.4 DC spikes and surges

4.7 Environmental conditions

4.7.1 Temperature

4.7.2 Humidity

4.7.3 Low pressure (altitude)

4.7.4 Salt fog

4.7.5 Solar radiation

4.7.6 Temperature shock

4.7.7 Transit

4.7.8 Crash hazard shock

4.7.9 Vibration

4.7.10 Immersion

4.7.11 Sand and dust

4.7.12 Rain

4.7.13 Fungus

4.7.14 Icing

4.7.15 Parachute landing fall impact

4.8 System safety

4.8.1 General safety

4.8.2 Electrical shock

4.8.3 Short circuit

4.8.4 Over/under-temperature

4.8.5 Safety features

4.9 Reliability

viii

4.10 System accessories

4.10.1 Solar panel

4.10.2 External AC to DC converter

4.10.3 Cables

4.10.4 Additional DC inputs

4.10.5 Hard cover

4.10.6 Soft cover

4.10.7 Transportation case

4.11 Repairability

5 PACKAGING

5.1 Packaging

6 NOTES

6.1 Intended use

6.2 Acquisition requirements

6.3 Battery interfaces

6.4 Government-run test

6.5 Random tests

6.6 Lessons learned and other information

6.6.1 Conformal Wearable Battery (CWB)

6.6.2 AN/PRC-148

6.6.3 AN/PRC-152

6.6.4 Reserved

6.6.5 AN/PRC-163

6.6.6 BB-2590/U, BB-390/U, and BB-2557/U

6.6.7 Batteries

6.6.8 NATO Slave

6.7 Definitions

6.7.1 Adapter

6.7.2 Battery channel

6.7.3 Adapter port

6.7.4 Battery position

6.7.5 Battery

6.7.6 Charger

ix

6.7.7 Cold Weather Glove System

6.7.8 Efficiency

6.7.9 Inspection lot

6.7.10 Mean time between essential function failure (MTBEFF)

6.7.11 Mean time to repair (MTTR)

6.7.12 Night Vision Imaging System (NVIS) Compatibility

6.7.13 Non-smart battery

6.7.14 Open sourced

6.7.15 Operational configuration

6.7.16 Preventive maintenance

6.7.17 Smart battery

6.7.18 State of charge

6.7.19 State of health (SoH)

6.7.20 Transport configuration

6.8 Subject term (key word) listing

7 APPENDIX(ES)

7.1 APPENDIX A

1 SCOPE

1.1 Scope.

This specification establishes the performance and verification requirements for the Platoon Battery

Charger (PBC) and accessories. The UBC-X is a platoon level ‘smart charger’ capable of charging multiple Soldier batteries for both military unique and commercial end items. It can operate from a variety of AC and DC input sources, is intended for Tier 1 (most austere) environments, and will be used by Soldiers under a variety of weather conditions.

2 APPLICABLE DOCUMENTS

2.1 General.

The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

Comments, suggestions, or questions on this document should be emailed peosoldierstp@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.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks.

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

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N w/CHANGE 1 Identification Marking of U.S. Military Property

MIL-STD-461G Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment

MIL-STD-810H w/CHANGE 1 Department of Defense Test Method Standard

MIL-STD-1275F Department of Defense Interface Standard: Characteristics of

28 Volt DC Input Power to Utilization Equipment in

Military Vehicles

MIL-STD-1472H Department of Defense Design Criteria Standard: Human

Engineering

MIL-STD-3009 Department of Defense Interface Standard: Lighting, Aircraft, Night Vision Imaging System (NVIS) Compatible

MIL-STD-13231 w/CHANGE 2 Marking of Electronic Items

(Copies of these documents are available online at https://assist.dla.mil)

2.2.2 Other Government documents, drawings, and publications.

The following other Government documents, drawings, and publications 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.

ADS-37A-PRF Electromagnetic Environmental Effects (E3) Performance and

Verification Requirements

(Relevant pages of this document can be found in APPENDIX A herein)

Title 47 FCC Part 15 Federal Communications Commission rules and regulations regarding unlicensed transmissions

(Copies of this document can be found at http://www.fcc.gov/encyclopedia/rules-regulations-title-47)

2.3 Non-Government publications.

The following documents 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.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

http://www.fcc.gov/encyclopedia/rules-regulations-title-47

ASME Y14.38 Abbreviations and Acronyms

(Copies of this document are available from ASME at www.asme.org)

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60320-3 Appliance couplers for household and similar general purposes –

Part 3: Standard sheets and gauges

(Copies of this document are available from online from IEC at www.iec.ch)

NEMA: National Electrical Manufacturers Association

ANSI/NEMA WD 6-2002 Wiring Devices - Dimensional Requirements

(Copies of this document are available from online from ANSI at webstore.ansi.org)

SAE INTERNATIONAL

SAE-AMS-STD-595 Colors Used in Government Procurement

(Copies of this specification are available online from SAE International www.sae.org)

SMART BATTERY CHARGER IMPLEMENTATION FORUM

Smart Battery Charger Specification, Rev 1.1

(Copies of this specifications are available online from SBS-IF at www.sbs-forum.org)

UNDERWRITERS LABORATORIES

UL 60950-1 Information Technology Equipment

(Copies of this specifications are available online from UL at www.ul.com)

USB IMPLEMENTERS FORUM

Battery Charging Specification, Revision 1.2

Universal Serial Bus Specification 3.2 Revision 3.1

(Copies of these specifications are available online from USB-IF at www.usb.org) file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.asme.org file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.iec.ch https://webstore.ansi.org/ file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.sae.org file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.sbs-forum.org http://www.ul.com/ file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.usb.org

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 Reserved.

3.2 Inspections.

3.2.1 First article.

When specified (See 6.2), a sample of chargers shall be subject to first article inspection in accordance with 4.1.

3.2.2 Certification of conformity.

Certification of conformity shall be provided for the following requirements. The Government reserves the right to verify any or all certifications.

TABLE I. Requirements requiring certification.

Requirement Paragraph

Handles. 3.4.6

Non-proprietary connectors. 3.4.8.1

Chemical agents. 3.4.10

Charger connection. 3.5.1.3.2

Upgradeability. 3.5.4.4

Reserved. 3.6.2

General safety. 3.8.1

Touch current (leakage current). 3.8.1.1

Electric strength. 3.8.1.2

Retained charge. 3.8.1.3

Radioactive or hazardous materials. 3.8.5.1

3.3 Reserved

3.4 Physical characteristics.

3.4.1 Dimensions.

Add: The charger volume shall be not greater than 1.6 cubic feet when in transport configuration (see

3.4.7). No individual measurement (e.g. height, length or width) shall be greater than 30 inches. Verify in accordance with 4.4.1.

TABLE II. System dimensions.

Dimension Charger in transport configuration

Width ≤ 30 inches

Length ≤ 18 inches

Height ≤ 12 inches

Volume ≤ 1.6 cu. ft.

3.4.2 Weight.

The total weight of the charger, in fully operational configuration including a full set of CWB adapters and the AC power cable, shall weigh not greater than 35 pounds. Verify in accordance with 4.4.2.

3.4.3 Color.

The charger and adapters shall be green (chip number 34088), tan (chip number 33446), or black (chip number 37030) per SAE-AMS-STD-595. Surfaces shall have a dull lusterless finish. Cables may be lusterless black (FED STD-595 color number 37038). Electrical contacts are excluded from this requirement. Verify in accordance with 4.4.3.

3.4.4 Visual inspection.

Products will be inspected prior to delivery to the government in samples or groups (size/frequency to be agreed upon with the government). The charger and all components shall be free from defects including but not limited to the following:

a. Loose screws or fasteners.

b. Misaligned parts.

c. Chips or scratches in the finish.

d. Dents.

e. Burrs or sharp edges.

f. Misaligned or peeling labels.

g. Material occluding electrical contacts.

Verify in accordance with 4.4.4.

3.4.5 Stackable.

When in transport configuration (see 3.4.7), the charger shall be stackable and stable up to 5 high without damage.

3.4.5.1 Vertical alignment.

The charger shall employ vertical alignment methods to prevent stacked chargers from shifting beyond the footprint of the bottom charger and ensure aligned stacking. Verify in accordance with 4.4.5.1.

3.4.6 Handles.

The charger shall have a carrying handle(s) that meets all requirements stated in MIL-STD-1472 for handles and grasp areas for a gloved or mittened hand. Certification of compliance with MIL-STD-1472 is required. Verify in accordance with 4.4.6.

3.4.6.1 Handle strength.

The charger carrying handle(s) shall be capable of withstanding forces not less than three times the weight of the charger. Verify in accordance with 4.4.6.1.

3.4.7 Transport configuration.

The charger shall be able to be safely transported with all external components required for operation, to include one full set of adapters and the AC cable. Any combination of adapters (see 3.5.1.3) required to charge batteries listed in TABLE V shall be capable of being transported fully installed and ready to operate. The charger and required components, in transport configuration, shall be capable of being carried by one person with one hand. Verify in accordance with 4.4.7.

3.4.8 System connectors.

Any connector placed on the exterior of the case shall not protrude beyond the maximum dimensions of the case. Any connector placed on the exterior of the case shall include some form of a tethered protection from damage while not in use. The connector protectors shall withstand not less than 5 lbs. of pull force when not on the connector. Verify in accordance with 4.4.8.

3.4.8.1 Non-proprietary connectors.

All system connectors, including battery interfaces, shall be open sourced to the government (see 6.7.14).

Verify in accordance with 4.4.8.1.

3.4.8.2 DC input connector.

The charger shall have one DC input connector. The DC input connector shall be clearly identified as such. Verify in accordance with 4.4.8.2.

TABLE III. Reserved.

Reserved.

Reserved..

FIGURE 1. Reserved.

3.4.8.3 AC input connector.

The charger shall have one AC input connector. The AC input connector shall be a 3-prong receptacle compliant with IEC 60320 type C14. The AC input connector shall be capable of mating with the AC

Cable defined in 3.10.3.1. Verify in accordance with 4.4.8.3.

3.4.8.4 System modular connector.

N/A.

3.4.8.5 USB ports.

There shall be no less than four USB Type-C PD ports. The maximum power of the port(s) shall be clearly labeled near the port(s) (ex. “PD100W”). The maximum supported power may be for individual, or all ports, but shall be clearly labeled as such. The port(s) shall have tethered cover(s) that can be installed and removed without the use of tools. The cover(s) shall be replaceable using a Phillips size screwdriver. Verify in accordance with 4.4.8.5.

3.4.8.6 Firmware upgrade port.

The charger shall include a port to allow for field programmable software / firmware updates. The firmware upgrade port shall use a USB Type-C receptacle. The firmware upgrade port shall be protected by a removable cover when not in use. The use of a PH0 or PH1 screwdriver is permitted for the user to access this port. Verify in accordance with 4.4.8.6.

3.4.9 Indicators.

All indicators/displays shall be readable in full sunlight at a distance of at least 3 feet. Verify in accordance with 4.4.9.

3.4.9.1 Blackout mode.

3.4.9.2 Charger status indicators.

The charger shall provide a visual indication of system status and battery charging status. Each battery’s charging status shall be displayed as indicated below in TABLE IV:

TABLE IV. Battery charging indicators.

Indication: Meaning / Remarks

Amber – Green –Red alternating Power on self-test

Rapid Flashing Amber Battery pre-charge check – initiated within 60 seconds of battery being emplaced.

Solid Amber Battery Charging

Flashing Green Battery Charged to > 90% of capacity

Solid Green Battery Fully charged (> 95%)

Solid Green for 1 sec with Solid Red for 1 sec alternating

Battery charged, State of Health (SoH)* less than 80%, but, battery charged to its maximum

Solid Amber for 1 sec to Solid Red for 1 sec alternating.

Battery Temperature too hot or too cold to charge

Solid Red Battery Fault

Flashing Red Charger Fault

*State of Health, see 6.7.19.

Verify in accordance with 4.4.9.2.

Battery capacity.

The charger shall have the capability to indicate the current available charge in each battery with a digital display (see 3.4.9.3). Verify in accordance with 4.4.9.2.1.

3.4.9.3 Digital display.

The charger shall provide digital (LCD or similar) display(s) which indicates, at a minimum:

a. State of charge (%) for each battery

b. State of health (%, see 6.7.19) for each battery. May be accessible through a menu or button selection.

c. Estimated time to complete charge for each battery (hh:mm format). May be accessible through a menu or button selection.

d. Any system or battery faults.

Verify in accordance with 4.4.9.3.

3.4.10 Chemical agents.

The charger and accessories shall be decontaminable to a level which permits negligible risk (less than five-percent incapacitation) to unprotected personnel after an exposure period not to exceed 24 hours.

Verify in accordance with 4.4.10.

3.4.11 Marking.

The charger and all component markings shall conform to MIL-STD-13231. The charger shall have an

Item Unique Identification Device (IUID) not less than ½ inch square, in accordance with MIL-STD-130.

Verify in accordance with 4.4.11.

3.4.11.1 Nameplate label.

The charger shall have a nameplate label. The material used for this label shall be non-reflective. The label shall have a background color that conforms to 3.4.3 with contrasting text color. The charger shall use character sizes in compliance with MIL-STD-130. Verify in accordance with 4.4.11.1.

Nameplate information.

The user readable nameplate label shall include the IUID matrix in accordance with MIL-STD-130 and both shall include the following information:

a. PP-XXXX (battery charger nomenclature when available)

b. National Stock Number (NSN)

c. Contract number

d. Serial number

e. Manufacturer’s part number

f. Manufacturer’s Commercial And Government Entity (CAGE) Code

g. Date of Manufacture (MM/YYYY)

h. Hardware revision number

i. Initial firmware revision number (see 3.4.11.2)

The nameplate label shall be visible to the operator. The material used for the label shall be weather-resistant and capable of withstanding the tactical and environmental requirements of this specification.

Verify in accordance with 4.4.11.1.1.

3.4.11.2 Firmware version label.

The charger shall have a label indicating the firmware version which is installed on the charger. There shall be provisions for the user to permanently indicate (e.g. using an indelible marker) newer versions on the label upon applying upgrades. Verify in accordance with 4.4.11.2.

3.4.11.3 Visibility of assembly markings.

Markings shall be readily visible with no disassembly of the charger other than the removal of the hard or soft covers. Verify in accordance with 4.4.11.3.

3.4.11.4 Battery interface nameplate labels.

All adapters for battery charging shall be labeled in accordance with MIL-STD-130 and shall include the following information:

a. System name (PP-XXXX)

b. Adapter name

c. National Stock Number (NSN)

d. Manufacturer’s part number

e. Serial number

f. Initial firmware revision number

g. Manufacturer’s Commercial and Government Entity (CAGE) Code

Verify in accordance with 4.4.11.4.

3.4.11.5 Battery interface markings.

Adapters shall be marked to identify the following information.

a. Battery(ies) charged by the adapter

b. Battery position (see 6.7.4) corresponding to the display

3.4.11.6 Power input/output label.

The charger shall include a permanent label indicating power input & output specifications. Power input shall be labeled in accordance with 3.5.5.1 and 3.5.5.2. Power output shall be labeled as the maximum possible power output for the battery interfaces (see 3.5.4.4.1). Additionally, this label should detail all possible USB DCP and USB PD port modes including voltages and maximum current levels. Verify in accordance with 4.4.11.6.

3.5 Performance characteristics.

3.5.1 Battery charging.

When operating at 21°C± 3°C, the charger shall be no less than 80% efficient when taking input power and distributing it to a full set of one type of battery. The charger shall be capable of charging batteries in the 5-33.6V range. The charger shall be capable of physically accepting and charging the batteries shown in section 3.5.1.1. While operating on its maximum specified input power, the charger shall charge the listed number of a specific battery, as shown in section 3.5.1.1, to 90% state of charge within the listed time. The charger shall continue charging batteries until 100% state of charge. Section 3.5.1.1 provides the number of each battery type, minimum factory capacity, and maximum times allowed for charging up to >90% SOC depleted batteries. Verify in accordance with 4.5.1.

3.5.1.1 Battery types and charge times.

TABLE V. Basic configuration and charge times.

Battery NSN

[Minimum] number required

Max charge time

(>90% SOC)

(hours)

BB-2590A/U 6140-01-633-9444 8 3.0

AN/PRC-148 Radio battery 6140-01-679-9214 16 2.0

AN/PRC-163 Radio battery 6140-01-678-7176 16 3.0

BB-2525 Conformal Wearable Battery (3.6) 6140-01-622-5688 15 3.5

BB-2525 Conformal Wearable Battery (3.6.2) 6140-01-705-6042 15 4.0

BB-2511 STUB 6140-01-699-2474 16 2.0

Minimum number of batteries charged shall be achieved using replaceable battery interface adapters alone, not STANREC 4819 interfaces or USB ports.

3.5.1.2 Charging protocols.

The charger shall charge only ‘smart’ (battery and charger communicate) batteries or batteries with charge enable pin. If the charger does not recognize the battery or establish communications, the battery shall not be charged and an error indication per 3.4.9.2 shall be displayed. Verify in accordance with

4.5.1.2.

System management bus (SMBus).

The charger shall be a Level 2/3 charger per Smart Battery Charger Specification Revision 1.1. The charger shall safely charge SMBus configured batteries, with a dedicated SMBus channel for each battery. The charger shall have at least two, independent cutoffs of power for battery type and temperature faults. The charger shall verify both SMBus safety signal pin (when available) and SMBus data prior to applying charge voltage and continuously during charging. The charger shall ensure that safely charging the battery is placed above meeting battery requested SMBus charging values. Verify in accordance with

4.5.1.2.1.

The charger shall include active pull-up circuits for SMBus clock and data signals to counter signal degradation over cables, connectors, and contact pads. The charger shall perform SMBus clock generation and arbitration according to the SMBus specification §4.3 to accommodate smart batteries acting as bus master or slave. Verify in accordance with 4.5.1.2.1.

Direct Query (DQ) protocol.

The charger shall be compliant to Texas Instrument’s BQ2050 standard sets and timing requirements. The charger shall safely charge DQ configured batteries. Verify in accordance with 4.5.1.2.2.

Non-smart rechargeable batteries.

The charger may provide charging to non-smart rechargeable batteries using unique replaceable battery interface(s) for those batteries. Detection of non-smart rechargeable batteries shall be limited to 1.68W power for no more than 60 seconds after the battery is emplaced on the charger. Verify in accordance with 4.5.1.2.3.

Charging priority.

Over-discharged batteries.

The charger shall attempt to revive over-discharged batteries. If communication or positive ID (in the case of a non-smart battery) is not established within 5 minutes, the charger shall cease to attempt to charge the battery and indicate the fault to the user (see para 3.4.9.2). The charger shall not attempt to charge the battery again until the battery is physically removed and reinserted by the user. Verify in accordance with

4.5.1.2.4.

3.5.1.3 Battery interface (adapters).

Replaceable battery interface.

The charger shall have the ability to be reconfigured to meet specific mission requirements through the use of interchangeable battery interfaces. The interchangeable battery interfaces shall allow the user to charge the batteries at the quantity stated as listed in 3.5.1.1, at a minimum, and provide a platform for future expansion. Each battery interface shall have a self-alignment feature to guide battery insertion and disallow reverse insertion. The battery interfaces should minimize the use of cables. The battery interface shall remain secured to the charger when in use and during transport. The battery interface shall be replaceable without the use of any tools and shall be able to be replaced in not greater than 30 seconds while wearing standard tactical military gloves. The battery interface shall be replaceable without the use of any tools while wearing Mission Oriented Protective Posture (MOPP) IV protective equipment and

Cold Weather Glove System. There shall be provisions for battery interface to self-align with the charger.

Battery interfaces should be optimized to charge the maximum number of batteries with the least amount of space and volume. Verify in accordance with 4.5.1.3.1.

Charger connection.

The mechanical design, the connections to the charger, and the communications protocol between the charger and the battery interface shall be open sourced to the government (see 6.7.14). All user accessible connections shall withstand 1000 mate / de-mate cycles. Verify in accordance with 4.5.1.3.2.

3.5.1.4 Charging with radios attached.

3.5.1.5 Battery hot swap.

The charger shall allow for removal of batteries at any time during charge without adversely affecting the battery or charger. The charger shall allow for batteries to be inserted to any open port at any time the charger is in operation, and the charger shall recognize the battery in not greater than 15 seconds. Verify in accordance with 4.5.1.5.

Leakage current.

When no battery is present, available current at charge contacts shall be limited to not greater than 100 mA. Verify in accordance with 4.5.1.5.1.

3.5.1.6 STANREC 4819 compliance.

The charger shall be compliant with NATO STANREC 4819 for interoperable charging. The minimum number of STANREC 4819 compliant interfaces shall be three. The STANREC 4819 interfaces shall be permanent fixed features on the charger, not provided by battery interface adapters. Verify in accordance with 4.5.1.6.

3.5.1.7 Efficiency.

The charger shall have an efficiency of at least 80%. Efficiency is taken as the combined total output power at the charger battery interfaces, over the measured AC input power (see 6.7.8). Verify in accordance with 4.5.1.7.

3.5.2 USB ports.

3.5.2.1 USB Type-A receptacles.

3.5.2.2 USB Type-C receptacles.

The USB Type-C PD port(s) shall be compliant with the Universal Serial Bus Power Delivery

Specification Revision 3.2 Version 1.0 (October 2023). The port(s) role shall be PD source. The port(s) may optionally support PD role swap to sink in order to power the charger. The port(s) shall support

Standard Power Range modes with a PDP of 100W minimum. The port(s) may optionally support Extend

Power Range up to 240W. The port(s) may optionally support Programmable Power Supply charging models. The port(s) shall be USB PD power only (no data). Verify in accordance with 4.5.2.2.

3.5.3 Operability.

The charger shall be operable, maintainable, and supportable by the central 90th percentile Soldiers (per

MIL-STD-1472). All of the functions and interfaces of the charger shall be designed to be operated by

Soldiers wearing Mission Oriented Protective Posture (MOPP) IV and Cold Weather Glove System.

Verify in accordance with 4.5.3.

3.5.3.1 Ease of systems operation.

The charger shall be capable of being operated while using one hand while wearing Army Combat

Gloves. The use of two hands to change battery interfaces is permitted. Verify in accordance with 4.5.3.1.

3.5.3.2 User interface.

Operational use modes shall be apparent to the user without special training or printed manuals present.

All modes of operation shall be indicated to the user either by text on the charger, indicators, or through interactive menus. No operation shall take more than 5 actions / steps to activate any mode / function.

Verify in accordance with 4.5.3.2.

3.5.4 System characteristics.

3.5.4.1 On / off switch.

The charger shall include an on / off switch. When powered off, the charger shall draw no more than 120 milliwatts. The switch shall be protected against inadvertent operation. Verify in accordance with 4.5.4.1.

3.5.4.2 Power on self-test.

The charger shall perform a self-test when powered on and shall indicate any fault condition to the user as a flashing RED status indicator of the charging port that is not functional. The charger shall commence the battery pre-charge check within 10 seconds from power on. Verify in accordance with 4.5.4.2.

3.5.4.3 Power sharing.

Power sharing hot swap.

3.5.4.4 Upgradeability.

The charger shall be upgradable without being returned to the manufacturer. Firmware loader supported operating system shall be Windows 10 and later. Firmware binary files and firmware loading application(s) shall be available to the government. Verify in accordance with 4.5.4.4.

New battery configurations.

The charger shall be field upgradeable to support new batteries that have cell configurations and voltages ranging from a minimum of 5V to 33.6V.

Any new or modified battery interfaces needed to upgrade the charger to support the new battery configuration shall meet the requirements of 3.5.1.3. New or modified battery interfaces shall not require a charger firmware or software update. The upgraded charger shall meet all of the requirements herein.

Verify in accordance with 4.5.4.4.1.

3.5.4.5 Cooling.

The charger may utilize a fan or fans for cooling. Acoustic signature of fans shall be limited to 55 dB at 1 meter. The charger should be capable of continued derated operation in the event of fan failures. The charger shall alert the user in the event of fan failures. Verify in accordance with 4.5.4.5.

3.5.4.6 Vehicle mounting.

FIGURE 2. Vehicle mounting interfaces.

3.5.4.7 Ground post.

The charger shall have a permanently installed ground post that connects to a continuous chassis ground.

The ground post will be a 10-32 threaded stud, no less the ¼ inch in length and shall be easily accessible.

The ground post length will not exceed the maximum envelope of the charger, and when not in use, will not prevent the stacking or storage of multiple chargers. Verify in accordance with 4.5.4.7.

3.5.5 Electrical characteristics.

3.5.5.1 Input voltage, AC.

Add: When operating under full load in an ambient temperature between 60°F and 80°F, the charger shall utilize no less than 1,500 Volt-Amps (VA) from a 120 VAC, 60 Hz source. Verify in accordance with

4.5.5.1.

3.5.5.2 Input voltage, DC.

The charger shall be able to operate at any voltage in the range of 20 to 33 VDC. The charger shall not be damaged by inputs of 9 to 46 VDC minimum to protect against items such as solar panel open circuit voltages. The charger shall not draw more than 46 Amps DC. The charger shall not be damaged by reverse voltage in the range of 9 to 46 VDC. The charger shall be capable of uninterrupted operation during starting disturbance from military vehicle power. Verify in accordance with 4.5.5.2.

3.5.5.3 Limited power sources.

The charger shall include user-selectable independent AC & DC power limits. Levels shall be 500 W, 750

W, 1,000 W, 1,250 W, Full Power, and Custom (user defined value). The default factory-programmed limit shall be Full Power for AC and Full Power for DC. The power limit settings shall persist through a charger power cycle. Verify in accordance with 4.5.5.3.

3.5.5.4 Automatic restart.

3.5.5.5 Maximum power point tracking.

3.5.5.6 Vehicle power.

The charger shall be capable of operating from vehicle power described by MIL-STD-1275. Verify in accordance with 4.5.5.6.

3.5.5.7 Power source priority.

The charger shall prioritize AC power. Verify in accordance with 4.5.5.7.

3.6 Electrical conditions.

3.6.1 Electromagnetic interference (EMI).

The charger shall comply with the following emission and susceptibility requirements of MIL-STD-461.

3.6.1.1 CE102 (Conducted Emissions, Radio Frequency Potentials, Power Leads).

Conducted emissions on power leads shall not exceed the limit values shown on Figure CE102-1. Verify in accordance with 4.6.1.1.

3.6.1.2 CS101 (Conducted Susceptibility, Power Leads).

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified indications, when subjected to a test signal with voltage levels as specified on Figure CS101-1. Verify in accordance with 4.6.1.2.

3.6.1.3 CS114 (Conducted Susceptibility, Bulk Cable Injection).

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified indications, when subjected to an injection probe drive level which has been pre-calibrated to the appropriate current limit shown on Figure CS114-1 and is modulated as specified in CS114. The appropriate limit curve on Figure CS114-1 shall be selected from CS114 Table VI for Army Ground platform and frequency range. Verify in accordance with 4.6.1.3.

3.6.1.4 CS115 (Conducted Susceptibility, Bulk Cable Injection, Impulse Excitation).

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified indications, when subjected to a pre-calibrated signal having rise and fall times, pulse width, and amplitude as specified on Figure CS115-1 at a 30 Hz rate for one minute. Verify in accordance with

4.6.1.4.

3.6.1.5 CS116 (Conducted Susceptibility, Dampened Sinusoidal Transients, Cables and Power

Leads).

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified indications, when subjected to a signal having the waveform shown on Figure CS116-1 and having a maximum current as specified on Figure CS116-2. The limit is applicable across the entire specified frequency range. Verify in accordance with 4.6.1.5.

3.6.1.6 CS118 (Conducted Susceptibility, Personnel Borne Electrostatic Discharge).

The charger shall withstand (survive) ESD to ±8kV contact discharge and ± 15kV air discharge on any surface, panel component, or connector, including exposed pins, in both operating and non-operating mode. Verify in accordance with 4.6.1.6.

3.6.1.7 RE102 (Radiated Emissions, Electric Field).

The charger shall withstand (survive) ESD to ±8kV contact discharge and ± 15kV air discharge on any surface, panel component, or connector, including exposed pins, in both operating and non-operating mode. Verify in accordance with 4.6.1.7.

3.6.1.8 RS103 (Radiated Susceptibility, Electric Field).

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified indications, when subjected to the radiated electric fields listed in MIL-STD-461 Table XI (Ground) and modulated as specified. Up to 30 MHz, the requirement shall be met for vertically polarized fields. Above

30 MHz, the requirement shall be met for both horizontally and vertically polarized fields. Circularly polarized fields are not acceptable. Verify in accordance with 4.6.1.8.

3.6.2 Reserved.

3.6.3 AC spikes and surges.

The AC input of the charger shall withstand ±2kV surges, line-to-line and line-to-ground. Verify in accordance with 4.6.3.

3.6.4 DC spikes and surges.

The charger shall operate properly and not sustain any damage from normal transients present on 28V military ground vehicle DC buses in accordance with MIL-STD-1275. Verify in accordance with 4.6.4.

3.7 Environmental conditions.

The charger and all components essential for its operation shall withstand the following environmental conditions. The finish shall remain intact and shall not peel, chip, crack, nor bubble following any of the following conditions (with the exception of the transit requirements of 3.7.7). Verify in accordance with

4.7.

3.7.1 Temperature.

3.7.1.1 Operation.

Low temperature operation.

The charger shall operate at a minimum ambient temperature of -25°F (-32°C). When tested as specified in 4.7.1.1.1, the charger shall experience no deleterious or unsafe effects and meet the full specification performance. Verify in accordance with 4.7.1.1.1.

High temperature operation.

The charger shall operate at a maximum ambient temperature of 131°F (55°C). When tested as specified in 4.7.1.1.2, the charger shall experience no deleterious or unsafe effects and meet the full specification performance. Verify in accordance with 4.7.1.1.2.

3.7.1.2 Storage.

Low temperature storage.

The charger non-operating shall withstand a minimum ambient temperature of -40°F (-40°C). When tested as specified in 4.7.1.2.1, the charger shall experience no deleterious or unsafe effects and meet the full specification performance. Verify in accordance with 4.7.1.2.1.

High temperature storage.

The charger non-operating shall withstand a maximum ambient temperature of 160°F (71°C). When tested as specified in 4.7.1.2.2, the charger shall experience no deleterious or unsafe effects and meet the full specification performance. Verify in accordance with 4.7.1.2.2.

3.7.2 Humidity.

The charger shall withstand high temperature-humidity conditions during both storage and operation.

When tested as specified in 4.7.2, the charger shall exhibit no physical damage such as corrosion, rust, blistering, or deterioration of parts and materials and shall meet full specification performance. Verify in accordance with 4.7.2.

3.7.3 Low pressure (altitude).

The charger shall operate up to 15,000 feet above sea level and shall be transportable up to 40,000 feet above sea level. During and after testing as specified in 4.7.3, the charger shall meet full specification performance. Verify in accordance with 4.7.3.

3.7.4 Salt fog.

The charger shall be operable in a salt fog atmosphere. When tested as specified in 4.7.4, the charger shall experience no deleterious effects and shall meet full specification performance after testing. Verify in accordance with 4.7.4.

3.7.5 Solar radiation.

The charger shall be capable of withstanding prolonged exposure to sunlight. When tested as specified in

4.7.5, the charger shall remain operational, experience no deleterious effects, and shall meet full specification performance after testing. Verify in accordance with 4.7.5.

3.7.6 Temperature shock.

3.7.7 Transit.

The charger shall be ruggedized and shall remain fully functional after transportation in a military tactical vehicle. Verify in accordance with 4.7.7.

3.7.7.1 Loose cargo.

The charger shall experience no negative performance effects from loose cargo while stored in transport configuration. The charger shall have no manufacturing materials become dislodged. Full specification performance shall be met after testing. Verify in accordance with 4.7.7.1.

3.7.7.2 Transit drop.

The charger shall experience no negative performance effects from transit drop (in transport configuration). The charger shall have no manufacturing materials become dislodged. Full specification performance shall be met after testing. Verify in accordance with 4.7.7.2.

3.7.8 Crash hazard shock.

3.7.9 Vibration.

3.7.10 Immersion.

The charger and accessories (as appropriate), in transport configuration, shall be capable of being immersed and have drain holes (or similar features) as appropriate to minimize water retention. After testing as specified in 4.7.10, the charger shall remain fully functional. Verify in accordance with 4.7.10.

3.7.11 Sand and dust.

Without any protective cover in place, the battery charger and accessories shall function after exposure to blowing dust. The battery charger and accessories shall function properly when configured as above after exposure to blowing sand environments. After testing as specified, the battery charger shall meet full specification performance. Verify in accordance with 4.7.11.

3.7.12 Rain.

Without any protective cover in place, the charger and accessories shall function properly while exposed to rain. During and after testing as specified in 4.7.12, the charger and accessories shall meet full specification performance. Verify in accordance with 4.7.12.

3.7.13 Fungus.

The charger and accessories, when tested, shall show no fungal growth. Verify in accordance with 4.7.13.

3.7.14 Icing.

The charger shall operate during and after exposure to icing/freezing rain, and shall not sustain damage following exposure. Verify in accordance with 4.7.14.

3.7.15 Parachute landing fall impact.

3.8 System safety.

3.8.1 General safety.

As applicable, the charger and accessories shall meet the requirements of UL 60950-1. Verify in accordance with 4.8.1.

3.8.1.1 Touch current (leakage current).

The charger and accessories shall meet the requirements of UL 60950-1 section 5.1. Verify in accordance with 4.8.1.1.

3.8.1.2 Electric strength.

The charger and accessories shall meet the requirements of UL 60950-1 section 5.2. Verify in accordance with 4.8.1.2.

3.8.1.3 Retained charge.

The charger and accessories shall meet the requirements of UL 60950-1 sections 2.1.1.7 and 2.1.1.8.

Verify in accordance with 4.8.1.3.

3.8.2 Electrical shock.

The charger and accessories shall not present an electrical shock hazard to the user under all operational conditions. Verify in accordance with 4.8.2.

3.8.3 Short circuit.

The charger and all applicable accessories shall be protected against damage due to any overload or short circuit condition. The charger and all applicable accessories shall resume operation upon removal of fault condition. Verify in accordance with 4.8.3.

3.8.4 Over/under-temperature.

The charger shall not charge batteries when battery temperature is below 32°F (0°C) or above 122°F

(50°C) unless otherwise dictated by a smart battery. Verify in accordance with 4.8.4.

3.8.5 Safety features.

3.8.5.1 Radioactive or hazardous materials.

The charger and all accessories shall be free of hazardous or toxic materials such as luminous dials/markings, Asbestos, Hexavalent Chromium, Mercury, Methyl Ethyl Ketone, Polychlorinated

Biphenyls (PCBs), Tetrachloroethylene, and Trichloroethylene. Lead, lead compounds, and cadmium shall be permitted in small quantities and employed only where there will be minimal exposure of these compounds to the user and where grinding, polishing and abrading of the material will not cause a toxic inhalation hazard. Verify in accordance with 4.8.5.1.

3.8.5.2 Non-rechargeable batteries.

Electrical and/or mechanical methods shall be employed to ensure that the charger cannot charge any non-rechargeable battery configurations. Verify in accordance with 4.8.5.2.

3.8.5.3 Surface temperature.

Under a full load configuration and while operating, no exposed surface of the charger and accessories shall be in excess of the appropriate (momentary or prolonged) contact and handling limits of MIL-STD-

1472. User controls shall meet the prolonged contact temperature for the appropriate material(s).

Replaceable battery interfaces shall meet the prolonged contact temperature for the appropriate material(s). The bottom surface of the charger is excluded from this requirement. All other surfaces shall meet the momentary contact temperature for the appropriate material(s). Verify in accordance with

4.8.5.3.

3.8.5.4 Power outputs.

All connections which provide power, with exception of interfaces to batteries, shall be female (i.e.

sockets not pins). Verify in accordance with 4.8.5.4.

3.9 Reliability.

The charger shall have a Mean Time Between Essential Function Failure (MTBEFF) of no less than 500 hours. A MTBEFF is defined as any failure that causes the system to not meet the performance requirements specified in paragraph 3.5 herein. Verify in accordance with 4.9.

3.10 System accessories.

3.10.1 Solar panel.

3.10.1.1 Solar panel characteristics.

3.10.1.2 Power output at different solar angles.

TABLE VI. Solar angle of incidence.

N/A

3.10.2 External AC to DC converter.

3.10.2.1 Environmental requirements.

3.10.3 Cables.

All wire cable terminal components and termination points shall not part from the connector when subjected to twisting, pulling, or tension force. The cable assemblies herein shall not be damaged when properly connected and subjected to 100 pounds of tension. Verify in accordance with 4.10.3.

3.10.3.1 AC input cable.

The AC Input Cable shall have an IEC 60320 type C13 connector on one end or tethered into the AC to

DC converter. The AC Input Cable shall have a 3 prong plug per figure 5-15 of ANSI/NEMA WD 6-2002 on the second end. The cable shall be 6 feet ± 3 inches long. The cable shall be a stranded wire with 3 conductors of minimum gauge required to meet safety requirements. The cable and plug shall be rated to handle at least 15A current. Verify in accordance with 4.10.3.1.

3.10.3.2 DC power interface cable.

The DC power interface cable allows for an external DC power source to be connected to the charger.

The DC power interface cable shall have stranded copper based wire capable of carrying voltage and current as specified in 3.5.5.2. The length shall be 6 feet +/- 3 inches. One end shall be capable of mating with the DC input connector (see 3.4.8.2) on the charger. The other end shall be unterminated leads of length 3 +/- 1 inches. Verify in accordance with 4.10.3.2.

FIGURE 3. Reserved.

3.10.3.3 DC extension cord cable (18 ft.).

3.10.4 Additional DC inputs.

FIGURE 4. Reserved.

3.10.4.1 NATO slave input power adapter.

The NATO slave plug shall be compatible with a Type I receptacle per NATO STANAG 4074 and be of the minimum size and weight required to meet the power and environmental requirements of this specification. Verify in accordance with 4.10.4.1.

3.10.4.2 Alligator clips input power adapter.

3.10.5 Hard cover.

The charger may have an integrated or removable hard cover which can be secured for transport configuration (see 3.4.7). The charger and hard cover shall be designed to ensure that the cover does not become a projectile [in a crash]. Verify in accordance with 4.10.5.

The hard cover shall:

a. Meet the color requirements of the charger (see 3.4.3).

b. Have all latching mechanisms and connectors (e.g. snaps, rivets, etc.) be lusterless. Hook and loop straps (e.g. Velcro™) shall not be used.

c. Have a carrying handle capable of supporting not less than 60 pounds.

d. (if removable) Not require more than 15 seconds (for each action) to remove and replace from the charger.

e. Be capable of storing the AC input cable and a full set of adapters required for charging batteries.

3.10.6 Soft cover.

3.10.7 Transportation case.

3.11 Repairability.

The charger shall be designed with the maximum amount of user reparability as possible. Special tools and techniques shall not be required for repair. The use of commercially available parts shall be maximized, and the overall repair part count shall be minimized. Verify in accordance with 4.11.

4 VERIFICATION

4.1 Verifications of inspections.

The inspection requirements specified herein are classified as follows:

a. First Article inspections (see 4.1.2).

b. Conformance inspection (see 4.2).

c. Certifications. Contractor shall provide written proof of all industry certifications with which the product complies.

4.1.1 First article units.

The contractor will furnish first article units of the complete battery charger. The quantity of first article units will be defined in the SoW. For all requirements where it states that verification or analysis is required, the contractor shall detail the proposed testing and test protocols in the FAT Plan for government review and acceptance.

4.1.2 First article inspection.

The first article inspection shall consist of inspections specified in TABLE VIII under Production

Qualification Test (PQT), and when specified (see 6.2) the accessories (see 4.1.2) shall be tested one each per charger. Tests shall be performed in the order indicated for each test sample.

4.1.3 Classification of verification.

Classifications of Verifications are as follows:

• Production Qualification Test (PQT)

• Quality Surveillance Test

• Government Test (Developmental and Operational)

The SOW guidance shall cover whether the PQT is a first article sample, a first production item, or the number of test items. These documents shall also include specific instructions regarding arrangements for examinations, approval of first article test results, and disposition of first articles.

4.1.4 Methods of verification.

Verification methods are provided in the below TABLE VII.

TABLE VII. Verification methods table.

Method Description

Analysis Involves a technical evaluation of design information such as equations, charts, graphs, drawings, schematics, and other data. If actual tests were conducted for a related or unrelated purpose, and utilization of these data will prove that requirement has been met, it should be considered “analysis”. Analysis methods include the use of modeling and simulation with a government-accredited model.

Demonstration Observable functional operation, under controlled conditions not requiring subsequent analysis of data, is used to verify that a given requirement is met.

Examination An element of verification and inspection consisting of investigation, without the use of special laboratory appliances or procedures, of items to determine conformance to those specified requirements which can be determined by such investigations. Examination is generally nondestructive, and typically includes the use of sight, hearing, smell, touch, and taste; simple physical manipulation; mechanical and electrical gauging and measurement; and other forms of investigation.

Test Involves observation or recording of data during operation of an…