B08-Drawings-W9098S-20-Q-0077-Attachment 003.pdf

NOTES:

1. APPLICABLE STANDARDS/SPECIFICATIONS:

ASME Y14.100

ASME Y14.5M-1994

2. IDENTIFICATION OF THE SUGGESTED SOURCE(S) OF SUPPLY

HEREON IS NOT TO BE CONSTRUED AS A GUARANTEE OF

PRESENT OR CONTINUED AVAILABILITY AS A SOURCE

FOR THE ITEM DESCRIBED ON THIS DRAWING.

ONLY THE MANUFACTURER S ITEM DESCRIBED ON THIS DRAWING IS

APPROVED FOR USE IN THE APPLICATION(S) SPECIFIED HEREON. A

SUBSTITUTE ITEM SHALL NOT BE USED WITHOUT PRIOR APPROVAL OF

TARA-PME, ROCK ISLAND, IL 61299-6400

38.000

SOURCE CONTROL DRAWING

RIA149333

40.00

ROCK ISLAND, IL 61201

4X

SEE NOTE 3

1.000

3. BOLT PATTERN TO MATCH GENERATOR MOUNT RIA148945, ON FLATRACK

ASSEMBLY RIA148965.

4. BOLT PATTERN TO MATCH DEFLECTOR RIA148773, ON GENERATOR SET

ASSEMBLY RIA149185.

5. VENDOR WILL PRODUCE AND SECURELY ATTACH A UNIQUE

IDENTIFICATION PLATE (UID) TO EACH UNIT.

6. SEE DRAWING SHEETS 2 AND 3 FOR DESCRIPTION OF GENERATING

SYSTEMS REQUIREMENTS FOR THE FORWARD REPAIR SYSTEM.

2X 19.625

2X 19.685

72.00

81.00

PART NO.

VENDOR

APPROVED SOURCE OF SUPPLY

96.00

2X 2.688

6X

SEE NOTE 4

.375

ITEM IDENTIFICATIONADDRESS

RIA149333

CAGE CODE

309-787-4300

CUMMINS GREAT PLAINS DIESEL

7820 42ND STREET WEST

SEE NOTE 3

41.275

38.196

1GQP5

IN TOP FLANGE OF CHANNEL, DIRECTLY

ABOVE THE GENERATOR MOUNTING HOLE

1.00

X-

DRAWING APPROVAL

DATE

MATERIAL

2 PLACE DECIMALS

USED ON

MAX

DO NOT APPLY MARKING

DO APPLY:

PREPARED

FINAL PROTECTIVE FINISH

3 PLACE DECIMALS

RH

YS

MECHANICAL

METHOD:

SIZE:

SCALE

DESIGN APPROVED

APPLICATION

BH

YS

INTERPRET DRAWING IN

ACCORDANCE WITH STANDARDS

PRESCRIBED BY MIL-STD-100

DRAWING NO.

ANGLES MARKING REQUIREMENTS

PER MIL-STD-130

NEXT ASSY

CHECKED

CONTRACT NO:UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN

EL 2

MIN

BREAK EDGES:

FILLETS:

FINISH:

SHEET OF

SIZE

ENGINEER

TOLERANCES:

MFR-

CAGE CODE

RA

PROPERTIES

DESCRIPTIONS

C

F

ZONE

C

D

E

APPROVED

F

REVISIONS

H

MF

B

G

E

H

DATE

E

B

A

LTR

A

E

D

5 1

G

CAD MAINTAINED. CHANGES SHALL BE

INCORPORATED BY THE DESIGN ACTIVITY.

U.S. ARMY \ ROCK ISLAND ARSENAL

JOINT MANUFACTURING AND TECHNOLOGY CENTER

ROCK ISLAND, ILLINOIS 61299-5000

19204

19204

RIA149333

R

IA

GENERATOR SET

000105

NA

DRH

TJD

1 3

INCHES

.010 .06

X

FRSRIA149185

RIA FORMAT 99

T. DAVOREN

D. ASSADI

- IRIA0000045, INIT REL 000105 RDH

A IRIA0000101, ADD NOTE 3 BE 001024 JRS

B IRIA0000115, MODEL UPDATE 001127 JRS

C IRIA0600008, ADD ACCESS HOLE 20060110 JRS

D IRIA0600541, ADDED 2 SHEETS 20061129 JRS

E IRIA1300047, DIST STATEMENT 20130124 DAT

DISTRIBUTION STATEMENT A

THIS IS APPROVED FOR PUBLIC RELEASE: DISTRIBUTION IS UNLIMITED.

DESCRIPTION FOR GENERATING SYSTEMS FOR THE FORWARD REPAIR SYSTEM

Diesel powered generating system, 35 KW at 0.8 pf at 60 HZ or 25 KW at 0.8 pf at 50 HZ prime rating, 120/208 VAC, 3 Phase, broad range, dual output 50/60 HZ. Engine: 4 cylinder in-line, 4 cycle, approved by EPA for mobile usage in U.S. Fuel consumption not to exceed 3.0 U.S. gal/hr at full load. Generator set shall include a 1500-watt immersion type engine coolant heater, adequate fan guarding, automatic fuel shutoff, and 125 amp 3-pole main line circuit breaker, and replaceable element air cleaner with restriction indicator and sand dump feature. Position low oil pressure and pre-low oil pressure switches on left side of engine. Position oil fill to top of engine in valve cover.

Position oil dipstick to the right side of engine. Alternator shall be brushless, 4 pole, drip proof construction with PMG excitation system. Temperature rise at rated load shall be 105 Deg C. Provide and install within the generator set skidbase a battery tray in accordance with drawing RIA149135 for 2 each 12 V GSA batteries, NSN 614000X975115. Include battery cables with MS75004-1/MS75004-2 terminal ends. Battery tie-downs shall be in accordance with drawing RIA149157. Generator set shall also include oil drain extension, critical exhaust silencer within the housing structure, flexible exhaust connection to engine, and flexible fuel lines. Provide and mount Parker Hannifin hydraulic pump PN PVP3336BRA to engine accessory gear drive location at the left front of engine. Provide and install a 3/8" steel support bracket for the hydraulic pump. Provide and install a 24 VDC NATO slave receptacle assembly, PN 12342917, mounted so that the receptacle can be readily utilized when viewing control panel. Provide battery disconnect switch and all interconnect battery cabling to permit disconnect of battery power during idle periods, mounted so the switch can be readily operated when viewing the generator set control panel. Provide ether start system for cold weather starting. Ether start system shall be a fully installed, solenoid controlled pushbutton actuated measured shot ether injection system interlocked with the engine starting and coolant system temperature monitoring circuits to allow ether injection only when needed as determined by status of engine cranking and cooling system temperature, and prevent potentially excessive ether injection, resulting in engine damage and personal injury. Ether injection button is to be readily accessible at the control end of the generator set.

Generator set shall include high ambient 130 degree F radiator cooling system with RIA designed radiator outlet air safety deflector guard installed. Demonstrated cold start capability down to 25 degree F with only ether starting aid. Proposals must include details of both high ambient testing and cold start test to demonstrate these capabilities with this specific generator set and housing with stated overall dimensions. Engine shall be capable of operating on a wide variety of commercial and military grade fuels, including military standard JP-8 fuel, commercial No. 1 or No. 2 diesel, and military Grade W-F-800 grade DF-1 and DF-2. Proposals shall include a written certification by the engine manufacturer of the ability of the engine to accommodate all of the listed fuels. Proposals without this certification from the engine manufacturer will not be accepted. Motor starting KVA of the generator set will be a minimum of 155 KVA at 60 HZ and 111 KVA at 50 HZ. Frequency dip shall be no more than 3% when 30 KW at

0.8 PF is applied to the generator set in a single step. Generator set shall have a demonstrated capability to survive a lightning strike (conductive surge) test IAW specification ANSI/IEEE C62.41-1991 (Recommended Practice on Surge Voltages in AC Power Circuits). Proposal must include the results of this testing. An aluminum diesel fuel tank in accordance with drawing RIA148962 shall be installed and plumbed. The fuel tank shall be sufficient to carry fuel for eight hours of continuous operation, located in a manner which will not allow spills or overflows. The tank shall be mounted in a protected location within the generator set skidbase frame near the control-end of the skidbase and be accessible for refueling without obstruction by way of the rear housing access door. Fuel tank will be bolted to the frame of the skidbase and include a protective rubber pad under the tank, and an overall protective belly pan under the entire skidbase. Proposals must include layout drawing details of the generator set skidbase structure and RIA 148962 fuel tank placement and mounting. Fuel tank shall include suction fitting for enclosure heater and mechanical fuel level gauge. Primary and secondary fuel filters are to be included.

Engine/Generator controller shall be unit mounted, PowerCommand 2100, microprocessor based. The controller shall be manufactured by Cummins Power Generation, Custom Applications Group. The controller enclosure shall be NEMA 3R configuration and constructed of non-corrosive material. The control shall contain a two line alphanumeric digital display capable of 20 characters/spaces per line with tactile feel membrane navigation switches for operator use. The front panel surface membrane shall be impervious to the effects of dust, moisture, oil, and exhaust fumes. The control shall contain an OFF/MANUAL/AUTO mode switch, as well as an additional manual RUN/STOP pushbutton switch panel active in MANUAL mode, and terminals for connecting multiple remote START/STOP pushbutton stations to allow the generator set to be started and/or stopped from any location. Control shall contain an emergency stop pushbutton with red mushroom operator and panel lamps with lamp test switch.

LED indicator lamps for GENERATOR SET RUNNING (green), REMOTE START SIGNAL RECEIVED (green), NOT IN AUTOMATIC (flashing red), COMMON SHUTDOW (red), COMMON WARNING (amber), LOW OIL PRESSURE WARNING (amber), HIGH ENGINE TEMPERATURE WARNING (amber), LOW OIL PRESSURE SHUTDOWN (red), OVERSPEED SHUTDOWN (red), FAIL TO START (red). Control to display the following functions digitally as well as with a full analogue bar graph display: output voltage (all phases), output amperages (all phases), KW, frequency, and power factor. Additional digital display of the following parameters is to be accomplished via navigation switches on the control panel:

KWH, engine starting battery voltage, engine lube oil pressure, and engine coolant temperature.

Engine protection functions shall include overspeed, low oil pressure warning, low oil pressure shutdown, high coolant temperature warning, high coolant temperature shutdown, low coolant level warning/shutdown, low coolant temperature warning, low and high battery voltage warning, weak battery warning, fail to start shutdown, fail to crank shutdown, cranking lockout, and sensor failure indication. The controller shall incorporate integral digital voltage regulating and engine speed governing functions. Voltage regulation is to be +/- 0.5% for any constant load between no load and full load. Isochronous speed control to be within +/- 0.25% for all constant loads. The front control panel shall have operator adjustment capability for output voltage (+/- 5%) and frequency (+/- 5%) without rotary potentiometers. Control shall incorporate temperature dynamic functionality to modify governing parameters as a function of engine temperature in order to optimize responsiveness at differing temperature levels. Fault current to be regulated at no more than 300% of rated current on any phase for either a single or three-phase fault. Control shall include integral generator overload protection which does not rely upon the line circuit breaker to protect the generator from thermal damage. The control shall contain algorithms to display overcurrent alarms and shutdowns for various time/current characteristics which could cause thermal damage to the generator. The thermal damage curve for the generator shall be the basis for all overload shutdown functions. Software algorithms shall also include alternator protection from repeated overcurrent conditions over short periods of time. Other generator protective functions shall include high AC voltage shutdown, low AC voltage shutdown, under frequency shut down, over frequency shutdown/warning, overload (KW) warning, and excitation fault shutdown on loss of voltage sensing inputs.

DRAWING APPROVAL

DATE

MATERIAL

2 PLACE DECIMALS

USED ON

MAX

DO NOT APPLY MARKING

DO APPLY:

PREPARED

FINAL PROTECTIVE FINISH

3 PLACE DECIMALS

RH

YS

MECHANICAL

METHOD:

SIZE:

SCALE

DESIGN APPROVED

APPLICATION

BH

YS

INTERPRET DRAWING IN

ACCORDANCE WITH STANDARDS

PRESCRIBED BY MIL-STD-100

DRAWING NO.

ANGLES MARKING REQUIREMENTS

PER MIL-STD-130

NEXT ASSY

CHECKED

CONTRACT NO:UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN

EL 2

MIN

BREAK EDGES:

FILLETS:

FINISH:

SHEET OF

SIZE

ENGINEER

TOLERANCES:

PROPERTIES

DESCRIPTIONS

C

F

ZONE

C

D

E

APPROVED

F

REVISIONS

H

MF

B

G

E

H

DATE

E

B

A

LTR

A

E

D

5 1

G

CAD MAINTAINED. CHANGES SHALL BE

INCORPORATED BY THE DESIGN ACTIVITY.

U.S. ARMY \ ROCK ISLAND ARSENAL

JOINT MANUFACTURING AND TECHNOLOGY CENTER

ROCK ISLAND, ILLINOIS 61299-5000

19204

19204

RIA149333

R

IA

GENERATOR SET

NA

JRS

2 3

INCHES

.010 .06

X

FRSRIA149185

RIA FORMAT 99

- IRIA0600541, INITIAL REL 20061129 JRS

E IRIA1300047, DIST STATEMENT 20130124 DAT

Generator set must have 24 VDC starting/control system. Controls are to be configured for both automatic and manual starting. Controls must also include provisions to allow remote starting and stopping commands from any of three remote locations away from the generator set. This control configuration must include the ability to stop the generator set at a location other than the point of last initiation of the start signal. The controller shall be suitable for proper operation without recalibration in ambient temperatures from -40C to +70C and for storage in ambient temperatures from -55C to +80C. The controller shall be UL508 listed. The vendor shall also provide FT 10 based hardware capable of remote monitoring and control of all genset functions from any location world wide. Overall generating system construction and mounting shall be such that neither vibration nor tightening of mounting devices will cause leaks to develop.

Include vibration isolators (between skidbase frame and engine/generator) with integral deflection limiters designed and tested so when installed on FRS, and the FRS is secured to a flatcar, the unit will withstand railroad humping without permanent deformation or damage in accordance with the Association of American Railroads (AAR). The generator set's steel skidbase and the sound attenuated housing shall both be capable of withstanding railroad humping without permanent deformation or damage in accordance with AAR. Evidence of successful off-road mobile and AAR testing of the complete specific overall package as required by this specification (i.e. including engine/generator, skidbase, housing, fuel tank, exhaust system, cooling system, control, hydraulic pump, and all other required components) shall be submitted with the proposal to demonstrate the capability of the generating system to survive the stresses of the application.

The housing shall be a specially modified Quiet Site II, weather protective housing with maximum sound pressure level of 70 dB(a) at 7 meters, with additional reinforcement necessary for proven required rail impact considerations and other stresses in off-road mobile use. Provide 4 each lift-off side doors (2 per side) with easy open latch design and padlock provision. The door on control end to be left-side hinged with viewing window for easy access to control panel.

All four side doors must be removable within a 3.0 inch wide space between the side of the housing and an external wall. Due to the access limitations of the FRS, design of three of the housing doors must be top-latching and bottom pivot/lift-off, and one door (left radiator-end door) is to be bottom latching and top pivot/lift-off design. Latch mechanism must be of spring loaded design to allow self latching of door when closed. The proposal shall include details of how these doors are constructed to meet the removal and clearance requirements, along with evidence of off-road mobile testing and railroad car hump testing to demonstrate that doors will not fall off under expected extremes of mobile operation on the FRS. Space claim restriction of overall unit package is 96 inch long x 40 inches wide x 72 inches high to top of housing, inclusive of fuel tank and internal exhaust silencer. Exhaust pipe to extend 9 inches above top of housing. Paint exterior of housing IAW MIL-C-53072, using finish 20.24 of MIL-STD-171, CARC paint colors tan or OD green, and option for camouflage pattern. Total component weight not to exceed 2650 LBS (1185Kg). Along with items mentioned above, the bidder's proposal must include detailed layout drawings of overall housing showing details of silencer, fuel tank, generator set, cooling system, hydraulic pump, battery racks, control, and all doors.

Drawings must demonstrate that the overall package size does not exceed the maximum overall dimensions stated. Proposal must certify that the layout drawings provided, including the housing, exhaust, and sound attenuation configuration, are of proven design pre-tested to comply with all dimensional, performance, and durability requirements of this specification.

Proposals for a product which has not yet been designed and proved in the configuration required will not be accepted due to the inability of this program schedule to accommodate prototype build, prototype testing, and pre-production phases of a new product program. Manufacturer's certification of prototype testing performed on a complete and functional unit to demonstrate compliance with all requirements in this specification shall be provided with quotation.

Component level type tests or tests that do not include all required items listed in the specification will not substitute for this requirement. Evidence of testing that must be submitted with the proposal include: high ambient cooling performance in the specified package size, low ambient cooling performance testing in the specified package size, maximum surge KW, maximum motor starting KVA, generator temperature rise, torsional analysis and testing, 500-hour factory durability test of actual product to be supplied, steady state performance, transient performance, harmonic analysis, electrical and mechanical strength when subjected to multiple single and three-phase bolted faults, lighting strike test, and mobile durability tests as described above. Results of all prototype tests are to be submitted with certifications. Warranty is to be for a period of 2 years or 6000 hours from initial customer usage.

Warranty must be provided directly by the vendor for the complete system. Individual component warranties from component suppliers will not be acceptable. Warranty policy must include parts, repair, and travel costs by the manufacturer's authorized representatives throughout the world. Proposals shall include Manufacturer's published warranty documents, shop drawings showing plan and elevation views with certified overall dimensions and internal layout details, as well as wiring interconnection details, interconnection wiring diagrams showing all external connections required; with field wiring terminals marked in a consistent point-to-point manner. The generating system, including the sound attenuated housing with the dimensional limitations as stated, must be a proven design which has been prototype tested to prove compliance with all specification requirements as stated above, and in regular production by the manufacturer for a minimum of 10 years in order to demonstrate acceptable field performance. Submissions shall also include quality data on the specific model and configuration proposed in order to demonstrate acceptable field performance. The manufacturer must have in place a world-wide, single source, distribution system which offers service and 24-hour parts availability to include all parts of the unit being provided.

All parts must be fully documented and available to this parts distribution system.. A listing of parts/service distributors shall be included with the proposal. As a minimum, the vendor shall maintain in his inventory a complete "dressed" engine and main alternator assembly available for immediate shipment if necessary. The vendor shall also have a minimum of one fully factory trained service technician permanently on call near the Rock Island Arsenal, and available to come to the Rock Island Arsenal within one hour to deal with any issues relating to product performance of any part of the generating system. The technician shall be an employee of the vendor awarded this contract. Contracting of this function to a third party company is unacceptable. This is necessary to maintain an efficient flow of information between the vendor and RIA. The technician shall also be fully trained, and have in his possession, all necessary hardware and software to fully interrogate the system controls as required to support the product. Provide a factory trained technician to certify the performance of each generating system after it is installed in the FRS and assist as required in the dynamic testing of the complete system prior to deployment. The technician shall be an employee of the vendor awarded this contract. The vendor's bid package must include a certification of inspection document from the original generating system manufacturer stating that any modifications made to the original manufactured product by the vendor complies with the manufacturers requirements for a fully operational system, per specification, and that the warranty will not be affected. Delivery of product in quantities to be determined by RIA shall be less than 100 days after award of contract.

DRAWING APPROVAL

DATE

MATERIAL

2 PLACE DECIMALS

USED ON

MAX

DO NOT APPLY MARKING

DO APPLY:

PREPARED

FINAL PROTECTIVE FINISH

3 PLACE DECIMALS

RH

YS

MECHANICAL

METHOD:

SIZE:

SCALE

DESIGN APPROVED

APPLICATION

BH

YS

INTERPRET DRAWING IN

ACCORDANCE WITH STANDARDS

PRESCRIBED BY MIL-STD-100

DRAWING NO.

ANGLES MARKING REQUIREMENTS

PER MIL-STD-130

NEXT ASSY

CHECKED

CONTRACT NO:UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN

EL 2

MIN

BREAK EDGES:

FILLETS:

FINISH:

SHEET OF

SIZE

ENGINEER

TOLERANCES:

PROPERTIES

DESCRIPTIONS

C

F

ZONE

C

D

E

APPROVED

F

REVISIONS

H

MF

B

G

E

H

DATE

E

B

A

LTR

A

E

D

5 1

G

CAD MAINTAINED. CHANGES SHALL BE

INCORPORATED BY THE DESIGN ACTIVITY.

U.S. ARMY \ ROCK ISLAND ARSENAL

JOINT MANUFACTURING AND TECHNOLOGY CENTER

ROCK ISLAND, ILLINOIS 61299-5000

19204

19204

RIA149333

R

IA

GENERATOR SETJRS

3 3

INCHES

.010 .06

X

FRSRIA149185

RIA FORMAT 99

- IRIA0600541, INITIAL REL 20061129 JRS

E IRIA1300047, DIST STATEMENT 20130124 DAT