DRAFT Performance Specifications_STEP 3kW EMD.pdf

PRF 6115-0133, 26 JULY 2021, DRAFT, NOT FOR PROCUREMENT

PRF 6115-0133 1

Original Design Activity: 2

CAGE Code 30554 3

Current Change Control Authority: 4

CAGE Code 30554 5

26 July 2021 6

PERFORMANCE SPECIFICATION 10

ITEM SPECIFICATION 12

FOR THE 14

GENERATOR, SMALL TACTICAL ELECTRIC POWER: 3 < KILOWATTS < 5 16

Prepared for: 18

Project Manager Expeditionary Energy & Sustainment Systems (PM E2S2), 19

5850 Delafield Road, Building 324, Fort Belvoir, VA 22060 20

Prepared by: 22

Product Director Small Expeditionary Power Sources (PdD SEPS), 23

5850 Delafield Road, Building 324, Fort Belvoir, VA 22060 24

SUBMITTED BY: (Authorizing Signature) DATE: ________ 27

XXXXXXXXXXXX 28

PdD SEPS Product Director 29

PdD SEPS 30

APPROVED FOR USE AS 33

FUNCTIONAL BASELINE BY: (Authorizing Signature) DATE: ________ 34

XXXXXXXXXXXX 35

PM E2S2 Program Manager 36

PM E2S2 37

PRF 6115-0133

09 JUL 21

DRAFT, NOT FOR PROCUREMENT

1.0 SCOPE 38

1.1 Scope. This specification covers the greater than or equal to 3 kilowatt (kW) to less 39 than 5kW Small Tactical Electric Power (STEP) generator set, hereinafter referred to as "set" or 40

"sets". This specification also covers any accessories that are used with the set(s). 41

1.2 Requirement levels. This specification lists two values for certain performance 42 parameters. The threshold (T) is the minimum acceptable level. The objective (O) is the desired 43 level at which performance of the generator set results in an operationally significant increase in 44 capabilities. When only one requirement is stated, it is the threshold requirement. 45

2.0 APPLICABLE DOCUMENTS 46

2.1 General. The documents listed in this section are specified in sections 3 or 4 of this 47 specification. This section does not include documents cited in other sections of this specification 48 or recommended for additional information or as examples. While every effort has been made to 49 ensure the completeness of this list, document users are cautioned that they must meet all 50 specified requirements of documents cited in sections 3 and 4 of this specification, whether or 51 not they are listed. 52

2.2 Government Documents. 53

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, 54 and handbooks form a part of this document to the extent specified herein. Unless otherwise 55 specified, the issues of these documents are those cited in the solicitations or contract. 56

COMMERCIAL ITEM DESCRIPTIONS 57

A-A-52624 - Antifreeze, Multi Engine type 58

A-A-55804 - Rods, Ground (with Attachments) 59

A-A-59592 - Can, Fuel, Military: 20-Liter Capacity 60

DEPARTMENT OF DEFENSE SPECIFICATIONS 61

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5 62

MIL-DTL-15024 - Plates and Tags for Identification of Equipment, General 63

Specification for 64

MIL-DTL-53072 - Chemical Agent Resistant Coating (CARC) System 65

Application Procedures and Quality Control Inspection 66

MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-67

34), NATO F-35, and JP-8+100 (NATO F-37) 68

MIL-L-85762 - Lighting, Aircraft, Interior, Night Vision Imaging System 69

(NVIS) Compatible 70

MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, 71

Combat/Tactical Service 72

MIL-PRF-10924 - Grease, Automotive and Artillery 73

MIL-PRF-21260 - Lubricating Oil, Internal Combustion Engine, Preservative 74

Break-in 75

MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic 76

DEPARTMENT OF DEFENSE STANDARDS 77

MIL-STD-129 - Military Marking for Shipment and Storage 78

MIL-STD-130 - Identification Marking of U.S. Military Property 79

MIL-STD-188-125-2 - High-Altitude Electromagnetic Pulse (HEMP) 80

Protection for Ground-Based C4I Facilities Performing 81

Critical, Time-Urgent Missions - Part 2 - Transportable 82

Systems 83

MIL-STD-209 - Lifting and Tie-down Provisions 84

MIL-STD-461 - Requirements for the Control of Electromagnetic 85

Interference Characteristics of Subsystems and Equipment 86

MIL-STD-705 - Generator Sets, Engine Driven Methods of Tests and 87

Instructions 88

MIL-STD-810 - Environmental Engineering Considerations and Laboratory 89

Tests 90

MIL-STD-814 - Requirements for Tiedown, Suspension and Extraction 91

Provisions on Military Materiel for Airdrop 92

MIL-STD-882 - System Safety 93

MIL-STD-889 - Dissimilar Metals 94

MIL-STD-1332 - Definitions of Tactical, Prime, Precise, and Utility 95

Terminologies for Classification of the DoD Mobile 96

Electric Power Engine Generator Set Family 97

MIL-STD-1472 - Human Engineering 98

MIL-STD-1474 - Noise Limits 99

MIL-STD-1651 - Insert Arrangements for SAE-AS50151, MIL-DTL-22992 100

(Classes C, J, and R), MIL-DTL-83723 (Series II) and 101

SAE-AS95234 Circular Electrical Connectors 102

MIL-STD-2169 - High-Altitude Electromagnetic Pulse (HEMP) Environment 103

(Secret) 104

MIL-STD-11991 - Parts, Materials, and Processes, General Standard for 105

MIL-STD-13231 - Marking of Electronic Items 106

MIL-D-16791 - Detergents, General Purpose (Liquid, Nonionic) 107

DEPARTMENT OF DEFENSE HANDBOOKS 108

MIL-HDBK-419 - Grounding, Bonding and Shielding for Electronic 109

Equipments and Facilities, (Handbook Contains both 110

Volume I Basic Theory, and Volume II Applications) 111

MIL-HDBK-454 - General Guidelines for Electronic Equipment 112

MIL-HDBK-831 - Preparation of Test Reports 113

MIL-HDBK-1857 - Grounding, Bonding and Shielding Design Practices 114

(Copies of these documents are available online at http://quicksearch.dla.mil/.) 115

2.2.2 Other Government documents, drawings and publication. The following other 116

Government documents, drawings, and publications form a part of this document to the extent 117 specified herein. Unless otherwise specified, the issues of these documents are those cited in the 118 solicitation or contract. 119

ABERDEEN TEST CENTER (ATC) 120

TOP 01-1-011 - Test Operating Procedure: Vehicle Test Facilities at 121

Aberdeen Test Center and Yuma Test Center 122

(Copies of this documents are available online at http://quicksearch.dla.mil/.) 123

ARMY PUBLISHING DIRECTORATE (APD) 124

AR 70-38 - Research, Development, Test and Evaluation of Materiel 125 for Extreme Climatic Conditions 126 http://quicksearch.dla.mil/ http://quicksearch.dla.mil/

AR 700-101 - Joint Operating Procedures Management and 127

Standardization of Mobile Electric Power Generating 128

Sources 129

AR 750-43 - Army Test, Measurement and Diagnostics Equipment 130

(TMDE) Program 131

ATP 3-11.32 - Multi-Service Tactics, Techniques, and Procedures for 132

Chemical, Biological, Radiological, and Nuclear Passive 133

Defense 134

TB 750-25 - Maintenance of Supplies and Equipment Army Test, 135

Measurement, and Diagnostic Equipment (TMDE) 136

Calibration and Repair Support (C&Rs) Program 137

(Copies of these documents are available from https://armypubs.army.mil/) 138

ENVIRONMENTAL PROTECTION AGENCY) 139

40 CFR 1068.225 - Title 40 - Protection of Environment: Chapter I - 140

Environmental Protection Agency: Subchapter U - Air 141

Pollution Controls: Part 1068 - General Compliance 142

Provisions For Highway, Stationary, and Nonroad 143

Programs: Subpart C - Exemptions and Exclusions: Section 144

§ 1068.225 - Exempting engines/equipment for national 145 security 146

(Copies of this documents is available from https://www.govinfo.gov/ or https://www.ecfr.gov/) 147

ENVIRONMENTAL PROTECTION AGENCY 148

40 CFR 1068.225 - Title 40 - Protection of Environment: Chapter I - 149

Environmental Protection Agency: Subchapter U - Air 150

Pollution Controls: Part 1068 - General Compliance 151

Provisions For Highway, Stationary, and Nonroad 152

Programs: Subpart C - Exemptions and Exclusions: Section 153

§ 1068.225 - Exempting engines/equipment for national 154 security 155

PRODUCT MANAGER SET, OUTFITS, & TOOLS (PdM-SKOT) 156

SC 4910-95-A81 - SATS - Standard Automotive Tool Set (NSN 4910-01-490-157

6453) 158

SC 4940-95-B36 - SECM - Shop Equipment Contact Maintenance (NSN 159

4940-01-548-9064) 160 https://armypubs.army.mil/ https://www.govinfo.gov/ https://www.ecfr.gov/

SC 4940-95-E42 - FRS - Forward Repair System (NSN 4940-01-533-1621) 161

SC 5180-95-B49 - GMTK - General Mechanics Tool Kit (NSN 5180-01-605-162

5146) 163

(Contents of these end items are available from https://www.peocscss.army.mil/pdmskot.html) 164

PROJECT MANAGER EXPEDITIONARY ENERGY & SUSTAINMENT SYSTEMS 165

(PM E2S2) 166

69-692 - Terminal, Load 167

69-668 - Line, Fuel, Auxiliary 168

88-20063 - Plate, Identification 169

95-8165 - Connector, Plug, Electrical, Intervehicle Power Cable 170

13226E7032 - Cable Assembly, GRP E, 20 AMP 171

TMS - Tactical Microgrid Standard 172

(Copies of these drawings and document required by contractors in connection with specific 173 acquisition functions should be obtained from the contracting activity or as directed by the 174

Contracting Officer.) 175

2.3 Non-Government publication. The following documents form a part of this 176 document to the extent specified herein. Unless otherwise indicated, the issues of these 177 documents are those cited in the solicitation or contract. 178

AMERICAN SOCIETY FOR QUALITY (ASQ) 179

ASQ/ANSI Z1.4 - Sampling Procedures and Tables for Inspections by 180

Attributes 181

(Copies of this document are available from https://www.asq.org/) 182

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) 183

ASTM D975 - Standard Specification for Diesel Fuel Oils 184

(Copies of this document are available from https://www.astm.org/) 185

ASSOCIATION OF AMERICAN RAILROADS (AAR) 186

AAR OTLR - Section 1 "General Rules for Loading All Commodities" 187 https://www.peocscss.army.mil/pdmskot.html https://www.asq.org/ https://www.astm.org/

AAR OTLR - Section 6 "Rules for Loading Military Equipment and 188

Materiel" 189

(Copies of these documents are available from https://aarpublications.com/) 190

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE) 191

IEEE-315 - Graphic Symbols for Electrical and Electronics Diagrams 192

IEEE-519 - Recommended Practices and Requirements for Harmonic 193

Control in Electrical Power Systems 194

(Copies of these documents are available from https://www.ieee.org/) 195

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC) 196

IEC 61000-2-2 - Electromagnetic compatibility (EMC) – Part 2-2: 197

Environment – Compatibility levels for low frequency 198 conducted disturbances and signalling in public low-199 voltage power supply systems 200

IEC 61000-3-2 - Electromagnetic compatibility (EMC) – Part 3-2: Limits – 201

Limits for harmonic current emissions (equipment input 202 current ≤16 A per phase) 203

IEC 61000-3-4 - Electromagnetic compatibility (EMC) – Part 3-4: Limits – 204

Limitation of emission of harmonic currents in low-voltage 205 power supply systems for equipment with rated current 206 greater than 16 A 207

IEC 61000-3-12 - Electromagnetic compatibility (EMC) – Part 3-12: Limits – 208

Limits for harmonic currents produced by equipment 209 connected to public low-voltage systems with input current 210

>16 A and ≤ 75 A per phase 211

IEC 61000-4-5 - Electromagnetic compatibility (EMC) – Part 4-5: Testing 212 and measurement techniques – Surge immunity test 213

IEC 61000-4-7 - Electromagnetic compatibility (EMC) – Part 4-7: Testing 214 and measurement techniques – General guide on harmonics 215 and interharmonics measurements and instrumentation, for 216 power supply systems and equipment connected thereto 217

IEC 61000-4-30 - Electromagnetic compatibility (EMC) – Part 4-30: Testing 218 and measurement techniques – Power quality measurement 219 methods 220 https://aarpublications.com/ https://www.ieee.org/

IEC 61032 - Protection of persons and equipment by enclosures - Probes 221 for verification 222

(Copies of these documents are available from https://www.iec.ch/) 223

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) 224

ISO 7000 - DATABASE SNAPSHOT - Graphical symbols for use on 225 equipment 226

ISO 12103-1 - Road vehicles - Test contaminants for filter evaluation – 227

Part 1: Arizona test dust 228

ISO/IEC 15418 - Information technology - Automatic identification and data 229 capture techniques - GS1 Application Identifiers and ASC 230

MH10 Data Identifiers and Maintenance 231

ISO/IEC 15434 - Information technology - Automatic identification and data 232 capture techniques - Syntax for high capacity ADC media 233

ISO/IEC 16022 - Information technology - Automatic identification and data 234 capture techniques - Data Matrix bar code symbology 235 specification 236

ISO/IEC 16388 - Information technology — Automatic identification and 237 data capture techniques — Code 39 bar code symbology 238 specification 239

(Copies of these documents are available from https://www.iso.org/) 240

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) 241

ANSI/NEMA WD 6 - Wiring Devices – Dimensional Specifications 242

NEMA MG 1 - Motors and Generators 243

NEMA MG 2 - Safety Standard for Construction and Guide for Selection, 244

Installation and Use of Electric Motors and Generators 245

(Copies of these documents are available from https://www.nema.org/) 246

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 247

NFPA 70 - National Electrical Code 248

NFPA 79 - Electrical Standard for Industrial Machinery 249 https://www.iec.ch/ https://www.iso.org/ https://www.nema.org/

(Copies of these documents are available from https://www.nfpa.org/) 250

NORTH ATLANTIC TREATY ORGANIZATION (NATO) 251

NATO STANAG 3747 - Guide Specifications (Minimum Quality Standards) 252 for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, 253

F-37, F-40 and F-44) 254

(Copies of this document are available from https://nso.nato.int/nso/) 255

SOCIETY OF AUTOMOBILE ENGINEERS (SAE) 256

SAE AMS-STD-595 - (R) Colors Used in Government Procurement 257

SAE AS25043 - Cover, Electrical As50151 Connector, Receptacle, AN 258

Type 259

SAE AS34021 - Connector, Receptacle, Electric, Box Mounting, Front 260

Release, Crimp Contact, AN Type 261

SAE AS39029/30 - Contacts, Electrical Connector, Socket, Crimp Removable 262

(For AS50151 As345XX Series and MIL-DTL-83723 263

Series II Connectors) 264

SAE AS50151 - Connectors, Electrical, Circular Threaded, AN Type, 265

General Specification for 266

SAE AS85049 - Connector Accessories, Electrical General Specification for 267

SAE AS85049/130 - Connector Accessories, 268

Electrical, Gasketing Material, Conductive/Nonconductive, 269

Flange Mount, Category 7 270

SAE J514 - Hydraulic Tube Fittings 271

SAE J2360 - Automotive Gear Lubricants for Commercial and Military 272

Use 273

(Copies of these documents are available from https://www.sae.org/) 274

UNDERWRITERS LABORATORIES (UL) 275

UL 94 - UL Standard for Safety Tests for Flammability of Plastic 276

Materials for Parts in Devices and Appliances 277

UL 746C - UL Standard for Safety Polymeric Materials – Use in 278

Electrical Equipment Evaluations 279 https://www.nfpa.org/ https://nso.nato.int/nso/ https://www.sae.org/

UL 943 - UL Standard for Safety Ground-Fault Circuit-Interrupters 280

(Copies of these documents are available from https://ulstandards.ul.com/) 281

2.4 Order of Precedence. In the event of a conflict between the text of this document 282 and the references cited herein (except for related specification sheets), the text of this document 283 takes precedence. Nothing in this document, however, supersedes applicable laws and 284 regulations unless a specific exemption is obtained. 285

3.0 REQUIREMENTS 286

3.1 Description. The Tactical Microgrid Standard (TMS) compliant set (3.22) shall 287 consist of an engine that can operate on the fuels specified in 3.9.1, permanent magnet or 288 brushless generator, power converter (6.4.34) or excitation system if needed, governing system, 289 fuel system, 24 volt direct current cranking system, control system, protection system and other 290 devices as required to achieve a complete set and to allow for the required performance. 291

3.1.1 Set rating. The set shall be rated (6.4.3) at no less than three (3) Kilowatt (kW), 0.8 292

Power Factor (PF) lagging, 60 Hertz (Hz), Alternating Current (AC) continuous at the AC load 293 terminals and shall be reconnectable for the following voltages: 294

a. 1 Phase, 2-wire, 120 Volts (V) (double the current of 3.1.1.b). (T) 295

b. 1 Phase, 3-wire, 120/240V. (T) 296

c. 28VDC integral to the AC power source (O) or an external DC power supply (T) 297

d. 120VAC 1PH 400Hz 2-wire, re-connectable to 120/240 VAC 1PH 3-wire integral to 298 the AC power source (O) or an external frequency converter (T) 299

e. All in one power source selectable to 28VDC/120VAC 1PH 50/60/400Hz 2-wire, 300 reconnectable to 120/240 VAC 1PH 3-wire (O) 301

Additional rating capabilities shall be considered (leading 0.8PF, 50Hz) if feasible given 302 other performance constraints (O). Additional load terminals, circuit interrupters, and load 303 receptacle rearrangement as well as control devices and indicators shall be provided for, if 304 appicable (T). Power (kW) shall be no less than five sixths (5/6) of 60Hz for 50 or 400Hz 305 continuous at the same PF, and no less than 1.8kW for 28VDC (18-30V, 60A continuous). As 306 applicable, power quality shall be no less than utility in accordance with MIL-STD-1332 and as 307 described herein (T). 308

3.2 Reliability. The minimum acceptable mean-time-between-failure (MTBF) for the 309 sets shall be 687 hours (T), 2290 hours (O) with a lower confidence of 80% under the conditions 310 specified in 4.7.9. 311

3.3 Audio noise. Audio noise sound pressure levels (SPL) emanating from the set shall 312 not exceed 72 dB(A) at 23.0 feet (7 meters) from the perimeter of the set when measured at 3.9 313 https://ulstandards.ul.com/ feet (1.2 meters) above the ground (T). In addition, audio noise SPL emanating from the set 314 shall not exceed 85 dB(A) at the operator's station, with the control panel doors open if used, 315 defined to be a 2.3 feet (0.7 meters) hemisphere radiating outward from any point on the plane 316 defined by the front of the control panel (T). These requirements apply under all operating 317 conditions specified herein with the set operating at all loads from the no-load to rated load 318

(6.4.3) (T). Audio noise SPL emanating from the set should be inaudible from the perimeter of 319 the set 328 feet (100 meters) away (O). 320

3.4 High-altitude electromagnetic pulse (HEMP). The sets and feeder boxes shall 321 withstand the HEMP (6.4.35) nuclear environment specified in MIL-STD-2169 in both operating 322 and non-operating conditions. The set and feeder box shall operate as specified herein after 323 being subjected to the applicable nuclear environments without damage (6.4.17). The set and 324 feeder box operating as a unit (not in parallel) shall meet operational requirements specified 325 herein within 5 minutes (recover) after being subjected to the specified HEMP environment. The 326 sets and feeder box operating in parallel (up to 3 sets and one feeder box) shall meet operational 327 requirements specified herein within the same time it takes to start, parallel remotely, and 328 provide rated power at rated load before and after being subjected to the specified HEMP 329 environment. The recovery for each may include manual or automatic correction of HEMP 330 induced changes in the set or feeder box, to include restart, but not the replacement of piece parts 331 or components. The cables to the load and for remote control shall be at least 100 feet in length 332 and sets and other equipment shall be configured for worst-case system response during the 333 exposure. 334

3.5 Chemical, biological, radiological and nuclear (CBRN) contamination survivability. 335

The set and feeder box shall have a Chemical Agent Resistant Coating (CARC) painted as 336 specified in 3.36. The set and feeder box shall be capable of being decontaminated (T), operated 337

(T), and serviced (O) (3.15) by personnel wearing Mission Oriented Protective Posture IV 338

(MOPP IV) chemical, biological, and radiological clothing (6.4.27) without special tools or 339 support equipment. The set shall not be damaged (6.4.17) and shall meet operational 340 requirements specified herein within 60 minutes after being decontaminated according to the 341 procedure specified in APPENDIX A. 342

3.6 Electrical performance. Set electrical performance shall be as specified herein. Set 343 rating shall be no less than 3 kW at 1,000 feet (305 meters) of altitude and with an ambient 344 temperature of +120°F (+49°C). Components of the set shall not be damaged (6.4.17) when the 345 set is operated continuously at all possible frequency and voltage adjustments. The set shall 346 provide the applicable load rating (3.7.2) at the output terminals under all operating conditions 347 specified herein. 348

3.7 Starting, operating, and stopping. The set, feeder box, and other accessories shall 349 perform in the various environments as required where applicable. The planning guidance for 350 realistic consideration of climatic conditions in the Research, Development, Test, and Evaluation 351

(RDT&E) of material used in combat by the Army is described in AR 70-38. 352

3.7.1 Starting. The set shall start (6.4.4) within 5 minutes of the first user action in 353 accordance with (IAW) the startup procedures (or auto-start signal receipt) both with and without 354 the battery under any combination of the following conditions: 355

a. At ambient temperatures from –25°F (–32°C) to +120°F (+49°C) using the electric 356 start at any possible humidity; and from +20°F (–7°C) to +120°F (+49°C) using the manual start 357 at any possible humidity (T). 358

b. At altitudes up to and including 8,000 feet (2,438 meters) above sea level. 359

c. With the base of the set in planes from level up to 15 degrees (0.27 radians) from 360 level in any orientation. 361

d. With up to 5 inches (127 millimeters) of rain per hour impinging on the set at angles 362 up to and including 90 degrees (1.571 radians) from the vertical. 363

e. With up to 355 British Thermal Units (BTUs) per square foot per hour (1,120 watts 364 per square meter) of solar radiation. 365

f. With a sand/dust particle concentration of up to 1,400 mg per cubic meter. Particle 366 sizes shall range from less than 74 micrometers in diameter to 1,000 micrometers, with the bulk 367 of the particles ranging in size from 74 to 350 micrometers. 368

g. With a steady wind speed of up to 73 feet per second (22 meters per second) and 369 gusts up to 95 feet per second (29 meters per second) at a height of 10 feet (3 meters) above 370 ground level. 371

h. With accumulations of ice glaze, freezing rain and hoarfrost of up to 0.5 inch (13 372 millimeter) and up to a specific gravity of 0.9. 373

i. In a salt fog or sea-spray environment. 374

j. With fuels, lubricants, and coolants specified in 3.9. 375

3.7.2 Operating. Immediately after starting or with the remaining time left from startup 376 while at no load operation, the set, feeder box, and all other accessories shall operate without 377 damage (6.4.6, 6.4.10, and 6.4.17) or failure (6.4.14.1, 6.4.14.4, and 6.4.14.5) at all loads, 378 continuous and intermittent, up to and including rated load under any of the conditions or 379 combinations of the conditions specified in 3.8.1. Except that for the set rating of no less than 380

3kW at 1,000 feet (305 meters) altitude and +107°F (+42°C): 381

a. Set rated load may be de-rated up to 3.33 percent (T), 1.67 percent (O) for each 1,000 382 feet (305 meters) above 1,000 feet (305 meters) altitude. 383

b. Set rated load may be de-rated up to 1 percent for each 10°F (5°C) above +107°F 384

(+42°C). 385

c. At 4,000 feet (1,219 meters) altitude and +95°F (+35°C), set de-rating shall not 386 exceed 10 percent (T), 5 percent (O). 387

d. At 8,000 feet (1,219 meters) altitude and +95°F (+35°C), set de-rating shall not 388 exceed 23.3 percent. 389

3.7.3 Stopping. The set shall stop (6.4.5) within 60 seconds after activation of any device 390 intended to stop the set. 391

3.7.4 Colder temperature. The set shall perform as prescribed in 3.7.1 through 3.7.3, 392 inherently, or with an accessory, at an ambient temperature of –65°F (–54°C) where the set is 393 electrically started and where the total time to start and operate is 10 minutes. (O) 394

3.8 Endurance (life). The set shall operate for 2,150 hours without critical failure 395

(6.4.14.5) at all loads, continuous and intermittent, up to and including rated load under all of the 396 conditions specified in 3.7.2. 397

3.9 Fuels, lubricants, and coolants. 398

3.9.1 Fuels. The set, while operating on F-24 fuel conforming to NATO STANAG 3747, 399

Jet Propulsion (JP)-8 fuel conforming to MIL-DTL-83133, or diesel fuel conforming to ASTM 400

D975, shall meet all the requirements specified herein. Diesel fuel shall be of grades very low or 401 low sulfur (No. 1-D S15, No. 2-D S15 [also known as Ultra Low Sulfur Diesel (ULSD)] or 1-D 402

S500, No. 2-D S500). The set, while operating on JP-5 conforming to MIL-DTL-5624, shall 403 meet all requirements herein, except rated load may be reduced up to 20 percent and a maximum 404 of 300 hours of operation on JP-5 per 2,150 hours of set operation shall be required. Operation 405 on JP-5 shall only be required at temperatures from 0°F (–18°C) to +100°F (+38°C) and at 406 altitudes up to 1,000 feet (305 meters). No manual adjustment is allowed when changing 407 between the above fuels. 408

3.9.2 Lubricants. The engine shall operate on lubricating oil conforming to MIL-PRF-409

2104 and MIL-PRF-46167, gear oil conforming to SAE J2360, grease conforming to MIL-PRF-410

10924, and preservative/break-in oils conforming to MIL-PRF-21260 as applicable. 411

3.9.3 Coolant. If a liquid cooled engine is used in the set, the engine shall be capable of 412 operating with coolants conforming to A-A-52624. 413

3.10 Other set requirements. 414

3.10.1 Overspeed. The set shall withstand engine operation at 110 percent of rated 415 speed (6.4.26) for 5 minutes without damage (6.4.17). 416

3.10.2 Flexural vibration and critical speeds. The set shall be free from dangerous 417 flexural vibrations (6.4.7) and dangerous torsional critical speeds (6.4.9) between the minimum 418 low idle speed and 115 percent of rated speed (6.4.26). 419

3.10.3 Vibration Stress. The set and feeder box shall be capable of withstanding 420 vibrational stresses without damage (6.4.17) during transportation and operational modes. 421

3.10.4 Maximum power. The minimum acceptable maximum power shall be 110 422 percent of rated load under all operating conditions specified herein, except that at altitudes 423 above sea level, the minimum maximum power shall be no less than the de-rating allowed at 424 altitudes and temperatures above sea level (3.7.2). Production sets shall have a maximum power 425 of not less than 2 percent below the average maximum power measured for the First Article Test 426

(FAT) sets when corrected for the same conditions. 427

3.10.5 Fuel consumption. The set shall consume JP-8 fuel (6.56 pounds per gallon) at 428 a rate less than 0.36 gallons per hour while operating at rated load in ambient conditions. 429

3.11 Transportability. 430

3.11.1 Lifting and tiedown provisions. Mechanical lifting and tiedown provisions shall 431 be provided in accordance with MIL-STD-209, except as specified herein. Slinging and 432 multipurpose tiedown provisions shall have a minimum inside clearance of 1.969 inches, and a 433 maximum inside clearance of 2.169 inches. Slinging and multipurpose tiedown provisions shall 434 have a minimum clearance from the set surface to the farthest inside edge of 1.969 inches and a 435 maximum clearance from the set surface to the farthest inside edge of 3.969 inches. The 436 identification of slinging, tiedown, or multipurpose provisions shall be in letters not less than 437

0.375 inches in height. The set, with fuel tank 1/4 full to full, with or without the battery shall 438 remain within 15 degrees of level when lifted. Lifting provisions shall be marked "LIFT 439

HERE", and tiedown provisions shall be marked "TIE-DOWN". 440

3.11.2 Rail tiedown procedures. Procedures for mounting of the sets to a rail flat car 441 for shipment (transportation) shall be provided. Mounting of the sets shall be in accordance with 442 standard loading and bracing methods as shown in Section 1 “General Rules for Loading All 443

Commodities” and Section 6 "Rules for Loading Military Equipment and Materiel" of 444

Association of American Railroads (AAR) Open Top Loading Rules (OTRL) Manual. 445

3.11.3 Air transportability. The set and feeder box shall not be damaged (6.4.10 and 446

6.4.17) by aircraft and helicopter transportation (6.4.13), and shall be transportable while facing 447 forward, aft and to either side. 448

3.11.3.1 Internal air transport. The lifting and tiedown provisions (3.11.1) shall meet the 449 requirements of MIL-STD-209. The set and feeder box shall be capable of being transported in a 450

C-130 or larger aircraft and inside utility rotary wing aircraft while facing forward, aft, or to 451 either side. 452

3.11.3.2 Military airdrop. The sets and feeder boxes shall be capable of being platform 453 mounted while facing forward, aft, or to either side. The set and feeder box shall meet the 454 requirements of MIL-STD-814 for Low Velocity Airdrop (LVAD). 455

3.11.4 Rail transport. The set and feeder box while facing forward, aft and to either 456 side shall be capable of being rail transported (6.4.11) on wood-decked, all open top railcars 457 without damage (6.4.10 and 6.4.17). 458

3.11.5 Utility vehicle and trailer transport. The set and feeder box shall be capable of 459 being transported by utility vehicle, truck, or trailer transportation (6.4.12) while facing forward, 460 aft, or to either side without damage (6.4.10 and 6.4.17). 461

3.11.6 Inclined transportation. The set and feeder box shall be capable of being 462 transported while in an operable condition but not operating, when inclined at any angle from 463 horizontal to 25 degrees from horizontal in any direction, and with the set fuel tank at any 464 possible level from empty to full, with no spillage or seepage from the set or any of its 465 components. 466

3.11.7 Forklift openings. Openings shall be provided in the skid base to permit 467 insertion of forklift tines. Each opening shall be not less than 8 inches long and 2.5 inches in 468 height and the openings shall be located such that the center of gravity of the set falls 469 approximately midway between the centers of the forklift openings. The distance between the 470 centers of the openings shall be a multiple of 2 inches but not more than 28 inches nor less than 471

18 inches. The openings shall be reinforced and equipped with guides such that the set will not 472 be damaged (6.4.10 and 6.4.17) if it is lifted by a forklift, with the tines not extended completely 473 through the base. Each opening shall be marked "FORKLIFT HERE" in 0.75 inch minimum 474 letter height. 475

3.11.8 Handling. The set shall have provisions such that six soldiers can manually lift 476 and transport the set. These provisions shall be located below the centerline of the set, and shall 477 be suitable for use by personnel wearing arctic mittens and MOPP IV clothing. Handles shall be 478 located so that six personnel can lift and carry the set without interfering with one another. The 479 handling provisions shall be within the set maximum dimension (3.17) when not in use. If non-480 fixed handles are used, the handles must have a stop position perpendicular to the surface on 481 which they are mounted, and be parallel to the ground when positioned for use. Any two 482 opposing handles shall be capable of supporting the weight of the set. 483

3.11.9 Wheel and handle. If the set weights more than 100 lbs. (45 kg), the set shall 484 have a detachable wheel and handle accessory suitable for one solider to pull the set over paved 485 and unpaved firm or gravel surfaces; and packed dirt or sand. The accessory shall include any 486 and all hardware required to install on the set. 487

3.12 Storage. The set and feeder box without packaging shall not be damaged (6.4.6 and 488

6.4.17) by exposure to: 489

a. Storage at –60°F (–51°C) to +160°F (+71°C). 490

b. Salt fog environment. 491

c. All possible relative humidities. 492

The set and feeder box shall be operational with minimal preparation after removal from storage 493 consistent with standard DoD practice. Procedures for storage and preservation shall be 494 incorporated in the technical manuals. 495

3.13 Safety. The set shall meet the provisions of MIL-STD-882, Warnings, hazards, and 496 safety of MIL-STD-1472 (as specified in 3.24), and should use the guidelines of MIL-HDBK-497

454 for guidance, specifically guideline 1. Exposed parts of such nature as to be a hazard to 498 personnel shall be insulated, enclosed or guarded without impairing the functioning of these 499 parts. 500

3.14 Electromagnetic interference (EMI). EMI and susceptibility characteristics shall 501 comply with the requirements of MIL-STD-461 for conducted emissions (CE102), conducted 502 susceptibility (CS101, CS114, CS115, CS116, and CS118), radiated emissions (RE102), and 503 radiated susceptibility (RS103). A 5 meter (T), 3 meter (O) standoff distance is allowable in 504 order to meet this requirement. 505

3.15 Servicing, operation and maintenance. The design and construction of the set shall 506 permit routine service and maintenance under military field conditions. Any unscheduled 507 maintenance which requires the removal of the set housing shall be validated before the set 508 housing is replaced. The set shall be capable of being started and operated by one operator under 509 all conditions. Starting or stopping the set shall not require manipulation of more than one 510 control or switch, except for the activation of the engine starting aid control device (3.32.1.7). 511

Hardware which requires torqueing shall be installed such that the nut, bolt or screw head is 512 accessible for torque wrench application. A spare fuse shall be stored and properly marked close 513 to the location of the fuse it is a spare for. In assemblies where both a bolt and nut are used, the 514 nut shall be accessible for torque wrench application. When Test, Measurement and Diagnostic 515

Equipment (TMDE) is required, TMDE shall be selected from the TMDE Preferred Items List 516

(PIL) (See Appendix B). Requirements for any new TMDE shall be developed in accordance 517 with AR 750-43, Army TMDE Program. The design shall maximize the use of existing tools 518 available in the following tool kits: the General Mechanic's Tool Kit (GMTK) NSN 5180-01-519

605-5146 (SC 5180 95-B49), the Standard Automotive Tool Set (SATS) NSN 4910-01-490-520

6453 (SC 4910-95-A81), the Forward Repair System (FRS) NSN 4940-01-533-1621 (SC 4940-521

95-E42), and the Shop Equipment Contact Maintenance (SECM) NSN 4940-01-548-9064 (SC 522

4940-95-B36) for all set maintenance and service actions if not already tethered to the set. The 523 design should avoid the need for a new special tool or new TMDE, and if required, the request 524 shall be made as soon as the need is recognized in the design. Servicing, operation and 525 maintenance requirements shall be met with the set on the ground. Design for maintainability 526 shall comply with 3.24. Particular design attention shall be given to paragraph 5.9 (especially 527

5.9.11.3 - Captive fasteners) of MIL-STD-1472 as specified in 3.24. Fasteners used for 528 scheduled maintenance shall be visible to the maintainer. Fluid indicators shall be easily and 529 readily accessible. 530

3.15.1 Alternate clothing servicing. Parts that require adjustment or servicing shall be 531 capable of being adjusted or serviced by personnel wearing arctic clothing, and/or MOPP IV 532 chemical, biological and radiological clothing. (O) 533

3.15.2 Maintainability requirements. Maintainability requirements shall be applicable 534 to the generator set while operating on the ground. The complete maintenance schedule, 535 preventive and scheduled, shall be followed throughout the First Article Test (FAT) and 536 demonstrated during the First Article Inspection (4.4). 537

3.15.2.1 Preventive maintenance. The minimum interval (hours of set operation) 538 between scheduled preventive maintenance (checks, inspections, services), known as 539

Preventative Maintenance Checks and Services (PMCS), shall be 24 hours (T), 36 hours (O). 540

Preventive maintenance shall be simple enough for any Soldier (regardless of specialty) to 541 perform in less than 15 minutes (T), 5 minutes (O). Preventive maintenance actions shall include 542 but not be limited to the following: 543

a. Inspecting for loose connections, leaks, cracks, and making minor adjustments. 544

b. Checking and adding lubricating oil. 545

c. Draining of contaminants from fuel filters and water separators through drain valves. 546

d. Checking and servicing of the battery. 547

e. Checking and adding coolant if applicable. 548

f. Checking and servicing of air filters. 549

3.15.2.1.1 Oil level. The oil level shall be able to be checked while the set is in operation 550 without causing damage (6.4.17). (O) 551

3.15.2.2 Scheduled maintenance. The minimum interval (hours of set operation) 552 between scheduled maintenance services (adjustments, replacements, etc.) shall be not less than 553

100 hours (T), 150 hours (O). Scheduled maintenance service intervals for the set life (3.8) shall 554 be as recommended by the contractor. The maximum time for all scheduled maintenance actions 555 at each scheduled maintenance interval, performed at intervals less than 2,000 hours, shall be 2 556 hours when conducted by one person (MOS-91D). Without tools, one person shall be able to 557 change the oil and replace the oil filter, or replace or clean the fuel and air filters, within 20 558 minutes (T), 10 minutes (O). 559

3.15.2.3 Unscheduled maintenance. The Median Time to Repair (MTTR) (6.4.28) for all 560 unscheduled maintenance actions at the field level shall not exceed 1 hour (T), 0.5 hours (O). 561

The Maximum Time to Repair (MAXTTR) (6.4.29) for 90 percent of all unscheduled 562 maintenance actions shall not exceed 2 hours (T), 1 hour (O). MTTR and MAXTTR shall be 563 determined for all unscheduled maintenance actions that occur during the endurance (4.8.28) and 564 reliability/endurance/maintainability (4.8.9) tests. 565

3.15.3 Maintenance Ratio. The maintenance ratio (6.4.18) of the set shall not exceed 566

0.028 (T), 0.020 (O) maintenance man-hours per operating hour for the combined organizational 567 and direct support maintenance levels. 568

3.15.4 Diagnostic test points. The set shall include diagnostic test points as necessary 569 to fully monitor and troubleshoot the set. All diagnostic test points shall be located in one easily 570 accessible area inside the control panel. All test points shall be labeled and identified (3.38.3.9). 571

3.15.4.1 Self-diagnostics. In lieu of or in addition to the diagnostic test points, the set 572 shall conduct and display to the operator or maintainer a self-diagnosis of all Line Replaceable 573

Units (LRUs) during start-up and during operation to allow operators and maintainers to take 574 corrective actions and to enhance troubleshooting of the set. (O) 575

3.15.4.2 Prognostics. If self-diagnostics capable, the set shall monitor the internal health 576 of the system and identify malfunctions and warn of performance anomalies before they become 577 failures. It shall also store warnings, faults, and maintenance actions, and set operational data 578 that may be displayed to the operator but shall be accessed through the remote one port in 579 accordance with the tactical microgrid standard. 580

3.15.5 Engine/generator lifting attachments. A single lifting attachment shall be 581 provided for removal of both the engine and generator. The lifting attachment shall withstand, 582 without damage (6.4.10 and 6.4.17), a minimum of 3.5 times the weight of the lifted assembly. 583

The inside dimensions of the lifting attachment shall permit passage of a 2-inch diameter lifting 584 device. 585

3.15.6 Maintenance mode. The set shall have a mode for performing maintenance 586 which is entered by actuating a series of control panel control devices. This mode shall only be 587 exited by the cycling (removal and reconnection) of DC control power. While in maintenance 588 mode the set shall not open the AC circuit interrupter (or DC circuit interrupter if equipped) in 589 the event that the energized AC load terminals (or DC load terminals if equipped) become 590 exposed. The control system shall report through the remote one interface the set state of this 591 mode while in the remote TMS state. If a continuous display is provided, then the continuous 592 display shall indicate the same mode state. 593

3.16 Interchangeability. Future sets realized from this specification, shall use the same 594 engine, governing system, skid base, housing, frame, wiring harness, mounts, battery, battery 595 charging system, fuel system, air filter, oil filter, fuel filter, muffler and as many other common 596 components as practical of sets initially realized from this specification unless otherwise stated 597 elsewhere. 598

3.17 Physical configuration. 599

3.17.1 Shape. The shape of the set shall be rectangular to optimize the storage volume 600 within tactical vehicles. The set housing shall inherently or with an ancillary accessory allow for 601 stackability to further optimize the storage volume within tactical vehicles. This capability shall 602 support at least the weight of the same set stacked on top. The set top shall also inherently have 603 features to enable nesting into matching features in the skid base to further enhance the 604 capability. (O) 605

3.17.2 Size. The size of the set may take on the following dimensions. 606

a. Length – 34.75 inches (882.65 millimeters) 607

b. Width – 27.80 inches (706.12 millimeters) 608

c. Height – 26.50 inches (673.10 millimeters) 609

3.17.3 Weight. The set dry weight (6.4.25) shall not weigh more than 308 pounds (140 611 kilograms). 612

3.17.4 Skid base. The set shall have a skid base that extends horizontally beyond all 613 components of the set. The skid base shall be provided with a method to drain spilled liquids 614 from the interior of the set. There shall be at least a 1-inch clearance between the lowest 615 projection of the set and the bottom of the skid base. The set shall not move or "walk" when 616 operating unrestrained, on a level concrete surface, under all operating conditions specified 617 herein. The skid base may be integral with the set housing. A four (4) hole bolt pattern shall be 618 provided in the skid base of the set. The bolt pattern shall be located such that that the 619 longitudinal and lateral center of gravity of the set falls approximately between the centers of the 620 bolt holes. The bolt holes shall be large enough to accommodate a half inch diameter bolt. 621

3.17.5 Housing. The set housing shall be removable to perform unscheduled 622 maintenance actions including removal of engine, generator or other components. The housing 623 shall provide for access to the interior of the set, without removal of panels, as necessary to 624 perform all preventative and scheduled maintenance service (3.15.2) actions and also permit 625 replacement of the set battery while setting on the ground. Hinged doors, if used, shall be self-626 supporting in the open position. The door swing for any hinged door shall not exceed 20 inches. 627

The housing shall be permanently marked with a CAUTION against standing or storage of heavy 628 objects on its top and/or specifics about its limits. The housing shall have drain holes to allow 629 liquids to drain from within the housing. The set housing shall not cause injury to personnel as a 630 result of increased temperatures from internal components. The set housing shall exclude wind-631 driven rain, snow and sand from the interior of the set to the extent necessary to meet all 632 requirements herein. If a gasket is used, it shall be mechanically fastened to the housing. 633

3.17.6 Hinges and latches. Hinges or hinge pins shall be peened at the ends, or other 634 means shall be provided to prevent workout of the pins. Hinges shall be removable. Latches 635 shall require manual, not spring action, for closing. All parts of the latches having relative 636 motion with each other shall be of corrosion-resistant metal. Access door latches (3.17.5) shall 637 be flush mounted, non-key locking, dead bolt, and shall not require the use of tools for operation 638 or require more than a half turn to latch or unlatch a door. 639

3.17.7 Grounding and Bonding. Grounding and bonding (6.4.31 and 6.4.32) of the set 640 and accessories shall be in accordance with article 250 of the National Electrical Code (NEC) 641

NFPA70. The set shall be capable of being connected to earth to limit the affects imposed by 642

HEMP, EMI, lightning, and static charges. All non-current-carrying metal parts that are 643 accessible to users and are likely to become energized due to an electrical fault shall be bonded 644 and grounded. Panels and doors shall be attached or hinged in such a manner as to ensure that 645 they are at the same ground potential as the rest of the set in which they are mounted, whether in 646 a closed or open position. Hinges or slides shall not be used for grounding paths. Ground 647 connections to shields, hinges, and other mechanical parts shall not be used to complete electrical 648 circuits. The impedance between the set ground (3.18.1.2) and to any bonded non-current 649 carrying metal part shall be less than 0.1 ohms. 650

3.17.7.1 Set ground rod. A three-section ground rod and the ground rod accessories 651

(grounding conductor, grounding conductor clamp, and ground rod section interconnects) 652 conforming to A-A-55804-III-B shall be provided with each set (including both first article and 653 production). Provisions for storage of the ground rod sections and its accessories, internal to the 654 set, shall be provided, if the size of the set is large enough to allow for storage of ground rods 655 and its accessories. If the ground rods and its accessories are stored within the set, door(s) 656 through which ground rods are accessed shall be marked "GROUND ROD" on the outside. 657

3.17.8 Spacings. The minimum creepage and clearance (6.4.33) distances between 658 uninsulated live parts of opposite polarity and between uninsulated live parts and non-current-659 carrying metal parts shall be no less than the spacing distances in Table I. The shortest distance 660 between any output load terminal, including the ground terminal (3.18.1), shall be no less than 661

1.25 inches (31.8 millimeters). 662

TABLE I. Spacings. 663

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)

3.18 Load terminals, load receptacles, and circuit interrupter. Load terminals, load 666 receptacles, and circuit interrupters shall be protected from accidental contact and shall be 667 protected from the environments while in use or not in use. The AC load terminals shall not be 668 energized if a protective door, lid, or cover has opened or has been removed. Exception is when 669 the set is put into the maintenance mode (3.15.6) or in battle short mode. The control system 670 shall monitor if any door, lid, or cover is exposing energized terminals to the user and report on 671 its current state through the remote one interface in accordance with the tactical microgrid 672 standard when in the TMS position. 673

3.18.1 Load terminals. Load terminals shall be sized to carry the full power of the set 674 in all capable configurations (3.1.1). Load terminals shall conform to drawing 30554-69-692. 675

Load terminals shall be rigidly mounted; studs shall not twist or turn in their mountings when 676 hexagonal bar nuts are tightened. Terminals shall be readily accessible for connection of 677 external output wires. 678

3.18.1.1 AC load terminals. The set shall be equipped with three (3) load terminals for 679

AC power. The load terminals shall be conspicuously marked "L1," "L2," and "N"; terminal "N" 680 being neutral. The load terminals shall be arranged in line in the sequence "L1," "L2," and "N" 681 when reading from left to right or from top to bottom. 682

3.18.1.2 Ground terminal. The set shall be equipped with an appropriately sized ground 683 terminal marked "GND". The ground plane shall contain the ground terminal and be 684 permanently connected to the skid base by means of a low impedance, corrosion free connection. 685

The ground terminal shall be provided next to the AC load terminals to serve as equipment 686 ground for the set with proper spacing (3.17.8). The set mounting arrangement shall permit a 687 removable, low impedance connection between "N" and "GND" terminals. The connection shall 688 be sized in accordance with the NFPA70 National Electrical Code. The control system shall 689 monitor if the neutral ground (N-G) bond is in place or not and report on its current state to the 690 continuous display, if equipped, and through the remote one interface in accordance with the 691 tactical microgrid standard when in the TMS position. 692

3.18.1.3 Load terminals AC circuit interrupter. A dedicated AC circuit interrupter shall 693 be connected between the voltage reconnection system and the AC load terminals.