MTE_450V_PS_SRD.pdf

SYSTEM REQUIREMENTS DOCUMENT (SRD)

FOR

AN/MSQ-T43(V)1&4)

MODULAR THREAT EMITTER (MTE)

450 Volt Power Supply (1A3PS1)

PREPARED BY COMBAT & MISSION SUPPORT BRANCH

AFLCMC/HBZCA

6057 BOX ELDER LN, BLDG 1285 HILL AFB, UT

84056-5811

Contents

1. SCOPE

1.1 Background

2. APPLICABLE DOCUMENTS

2.1 Government Military Standards

2.2 Other Publications

2.3 Interface Control Documents

3. REQUIREMENTS

3.1 General Requirements

3.2 Performance Requirements

3.3 User Interfaces

3.4 Logistics (RAM)

3.5 Test Diagnostic Capability and User Maintenance

3.6 Marking and Item Identification

4. QUALITY ASSURANCE PROVISIONS

4.1 Verification Methods

4.2 Verification Matrix

5. NOTES

5.1 DEFINITIONS

SCOPE

This document defines the requirements for a 450 (+4%) volt, 3-phase, 60 Hz, high voltage power supply.

The power supply sources the voltage and current to the transmitter circuits that drive the Pulse Forming

Network (PFN), Pulse Transformer (PT), magnetron and other low current, sensing and switching circuits. The power supply is installed within a weather resistant enclosure and mounted on the radar platform. The AN/MSQ-T43(V)1&4 is a mobile, ground-based system.

Background

The 450 volt, high voltage power supply sources voltage and current to the system track transmitter. It is a linear, non-regulated supply consisting of a Wye to Delta step-up transformer (T1) and the rectifier filter assembly (PS1) which houses the 3-phase bridge rectifier, storage capacitors, inductor, resistors and fault relay K1. Transformer T1 receives 3-phase, 120 VAC from a commercial or generator power source and outputs 3 phase, 350 VAC to the PS1 assembly. The PS1 assembly rectifies and filters the 350 VAC to a nominal 450 VDC (+4%). Fault relay K1 is used to disable high voltage when certain transmitter faults occur. When a candidate fault occurs, the +28 volts that is connected to the coil of relay K1 in the PS1 assembly goes to zero which opens the relay and disables the high voltage to the modulator. Control of the +28 volt supply is independent of the PS1 assembly.

Furthermore, as described in the system TO (43D7-11-36-1, paragraph 5.16.5.7), and external to the 450

V power supply, there is a, “… charging SCR assembly that controls the charging of the modulator energy storage capacitor. The storage capacitor charging procedure is initiated when charging SCR Q1 is fired by the delayed trigger input pulse. Charging SCR Q1 then connects charging choke 1A8L1 to the modulator storage capacitor. The charging reactor and the storage capacitor form a DC resonant charging network which nearly doubles the 450V power supply voltage. The storage capacitor charge level is maintained on a pulse-by-pulse basis in order to ensure a constant magnetron output from pulse to pulse.

The regulation procedure is initiated when regulator SCR Q2 is fired by the energy regulator trigger pulse. Conduction current through Q2 is then routed through a second (bucking) winding on the charging choke. This current, when induced into the charging choke main winding, is equal to the charging current in amplitude, but opposite in phase, thus stopping the storage capacitor charging. Almost all of the bucking current is discharged back into the 450 volt power supply assembly 1A3PS1, thereby enhancing regulator efficiency”.

APPLICABLE DOCUMENTS

Unless otherwise specified, the following documents of the issue in effect on the date of the invitation for bids or requests for proposal form a part of this specification to the extent specified herein.

Government Military Standards

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

MIL-STD-20703-1 Standard Practice for Military Packaging

MIL-STD-2073-1E3, Method 10

DFAR-252.211-7003 Item Unique Identification and Valuation

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

MIL-HDBK-781A Reliability Test Methods, Plans, and Environments for Engineering

Development, Qualification, and Production

Other Publications

ISO 9001:2015 Model for Quality Assurance in Design, Development, Production, Installation and Servicing

Interface Control Documents

716436 Power Supply Assembly 450V

SD716436 450V Power Supply Schematic Diagram

BTP716436 Power Supply Assembly, 450V Bench Test Procedure

WD714577 Power Distribution Wiring Diagram

REQUIREMENTS

This project will replace the original 450 volt linear, DC power supply with a linear, regulated, variable

200 - 450 volt DC supply (power supply variability may go to 0 volts).

General Requirements

[R001] The contractor shall be responsible for validating the operational voltage and current requirements of the existing supply to ensure that the new supply performs as required under static and dynamic load conditions. As described in Section 3 above, relay K1 (located within 1A3PS1 assembly) inhibits the high voltage when certain system faults are encountered.

[R002] The contractor shall ensure that this functionality is included in the new power supply by either using the existing K1 relay or by implementing an equivalent method.

[R003] The new power supply shall also be required to sink the bucking current described in Section 3 above without damage to the power supply or host system.

[R004] The power supply shall not induce disruptive power supply spikes or low/high frequency noise into the host system.

[R005] The 450 VDC Power Supply shall be fabricated using best-commercial practices and utilize

Government Off-The-Shelf (GOTS) or Commercial Off-The-Shelf (COTS) and Non-Developmental

Items (NDI) to the maximum extent possible in an effort to reduce NRE and to benefit from current, state-of-the-art technologies. Documented modification of COTS or GOTS equipment to meet the requirements of this project is acceptable. Modification data as ‘Altered Item Data ‘shall be delivered in the CDRL

A009 submittal.

Performance Requirements

3.2.1 Electrical Characteristics

Electrical connection from the system to the power supply, both T1 and PS1, is accomplished with terminal boards that accept #8 lugs.

[R006] The power supply unit shall meet its operational requirements of being able to provide an output set-point voltages of between 200 VDC and 450 VDC, and for the DC output voltage to be able to be switched-on via a 28 Volt signal trigger after the power supply unit has initially been turned-on and stabilizes.

[R007] The rise time characteristic of the 28 volt triggered DC output voltage shall meets its intended set-point DC voltage of no greater than 3 seconds from the time the 28 Volt signal trigger is activated.

The rise time is defined from the measured 10% to 90% points of the power supply DC output voltage.

The 120 VAC input power is always present during the ON/OFF sequencing. The 120 VAC is always energized to the power supply.

The 450 VDC Power Supply shall, at a minimum, meet the following electrical performance requirements:

Requirement

Number

Title Specification

[R008] Input Voltage 350 to 405VAC, 3-phase Delta, 60 Hz – Measured phase to phase, THD < 1% (from Transponder 1A3T1)

[R009] Line Regulation < 0.1% of max V for line change within specified input voltage range

[R010] Typical Output Current 8.5 – 9.5A, Typical operating Approximately 30-50 A instantaneous peak current (Transmitter operating at .0014 (.14%) Duty

Cycle – max)

50A Maximum peak pulsed capability for 70uS –

Repetition rate 2KHz Max

[R011] Output Voltage Regulated, Variable 200 – 470 VDC via front panel potentiometer

[R012] Load Regulation < 0.1% into static load 10 – 95%

< 1.0 % of max V at full load current pulse

[R013] Voltage Ripple < 30 mV RMS into static resistive load

[R014] Stability < 1% max/8 hours at constant voltage, current and temperature

[R015] Temperature Coefficient < 0.05%/C allowing for a 30 minute warm-up

[R016] Max Output Power The specification for the max output power of the original power supply is not recorded in any documents available to the AF. Output power to be determined by the contractor based on static and dynamic operating conditions of the system.

[R017] Protection Circuitry The Air Force is not in possession of certain minimum specifications for the original power supply such as noise, efficiency, isolation, missing phase protection, over temperature, over current, or over/under voltage protection requirements. Protections shall be included in the power supply, typical to industry standards that will protect itself and the host system from damage or failure.

3.2.2 Environmental Requirements

Requirement

Number

Title Specification

[R018] Temperature Operating -30 to +55 Degrees C (-22 to 131 F)

Storage -51 to +68 Degrees C (-59.8 to 154.4 F)

[R019] Humidity 5 TO 95% Relative Humidity, Non-condensing, Operating, and Storage

[R020] Shock (Non-Operating) 20 G, 11 ms, in 3 Axes, Both Directions

[R021] Vibration (Non-

Operating)

See Fig. 1.

Figure 1. Vibration Level

3.2.3 Mechanical Size and Weight Requirements

[R023] The new 450V Power Supply shall be fit compatible with the existing AN/MSQ-T43(V) MTE

Power Distribution Unit. In the event that a COTS or GOTS solution is not fit compatible but meets the other specifications, the COTS or GOTS solution can be repackaged or installed into a new housing that is fit compatible.

[R024] The new housing shall provide equivalent or better environmental protection as the original equipment.

[R025] The 450V Power Supply lid/top cover will be fastened by screws that are accessible on both ends, (Not on top of lid/cover).

Requirement

Number

Title Specification

[R026] Weight (See Fig. 2) The maximum weight of the new 450 VDC Power

Supply shall not exceed the legacy 450 VDC Power

Supply.

Weight PS1 64 lbs.

Weight T1 100 lbs. max

Total Weight < 164 lbs.

[R027] Dimension (See Fig. 2) PS1 8 x 16.75 x 9.25 inches (H x W x D)

T1 8 x 12 x 8.5 inches (H x W x D)

Freq (Hz) PSD value g2/Hz

5 0.015

50 0.015

55 0.01

200 0.01

500 0.005

Duration: 150 Minutes per each of 3 orthogonal axes

FIGURE 3. – System Location

TOP VIEW

SIDE VIEW FIGURE 2. – Location and Dimensions

FIGURE 4. – Redesigned Power Supply

User Interfaces

[R028] The 450 V power supply design shall provide local means to set and display voltage and current levels.

[R029] Display methods selected shall operate at the minimum specified temperature and be viewable in both low light and sunlight conditions.

Logistics (RAM)

3.4.1 Reliability

Reliability type failures are chargeable failures as referenced and defined in MIL-HDBK-781A

(paragraph 3.1.4.1 and 4.7).

[R030] The new 450 VDC Power Supply shall have a MTBF of no less than 10,000 hours.

[R031] COTS and non-developmental items shall be included in the MTBF requirements.

3.4.2 Availability

[R032] The new 450 VDC Power Supply shall have an Operational Availability (Ao) of 95%. The total operational time for a given year is defined as 10 hours per day, 5 days per week, and 50 weeks per year for the life of the system. Expected life of the system is 20 years. (Ao = Uptime/Total Time)

3.4.3 Maintainability

[R033] The new 450 VDC Power Supply shall be designed to facilitate easy repair with minimum, calibration, alignment, and adjustment.

[R034] The maximum time to correct a fault (i.e., a reported error) shall be no greater than 30 minutes exclusive of travel time and access time.

[R035] When repaired by a maintenance technician of skill level 5 or equivalent, 60% of all failures shall be corrected within 30 minutes or less and 90% of failures shall be corrected within 60 minutes or less.

[R036] Troubleshooting and replacement shall be to the line replaceable unit (LRU) level.

[R037] The new 450 VDC Power Supply scheduled maintenance period shall not exceed 10 minutes, excluding travel time and access time.

[R038] Scheduled maintenance periods shall be required no more frequently than once per 6 month (180 days).

[R039] Local and field repair of the new 450 VDC Power Supply components shall be within the capability of unit maintenance personnel.

Test Diagnostic Capability and User Maintenance

[R040] The new 450 VDC Power Supply shall include hardware that will facilitate fault isolation and test in support of Line Replaceable Unit (LRU) level maintenance.

[R041] As a minimum, the 450 V power supply design shall provide local means and appropriate maintenance access to isolate power supply faults and failures through use of such features as panel indicators, test points and/or access ports.

[R042] The minimum level of maintenance and repair shall be at the Line Replaceable Unit level. As an objective, repair options will include modules or parts, as recommended by the manufacturer, which can reasonably be replaced in the field thus reducing system down time and MTTR.

Marking and Item Identification

[R043] Marking shall be in accordance with MIL-STD-130.

[R044] All Power Supply CI’s shall use IUID marking IAW DFAR-252.211-7003.

QUALITY ASSURANCE PROVISIONS

Verification Methods

4.1.1 Demonstration (D). Demonstration is a verification method whereby success is determined by observation. Also included in this category are tests that require simple quantitative measurements such as dimensions, time to perform, etc.

4.1.2 Test (T). Test is defined as verification of the specification requirements through the application of established test procedures within specified environmental conditions and subsequent compliance confirmation through analysis of the data generated. This requirement may be fulfilled by submission of data which demonstrates the required test has been successfully completed.

4.1.3 Analysis (A). Analysis is defined as verification that specification requirements have been met by technical evaluation of equations, charts, reduced data, etc.

4.1.4 Inspection (I). Inspection is defined as a visual verification that the system (including system documentation) complies with specification requirements.

Verification Matrix

Requirement Name/Section Title Requirement

Number

Verification

Method

Comments

Requirements R001 T

Requirements R002 T/A

Requirements R003 T/A

Requirements R004 T/A

General Requirements R005 D/A/I

Electrical Characteristics R006 T

Electrical Characteristics R007 T

Electrical Characteristics R008 T

Electrical Characteristics R009 T

Electrical Characteristics R010 T

Electrical Characteristics R011 T

Electrical Characteristics R012 T

Electrical Characteristics R013 T

Electrical Characteristics R014 T

Electrical Characteristics R015 T

Electrical Characteristics R016 T/A

Electrical Characteristics R017 T/A

Environmental Requirements R018 T

Environmental Requirements R019 T

Environmental Requirements R020 T

Environmental Requirements R021 T

Mechanical Size and Weight Requirements R023 D

Mechanical Size and Weight Requirements R024 D

Mechanical Size and Weight Requirements R025 D

Mechanical Size and Weight Requirements R026 D

Mechanical Size and Weight Requirements R027 D

User Interface R028 D

User Interface R029 D

Reliability R030 A

Reliability R031 A

Availability R032 D

Maintainability R033 D

Maintainability R034 D

Maintainability R035 D

Maintainability R036 D

Maintainability R037 D

Maintainability R038 D

Maintainability R039 D

Maintainability R040 D

Maintainability R041 D

Maintainability R042 D

Marking and Item Identification R043 D

Marking and Item Identification R044 D

Table 1. Verification Matrix

NOTES

DEFINITIONS

COTS – Commercial Off-The-Shelf

GOTS – Government Off-The-Shelf

MTBF – Mean time between failures (MTBF) is defined as cumulative operation time divided by the number of failures occurring within the time period.

MTTR – For the purpose of this specification, the Mean Time To Repair (MTTR) time includes all maintenance actions required to correct the malfunction and restore the power supply to full operation

(includes preparation, test, troubleshooting, removal and replacement of components, repair, adjustment, functional check, and reconfiguration).

Cumulative time basis – The cumulative time basis is the total operating (on) hours, including standby and active (radiate) states. Any exceptions to this general rule of chargeable failures are stated under each requirement.

Failure – a condition caused by operational, maintenance, physical, or other environments, which result in the inability of the equipment to perform its required or expected functions.

Fault – a declared error by the software or hardware that may be resettable or if not resettable, it becomes a failure.

END SRD