Attachment_001_Description_for_Purchase.pdf

Description for Purchase Compressor Unit, Rotary (35 scfm, 150 psig)

DFP 652

1. Background

1.1. Background. This description for purchase establishes the detailed requirements for the Compressor Unit, Rotary (35 scfm, 150 psig) NSN: XXXX-XX-XXX-XXXX, Federal Supply Code: 6115, Model Number: XXXX, CAGE: XXXXX, hereafter called the Diesel Powered Air Compressor. The Diesel Powered Air Compressor is a screw-type air compressor used for the maintenance of wheeled and tracked Marine Corps equipment. The Diesel Powered Air Compressor is intended to supply compressed air for the operation of air tools and the inflation of tires and electrical power for the operation of power tools, a crane, and lighting. It is intended to be interchangeable with the current Diesel Powered Air Compressor within the Lube Unit, Power Operated (LUPO). The Diesel Powered Air Compressor will operate on both JP-8 and diesel fuel. Figure 1 contains an interactive 3-dimensional model of the Diesel Powered Air Compressor that can be activated by clicking on the figure. See Appendix A for drawings of the Diesel Powered Air Compressor and the remote panel.

Beneficial comments and any pertinent data which may be used in improving this document should be addressed to: HQ ARDEC, RDAR-EIL-TC, Rock Island IL 61299-7300.

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

Figure 1. Diesel Powered Air Compressor model

7/8/2013

2. Applicable Documents

2.1. General. The documents listed in this section are specified in sections 3 and 4 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 documents cited in sections 3 and 4 of this specification, whether or not they are listed.

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 listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS).

SPECIFICATIONS

FEDERAL

A-A-50271 - Plate, Identification

A-A-52624 - Antifreeze, Multi-Engine Type

MS90555 - Connector, Receptacle, Electrical, Wall Mounting, Class L (Power Source Receptacle)

MS90556 - Connector, Plug, Electrical, Straight, Class L

MS90558 - Connector, Receptacle, Electrical, Wall Mounting, (With Coupling Ring) Class L, (Equipment Receptacle)

STANDARDS

DEPARTMENT OF DEFENSE

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

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

MIL-STC-810 - Department of Defense Test Method Standard, Environmental Engineering Considerations and Laboratory Tests

MIL-STD-1472 - Department of Defense Design Criteria Standard, Human Engineering

MIL-STD-1474 - Department of Defense Design Criteria Standard, Noise Limits

FEDERAL

FED-STD-595 - Colors Used in Government Procurement

(Copies of these documents are available online at https://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094).

2.2.2. Other Government documents, drawings and publications. The following other Government documents, drawings, and publications form a part of this document to extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

TECHNICAL MANUALS

U.S. MARINE CORP.

TM 4750-OD - Painting and Registration Marking for Marine Corps Combat and Tactical Equipment

(Application for copies should be addressed to RDECOM/ARDEC, ATTN: RDAR-EIL-TC, Bldg 62 Rock Island Arsenal, Rock Island, IL 61299.)

2.3. Non-Government publications. The following document(s) form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents that are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation.

INTERNATIONAL STANDARDS ORGANIZATION

ISO/IEC 16022 - Information Technology – International symbology specification – Data Matrix

(Application for copies should be addressed to the American National Standards Institute, 11 W.

42nd Street, New York, New York 10036.)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA WD6 - Wiring Devices – Dimensional Specification

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 North 17th Street, Rosslyn, Virginia 22209.)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 - National Electrical Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL

SAE AS 5942 - Marking of Electrical Insulating Materials

SAE AS 5756 - Cable, Power, Electrical, Portable General Specification for

SAE AS 39029 - Contacts, Electrical Connector, General Specification for

SAE J1074 - Engine Sound Level Measurement Procedure

(Application for copies should be addressed to SAE International, 400 Commonwealth Drive, Warrenville, Pennsylvania, 15096)

UNDERWRITERS LABORATORIES

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

2.4. Order of precedence. 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. Disclaimers.

3.1.1. Pictorial representations. The figures included in this DFP represent the government’s proposed design concept. The controlling requirements for the Diesel Powered Air Compressor are the text requirements of this DFP; the figures are included only for additional clarity. It is the responsibility of the manufacturer to ensure that each item offered meets all of the requirements related to the item.

3.1.2. Construction. The quality of workmanship imparted to the Diesel Powered Air Compressor shall be equal to or exceed what is typically provided in a commercial product of this type. The Diesel Powered Air Compressor, when presented for acceptance, shall have been manufactured with skill and care; shall be uniform, neat and clean; and shall be free from irregularities and anomalies which degrade form, fit, function, performance or appearance.

3.1.3. Alternate design. The pictures and descriptions in this specification should not restrict the offeror from proposing alternate better (higher quality, faster manufacturability, greater maintainability, lower cost, or shorter lead time) designs. Proposal of an alternate design does not negate any of the requirements. Any design proposed shall meet all requirements.

3.1.4. Frame of reference. The frame of reference for the Diesel Powered Air Compressor shall be as follows: The front of the Diesel Powered Air Compressor shall be the side that contains the gages. The rear shall be the side opposite the front and shall contain the compressed air and remote panel outputs. Roadside and curbside are defined as if the compressor were a vehicle, traveling down the road, front-first. For further clarity, see Figure 2.

3.1.5. Application. The Diesel Powered Air Compressor is currently used on the LUPO.

3.1.6. Drawings. Appendix A contains drawings of the Diesel Powered Air Compressor. The drawings contained in Appendix A are for reference only. If any details on the drawings contradict the text of this document, the text of this document takes precedence and is the true requirement for the Diesel Powered Air Compressor.

3.2. Diesel Powered Air Compressor. The Diesel Powered Air Compressor shall simultaneously supply compressed air and electrical power. It shall consist of a base system and a remote panel.

3.2.1. Base system. The base system shall contain three main assemblies: the air compressor, the generator, and the diesel engine power unit. See section 3.4 for further discussion of the base system. For a photograph of the current base system, see Figure 3. For further information about the locations of the interface dimensions, please refer to the drawings in Appendix A.

Front

Curbside Rear

Roadside

U.S. Army 3D Model

Figure 2. Frame of reference

3.2.2. Remote panel. The remote panel shall connect to the base system and control the operation of the Diesel Powered Air Compressor. For further detail on the remote panel, see 3.5. All electrical and control outputs shall be routed to the control panel in a manner identical to the wiring harness found on the current Diesel Powered Air Compressor to ensure interoperability with the LUPO wiring.

3.2.3. Wiring harness. The wiring harness shall attach the base system to the remote panel. It shall consist of a single group of wires, and shall be nominally 72 inches in length. For further detail on the wiring harness, see 3.6. The wiring harness shall be integrally attached to the remote panel.

3.2.4. Interface requirements. The Diesel Powered Air Compressor shall mount on the base of the LUPO and interface identically as the current Diesel Powered Air Compressor. For an example of the current Diesel Powered Air Compressor mounted in a LUPO, see Figure 4.

U.S. Army Photo

Figure 3. Base system

3.2.4.1. Compressed air interface. The compressed air output shall exit the enclosure at the rear.

The connection shall be a female 3/4 inch NPT thread connected from a ball-valve. Neither the size nor the location of the ball valve is allowed to change, to ensure that the base unit is interchangeable with the current base units installed in the LUPO.

3.2.4.2. Remote panel mounting. The remote panel shall exhibit mounting locations identical to the mounting locations on the current Diesel Powered Air Compressor’s remote panel, in order to allow exchange without modification to the LUPO. Wire entry and exit points shall be identical to the current remote panel. No additional wire length shall be required in the remote panel, to ensure that no additional wire is required to connect the remote panel.

3.2.4.3. Power interface. The power output shall be routed to the remote panel. Routing beyond the breakers provided in the remote panel is not required. Routing the power beyond the remote panel’s breakers will be accomplished by those who integrate the Diesel Powered Air Compressor into the LUPO. An exception to this is the power for lighting. The power for lighting shall be routed to the switch on the remote panel. Routing power beyond the switch for the lights shall be completed in the integration into the LUPO.

3.2.4.3.1 Power output interface. Routing power beyond the remote panel is not required.

Connections to the remote panel’s outputs will be made when the Diesel Powered Air Compressor is integrated into the LUPO. Access to the breaker’s output is required. Acceptable paths for routing wire to this access shall be described in the operational manual.

3.3. Crane power interface. The LUPO exhibits a crane that is powered from the 12V battery system of the Diesel Powered Air Compressor. Currently, in the integration of the LUPO, a 12V power switch is added to the remote panel. This switch is not required to be supplied with the Diesel Powered Air Compressor; however, the remote panel shall exhibit sufficient open internal

U.S. Army Photo Figure 4. LUPO mounting

Diesel Powered Air Compressor area to both mount the switch to the remote panel and to route the 12V wires to the switch. For a photograph of how the crane switch is mounted to the remote panel, see Figure 5.

3.4. Base system. The base system shall contain three main assemblies: the air compressor, the generator, and the diesel engine power unit, and shall interface with the LUPO and with the remote panel through the wiring harness. As stated in 3.2.4, all interfaces with the base system shall be identical to the current base system to allow replacement of the current system with a minimal amount of effort and no modifications to either the LUPO or the Diesel Powered Air Compressor.

3.4.1. Air compressor. The air compressor shall be a single stage, oil injected air compression unit that can maintain continual air use without an air tank. The air compressor shall exhibit either rotary screw or rotary vane compression methods. The Diesel Powered Air Compressor shall be capable of delivering at least 35 standard cubic feet per minute (scfm) at a pressure of 150 pounds per square inch, gage (psig). For reference only, the current Diesel Powered Air Compressor utilizes Rotorcomp/Verdichter’s NK-40 rotary screw compressor.

3.4.1.1. Compressed air tank. The Diesel Powered Air Compressor shall not include an air tank.

The compressor shall be activated by the demand for air.

3.4.1.2. Air filtration. The Diesel Powered Air Compressor shall exhibit a two stage, dry type air filter.

3.4.1.3. Cooling system. The compressor shall exhibit cooling through an air to oil heat exchanger.

3.4.2. Power delivery. The Diesel Powered Air Compressor shall be capable of delivering at least

3.3 kilowatts (kW) of power at 120 Volts AC at 60 Hertz. For reference only, the current Diesel Powered Air Compressor utilizes Mecc Alte’s S16W-90/C generator.

Figure 5. Crane power switch

3.4.3. Operation mode. The Diesel Powered Air Compressor shall be able to supply both compressed air and electrical power at the same time. Drawing electrical power and compressed air simultaneously shall not prematurely limit the outputs. Both compressed air and electrical power shall exhibit full draw at the same time.

3.4.4. Diesel engine. The Diesel Powered Air Compressor shall operate using a diesel engine.

This engine shall be liquid-cooled and shall operate to full capacity on both JP-8 and diesel fuel.

For reference only, the current Diesel Powered Air Compressor utilizes Kubota’s D902 E3B engine.

3.4.4.1. Electrical system. The diesel engine shall operate on a 12V direct current electrical system for activating the engine starter, powering the crane, and charging the system battery.

3.4.4.1.1 System battery. The Diesel Powered Air Compressor shall be activated using a 12V battery. The salient characteristics of the battery are that it shall consist of a wound cell Absorption Glass Mat type battery that is available through the DoD supply system with a NSN and that it shall be suitable for starting the system in all required conditions. For reference only, the current Diesel Powered Air Compressor utilizes Optima’s YellowTop D34 battery NSN 6140-01-0457-5392.

3.4.4.2. Liquid cooled. In order to reduce the level of noise generated by the diesel engine, the engine shall be liquid cooled. The liquid used to cool the engine shall be heavy-duty ethylene glycol conforming to A-A-52624.

3.4.4.3. Muffler. In order to further reduce the noise of the diesel engine, it shall be equipped with a muffler. The muffler shall exhibit sizing sufficient for the flow of the exhaust and to reduce engine noise to an acceptable level. See 3.7 for more requirements surrounding the noise of the Diesel Powered Air Compressor.

3.4.4.4. Enclosure insulation. Sound-dampening insulation shall be included on the interior of the enclosure. The insulation shall be attached to the enclosure permanently, and shall not be degraded by the anticipated operating environments. Because the enclosure is not anticipated to be watertight and the Diesel Powered Air Compressor is required to operate in all weather conditions, water infiltration shall not cause damage to or degradation of performance of the insulation. See 3.7 for more requirements surrounding the noise of the Diesel Powered Air Compressor.

3.4.5. Operating temperature. The Diesel Powered Air Compressor shall be capable of operation in temperatures ranging from -20°F to 120°F.

3.4.6. Size. The envelope allowable for the base system, excluding any exhaust points, air outlets and pressure relief safety valves, shall not exceed the current envelope dimensions of a height of

32.3 inches, a length of 41.3 inches, and a width of 31.3 inches. The placement and size of the exhaust points, lifting hooks, air outlets, and pressure relief safety valves shall not impede the storage, removal, or operation of the Diesel Powered Air Compressor when installed on the LUPO. Note that the base system unit dimensions do not include the dimensions of the slide.

3.4.6.1. Mounting. To attach to the LUPO, the Diesel Powered Air Compressor is bolted to the base. The Diesel Powered Air Compressor shall exhibit mounting provisions that mate to the current holes of the base of the LUPO identically to the current Diesel Powered Air Compressor.

3.4.6.2. Vibration dampening. The mounting between the Diesel Powered Air Compressor and the mounting areas shall exhibit provisions to dampen the vibration that the unit would experience during transport. The base plate of the unit shall be isolated from the mounting brackets by the addition of rubber vibration dampeners. Other methods of reducing vibration will be considered on a case-by-case basis.

3.4.6.3. Vibration endurance. The Diesel Powered Air Compressor shall be certified by the manufacturer to be suitable for use after transportation of the LUPO in the bed of a Medium Tactical Vehicle Replacement (MTVR). To mimic the vibrations of this transport, the Diesel Powered Air Compressor shall withstand the vibration testing described in MIL-STD-810 Method 514.6 Annex C. This testing shall be tailored to be specific to the Composite Wheeled Vehicle and the mounting specific to the intended mounting in the LUPO.

3.4.7. Weight. The base system shall not weigh more than 870 pounds when fully filled with fluids and ready for operation. When placed in long-term storage mode, the Diesel Powered Air Compressor shall weigh less than in operational mode. Note that this is the base system weight, and that the weight of the remote panel and the wiring harness are not required to be included in this weight.

3.4.7.1. Operation time. The Diesel Powered Air Compressor shall operate for no less than 8 hours at full load without refueling.

3.4.7.2. Refueling. The Diesel Powered Air Compressor shall refuel through a cap located on the side of the compressor. This cap shall be able to be removed and replaced without moving any plates or panels. When the compressor is fueled, the level of fuel shall be readily evident on the remote panel, allowing the user to reduce the amount of overfill when fueling.

3.4.8. Exhaust output. The exhaust from the Diesel Powered Air Compressor shall be routed to a

1.75 inch stainless steel pipe located at the top of the enclosure. Due to the exterior mounting of the LUPO, the exhaust shall exhibit a rain guard that prohibits rain from entering the exhaust system when the Diesel Powered Air Compressor is not activated.

3.4.9. Wire marking. All wires shall be marked in accordance with SAE AS 5942. The markings on the wires shall correspond directly to the label of the wires on the wiring diagram required in the maintenance manual.

3.4.10. Wire connections. The Diesel Powered Air Compressor shall exhibit automotive-style connections between interior wires that are sealed and weather tight. The connectors shall be suitable for use in an off-road location with vibration characteristics. The connectors shall utilize a pin and socket system that conforms to SAE AS39029. The material for the connectors shall pass the testing in UL 94 HB. For reference only, a source of internal electrical connectors is Tyco Electronics’ AMPSEAL 16 series.

3.4.11. Wires. All wires utilized in the Diesel Powered Air Compressor shall conform to SAE

AS 5756.

3.4.12. Compressor gages. To ensure safe operation of the air compressor, the base system shall have two gages placed on the exterior of the enclosure. These gages shall indicate compressor discharge oil temperature and compressor line pressure. These gages shall also contain a switch which activates at pre-set levels and sends a signal to the safety reset switch to cause operation to cease. The safety reset switch shall be located on the remote panel as stated in 3.5.4. The pre-set levels shall preclude damage to the unit from problems that increase oil temperature or compressor line pressure.

3.4.13. Lifting interface. The base system shall exhibit 4 lifting points on the top of the unit.

These points shall allow the unit to be sling lifted and shall exhibit an even load between the points.

3.4.13.1. Lifting points. The Diesel Powered Air Compressor shall exhibit no fewer than four lifting points located on the top of the base unit. These lifting points shall be recessed and spring loaded. Recessing the lifting points shall allow the points to fall completely within the envelope of the Diesel Powered Air Compressor when the unit is not being lifted. Spring-loading the lifting points shall cause the points to return to the resting position when not in use. The strength of each point shall be rated in accordance with MIL-STD-209. For a photograph of the top of the current Diesel Powered Air Compressor, see Figure 6. For reference only, the current Diesel Powered Air Compressor utilizes Eberhard Manufacturing Company’s part number 3-172.

3.5. Remote panel. The Diesel Powered Air Compressor shall include a panel that mounts remotely from the system as stated in 3.2.2. This remote panel shall be able to be disconnected by a plug containing only electrical connections. The remote panel shall include controls and gages that allow remote feedback and control of the system. For a photograph of the remote panel of the current LUPO, see Figure 7. Other layouts of gages may also be acceptable and will

Lifting points

U.S. Army Photo

Figure 6. Compressor lifting points be considered on a case-by-case basis. Note that the pressure and temperature gages on the pictured remote panel should be located on the front of the base system and that the pictured 12 V DC Crane switch will be installed during the integration of the system.

3.5.1. Size. The remote control panel shall be no greater than 12.5 inches wide, 14.5 inches high and 6.25 inches deep. Note that these dimensions do not include the 12 V DC Crane switch.

3.5.2. Control panel enclosure. The remote control panel shall be contained in a NEMA type 13 enclosure.

3.5.3. Starting provision. The remote control panel shall include provisions for the ability to start and stop the Diesel Powered Air Compressor.

3.5.4. Safety reset switch. The remote control panel shall include a safety reset switch. When the compressor gages in 3.4.12 send a signal of temperature or pressure exceeding the set limit, the safety reset switch shall activate and shut down the system. When the compressor temperature and pressure return to acceptable levels, this switch shall allow a manual reset that permits the engine to be re-started.

3.5.5. Electrical breakers. The power output from the generator shall be routed to no fewer than 2 20-Amp GFCI electrical breakers. The breakers shall be push-reset type, to allow for easier operation on the remote panel. See 3.2.4.3 for more information on routing the power output from the generator.

3.5.6. Warning provisions. The remote control panel shall include warning lights to provide information about the engine coolant temperature and the engine oil pressure. These lights shall activate if the coolant temperature or oil pressure exceed safety margins defined by the engine manufacturer.

U.S. Army Photo Figure 7. Remote control panel

3.5.7. Switches. Two switches are required on the remote panel. The first switch shall activate the red flood lights. The second switch shall activate the white flood lights. Each position of each switch shall be clearly labeled with the function of the position.

3.5.8. Gages. The remote control panel shall include gages detailing the number of hours that the system has been operational, the fuel level of the system, and the A-C voltage of the system. For an example of the control and gage remote panel from the current LUPO, see Figure 7.

3.6. Wiring harness connection. The remote control panel shall be connected to the base system by a wiring harness. The wiring harness shall have a plug at one end to connect to the base system and be integrally connected to the remote panel at the other end. The connection to the remote panel shall be on the rear of the panel, directly below the outlet.

3.6.1. Wiring harness plug. The plug that connects the base system to the wiring harness shall exhibit an arrangement of pins in the plug that disallows the insertion of the plug in any manner other than its intended orientation. The plug shall be adequately sized for the anticipated amperage loads. The plug shall exhibit an environmentally sealed, multi-pin circular connector.

For reference only, the current Diesel Powered Air Compressor utilizes a Deutsch HD30 series 16 pin connector.

3.6.2. Wiring harness properties. The wires that compose the wiring harness shall be wrapped to inhibit separation. If all wires within the harness are correctly sealed and individually weather-tight, the wrapping is not required to seal the wires; however, the wiring harness shall be watertight and able to be immersed in water without damage or any loss of functionality. This requirement only applies to the harness, not to the ends, the base unit, or the remote panel.

3.7. Noise. The Diesel Powered Air Compressor shall comply with the steady-state noise limit in MIL-STD-1474 Requirement 3 when measured as a mobile generator set. Under full load, the Diesel Powered Air Compressor shall produce less than 70 decibels (dB) of noise when measured at a distance of 7 meters. Components like the insulation and the muffler shall be designed using state-of-the-art technology to reduce the noise output of the system to this level.

Measurements at 7 meters shall be taken at no fewer than 8 locations: once offset from each of the front, rear, roadside, and curbside, and once offset from each corner. All other measurement criteria shall be in accordance with SAE J1074 for layout and testing. The Diesel Powered Air Compressor shall be tested as a unit with full draw of both electrical power and compressed air.

3.7.1. Sound profile. The noise profile of the Diesel Powered Air Compressor shall be measured and marked on a sound profile map. First, the noise levels at 7 meters shall be measured. Second, if any areas exhibit noise levels above 85 dB, they shall be marked on the map. Finally, sound measurements 1 meter from each plane of the Diesel Powered Air Compressor shall be marked.

No sound measurement below the Diesel Powered Air Compressor is required, but a measurement 1 meter above the unit shall be marked on the map.

3.7.2. Maximum noise. No sound measurements of the Diesel Powered Air Compressor shall require a caution label in accordance with MIL-STD-1474. Therefore, all measured sound levels shall be less than 100 dB.

3.8. Diesel Powered Air Compressor shipping. The method of shipping the Diesel Powered Air Compressor shall allow for storage times of up to 36 months without operation. In order to allow for this, it is acceptable to ship the Diesel Powered Air Compressor in a long term storage mode where preparation is required before the unit is operational. Note that preparations may be required for the diesel engine, the air compressor, and the generator. No preparations requiring access to the remote panel shall be allowed. Only common hand tools shall be required to return the unit to operation; a list of tools considered common can be made available upon request.

3.8.1. Long term storage material kit. All materials necessary to transfer between long term storage mode and use mode shall be supplied in a kit. This material may include oil, filters, belts, hoses, hose clamps, port plugs, cleaning solution, wipes, etc. This material, along with the long term storage documentation, shall be supplied in a durable sealed plastic bag and secured to the enclosure of the compressed air unit by use of a zip tie. Other methods of storing or securing the kit will be considered on a case-by-case basis.

3.9. Plates and labels. All identification, warning, and instruction plates and labels shall be permanently affixed to the exterior of the base unit’s enclosure. They shall be resistant to deterioration caused by heat, cold, solar radiation, water, and petroleum products to the extent that they will remain intact and readily legible for the expected economic life of the Diesel Powered Air Compressor. Marking shall be accomplished in a manner that does not adversely affect the life and utility of the Diesel Powered Air Compressor. All plates and labels shall be printed in the English language, and may be supplemented by graphical symbols.

3.9.1. Item identification plate. A plate conforming to A-A-50271, Composition A, Class 2, and containing the following data, including the Unique Identification (UID) information from 3.9.2, shall identify each Diesel Powered Air Compressor. The item identification plate shall be securely fastened to the exterior of the Diesel Powered Air Compressor in a location that is plainly visible and not hindering normal use. For an example of an item identification plate, see Figure 8.

a. Nomenclature: COMPRESSOR UNIT, ROTARY (35 SCFM, 150 PSIG)

b. NSN: XXXX-XX-XXX-XXXX

c. SERIAL NUMBER: (as specified in contract)

d. USMC ID: xxxxxx

e. MODEL NUMBER:

f. MANUFACTURER:

g. CAGE CODE:

h. MFG PART NUMBER: 050616

i. CONTRACT NUMBER:

j. UNDER CONTRACT TO: MARINE CORPS SYSTEMS COMMAND

k. Marine Corps Logo

l. UID information (see 3.9.2)

3.9.2. Unique identification (UID). Each Diesel Powered Air Compressor shall be marked with a UID containing a unique item identifier (UII) and the additional information listed in 3.9.2.1 that has machine-readable data elements that will distinguish it from all other like and unlike items.

The required marking shall be applied to the item identification plate from 3.9.1. The UID data elements shall be contained in a Data Matrix ECC200 symbol in accordance with ISO/IEC 16022. Marking shall conform to MIL-STD-130. The identifier shall remain intact and readily machine readable for the expected life of the set. Further guidance on the UID may be found at http://www.acq.osd.mil/dpap/UID/. For an example of a UID, see Figure 9.

3.9.2.1. UID data. The Data Matrix ECC200 symbol shall include a UII in the form of Construct 2: Contractor’s CAGE Code (XXXXX; eg. 59678) + Model Number (050616) + Serial Number (XXXX; eg. 0001). Each UII shall be globally unique in that no serial numbers are repeated

Figure 9. UID example

COMPRESSOR UNIT, ROTARY (35 SCFM, 150 PSIG)

XXXX-XX-XXX-XXXXNSN:

0001SERIAL NUMBER:

XXXXXXUSMC ID NUMBER:

XXXXXXXXXMODEL NUMBER:

MANUFACTURER:

CAGE CODE: MFG P/N:

CONTRACT NUMBER:

UNDER CONTRACT TO: MARINE CORPS SYSTEMS COMMAND

Figure 8. Item identification example during the life of the contract. For additional information on the UII and the Data Matrix ECC200 symbol, see the DoD Guide to Uniquely Identifying Items at http://www.acq.osd.mil/dpap/UID/attachments/DoDUIDGuide.pdf.

3.9.2.2. Item unique identification (IUID) registration. The UII shall be registered in the IUID registry with the Concatenated UII (including the Issuing Agency Code: D for CAGE Code) to verify global uniqueness and correlate existing data to the UII. When registered, the Concatenated UII should appear in the form DXXXXXXXXXXXXXXX. This registration can be completed through the Wide Area Work Flow (WAWF) or at the website https://www.bpn.gov/iuid/. For more information on the process of IUID registration and a list of data that shall be correlated to the UII through the IUID registry, see http://www.acq.osd.mil/dpap/UID/UIDRegistry.htm as well as http://www.acq.osd.mil/dpap/UID/guides.htm.

3.9.3. Shipping data plate. A shipping data plate shall be furnished for each Diesel Powered Air Compressor and shall conform to A-A-50271, Composition A, Class 2. Silhouettes of the Diesel Powered Air Compressor that indicate the center of gravity along each axis shall be included on the data plate. The shipping data plate shall be mounted in a location on the exterior that is plainly visible, directly below the Item Identification Plate. The weights and locations of centers on the shelter shall detail the unit fully filled with fluids and ready for operation, not the unit in long term storage mode. The shipping data plate shall conform to MIL-STD-129. For an example of a shipping data plate, see Figure 10.

3.9.4. Marking. The Diesel Powered Air Compressor shall be marked using TM 4750-OD as a guide for registration marking. Letters and numbers shall be black, except over a black background, which shall be Seafoam Green (color 24533). Markings required on the exterior of

Figure 10. Shipping data plate the Diesel Powered Air Compressor include marking the center of gravity and the function of any transportation provisions.

3.10. Exterior finish. The exterior surface finish shall be clean and clear from visible imperfections. The finish shall exhibit corrosion resistance, and shall have no sharp edges or projections.

3.10.1. Powder coat. The exterior of the Diesel Powered Air Compressor shall be finished with a powder coat paint that is durable and scratch resistant. In order to ease cleaning and maintenance requirements, panels on the interior of the Diesel Powered Air Compressor shall be powder coated wherever possible. Note that many areas are not feasible to powder-coat on the interior, and these areas are not required to be powder coated.

3.10.2. Surface condition. Coating is not required on certain types of surfaces such as fabrics, glass, plastics, rubber, metal parts not requiring corrosion protection, metal parts that are pre-coated, where coating interferes with function, and surfaces specifically intended for electrical contact or heat conduction. These surfaces shall be masked or otherwise protected during coating. Surfaces not coated require other methods of corrosion prevention, in accordance with their function.

3.10.3. Surface performance. For surfaces intended to be powder coated, the condition, profile, and cleanliness of the surface shall meet the manufacturer’s recommendations of subsequent pretreatments, primers, or other intermediate costs. Workmanship shall be consistent with good commercial practice. The Diesel Powered Air Compressor shall be inspected for surface imperfections and for total film thickness. The minimum dry film thickness (DFT) shall be the sum of the minimum thickness specified by the manufacturers for the individual elements of the preservation system. The frequency and location of DFT readings per unit and the repair procedure for deficiencies shall be per the contractor’s procedures. Base materials shall be free of cracks, burns, sharp edges, and weld splatter that may affect the corrosion performance and coating system adhesion.

3.10.4. Color. The color of the unit shall be Tan 686, Color chip number 33446 from FED-STD- 595, with a 90% gloss rating and shall not need repainting during the economic life of the system.

3.11. Safety. The Diesel Powered Air Compressor shall not present any uncontrolled safety or health hazards throughout the life cycle of the system.

3.11.1. Physical hazard control. Mechanical guards, electrical insulation, thermal insulation, and other safety devices shall be provided to protect operators and maintenance personnel from inadvertent contact with electrically energized parts, high temperature surfaces, and other physical hazards. The safety devices shall not interfere with the operation of the Diesel Powered Air Compressor. Exposed sharp corners and sharp edges shall be eliminated if they serve no functional purpose. Hazards that cannot be eliminated, cannot be controlled by equipment placement, and cannot be controlled by protective devices shall be identified to the user by printed warnings or cautions. Product safety signs and labels shall conform to ANSI Z535.4.

3.11.2. Human engineering. The Diesel Powered Air Compressor shall be suitable for setup, operation, and maintenance by the majority of U.S. Marine Corps personnel, from the fifth percentile female to the ninety-fifth percentile male. Basic U.S. Marine Corps anthropometrics charts and applicable DoD human engineering guidelines can be found in MIL-HDBK-759.

3.11.2.1. Access and operation. The Diesel Powered Air Compressor shall comply with the human engineering directives outlined in MIL-STD-1472.

3.11.2.2. Protective clothing. The Diesel Powered Air Compressor shall be operable and maintainable by personnel wearing heavy gloves and clothing suitable for cold weather.

3.11.3. Environment requirements. The operation of the Diesel Powered Air Compressor shall not be hindered by either terrain or weather. It shall be capable of successfully performing all operations in arctic, tropical, temperate, and desert climates and in geographical areas that include sand, swamp, tundra, grassland, forest, jungle, urban areas, snow and ice, mountain, and salt water. The Diesel Powered Air Compressor shall be capable of successfully performing all operations in the following environmental conditions: rain, snow, hail, ice, fog, dust, sand, high humidity, solar radiation, and extreme temperatures.

3.11.3.1. Weather-tightness. The Diesel Powered Air Compressor shall be able to operate in all weather conditions.

3.11.3.2. Corrosion resistance. The Diesel Powered Air Compressor shall exhibit a conformal coating that protects all electronic components from corrosion due to environmental conditions.

The conformal coating shall allow all electronics to operate in all environments without degradation. The Diesel Powered Air Compressor will be deployed in locations adjacent to salt water and will operate in salt spray environments. In order to better withstand the corrosive environments expected when deployed, all electrical connections, circuit cards and other electronic components within the unit that may be susceptible to corrosion shall be coated with a corrosion resistant layer. Note that this requirement includes all circuit boards, electrical connection areas, and gage connections, as well as other areas within the unit that could be prone to damage by corrosion. This requirement covers the base system, the remote panel, and the wiring harness. For reference only, a conformal coating that protects electronics from this type of corrosion is Parylene.

3.11.3.3. Operating altitude. The Diesel Powered Air Compressor shall include an analysis of the effects of the altitude of operation on the output of the Diesel Powered Air Compressor. This analysis shall show the compressed air output at 150 psi from operation with both diesel and JP-8 from sea level to 15,000 feet at increments of no less than 500 feet. This information shall be plotted on a graph that shows the flow output on the vertical axis and the elevation on the horizontal axis. Inclusion of the altitude report will constitute passing this requirement.

3.11.4. Economic life. The Diesel Powered Air Compressor shall exhibit an economic life of no less than 20 years.

4. Test and Verification

4.1. General provisions. Prior to the delivery of any other unit, a first production unit shall be delivered. The verifications / demonstrations herein shall be performed to demonstrate that the item delivered conforms to portions of section 3 of this specification.

4.2. Demonstration conditions. Unless otherwise specified, the contractor shall perform all demonstrations in accordance with the conditions specified herein. The demonstrations are related to the requirements as shown in Table I. The demonstrations are to be performed at the contractor’s expense at the location of delivery, as stated in the contract or order. The contractor shall provide all measurement and loading equipment required to demonstrate that the requirements are met.

4.2.1. LUPO availability. In order to facilitate the demonstrations at the location of delivery, a LUPO with the current Diesel Powered Air Compressor will be available to demonstrate the exchange.

4.3. Rejection. If any assembly, specimen or component fails to comply with any of the applicable requirements; the sample shall be rejected. The Government reserves the right to terminate demonstration upon any failure of an assembly or component during the demonstration. Upon Government request, the contractor shall make any necessary changes, modifications or repairs to the Diesel Powered Air Compressor or provide another such unit for test and verification. All costs related to test and verification are to be borne by the Contractor, including any and all costs for additional tests following a disapproval. The Contractor shall perform any additional test and verification under the terms and conditions and within the time specified by the Government. The Government reserves the right to require an equitable adjustment of the contract price for any extension of the delivery schedule, or for any additional costs to the Government related to the test and verification. Any test or verification failure shall be deemed a failure of the Contractor to make delivery within the meaning of the Default clause of the contract.

4.4. Preparation. The contractor shall prepare the Diesel Powered Air Compressor for demonstration by performing any normal service, lubrication, and adjustment as described within the operator’s technical manual.

4.5. Verifications.

4.5.1. Long term storage. Verify that the Diesel Powered Air Compressor is in long-term storage mode. Confirm that all required warnings and instructions are present. Prepare the compressed air unit for use by following the instructions attached to the remote panel. When the demonstrations are complete, prepare the unit for long term storage by following the provided instructions.

4.5.2. Compressed air generation. Activate the Diesel Powered Air Compressor. Draw a full load of compressed air. Confirm that 35 cubic feet per minute of compressed air at 150 psi gage is supplied.

Table I. Verification / Demonstration Matrix

Title Section 3

Requirement Section 4 Test / Demonstration

Long term storage 3.8 4.5.1

Compressed air generation 3.4.1 4.5.2

Power generation 3.4.2 4.5.3

Weight / dimensions 3.4.6, 3.4.7 4.5.4

Interoperability 3.4.6.1, 3.4.8, 3.4.6.3 4.5.5

Remote panel 3.5 4.5.6

Noise levels 3.7 4.5.7

Data plates 3.9.1, 3.9.3 4.5.8

Visual inspection 3 4.5.9

4.5.3. Power generation. While 35 cubic feet per minute of compressed air at 150 psi gage is being supplied, draw 3.3 kW from the electrical source. Confirm that the voltage is maintained and that the power is successfully generated. Confirm that drawing electrical power and compressed air simultaneously does not over load the diesel engine. Empty the fuel tank. Place JP-8 in the fuel tank. Activate the Diesel Powered Air Compressor and draw 35 cubic feet per minute at 150 psi gage and 3.3 kW at the same time. Confirm that drawing electrical power and compressed air simultaneously while operating with JP-8 does not over load the engine.

4.5.4. Weight / dimensions. Weigh the fully filled and operational base system of the Diesel Powered Air Compressor to confirm that the weight is 870 pounds or less. Measure the base system. Confirm that the dimensions are less than 41.3 inches in length, 31.3 inches in width, and 32.3 inches in height. Measure the remote panel. Confirm that the remote panel is no greater than 12.5 inches in width, 14.5 inches in height, and 6.3 inches in depth.

4.5.5. Interoperability. Mount the Diesel Powered Air Compressor to the LUPO. Confirm that mounting the unit does not impair the operation of LUPO or any function of the Diesel Powered Air Compressor. Confirm that all interface dimensions are maintained and that the unit properly operates. Examine the connection locations for the electrical connections, the compressed air connections and the crane power connection and confirm that the layout of the remote panel allows for the existing wiring to be used in all of these connections. Examine the vibration testing certification to confirm that the Diesel Powered Air Compressor is suitable for transportation on the LUPO.

4.5.6. Remote panel. Examine the remote panel. Confirm that the negotiated layout is used.

Confirm that the electrical power generation is routed to the panel. Confirm that the mounting locations are identical to the mounting locations on the LUPO. Activate the Diesel Powered Air Compressor from the remote panel. Confirm that all switches and gages are operational.

4.5.7. Noise levels. Activate the Diesel Powered Air Compressor. Measure the noise level 7 meters from the center of the unit. Confirm that no more than 70 dB of noise is measured.

Examine the profile map produced by measuring the noise levels of the Diesel Powered Air Compressor to confirm that noise levels are marked on the map at 7 meters, 1 meter and wherever the noise level is above 85 dB. Confirm that the profile map does not exhibit a noise level of 100 dB anywhere on the map. Compare the mapped sound profile to the sound profile measured to confirm that the published profile is accurate.

4.5.8. Data plates. Examine the data plates. Confirm that both item identification and shipping data plates are present. Confirm that a UID is present on the item identification plate. Confirm that the data plates use the negotiated layouts. Scan the UID to confirm that the required data is present in the marking.

4.5.9. Visual inspection. Confirm that the Diesel Powered Air Compressor conforms to all items in Section 3 that are easily confirmed by a visual inspection.

5. PACKAGING

5.1. Packaging. Preservation, packaging, packing, unitization and marking furnished by the supplier shall provide protection for a minimum of one year, provide for multiple handling, redistribution and shipment by any mode and meet or exceed the following requirements.

5.1.1. Cleanliness. Items shall be free of dirt and other contaminants which would contribute to the deterioration of the item or which would require cleaning by the customer prior to use.

Coatings and preservatives applied to the item for protection are not considered contaminants.

5.1.2. Preservation. Items susceptible to corrosion or deterioration shall be provided protection by means of preservative coatings, volatile corrosion inhibitors, desiccants, waterproof and/or water/vaporproof barriers.

5.2. Unit package. The unit package shall be so designed and constructed that it will contain the contents with no damage to the item, with minimal damage to the unit pack during shipment and storage in the shipping container, and with allowance for subsequent handling. The outermost component of the unit package shall be sealed.

5.2.1. Unit package material. The “Brand Name” packaging wrap is Dr. Shrink, Inc. The salient characteristics of this wrap are as follows: The wrap shall consist of opaque white waterproof and UV protective marine grade shrink wrap, sealed around the unit through heat shrink. This wrapping shall serve two purposes: first, it shall inhibit damage from inclement weather, and second, it shall show conclusively if the unit’s seal is broken from tampering or theft.

5.2.2. Unit package quantity. Unless otherwise specified, the unit package quantity shall be one Diesel Powered Air Compressor.

5.3. Shipping packaging. The shipping packaging (including any necessary blocking, bracing, cushioning, or waterproofing) shall comply with the regulations of the carrier used and shall provide safe delivery to the destination. The shipping packaging shall be capable of multiple handling and storage under most conditions (such as stacked storage and exterior storage) for a minimum of one year. To survive exterior storage and transport, each Diesel Powered Air Compressor shall be wrapped with an opaque white waterproof and UV protective marine grade shrink wrap suitable for interstate highway travel loaded on an open truck. For examples of wrapped shipping units, see Figure 11.

5.4. Unitization. It is unacceptable to ship the Diesel Powered Air Compressor utilizing the exterior of the unit as a shipping container; however, covering the unit with opaque white plastic wrapping to ensure that no portions of the exterior of the Diesel Powered Air Compressor exhibit wear or damage from normal shipping activities, like transport or exposure to weather, is acceptable. All items in the Diesel Powered Air Compressor shall be contained in a manner that will permit safe handling during shipment and storage, both by preventing safety hazards to personnel and by preventing damage to the shop.

5.5. Marking. Each shipping container shall be marked in accordance with MIL-STD-129, including bar coding. The contractor is responsible for application of special markings as discussed in the Military Standard regardless of whether specified in the contract or not. Special markings include, but are not limited to shelf-life markings, structural markings, and transportation special handling markings. The marking of pilferable and sensitive materiel will not identify the nature of the materiel. RFID tags are required. If the item has Unique Identification Data markings, then each unit package also requires a RFID tag to include the

UID.

5.5.1. Identification and address. Contractors and vendors shall apply identification and address markings with bar codes in accordance with this standard. For shipments moving to overseas locations and for mobile deployable units, the in-the-clear address must also include the host country geographic address and the APO/FPO address. The MSL will include both linear and 2D bar codes per the standard. The DD Form 250 or the commercial packing list shall have bar coding applied as per Direct Vendor Delivery Shipments in the standard (except for deliveries to DLA Distribution Depots, e.g. New Cumberland, San Joaquin, Red River, Anniston).