MEHPS Update PSpec 24Mar2020 - Signature1.pdf

MEHPS PSpec w/ Change 1 March 2020

Superseding December 2019

PERFORMANCE SPECIFICATION

FOR

MOBILE ELECTRIC HYBRID POWER SOURCES

Prepared by:

Power Team

Program Manager Engineer Systems Marine Corps Systems Command

SUBMITTED BY: DATE:

Jeremy Chen Power Team Engineer

APPROVED BY: DATE:

Deborah C. Olson Program Manager i

Summary of Changes

Paragraph 2.2.1: Added MIL-STD-1275E to list of DoD Standards.

Original: N/A

Change: MIL-STD-1275E - Department of Defense Interface Standard: Characteristics of 28 Volt DC Input Power To Utilization Equipment in Military Vehicles

Reasoning: To account for the addition of paragraph 3.5.32 DC power output.

Paragraph 3.5.2: Changed requirement to synchronize voltage, frequency and relative phase angle from a threshold to an objective.

Original: Backup power generation. The system shall allow connection of a second generator of the same size as a backup for the main generator in the case the main generator fails to start or is down for maintenance. (T) The system shall have the ability to synchronize voltage, frequency, and relative phase angle between two systems in order to allow transfer of load from one MEHPS to another without interrupting output power. (T).

Change: Backup power generation. The system shall allow connection of a second generator of the same size as a backup for the main generator in the case the main generator fails to start or is down for maintenance. (T) The system shall have the ability to synchronize voltage, frequency, and relative phase angle between two systems in order to allow transfer of load from one MEHPS to another without interrupting output power. (O).

Reasoning: Based on discussion in a meeting with CD&I on February 20, 2020, currently the 5 kW and 10 kW AMMPS generators are not being paralleled where one generator is on spinning reserve to provide backup power to a critical load. Thus, expectation is that there will be very few cases where a 5 kW to 10 kW MEHPS will be used in parallel with another MEHPS to provide backup power. Also, the second paralleled MEHPS on backup standby will have a parasitic power draw, thus reducing the amount of fuel savings which is one of the KPPs of MEHPS. Lastly, government subject matter experts advise that the paralleling capability of MEHPS will be technically challenging to build due to the increased complexity from doubling the amount of components to be controlled and synchronized, and also due to ADCS control of the generators being proprietary.

Paragraph 3.5.5: Changed requirement to operate MEHPS in parallel from a threshold to an objective.

Original: Output paralleling. MEHPS shall be capable of operating in parallel with another MEHPS (same size / mode) to provide back-up power (T).

Change: Output paralleling. MEHPS shall be capable of operating in parallel with another MEHPS (same size / mode) to provide back-up power (O).

ii

Reasoning: Based on discussion in a meeting with CD&I on February 20, 2020, currently the 5 kW and 10 kW AMMPS generators are not being paralleled where one generator is on spinning reserve to provide backup power to a critical load. Thus, expectation is that there will be very few cases where a 5 kW to 10 kW MEHPS will be used in parallel with another MEHPS to provide backup power. Also, the second paralleled MEHPS on backup standby will have a parasitic power draw, thus reducing the amount of fuel savings which is one of the KPPs of MEHPS. Lastly, government subject matter experts advise that the paralleling capability of MEHPS will be technically challenging to build due to the increased complexity from doubling the amount of components to be controlled and synchronized, and also due to ADCS control of the generators being proprietary.

Paragraph 3.5.32: Added requirement for DC power output as an objective.

Original: N/A

Change: DC power output. The system shall provide 2 kW of 28-Volts nominal DC output power with quality that meets the requirements in MIL-STD-1275E. (O)

Reasoning: This requirement is currently in the MEHPS CDD as an Objective and this will allow MEHPS to provide DC power to a future-separately-developed more efficient DC power distribution device.

Paragraph 3.7.1.4: Changed AMMPS Riser Rails to be mandatory instead of optional on the LTT-MCC. Added that the same MEHPS mounting components will be used for both trailers. Added that AMMPS Riser Rails shall not be used on the JLTV trailer. Added that trailer drawings will be provided post contract award.

Original: Trailer mounting of LTT-MCC. The system shall use the LTT-MCC integrated generator mounting rails for mounting all MEHPS components onto the LTT-MCC trailer. (T) The system may also use the Marine Corps standard AMMPS rails for mounting to the LTT- MCC. Rail drawings will be provided post contract award.

Change: Trailer mounting of LTT-MCC. The system shall use the Marine Corps standard AMMPS rails for mounting all MEHPS components onto the LTT-MCC trailer. Other than the AMMPS rails, the same MEHPS mounting components shall be used to mount MEHPS on both the LTT-MCC trailer and the JLTV trailer. The AMMPS rails shall not be used on the JLTV trailer. (T) Rail and trailer drawings will be provided post contract award.

Reasoning:

1) The AMMPS generator requires a rail/adaptor to mount on the LTT-MCC. By requiring the AMMPS Riser Rails on the LTT-MCC means that the MEHPS vendor will not create another unique-to-MEHPS mounting rail/adaptor to mount the 5 kW and 10 kW AMMPS generators which will be one less piece of mounting equipment that Utilities Marines will have to account for.

iii

2) With the AMMPS Riser Rails already on the LTT-MCC, the trailer can be more quickly converted to transporting other combinations and sizes of AMMPS generators and ECUs by simply removing the MEHPS components from the trailer.

3) By not using the Riser Rails on the JLTV trailer, the Utilities Marines will not have to account for it anymore once the JLTV trailer completely replaces the LTT-MCC.

4) By utilizing the same MEHPS mounting components on both trailers, there’s no extra MEHPS mounting components that have to be accounted for when switching between trailers.

5) If total weight on the LTT-MCC becomes an issue in the future from using the AMMPS Riser Rails, then the program office, CD&I, and the vendor will address it after contract award.

Paragraph 4.2, Table 2: Added verification method for DC power output requirement.

Original: N/A

Change:

Requirement Verification Method

Test Method or Test Paragraph Number Name

In sp ec t

A na ly ze

D em on st ra te

T es t

3.5.32 DC power output x MIL-STD-1275E

Reasoning: To account for the addition of paragraph 3.5.32 DC power output.

This specification is approved for use by the Marine Corps Systems Command and is available for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1. Scope. This performance specification covers the requirements for the Mobile Electric Hybrid Power Sources (MEHPS).

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

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 of documents cited in Sections 3 and 4 of this specification, whether or not they are listed.

2.2. Government Documents

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

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129R-CHG-2 - Department of Defense Standard Practice: Military Marking for Shipment and Storage

MIL-STD-130N - Department of Defense Standard Practice: Identification Marking of U.S. Military Property

MIL-STD-209K - Department of Defense Interface Standard for Lifting and TieDown Provisions

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

MIL-STD-705D Department of Defense Test Method Standard: Mobile Electric Power Systems

MIL-STD-810H - Department of Defense Test Method Standard:

Environmental Engineering Considerations and Laboratory Tests

MIL-STD-889C - Department of Defense Standard Practice: Dissimilar Metals

MIL-STD-913A - Requirements for the Certification of Sling Loaded Military Equipment for External Transportation by Department of Defense Helicopters

MIL-STD-1332B - Military Standard: Definitions of Tactical, Prime, Precise, and Utility Terminologies for Classification of the DoD Mobile Electric Power Engine Generator Set Family

MIL-STD-1366E - Department of Defense: Interface Standard for Transportability Criteria

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

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

MIL-STD-1791C_CHG-1- Department of Defense Interface Standard: Designing For Internal Aerial Delivery In Fixed Wing Aircraft

MIL-STD-7179B - Department of Defense Standard Practice: Finishes, Coatings, and Sealants, For The Protection Of Aerospace Weapons Systems

MIL-HDBK-729 - Military Handbook: Corrosion And Corrosion Prevention Metals

MIL-PRF-32565B - Performance Specification: Battery, Rechargeable, Sealed, 6T Lithium-Ion

MIL-STD-1275E - Department of Defense Interface Standard: Characteristics of 28 Volt DC Input Power To Utilization Equipment in Military Vehicles

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

FEDERAL STANDARDS

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

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

NAVAL SEA SYSTEMS COMMAND

http://quicksearch.dla.mil/

SG270-BV-SAF-010 - High-Energy Storage System Safety Manual

S9310-AQ-SAF-010 - Navy Lithium Battery Safety Program Responsibilities and Procedures

FM 3-11.5 - CBRN Decontamination Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination

(Copies of these documents are available from Naval Weapons Support Center, Code 3057, Building 36, Crane, IN 47522-5060.)

CODE OF FEDERAL REGULATIONS

Title 49, Part 173 - Shippers – General Requirements for Shipments and Packages

(Copies of this document are available online at http://www.gpo.gov/fdsys/browse/collectionCfr.action?collectionCode=CFR.)

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Y14.38 - Abbreviations and Acronyms

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

ASTM INTERNATIONAL

ASTM D 3591 - Standard Practice for Commercial Packaging

(Copies of this document are available from www.astm.org.)

NATIONAL FIRE PROTECTION AGENCY

NFPA70 - National Electric Code

(Copies of this document are available from www.nfpa.org.)

USB IMPLEMENTERS FORUM

http://www.asme.org/ http://www.astm.org/ http://www.nfpa.org/

Universal Serial Bus Micro-USB Cables and Connectors Specification Revision 1.01 Universal Serial Bus Specification Revision 3.0 Universal Serial Bus Power Delivery Specification

(Copies of these specifications are available online from USB-IF at http://www.usb.org)

2.4. Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. System Overview. MEHPS shall be comprised of a generator, energy storage modules, MEHPS solar arrays (MEHPS-SA), power converters, a control system, a human machine interface (HMI), and all connectors and cables required to connect all components. MEHPS shall be capable of being mounted to the M1102 Light Tactical Trailer – Marine Corps Chassis (LTT-MCC) and the Joint Light Tactical Vehicle (JLTV) trailer. The generator shall be a 10kW Advanced Medium Mobile Power Source (AMMPS) generator. MEHPS shall be modular to be operated with a 5kW AMMPS generator. The specifications listed in this section are the requirements for the MEHPS using either the 10kW or 5kW AMMPS generator.

3.2. Key performance requirements

3.2.1. Interfacing. All MEHPS components including energy generators, energy collectors, energy storage, and power management, shall interface electrically. (T)

3.2.2. Fuel consumption. Fuel consumption shall be tested according to Power Quality and Efficiency Testing of Tactical Hybrid Power Sources Test Operations Procedure 09-2-290, see Appendix C. The gallons per day fuel consumption shall be less than or equal to the threshold linear trend requirements shown in Figure 1 with and without solar power. The gallons per day fuel consumption for the MEHPS using the 5kW generator shall be less than or equal to the threshold linear trend requirements shown in Figure 2 with and without solar power. (T) http://www.usb.org/

Figure 1. MEHPS Fuel Consumption Requirements (10 kW)

Figure 2. MEHPS Fuel Consumption Requirements (5 kW)

3.2.3. Output power type. The MEHPS shall provide Alternating Current (AC) power output. (T)

3.2.4. Output power quantity. The MEHPS shall provide 10 kW of power output (T).

MEHPS (5 kW) shall provide 5 kW of power output. (T) The MEHPS shall provide 15kW of power output. (O)

3.2.5. AC power quality. The MEHPS shall maintain an AC power output voltage and frequency within the limits defined in Table 1 CLASS 2B-H when tested according to Appendix C, Power Quality and Efficiency Testing of Tactical Hybrid Power Sources Test Operations Procedure (TOP) 09-2-290. (T) Transient performance for voltage and frequency shall remain within envelope limits as defined in Figure 3. The maximum and minimum transient values and maximum recovery times are defined in Table 1.

Figure 3. Voltage and Frequency Transient Performance Recovery Envelope Limits

3.2.5.1. Regulation and Stability. The MEHPS shall maintain output voltage and frequency within the limits of Table 1 (See Below) which is in accordance with Table 3 of the TOP. The MEHPS shall also utilize the CLASS 2B-H Regulation and stability (a.1. and b.1.) when tested in accordance with Section 4.1.1 of TOP 09-2-290. (T)

3.2.5.2. Transient Response. The MEHPS shall maintain output voltage and frequency within the limits of Table 1 (See Below) which is in accordance with Table 3 of the TOP. The MEHPS shall also utilize the CLASS 2B-H Transient Performance (a.2. and b.2.) when tested in accordance with Section 4.1.1 of TOP 09-2-290. (T)

3.2.5.3. Long Term Stability. The MEHPS shall maintain output voltage and frequency within the limits of Table 1 (See Below) which is in accordance with Table 3 of the TOP. The MEHPS shall also utilize the CLASS 2B-H Regulation and stability (a.1. and b.1.) when tested in accordance with Section 4.1.2 of TOP 09-2-290. (T)

3.2.5.4. Source Switching. The MEHPS shall maintain output voltage and frequency within the limits of Table 1 (See Below) which is in accordance with Table 3 of the TOP. The MEHPS shall also utilize the CLASS 2B-H Transient Performance (a.2. and b.2.) (T) / CLASS 2B-H Regulation and stability (a.1. and b.1.) (O), which includes source switching due to an unplanned failure of the generator, when tested in accordance with Section 4.1.2 of TOP 09-2-290.

3.2.5.5. Low Power Factor. The MEHPS shall maintain output voltage within the limits of Table 1 (See Below) which is in accordance with Table 3 of the TOP. The MEHPS shall also utilize the CLASS 2B-H Application of Simulated Motor Load (Low Power Factor) (a.2.(c)) when tested in accordance with Section 4.1.4 of TOP 09-2-290. (T)

3.2.5.6. Waveform Characteristics. The MEHPS shall maintain output voltage and current within the limits of Table 1 (See Below) which is in accordance The MEHPS shall also utilize the with Table 3 of the TOP. CLASS 2B-H Waveform (a.3.) when tested in accordance with Section 4.1.3 of TOP 09-2-290. (T)

TABLE 1. DERIVED PARAMETERS FOR TACTICAL HYBRID POWER SOURCES

FROM MIL-STD-1332B

CHARACTERISTIC PARAMETER

HYBRID

PRECISE

CLASS 1-H

HYBRID UTILITY

CLASS

2A-H

CLASS

2B-H

CLASS

2C-H

a. Voltage Characteristics

1. Regulation and stability (bandwidth % from nominal) 2 3 5 6

2. Transient Performance

(a) Application of Rated Load

(1) Dip (%) 15 20 20 30

(2) Recovery (s) 0.5 3 3 3

(b) Rejection of Rated Load

(1) Rise (%) 15 30 30 30

(2) Recovery (s) 0.5 3 3 3

(c) Application of Simulated Motor Load (Low Power Factor)

(1) Dip (%) 30 N/A 40 N/A

(2) Recovery (s) 95% Rate Voltage 0.7 N/A 5 N/A

3. Waveform

(a) Maximum Total Harmonic Distortion (%) 5 5 5 6

(b) Maximum Individual Harmonics (%) 2 2 2 3

b. Frequency Characteristics

1. Regulation and stability (bandwidth %) 1 1 3 4

2. Transient Performance

(a) Application of Rated Load

(1) Undershoot (%) 4 4 4 4

(2) Recovery (s) 2 4 4 4

(b) Rejection of Rated Load

(1) Overshoot (%) 4 4 4 5

(2) Recovery (s) 2 4 4 6

Note: This table is Table 3 in the Power Quality and Efficiency Testing of Tactical Hybrid Power Sources Test Operations Procedure 09-2-290.

3.2.6. Reliability. MEHPS shall operate 720 hours (T) / 1250 hours (O) between Essential Function Failure (see 6.1.5).

3.2.7. Mean Time to Repair. The Mean Time to Repair (see 6.1.6) shall be less than or equal to 1.5 hours. (T) This requirement does not include corrective maintenance actions to the generator.

3.2.8. Maximum repair time. The maximum repair time shall be less than or equal to 2 hours. (T) This requirement does not include corrective maintenance actions to the generator.

3.3. Scalability

3.3.1. System scalability. MEHPS shall be designed to minimize the total number of system components. MEHPS shall be scalable such that when used with a 5kW generator, weight and volume reduction can be achieved through the removal of energy storage modules or photovoltaic modules while complying with all requirements specified for a given generator configuration. (T)

3.3.2. Component modularity. Components with similar functions shall be of the same design. (T)

3.4. Physical

3.4.1. Set-up and Teardown

3.4.1.1. Set-up time. It shall take no more than 40 minutes (T) / 20 minutes (O) for 6 Marines to set-up the system. This set-up time includes every action that needs to be performed to make the system capable of meeting all requirements pertaining to system operation starting from a system that is fully prepared for transportation.

3.4.1.2. Start-up time. It shall take no more than 1 minute (T) / 30 seconds (O) for the system to be able to provide the full rated output power after set-up is complete.

3.4.1.3. Start-up time under excessive climatic conditions. If conditions exceed the basic climatic conditions (see 6.1.3), it shall take no more than 5 minutes (T) / 2 minutes (O) for the system to provide full rated power after set-up is complete.

3.4.1.4. Teardown time. It shall take no more than 40 minutes (T) / 20 minutes (O) for 6 Marines to tear down the system. This teardown times includes every action that needs to be performed to make the system fully ready for transportation and capable of meeting all transportability requirements (see 3.7) starting from a system that has been fully deployed.

3.4.2. Human Interface

3.4.2.1. User interaction. Once fully set-up and operating, the system shall react to varying loads presented to the system without user interaction. (T)

3.4.2.2. Main display contents. The system shall display the following information on the HMI main screen:

• Power flow between all system components including individual phase power and voltage on multi-phase connections (T)

• System output power including individual phase power and voltage on multi-phase connections (T)

• Generator input power including individual phase power and voltage on multi-phase connections (T)

• Average system state of charge (SOC) (T)

• Total system run time (T)

• System fault status (T)

• Current system mode (see 3.5.16) (T)

• Silent watch time available based on the average load of the previous 5 minutes (T)

• Generator fuel level (T)

3.4.2.3. Secondary display screens. MEHPS shall have secondary screen(s) to display detailed information from components and/or functionalities that are not on the main display screen. (T) The number of secondary screens and the arrangement of information on the secondary screens is at the discretion of the vendor but all information must be labeled to indicate its representation.

3.4.2.4. Advanced User Settings. The system shall have an advanced user setting screen that allows the user to adjust the following parameters: generator start/stop thresholds, generator utilization (load threshold), date/time, output voltage adjustment (114 V -126 V Line-to-Neutral) (T), (114 V – 138 V Line-to-Neutral) (O), and output frequency adjustment to 60 Hz (T).

3.4.2.5. Remote monitoring and control. MEHPS shall include a physical interface port for the purpose of accessing all information available on the system’s HMI. The MEHPS vendor shall provide an interface control document specifying the physical interface, communication protocols required and intellectual property required to derive all displayed HMI parameters for development of future remote monitoring and control. (T) MEHPS shall allow users to monitor and control the system remotely. (O)

3.4.2.6. Software/firmware version display. For any system component that has updateable software or firmware, excluding the generator, the system shall display the current software/firmware version. (T)

3.4.2.7. Visibility. All controls and indicators, excluding those on the generator, shall be visible during all environmental and weather conditions. (T)

3.4.2.8. Display Cover. The display shall have a cover that closes to protect the screen while not being viewed and shades the screen to reduce glare from other light sources. (T)

3.4.2.9. Display blackout. The system shall have the ability to eliminate all visible light from all displays while set-up and running. (T)

3.4.2.10. Night vision compatibility. Displays or indicators shall prevent direct / indirect glare from affecting the vision of personnel in proximity to MEHPS using or not using night vision imaging systems. (T)

3.4.2.11. Color perception. Interpretation of status indicators shall not rely on the user’s color perception. (T)

3.4.2.12. Cold weather set up and operation. The system shall be able to be set up and operated while personnel are wearing combat and cold weather uniforms. (T)

3.4.2.13. Mission Oriented Protective Posture (MOPP) controls. The system controls shall be operational by personnel wearing MOPP Level-IV uniforms. (T)

3.4.2.14. Breaker traceability. Devices, such as breakers or switches, which control a specific input or output, shall be labeled with the name of that input or output and easily traceable to the input or output of the device that it is designed to control or protect. (T)

3.4.2.15. Breaker visibility. A 2nd to 98th percentile Marine standing 2 feet from a panel shall be able to visually determine the position of all breakers and switches used on that panel. (T)

3.4.2.16. Breaker access. All control devices, such as breakers, switches and touchscreens, used in system shall have unobstructed access from at least one (T) / three (O) direction(s) when the system is fully set-up. Straight down shall not be counted as a direction. Breakers or safety devices housed under a protective cover for weather resistance shall be considered unobstructed.

3.4.2.17. Breaker protection. All breakers and switches shall be positioned to avoid accidental activation or deactivation. (T)

3.4.3. Stackable components. When components are not being transported on the LTT- MCC, components shall be stackable with other components of the same footprint up to 4 high without damage incurring. (T) System shall have alignment mechanism to improve stacking alignment and rigidity. (O)

3.4.4. Component size. All components shall have sufficient space and handles to allow the requisite number of personnel to lift the object IAW MIL-STD-1472G. (T)

3.4.5. Component weight. Individual components, excluding the solar arrays, shall weigh less than or equal to 210 lbs (T) / 147 lbs (O). The solar arrays shall have a maximum weight of 88 lbs (see Appendix A) (T).

3.4.6. System weight. When mounted on the LTT-MCC, the total weight including the trailer, the trailer Basic Issue Item (BII) (60 lbs), the generator fully fueled, and all system components, not including additional fuel, shall be less than or equal to 4200 lbs. (T)

3.4.7. System volume. When mounted on the LTT-MCC or JLTV trailer in the transport configuration, all components shall be contained within the footprint of the trailer. (T)

3.4.8. Deployment Configuration. The system shall be capable of full operations while all components, excluding the solar arrays and cable box, are on the trailer and not being transported. (T)

3.4.9. Color. All component cases shall be the same color and either tan, green, or black. (T)

3.4.10. Component labels. All components shall have a label that contains (T):

• System name

• Component name

• Component part number

• Component serial number

• Date of manufacture

• Component NSN, if assigned

• Manufacturer name

• Manufacturer model number

• Manufacturer CAGE code

• Component weight

• Component person lift requirement, if over 1 person

3.4.11. System level data plate. The MEHPS system level data plate shall contain (T):

• Item name and model number

• Serial number

• National Stock Number (NSN)

• Table of Authorized Materiel Control Number (TAMCN)

• Government ownership designation

• Special characteristics

• Contract number

• Commercial and Government Entity (CAGE) code

• Part number

• Unique Item Identification (UII) Data Matrix Symbol

3.4.12. Label permanence and durability. All labels and markings on all components of the system shall show no evidence of blistering, delamination, separation, discoloration, chipping, dissolving, softening, illegibility, corrosion, loosening, splitting, flaking, cracking, peeling, warping, or fading after independent government testing of all requirements of this specification.

(T)

3.4.13. Electrical diagrams. Electrical diagrams shall be provided for power converters and control systems and shall be enclosed within those components and meet the same labeling requirements per 3.4.12.

3.5. Electrical

3.5.1. System generator. The system shall use the 10 kW AMMPS generator (MEP-1040) as the integrated system generator. (T) The system shall also be able to use the 5 kW AMMPS (MEP-1030) generator as the integrated system generator in place of the 10 kW AMMPS generator for a reduced power system. (T) The system shall be able to use the 15 kW AMMPS generator (MEP-1050) as the integrated system generator. (O) The physical characteristics and fuel consumption for the generators is provided in Appendix B.

3.5.2. Backup power generation. The system shall allow connection of a second generator of the same size as a backup for the main generator in the case the main generator fails to start or is down for maintenance. (T) The system shall have the ability to synchronize voltage, frequency, and relative phase angle between two systems in order to allow transfer of load from one MEHPS to another without interrupting output power. (O)

• Input AC connectors. The system shall have two 3-phase, 5-wire, 30 Amp IEC 60309 pin and sleeve receptacles to accept the connection of two generators of the following configuration to the system: 1) two 10 kW generators or 2) two 5 kW generators. The ability for the system to connect to a combination of generators of different power ratings is not required (i.e. 5 kW and 10 kW concurrently). (T) In addition, the system shall have two 3-phase, 5-wire, 60 Amp IEC 60309 pin and sleeve receptacles. (O)

• Automatic generator selection to start. The system shall have the ability to auto-start the second generator without operator input if the main generator fails to start and/or fails during generator operation. (T) The system shall operate only one generator at a time. (T)

• Generator feedback protection. The system shall isolate the generators from each other to ensure the operating generator does not back-feed the generator that is in the off state. (T)

3.5.3. Generator isolation. The system shall allow the operator to remove the generator from the system and/or place the generator in a safe state in order to perform maintenance as outlined in the generator’s Technical Manual provided as Government Furnished Information

(GFI). (T)

3.5.4. System state during generator maintenance. The system shall allow the MEHPS to continue to operate to provide power to the load while the generator is isolated from the system for maintenance. (T)

3.5.5. Output paralleling. MEHPS shall be capable of operating in parallel with another MEHPS (same size / mode) to provide back-up power (O).

3.5.6. AC power rating. The system shall provide 10 kW (T) of 120/208 VAC 60 Hz 3-phase AC power. (T) The system shall provide 5 kW of 3- phase AC power when using the 5 kW AMMPS generator. (T) The system shall provide 15 kW of 3-phase AC power when using the 15 kW AMMPS generator. (O)

3.5.7. Output AC connector. The system shall have two 3-phase, 5-wire, 30 Amp IEC 60309 pin and sleeve receptacle for output AC power. (T) The system shall have one 1-phase, 3 wire, 20 Amp IEC 60309 pin and sleeve receptacle for output AC power. (T) The system shall have one 3-phase, 5-wire, 60 Amp IEC 60309 pin and sleeve receptacle for output AC power.

(T)

3.5.8. Convenience receptacles. Two convenience receptacles shall be provided on the system and they shall be NEMA 5-15 connectors. (T) The outlets shall be UL 953 Class A, Ground Fault Circuit Interrupter (GFCI) protected. (T)

3.5.9. Convenience receptacle power. Convenience receptacles shall provide Class 2B utility power IAW paragraph 3.2.5 AC Power Quality. (T)

3.5.10. Input AC power level. The system shall accept full rated power from an integrated 10 kW generator. (T) The system shall accept full rated power from an integrated 5 kW generator for the reduced power system. (T) The system shall accept full rated power from an integrated 15 kW generator. (O)

3.5.11. Input solar power level. The system shall be able to accept power from a solar array rated at 4 kW or greater. (T) The solar input ports shall also be able to accept 4 kW of power from other power sources including power scavenging systems. (T)

3.5.12. Solar input. The system shall be designed with a maximum solar input voltage capability of at least 20% above the maximum open circuit voltage (OCV) of the panels to accommodate potential voltage spikes. (T)

3.5.13. System start-up. The system shall be able to start-up from both generator power and energy storage module power. (T)

3.5.14. Power output control. After start-up and the user has verified system voltage and frequency, the system shall require user input to activate the availability of output power at the output terminal. (T) The device used for this purpose shall deactivate whenever the system is shut down. (T) Shut down is considered a total loss of power to and from all components, excluding the generator. The user input device shall be located on the MEHPS main control panel and cannot be activated via touchscreen. (T)

3.5.15. Output power indicator. The system shall have an indicator showing when output power is active. If an LED is used for this indicator, it shall be red in color. (T)

3.5.16. System operational modes. The MEHPS shall have three operational modes: hybrid mode, generator only mode, and silent watch mode. Operational mode shall be selected via the main control panel. (T) Further description of the modes is provided:

• Hybrid mode shall allow the system to operate autonomously and meet all fuel consumption requirements. (T) Hybrid mode starts and stops the generator based on the energy storage modules high and low state of charge thresholds.

• Generator only mode shall start the generator and not shut it down while this mode is activated. (T) This mode shall not override any generator shutdown faults. (T) Fuel consumption requirements do not apply when in this mode.

The system shall charge the energy storage modules while in this mode. (T)

• Silent watch mode shall implement silent watch IAW 3.5.17 through 3.5.22.

(T)

3.5.17. Planned silent watch. The system shall have the ability to execute a planned silent watch which shall allow the user to fully charge the energy storage modules in generator only mode and perform any other actions needed for silent watch. (T) The system shall also provide the user with feedback indicating silent watch time available based on current load levels. (T)

3.5.18. Planned silent watch duration. The system shall provide 3 hours (T) / 8 hours (O) of silent watch powering a constant 3.2 kW load with a 10kW AMMPS generator.

3.5.19. Silent watch noise level. During silent watch, the system shall not emit audible noise discernible at 65.6 feet IAW MIL-STD-1474E Appendix C Level I non-detectability limits. (T)

3.5.20. Silent watch maximum power. During silent watch, the system shall be able to provide power up to the system’s maximum power rating per 3.5.6. (T)

3.5.21. Silent watch activation. Silent watch mode shall be able to be activated by a user at any time or at a prescheduled time via the main control panel. (T) If silent watch has not been planned (see 3.5.17), silent watch need not be provided for the full length of time specified in

3.5.18. (T)

3.5.22. End of silent watch. The default setting shall be for the system to return to hybrid mode when the energy storage module’s lower limit SOC has been reached for normal hybrid mode operation. (T) The user shall have the option to change the setting from the default mode to allow silent watch operation to continue when the energy storage module’s lower limit SOC has been reached for normal hybrid mode operation and not automatically turn on the generator.

(T)

3.5.23. Reserve energy storage capacity. The system shall allow the energy storage modules to continue to provide power for 30 minutes after the lower limit of the energy storage modules SOC for hybrid mode operation has been reached to power a constant 3.2 kW load (10 kW

AMMPS). (T)

3.5.24. Reserve energy storage maximum power. During reserve energy storage the system shall be able to provide power up to the system’s maximum power rating per 3.5.6. (T)

3.5.25. Reserve energy storage mode advisory. The system shall provide an audible advisory at a noise level no greater than 68 dBA at 23 ft and a visual advisory on the active display screen warning users that the system is operating in reserve energy storage mode. The audible advisory shall be distinct from all other audible signals on the system as defined in MIL-STD 1472G, paragraphs 5.1.2.5 (c) and 5.3.1.3.1. (T)

3.5.26. Embedded energy storage modules. The system shall not contain any energy storage other than the energy storage modules. (T) Coin cells used for data backup or time keeping are acceptable but shall have a minimum of a 7 year maintenance cycle. Batteries internal to the system generator shall remain unmodified. (T)

3.5.27. Emergency Stop Switch. Two maintaining-push-to-activate switches shall be provided to disconnect output power within 150 milliseconds, stop the generator (if running), and disconnect the control power upon activation. (T) Activation of the emergency stop shall not adversely affect the system. There shall be no more than 1 mA current drawn from any power source when the switch is activated. (T) The switch shall be labeled "EMERGENCY STOP" and "PUSH TO STOP". (T) The emergency stop switch shall be located on opposing corners (example: front curb side and rear road side) in an area that reduces the possibility of accidental actuation when operating other generator controls. (T) If the emergency stop switch on the generator is activated, it shall perform all of the same functions as the emergency stop switch on the main system. (T)

3.5.28. Battle short switch. A switch shall be provided on the main control panel of the system which will prevent shutdown of the system or interruption of output power under the action of any safety or protective device except short circuit, energy storage over temperature, and energy storage over charge or discharge. (T) It shall be provided with a hinged red cover that can be quickly raised to provide access to the switch and which returns the switch to "OFF" when lowered. (T) The system shall only be able to start when this switch is in the "OFF" position. (T) The switch shall be labeled "BATTLE SHORT", "ON" in the up position, "OFF" in the down position. (T)

3.5.29. Generator start failure. The system shall warn the user on the MEHPS main control panel if the system generator fails to start for any reason. (T)

3.5.30. System shutdown. The system shall have a controlled response to component failures, such as the generator, that allows the system to shut down without tripping breakers or other power interrupting faults. (T)

3.5.31. Universal Serial Bus (USB) upgrade port. The system shall have one USB-C interface receptacle (latest version available) compliant with USB Cables and Connectors. (T) This port shall be configured to allow loading of software / firmware updates. (T) The USB Data receptacle shall be protected by a flat cover when not in use. (T) The use of a #1 or #2 Phillips screwdriver is permitted for the user to access this port. (T) This port shall also be an access point for downloading system faults and accessing internally logged data, which includes the parameters displayed on the main control panel. (T)

3.5.32. DC Power Output. The system shall provide 2 kW of 28-Volts nominal DC output power with quality that meets the requirements in MIL-STD-1275E. (O)

3.6. Environmental. The system and all components, when exposed to the conditions of 3.6, shall show no evidence of structural damage, misalignment or malfunction of components, leaks, fractures, abnormal vibrations, or any other irregular operation and shall continue to operate at all performance levels stated in section 3. (T)

3.6.1. Operational temperature. The system shall start and operate at full rated load at temperatures from -25°F to 125°F at sea level. (T) The rated load of the generator may be reduced by 3 percent for each 18°F increment above 125°F.

3.6.2. Storage temperature. The system and all components shall experience no malfunction or degradation of performance after storage in temperatures from -40°F to 160°F. (T)

3.6.3. Altitude operation. The system shall start and operate at full rated load at temperatures from -25°F to 95°F at 4,000 ft above sea level. (T)

3.6.4. High altitude operation. The system shall start and operate with derating less than or equal to the generator’s derating at temperatures from -25°F to 95°F up to 10,000 ft above sea level. (T)

3.6.5. Humidity. The system shall be able to operate at all possible relative humidity with temperatures up to 125° F at sea level, and temperatures up to 95°F at altitudes ranging from 4,000 ft to 10,000 ft without damage. (T)

3.6.6. Rain resistance. The system and all components shall not incur damage or degradation of performance when exposed to blowing rain. (T)

3.6.7. Immersion. The system and all components shall be able to withstand fording at a 3 ft depth while in their transport configuration. (T)

3.6.8. Salt fog. The system shall not incur degradation of performance after exposure to a salt fog atmosphere. (T)

3.6.9. Dissimilar metals. Protection against electrolysis and corrosion shall be provided when dissimilar metals, which would adversely affect performance, are used in direct contact with each other. (T)

3.6.10. Corrosion. MEHPS shall be designed and manufactured to resist corrosion during operation and storage and IAW the operational environmental requirements in this specification.

Materials and processes for metallic parts shall conform to applicable requirements in MIL-STD- 889C. Protective coatings and surface treatments shall be IAW MIL-STD-7179B and MIL- HDBK-729. Protective coatings shall not be used in areas which lose that coating during the normal course of operation, testing, and maintenance.

3.6.11. Sand and dust. The system shall not incur degradation of performance or function in an environment with blowing sand and dust. (T)

3.6.12. System employment angle. The system and all individual components shall operate on uneven terrain with omni-directional grades up to 15 degrees. (T)

3.6.13. Electromagnetic interference (EMI)

3.6.13.1. Conducted emissions. In all operational modes, the system shall not exceed the CE102 conducted emissions levels found in MIL-STD-461G (T).

3.6.13.2. Radiated emissions. In all operational modes, the system shall not exceed the RE102 Ground, Navy Mobile & Army radiated emissions levels found in MIL-STD-461G. (T)

3.6.13.3. Radiated magnetic susceptibility. In all operational modes, the system shall not exhibit any malfunction or degradation of performance when subjected to a radiated magnetic field IAW the Navy requirements of RS101 in MIL-STD-461G. (T)

3.6.13.4. Radiated electric susceptibility. In all operational modes, the system shall not exhibit any malfunction or degradation of performance when subjected to radiated electric fields in the 2 MHz to 18 GHz range IAW the Navy Ground requirements of RS103 in MIL-STD- 461G. (T)

3.6.13.5. Conducted susceptibility bulk cable injection frequency range. In all operational modes, the system shall not exhibit any malfunction or degradation of performance when subjected to injected probe drive IAW the Navy Ground requirements of CS114 in MIL-STD- 461G. (O)

3.6.13.6. Conducted susceptibility bulk cable injection impulse excitation. In all operational modes, the system shall not exhibit any malfunction or degradation of performance when subjected to the signal specified in CS115 of MIL-STD-461G. (O)

3.6.13.7. Conducted susceptibility, damped sinusoidal transients. In all operational modes, the system shall not exhibit any malfunction of degradation of performance when subjected to the signal specified in CS116 of MIL-STD-461G. (O)

3.6.14. Chemical, Biological, Radiological, and Nuclear (CBRN) attack. The system, excluding the generator, shall be able to be operationally decontaminated using standard decontaminants and procedures as specified in FM 3-11.5 Chapter IV after a CBRN attack. (T) The decontamination shall be able to be performed while personnel are wearing MOPP Level IV uniforms (O).

3.7. Transportability. The MEHPS shall be capable of being transported worldwide by rail, marine, highway, and air modes to include external helicopter lift. (T) Guidance on transportability criteria is defined in MIL-STD-1366E.

3.7.1. System trailer. MEHPS shall be capable of being mounted to the M1102 LTT-MCC and to the JLTV trailer. (T)

3.7.1.1.LTT-MCC components. The Basic Issue Items (BII) provided on the LTT-MCC (such as accessory box, rear landing legs, etc.) shall not be removed. (T)

3.7.1.2.LTT-MCC center of gravity. When the system is mounted on the LTT-MCC in the transport configuration, the center of gravity of the trailer shall be no higher than 46.0 inches above ground level, shall be between 4.7 and 9.4 inches in front of the axle centerline, and shall be within 1 inch of the longitudinal centerline of the trailer. (T)

3.7.1.3. Transportation without generator. MEHPS shall be capable of being rearranged to be transported via trailer without the generator. (T)

3.7.1.4.Trailer mounting of LTT-MCC. The system shall use the Marine Corps standard AMMPS rails for mounting all MEHPS components onto the LTT-MCC trailer. Other than the AMMPS rails, the same MEHPS mounting components shall be used to mount MEHPS on both the LTT-MCC and the JLTV trailer. The AMMPS rails shall not be used on the JLTV Trailer.

(T) Rail and trailer drawings will be provided post contract award.

3.7.1.5.Trailer mounting tools. No special tools (T) / no tools (O) shall be required to mount the system to the LTT-MCC or the JLTV trailer.

3.7.1.6.Trailer modifications. The trailer shall not be modified other than to provide for system mounting provisions. (T) The trailer shall not be modified (O). Additions of AMMPS rails are not included in this requirement.

3.7.1.7.Generator configuration. The space on top on the generator shall not be used to store or transport other system components. (T)

3.7.1.8.Generator Access. Access shall be provided such that all essential operational functions can be performed on the generator while in its transport configuration excluding solar arrays. (T) These actions include accessing the dead crank switch, battery disconnect switch and all PMCS locations.

3.7.1.9.Sling load configuration. When mounted on the LTT-MCC or JLTV trailer the system shall be sling load capable with the trailer and not interfere with sling legs. (T)

3.7.2. Transport Configuration. All MEHPS cabling shall remain connected while in transport configuration with exception of the solar arrays and load cables. (T)

3.7.3. Rail impact. The MEHPS shall be rail transportable in Continental United States (CONUS) and NATO countries without restrictions. (T) Reference MIL-STD-1366E. The MEHPS shall be capable of withstanding shock loads resulting from rail impact testing without failure, damage, or permanent deformation. (T) When loaded on a 51-inch high rail car, the MEHPS shall meet the dimensional requirements of the Association of American Railroads (AAR) outline diagram for single loads, without end overhang, on open-top cars. (T) The MEHPS shall meet the dimensional requirements of Gabarit International de Chargement (GIC) equipment gauge diagram. (T) These diagrams apply to standard gauge rail lines in the CONUS and NATO countries.

3.7.4. Marine transport. The MEHPS shall be capable of transport on US Naval crafts to include SSC, LCAC, LCU, JHSV, INLS, LHA-1, LHD-1,LSD-41, LSD-49, LPD-17, Lift- On/Lift-Off (LOLO), Roll-On/Roll-Off (RORO), break bulk (general cargo), and barge carrying (LASH and SEABEE) ships. (T)

3.7.5. Highway transport. The MEHPS shall be highway transportable by the M870 series/semi-trailer, which has a deck height of 42 inches, while meeting worldwide transportation requirement. (T)

3.7.6. Air transport. The MEHPS shall be capable of being transported by C-130, C-17 and C-5 aircraft in accordance with MIL-STD-1791C_CHG-1 design criteria. (T) The system shall be less than 8.5 ft in height while in transportation configuration. (T)

3.7.7. External helicopter transport. The MEHPS shall be capable of being transported externally by CH-53 and MV-22 helicopters in accordance with MIL-STD-913A and MIL-STD- 209K. (T) The use of spreader bars is not permitted. Approval for external air lift by helicopter shall be provided by the U.S. Army Natick Soldier Center via MCSC Transportability. (T)

3.7.8. Secured cargo transport. The system components shall not incur damage or degradation of performance when transported securely in the bed of a military vehicle. (T)

3.7.9. Road profile. The system and all individual components, when transported on any tactical vehicle in the USMC inventory, shall be capable of being transported over the mission profile described in MIL-STD-810H, method 514.8, Annex C, Category 4, without degradation of performance. (T)

3.7.10. Transit Drop. All system components over 100 lbs. shall not incur degradation of performance after being dropped 8 times from a height of 30 inches. (T) All system components of 100 lbs. or less shall not incur degradation of performance after being dropped 8 times from a height of 48 inches. (T) The system as a whole will not be subject to this requirement, however, all components shall individually survive transit drop.

3.7.11. Forklift capability. All MEHPS components, excluding the generator, shall be capable of being forklifted together as a single load on and off the trailer. Forklift specifications are provided in Appendix D.

3.8. System storage

3.8.1. Storage preparation. Preparation for storage by two Marines shall be less than or equal to 1 hour for all system components with the exception of charging energy storage modules. (T) This time includes any action that needs to be performed to prepare the system to be stored in an unused state for periods greater than one year.

3.8.2. Removal from storage. It shall take less than 1 hour for two Marines to make the system provide full output power after storage. This excludes the time required to recharge the energy storage. (T) This time includes any action that needs to be performed to ready the system to provide full output power starting from the state described in 3.8.1.

3.9. Safety

3.9.1. Energy storage access. Electrochemical cells and electronics used in the energy storage modules shall not be accessible to a user without the use of commercially available specialty tools. (T) The energy storage modules shall be able to be resealed to its IP67 rating without the need of additional material such as new O-rings, or room temperature vulcanizing (RTV) type sealants. (T)

3.9.2. Shock hazard. All components of…