MIL-PRF-XXXXX-1 - bulk charger - draft - 2024-09-03.pdf

DO NOT USE FOR PROCUREMENT

NOTE: This draft, dated 3 September 2024, has not been approved for procurement.

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

9519951852 INCH-POUND

MIL-PRF-#####/1

3 September 2024

PERFORMANCE SPECIFICATION SHEET 1

CHARGER, BATTERY, PP-xxxx()/U 3

BULK CHARGER 4

This specification is approved for use by all 6

Departments and Agencies of the Department of Defense. 7

1 SCOPE 9

1.1 Scope. 12

The requirements for acquiring the product described herein shall consist of this specification sheet and 13

MIL-PRF-#####. 14

2 APPLICABLE DOCUMENTS 16

2.1 General. 19

The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section 20 does not include documents cited in other sections of this specification or recommended for additional 21 information or as examples. While every effort has been made to ensure the completeness of this list, 22 document users are cautioned that they must meet all specified requirements of documents cited in 23 sections 3, 4, or 5 of this specification, whether or not they are listed. 24

Comments, suggestions, or questions on this document should be emailed peosoldierstp@army.mil. Since 26 contact information can change, you may want to verify the currency of this address information using the 27

ASSIST Online database at https://assist.dla.mil. 28

NOTE: This draft, dated 3 September 2024 prepared by US

Army XXXXXX, has not been approved and is subject to modification. DO NOT USE PRIOR TO APPROVAL.

(Project 6130-xxxxx)

2.2 Government documents. 30

2.2.1 Specifications, standards, and handbooks. 32

As stated. 33

2.2.2 Other Government documents, drawings, and publications. 35

As stated. 36

2.3 Non-Government publications. 38

As stated. 39

2.4 Order of precedence. 40

As stated. 41

3 REQUIREMENTS 43

3.1 Specification sheets. 45

The individual item requirements shall be as specified herein and in accordance with MIL-PRF-XXXXX. 46

In the event of any conflict between the requirements of this specification sheet and MIL-PRF-XXXXX, 47 this specification sheet shall govern. 48

3.2 Inspections. 50

3.2.1 First article. 52

As stated. 53

3.2.2 Certification of conformity. 55

As stated. 56

TABLE I. Requirements requiring certification. 58

As stated.

3.3 Reserved 60

3.4 Physical characteristics. 62

3.4.1 Dimensions. 64

Add: The charger volume shall be not greater than 1.6 cubic feet when in transport configuration (see 65

3.4.7). No individual measurement (e.g. height, length or width) shall be greater than 30 inches. Verify in 66 accordance with 4.4.1. 67

TABLE II. System dimensions. 69

Dimension Charger in transport configuration

Width ≤ 30 inches

Length ≤ 18 inches

Height ≤ 12 inches

Volume ≤ 1.6 cu. ft.

3.4.2 Weight. 71

Add: The total weight of the charger, in fully operational configuration including the AC power cable, 72 shall weigh not greater than 35 pounds. Verify in accordance with 4.4.2. 73

3.4.3 Color. 75

Add: The charger and adapters shall be green (chip number 34088), tan (chip number 33446), or black 76

(chip number 37030) per SAE-AMS-STD-595. Surfaces shall have a dull lusterless finish. Cables may be 77 lusterless black (FED STD-595 color number 37038). Verify in accordance with 4.4.3. 78

3.4.4 Visual inspection. 80

As stated. 81

3.4.5 Stackable. 83

Add: When in transport configuration (see 3.4.7), the charger shall be stackable and stable up to 5 high 84 without damage. 85

3.4.5.1 Vertical alignment. 87

Add: The charger shall employ vertical alignment methods to prevent stacked chargers from shifting 88 beyond the footprint of the bottom charger and ensure aligned stacking. Verify in accordance with 4.4.5.1. 89

3.4.6 Handles. 91

As stated. 92

3.4.6.1 Handle strength. 94

As stated. 95

3.4.7 Transport configuration. 97

Add: The charger shall be able to be safely transported with all external components required for 98 operation, to include one full set of adapters and the AC cable. Any combination of adapters (see 3.5.1.3) 99 required to charge batteries listed in TABLE V shall be capable of being transported fully installed and 100 ready to operate. The charger and required components, in transport configuration, shall be capable of 101 being carried by one person with one hand. Verify in accordance with 4.4.7. 102

3.4.8 System connectors. 104

Any connector placed on the exterior of the case shall not protrude beyond the maximum dimensions of 105 the case. Any connector placed on the exterior of the case shall include some form of a tethered protection 106 from damage while not in use. 107

3.4.8.1 Non-proprietary connectors. 109

As stated. 110

3.4.8.2 DC input connector. 112

Add: The charger shall have one DC input connector. The DC input connector shall be clearly identified 113 as such. Verify in accordance with 4.4.8.2. 114

TABLE III. Reserved. 116

Reserved.

Reserved..

FIGURE 1. Reserved. 118

3.4.8.3 AC input connector. 120

Add: The charger shall have one AC input connector. The AC input connector shall be a 3-prong 121 receptacle compliant with IEC 60320 type C14. The AC input connector shall be capable of mating with 122 the AC Cable defined in 3.10.3.1. Verify in accordance with 4.4.8.3. 123

3.4.8.4 System modular connector. 125

N/A. 126

3.4.8.5 USB ports. 128

Modify: USB Type-C PD port minimum quantity shall be four. 129

3.4.8.6 Firmware upgrade port. 131

As stated. 132

3.4.9 Indicators. 134

As stated. 135

3.4.9.1 Blackout mode. 137

As stated. 138

3.4.9.2 Charger status indicators. 140

As stated. 141

TABLE IV. Battery charging indicators. 142

As stated.

Battery capacity. 144

As stated. 145

3.4.9.3 Digital display. 147

As stated. 148

3.4.10 Chemical agents. 150

As stated. 151

3.4.11 Marking. 153

As stated. 154

3.4.11.1 Nameplate label. 156

As stated. 157

Nameplate information. 159

As stated. 160

3.4.11.2 Firmware version label. 162

As stated. 163

3.4.11.3 Visibility of assembly markings. 165

As stated. 166

3.4.11.4 Battery interface nameplate labels. 168

As stated. 169

3.4.11.5 Battery interface markings. 171

As stated. 172

3.4.11.6 Power input/output label. 174

As stated. 175

3.5 Performance characteristics. 177

3.5.1 Battery charging. 179

As stated. 180

3.5.1.1 Battery types and charge times. 182

Add: 184

TABLE V. Basic configuration and charge times. 185

Battery [Minimum] number required

Energy (watt-hours) per battery

Max charge time (>90%

SOC)

(hours)

BB-2590/U 8 200 3

AN/PRC-148 Radio battery 16 52 2

AN/PRC-163 Radio battery 16 74 3

Conformal Wearable Battery (3.5/3.6) 16 148 3.5

Conformal Wearable Battery (3.6.2) 16 196 4.0

3.5.1.2 Charging protocols. 188

As stated. 189

System management bus (SMBus). 191

As stated. 192

Direct Query (DQ) protocol. 194

As stated. 195

Charging priority. 197

N/A. 198

Over-discharged batteries. 200

As stated. 201

3.5.1.3 Battery interface. 203

Replaceable battery interface. 205

Modify: The battery interfaces may utilize cables. 206

Charger connection. 208

As stated. 209

3.5.1.4 Charging with radios attached. 211

N/A. 212

3.5.1.5 Battery hot swap. 214

As stated. 215

Battery detect. 217

As stated. 218

3.5.1.6 STANREC 4819 compliance. 220

As stated. 221

3.5.2 USB ports. 223

3.5.2.1 USB Type-A receptacles. 225

As stated. 226

3.5.2.2 USB Type-C receptacles. 228

As stated. 229

3.5.3 Operability. 231

As stated. 232

3.5.3.1 Ease of systems operation. 234

As stated. 235

3.5.3.2 User interface. 237

As stated. 238

3.5.4 System characteristics. 240

3.5.4.1 On / off switch. 242

As stated. 243

3.5.4.2 Power on self-test. 245

As stated. 246

3.5.4.3 Power sharing. 248

N/A. 249

Power sharing hot swap. 251

N/A. 252

3.5.4.4 Upgradeability. 254

As stated. 255

New battery configurations. 257

As stated. 258

3.5.4.5 Cooling. 260

The charger may utilize a fan or fans for cooling. If fans are utilized for cooling, they shall be removable 261 and replaceable without tools or using a Phillips #1 or #2 screwdriver . Acoustic signature of fans shall be 262 limited to 35 dB at 1 meter. Verify in accordance with 4.5.4.5. 263

3.5.4.6 Vehicle mounting. 265

N/A. 266

N/A.

FIGURE 2. Vehicle mounting interfaces. 268

3.5.4.7 Ground post. 270

N/A. 271

3.5.5 Electrical characteristics. 273

3.5.5.1 Input voltage, AC. 275

Add: When operating under full load at 22°C±2°C, the charger shall utilize no less than 1,500 Volt-Amps 276

(VA) from a 120 VAC, 60 Hz source. 277

3.5.5.2 Input voltage, DC. 279

As stated. 280

3.5.5.3 Limited power sources. 282

The charger shall include user-selectable independent AC & DC power limits. Levels shall be 500 W, 750 283

W, 1,000 W, 1,250 W, Full Power, and Custom (user defined value). The default factory-programmed 284 limit shall be Full Power for AC and Full Power for DC. The power limit settings shall persist through a 285 charger power cycle. Verify in accordance with 4.5.5.3. 286

3.5.5.4 Automatic restart. 288

As stated. 289

3.5.5.5 Maximum power point tracking. 291

N/A. 292

3.5.5.6 Vehicle power. 294

N/A. 295

3.5.5.7 Reserved. 297

3.6 Electrical conditions. 299

3.6.1 Electromagnetic interference (EMI). 301

As stated. 302

3.6.1.1 CE102 (Conducted Emissions, Radio Frequency Potentials, Power Leads). 304

As stated. 305

3.6.1.2 CS101 (Conducted Susceptibility, Power Leads). 307

As stated. 308

3.6.1.3 CS114 (Conducted Susceptibility, Bulk Cable Injection). 310

As stated. 311

3.6.1.4 CS115 (Conducted Susceptibility, Bulk Cable Injection, Impulse Excitation). 313

As stated. 314

3.6.1.5 CS116 (Conducted Susceptibility, Dampened Sinusoidal Transients, Cables and Power 316

Leads). 317

As stated. 318

3.6.1.6 CS118 (Conducted Susceptibility, Personnel Borne Electrostatic Discharge). 320

As stated. 321

3.6.1.7 RE102 (Radiated Emissions, Electric Field). 323

As stated. 324

3.6.1.8 RS103 (Radiated Susceptibility, Electric Field). 326

As stated. 327

3.6.2 Reserved. 329

3.6.3 AC spikes and surges. 331

As stated. 332

3.6.4 DC spikes and surges. 334

As stated. 335

3.7 Environmental conditions. 337

As stated. 338

3.7.1 Temperature. 340

3.7.1.1 Operation. 342

Low temperature operation. 344

As stated. 345

High temperature operation. 347

As stated. 348

3.7.1.2 Storage. 350

Low temperature storage. 352

As stated. 353

High temperature storage. 355

As stated. 356

3.7.2 Humidity. 358

As stated. 359

3.7.3 Low pressure (altitude). 361

As stated. 362

3.7.4 Salt fog. 364

As stated. 365

3.7.5 Solar radiation. 367

As stated. 368

3.7.6 Temperature shock. 370

Replace: The charger, in transport configuration, shall withstand temperature shock in the range of -22°F 371

(-30°C) to +160°F (+71°C). When tested as specified in 4.7.6, the charger shall experience no deleterious 372 effects and shall meet full specification performance after testing. Verify in accordance with 4.7.6. 373

3.7.7 Transit. 375

As stated. 376

3.7.7.1 Loose cargo. 378

Add: This requirement applies to the charger in transport configuration. 379

3.7.7.2 Transit drop. 381

Add: This requirement applies to the charger in transport configuration. 382

3.7.8 Crash hazard shock. 384

N/A. 385

3.7.9 Vibration. 387

N/A. 388

3.7.10 Immersion. 390

Replace: The charger and accessories (as appropriate), in transport configuration, shall be capable of 391 being immersed and have drain holes (or similar features) as appropriate to minimize water retention. 392

After testing as specified in 4.7.10, the charger shall remain fully functional. Verify in accordance with 393

4.7.10. 394

3.7.11 Sand and dust. 396

As stated. 397

3.7.12 Rain. 399

As stated. 400

3.7.13 Fungus. 402

As stated. 403

3.7.14 Icing. 405

As stated. 406

3.7.15 Parachute landing fall impact. 408

N/A. 409

3.8 System safety. 411

3.8.1 General safety. 413

As stated. 414

3.8.1.1 Touch current (leakage current). 416

As stated. 417

3.8.1.2 Electric strength. 419

As stated. 420

3.8.1.3 Retained charge. 422

As stated. 423

3.8.2 Electrical shock. 425

As stated. 426

3.8.3 Short circuit. 428

As stated. 429

3.8.4 Over/under-temperature. 431

As stated. 432

3.8.5 Safety features. 434

3.8.5.1 Radioactive or hazardous materials. 436

As stated. 437

3.8.5.2 Non-rechargeable batteries. 439

As stated. 440

3.8.5.3 Surface temperature. 442

As stated. 443

3.8.5.4 Power outputs. 445

As stated. 446

3.9 Reliability. 448

As stated. 449

3.10 System accessories. 451

3.10.1 Solar panel. 453

N/A. 454

3.10.1.1 Solar panel characteristics. 456

N/A. 457

3.10.1.2 Power output at different solar angles. 459

N/A. 460

TABLE VI. Solar angle of incidence. 462

N/A

3.10.2 External AC to DC converter. 464

N/A. 465

3.10.2.1 Environmental requirements. 467

N/A. 468

3.10.3 Cables. 470

As stated. 471

3.10.3.1 AC input cable. 473

As stated. 474

3.10.3.2 DC power interface cable. 476

The DC power interface cable allows for an external DC power source to be connected to the charger. 477

The DC power interface cable shall have stranded copper based wire capable of carrying voltage and 478 current as specified in 3.5.5.2. The length shall be 6 feet +/- 3 inches. One end shall be capable of mating 479 with the DC input connector (see 3.4.8.2) on the charger. The other end shall be unterminated leads of 480 length 3 +/- 1 inches. Verify in accordance with 4.10.3.2. 481

N/A

FIGURE 3. Non-shrouded two wire “trailer hitch” connector. 483

3.10.3.3 DC extension cord cable (18 ft.). 485

N/A. 486

3.10.4 Additional DC inputs. 488

N/A. 489

N/A

FIGURE 4. Shrouded two wire “trailer hitch” connector. 491

3.10.4.1 NATO slave input power adapter. 493

The NATO slave plug shall be compatible with a Type I receptacle per NATO STANAG 4074 and be of 494 the minimum size and weight required to meet the power and environmental requirements of this 495 specification. 496

3.10.4.2 Alligator clips input power adapter. 498

N/A. 499

3.10.5 Hard cover. 501

The charger may have an integrated or removable hard cover which can be secured for transport 502 configuration (see 3.4.7). The charger and hard cover shall be designed to ensure that the cover does not 503 become a projectile. Verify in accordance with 4.10.5. 504

The system cover shall: 506

a. Meet the color requirements of the charger (see 3.4.3). 507

b. Have all latching mechanisms and connectors (e.g. snaps, rivets, etc) be lusterless. Hook and loop 508 straps (e.g. Velcro™) shall not be used. 509

c. Have a carrying handle capable of supporting not less than 60 pounds. 510

d. (if removable) Not require more than 15 seconds (for each action) to remove and replace from the 511 charger. 512

e. Be capable of storing the AC input cable and a full set of adapters required for charging batteries. 513

3.10.6 Soft cover. 515

N/A. 516

3.10.7 Transportation case. 518

N/A. 519

3.11 Repairability. 521

As stated. 522

4 VERIFICATION 524

4.1 Verifications of inspections. 526

As stated. 527

4.1.1 First article units. 529

The contractor will furnish first article units of the complete battery charger. The quantity of first article 530 units will be defined in the SoW. For all requirements where it states that verification or analysis is 531 required, the contractor shall detail the proposed testing and test protocols in the FAT Plan for 532 government review and acceptance. The presence of one or more defects shall be cause for rejection of 533

First Article and require all units to be tested for compliance with TABLE VIII. 534

4.1.2 First article inspection. 536

As stated. 537

4.1.3 Classification of verification. 539

As stated. 540

4.1.4 Methods of verification. 542

As stated. 543

TABLE VII. Verification methods table. 545

As stated.

4.1.5 Basis for verification. 547

The failure of any assembly, device, component, or test specimen to meet any of the verification criteria 548 shall be cause for rejection. The Government may use a waiver to accept products “as is” or terminate 549 verification requirements activities upon any failure to meet any of the requirements. The charger is 550 expected to meet all verifications as noted in TABLE VIII. 551

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

TABLE VIII. Performance Requirements - Verification Cross-Reference. 553

Section 4 Verification Method(s) of

Verification When Verified Sample/group

N /A

A n a ly si s

E x a m in a ti o

T es t

D em o n st ra ti

G v er n m en t

T es t*

P ro d u ct io n Q u a li fi ca ti

C n fo rm a n ce

A cc ep ta ce

R

P h y si ca l

(3 e a

R el ia b il it y e

T ra n si t D ro p e

E M

I/ E

M C e

T em p er a tu re e

E n v ir o n m en ta l

A e

E n v ir o n m en ta l

B e

B a tt er y c h a rg in g e

I n te rf a ce s (1 e

S a fe ty e

4.4 Physical characteristics. X

4.4.1 Dimensions. E X X ✔

4.4.2 Weight.visual E X ✔

4.4.3 Color. E X ✔

4.4.4 Visual inspection. E X X X ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

4.4.5 Stackable. D X ✔

4.4.5.1 Vertical alignment. E X ✔

4.4.6 Handles. E X ✔

4.4.6.1 Handle strength. E X ✔

4.4.7 Transport configuration. D X ✔

4.4.8 System connectors. X

4.4.8.1 Non-proprietary connectors. A X

4.4.8.2 DC input connector. X

4.4.8.3 AC input connector. A X

4.4.8.4 System modular connector. X

4.4.8.5 USB ports. A X

4.4.8.6 Firmware upgrade port. A D X X ✔

4.4.9 Indicators. T X X ✔

4.4.9.1 Blackout mode. X

4.4.9.2 Charger status indicators. A T X ✔

4.4.9.2.1 Battery capacity. A X X

4.4.9.3 Digital display T X ✔

4.4.10 Chemical agents. T X ✔

4.4.11 Marking. E D X ✔

4.4.11.1 Nameplate label. E X X ✔

4.4.11.1.1 Nameplate information. E X X ✔

4.4.11.2 Firmware version label. E X ✔

4.4.11.3 Visibility of assembly markings. E X ✔

4.4.11.4 Battery interface nameplate labels. E X ✔

4.4.11.5 Battery interface markings. E X ✔

4.5 Performance characteristics. X

4.5.1 Battery charging. A T X X ✔

4.5.1.1 Battery types and charge times. A T X X ✔

4.5.1.2 Charging protocols. A X

4.5.1.2.1 System management bus (SMBus). A X

4.5.1.2.2 Direct Query (DQ) protocol. A X

4.5.1.2.3 Charging priority. X

4.5.1.2.4 Over-discharged batteries. T X ✔

4.5.1.3 Battery interface. X

4.5.1.3.1 Replaceable battery interface. A T X ✔

4.5.1.3.2 Charger connection. A T X ✔

4.5.1.4 Charging with radios attached. X

4.5.1.5 Battery hot swap. D X ✔

4.5.1.5.1 Battery detect. E X ✔

4.5.2 USB ports. T X ✔

4.5.3 Operability. D X ✔

4.5.3.1 Ease of systems operation. D X ✔

4.5.3.2 User interface. D X ✔

4.5.4 System characteristics. X

4.5.4.1 On / off switch. T X ✔

4.5.4.2 Power on self-test. T D X ✔

4.5.4.3 Power sharing. X

4.5.4.3.1 Power sharing hot swap. X

4.5.4.4 Upgradeability. A X

4.5.4.4.1 New battery configurations. A X

4.5.4.5 Cooling. E X ✔

4.5.4.6 Vehicle mounting. X

4.5.5 Electrical characteristics. X

4.5.5.1 Input voltage, AC. D X X ✔

4.5.5.2 Input voltage, DC. D X X ✔

4.5.5.3 Limited power sources. D X ✔

4.5.5.4 Automatic restart. D X ✔

4.5.5.5 Maximum power point tracking. X

4.5.5.6 Vehicle power. X

4.6 Electrical conditions. X

4.6.1 Electromagnetic interference (EMI). T X ✔

4.6.2 Reserved. T X

4.6.3 AC spikes and surges. T X ✔

4.6.4 DC spikes and surges. X ✔

4.7 Environmental conditions. X

4.7.1 Temperature. T X ✔ ✔

4.7.2 Humidity. T X ✔

4.7.3 Low pressure (altitude). T X ✔

4.7.4 Salt fog. T X ✔

4.7.5 Solar radiation. T X ✔

4.7.6 Temperature shock. T X ✔

4.7.7 Transit. X

4.7.7.1 Loose cargo. T X ✔

4.7.7.2 Transit drop. T X ✔

4.7.8 Crash hazard shock. X

4.7.9 Vibration. T X ✔

4.7.10 Immersion. T X ✔

4.7.11 Sand and dust. T X ✔

4.7.12 Rain. T X ✔

4.7.13 Fungus. A T X ✔

4.7.14 Icing. T X ✔

4.7.15 Parachute landing fall impact. X

4.8 System safety. X

4.8.1 General safety. E X X ✔ ✔

4.8.1.1 Touch current (leakage current). T X ✔

4.8.1.2 Electric strength. T X ✔

4.8.1.3 Retained charge. T X ✔

4.8.2 Electrical shock. A X

4.8.3 Short circuit. A X

4.8.4 Over/under-temperature. T X ✔

4.8.5 Safety features. X

4.8.5.1 Radioactive or hazardous materials. A X

4.8.5.2 Non-rechargeable batteries. D X ✔

4.8.5.3 Surface temperature. E X ✔

4.8.5.4 Power outputs. E X ✔

4.9 Reliability. T X ✔

4.10 System accessories. X

4.10.1 Solar panel. X

4.10.1.1 Solar panel characteristics. X

4.10.1.2 Power output at different solar angles. X

4.10.2 External AC to DC converter. X

4.10.2.1 Environmental requirements. X

4.10.3 Cables. T X ✔

4.10.3.1 AC input cable. E X ✔

4.10.3.2 DC power interface cable. E X ✔

4.10.3.3 DC extension cord cable (18 ft.). X

4.10.4 Additional DC inputs. X

4.10.4.1 NATO slave input power adapter. E X ✔

4.10.4.2 Alligator clips input power adapter. X

4.10.5 Hard cover. E X ✔

4.10.6 Soft cover. X

4.10.7 Transportation case. X

4.11 Repairability. A

* Government test does not negate the need for contractor production qualification testing. Government test is an independent verification performed in addition to 554 contractor production qualification testing. 555

TABLE IX. Applicable System Accessories for Test. 557

N/A

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

4.2 Conformance inspection. 560

As stated. 561

4.2.1 Nonconformance. 563

As stated. 564

4.2.2 Sampling and order of inspection. 566

As stated. 567

4.3 Common procedures. 569

As stated. 570

4.3.1 Basic operational test (BOT). 572

At ambient temperature charge twelve conformal wearable batteries (3.5/3.6), two BB-2590 batteries, and 573 two USB devices to not less than 90% state of charge. The charger shall meet the performance 574 requirements of 3.5.1 for these batteries. Verify the status indicators meet the requirements of 3.4.9 during 575 charge. 576

4.3.2 Basic functional test (BFT). 578

Connect the charger to its AC power source and allow the charger to perform a power on self-test (see 579

3.5.4.2). Connect an appropriate battery to each battery port and ensure charge is initiated. Connect a 580

USB compliant load to each USB charging receptacle (see 3.4.8.5) and verify that they meet the 581 requirements of 3.5.2. Connect a USB compliant computer to the USB data receptacle (3.4.8.6) and 582 ensure communications can be established. Verify operation of the Digital Display (3.4.9.3). Verify the 583 proper functionality of the blackout mode of 3.4.9.1. If accessories are being tested, perform the 584 appropriate test in paragraph 4.3.2.1 through 4.3.2.2. 585

4.3.2.1 BFT for DC power input accessories. 587

N/A. 588

4.3.2.2 BFT for additional battery interfaces. 590

Perform the BFT of 4.3.2 for each interface type installed. 591

4.4 Physical characteristics. 593

4.4.1 Dimensions. 595

Place the charger in transport configuration (see 3.4.7). Measure the charger including all protrusions to 596 the nearest tenth of an inch. System dimensions (width, length, and height) shall be from the largest flat 597 surface of each axis and shall not include any connector protrusions. Charger feet shall be considered in 598 the system height measurement. Verify that no dimension is greater than the value given in TABLE II. 599

Verify the total volume (L x W x H) is less than 1.6 cubic feet. 600

4.4.2 Weight. 602

Weigh the charger, not including battery interface adapters, AC and DC power cables, and verify that the 603 weight is not greater than 35 lbs. 604

4.4.3 Color. 606

Visually examine and verify that the color of the charger, cables, battery interfaces, and adapters is in 607 accordance with 3.4.3. 608

4.4.4 Visual inspection. 610

As stated. 611

4.4.5 Stackable. 613

The following test shall be performed. The charger shall meet the requirements of 3.4.5 and 3.4.5.1. 614

a. Configure five chargers in transportation configuration and stack them. 615

b. Apply increasing pressure to the front of the top charger until either 5 pounds of pressure is 616 applied or the charger has a lateral movement of 1 inch, whichever comes first. 617

c. Rapidly remove the pressure. 618

d. Verify that no charger falls and that no damage occurs. 619

e. Repeat steps b through d for each sides and the rear of the charger. 620

4.4.5.1 Vertical alignment. 622

Verify through examination that the charger, in transport configuration, has a method to align multiple 623 units when stacked on top of one another. 624

4.4.6 Handles. 626

As stated. 627

4.4.6.1 Handle strength. 629

As stated. 630

4.4.7 Transport configuration. 632

Verify through demonstration that the charger can be configured for transport with all external 633 components required for operation, to include one full set of adapters and the AC cable. Verify through 634 demonstration that the charger and required components, in transport configuration, can be carried by one 635 person with one hand. 636

4.4.8 System connectors. 638

N/A. 639

4.4.8.1 Non-proprietary connectors. 641

As stated. 642

4.4.8.2 DC input connector. 644

Verify through examination that the charger has one DC input connector and that the DC input is clearly 645 identified as such. 646

4.4.8.3 AC input connector. 648

Verify through examination that the charger includes an AC input using an IEC 60320 type C14 socket. 649

4.4.8.4 System modular connector. 651

N/A 652

4.4.8.5 USB ports. 654

As stated. 655

4.4.8.6 Firmware upgrade port. 657

As stated. 658

4.4.9 Indicators. 660

As stated. 661

4.4.9.1 Blackout mode. 663

As stated. 664

4.4.9.2 Charger status indicators. 666

As stated. 667

Battery capacity. 669

As stated. 670

4.4.9.3 Digital display 672

As stated. 673

4.4.10 Chemical agents. 675

As stated. 676

4.4.11 Marking. 678

As stated. 679

4.4.11.1 Nameplate label. 681

As stated. 682

Nameplate information. 684

As stated. 685

4.4.11.2 Firmware version label. 687

As stated. 688

4.4.11.3 Visibility of assembly markings. 690

As stated. 691

4.4.11.4 Battery interface nameplate labels. 693

As stated. 694

4.4.11.5 Battery interface markings. 696

As stated. 697

4.4.11.6 Battery interface markings. 699

As stated. 700

4.5 Performance characteristics. 702

4.5.1 Battery charging. 704

As stated. 705

4.5.1.1 Battery types and charge times. 707

As stated. 708

4.5.1.2 Charging protocols. 710

As stated. 711

System management bus (SMBus). 713

As stated. 714

Direct Query (DQ) protocol. 716

As stated. 717

Charging priority. 719

N/A. 720

Over-discharged batteries. 722

As stated. 723

4.5.1.3 Battery interface. 725

Replaceable battery interface. 727

As stated. 728

Charger connection. 730

As stated. 731

4.5.1.4 Charging with radios attached. 733

N/A. 734

4.5.1.5 Battery hot swap. 736

As stated. 737

Battery detect. 739

As stated. 740

4.5.1.6 STANREC 4819 compliance. 742

As stated. 743

4.5.2 USB ports. 745

4.5.2.1 USB Type-A receptacles. 747

As stated. 748

4.5.2.2 USB Type-C receptacles. 750

As stated. 751

4.5.3 Operability. 753

As stated. 754

4.5.3.1 Ease of systems operation. 756

As stated. 757

4.5.3.2 User interface. 759

As stated. 760

4.5.4 System characteristics. 762

4.5.4.1 On / off switch. 764

As stated. 765

4.5.4.2 Power on self-test. 767

As stated. 768

4.5.4.3 Power sharing. 770

N/A. 771

Power sharing hot swap. 773

N/A. 774

4.5.4.4 Upgradeability. 776

As stated. 777

New battery configurations. 779

As stated. 780

4.5.4.5 Cooling. 782

Visually inspect the charger to establish whether fan(s) are present. Verify through analysis (such as 783 system block diagrams or schematics) whether the charger utilizes fans for cooling. If so, verify through 784 demonstration that all fans can be removed and replaced without tools, or using a Phillips #1 or #2 785 screwdriver. At 22°C ±2°C, load the charger with a full set of discharged CWBs such that the charger 786 operates at maximum power. When all fans are active, verify that the acoustic level during operation is 787

<35 dB at a distance of 1 meter. 788

4.5.4.6 Vehicle mounting. 790

N/A. 791

4.5.4.7 Ground post. 793

N/A. 794

4.5.5 Electrical characteristics. 796

4.5.5.1 Input voltage, AC. 798

Add: Verify through test with a battery charging configuration causing the charger to operate at full load 799 at 22°C±2°C, the charger utilizes no less than 1,500 Volt-Amps (VA) from a 120 VAC, 60 Hz source. 800

TABLE X. Input voltage – frequency matrix. 802

As stated.

4.5.5.2 Input voltage, DC. 804

As stated. 805

4.5.5.3 Limited power sources. 807

Verify through examination that the charger includes user-selectable AC & DC power limiting with limits 808 specified in 3.5.5.3. Verify that the factory default limits are set to Full Power for AC and DC. Verify 809 through demonstration that the “custom” level can be changed. Verify through demonstration the charger 810 limits the AC power to each selected level by loading the charger with a full set of batteries and 811 monitoring the AC power source as the power limit setting is changed. Verify through demonstration the 812 charger limits the DC power to each selected level by loading the charger with a full set of batteries and 813 monitoring the DC power source as the power limit setting is changed. 814

4.5.5.4 Automatic restart. 817

As stated. 818

4.5.5.5 Maximum power point tracking. 820

N/A. 821

4.5.5.6 Vehicle power. 823

N/A. 824

4.5.5.7 Reserved.AC power limit negotiation (objective) 826

Verify though test that the charger can limit power draw in order to prevent overloading of a generator 827 supplying AC power. 828

4.6 Electrical conditions. 830

4.6.1 Electromagnetic interference (EMI). 832

As stated. 833

4.6.1.1 CE102 (Conducted Emissions, Radio Frequency Potentials, Power Leads). 835

As stated. 836

4.6.1.2 CS101 (Conducted Susceptibility, Power Leads). 838

As stated. 839

4.6.1.3 CS114 (Conducted Susceptibility, Bulk Cable Injection). 841

As stated. 842

4.6.1.4 CS115 (Conducted Susceptibility, Bulk Cable Injection, Impulse Excitation). 844

As stated. 845

4.6.1.5 CS116 (Conducted Susceptibility, Dampened Sinusoidal Transients, Cables and Power 847

Leads). 848

As stated. 849

4.6.1.6 CS118 (Conducted Susceptibility, Personnel Borne Electrostatic Discharge). 851

As stated. 852

TABLE XI. CS118 Discharge Table. 854

Discharge Location Type

1 Case (closed), Left Side Contact (±8 kV) & Air (±15 kV)

2 Case (closed), Right Side Contact (±8 kV) & Air (±15 kV)

3 Case (closed), Front Contact (±8 kV) & Air (±15 kV)

4 Case (closed), Back Contact (±8 kV) & Air (±15 kV)

5 Case (closed), Top Contact (±8 kV) & Air (±15 kV)

6 Case (closed), Bottom Contact (±8 kV) & Air (±15 kV)

7 Carrying handle Contact (±8 kV) & Air (±15 kV)

8 AC input socket, Ground Contact (±8 kV) & Air (±15 kV)

9 AC input socket, Line Contact (±8 kV) & Air (±15 kV)

10 AC input socket, Neutral Contact (±8 kV) & Air (±15 kV)

11 DC input connector, +VDC Contact (±8 kV) & Air (±15 kV)

12 DC input connector, Gnd Contact (±8 kV) & Air (±15 kV)

13 DC input connector, Shell Contact (±8 kV) & Air (±15 kV)

14 Digital display Contact (±8 kV) & Air (±15 kV)

15 Control button(s)/knob(s) Contact (±8 kV) & Air (±15 kV)

16 Charger contact(s) for battery interface (adapter) Contact (±8 kV) & Air (±15 kV)

17 Battery interface (adapter) contacts for batteries Contact (±8 kV) & Air (±15 kV)

18 USB Type-A socket(s), Shell Contact (±8 kV) & Air (±15 kV)

19 USB Type-C socket(s), Shell Contact (±8 kV) & Air (±15 kV)

4.6.1.7 RE102 (Radiated Emissions, Electric Field). 856

As stated. 857

4.6.1.8 RS103 (Radiated Susceptibility, Electric Field). 859

As stated. 860

4.6.2 Reserved. 862

4.6.3 AC spikes and surges. 864

As stated. 865

4.6.4 DC spikes and surges. 867

As stated. 868

4.7 Environmental conditions. 870

As stated. 871

4.7.1 Temperature. 873

4.7.1.1 Operation. 875

Low temperature operation. 877

As stated. 878

High temperature operation. 880

As stated. 881

4.7.1.2 Storage. 883

Low temperature storage. 885

As stated. 886

High temperature storage. 888

As stated. 889

4.7.2 Humidity. 891

As stated. 892

4.7.3 Low pressure (altitude). 894

As stated. 895

4.7.4 Salt fog. 897

As stated. 898

4.7.5 Solar radiation. 900

As stated. 901

4.7.6 Temperature shock. 903

Add: Procedure to be conducted with the charger in transport configuration. 904

4.7.7 Transit. 906

4.7.7.1 Loose cargo. 908

Place the charger in transport configuration and subject it to loose cargo testing in accordance with MIL-909

STD-810 Method 514 Procedure II for not less than 20 minutes in duration. During Step 4 conduct a BFT 910 as defined in 4.3.2 to determine operational status. Initial orientation shall be in the normal transportation 911 condition. Before and after testing, an operational checkout shall be performed and shall consist of the 912

BFT of 4.3.2. Verify that no damage occurs to the charger. 913

4.7.7.2 Transit drop. 915

The charger and accessories shall be tested in transport configuration. Verification shall be conducted in 916 accordance with Method 516, Procedure IV, of MIL-STD-810. Six samples shall be tested. Three of the 917 samples shall be tested at the minimum temperature of 3.7.1.2.1 and three of the samples shall be tested at 918 the maximum temperature of 3.7.1.2.2. All samples shall be dropped once on each face, edge, and corner. 919

All samples shall be soaked at the target temperature for a minimum of two hours, and all drops shall be 920 performed within thirty minutes of removal from the environmental chamber. After the completion of all 921 drops, verify that the charger remains functional by conducting a BFT as defined in 4.3.2. 922

4.7.8 Crash hazard shock. 924

N/A. 925

4.7.9 Vibration. 927

Verification test shall be conducted with the charger in transport configuration. Test in accordance with 928

MIL-STD-810 Method 514, Procedure I, (General vibration, operational service), Category 4 using the 929 composite wheeled vehicle vibration profile spectra (Figure 514.6C-3/Table 514.6C-VI). Conduct 930 operational checkout during Step 13 and as specified in the procedure using the BFT of 4.3.2. Verify that 931 no materials used to assemble the charger become dislodged during test. Repeat the verification for each 932 of the 3 major excitation axes. 933

TABLE XII. Battery configurations for vibration shock testing. 934

N/A

4.7.10 Immersion. 936

Add: Procedure to be conducted with the charger in transport configuration. 937

4.7.11 Sand and dust. 939

As stated. 940

4.7.12 Rain. 942

As stated. 943

4.7.13 Fungus. 945

As stated. 946

4.7.14 Icing. 948

As stated. 949

4.7.15 Parachute landing fall impact. 951

N/A. 952

4.8 System safety. 954

4.8.1 General safety. 956

As stated. 957

4.8.1.1 Touch current (leakage current). 959

As stated. 960

4.8.1.2 Electric strength. 962

As stated. 963

4.8.1.3 Retained charge. 965

As stated. 966

4.8.2 Electrical shock. 968

As stated. 969

4.8.3 Short circuit. 971

As stated. 972

4.8.4 Over/under-temperature. 974

As stated. 975

4.8.5 Safety features. 977

As stated. 978

4.8.5.1 Radioactive or hazardous materials. 980

As stated. 981

4.8.5.2 Non-rechargeable batteries. 983

As stated. 984

4.8.5.3 Surface temperature. 986

Load the charger with sixteen conformal wearable batteries and four USB PD 100W devices. Each battery 987 shall be less than 20% state of charge. The ambient temperature shall be 25°C +/- 3°C. Charge the 988 batteries and continually monitor the surface temperature of the charger during the charge to 95% or 989 higher state of charge. Verify that no surface temperature exceeds the touch temperature of MIL-STD-990

1472. 991

Repeat test at 45°C +/- 3°C. Store the charger and batteries at temperature for no less than four (4) hours 993 before starting charge. Charge the batteries and continually monitor the surface temperature of the 994 charger during the charge to 95% or higher state of charge. Verify that no surface temperature exceeds the 995 touch temperature of MIL-STD-1472. 996

4.8.5.4 Power outputs. 998

As stated. 999

4.9 Reliability. 1001

The following reliability test shall be performed on 3 charger systems to demonstrate requirements of 3.9. 1002

The systems shall accumulate a total cumulative hours of 895 operational hours with 3 maximum 1003 allowable failures. No one charger system shall accrue less than 220 hours. A failure is any hardware or 1004 firmware event that results in the inability of the charger to meet any specified performance requirements. 1005

Each charger shall be subjected to repeated 24-hour operational cycles, as described below, until the total 1007 cumulative hours are met. For all charging sessions, batteries under charge shall start from less than 10% 1008 state of charge. If necessary, to keep the charger in a charging state, charged batteries can be replaced 1009 with depleted batteries as needed for the duration of each charging session. For the purposes of this test, 1010 four PRC-148 batteries, two BB-2590 batteries, eight CWBs, two USB devices, and two USB PD 1011 devices, shall be referred to as a Battery Test Set. 1012

a. Place the charger in a test chamber capable of maintaining 45 ± 3°C. Connect the charger to a 120 1014

VAC source. 1015

b. At ambient room temperature (21 ± 3°C) load the charger with the Battery Test Set and begin 1016 charging. Charge batteries for not less than 4 hours. Remove batteries from charger, but leave the 1017 charger turned on. 1018

c. Set the chamber to 45 ± 3°C. Once the test temperature is reached allow the test items to stabilize 1019 for not less than four hours. 1020

d. Load the charger with the Battery Test Set and begin charging. Charge the batteries for not less 1021 than 4 hours. At the end of the charging session remove batteries from the charger. 1022

e. Place the charger in a vibration test chamber and subject the charger to Test Method Procedure I - 1023

General Vibration of MIL-STD-810. The vibration levels shall be as identified in Figure 514.6C-1024

3 - Category 4 - Composite Wheeled Vehicle Vibration Exposure. 1025

f. Connect the charger to a 120 VAC source. Load the charger with the Battery Test Set and start 1026 charging. Subject the charger with charging batteries to the vibration levels described by step e 1027 above for not less than 4 hours. This step shall be performed at ambient room temperature. 1028

g. Perform Basic Functional Test on the charger and batteries. Document any defects and anomalies. 1029

Remove batteries from charger, but leave the charger turned on. Allow the charger to soak at 1030 ambient room temperature (21 ± 3°C) for not less than 4 hours. 1031

h. Turn the charger off completely, and allow the charger to soak at ambient room temperature (21 ± 1032

3°C) for not less than 4 hours. 1033

i. Repeat cycle starting from step a until the chargers have accumulated the required operational 1034 hours. 1035

4.10 System accessories. 1037

As stated. 1038

4.10.1 Solar panel. 1040

N/A. 1041

4.10.1.1 Solar panel characteristics. 1043

N/A. 1044

4.10.1.2 Power output at different solar angles. 1046

N/A. 1047

4.10.2 External AC to DC converter. 1049

N/A. 1050

4.10.2.1 Environmental requirements. 1052

N/A. 1053

4.10.3 Cables. 1055

As stated. 1056

4.10.3.1 AC input cable. 1058

As stated. 1059

4.10.3.2 DC power interface cable. 1061

Verify through demonstration that the DC power interface cable is capable of mating with the DC input 1062 connector (see 3.4.8.2) on the charger. Verify that the DC cable has unterminated leads of length 3 +/- 1 1063 inches on the opposing end. Verify that the DC power interface cable has stranded copper based wire and 1064 is measured to be 6 feet +/- 3 inches long. (See 3.10.3.2) 1065

4.10.3.3 DC extension cord cable (18 ft.). 1067

N/A. 1068

4.10.4 Additional DC inputs. 1070

N/A. 1071

4.10.4.1 NATO slave input power adapter. 1073

Verify through examination that the NATO slave plug meets the requirements of a Type I receptacle per 1074

NATO STANAG 4074 and that no special tools are required. 1075

4.10.4.2 Alligator clips input power adapter. 1077

N/A. 1078

4.10.5 Hard cover. 1080

Through examination verify that the charger has an integrated or removable protective covering for 1081 transportation. 1082

Verify through visual inspection, and/or test, and/or analysis that the system cover: 1084

a. Is the same color as the charger (see 3.4.3). 1085

b. Has all lusterless quick release latching mechanisms and connectors (e.g. snaps, rivets, etc). Hook 1086 and loop straps (e.g. Velcro™) are not to be used. 1087

c. Does not have any sharp protrusions. 1088

d. Is capable of storing the AC input cable and a full set of adapters required for charging batteries. 1089

e. Has a strong carrying handle capable of supporting the weight the charger and AC cord. Apply a 1090 total of 60 lbs below the handle and lift 10 times 1 meter and verify that there is no degradation to 1091 the handle or cover attachment to the charger. 1092

4.10.6 Soft cover. 1094

N/A. 1095

4.10.7 Transportation case. 1097

N/A. 1098

4.11 Repairability. 1100

As stated. 1101

5 PACKAGING 1103

5.1 Packaging. 1105

As stated. 1106

6 NOTES 1108

6.1 Intended use. 1110

The bulk charger is a man-portable universal battery charger with interfaces to support a variety of current 1111 and future military batteries. The bulk charger should be rugged, one man lift when carried, stacked for 1112 storage, or transported in a vehicle. 1113

6.2 Acquisition requirements. 1115

As stated. 1116

6.3 Battery interfaces. 1118

As stated. 1119

6.4 Government-run test. 1121

As stated. 1122

6.5 Random tests. 1124

As stated. 1125

6.6 Lessons learned and other information. 1127

As stated. 1128

6.7 Definitions. 1130

As stated. 1131

6.8 Subject term (key word) listing. 1133

As stated. 1134

7 APPENDIX(ES). 1135

7.1 APPENDIX A 1137

As stated. 1138