MIL-PRF-XXXXX - charger top level - 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.

INCH-POUND

MIL-PRF-#####

3 September 2024

Performance Specification 1

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

General Specification for 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. 11

This specification covers battery chargers used by the US military. Detailed electrical and physical 12 requirements for individual chargers are specified on specification sheets. 13

2 APPLICABLE DOCUMENTS 15

2.1 General. 17

The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section 18 does not include documents cited in other sections of this specification or recommended for additional 19 information or as examples. While every effort has been made to ensure the completeness of this list, 20 document users are cautioned that they must meet all specified requirements of documents cited in 21 sections 3, 4, or 5 of this specification, whether or not they are listed. 22

Comments, suggestions, or questions on this document should be emailed peosoldierstp@army.mil. Since 24 contact information can change, you may want to verify the currency of this address information using the 25

ASSIST Online database at https://assist.dla.mil. 26

AMSC N/A FSC 6130 33

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. 34

2.2.1 Specifications, standards, and handbooks. 36

The following specifications, standards, and handbooks form a part of this document to the extent 37 specified herein. Unless otherwise specified, the issues of these documents are those cited in the 38 solicitation or contract. 39

DEPARTMENT OF DEFENSE STANDARDS 41

MIL-STD-130 Identification Marking of U.S. Military Property 42

MIL-STD-461 Requirements for the Control of Electromagnetic Interference 43

Characteristics of Subsystems and Equipment 44

MIL-STD-810 Department of Defense Test Method Standard 45

MIL-STD-1275 Department of Defense Interface Standard: Characteristics of 28 46

Volt DC Input Power to Utilization Equipment in Military 47

Vehicles 48

MIL-STD-1472 Department of Defense Design Criteria Standard: Human 49

Engineering 50

MIL-STD-3009 Department of Defense Interface Standard: Lighting, Aircraft, 51

Night Vision Imaging System (NVIS) Compatible 52

MIL-STD-13231 Marking of Electronic Items 53

(Copies of these documents are available online at https://assist.dla.mil) 55

2.2.2 Other Government documents, drawings, and publications. 57

The following other Government documents, drawings, and publications form a part of this document to 58 the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in 59 the solicitation or contract. 60

ADS-37A-PRF Electromagnetic Environmental Effects (E3) Performance and 61

Verification Requirements 62

(Relevant pages of this document can be found in APPENDIX A herein) 63

Title 47 FCC Part 15 Federal Communications Commission rules and regulations 64 regarding unlicensed transmissions 65

(Copies of this document can be found at http://www.fcc.gov/encyclopedia/rules-regulations-title-47) 66

2.3 Non-Government publications. 68

The following documents form a part of this document to the extent specified herein. Unless otherwise 69 specified, the issues of these documents are those cited in the solicitation or contract. 70 http://www.fcc.gov/encyclopedia/rules-regulations-title-47

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) 72

ASME Y14.38 Abbreviations and Acronyms 73

(Copies of this document are available from ASME at www.asme.org) 74

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC) 76

IEC 60320-3 Appliance couplers for household and similar general purposes – 77

Part 3: Standard sheets and gauges 78

(Copies of this document are available from online from IEC at www.iec.ch) 79

NEMA: National Electrical Manufacturers Association 81

ANSI/NEMA WD 6-2002 Wiring Devices - Dimensional Requirements 82

(Copies of this document are available from online from ANSI at webstore.ansi.org) 83

SAE INTERNATIONAL 85

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

(Copies of this specification are available online from SAE International www.sae.org) 87

SMART BATTERY CHARGER IMPLEMENTATION FORUM 89

Smart Battery Charger Specification, Rev 1.1 90

(Copies of this specifications are available online from SBS-IF at www.sbs-forum.org) 91

UNDERWRITERS LABORATORIES 93

UL 60950-1 Information Technology Equipment 94

(Copies of this specifications are available online from UL at www.ul.com) 95

USB IMPLEMENTERS FORUM 97

Battery Charging Specification, Revision 1.2 98

Universal Serial Bus Specification 3.2 Revision 3.1 99

(Copies of these specifications are available online from USB-IF at www.usb.org) 100 file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.asme.org file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.iec.ch https://webstore.ansi.org/ file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.sae.org file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.sbs-forum.org http://www.ul.com/ file:///C:/Users/ari.herman/Documents/Chargers/CLBC/www.usb.org

2.4 Order of precedence. 102

Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this 103 document and the references cited herein, the text of this document takes precedence. Nothing in this 104 document, however, supersedes applicable laws and regulations unless a specific exemption has been 105 obtained. 106

3 REQUIREMENTS 108

3.1 Specification sheets. 110

The individual item requirements shall be as specified herein and in accordance with the applicable detail 111 specification sheet. In the event of any conflict between the requirements of this specification and the 112 detail specification sheet, the latter shall govern. 113

3.2 Inspections. 115

3.2.1 First article. 117

When specified (See 6.2), a sample of chargers shall be subject to first article inspection in accordance 118 with 4.1. 119

3.2.2 Certification of conformity. 121

Certification of conformity shall be provided for the following requirements. The Government reserves 122 the right to verify any or all certifications. 123

TABLE I. Requirements requiring certification. 125

Requirement Paragraph

Handles. 3.4.6

Non-proprietary connectors. 3.4.8.1

Chemical agents. 3.4.10

Charger connection. 3.5.1.3.2

Upgradeability. 3.5.4.4

Reserved. 3.6.2

General safety. 3.8.1

Touch current (leakage current). 3.8.1.1

Electric strength. 3.8.1.2

Retained charge. 3.8.1.3

Radioactive or hazardous materials. 3.8.5.1

3.3 Reserved. 127

3.4 Physical characteristics. 129

3.4.1 Dimensions. 131

Requirement(s) will be shown on the applicable specification sheet. 132

TABLE II. System dimensions. 134

Requirement(s) will be shown on the applicable specification sheet.

3.4.2 Weight. 137

Requirement(s) will be shown on the applicable specification sheet. 138

3.4.3 Color. 140

Requirement(s) will be shown on the applicable specification sheet. 141

3.4.4 Visual inspection. 143

Products will be inspected prior to delivery to the government in samples or groups (size/frequency to be 144 agreed upon with the government). The charger and all components shall be free from defects including 145 but not limited to the following: 146

a. Loose screws or fasteners. 147

b. Misaligned parts. 148

c. Chips or scratches in the finish. 149

d. Dents. 150

e. Burrs or sharp edges. 151

f. Misaligned or peeling labels. 152

g. Material occluding electrical contacts. 153

Verify in accordance with 4.4.4. 154

3.4.5 Stackable. 156

Requirement(s) will be shown on the applicable specification sheet. 157

3.4.5.1 Vertical alignment. 159

Requirement(s) will be shown on the applicable specification sheet. 160

3.4.6 Handles. 162

The charger shall have a carrying handle(s) that meets all requirements stated in MIL-STD-1472 for 163 handles and grasp areas for a gloved or mittened hand. Certification of compliance with MIL-STD-1472 164 is required. Verify in accordance with 4.4.6. 165

3.4.6.1 Handle strength. 167

The charger carrying handle(s) shall be capable of withstanding forces not less than three times the weight 168 of the charger. Verify in accordance with 4.4.6.1. 169

3.4.7 Transport configuration. 171

Requirement(s) will be shown on the applicable specification sheet. 172

3.4.8 System connectors. 174

All connections shall have some form of tethered protection from damage when not in use. Connections 175 shall not present a snag hazard when the charger is placed in a rucksack. Connector protectors may 176 extend, when in use, beyond the surface of the charger, subject to the limits defined in section 3.4.1. 177

Connector protectors shall not come loose during charger use, transportation, or storage. The connector 178 protectors shall withstand not less than 5 lbs. of pull force when not on the connector. Verify in 179 accordance with 4.4.8. 180

3.4.8.1 Non-proprietary connectors. 182

All system connectors, including battery interfaces, shall be open sourced (see 6.7.14). Verify in 183 accordance with 4.4.8.1. 184

3.4.8.2 DC input connector. 186

Requirement(s) will be shown on the applicable specification sheet. 187

TABLE III. DC connector pin definitions. 189

Requirement(s) will be shown on the applicable specification sheet.

Will be shown on the applicable specification sheet.

FIGURE 1. DC connector pin locations. 191

3.4.8.3 AC input connector. 193

Requirement(s) will be shown on the applicable specification sheet. 194

3.4.8.4 System modular connector. 196

Requirement(s) will be shown on the applicable specification sheet. 197

3.4.8.5 USB ports. 199

There shall be no less than two USB Dedicated Charging Ports (DCP) that are Standard-A Dedicated 200 receptacles compliant with Figure 6-7 of the USB Specification Revision 2.0. The maximum supported 201 current of the port(s) shall be clearly labeled near the ports (ex. “2.4A”). The maximum supported current 202 may be for individual, or all ports, but shall be clearly labeled as such. The port(s) shall have tethered 203 cover(s) that can be installed and removed without the use of tools. The cover(s) shall be replaceable 204 using a Phillips screwdriver. Verify in accordance with 4.4.8.5. 205

There shall be no less than one USB Type-C PD port. The maximum power of the port(s) shall be clearly 207 labeled near the port(s) (ex. “PD100W”). The maximum supported power may be for individual, or all 208 ports, but shall be clearly labeled as such. The port(s) shall have tethered cover(s) that can be installed and 209 removed without the use of tools. The cover(s) shall be replaceable using a Phillips size screwdriver. 210

Verify in accordance with 4.4.8.5. 211

3.4.8.6 Firmware upgrade port. 213

The charger shall include a port to allow for field programmable software / firmware updates. The 214 firmware upgrade port shall be protected by a removable cover when not in use. The use of a PH0 or PH1 215 screwdriver is permitted for the user to access this port. Verify in accordance with 4.4.8.6. 216

3.4.9 Indicators. 218

All indicators/displays shall be readable in full sunlight at a distance of at least 3 feet and be NVIS 219 compatible (see 6.7.12). Verify in accordance with 4.4.9. 220

3.4.9.1 Blackout mode. 222

The charger shall provide a user selectable blackout mode wherein all indicators are disabled per user 223 demand. When in blackout mode, there shall be no visible light emissions from any display. There shall 224 be a method for the user to activate the charger displays at a reduced brightness. The charger shall have 225 the ability to be turned on and boot directly to a reduced brightness mode. Verify in accordance with 226

4.4.9.1. 227

3.4.9.2 Charger status indicators. 229

The charger shall provide a visual indication of system status and battery charging status. Each battery’s 230 charging status shall be displayed as indicated below in TABLE IV: 231

TABLE IV. Battery charging indicators. 233

Indication: Meaning / Remarks

Amber – Green –Red alternating Power on self-test

Rapid Flashing Amber Battery pre-charge check – initiated within 60 seconds of battery being emplaced.

Solid Amber Battery Charging

Flashing Green Battery Charged to > 90% of capacity

Solid Green Battery Fully charged (> 95%)

Solid Green for 1 sec with Solid Red for 1 sec alternating

Battery charged, State of Health (SoH)* less than 80%, but, battery charged to its maximum

Solid Amber for 1 sec to Solid Red for 1 sec alternating.

Battery Temperature too hot or too cold to charge

Solid Red Battery Fault

Flashing Red Charger Fault

*State of Health, see 6.7.19 234

Verify in accordance with 4.4.9.2. 236

Battery capacity. 238

The charger shall have the capability to indicate the current available charge in each battery with a 239 minimum of 5 increments or a digital display (see 3.4.9.3). The interpretation of the capacity reading shall 240 be clearly marked on the charger. Displays that use 5 increments shall illuminate the increments as 241 follows: 242

SEGMENTS STATE OF CHARGE

0 0% (Fully Discharged)

1 1 to 20%

2 21 to 40%

3 41 to 60%

4 61 to 80%

5 81 to 100%

The battery for which the state of charge is currently displayed shall be clearly indicated to the operator. 245

(See also 3.5.5.5). Verify in accordance with 4.4.9.2.1. 246

3.4.9.3 Digital display. 248

The charger shall provide digital (LCD or similar) display(s) which indicates, at a minimum: 249

a. State of charge (%) for each battery 250

b. State of health (%, see 6.7.19) for each battery. May be accessible through a menu or button 251 selection. 252

c. Estimated time to complete charge for each battery (hh:mm format). May be accessible through a 253 menu or button selection. 254

d. Any system or battery faults. 255

Verify in accordance with 4.4.9.3. 257

3.4.10 Chemical agents. 259

The charger and accessories shall be decontaminable to a level which permits negligible risk (less than 260 five-percent incapacitation) to unprotected personnel after an exposure period not to exceed 24 hours. 261

Verify in accordance with 4.4.10. 262

3.4.11 Marking. 264

The charger and all component markings shall conform to MIL-STD-13231. The charger shall have an 265

Item Unique Identification Device (IUID) not less than ½ inch square, in accordance with MIL-STD-130. 266

Verify in accordance with 4.4.11. 267

3.4.11.1 Nameplate label. 269

The charger shall have a nameplate label. The material used for this label shall be non-reflective. The 270 label shall have a background color that conforms to 3.4.3 with contrasting text color. The charger shall 271 use character sizes in compliance with MIL-STD-130. Verify in accordance with 4.4.11.1. 272

Nameplate information. 274

The user readable nameplate label shall include the IUID matrix in accordance with MIL-STD-130 and 275 both shall include the following information: 276

a. PP-XXXX (battery charger nomenclature when available) 277

b. National Stock Number (NSN) 278

c. Contract number 279

d. Serial number 280

e. Manufacturer’s part number 281

f. Manufacturer’s Commercial And Government Entity (CAGE) Code 282

g. Date of Manufacture (MM/YYYY) 283

h. Hardware revision number 284

i. Initial firmware revision number (see 3.4.8.2) 285

The nameplate label shall be visible to the operator. The material used for the label shall be weather-286 resistant and capable of withstanding the tactical and environmental requirements of this specification. 287

Verify in accordance with 4.4.11.1.1. 288

3.4.11.2 Firmware version label. 290

The charger shall have a label indicating the firmware version which is installed on the charger. There 291 shall be provisions for the user to permanently indicate (e.g. using an indelible marker) newer versions on 292 the label upon applying upgrades. Verify in accordance with 4.4.11.2. 293

3.4.11.3 Visibility of assembly markings. 295

Markings shall be readily visible with no disassembly of the charger other than the removal of the hard or 296 soft covers. Verify in accordance with 4.4.11.3. 297

3.4.11.4 Battery interface nameplate labels. 299

All adapters for battery charging shall be labeled in accordance with MIL-STD-130 and shall include the 300 following information: 301

a. System name (PP-XXXX) 302

b. Adapter name 303

c. National Stock Number (NSN) 304

d. Manufacturer’s part number 305

e. Serial number 306

f. Initial firmware revision number 307

g. Manufacturer’s Commercial and Government Entity (CAGE) Code 308

Verify in accordance with 4.4.11.4. 309

3.4.11.5 Battery interface markings. 311

Adapters shall be marked to identify the following information. 312

a. Battery(ies) charged by the adapter 313

b. Battery position (see 6.7.4) corresponding to the display 314

3.4.11.6 Power input/output label. 316

The charger shall include a permanent label indicating power input & output specifications. Power input 317 shall be labeled in accordance with 3.5.5.1 and 3.5.5.2. Power output shall be labeled as the maximum 318 possible power output for the battery interfaces (see 3.5.4.4.1). Additionally, this label should detail all 319 possible USB DCP and USB PD port modes including voltages and maximum current levels. Verify in 320 accordance with 4.4.11.6. 321

3.5 Performance characteristics. 323

3.5.1 Battery charging. 325

When operating at 21°C± 3°C, the charger shall be no less than 80% efficient when taking input power 326 and distributing it to a full set of one type of battery. The charger shall be capable of charging batteries in 327 the 4-33.6V range. The charger shall be capable of physically accepting and charging the batteries shown 328 in section 3.5.1.1. While operating on its maximum specified input power, the charger shall charge the 329 listed number of a specific battery, as shown in section 3.5.1.1, to 90% state of charge within the listed 330 time. The charger shall continue charging batteries until 100% state of charge. Section 3.5.1.1 provides 331 the number of each battery type, minimum factory capacity, and maximum times allowed for charging up 332 to >90% SOC depleted batteries. Verify in accordance with 4.5.1. 333

3.5.1.1 Battery types and charge times. 335

Requirement(s) will be shown on the applicable specification sheet. 336

TABLE V. Basic configuration and charge times. 338

Requirement(s) will be shown on the applicable specification sheet.

3.5.1.2 Charging protocols. 341

The charger shall charge only ‘smart’ (battery and charger communicate) batteries or batteries with 342 charge enable pin. If the charger does not recognize the battery or establish communications, the battery 343 shall not be charged and an error message per 3.4.9.2 shall be displayed. Verify in accordance with 344

4.5.1.2. 345

System management bus (SMBus). 347

The charger shall be a Level 2/3 charger per Smart Battery Charger Specification Revision 1.1. The 348 charger shall safely charge SMBus configured batteries, with a dedicated SMBus channel for each 349 battery. The charger shall have at least two, independent cutoffs of power for battery type and temperature 350 faults. The charger shall verify both SMBus safety signal pin and SMBus data prior to applying charge 351 voltage and continuously during charging. The charger shall ensure that safely charging the battery is 352 placed above meeting battery requested SMBus charging values. Verify in accordance with 4.5.1.2.1. 353

The charger shall include active pull-up circuits for SMBus clock and data signals to counter signal 355 degradation over cables, connectors, and contact pads. The charger shall perform SMBus clock generation 356 and arbitration according to the SMBus specification §4.3 to accommodate smart batteries acting as bus 357 master or slave. Verify in accordance with 4.5.1.2.1. 358

Direct Query (DQ) protocol. 360

The charger shall be compliant to Texas Instrument’s BQ2050 standard sets and timing requirements. The 361 charger shall safely charge DQ configured batteries. Verify in accordance with 4.5.1.2.2. 362

Charging priority. 364

During prioritization the charger shall interrogate each battery/device connected to it to determine which 365 is at the highest state of charge. The battery/device at the highest state of charge shall have charging 366 priority in terms of power distribution. Priority shall be given to batteries over USB connected devices. 367

When power is being prioritized, the USB dedicated charging ports shall provide a minimum of 1 A to be 368 distributed between USB connectors, and any available power remaining shall be dedicated to the Type C 369

PD ports. Verify in accordance with 4.5.1.2.3. 370

Over-discharged batteries. 372

The charger shall attempt to revive over-discharged batteries. If communication or positive ID (in the case 373 of a non-smart battery) is not established within 5 minutes, the charger shall cease to attempt to charge the 374 battery and indicate the fault to the user (see para 3.4.9.2). The charger shall not attempt to charge the 375 battery again until the battery is physically removed and reinserted by the user. Verify in accordance with 376

4.5.1.2.4. 377

3.5.1.3 Battery interface (adapters). 379

Replaceable battery interface. 381

The charger shall have the ability to be reconfigured to meet specific mission requirements through the 382 use of interchangeable battery interfaces. The interchangeable battery interfaces shall allow the user to 383 charge the batteries at the quantity stated as listed in 3.5.1.1, at a minimum, and provide a platform for 384 future expansion. Each battery interface shall have a self-alignment feature to guide battery insertion and 385 disallow reverse insertion. The battery interfaces shall not use cables. The battery interface shall remain 386 secured to the charger when in use and during transport. The battery interface shall be replaceable without 387 the use of any tools and shall be able to be replaced in not greater than 30 seconds while wearing standard 388 tactical military gloves. The battery interface shall be replaceable without the use of any tools while 389 wearing Mission Oriented Protective Posture (MOPP) IV protective equipment and Cold Weather Glove 390

System. There shall be provisions for battery interface to self-align with the charger. Battery interfaces 391 should be optimized to charge the maximum amount of batteries with the least amount of space and 392 volume. Verify in accordance with 4.5.1.3.1. 393

Charger connection. 395

The mechanical design, the connections to the charger, and the communications protocol between the 396 charger and the battery interface shall be open sourced (see 6.7.14). All user accessible connections shall 397 withstand 1000 mate / de-mate cycles. Verify in accordance with 4.5.1.3.2. 398

3.5.1.4 Charging with radios attached. 400

The charger shall allow charging of at least 4 handheld radios (AN/PRC-148, AN/PRC-152, and 401

AN/PRC-163) without a cover. The charger shall support 4 of the same handheld radio type with battery 402 pack attached and additional hardware, cable or adapters. The charger shall support a blend of 403 aforementioned handheld radio types with battery pack attached and no additional hardware, cable or 404 adapters. There shall be a failsafe mechanism in the battery interface (see 3.5.1.3) to protect the radio 405 from damage in the event of a charger failure. Verify in accordance with 4.5.1.4. 406

3.5.1.5 Battery hot swap. 408

The charger shall allow for removal of batteries at any time during charge without adversely affecting the 409 battery or charger. The charger shall allow for batteries to be inserted to any open port at any time the 410 charger is in operation, and the charger shall recognize the battery in not greater than 15 seconds. Verify 411 in accordance with 4.5.1.5. 412

Battery detect. 414

When no battery is present, available current at charge contacts shall be limited to not greater than 100 415 mA. Verify in accordance with 4.5.1.5.1. 416

3.5.1.6 STANREC 4819 compliance. 418

The charger shall be compliant with NATO STANREC 4819 for interoperable charging. 419

3.5.2 USB ports. 421

3.5.2.1 USB Type-A receptacles. 423

The USB DCP receptacles (see 3.4.8.5) shall be compliant with Battery Charging Specification, Revision 425

1.2 (of the USB Implementers Forum) and source not less than 2 A each, subject to available charging 426 power (see 3.5.1.2.3). Verify in accordance with 4.5.2.1. 427

3.5.2.2 USB Type-C receptacles. 429

The USB Type-C PD port(s) shall be compliant with the Universal Serial Bus Power Delivery 431

Specification Revision 3.2 Version 1.0 (October 2023). The port(s) role shall be PD source. The port(s) 432 may optionally support PD role swap to sink in order to power the charger. The port(s) shall support 433

Standard Power Range modes with a PDP of 100W minimum. The port(s) may optionally support Extend 434

Power Range up to 240W. The port(s) may optionally support Programmable Power Supply charging 435 models. The port(s) shall be USB PD power only (no data). Verify in accordance with 4.5.2.2. 436

3.5.3 Operability. 438

The charger shall be operable, maintainable, and supportable by the central 90th percentile Soldiers (per 439

MIL-STD-1472). All of the functions and interfaces of the charger shall be designed to be operated by 440

Soldiers wearing Mission Oriented Protective Posture (MOPP) IV and Cold Weather Glove System. 441

Verify in accordance with 4.5.3. 442

3.5.3.1 Ease of systems operation. 444

The charger shall be capable of being operated while using one hand while wearing Army Combat 445

Gloves. The use of two hands to change battery interfaces is permitted. Verify in accordance with 4.5.3.1. 446

3.5.3.2 User interface. 448

Operational use modes shall be apparent to the user without special training or printed manuals present. 449

All modes of operation shall be indicated to the user either by text on the charger, indicators, or through 450 interactive menus. No operation shall take more than 5 actions / steps to activate any mode / function. 451

Verify in accordance with 4.5.3.2. 452

3.5.4 System characteristics. 454

3.5.4.1 On / off switch. 456

The charger shall include an on / off switch. When powered off, the charger shall draw no more than 120 457 milliwatts. The switch shall be protected against inadvertent operation. Verify in accordance with 4.5.4.1. 458

3.5.4.2 Power on self-test. 460

The charger shall perform a self-test when powered on and shall indicate any fault condition to the user as 461 a flashing RED status indicator of the charging port that is not functional. The charger shall commence 462 the battery pre-charge check within 10 seconds from power on. Verify in accordance with 4.5.4.2. 463

3.5.4.3 Power sharing. 465

Requirement(s) will be shown on the applicable specification sheet. 466

Power sharing hot swap. 468

Requirement(s) will be shown on the applicable specification sheet. 469

3.5.4.4 Upgradeability. 471

The charger shall be upgradable without being returned to the manufacturer. Firmware loader supported 472 operating system shall be Windows 10 or later. All firmwar e and firmware loading applications shall be 473 open sourced (see 6.7.14) with the appropriate Certificate of Net-worthiness to permit installation on DoD 474 computer systems. Verify in accordance with 4.5.4.4. 475

New battery configurations. 477

The charger shall be field upgradeable to support new batteries that have cell configurations and voltages 478 ranging from a minimum of 4V to 33.6V. 479

Any new or modified battery interfaces needed to upgrade the charger to support the new battery 481 configuration shall meet the requirements of 3.5.1.3. New or modified battery interfaces shall not require 482 a charger firmware or software update. The upgraded charger shall meet all of the requirements herein. 483

Verify in accordance with 4.5.4.4.1. 484

3.5.4.5 Cooling. 486

Requirement(s) will be shown on the applicable specification sheet. 487

3.5.4.6 Vehicle mounting. 489

Requirement(s) will be shown on the applicable specification sheet. 490

Will be shown on the applicable specification sheet.

FIGURE 2. Vehicle mounting interfaces. 492

3.5.4.7 Ground post. 493

The charger shall have a permanently installed ground post that connects to a continuous chassis ground. 494

The ground post will be a 10-32 threaded stud, no less the ¼ inch in length and shall be easily accessible. 495

The ground post length will not exceed the maximum envelope of the charger, and when not in use, will 496 not prevent the stacking or storage of multiple chargers. Verify in accordance with 4.5.4.7. 497

3.5.5 Electrical characteristics. 499

3.5.5.1 Input voltage, AC. 501

The charger shall be able to operate at any voltage in the range of 110 to 240 VAC at any frequency from 502

50 to 60 Hz. The charger shall withstand a droop in AC voltage down to 80 VAC without sustaining 503 permanent damage. During a voltage droop, the charger may power off but shall recover automatically 504 when normal voltage is restored. Verify in accordance with 4.5.5.1. 505

3.5.5.2 Input voltage, DC. 507

The charger shall be able to operate at any voltage in the range of 10 to 33.6 VDC. The charger shall not 508 be damaged by inputs of 9 to 46 VDC minimum to protect against items such as solar panel open circuit 509 voltages. The charger shall not draw more than 46 Amps DC. The charger shall not be damaged by 510 reverse voltage in the range of 9 to 46 VDC. Verify in accordance with 4.5.5.2. 511

3.5.5.3 Limited power sources. 513

Requirement(s) will be shown on the applicable specification sheet. 514

3.5.5.4 Automatic restart. 516

The charger shall automatically resume charging connected batteries when input power is lost and 517 subsequently restored. Verify in accordance with 4.5.5.4. 518

3.5.5.5 Maximum power point tracking. 520

The DC input shall automatically utilize maximum power point tracking (MPPT) technology or similar 521 input voltage tracking methods to attain the highest level of power available from solar panels operating 522 in the 10 – 33.6 VDC range defined above (see 3.5.5.2). The charger shall draw not less than 90% of the 523 absolute maximum power available from a solar panel under the present conditions for inputs no less than 524

20 W. The charger shall indicate to the user relative solar power consumption, defined as power output to 525 the batteries, which will change with battery load and available solar power. The algorithm update period 526 shall be once every 0.01 seconds or faster. MPPT algorithm efficiency must be performed in compliance 527 with the EN50530 dynamic MPPT testing regiment. The MPPT operation shall be in effect under all 528 battery charging conditions, including mixed battery types and mixed battery state of charge. Verify in 529 accordance with 4.5.5.5. 530

3.5.5.6 Vehicle power. 532

Requirement(s) will be shown on the applicable specification sheet. 533

3.5.5.7 Reserved. 535

3.6 Electrical conditions. 537

3.6.1 Electromagnetic interference (EMI). 539

The charger shall comply with the following emission and susceptibility requirements of MIL-STD-461. 540

3.6.1.1 CE102 (Conducted Emissions, Radio Frequency Potentials, Power Leads). 542

Conducted emissions on power leads shall not exceed the limit values shown on Figure CE102-1. Verify 543 in accordance with 4.6.1.1. 544

3.6.1.2 CS101 (Conducted Susceptibility, Power Leads). 546

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified 547 indications, when subjected to a test signal with voltage levels as specified on Figure CS101-1. Verify in 548 accordance with 4.6.1.2. 549

3.6.1.3 CS114 (Conducted Susceptibility, Bulk Cable Injection). 551

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified 552 indications, when subjected to an injection probe drive level which has been pre-calibrated to the 553 appropriate current limit shown on Figure CS114-1 and is modulated as specified in CS114. The 554 appropriate limit curve on Figure CS114-1 shall be selected from CS114 Table VI for Army Ground 555 platform and frequency range. Verify in accordance with 4.6.1.3. 556

3.6.1.4 CS115 (Conducted Susceptibility, Bulk Cable Injection, Impulse Excitation). 558

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified 559 indications, when subjected to a pre-calibrated signal having rise and fall times, pulse width, and 560 amplitude as specified on Figure CS115-1 at a 30 Hz rate for one minute. Verify in accordance with 561

4.6.1.4. 562

3.6.1.5 CS116 (Conducted Susceptibility, Dampened Sinusoidal Transients, Cables and Power 564

Leads). 565

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified 566 indications, when subjected to a signal having the waveform shown on Figure CS116-1 and having a 567 maximum current as specified on Figure CS116-2. The limit is applicable across the entire specified 568 frequency range. Verify in accordance with 4.6.1.5. 569

3.6.1.6 CS118 (Conducted Susceptibility, Personnel Borne Electrostatic Discharge). 571

The charger shall withstand (survive) ESD to ±8kV contact discharge and ± 15kV air discharge on any 572 surface, panel component, or connector, including exposed pins, in both operating and non-operating 573 mode. Verify in accordance with 4.6.1.6. 574

3.6.1.7 RE102 (Radiated Emissions, Electric Field). 576

Electric field emissions shall not be radiated in excess of those shown on Figure RE102-4 Navy Mobile & 577

Army curve. Above 30 MHz, the limits shall be met for both horizontally and vertically polarized fields. 578

Verify in accordance with 4.6.1.7. 579

3.6.1.8 RS103 (Radiated Susceptibility, Electric Field). 581

The charger shall not exhibit any malfunction, degradation of performance, or deviation from specified 582 indications, when subjected to the radiated electric fields listed in MIL-STD-461 Table XI (Ground) and 583 modulated as specified. Up to 30 MHz, the requirement shall be met for vertically polarized fields. Above 584

30 MHz, the requirement shall be met for both horizontally and vertically polarized fields. Circularly 585 polarized fields are not acceptable. Verify in accordance with 4.6.1.8. 586

3.6.2 Reserved. 588

3.6.3 AC spikes and surges. 590

The AC input of the charger shall withstand ±2kV surges, line-to-line and line-to-ground. Verify in 591 accordance with 4.6.3. 592

3.6.4 DC spikes and surges. 594

The charger shall operate properly and not sustain any damage from normal transients present on 28V 595 military ground vehicle DC buses in accordance with MIL-STD-1275. Verify in accordance with 4.6.4 596

3.7 Environmental conditions. 598

The charger and all components essential for its operation shall withstand the following environmental 599 conditions. The finish shall remain intact and shall not peel, chip, crack, nor bubble following any of the 600 following conditions (with the exception of the transit requirements of 3.7.7). Verify in accordance with 601

4.7. 602

3.7.1 Temperature. 604

3.7.1.1 Operation. 606

Low temperature operation. 608

The charger shall operate at a minimum ambient temperature of -25°F (-32°C). When tested as specified 609 in 4.7.1.1.1, the charger shall experience no deleterious or unsafe effects and meet the full specification 610 performance. Verify in accordance with 4.7.1.1.1. 611

High temperature operation. 613

The charger shall operate at a maximum ambient temperature of 120°F (49°C). When tested as specified 614 in 4.7.1.1.2, the charger shall experience no deleterious or unsafe effects and meet the full specification 615 performance. Verify in accordance with 4.7.1.1.2. 616

3.7.1.2 Storage. 618

Low temperature storage. 620

The charger non-operating shall withstand a minimum ambient temperature of -40°F (-40°C). When 621 tested as specified in 4.7.1.2.1, the charger shall experience no deleterious or unsafe effects and meet the 622 full specification performance. Verify in accordance with 4.7.1.2.1. 623

High temperature storage. 625

The charger non-operating shall withstand a maximum ambient temperature of 160°F (71°C). When 626 tested as specified in 4.7.1.2.2, the charger shall experience no deleterious or unsafe effects and meet the 627 full specification performance. Verify in accordance with 4.7.1.2.2. 628

3.7.2 Humidity. 630

The charger shall withstand high temperature-humidity conditions during both storage and operation. 631

When tested as specified in 4.7.2, the charger shall exhibit no physical damage such as corrosion, rust, 632 blistering, or deterioration of parts and materials and shall meet full specification performance. Verify in 633 accordance with 4.7.2. 634

3.7.3 Low pressure (altitude). 636

The charger shall operate up to 15,000 feet above sea level and shall be transportable up to 40,000 feet 637 above sea level. During and after testing as specified in 4.7.3, the charger shall meet full specification 638 performance. Verify in accordance with 4.7.3. 639

3.7.4 Salt fog. 641

The charger shall be operable in a salt fog atmosphere. When tested as specified in 4.7.4, the charger shall 642 experience no deleterious effects and shall meet full specification performance after testing. Verify in 643 accordance with 4.7.4. 644

3.7.5 Solar radiation. 646

The charger shall be capable of withstanding prolonged exposure to sunlight. When tested as specified in 647

4.7.5, the charger shall remain operational, experience no deleterious effects, and shall meet full 648 specification performance after testing. Verify in accordance with 4.7.5. 649

3.7.6 Temperature shock. 651

The charger shall withstand temperature shock in the range of -60°F (-51°C) to +160°F (+71°C). When 652 tested as specified in 4.7.6, the charger shall experience no deleterious effects and shall meet full 653 specification performance after testing. Verify in accordance with 4.7.6. 654

3.7.7 Transit. 656

The charger shall be ruggedized and shall remain fully functional after transportation in a military tactical 657 vehicle. Verify in accordance with 4.7.7. 658

3.7.7.1 Loose cargo. 660

The charger shall experience no negative performance effects from loose cargo while stored in transit 661 case. The charger shall have no manufacturing materials become dislodged. Full specification 662 performance shall be met after testing. Verify in accordance with 4.7.7.1. 663

3.7.7.2 Transit drop. 665

The charger shall experience no negative performance effects from transit drop (without transit case). The 666 charger shall have no manufacturing materials become dislodged. Full specification performance shall be 667 met after testing. Verify in accordance with 4.7.7.2. 668

3.7.8 Crash hazard shock. 670

The charger, hard cover, and the batteries contained within shall not become secondary projectiles when 671 exposed to a Crash Hazard. Verify in accordance with 4.7.8. 672

3.7.9 Vibration. 674

The charger and accessories (as appropriate) shall remain operational while in a moving vehicle when 675 properly integrated. Verify in accordance with 4.7.9. 676

3.7.10 Immersion. 678

The charger and accessories (as appropriate) shall be capable of being immersed and have drain holes (or 679 similar features) as appropriate to minimize water retention. After testing as specified in 4.7.10, the 680 charger shall remain fully functional. Verify in accordance with 4.7.10. 681

3.7.11 Sand and dust. 683

Without any protective cover in place, the battery charger and accessories shall function after exposure to 684 blowing dust. The battery charger and accessories shall function properly when configured as above after 685 exposure to blowing sand environments. After testing as specified, the battery charger shall meet full 686 specification performance. Verify in accordance with 4.7.11. 687

3.7.12 Rain. 689

Without any protective cover in place, the charger and accessories shall function properly while exposed 690 to rain. During and after testing as specified in 4.7.12, the charger and accessories shall meet full 691 specification performance. Verify in accordance with 4.7.12. 692

3.7.13 Fungus. 694

The charger and accessories, when tested, shall show no fungal growth. Verify in accordance with 4.7.13. 695

3.7.14 Icing. 697

The charger shall operate during and after exposure to icing/freezing rain, and shall not sustain damage 698 following exposure. Verify in accordance with 4.7.14. 699

3.7.15 Parachute landing fall impact. 701

The charger and its accessories shall be able to survive a parachute landing fall impact when placed in a 702 medium rucksack with material emulating a standard Falcon packing list gear without any adverse impact 703 to charger or its accessories when packed together. Verify in accordance with 4.7.15. 704

3.8 System safety. 706

3.8.1 General safety. 708

As applicable, the charger and accessories shall meet the requirements of UL 60950-1. Verify in 709 accordance with 4.8.1. 710

3.8.1.1 Touch current (leakage current). 712

The charger and accessories shall meet the requirements of UL 60950-1 section 5.1. Verify in accordance 713 with 4.8.1.1. 714

3.8.1.2 Electric strength. 716

The charger and accessories shall meet the requirements of UL 60950-1 section 5.2. Verify in accordance 717 with 4.8.1.2. 718

3.8.1.3 Retained charge. 720

The charger and accessories shall meet the requirements of UL 60950-1 sections 2.1.1.7 and 2.1.1.8. 721

Verify in accordance with 4.8.1.3. 722

3.8.2 Electrical shock. 724

The charger and accessories shall not present an electrical shock hazard to the user under all operational 725 conditions. Verify in accordance with 4.8.2. 726

3.8.3 Short circuit. 728

The charger and all applicable accessories shall be protected against damage due to any overload or short 729 circuit condition. The charger and all applicable accessories shall resume operation upon removal of fault 730 condition. Verify in accordance with 4.8.3. 731

3.8.4 Over/under-temperature. 733

The charger shall not charge batteries when battery temperature is below 32°F (0°C) or above 122°F 734

(50°C) unless otherwise dictated by a smart battery. Verify in accordance with 4.8.4. 735

3.8.5 Safety features. 737

3.8.5.1 Radioactive or hazardous materials. 739

The charger and all accessories shall be free of hazardous or toxic materials such as luminous 740 dials/markings, Asbestos, Hexavalent Chromium, Mercury, Methyl Ethyl Ketone, Polychlorinated 741

Biphenyls (PCBs), Tetrachloroethylene, and Trichloroethylene. Lead, lead compounds, and cadmium 742 shall be permitted in small quantities and employed only where there will be minimal exposure of these 743 compounds to the user and where grinding, polishing and abrading of the material will not cause a toxic 744 inhalation hazard. Verify in accordance with 4.8.5.1. 745

3.8.5.2 Non-rechargeable batteries. 747

Electrical and/or mechanical methods shall be employed to ensure that the charger cannot charge any 748 non-rechargeable battery configurations. Verify in accordance with 4.8.5.2. 749

3.8.5.3 Surface temperature. 751

Under all full load configurations and while operating, no exposed surface of the charger and accessories 752 shall be in excess of the momentary or prolonged contact and handling limits of MIL-STD-1472. Verify 753 in accordance with 4.8.5.3. 754

3.8.5.4 Power outputs. 756

All connections which provide power, with exception of interfaces to batteries, shall be female (i.e. 757 sockets not pins). Verify in accordance with 4.8.5.4. 758

3.9 Reliability. 760

The charger shall have a Mean Time Between Essential Function Failure (MTBEFF) of no less than 500 761 hours. A MTBEFF is defined as any failure that causes the system to not meet the performance 762 requirements specified in paragraph 3.5 herein. Verify in accordance with 4.9. 763

3.10 System accessories. 765

3.10.1 Solar panel. 767

Requirement(s) will be shown on the applicable specification sheet. 768

3.10.1.1 Solar panel characteristics. 771

Requirement(s) will be shown on the applicable specification sheet. 772

3.10.1.2 Power output at different solar angles. 774

Requirement(s) will be shown on the applicable specification sheet. 775

TABLE VI. Solar angle of incidence. 777

Requirement(s) will be shown on the applicable specification sheet.

3.10.2 External AC to DC converter. 779

Requirement(s) will be shown on the applicable specification sheet. 780

3.10.2.1 Environmental requirements. 782

Requirement(s) will be shown on the applicable specification sheet. 783

3.10.3 Cables. 785

All wire cable terminal components and termination points shall not part from the connector when 786 subjected to twisting, pulling, or tension force. The cable assemblies herein shall not be damaged when 787 properly connected and subjected to 100 pounds of tension. Verify in accordance with 4.10.3. 788

3.10.3.1 AC input cable. 790

The AC Input Cable shall have an IEC 60320 type C13 connector on one end or tethered into the AC to 791

DC converter. The AC Input Cable shall have a 3 prong plug per figure 5-15 of ANSI/NEMA WD 6-2002 792 on the second end. The cable shall be 6 feet ± 3 inches long. The cable shall be a stranded wire with 3 793 conductors of minimum gauge required to meet safety requirements. The cable and plug shall be rated to 794 handle at least 15A current. Verify in accordance with 4.10.3.1. 795

3.10.3.2 DC power interface cable. 797

Requirement(s) will be shown on the applicable specification sheet. 798

Will be shown on the applicable specification sheet.

FIGURE 3. Non-shrouded two wire “trailer hitch” connector. 800

3.10.3.3 DC extension cord cable (18 ft.). 802

Requirement(s) will be shown on the applicable specification sheet. 803

3.10.4 Additional DC inputs. 805

Requirement(s) will be shown on the applicable specification sheet. 806

Will be shown on the applicable specification sheet.

FIGURE 4. Shrouded two wire “trailer hitch” connector. 808

3.10.4.1 NATO slave input power adapter. 810

Requirement(s) will be shown on the applicable specification sheet. 811

3.10.4.2 Alligator clips input power adapter. 813

Requirement(s) will be shown on the applicable specification sheet. 814

3.10.5 Hard cover. 816

Requirement(s) will be shown on the applicable specification sheet. 817

3.10.6 Soft cover. 819

Requirement(s) will be shown on the applicable specification sheet. 820

3.10.7 Transportation case. 822

Requirement(s) will be shown on the applicable specification sheet. 823

3.11 Repairability. 825

The charger shall be designed with the maximum amount of user reparability as possible. Special tools 826 and techniques shall not be required for repair. The use of commercially available parts shall be 827 maximized, and the overall repair part count shall be minimized. Verify in accordance with 4.11. 828

4 VERIFICATION 830

4.1 Verifications of inspections. 832

The inspection requirements specified herein are classified as follows: 833

a. First Article inspections (see 4.1.2). 834

b. Conformance inspection (see 4.2). 835

c. Certifications. Contractor shall provide written proof of all industry certifications with which the 836 product complies. 837

4.1.1 First article units. 839

Requirement(s) will be shown on the applicable specification sheet. 840

4.1.2 First article inspection. 842

The first article inspection shall consist of inspections specified in TABLE VIII under Production 843

Qualification Test (PQT), and when specified (see 6.2) the accessories (see 4.1.2) shall be tested one each 844 per charger. Tests shall be performed in the order indicated for each test sample. 845

4.1.3 Classification of verification. 847

Classifications of Verifications are as follows: 848

• Production Qualification Test (PQT) 849

• Quality Surveillance Test 850

• Government Test (Developmental and Operational) 851

The SOW guidance shall cover whether the PQT is a first article sample, a first production item, or the 852 number of test items. These documents shall also include specific instructions regarding arrangements for 853 examinations, approval of first article test results, and disposition of first articles. 854

4.1.4 Methods of verification. 856

Verification methods are provided in the below Table VII. 857

Table VII. Verification methods table. 859

Method Description

Analysis Involves a technical evaluation of design information such as equations, charts, graphs, drawings, schematics, and other data. If actual tests were conducted for a related or unrelated purpose, and utilization of these data will prove that requirement has been met, it should be considered “analysis”. Analysis methods include the use of modeling and simulation with a government-accredited model.

Demonstration Observable functional operation, under controlled conditions not requiring subsequent analysis of data, is used to verify that a given requirement is met.

Examination An element of verification and inspection consisting of investigation, without the use of special laboratory appliances or procedures, of items to determine conformance to those specified requirements which can be determined by such investigations. Examination is generally nondestructive, and typically includes the use of sight, hearing, smell, touch, and taste; simple physical manipulation; mechanical and electrical gauging and measurement; and other forms of investigation.

Test Involves observation or recording of data during operation of an item. Where “test” is the designated verification method, it is understood that some degree of analysis is inherent in the verification process and need not be so identified on the verification cross-reference matrix.

Where not otherwise noted, verifications shall be conducted at “room temperature” standard 861 temperature/altitude/humidity conditions. 862

4.1.5 Basis for verification. 864

Requirement(s) will be shown on the applicable specification sheet. 865

TABLE VIII. Performance Requirements - Verification Cross-Reference. 867

Requirement(s) will be shown on the applicable specification sheet.

TABLE IX. Applicable System Accessories for Test. 869

Requirement(s) will be shown on the applicable specification sheet.

4.2 Conformance inspection. 871

Conformance…