Attachment 0002 - MIL-DTL-53126A.pdf

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: US Army RDECOM CERDEC PRD, ATTN:

RDER-PRA-GS, Fort Belvoir, VA 22060-5817 Or e-mail: daniel.ojeifoh@us.army.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at: https://assist.dla.mil

AMSC N/A FSC 6150

Distribution Statement A. Approved for public release, distribution is unlimited.

INCH-POUND

MIL-DTL-53126A

16 October 2012

SUPERSEDING

MIL-E-53126(ME)

20 April 1992

DETAIL SPECIFICATION

POWER DISTRIBUTION, ILLUMINATION SYSTEMS, ELECTRICAL

GENERAL SPECIFICATION FOR

This specification is approved for use within US Army Research Development and Engineering Command, Communications and Electronics Research and Development Center, Product Realization Directorate, Department of the Army and is available for use by all Departments and Agencies of the Department of Defense.

1 SCOPE

1.1 Scope. This specification covers soldier-portable, power distribution systems for use with the DoD Standard Family of Generator Sets and illumination utility sets. Three of the end items are three phase systems, one is a single phase system, and the utility set contains extension cords, branch circuits and 1ighting equipment. The three phase systems can be used in various combinations with each other to create a power grid which is generally 1imited to a 100 feet radius per system (i.e. 300 feet total) in order to prevent excessive voltage loss. The utility set can be used with any of the systems to achieve internal shelter wiring and lighting.

1.2 Classification. The Power Distribution Illumination System, Electrical (herein after to be known as PDISE) are of the following types, as specified herein (see 6.2).

1.2.1 Type. The PDISE systems will be of the following types:

Type I Feeder System, electrical, three phase, single source

Type II Feeder System, electrical, three phase, multiple sources

Type III Distribution System, electrical, three phase

Type IV Distribution System, electrical, single phase

Type V Illumination System, single phase

Type VI Universal Adapter

Source: http://assist.dla.mil -- Downloaded: 2019-02-04T12:42Z Check the source to verify that this is the current version before use.

MIL-DTL-53126A

1.3 Rating. The PDISE are to be rated as follows:

Rating Model Description

200 Amps/Phase (A/P) M200 A/P Feeder System, electrical, three phase

100 Amps/Phase (A/P) M100 A/P Feeder System, electrical, three phase

60 Amps/Phase (A/P) M60 A/P Distribution System, electrical, single phase

40 Amps/Phase (A/P) M40 A/P Distribution System, electrical, three phase

2 APPLICABLE DOCUMENTS

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

2.2 Government documents.

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

SPECIFICATIONS

FEDERAL

A-A-1898 Cushioning Material, Celulosic, Packaging

A-A-3174 Plastic Sheet, Polyolefin

DEPARTMENT OF DEFENSE

MIL-DTL-52286 Cable Assembly, Power, Electrical (with Molded On Terminations), General Specifications for

MIL-DTL-53039 Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

SAE-AS34011 Connectors, Receptacle, Electric, Cable Connecting, Front Release, Crimp Contact, AN Type

SAE-AS34021 Connector, Receptacle, Electric, Box Mounting, Front Release, Crimp Contact, AN Type

SAE-AS34061 Connectors, Plug, Electric, Front Release, Crimp Contact, AN Type

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

MS90556 Connector, Plug, Electrical, Straight, Class L

MS90557 Connector, Receptacle, Electrical, Cable Connecting (without Coupling Ring), Class L

MS90558 Connector, Plug, Electrical Wall Mounting, (with Coupling Ring) Class L (Equipment)

MILITARY

MIL-DTL-22992 Connectors, Plugs and Receptacles, Electrical, Waterproof, Quick Disconnect, Heavy Duty Tape, General Specification for

MIL-DTL-53039 Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

MIL-DTL-53072 Chemical Agent Resistant Coating (CARC) System Application Procedures and Quality Control Inspection

MIL-DTL-64159 Camouflage Coating. Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant

MIL-L-85762 Lighting, Aircraft, Interior, Night Vision Imaging System (NVIS) Compatible

MIL-PRF-121 Barrier Materials, Greaseproof, Waterproof, Flexible, Heat-Sealable

MIL-T-704 Treatment and Painting of Material

(See Supplement 1 for a list of associated specification sheets).

STANDARDS

FEDERAL

FED-STD-595-34094 Color Used in Government Procurement

DEPARTMENT OF DEFENSE

MIL-STD-129 Military Marking for Shipment and Storage

MIL-STD-209 Lifting and Tiedown Provisions

MIL-STD-810 Environmental Engineering Considerations and Laboratory Tests

MIL-STD-882 System Safety

MIL-STD-889 Dissimilar Metals

MIL-STD-1472 Human Engineering

MIL-STD-1916 DoD Preferred Methods for Acceptance of Product

MIL-STD-2073-1E Standard Practice for Military Packaging

(Copies of these documents are available online at https://assist.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 1911-5094.)

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

2.2.2.1 Documents.

TM 9-6150-226-13 Technical Manual Operator and Field Maintenance Manual for Distribution Illumination Systems, Electrical (DISE) and Power Distribution Illumination Systems, Electrical (PDISE)

(Copies of the technical manuals required in connection with specific acquisition functions should be obtained from the US Army Communications and Electronics Command, ATTN:

AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846.)

2.2.2.2 Drawings.

TABLE I – Drawing list

DRAWING# NOMENCLATURE DRAWING # NOMENCLATURE

CECOM & PM-MEP Drawings - Cage Code: 97403 and 30554 13230E7022 Plate, Identification 13229E6352 Distribution System, Electrical, Single

Phase, 60 Amperes/Phase

13229E6353 Distribution System, Electrical, Single Phase, 40 Amperes/Phase

13226E7046 Utility Assembly, Electrical, Receptacles and Lighting

13230E7021 Packaging, PDISE M40/M60 A/P 08-26001 Packaging, PDISE M60

08-26000 Packaging, PDISE M40 13229E6351 Feeder System, Electrical, Three Phase, 100 Amperes/Phase

13230E7020 Packaging, PDISE M100 A/P 08-26002 Packaging, PDISE M100

08-26003 Packaging, PDISE M200 13229E6350 Feeder System, Electrical, Three Phase, 200 Amperes/Phase

13229E6362 Container, Storage, Utility

2.2.2.3 Catalogs and manuals.

FM 3-11.4 Multiservice Tactics, Techniques, and Procedures for

Nuclear, Biological and Chemical (NBC) Protection

(Copies of specifications, standards, handbooks, drawings, publications, and other Government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Officer.)

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

INTERNATIONAL

ASTM D1974/D1974M Standard Practice for Methods of Closing, Sealing, and Reinforcing Fiberboard Boxes

ASTM D3953 Steel and Seals, Flat, Strapping

ASTM D4675 Materials, Flat Strapping, Selection and Use of

ASTM D5118/D5118 Standard Practice for Fabrication of Fiberboard Shipping Boxes

ASTM

D5486/D65486M

Standard Specification for Pressure-Sensitive Tape for Packaging, box Closure, and Sealing

ASTM D6251/D625M Natural Wood-Cleaterd Panelboard Shipping Boxes

(Application for copies should be addressed to the 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 or copies are available from http://www.astm.org)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration Laboratories – Second Edition

ISO 10012 Quality Assurance Requirements for Measuring Equipment

(Application for copies should be addressed to the ISO Copyright office, Case postale 56, CH-1211 Geneva 20 or copies are available from www.iso.org)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA WD 6 Wiring, Devices – Dimensional Requirements

(Applications for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209 or copies are available from www.nema.org)

AMERICAN NATIONAL STANDARDS INSTITUTE, INC

ANSI Z535.2 Environmental and Facility Safety Signs

(Applications for copies should be addressed to the American National Institute, Inc. 1899 L Street, NW 11th Floor, Washington, DC 20036 or copies are available from www.ansi.org)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electric Code (NEC)

(Application for copies should be addressed to the National Fire Protection Association International, 1 Batterymarch Park, Quincy, MA 02269 or copies are available from www.nfpa.org)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE-ARP1199 Devices, Electric Overcurrent Protective, Selection, Application, and Inspection of

SAE AS34011 Connectors, Receptacle, Electric, Cable Connecting, Front Release, Crimp Contact, AN Type

SAE AS34021 Connector, Receptacle, Electric, Box Mounting, Front Release, Crimp Contact, AN Type with

SAE AS34061 Connectors, Plug, Electric, Front Release, Crimp Contact, AN Type

SAE AS50151 Connectors, Electrical, Circular Threaded, AN Type, General Specification For

(Application for copies should be addressed to the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA or copies are available from www.sae.org)

UNDERWRITER'S LABORATORIES INC. (UL)

UL 943 Interrupter, Ground-Fault Circuit - Standard For Safety

(Application for copies should be addressed to Underwriters Laboratories Inc., 333 Pfingston Road, Northbrook, IL 60062-2096 or copies are available from www.ul.com.)

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

3 REQUIREMENTS

3.1 Specification sheets. The individual item requirements shall be as specified herein and IAW the applicable specification sheets. In the event of any conflict between the requirements of this specification and the specification sheets, the latter shall govern.

3.1.1 Drawings. The drawings forming a part of this specification (as listed in the applicable specification sheets, MIL-DTL-53126/1, /2, /3, /4, /5), are end product drawings. No deviation from the prescribed drawing requirements is permissible without prior approval of the contracting officer. Where tolerances could cumulatively result in incorrect fits, the contractor shall provide tolerances within those prescribed on the drawings to ensure correct fit, assembly, and operation of the set. Any data (e.g. shop drawings, layouts, flow sheets, processing procedures, etc.) prepared by the contractor or obtained from a vendor to support fabrication and manufacture of the production item shall be made available, upon request, for inspection by the contracting officer or the designated representative.

3.2 First article. When specified (see 6.2), a sample shall be subjected to first article inspection IAW 4.1.

3.3 Materials. All material shall be as specified herein and on the drawings. Materials not specified shall be selected by the contractor and shall be subject to all provisions of this specification. Materials shall be of sufficient durability to meet the performance requirements, in any of the environments, specified herein. The PDISE and accessories shall not be made from, leach, or otherwise develop toxins, hazardous materials, or ozone depleting substances.

3.3.1 Deterioration prevention and control. The PDISE and accessories shall be fabricated from compatible materials, inherently corrosion resistant, or treated to provide protection against the various forms of corrosion and deterioration to which they are susceptible.

3.3.2 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials shall be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life-cycle costs. Used, rebuilt, or remanufactured components, pieces, and parts shall not be used.

3.3.3 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be used in intimate contact with each other unless protected against galvanic corrosion. Methods of protection against galvanic corrosion shall be IAW MIL-STD-889.

3.3.4 Design. The PDISE design shall be as specified herein and IAW the applicable specification sheets. The PDISE shall be capable of interfacing with all members of the DoD Standard Family of Generator sets which are capable of providing 120/208 V, 3 phase or 120 V, single phase power.

3.3.5 PDISE inputs. The PDISE shall be capable of connecting one generator set (Type I PDISE) or multiple generator sets (Type II PDISE). The PDISE input shall interface with the generator set using a 5-wire system. The 5-wire system shall consist of individual conductors per phase, neutral and ground/bonding. The single phase distribution system (Type III PDISE) shall use a 3-wire system where the phase, neutral and ground/bonding connections are individual conductors.

3.3.6 Main AC circuit interrupter. Each PDISE shall have a main AC circuit interrupter rated for the amperage capability of the system. This circuit interrupter shall be capable of disconnecting all input power from the output circuits. The AC circuit interrupter shall provide overload protection for each PDISE. The AC circuit interrupter shall activate at 125% rated current within 880 seconds. At loads above 125%, the AC circuit interrupter shall activate using an inverse time principle.

3.3.7 Output circuits. Each PDISE shall have output circuits as specified in the specification sheets. Each circuit shall be capable of being isolated from the main circuit by the operator. Output circuits shall meet the requirements of the NPFA 70.

3.3.8 Overload protection. Each output circuit shall be protected from current overload.

The overload protection shall be accomplished by the use of a resettable circuit breaker rated for 50/60 Hz operation, with solderless connector terminals, IAW the requirements of SAE ARP1199. The overload protection shall not trip for currents up to 125% of rated current for the circuit. This device shall activate within 880 seconds when 125% of rated current in any phase is reached. At currents above 125%, the AC circuit interrupter shall activate using an inverse time principle. Circuit breakers shall be capable of accurate operation in temperatures ranging from -40 °F to 185 °F.

3.3.8.1 Control panel. All controls and indicators shall be mounted on a control panel that is accessible from the exterior of the PDISE without the use of tools. The controls shall be protected from accidental activation/deactivation. Indicators shall be used to indicate status of the input and output circuits of the PDISE. The indicators and controls shall be separately grouped to indicate input(s) and outputs. The output circuit controls shall identify which circuit they are associated with. Circuit breakers shall be installed so that they are all aligned, in the “on” and “off” positions; and ganged for three phase circuits when appropriate. The PDISE control panel shall be protected from the environment by a hinged cover.

3.3.9 Housing. The PDISE shall be housed in a suitable container to prevent damage due to transportability, and operational environment requirements specified herein. The PDISE shall be skid mounted where the bottom of the housing shall be no less than 7 inches from the ground. The housing shall include:

a. A permanently attached hinged cover with a means to close the unattended cover, and latching device(s). A wiring diagram, with each circuit labeled, shall be permanently attached to the inside of the cover.

b. Carrying handles, capable of supporting the unit indefinitely, suitable for use by personnel wearing arctic mittens. The placement and quantity of handles shall be consistent with an individual lift capability of 40 pounds and afford a balanced distribution of the weight.

c. A configuration that directs the attaching cables toward the ground, to minimize strain, with sufficient clearance to ensure the NPFA 70, recommended bends for the cables are not encroached.

3.3.10 Illuminated indicators. All illuminated indicators shall meet the following secure lighting (blue/green) requirements:

a. Light sources shall consist of light emitting diodes (LEDs).

b. 95 percent of the light energy emitted by each light source shall be at wavelengths below 700 nanometers.

c. All light sources shall be visible in bright sunlight.

d. All light sources shall be compatible with NVIS Soldier equipment IAW

MIL-L-85762.

3.3.11 Illumination system. The PDISE Type V, Illumination System, single phase, shall consist of utility lights, extension cords, a branch circuit assembly, outlet boxes, etc. as described in the specification sheet (MIL-DTL-53126/5).

3.3.12 Universal adapter. The PDISE Type VI, Universal Adapter, shall enable the PDISE to interface with and provide power to any load.

3.3.13 Wiring. Wiring shall conform to NFPA 70. Where appropriate, all wires shall be secured neatly into harnesses. Wires in all harnesses shall be of the proper length and shall be so run and secured (with insulated clamps) as to protect insulation against contact with sharp corners and edges, pinching, sharp bending and twisting, abrasion due to vibration and exposure to fuel or lubricating oil. Wires shall not be spliced. All wires shall terminate in connectors, terminal lugs or tinned ends. Solder connection shall not be used except where connections are made to potentiometers, resistors, semiconductors, capacitors, and press-to-test indicator lights.

A means shall be provided to prevent liquids from coming in contact with any electrical connection for all operating conditions specified herein. Not more than two terminal lugs shall be attached with any one screw on screw type terminal boards, and not more than four terminal lugs shall be attached to any one stud on stud-type terminal boards. Terminals on electrical components shall not have more than one wire attached.

3.3.14 Wire and wire marking. Wire shall be multi-stranded copper conductor, flame retardant, moisture, heat and oil resistant IAW the NFPA-70. All wire shall be numbered for easy identification. Each wire shall be identified by circuit number and terminations. The marking shall be permanently applied to the wire to withstand all specified operating conditions herein throughout the life of the set. Marking shall be within three inches of each end and at intervals of 5 inches throughout the wire length. The wire numbering scheme shall be consistent with that currently being employed by Industry Standards. All wires shall be marked using black characters. Except when used in a cable, the use of colored wire coating as a marking scheme is prohibited.

3.3.15 Treatment and painting. Treatment and painting shall be IAW MIL-DTL-53072. Specific treatment and painting requirements are as specified in the specification sheets. All interior and exterior surfaces shall have a finish coat of Chemical Agent Resistive Coating (CARC) paint IAW MIL-DTL-64159 or MIL-DTL-53039 except as specified herein or on applicable drawings. The color shall be green 383, color chip 34094IAW FED- STD-595. The internal components may be finished with the manufacturer's standard commercial color and paint, plating, or treatment. Non-permissible galvanic couples (dissimilar metals) as defined in MIL-T-704 shall be insulated as specified in MIL-T-704.

3.3.15.1 Unpainted surfaces. The extension cables, utility lights, loose connector, non-metal containers, branch circuits, ropes and power cable assemblies shall not be painted.

3.3.16 Connectors. Input and output connectors shall be as specified in SAE-AS50151 and MIL-DTL-22992 (see TABLE II and Table III) IAW the specification sheets (MIL-DTL-53126/1, /2, /3, /4, /5) and drawings(see TABLE I). Each shall be identified by circuit number and amperage, consistent with corresponding identification on the control panel.

Receptacles shall be keyed to accept only a plug of the same rating. Connectors shall be provided with tethered environmental resistant covers.

3.3.16.1 Bulkhead connectors. Bulkhead connectors shall mate with MS90557 connectors, for input; and MS3406 and MS90556 connectors, for output as specified in the specification sheets (MIL-DTL-53126/1, /2, /3, /4). Location of connectors shall have sufficient clearance to facilitate coupling and de-coupling by personnel wearing arctic mittens, taking into account the captive caps and plugs. The bulkhead connectors shall be straight connectors, with covers, matching the following shell sizes and configurations:

TABLE II. Bulkhead connectors.

Rating Input (plugs) shall mate with

Output (sockets) shall mate with

200 A/P M90557C52413S —

100 A/P M90557C44413S M90556C44413P

60/40 A/P M90557C32413S M90556C32413P

60 ampere M90557C32405S —

20 ampere — M3406D16-10S

3.3.16.2 Cable connectors. Cable connectors shall mate with MS3401, MS3402, MS90555, and MS90557 connectors, for input; and MS3406, MS90556, and MS90558 connectors, for output as specified in the specification sheets (MIL-DTL-53126/1, /2, /3, /4, /5).

Cable connectors shall be straight connectors, with covers, matching the following shell sizes and configurations:

TABLE III. Cable connectors.

Rating Input (plugs) shall mate with

Output (sockets) shall mate with

200 A/P — M90557C52413S M90558C52413P M90556C52413P

100 A/P M90555C44413S M90557C44413S M90558C44413P M90556C44413P

60/40 A/P M90555C32413S M90557C32413S M90558C32413P M90556C32413P

60 ampere — M90557C32405S M90558C32405P M90556C32405P

20 ampere M3402D16-10S M3401D16-10S — M3406D16-10S

3.3.17 Receptacle assembly. The receptacle assembly shall consist of an input connector (see 3.3.16.2) fitted, 120V, 20 ampere, electrical lead, 12.00 ± 1.00 inches long, terminating in two dual duplex, straight blade, isolated ground, output receptacles IAW NEMA WD 6, 5-20R, housed in a weatherproof box. The receptacles shall conform to UL 943 and be wired IAW NFPA 70.

3.3.18 Cables. Cable design shall be IAW the drawings specified in the individual specification sheets. All cables shall comply with the requirements of NFPA 70, for flexible cords and cables and shall be IAW individual specification sheets (MIL-DTL-53126/1, /2, /3, /4, /5).

3.3.18.1 Input interface cable assembly. The input interface cable assembly shall be 4 ± 0.25 feet long, exclusive of the connector, and rated as specified herein and in the individual specification sheets (MIL-DTL-53126/1, /2, /3, /4, /5). One end of the cable assembly shall have an output connector (see 3.3.16.2) and the other end shall have the shielding stripped 14.50 ±

0.50 inches, with the individual conductors stripped 1.00 ± 0.25 inch, and protected against fraying.

3.3.18.2 200 A/P cable assembly. The 200 A/P cable assembly shall be 25 ± 0.25 feet long, exclusive of the connectors and rated as specified herein and in the individual specification sheet (MIL-DTL-53126/1). One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 200 A/P service.

3.3.18.3 100 A/P cable assembly. The 100 A/P cable assembly shall be 50 ± 0.25 feet long, exclusive of the connectors and rated as specified herein and individual specification sheet (MIL-DTL-53126/2). One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 100 A/P service.

3.3.18.4 40/60 A/P cable assembly. The 40/60 A/P cable assembly shall be 50 ± 0.25 feet long, exclusive of the connectors and rated as specified herein and in the individual specification sheet (MIL-DTL-53126/3). One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 40/60 A/P service.

3.3.18.5 60 ampere cable assembly. The 60 ampere cable assembly shall be 100 ± 0.25 feet long, exclusive of the connectors and rated as specified herein and in the individual specification sheet (MIL-DTL-53126/4). One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 60 ampere service.

3.3.18.6 20 ampere cable assembly. The 20 ampere cable assembly shall be provided in the following lengths: 50 ± 0.25 feet long and 25 ± 0.25 feet long, exclusive of the connectors and rated as specified herein and in the individual specification sheets (MIL-DTL-53126/3, /4).

One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 20 ampere service; both connectors shall be supplied with backshells.

3.3.18.7 Extension cable assembly. The extension cable assembly shall be 15 ± 0.25 feet long, exclusive of the connectors and rated as specified herein and in the individual specification sheets (MIL-DTL-53126/5). One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 20 ampere service; both connectors shall be supplied with backshells.

3.3.18.8 Transition cable assembly. The transition cable assembly shall be a single female molded-plug terminated cable, 3 ± 0.25 feet long, IAW MIL-C-52286; rated for 120V, 20 ampere service. It shall be fitted with an input connector (see 3.3.16.2) with a backshell.

3.3.18.9 Branch circuit assembly, 12-outlet. The branch circuit assembly shall be a 120V, 20 ampere trunk, 24 ± 0.25 feet long, with three drop lead taps, 12.00 ± 1.00 inches long, spaced 96.00 ± 2.00 inches apart in the middle of the trunk, exclusive of the connectors and rated as specified herein and in the individual specification sheet (MIL-DTL-53126/5). These junctions shall be constructed with reinforced eyelet holes of sufficient strength to suspend the branch circuit assembly from installed “S” hooks. The trunk run shall have an input connector on one end, an output on the other, and each branch fitted with an output connector (see 3.3.16.2) with backshells. Each branch shall have a receptacle assembly IAW 3.3.17 attached to provide the branch circuit assembly.

3.3.18.10 In-line GFCI cable assembly. The in-line GFCI cable assembly shall be a maximum of 3.0 feet, inclusive of the connectors and rated as specified herein and in the individual specification sheets (MIL-DTL-53126/3, /4, /5). One end shall have an input connector and the opposite end an output connector (see 3.3.16.2) rated for 20 ampere service;

both connectors shall be supplied with backshells.

3.3.19 Straps.

3.3.19.1 Cinching strap. The cinching strap shall be IAW the individual specification sheets (MIL-DTL-53126/3, /4, /5) and shall be made of hook and pile tape or other functionally equivalent materials. It shall be constructed of a length of the hook portion of the tape with a 1-inch (internal) D-ring attached at one end and a 2.00 inch length of the pile portion attached to the other. Other materials used shall permit fastening at any point along the length of the strap looped back onto itself through the D-ring, which shall be capable of being accomplished by a person (see 3.5.9) wearing arctic mittens. The overall length of the strap assembly shall be 18.00 ± 0.25 inches, and the strap shall be made from 1.00-inch wide stock. Unless otherwise specified (see 6.2), the color shall approximate camouflage green, color no. 34094 of FED-STD-595.

3.3.19.2 Single-strap carrier. The single strap carrier shall be IAW the individual specification sheets (MIL-DTL-53126/3) and shall encompass and hold cable assemblies and provide means of easy transporting of the cable assembly. It shall be made of textile webbing or other pliable material of similar strength, capable of being cinched by a self-clasping buckle attached at one end. If the material used is susceptible to fraying, means shall be employed to ensure that it will not interfere with issue through or the functioning of the buckle. The overall length of the strap portion shall be 20.75 ± 0.25 inches, and the strap shall be made from 1.50-inch wide stock. Unless otherwise specified (see 6.2), the color shall approximate camouflage green, color no. 34094 of FED-STD-595. A carrying handle, of the same material, shall be permanently attached to the strap adjacent to the buckle. The handle shall be suitable for use by personnel (see 3.5.9) wearing arctic mittens. An identification tag, of the same or similar material in white, shall be permanently attached to the strap in a conspicuous location.

3.3.19.3 Double-strap carrier. The double-strap carrier shall be IAW the individual specification sheets (MIL-DTL-53126/1, /2, /4)and shall be of the same construction as the single-strap (see 3.3.19.2) but shall consist of two straps, 27.75 ± 0.25 inches long, joined below the carrying handle to form an assembly 10.00 ± 0.50 inches across. The handle of the carrier shall be attached, one strap to the other, across the assembly.

3.3.20 Transit and storage containers. Cabling and accessories shall be stored in transit containers as specified in the individual specification sheets (MIL-DTL-53126/3, /4, /5). The containers shall be reusable and protect the cabling and accessories during all transportation and storage modes. The transit and storage container shall be sized appropriately to contain all cables and accessories as specified in the individual specification sheets (MIL-DTL-53126/3, /4, /5)

3.4 Interface.

3.4.1 Power source compatibility. The feeder and distribution systems and electrical ancillary items shall physically inter-connect with DoD Standard Family of Generator sets, which operate at 120 volts, single phase and 120/208 volts, three phase, at 50 Hz or 60 Hz. Each system shall be usable with 120/130 volt, 50 Hz or 60 Hz, commercial utility power.Interconnection. The feeder, distribution and illumination systems shall interconnect with one another in order to form an electrical grid.

3.4.3 Universal adapter. The universal adapter shall provide a universal interface for loads that cannot interface using output connectors as specified herein.

3.5 Environmental parameters. The PDISE feeder and distribution systems shall withstand the following environmental conditions:

3.5.1 Operating temperatures. The PDISE shall perform continuously for not less than 12 hours, in any ambient temperature from -25 °F to 120 °F, without performance degradation, or mechanical or electrical failure.

3.5.2 Storage temperatures. The PDISE shall withstand indefinite storage in any ambient temperature from -50 °F to 160 °F, without subsequent performance degradation, or mechanical or electrical failure.

3.5.3 High/low pressures. The PDISE shall be operable, transportable, and storable at elevations up to 10,000 feet above sea level, and shall withstand normal atmospheric pressure changes during operation. It shall be air transportable through varying atmospheric pressures, and shall survive rapid decompression.

3.5.4 Humidity. The PDISE shall withstand prolonged storage and operation in all possible relative humidities, with ambient temperatures ranging from -50°F to 160°F (-46°C to 52°C) at sea level.

3.5.5 Fungus and moisture resistance. The PDISE shall withstand the effects of fungus and moisture. The electrical circuitry, components, and connections that are not inherently fungus and moisture resistant or hermetically sealed shall be protected from fungus growth and moisture by an appropriate coating treatment.

3.5.6 Rain. The PDISE shall operate with 5 inches (127 millimeters) of rain per hour impinging on the PDISE at angles from vertical up to 45 degrees.

3.5.7 Sand and dust. The PDISE shall operate in a sand and dust environment with particle concentrations up to 1,400 milligrams per cubic meter (mg/m³) and particle sizes ranging from less than 74 micrometers in diameter to 1,000 micrometers with the bulk of the particles ranging in size from 74 to 350 micrometers.

3.5.8 Chemical, Biological, Radiological and Nuclear (CBRN) Contamination Survivability. The PDISE shall have a Chemical Agent Resistant Coating (CARC) painted as specified herein. The PDISE shall be capable of being serviced and maintained by personnel wearing Mission Oriented Protective Posture (MOPP) IV chemical, biological, and radiological clothing (see 6.5.4) without special tools or support equipment.

3.5.9 Human Factors Engineering (HFE). The PDISE shall be designed IAW accepted criteria of design for HFE as described in MIL-STD-1472. The PDISE shall be operable and maintainable during day and night by 5th percentile female through 95th percentile male soldiers when wearing the clothing, which is appropriate to the environments detailed herein.

3.5.10 Safety. The PDISE shall meet the provisions of MIL-STD-882; Hazards and safety requirements of MIL-STD-1472; and the safety design criteria specified herein. Exposed parts of such nature as to be a hazard to personnel shall be insulated, enclosed or guarded without impairing the functioning of these parts. Except where functionally required, exposed surfaces shall be free from burrs, sharp edges and corners, or other features that present a personnel safety hazard (see 6.5.1); or shall be shielded against contact. Danger or caution signs, labels, and markings (see 3.6.2) shall be used to warn of potential or specific hazards. The sign(s) shall be prominently displayed on the PDISE, and visible from any angle of approach.

3.5.11 Transportability. The PDISE shall not be damaged by rough handling (see 6.5.5) which could be encountered during rail (see 6.5.6), truck or trailer (see 6.5.7), and aircraft transportation (see 6.5.1). The utility kit and feeder/distribution systems in operational mode but without cables attached shall be soldier-portable, indefinitely, over battlefield terrain, without damage (see 6.5.3) or malfunction. The utility storage box shall be capable of being stacked 8 boxes high without damage.

3.6 Marking. The PDISE shall have marking or permanently attached data plates, in a location where the data will be prominent and legible but not interfere with PDISE operation or maintenance. Legibility shall be IAW MIL-STD-1472 (see 3.5.9). Safety and instructional markings shall not be obscured by components, to include occasionally positioned levers, etc., from the operator's position. Marking shall be of a contrasting color to the surface on which it is inscribed, and indelible for the anticipated life of the PDISE. Plates shall be constructed of a durable material that is corrosion, ozone, and weather resistant.

3.6.1 Identification. The PDISE shall have an identification plate IAW drawing 13230E7022.

3.6.2 Safety, instructional, and component labeling. Warning and caution markings shall be IAW NEMA Z 535.2. For the systems, at a minimum, a “POWER IN” decal shall be located adjacent to the indicator(s); a warning decal stating “WARNING LETHAL VOLTAGE.

DISCONNECT POWER BEFORE SERVICING” shall be prominently positioned at access to the interior. The input and output connector ratings; the bus bars, connectors, and grounding points shall also be identified. The contents of the utility set shall be identified on the exterior of its storage container.

4 VERIFICATION

4.1 Classification of inspection. Inspections as specified herein, shall be classified as follows:

a. First article preproduction inspection (see 4.3).

b. Conformance inspection (see 4.4).

c. Inspection comparison (see 4.5).

d. Inspection of packaging (see 4.6).

4.2 Test schedule. Testing shall be performed on a complete assembled PDISE.

PDISE components may be networked, and tested as a single assembly. Components and other devices, or load banks shall be used to test throughput of the PDISE. Electric power shall be supplied from a regulated, three phase, 120/208 VAC, 50 or 60 Hz source. Unless otherwise specified in the contract, testing shall be performed in the sequence noted in TABLE IV.

TABLE IV - Test schedule.

1 2 3 4 5 First

Article Conformance

Inspection

P P T

SEE 4.3

I N D I

SEE 4.4

TEST

TEST METHOD (MIL-STD-705)

AND

TEST PARAGRAPH

BASIC

REQUIREMENT

PARAGRAPH

X X Operational 4.7.1 3.1

X X Circuit Interrupter (Overload Current)

4.7.1.2, TM 512.2d 3.3.6, 3.3.8

X X Interface 4.7.1.3 3.4

X High Temperature TM 710.1d at 135°F (57°C) Operate for 2 hours.

3.5.1

X Size and Weight 4.7.4 3.1

X Safety 4.7.1.1 3.5.10

X Human engineering 4.7.1.1 3.5.9

X Rain 4.7.2.5; MIL-STD-810, TM 506.5

3.5.6

X Carry 4.7.3.1 3.5.11

X Stacking 4.7.3.2 3.1.3of

MIL-DTL-

53126A/5

TABLE V. - Additional test schedule.

1 2 3

TEST

TEST METHOD (MIL-STD-705)

AND

TEST PARAGRAPH

BASIC

REQUIREMENT

PARAGRAPH

Altitude test 4.7.2.3 3.5.3 Extreme Cold Storage 3.5.2; TM 731.1c 3.5.2

Drop 4.7.3.3 3.5.11 Fungus and moisture resistance 4.7.2.4; (TM 507.5, Procedure

II, MIL-STD-810)

3.5.5

Hot Storage Test 4.7.2.1 3.5.2

TABLE V. - Additional test schedule.

1 2 3

TEST

TEST METHOD (MIL-STD-705)

AND

TEST PARAGRAPH

BASIC

REQUIREMENT

PARAGRAPH

Humidity 4.7.2.4; (TM 507.5, Procedure

II, MIL-STD-810)

3.5.4

Lifting and Tie-down 4.7.3; MIL-STD-209 3.3.9b, 3.5.11 Low Temperature 4.7.2.2 3.5.1 Railroad Impact 4.7.3; MIL-STD-810, TM 526 3.5.11 Sand and dust 4.7.2.6; MIL-STD-810, TM

510.5 3.5.7

Transportability 4.7.3 3.5.11

4.3 First article preproduction inspection. The preproduction PDISE shall be examined and tested as specified herein to determine compliance with this specification and the applicable specification sheets (see 3.1). This inspection shall include the examination of 4.3.1 and the tests of 4.3.2. Non-conformance to any specified requirement, the presence of one or more defects, or the failure of any test shall constitute cause for rejection.

4.3.1 Examination of PDISE. The PDISE shall be examined for defects and conformance to the TDP. The defects include those listed in TABLE VI. Circuit breaker, connector, and internal wire markings and terminations shall be verified for all circuits.

Evidence that the PDISE do not comply with the drawings shall be cause for rejection of the

PDISE.

4.3.1.1 Examination of components and subassemblies. Examination of components and subassemblies shall be made prior to assembly of the PDISE. Evidence of any components or subassemblies that do not comply with the requirements of this specification shall be cause for rejection of that component or subassembly.

TABLE VI – Examination schedule.

Exam Defect Exam method Reqt para

E1 Input interface cable assembly not as specified. Visual/Doc/SIE 3.3.18.1

E2 200 A/P cable assembly not as specified. Visual/Doc/SIE 3.3.18.2

E3 100 A/P cable assembly not as specified. Visual/Doc/SIE 3.3.18.3

E4 40/60 A/P cable assembly not as specified. Visual/Doc/SIE 3.3.18.4

E5 60 ampere cable assembly not as specified. Visual/Doc/SIE 3.3.18.5

E6 20 ampere cable assembly not as specified. Visual/Doc/SIE 3.3.18.6

E7 Extension cable assembly not as specified. Visual/Doc/SIE 3.3.18.7

E8 Transition cable assembly not as specified. Visual/Doc/SIE 3.3.18.8

E9 12-outlet, branch circuit, cable assembly not as specified. Visual/Doc/SIE 3.3.18.9

E10 Cinching strap not as specified. Visual/SIE 3.3.19.1

E11 Single-strap carrier not as specified. Visual/SIE 3.3.19.2

E12 Double-strap carrier not as specified. Visual/SIE 3.3.19.3

E13 Type I feeder system not as specified. Visual/Doc/SIE MIL-DTL- 53126A/1

E14 Type II feeder system not as specified. Visual/Doc/SIE MIL-DTL- 53126A/2

E15 Type III distribution system not as specified. Visual/Doc/SIE MIL-DTL- 53126A/3

E16 Type IV distribution system not as specified. Visual/Doc/SIE MIL-DTL- 53126A/4

E17 Type V utility set not as specified. Visual/Doc/SIE MIL-DTL- 53126A/5

E18 Utility light not as specified. Visual/Doc/SIE MIL-DTL- 53126A/ 5

E19 Support line not as specified. Visual/Doc/SIE MIL-DTL- 53126A/5

E20 Storage container not as specified. Visual/Doc/SIE MIL-DTL- 53126A/5

E21 Interconnection not as specified Visual/Doc/SIE 3.4.2

E22 Human Engineering characteristics not as specified Visual/Doc/SIE 3.5.9

E23 Materials not as specified Visual/Doc 3.3

TABLE VI – Examination schedule.

Exam Defect Exam method Reqt para

E24 Marking not as specified Visual/Doc 3.6

4.3.2 First article preproduction tests. Two preproduction PDISE of each type shall be subjected to the applicable tests marked "X" under column 1 of TABLE IV. In addition to any test specified as part of the preproduction tests, the Government reserves that right to conduct any and all preproduction tests and failures of such additional tests shall have the same effect as failures of those tests specified as preproduction tests.

4.4 Conformance inspection. Each individual production PDISE shall be examined and tested as specified herein to determine compliance with this specification and the applicable specification sheets (see 3.1). This inspection shall include the examination of 4.4.1 and the tests of 4.4.2. Non-conformance to any specified requirement, the presence of one or more defects, or the failure of any test shall constitute cause for rejection.

4.4.1 Conformance examination of PDISE. The PDISE shall be examined for defects and conformance to the TDP. The defects include those listed in TABLE VI. Circuit breaker, connector, and internal wire markings and terminations shall be verified for all circuits.

Evidence that the PDISE do not comply with the drawings shall be cause for rejection of the

PDISE.

4.4.1.1 Conformance examination of components and subassemblies. Examination of components and subassemblies shall be made prior to assembly of the PDISE. Evidence that any components or subassemblies do not comply with the requirements of this specification shall be cause for rejection of that component or subassembly.

4.4.2 Conformance tests. Each individual production PDISE shall be subjected to the applicable tests marked "X" under column 2 of TABLE IV. In addition to any test specified as part of the conformance tests, the Government reserves that right to conduct any and all conformance tests and failures of such additional tests shall have the same effect as failures of those tests specified as conformance tests

4.5 Inspection comparison. The Government may select PDISE at any time during the contract production period and subject these PDISE to any examination and test specified herein, necessary to determine that the selected PDISE meet all requirements of this specification. The inspection shall be performed by the Government at a site selected by the Government. PDISE will be selected at random from those that have been accepted by the Government, and shall not include the previously inspected preproduction and production PDISE. Acceptance of an inspection comparison PDISE shall not exclude the remaining PDISE from the quality conformance inspection and acceptance provisions specified in section 4.4. In addition to any test specified as part of the inspection comparison, the Government reserves the right to conduct any and all other tests contained in this specification as part of the inspection comparison, and failure of such additional tests shall have the same effect as failure of those tests specified as inspection comparison.

4.5.1 Inspection failure. Failure of an inspection comparison PDISE to meet any requirement specified herein, during and as a result of the examination and tests specified in 4.5, shall be cause for refusal by the Government to continue acceptance of production PDISE until the contractor has provided evidence that corrective action has been taken to eliminate the deficiencies. Correction of such deficiencies shall be accomplished by the contractor at no cost to the Government on PDISE previously accepted and produced under the contract. Any deficiencies found as a result of the inspection comparison will be considered prima facie evidence that all PDISE accepted prior to completion of the inspection comparison are similarly deficient unless evidence to the contrary is furnished by the contractor and such evidence is acceptable to the contracting office.

4.6 Inspection of packaging,

4.7 Tests. Testing shall be performed on a complete, assembled PDISE that shall include, at a minimum, one each of every component of the utility kit connected to the power distribution system under test. Feeder systems, distribution systems, and utility set components may be networked, and tested as a single assembly. Singular feeder system testing shall utilize a distribution system, or another method devised, to accomplish connection of the utility set components. Components and other devices, or load banks shall be used to test throughput of the feeder/distribution systems. Electric power shall be supplied from a regulated, three phase, 120/130 VAC, 50 or 60 Hz source. Testing shall be conducted without cover, at any ambient conditions permitted in 3.5, except as required for environmental tests.

4.7.1 Operational test. During this procedure, every input circuit breaker shall be operated at its rated load for not less than 4 continuous hours, and every output circuit breaker shall be operated at its rated load for not less than 2 continuous hours. Every cable, receptacle assembly, and other electrical component of the end item shall be utilized or operated at its rated capacity for not less than 1 continuous hour. All switches shall be turned on and off under rated load not less than twice to ascertain functionality. Inability to provide a sustained transfer of capacities specified or other nonconformance to the requirements specified herein and applicable specification sheets, shall constitute failure of this test. Any lack of ground continuity or instance of open or short circuits, safety hazard (see 6.5.2), damage (see 6.5.3) to components, or malfunctions that reduce the specified efficiency of the system or any component shall also constitute failure of this test.

4.7.1.1 Human engineering and safety examination. During the operational test(s), the design shall be evaluated for conformance to the human factors, accessibility, and safety requirements specified in 3.5.9 (see C.A.1).

4.7.1.2 Circuit Interrupter (Overload Current). During the operational test(s), the circuit interrupter shall be tested to determine compliance with specified overload protection.

The test shall be conducted IAW TM 512.2d, MIL-STD-705 for each circuit breaker in the feeder or distribution system.

4.7.1.3 Interface. Proper interface shall be determined during operational test. Each item shall be interconnected to determine proper form, fit and function.

4.7.1.4 Continuity test. The continuity of each circuit shall be tested with an ohmmeter.

A resistance greater than 1 ohm shall constitute failure of this test.

4.7.1.5 Bonding test. The continuity of the housing, ground bus bar, and connectors to ground shall be tested with an ohmmeter. A resistance greater than 1 ohm shall constitute failure of this test.

4.7.2 Environmental. During the subordinate temperature tests, the Type V PDISE utility lights shall be connected to the PDISE feeder/distribution system under test, and operated for not less than 30 minutes of each test. The M46 storage box shall be opened and shall remain open, unassisted, for not less than 15 minutes of each test.

4.7.2.1 High temperature. The PDISE shall be tested IAW MIL-STD-810, TM 501.5, Procedure I and II. The PDISE shall be soaked at a temperature of 160 °F, without solar radiation, for not less than 24 hours; then the temperature shall be lowered to 120 °F. After unit temperature stabilization at 120 °F, the Type I through IV and V PDISE shall be connected to the power source and operated at rated capacity for not less than 12 hours. In addition to failure criteria specified in MIL-STD-810, nonconformance to 3.5.1 and 3.5.2 shall constitute failure of this test. Failure of the lights to operate, or the box to remain open shall also constitute failure of this test, for the Type V PDISE only.

4.7.2.2 Low temperature. The PDISE shall be tested IAW MIL-STD-810, TM 502.5, Procedure I, II, and III. The PDISE shall be soaked at a temperature of -28 °F, without solar radiation, for not less than 24 hours; then the temperature shall be raised to -25 °F. After unit temperature stabilization at -25 °F, the Type I through IV and VI PDISE shall be connected to the power source and operated at rated capacity for not less than 12 hours. In addition to failure criteria specified in MIL-STD-810, nonconformance to 3.5.1 and 3.5.2 shall constitute failure of this test. Failure of the lights to operate, or the box to remain open shall also constitute failure of this test, for the Type V PDISE only.

4.7.2.3 High/low pressure. The PDISE shall be tested IAW MIL-STD-810, TM 500.5, Procedure I, II, and III in an atmospheric pressure (altitude simulating) chamber selected by the contractor and approved by the Government.