ATT0009.pdf

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

DESCRIPTION FOR PURCHASE (DFP)

FOR

LOAD BANK SYSTEM (LBS)

(Representative Sample)

Product Manager, Sets, Kits, Outfits, & Tools (PM SKOT)

ATTACHMENT 0009

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

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

DFP ECB-074

11 December 2014

Revision –

DESCRIPTION FOR PURCHASE

LOAD BANKS

1. SCOPE.

1.1. Distribution. Distribution Statement A. Approved for public release; distribution is unlimited.

1.2. Scope. This Description for Purchase (DFP) describes a portable load bank, power cables and transport case.

1.3. Abstract. The Army has not procured or replaced load banks since 1985 and the fielded TS-4216/G load banks were classified obsolete. The load bank is to be used by the Military Occupational Specialty (MOS) 91D – Power Generation Equipment Repairer during maintenance and repair of tactical electric generators. This purchase description depicts the essential characteristics and functions of the desired load bank solution.

2. APPLICABLE DOCUMENTS.

2.1. General. The documents listed in this section are those documents known to apply to the project as described. The system integrator shall augment this list as required to ensure the safety of the end operator of the equipment.

2.2. Government Documents.

2.2.1. Specifications, Standards and Handbooks. The following specifications, standards and handbooks form a part of this document. These documents are available on the ASSIST Portal (http://quicksearch.dla.mil/). Unless otherwise specified, use the current release of these documents.

SPECIFICATIONS

FEDERAL

A-A-59486 Padlock Set (Individually Keyed or Keyed Alike)

DEPARTMENT OF DEFENSE

MIL-STD-648 Design Criteria for Specialized Shipping Containers MIL-STD-810 Environmental Engineering Considerations & Lab. Tests

MIL-STD-1472

Department of Defense Design Criteria Standard, Human Engineering

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

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

MIL-W-63150

Weapons and Support Materiel Standard Quality Assurance Provisions For

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robins Avenue, Building 4D, Philadelphia, PA 19111-5094)

2.3. Non-Government publications. The following document(s) form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DOD adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation (see 6.2)

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI Z535.4 For Product Safety Signs and Labels

(Application for copies should be addressed to the American National Standards Institute, 11 W. 42nd Street, New York, New York 10036.)

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS

IEEE SI10

Use of International System of Units (SI): The Modern Metric System

IEEE 1413 Standard Framework for Reliability Prediction of Hardware

(Application for copies should be addressed to IEEE Service Center, 445 Hoes Lane, P.O.Box

1331, NJ 08855-1331)

National Fire Protection Association (NFPA) NFPA 70 National Electric Code (NEC)

(Application for copies should be addressed to NFPA Membership Services Center, 11 Tracy Drive, Avon, MA 02322-9908. 800-344-3555)

American Society for Testing and Materials ASTM B-172 Standard Specification for Rope-Lay-Stranded Copper

Conductors Having Bunch-Stranded Members, for Electrical Conductors

(Application for copies should be addressed to the American Society for Testing and Materials, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428.)

2.4. Order of Precedence. In the event of conflict between the text of this document and the references cited herein, text of this document takes precedence. Nothing in this document supersedes applicable law and regulation unless a specific exemption has been obtained.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

3. REQUIREMENTS. The load bank configuration shall be a complete and ready to run solution that includes one load bank, generator cabling, control power cable to power the load bank (if externally powered), a transport case, cable bag and any accessories required to meet the described requirements.

3.1. Operating Temperature Range. The load bank, cabling and any accessories shall be appropriately configured for continuous duty use between -25 and 120 degrees Fahrenheit ambient temperature.

3.2. Storage Temperature Range. The load bank, power cables, transport case and any supplied accessories shall be suitable for storage in environments ranging from -40 to 160 degrees Fahrenheit.

3.3. Load Bank. The load bank shall conform to the following requirements.

3.3.1. Performance Characteristics. The load bank shall be capable of testing both single and three-phase power sources. The load bank shall be capable of continuous, resistive load testing of military generator sets by providing loads ranging from 5 to 60 KILOWATTS (kW) at 208 and 416 volts alternating current (VAC), 3-phase, 4-wire, 60Hz; 2 to 10 kW at 120 and 240 VAC, 1-phase, 2-wire and 3-wire, 60Hz.

3.3.1.1. Load Steps. The load bank shall provide a means to apply incremental loading (step loading). The tolerance on all load steps shall be -0 to +2.5 percent of indicated values for prescribed voltages.

3.3.1.1.1. Single Phase. The load bank shall have a combination of load steps that allows for testing at 2, 3, 4, 5, 6, 7, 8, 9, and 10kW -0/+2.5% for 120VAC and 240VAC, 1-phase, 2-wire and 3-wire, 60Hz.

3.3.1.1.2. Three Phase. The load bank shall have a combination of load steps that allows for testing at 5, 10, 15, 30 and 60kW -0/+2.5% for 208VAC and 416VAC, 3-phase, 4-wire, 60Hz.

3.3.1.2. Continuous operation. The load bank shall be rated for continuous use.

Typical operations will last 30 minutes but durations of continuous testing at any of the required voltages or power levels, lasting four hours in duration, shall not result in any damage or deterioration throughout the ambient temperature profile defined in 3.1.

3.3.2. Construction. The load bank shall be constructed to withstand the strains, shocks, vibrations and other conditions incident to shipping, storage, service and operation.

Electrical components shall be designed to withstand transient voltage and current level sags and surges associated with load testing generator sets. Enclosure finishes and other components shall employ best commercial design practices to prevent corrosion and withstand the high temperatures and exposures normally associated with load bank operations. Cooling air intake and exhaust openings shall be covered to protect load

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

elements from foreign object damage as well as preventing operator contact with live voltages and high temperatures. Access to internal load bank components shall be through removable panels.

3.3.2.1. Size. The dimensions of the load bank shall not exceed 30 inches long x 17 inches wide x 25 inches tall.

3.3.2.2. Weight. The load bank weight shall not exceed 84 pounds not counting cables and shipping case.

3.3.2.3. Operational Environmental requirements. The load bank shall be designed for indoor/sheltered use with limited outdoor use expected. The load bank shall be clearly marked “ELECTRICAL EQUIPMENT, DO NOT OPERATE IN WET

ENVIRONMENTS OR EXPOSE IT TO MOISTURE”.

3.3.2.4. Controls. The load bank shall have a centralized operator control panel that contains all the meters, switches, alarms, indicators and labels necessary for proper operation of the load bank. The design of the operator control panel shall include the minimal number of switches/function keys to control basic functions.

3.3.2.4.1. Metering/Status Indicators. The load bank shall have analog or digital meters that allow for the display of the following parameters: line-to-line voltage, line-to-neutral voltage, current, frequency and power from the generator under test. The meters shall either allow for the display of all parameters for a single phase at the same time without having to scroll/switch through parameters; or the display of all phases being monitored at the same time for a single parameter. Units of measure for each parameter shall be as follows: potential shall be in volts; current shall be in amperes; frequency shall be in Hertz; and power shall be in watts or kilowatts. The load bank control panel shall include lamps to indicate the on/off status of the load bank; the status of the cooling air-flow; and over-temperature indicators.

3.3.2.4.2. Load Disconnect. The load bank shall have a master disconnect switch for instantaneous application or disconnection of all selected load elements. This will allow for a manual shutdown in the case of failures in the automatic protection circuitry as well as transient loading at any of the available combinations of load steps.

3.3.2.4.3. Test Points. The load bank shall provide plug test points for the connection of external measurement equipment. The test points shall provide sufficient shielding to protect the operator from inadvertently making contact with live voltages. The test points shall be 4mm banana style jacks.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

3.3.2.4.4. Calibration. The Load Bank shall be calibrated and be capable of being re-calibrated as required by the contract. The manufacturer shall provide recommended calibration intervals and procedures for recalibration. The date of calibration and expiration shall be provided in close proximity to the operator control panel on a removable label.

3.3.2.5. Over-temperature. The load bank shall automatically disconnect the resistive elements in the event of an over-temperature condition. An indicator lamp shall also illuminate at that time.

3.3.2.6. Over-voltage/Short-circuit. The load bank shall provide protection circuitry to automatically shutdown operation to protect the resistive elements, controls and operator in the event of an over-voltage or short-circuit condition.

The load bank shall also provide over-voltage protection for the 120VAC control power (if not derived from the generator under test).

3.3.2.7. Cooling. The load bank shall provide adequate cooling to keep the system from reaching an over-temperature condition throughout the ambient temperature profile defined in 3.1 for any duration of operation. The load bank shall not require more than 30 minutes of cooling time after the disconnection of the resistive elements before it is safe to store in the shipping case. The load bank shall not suffer any damage from a failure in the cooling system that results in an over-temperature shutdown. The load bank shall not suffer any damage from not being allowed to cool down after the completion of a test.

3.3.2.8. Control Power. Control power for the load bank shall either be derived from the generator under test or from an external 120VAC, 60Hz, National Electrical Manufacturers Association (NEMA) 5-15 receptacle. If an external control power source is being utilized, the control power cable shall be detachable without tools. A 10-foot long control power cord appropriately sized for the power requirements shall be provided if the load bank utilizes a separate control power source.

3.3.2.9. Grounding/Bonding. Electrical grounding and bonding shall be accomplished in accordance with National Fire Protection Association’s (NFPA) 70, National Electric Code (NEC), Article 250.

3.3.2.10. Quick Disconnect Sockets. The load bank shall have quick disconnect sockets for connecting the power and ground cables that connect the load bank to the generator under test. No tools shall be required to connect the cables to the load bank. The sockets shall be keyed or color coded to assist the operator in connecting the load bank properly. All quick disconnect sockets shall be rated per the aforementioned power requirements and operating temperature ranges. Safety plugs shall be provided if sockets not used during any particular mode of testing present a safety hazard.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

3.3.2.11. Handles. The load bank shall have handles sufficient for a two handed lift and carry by one or two persons. All handles on the load bank shall be rated for 1.5 times the weight of the load bank.

3.3.2.12. Workmanship and Wiring. The load bank shall be manufactured with the best commercial practices and be free from defects. Wiring and materials will be in accordance with NEC and NEMA guidelines. All wiring shall be neatly routed, terminated and identified.

3.3.2.13. Maintenance. The average time required to perform repairs on the load bank shall not exceed 6 hours per year based on 30 minutes of load bank runtime per use when used up to 1725 hours per year not counting preventative maintenance checks and services (PMCS). PMCS time using the aforementioned usage profile, shall not exceed 12 hours per year. All components likely to fail over the lifetime of the load bank shall be replaceable by the generator mechanics using standard automotive shop tools.

3.4. Generator Cabling. The cabling to connect the load bank to the generator being tested will consist of 10 foot long cables and sets of cable stubs sized to accommodate the range of generator lugs described herein. The cables and cable stubs shall be flexible single conductor cables conforming to NEC, Article 400, Flexible Cords and Cables, Table 400.5(A)(2). The cables shall be sized appropriately for the load capability of the load bank and operating temperature ranges as dictated by the NEC. The cable shall be rated for 600VAC, -50 to 105 degrees Celsius; resistant to oil, solvents, ozone, aging and abrasion; rated for indoor and outdoor use; and constructed from fully annealed stranded copper per ASTM B-172. The cable shall meet or exceed flame test requirements of Mine Safety and Health Administration (MSHA) and Underwriters Laboratories (UL). All couplings used on the cables shall be rated for the aforementioned power requirements and operating temperature ranges. The cables and cable stubs to connect the load bank to the generator shall be color coded (color bands are acceptable) using industry standard colorings or labeled to assist in the proper connection of the load bank with the generator.

3.4.1. Cables. The cables shall be 10-foot in length (not counting cable stubs) and allow for two and three wire 1-phase testing as well as four wire 3-phase testing. The cables shall have quick disconnect plugs that mate with the quick disconnect sockets on the load bank on one end. The other end of the cables shall have quick disconnect couplings that mate with the 12 inch Cable Stubs. All cables shall be the same gauge wire (excluding grounding cable).

3.4.2. Cable Stubs. Sets of 12 inch cable stubs shall be provided that connect the generator power cables to the generator output terminal lugs. Each set shall contain 4 stubs (3-phases and neutral). Each stub shall have its own quick disconnect coupling to mate with the power cables and shall not require the swapping of couplings. The non-coupling end of the cable stubs shall have 1 inch of insulation stripped and solder tinned.

The cable stub sets provided shall be sized to allow for connection to the following generator lug sizes: AWG #6 (0.203 inch max diameter); AWG #4 (0.281 inch max

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

diameter); AWG #2 (0.344 inch max diameter); AWG 2/0 (0.469 inch max diameter) and AWG 4/0 (0.703 inch max diameter).

3.4.3. Grounding Cable. The grounding cable to connect the load bank to the generator shall be 10-foot in length and 6AWG in size. The grounding cable shall have a quick disconnect plug that mates with the quick disconnect socket on the load bank on one end.

The other end of the ground cable shall have 1 inch of insulation stripped and solder tinned.

3.5. Transport Case/Cable Bag. The load bank, cables and accessories shall fit in the following bag and case.

3.5.1. Cable Bag. The cable bag shall be sized appropriately to hold all the cables and accessories. The cable bag shall be constructed of nylon yarn not less than 1000 denier weight, mildew resistant, in one of the following subdued non-reflective colors: dark blue, dark green, black, tan or olive drab. The bags shall utilize a heavy-duty zipper for closure that runs the length of the bag across the top. Each bag shall have reinforced carry handles on either side of the zipper. Each bag shall include a carrying shoulder strap that can be clipped onto and off of the bag. Both the handles and the straps shall be suitable for the weight to be carried in the bag.

3.5.2. Transport Case. The transport case shall hold the load bank and the government supplied technical manual (TM) and/or the commercial TM. The transport case shall be lightweight and rugged and meet all the following requirements.

3.5.2.1. Color. The color of the transport case shall be one of the following subdued non-reflective colors: dark blue, dark green, black, tan or olive drab.

3.5.2.2. Lockable. The transport case shall have the capability to be locked with a key-operated, tumbler type padlock conforming to CID A-A-59486.

3.5.2.3. Weight. Total weight of the load bank and transport case shall not exceed 147 pounds (four man lift limit).

3.5.2.4. Latches. The transport case shall have a series of latches to secure the lid that is adequate for meeting all requirements herein. No tools or external aids shall be required to secure the lid for shipment.

3.5.2.5. Lifting Handles. The transport case shall include two lifting handles on each end of the case sized to allow for a 4-man lift and carry. Each handle on the Transport Case shall be rated for 1.5 times the weight of the fully loaded Transport Case.

3.5.2.6. Movement Aids. The case shall include a set of permanently attached wheels and retractable handle that will aid in moving the case around. The

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

movement aids shall be appropriately configured to create a stable platform that does not easily tip over when cornering or rolling on sloped surfaces.

3.5.2.6.1. Wheels. The wheels shall provide a single user the ability to roll the case around on paved surfaces utilizing only one hand. The wheels shall be integrated into the design of the case. Wheels, axles and any wheel mounting brackets shall be rugged and shall withstand being rolled over bumps and cracks in pavement, and shall withstand shocks incurred when the fully loaded transport case is dropped to pavement from a height of 24 inches. See 3.5.2.7.1. The presence of the wheels shall not interfere with the ability to stack multiple cases on top of each other. The wheels shall be replaceable using standard automotive tools.

3.5.2.6.2. Handle. The handle shall be retractable and shall fully retract within the envelope of the case exterior. The handle shall be long enough to provide a user that is 6 feet 2 inches tall with the ability to pull the case across the floor without having to stoop over to grip the handle. The handle used for this purpose shall not be one of the handles that are used for lifting and carrying the case. The handle shall provide complete and solid control of the direction of the case as it moves about. The handle shall withstand repeated use without deforming or becoming unstable.

3.5.2.7. Components protection. The interior of the transport case shall be designed to protect the load bank against damage from rough handling, shock, and vibration encountered during transportation, shipping, and handling. Suitable cushions and restraints shall be provided to keep the load bank secured inside the case. The cushions and restraints used shall not have any deleterious effect on the load bank.

3.5.2.7.1. Rough Handling. The transport case shall be able to withstand MIL-STD-648 drop testing, procedure B, using a test height of 24 inches without sustaining any damage that would affect operation. Damage that would affect performance of the transport case or any of the contents would be considered a failure to meet this requirement.

3.5.2.7.2. Transportation. The transport case shall be transportable as loose cargo on 3/4 to 22 ton trailers and tactical wheeled vehicles up to 5 ton trucks.

3.5.2.8. Water Intrusion Prevention. The transport case shall be designed to prevent water entry into the case in accordance with 4.4.7.5. If a rubberized seal is used to meet this requirement, then it shall be easily replaced when damaged in the field.

3.5.2.9. Pressure differential compensation. The transport case shall be designed to compensate for differential pressures that may develop as a result of changes in

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

temperature or in altitude. A device such as a pressure relief valve may serve this purpose.

3.5.2.10. Corrosion Prevention. To minimize the occurrence of corrosion in storage, the transport case shall include a volatile corrosion inhibitor (VCI) module positioned such that the molecules released by the VCI can circulate into the load bank cooling air vents to protect the internal components from corrosion. The VCI module shall be easily replaced.

3.6. Safety. The load bank shall not present any uncontrolled safety or health hazards and shall protect the MOS 91D – Power Generation Equipment Repairer from inadvertent contact with exposed connections under normal use. The load bank shall comply with applicable NEC and Underwriters Laboratories (UL) safety standards. The exterior of the load bank and cabling shall not present any burn hazards to the operator during use. Warning labels, icons and markings shall alert end-users of potential or specific hazards. Warning labels shall conform to ANSIZ535.

3.6.1. Lift Hazards. Caution signs shall be provided for all items that exceed the MIL- STD-1472 safe limits for a single person lift. Product safety signs and labels shall conform to ANSI Z535. The number of persons assigned for lifting each item shall be determined using the guidance per paragraph 5.9.11.3.1 of MIL-STD-1472. Lifting limits established for a single person is 42 lbs per Table XVII.

3.7. Hazardous Material Restrictions. Asbestos, beryllium, beryllium alloys, cadmium, cadmium alloys, Class I and Class II Ozone Depleting Substances, hexavalent chromium, lead, leaded alloys, mercury, nickel, nickel alloys, radioactive materials and other Group 1 Agents classified as “carcinogenic to humans” by the International Agency for Research on Cancer (IARC) Monographs, shall not be present in or on any delivered materials, required for the operation and sustainment of the system, or used in final system manufacture and assembly processes.

The following materials may be used without prior approval from the Government:

Cadmium on electrical connectors and back shells used to mate with cadmium electrical connectors on Government Furnished Equipment (GFE) Chemical Agent Resistant Coating (CARC) primers and topcoats Lead-acid batteries Lead solder Steel containing up to 0.35% lead by weight Aluminum containing up to 0.4% lead by weight Copper and Brass alloys containing up to 4% lead by weight Beryllium and Beryllium alloys used in electrical components Nickel and Nickel alloys used in electrical components Mercury containing components compliant with European Union (EU) Directive

2002/95/EC (RoHS)

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

3.8. Disposal. The system shall be designed such that the user shall have the ability to dispose of the system in full compliance with applicable Unites States Federal environmental quality laws and regulations.”

3.9. Deployment. The load bank shall require no more than 10 minutes for a single MOS 91D

– Power Generation Equipment Repairer to connect and configure for operation.

3.10. Data Plate. Each load bank shall have a data plate permanently and legibly marked with the following information, including all information required to be inserted in the blanks indicated.

a. End Item Nomenclature : TBD ***

b. End Item LIN: TBD ***

c. End item NSN: TBD ***

d. End Item Serial No.: *

e. Nomenclature: TBD (see 6.2.2)

f. Specification data: DFP ECB-074

g. Weight_____lbs, Volume_____cu ft, Length____in, Width_____in, Height______in

h. Manufacturer: CAGE or FSCM and PIN **

i. Acquisition instrument identification number: **

* Format optional ** See definitions *** Will be provided XX DAC

The data plate shall conform to Commercial Item Description A-A-50271 Composition A, Class 2 or Composition D. The data plate shall be placed in a plainly visible location on the exterior of the load bank. Data plates shall be placed on the transport case and cable bag in a plainly visible location. The data plates on the transport case and cable bag shall not include the serial number.

3.11. Item Unique Identification (IUID). In addition to the requirements stated above and those of DFARS clause 252.211-7003 incorporated elsewhere in the contract, each load bank shall be marked with an item unique identifier that has machine-readable data elements that shall distinguish it from all other like and unlike items. Each unique item identifier shall be globally unique and unambiguous. The IUID data elements shall be contained in a Data Matrix ECC200 symbol in accordance with ISO/IEC 16022. Marking shall conform to MIL- STD-130. The identifier shall remain intact and readily human and machine readable for the expected life of the load bank. The unique item identifier shall not be repeated during the life of the contract. If construct number 2 is used (serialization within the original part number of the enterprise), the contractor shall maintain the original part number on the item for the life of the item. The contractor shall bear the responsibility to populate the IUID registry with the parent IUID and any children (components) relating to that parent UID. Further guidance on unique item identification may be found at http://www.acq.osd.mil/dpap/pdi/uid/index.html.

The contractor shall coordinate the physical location of the IUID marking with the assigned Government Representative.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

3.12. Warranty Information. A human readable warranty information plate at least 5 inches wide and 2.5 inches high shall be furnished for each load bank. The warranty information plate shall be located in a conspicuous place and shall conform to the current version of the following image. This image is always subject to change. The contractor shall contact PM- SKOT to ensure they have the current version prior to use.

3.12.1. Warranty. Warranty information for the load bank, cables, and the transport case shall be permanently affixed to the load bank. Warranty information shall include the following:

1. Government contract and delivery order number

2. Date of manufacture (month and year)

3. Instructions for submitting a claim including

(i) Preferred claim method – via Internet site at https://tools.army.mil

(ii) Alternate claim method – via email to usarmy.detroit.peo-cs-css.mail.pm-skot@mail.mil. Call (877) 476-7568, (586) 239-3667 or DSN 273-3667 for verification or assistance.

(iii) Information required to submit a claim including Individual with responsibility to authorize claim Date and location of incident Unit location and DODAAC Ship to address Description of circumstances of component failure

4. Name and address of contractor, and any other means of contacting the contractor such as data fax number or e-mail address.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

5. A complete list of warranties for each component including the nomenclature, manufacturer’s part number and NSN, when known, shall also be permanently affixed to the lid.

3.12.2. Non-warranty. For the non-warranty ordering of replacement parts from the contractor, the procedures as determined by the contractor (including phone number, web site and email address if they are applicable) shall be provided separately or included with or near the above information. All information shall be provided on a permanent, water resistant, scuff resistant label, which is permanently affixed to the load bank.

3.13. Labels and Plates. All identification plates and labels shall be permanently affixed.

They shall be resistant to deterioration caused by heat, cold, solar radiation, water, and petroleum products to the extent that they shall remain intact and readily legible for the expected life of the load bank. Marking shall be accomplished in a manner that does not adversely affect the life and utility of the set or its equipment. All plates and labels shall be printed in English language and may be supplemented by graphical symbols.

3.14. Warranty. The manufacturer shall warrant all supplied items are free of defects in material and workmanship for a period of one (1) year from the date of delivery. The manufacturer shall warrant the load bank’s components are free of defects in material and workmanship for a period of two (2) years from the date of delivery.

4. QUALITY ASSURANCE PROVISIONS.

4.1. General provisions. The inspections (examinations and tests) herein shall be performed to determine whether the test set conforms to Section 3 of this DFP.

4.1.1. Responsibility for inspection and product performance verification. Unless otherwise specified in the contract, the contractor is responsible for inspecting and verifying that product performance meets all requirements as specified herein. Except as otherwise specified in the contract, the contractor may use any facility suitable for the performance of the inspection and product verification in accordance with the requirements specified herein unless disapproved by the Government. The contractor shall provide certification and warranty that all inspection and product verification has been performed on the unit in accordance with the requirements specified herein and that the unit has successfully met all of the requirements. Failure of the contractor to provide this certification and warranty shall be cause for rejection. The Government reserves the right to perform inspection and product verification as set forth in the requirements of this specification at any time where such inspection and product verification are deemed necessary to assure equipment and services conform to prescribed requirements.

4.1.2. Responsibility for compliance. All items must meet all requirements of Sections 3 and 5. The inspections set forth in this specification shall become a part of the contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products submitted to the government for acceptance comply with all requirements of the contract.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

4.1.3. Verification. The product offered shall be demonstrated in such a manner to verify that it meets all of the contract requirements. Verifications consist of three basic types 1) visual inspections; 2) performance demonstration; and 3) Certificates of Conformance.

Each requirement set forth in section 3 above shall be verified by one or more of the three types. All testing to assure that the products offered are properly designed to perform as required shall have been completed with satisfactory results before products are presented to Government personnel witnessing the demonstration of the product. Verification shall include conformance to design, adequacy of markings, proper cleaning, and freedom from identified defects. The verification provisions may be applied at the earliest practical point in manufacturing at which it is feasible to inspect for acceptance without risk of change in the characteristic by subsequent operation. Failure of the contractor to provide objective evidence that the item and its components have passed the examinations prescribed for them by the contractor's inspection system shall be cause for rejection. The required Certificates of Conformance (COC) shall be submitted to the Government with the preproduction performance verification test report.

4.1.4. Classification of inspections. The inspection requirements specified herein are classified as follows:

a. Product verification inspection (see Paragraph 4.2)

b. Conformance inspection (see Paragraph 4.3)

4.1.5. Changes to materials, processes, or configuration. The Procurement Contracting Officer (PCO) shall be informed of any changes to the materials, processes, or configuration of any characteristic of the units. The contracting officer shall determine if the reported changes to materials, processes, or configuration shall require any of the verifications under paragraph 4.2 to be repeated.

4.1.6. COC format requirements. COCs shall contain the following information. Refer to MIL-W-63150.

a. Name of company providing the COC and the date of submittal.

b. Contract number and DFP paragraph number that the COC applies to.

c. A brief description of the item for which the COC is being provided.

d. The test standard used to certify the requirement.

e. The signature and title of the certifying official.

4.2. Product Verification Inspection.

4.2.1. Submission. The contractor shall submit a product verification sample as designated by the Contracting Officer. The product verification inspection shall consist of a minimum of one complete Load Banks System.

4.2.2. Inspections to be performed. The product verification sample will be subjected to all of the verification methods specified in 4.4.

4.3. Conformance Inspection.

FOR OFFICIAL USE ONLY (FOUO) LBS DESCRIPTION FOR PURCHASE (DFP)

4.3.1. Compliance. Conformance inspection shall be applied to production units being offered for acceptance under the contract. Lot formation shall be in accordance with Section 4 of MIL-STD-1916. Inspections shall include all verification methods in 4.4.

4.3.1.1. Sampling plan determination. When required by contract or cited herein, attribute-sampling inspections shall be conducted in accordance with MIL-STD- 1916 using Verification Level (VL) I.

4.3.2. Conformance of subsequent production quantity. All products offered for acceptance throughout the life of the contract shall conform to all of the requirements of the contract. The Government reserves the right to re-verify conformance with requirements, at its own facility and at its own expense, at any time during the life of the contract and return to the contractor for warranty replacement such product that does not conform to the specified requirements.

4.4. Verification.

4.4.1. Workmanship. Contractor will provide certification that the Load Banks System has been manufactured with skill and care and free from irregularities and anomalies that degrade form, fit, function, performance or appearance.

4.4.2. Warranty. Verify that warranties are provided in accordance with paragraph 3.14.

4.4.3. Load Steps. Verify by test that the load bank provides a means to apply incremental loading. Para 3.3.1.1.

4.4.3.1. Single Phase. Connect the load bank to a power source and test it at 2, 3, 4, 5, 6, 7, 8, 9, and 10kW for 120VAC and 240VAC, 1-phase, 2-wire and 3-wire, 60Hz. Verify the loads are within the stated tolerance of -0/+2.5%. Para 3.3.1.1.1.

4.4.3.2. Three Phase. Connect the load bank to a power source and test it at 5, 10, 15, 30 and 60kW for 208VAC and 416VAC, 3-phase, 4-wire, 60Hz. Verify the loads are within the stated tolerance of -0/+2.5%. Para 3.3.1.1.2.

4.4.4. Continuous Operation. Verify by test that the load bank can withstand durations of continuous testing at any of the required voltages or power levels. Connect the load bank to a power source and test at 120 and 240VAC single phase; and 208 and 416VAC three phase with the load bank configured to draw the maximum amperage the load bank is capable of drawing for each of the voltages. Each test shall last for no less than 4 hours at ambient temperature. After each 4 hour test, wait 30 minutes to allow the load bank time to cool. At the completion of all the 4 hour testing, verify the load bank has not suffered damage by retesting the load steps and performing a visual inspection of the load banks components. Failure to complete any of these tests is cause for rejection. Para 3.3.1.2.

4.4.5. Construction. Visually verify that the cooling air intake and exhaust openings are covered to protect load elements from foreign object damage as well as preventing operator contact with live voltages and high temperatures. Verify that the internal load bank components are accessible through removable panels. Para 3.3.2.

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4.4.5.1. Size. Verify by measurement the dimensions of the load bank do not exceed 30 inches long x 17 inches wide x 25 inches tall. Para 3.3.2.1.

4.4.5.2. Weight. Verify the load bank does not exceed 84 pounds. This weight excludes cables and shipping case. Para 3.3.2.2.

4.4.5.3. Operational Environment requirements. Verify by CoC that the load bank is designed for indoor/sheltered use with limited outdoor use expected. Visually verify the load bank is clearly marked “ELECTRICAL EQUIPMENT, DO NOT OPERATE IN WET ENVIRONMENTS OR EXPOSE IT TO MOISTURE”. Para 3.3.2.3.

4.4.5.4. Controls. Verify by visual inspection that the load bank has a centralized operator control panel that contains all the meters, switches, alarms, indicators and labels necessary for proper operation of the load bank. Para 3.3.2.4.

4.4.5.4.1. Metering/Status Indicators. Verify by visual inspection that the load bank has analog or digital meters that allow for the display of the following parameters: line-to-line voltage, line-to-neutral voltage, current, frequency and power from the generator under test. Verify by visual inspection that the meters either allow for the display of all parameters for a single phase at the same time without having to scroll/switch through parameters; or the display of all phases being monitored at the same time for a single parameter. Verify the units of measure are in volts, amperes, Hertz, and watts (or kilowatts). Verify by visual inspection that the load bank control panel includes lamps to indicate the on/off status of the load bank; the status of the cooling air-flow; and over-temperature indicators Para 3.3.2.4.1.

4.4.5.4.2. Load Disconnect. Verify by test that the load bank contains a disconnect switch for instantaneous application or disconnection of all selected load elements. Perform tests for each voltage and phase at maximum load. Visually inspect the load bank for damage. Para 3.3.2.4.2.

4.4.5.4.3. Test Points. Verify by visual inspection that the load bank contains test points for the connection of external measurement equipment.

Verify the test points are a 4mm banana style jack and are sufficiently shielded to protect the operator from inadvertently making contact with live voltages. Para 3.3.2.4.3.

4.4.5.4.4. Calibration. Verify by CoC that recommended calibration intervals and procedures for recalibration are provided. Verify the date of calibration and expiration is in close proximity to the operator control panel on a removable label. Para 3.3.2.4.4.

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4.4.5.5. Over-temperature. Verify by test that the load bank provides an automatic disconnection of the resistive elements from the generator in the event of an over-temperature condition. Utilizing a test setup similar to that specified for the hot temperature demonstration, gradually increase the air temperature of the environmental chamber until the load bank overheats and shuts down. After cooling down, retest the load steps, and perform a visual inspection of the load bank. Damage affecting performance or safety would be cause for rejection. Para 3.3.2.5.

4.4.5.6. Over-voltage/Short-Circuit. Verify by CoC that the load bank provides protection circuitry to automatically shutdown operation to protect the resistive elements, controls and the operator in the event of an over-voltage condition. Para 3.3.2.6.

4.4.5.7. Cooling. Verify during testing of operating temperatures in paragraph

4.4.8.2. Para 3.3.2.7.

4.4.5.8. Control Power. Verify the control power for the load bank is either derived from the generator under test or from an external 120VAC, 60Hz, National Electrical Manufacturers Association (NEMA) 5-15 receptacle. If an external control power source is being utilized, verify that the control power cable is detachable without tools and a 10-foot long control power cord appropriately sized for the power requirements is provided. Para 3.3.2.8.

4.4.5.9. Grounding/Bonding. Verify by CoC that the electrical grounding and bonding is accomplished in accordance with National Fire Protection Association’s (NFPA) 70, National Electric Code (NEC), Article 250. Para 3.3.2.9.

4.4.5.10. Quick Disconnect Sockets. Verify by CoC that the provided sockets are adequate for the voltages, loads and operating temperatures described herein.

Verify by visual/manual inspection that the sockets are keyed or color coded and do not require tools to remove the cables. Verify safety plugs are present if required and fit properly in the designated sockets. Para 3.3.2.10.

4.4.5.11. Handles. Verify by CoC that the load bank contains handles sufficient for a two handed lift and carry by one or two persons per MIL-STD-1472. Para 3.3.2.11.

4.4.5.12. Wiring. Verify by CoC the wiring materials are in accordance with NEC and NEMA guidelines. Visually inspect the wiring is neatly routed, terminated and identified. Para 3.3.2.12.

4.4.5.13. Maintenance. Verify by CoC the average time required to perform maintenance/repairs on the load bank using standard automotive shop tools does not exceed 6 hours per year based on 30 minutes of load bank runtime per use when used up to 1725 hours per year. Para 3.3.2.13.

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4.4.6. Cables. Verify by objective evidence the cables and cable stubs meet or exceed the requirements of 3.4 and all subparagraphs. Para 3.4.

4.4.7. Transport Bag/Case.

4.4.7.1. Cable Bag. Verify by objective evidence conformance to the requirements of 3.5.1.

4.4.7.2. Transport Case. Verify by demonstration the transport case holds the load bank and government supplied TM. Para 3.5.2.

4.4.7.2.1. Color. Visually verify the transport case color is one of the following subdued non-reflective colors: dark blue, dark green, black, tan or olive drab. Para 3.5.2.1.

4.4.7.2.2. Lock. Visually and manually verify the transport case has the capability to be locked with a key-operated, tumbler type padlock conforming to CID A-A-59486. Para 3.5.2.2.

4.4.7.2.3. Weight. Verify by test the total weight of the load bank and transport case does not exceed 147 pounds. 3.5.2.3.

4.4.7.2.4. Latches. Manually verify that the transport case contains a series of latches adequate for securing the lid without using external aides. Para 3.5.2.4.

4.4.7.2.5. Lifting Handles. Verify by CoC that the load bank contains handles sufficient for lift and carry by four persons per MIL-STD-1472.

Para 3.5.2.5.

4.4.7.3. Movement Aides. Visually/manually verify the transport case contains permanently attached wheels, retractable handle, and is appropriately configured to create a stable platform that does not easily tip over when cornering or rolling on sloped surfaces. Para 3.5.2.6.

4.4.7.3.1. Wheels. Verify by demonstration that the wheels provide a single user the ability to roll the case around on paved surfaces utilizing only one hand and are integrated into the design of the case. Stack 2 cases on top of each other to verify the wheels do not interfere when stacking multiple cases on top of each other. Verification for the wheel mounting bracket strength will be verified in paragraph 4.4.7.4.1. Para 3.5.2.6.1.

4.4.7.3.2. Handle. Manually verify the retractable handle can fully retract within the envelope of the case exterior. Verify a person 6 feet 2 inches tall

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can pull the case across the floor without having to stoop over to grip the handle. Para 3.5.2.6.2.

4.4.7.4. Components Protection. Verify with the following test that the transport is designed to protect the load bank against damage from rough handling, shock, and vibration encountered during transportation, shipping, and handling. Para 3.5.2.7.

4.4.7.4.1. Rough Handling. Per 3.5.2.7.1, perform drops on each face of the transport case from a height of 24 inches IAW MIL-STD-648. Drops shall be performed onto concrete or other similar unyielding surface.

Following testing, the load bank and transport case shall be inspected for damage. Damage that would affect performance or safety would be considered a failure to meet this requirement.

4.4.7.4.2. Transportation. MIL-STD-810, Method 514.5, Procedure II testing shall be conducted on the transport case to assess compliancy with

3.5.2.7.2. Testing shall be conducted at ambient temperature. Test time shall be 20-minutes. Damage that would affect the operational effectiveness of the transport case and load bank shall constitute failure to meet this requirement. Para 3.5.2.7.2.

4.4.7.5. Water Intrusion Prevention. Water entry resistance demonstration shall be performed using one of the following three methods. The first is a submersion method in which the case is completely immersed in a tank of water. The second is a pneumatic procedure in which a pressure gauge is attached to the case and an airline attached to build pressure inside the case. The third is a windblown rain procedure. Para 3.5.2.8.

4.4.7.5.1. Water immersion procedure. Close and fasten the case, with the load bank in it. At the contractor’s option, a weight may be placed in the case to keep it from floating or any other tie down method may be used so long as it does not affect the operation of the seal. Immerse the case in a tank of water to a depth at which the lid is under water and orient the case with the closed lid in its upright position. Keep the case under water for not less than 10 minutes. After ten minutes remove the case from the tank and towel dry the exterior. Open the case and conduct a visual inspection of the inside. Make note of any water found on the interior of the case.

Accumulation of moisture inside the case shall constitute failure of this requirement.

4.4.7.5.2. Pneumatic procedure. Drill a hole in the side of a case and insert a pneumatic pressure gage. Drill another hole and insert a pneumatic fitting. The hole for the pressure relief valve may be utilized for this purpose so long as the valve itself is certified to hold not less than the same pressure for the same amount of time. Close and latch the case, with load bank in it. Attach a source of compressed air and raise the pressure inside

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the case to one half (.5) pound per square inch gage, or higher. Detach the source of the compressed air and hold the pressure for 30 minutes, or longer. The pressure as shown on the gage shall not decrease more than 10 percent in the 30 minute time period. Failure to hold the required pressure for the required time period shall constitute a failure of the requirement.

4.4.7.5.3. Rain and wind blown rain procedure. Close and fasten the case with the load bank, cables and accessories. Submit the case to the following verification procedure utilizing apparatus that meets the requirements as stated.

4.4.7.5.3.1 Rain apparatus. The rain making apparatus shall

produce falling rain at the rate of 4 inches per hour. The water distribution device shall produce droplets having a diameter range predominantly between 0.5 mm and 4.5 mm. The rain shall be dispersed completely over the case. Position the spray nozzles at a height sufficient to ensure the drops approach terminal velocity as if they had fallen through the atmosphere from the sky. Water used for this verification procedure can be from local water supply sources. It is not necessary to use de-ionized or distilled water for this verification procedure.

4.4.7.5.3.2 Controls. Immediately prior to performing the

verification:

a. Verify the rainfall rate to be 4 inches per hour or more

b. Adjust the temperature differential between the water and the case to be no less than 10 degrees C. The case shall be the warmer value.

4.4.7.5.3.1. Interruptions. Interruption of the water entry

resistance verification procedure is unlikely to generate any adverse effects. Therefore, if an interruption occurs, the procedure may be continued from the point of interruption.

4.4.7.5.3.2. Procedure. Follow the 3-step procedure as outlined below. Accumulation of moisture inside the case shall constitute failure of this requirement.

1. With the case in the apparatus and in its normal storage position, adjust the rainfall rate to 4 inches per hour.

2. Continue the rain for a 30-minute period.

3. Remove the case from the test apparatus, towel dry the exterior, open the case and conduct a visual inspection of the inside making note of any water found on the interior of the case.

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4.4.8. Operating Temperature Range. Verify by test the load bank, cabling and any accessories provided are appropriately configured for continuous duty use IAW the following tests.

4.4.8.1. Cold Temperature Demonstration. Precondition the load bank for 3 hours in a cold temperature environment of -25°F (+/-3°F). With the load bank still in the cold temperature environment, connect the load bank to a power source and operate it at 208VAC for 30 minutes with the load configured to draw the maximum amperage the load bank is capable of drawing…