Performance_Specification_for_the_Direct_DC-DC_12986349_Attachment_002.pdf

Status: RELEASED Date: 1/13/2005

19200-12986349 Rev C 13 August 2004

REV DATE DESCRIPTION AUTHORITY APPROVED

A 17 May 00 Product Baseline ERR FOM U3891 B. A.

J. L.

B 5 Aug. 02 Incorporation of ADCN 133832

DIRECT ERR L2M5253 B. A.

J. L.

C 13 Aug 04 Incorporation of ADCN 122421

DIRECT ERR

L04M5117

B. A.

M. W.

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TABLE OF CONTENTS

1. SCOPE

1.1 Scope

1.2 Item Overview

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 Specifications, Standards and Handbooks

2.1.2 Other Government Documents, Drawings, and Publications

2.2 Non-Government Publications

2.3 Order of Precedence

3. REQUIREMENTS

3.1 First Article

3.2 Materials

3.2.1 Fungal Growth

3.2.2 Corrosion Resistance

3.3 Design and Construction

3.3.1 Physical Characteristics

3.3.1.1 Dimensions and Tolerances

3.3.1.2 Weight

3.3.2 Protective Finish

3.3.3 Manufacturing Processes

3.3.3.1 Printed Wiring

3.3.3.2 Wire Marking

3.3.3.3 Soldering

3.3.3.4 Conformal Coating

3.3.3.5 Environmental Stress Screening (ESS)

3.3.3.6 Electrostatic Discharge (ESD)

3.3.4 Bonds and Grounds

3.3.5 Connector Requirements

3.3.6 Dielectric Withstanding Voltage and Insulation Resistance

3.3.7 Safety of Components

3.3.8 Product Marking

3.3.9 Workmanship

3.4 Performance Requirements

3.4.1 Interfaces

3.4.2 Power Requirements

3.4.2.1 Input Supply Voltage

3.4.2.1.1 Minimum, Median and Maximum Operating Voltage…………………..4

3.4.2.1.2 Engine Starting Disturbance……………………………………………...5

3.4.2.1.3 Reduced Voltage Operating………………………………………………5

3.4.2.2 Supply Input Inrush Current

3.4.2.3 Power Line to Case Isolation

3.4.2.4 Power Input to Output Isolation. ....................................................……5

3.4.2.5 Input Power…………………………………………………………………….5

3.4.2.6 Transient Conditions…………………………………………………………...5

3.4.2.7 Reverse Voltage Ouput Protection

3.4.3 Built-in Test

ii

3.4.4 Reprogramming Capability

3.4.5 Output Voltages

3.4.6 Power Supply Efficiency

3.4.7 Over Voltage Protection

3.4.8 Overload Protection

3.4.9 Output Inhibit Signal

3.5 Environmental Conditions

3.5.1 Functional Shock

3.5.2 Vibration

3.5.3 High Temperature

3.5.3.1 Storage

3.5.3.2 Operation

3.5.4 Low Temperature

3.5.4.1 Storage

3.5.4.2 Operation

3.5.5 Humidity

3.6 Electromagnetic Interference/Compatibility (EMI/EMC)

3.6.1 Conducted Emission Requirements

3.6.2 Radiated Emission Requirements

3.6.3 Conducted Susceptibility Requirements

3.6.4 Radiated Susceptibility Requirements

3.7. Nuclear Hardening

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection

4.1.1 Responsibility for Compliance

4.1.2 Materials and Manufacturing Processes

4.1.3 Automatic Test Equipment (ATE)

4.1.3.1 ATE Fault Insertion

4.1.3.2 Failure

4.2 Classification of Inspections

4.3 Inspection Conditions

4.4 First-article Inspection

4.4.1 Inspection Routine

4.4.2 First-article Failure

4.4.3 Retention of First-article Approval

4.4.4 Disposition of Samples

4.4.5 Changes to Design, Processes, Procedures, or Location

4.5 Quality Conformance Inspection

4.5.1 Inspection of Product for Delivery

4.5.1.1 100 Percent Inspection

4.5.1.2 Lot-by-Lot Sampling Inspection

4.5.1.2.1 Lot-by-Lot Sampling Plan

4.5.2 Production Quality Control Tests

4.5.2.1 Control Test Sampling Plan

4.5.2.2 Noncompliance

4.5.2.3 Disposition of Control Test Samples

4.5.3 Nonconforming Parts

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4.6 Methods of Inspection

4.6.1 Engineering Analysis

4.6.2 Design and Construction

4.6.3 Performance Tests

4.6.3.1 Interfaces

4.6.3.2 Power Requirements

4.6.3.2.1 Input Supply Voltage and Inrush Current

4.6.3.2.2 Power Line-to-Case Isolation

4.6.3.2.3 Power Input to Output Isolation………………………………………..16

4.6.3.2.4 Input Power

4.6.3.2.5 Transient Conditions

4.6.3.3 Built-in-Test

4.6.3.4 Reprogramming Capability

4.6.3.5 Output Voltages

4.6.3.6 Engine Starting Disturbance

4.6.3.7 Reduced Voltage Operation………………………………………………...17

4.6.3.8 Overload Protection

4.6.3.9 Output Inhibit

4.6.4 Environmental Tests

4.6.4.1 Functional Shock……………………………………………………………..19

4.6.4.2 Vibration

4.6.4.3 High Temperature

4.6.4.3.1 Storage

4.6.4.3.2 Operation

4.6.4.4 Low Temperature

4.6.4.4.1 Storage

4.6.4.4.2 Operation

4.6.4.5 Humidity

4.6.6 Electromagnetic Compatibility

4.6.7 Nuclear Hardening

5. PACKAGING

6. NOTES

6.1 Intended Use

6.2 Acquisition Requirements

6.2.1 First Article

6.2.2 First-article Inspection

6.3 Definitions

6.3.1 Environmental Stress Screening (ESS)

6.3.2 Abbreviations, Acronyms, and Symbols

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LIST OF FIGURES

FIGURE 1. STARTING DISTURBANCES

FIGURE 2. LOCI OF SURGES

FIGURE 3. LOCI OF SPIKES

FIGURE 4. TYPICAL NUCLEAR EVENT DETECTOR

LIST OF TABLES

TABLE I. INTERFACES

TABLE II. STEADY STATE SUPPLY VOLTAGE REQUIREMENTS

TABLE III. NARROWBAND RANDOM-ON-RANDOM VIBRATION PROGRAM……….8

TABLE IV. INSPECTION REQUIREMENTS

TABLE V. LOT-BY-LOT SAMPLING PLAN

1. SCOPE

1.1 Scope. This specification covers the performance, test, manufacture and acceptance requirements for the DC-DC Converter Power Supply Module, referred to herein as the Power Supply. Its description is given on Drawing 19200-12995064.

1.2 Item Overview. The Power Supply provides stable +5, +15, and -15V power suitable for electronic circuitry. The Power Supply is a component of several different assemblies. The herein specified assembly incorporates a number of design improvements, and is recommended for all new applications.

2. APPLICABLE DOCUMENTS

2.1 Government Documents.

2.1.1 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 listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplements thereto, cited in the solicitation. In addition, the standards and specifications cited in Drawing 19200-12995064 shall be met.

MILITARY STANDARDS

MIL-STD-461D Requirements for the Control of Electromagnetic Interference, Emission and Susceptibility

MIL-STD-462D Electromagnetic Interference Characteristics, Measurement of

MIL-STD-464 Electromagnetic Environmental Effects, Requirements for Systems

MIL-STD-810 Environmental Test Methods and Engineering Guidelines

MIL-STD-1275A Characteristics of 28 Volt DC Electrical Systems in Military Vehicles

MIL-STD-1686B Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

Unless otherwise indicated, copies of federal and military specifications, standards, and handbooks are available from the Naval Publications and Forms Center, (ATTN:

NPODS), 5801 Tabor Avenue, Philadelphia, PA 19120-5099.

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

DRAWINGS

19200-12995064 Power Supply, DC-DC Converter

19200-12992072 Procedure, Environmental Stress Screening for the Power Supply, DC-DC Converter 19200- 12995064

OTHER PUBLICATIONS

US Army Nuclear & Chemical Nuclear Survivability Requirements for Agency (USANCA) Document the Bradley A3, 27 July 1993 (Classified)

Copies of specifications, standards, handbooks, drawings and publications required by manufacturers in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the contracting officer.

2.2 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 that 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.

IPC D-275 Design Standard for Rigid Printed Boards and Rigid Printed Board Assemblies. (Institute for Interconnecting and Packaging Electronic Circuits) J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies

Non-Government standards and other publications are normally available from the organizations that prepare or distribute the documents. These documents may also be available in or through libraries or other informational services.

2.3 Order of Precedence. If there is a conflict between the text of this document and the references cited herein (except for related associated detail specifications, specification sheets or military standards), 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 First Article. When specified (see 6.3), the Power Supply shall be subjected to first article inspection (see 4.4) to demonstrate the adequacy and suitability of the supplier’s processes and procedures in achieving the specified performance.

3.2 Materials. Materials shall be in accordance with Drawing 19200-12995064. All materials shall be uniform in quality and free from defects that would be considered unacceptable in the consumer market for a comparable commercial product.

3.2.1 Fungal Growth. Materials used in construction of the Power Supply shall not support fungal growth.

3.2.2 Corrosion Resistance. Metals and alloys used in construction of the Power Supply, that are exposed to corrosive environmental conditions, shall be corrosion resistant or shall be coated or metallurgically processed to resist corrosion. Dissimilar metal combinations that promote corrosion through galvanic action shall be insulated to prevent corrosion.

3.3 Design and Construction. Design and construction of the Power Supply shall be in accordance with Drawing 19200-12995064 and the standards, specifications, pamphlets, regulations and other documents specified herein.

3.3.1 Physical Characteristics.

3.3.1.1 Dimensions and Tolerances. Dimensions and tolerances shall be in accordance with Drawing 19200-12995064.

3.3.1.2 Weight. The weight of the Power Supply shall not exceed 0.75 pounds.

3.3.2 Protective Finish. The Power Supply shall be protected with an anti-corrosion finish as shown on Drawing 19200-12995064.

3.3.3 Manufacturing Processes.

3.3.3.1 Printed Wiring. Printed wiring shall be in accordance with IPC D-275.

3.3.3.2 Wire Marking. Not Applicable.

3.3.3.3 Soldering. Soldering of electrical and electronic components shall be in accordance with J-STD-001.

3.3.3.4 Conformal Coating. Not Applicable.

3.3.3.5 Environmental Stress Screening (ESS). Unless otherwise specified (see 6.2), the power supply shall be subjected to ESS in accordance with drawing 19200- 12992072.

3.3.3.6 Electrostatic Discharge (ESD). The Power Supply shall be immune to damage or upset from personnel-borne electrostatic discharge and shall comply with

MIL-STD-1686B.

3.3.4 Bonds and Grounds. The case of the Power Supply shall be electrically isolated from all internal circuitry by at least 10.0 M DC resistance.

3.3.5 Connector Requirements. Reserved.

3.3.6 Dielectric Withstanding Voltage and Insulation Resistance. Reserved.

3.3.7 Safety of Components. Reserved.

3.3.8 Product Marking. Product marking shall be applied to the Power Supply as specified on Drawing 19200-12995064.

3.3.9 Workmanship. Power Supplies shall be free of cracks, dents, scratches, burrs, sharp edges, loose parts, foreign matter, or any other evidence of poor workmanship that would render the unit unsuitable for its intended use. Acceptance criteria for all quality characteristics not specifically addressed in this specification or in referenced documents shall be at least as high as criteria for acceptable workmanship in the consumer market for a comparable commercial product.

3.4 Performance Requirements.

3.4.1 Interfaces. The Power Supply shall accept and provide interface signals as shown on Drawing 19200-12995064 and in Table I.

Table I. Interfaces.

Pin # Signal Name Signal Description 4, 5 +28V IN Power input 2, 3 +28V RTN Power input return 1 OUTPUT INHIBIT Input 0.7 V disables all output voltages 9 +5V +5 V power source 8 +15V +15 V power source 7 COMMON RTN Return for all output voltages 6 -15V -15 V power source

3.4.2 Power Requirements.

3.4.2.1 Input Supply Voltage.

3.4.2.1.1 Minimum, Median and Maximum Operating Voltages. The Power Supply shall operate from +28VDC at the three voltage levels specified in Table II including the frequency components of the input ripple within the 50 Hz to 200 kHz range.

Table II. Steady State Supply Voltage Requirements.

Nominal Voltage Lower Limit (V) Upper Limit (V) Feed Pin/

Return Pin Steady State

Voltage

Ripple:

Peak

Amplitude (V)

Steady State

Voltage

Ripple:

Peak

Amplitude (V)

Steady State

Voltage

Ripple:

Peak

Amplitude (V)

4, 5 / 2, 3 +28.0 2.0 18.0 2.0 33.0 7.0

3.4.2.1.2 Engine Starting Disturbance. The Power Supply shall be capable of maintaining its +5 V output (with up to a 1 A load) within specified limits during an input voltage drop to +6 V as described in Figure 1.

3.4.2.1.3 Reduced Voltage Operation. After one minute of operation at 20 V, followed by a drop to 16 V, it should operate with +5V at 3A and +15V and – 15V each at 0.38A for 60 s before returning to the normal operating range.

3.4.2.2 Supply Input Inrush Current. The inrush current upon application of supply voltage of 28VDC to the Power Supply input shall not average over 15 amps for a period of less than 20 milli sec when measured at room temperature.

3.4.2.3 Power Line to Case Isolation. .

All power inputs shall be isolated from the power supply case by a minimum of 1M at 50 VDC when measured at room temperature.

3.4.2.4 Power Input to Output Isolation. All outputs shall be isolated from the input.

Input to output isolation shall be 100 megohm minimum at 100 VDC when measured at room temperature.

3.4.2.5 Input Power. Power-supply input power shall not exceed 58 watts under all steady-state 28VDC input at 100% load when measured at room temperature.

3.4.2.6 Transient Conditions. Transients exported and imported by the Power Supply shall be within the limits specified in Figure 2. The Power Supply shall not cause any excursion outside these limits nor cause damage to other equipment designed to tolerate transients within these limits. The power supply shall not export a spike to other

Figure 1. Starting Disturbances

28V equipment greater than that shown in Figure 3. The power supply shall meet the imported spike requirements of MIL-STD-1275A without damage or failure in operation.

Fault Free Condition with Battery

0.001 0.01 0.1 1

Recovery Time ( seconds )

Peak Volts 25

Note: Surges originate from a source impedance of approx. 20 milliohms

Figure 2. Loci of Surges.

-50

-100

-150

-200

-250

Steady-State Voltage

Spike Duration in milliseconds

0.001 0.01 0.05 0.1 1.0

Maximum Energy Content 15 milli-Joules

Peak Spike

Voltage

VE

Figure 3. Loci of Spikes.

3.4.2.7 Reverse Voltage Output Protection. Power supply outputs shall have reverse voltage protection diodes clamping external transients to no lower than –1.2V for a spike or surge of no greater than –40Vdc lasting no longer than 8.3 milliseconds wit a maximum current of 40A at room temperature.

3.4.3 Built-in Test. Not Applicable.

Maximum Energy Content 15 milli-Joules

3.4.4 Reprogramming Capability. Not Applicable.

3.4.5 Output Voltages. The Power Supply shall provide nominal +5 VDC, +15 VDC, and -15 VDC sources with the following characteristics.

+5 VDC output:

a. Load capacity: 3.0 A

b. Voltage range 5 0.25V over operating temperature range, 0 to full load

c. Line Regulation 25 mV max

d. Load Regulation 50 mV

e. Ripple: 50 mV peak-to-peak, DC to 20 MHz

f. Startup time: 20 ms

g. Startup overshoot: 0.5V.

+15V and -15V Outputs:

a. Load Capacity: 0.0 - 0.75 A

b. Voltage range +15 0.75 V and –15 0.75 V over operating temperature range and load capacity range

c. Ripple: 150 mV peak-to-peak, DC to 20 MHz

d. Line Regulation 75 mV max

e. Load Regulation 75 mV

f. Startup time: 20 ms

g. Startup overshoot: 0.75 V.

3.4.6 Power Supply Efficiency. Power Supply efficiency shall be greater than 65% at 75% load with a 28 VDC input.

3.4.7 Over Voltage Protection. In the event the +5V output exceeds 6.9 V, the Power Supply shall automatically reduce the voltage to less than 1.7 V within 8 s.

3.4.8 Overload Protection. All Power Supply outputs shall be capable of enduring overload or short-circuit conditions without damage, and shall automatically recover to full performance within 20 ms after removal of any such condition. The Power Supply shall go into overload condition at a total output load 50 watts. When overloaded, the Power Supply shall decrease output voltages as necessary to limit the total load to not exceed 50 watts. .

3.4.9 Output Inhibit Signal. When an input signal 0.7 V relative to the input return is applied to OUTPUT INHIBIT (pin 1), all output voltages shall decay to ground until the output inhibit signal is removed. The inhibit pin shall sink a current of 4-10 mA. A Nuclear Event Detector (NED), shown in Figure 4, connected across each output shall when fired reduce the output voltage to 37% of nominal within 400 s and to 1.5 V or less within 2 ms when measured at room temperature.

2N2323

+ V

- V

10K .001 uf

GATE

Figure 4. Typical Nuclear Event Detector.

3.5 Environmental Conditions.

3.5.1 Functional Shock. The Power Supply shall be resistant to functional shock stresses of 40 g for 11 ms, and 18 half-sine shock pulses under full load conditions.

3.5.2 Vibration. The Power Supply shall operate under vibrational stresses with full load conditions as shown in Table III:

Table III. Narrowband Random-on-Random Vibration Program.

5-500 Hz Narrowband 1 Narrowband 2 Baseband Time/ Sweep Sweep Overall

Test Level Phase No. BW Ampl BW BW Ampl BW Level Phase g2/Hz Mins. Sweeps Hz g2/Hz Hz Hz g2/Hz Hz g RMS

V01 0.0013 8 4 12 -20 - 2 24 -40 - 4 .80 V02 0.0039 15 2 22 -36 .0260 8 44 -72 - 16 1.14 V03 0.0156 23 4 38 -50 .260 6 76 -100 - 12 2.96 V04 0.0156 23 3 52 -66 .1456 8 104 -132 - 16 2.88 V05 0.0156 23 4 68 -80 .1680 6 136 -160 - 12 2.90 V06 0.0156 23 3 82 -96 .3536 8 164 -192 .1040 16 3.16 V07 0.0260 38 5 98 -112 .5304 8 196 -224 .2600 16 4.13

T01 0.0013 8 4 12 -20 - 2 24 -40 - 4 .80 T02 0.0039 15 2 22 -36 .0260 8 44 -72 - 16 1.14 T03 0.0156 23 4 38 -50 .260 6 76 -100 - 12 2.96 T04 0.0156 23 3 52 -66 .1456 8 104 -132 - 16 2.88 T05 0.0156 23 4 68 -80 .1680 6 136 -160 - 12 2.90 T06 0.0156 23 3 82 -96 .3536 8 164 -192 .1040 16 3.16 T07 0.0260 38 5 98 -112 .5304 8 196 -224 .2600 16 4.13

L01 0.0013 8 4 12 -20 - 2 24 -40 - 4 .80 L02 0.0039 15 2 22 -36 .0260 8 44 -72 - 16 1.14 L03 0.0156 23 4 38 -50 .260 6 76 -100 - 12 2.96 L04 0.0156 23 3 52 -66 .1456 8 104 -132 - 16 2.88 L05 0.0156 23 4 68 -80 .1680 6 136 -160 - 12 2.90 L06 0.0156 23 3 82 -96 .3536 8 164 -192 .1040 16 3.16 L07 0.0260 38 5 98 -112 .5304 8 196 -224 .2600 16 4.13

Exaggeration Factor = 2.6

3.5.3 High Temperature.

3.5.3.1 Storage. The Power Supply shall demonstrate no performance or physical degradation after 24 hours storage at an ambient temperature of 212°F (100°C).

3.5.3.2 Operation. The Power Supply shall demonstrate no performance or physical degradation when operated at a base plate temperature of 212°F (100°C) with full load conditions during 4 hours of exposure.

3.5.4 Low Temperature.

3.5.4.1 Storage. The Power Supply shall demonstrate no performance or physical degradation after 24 hours storage exposure to an ambient temperature of -60°F (- 51°C).

3.5.4.2 Operation. The Power Supply shall demonstrate no performance or physical degradation when operated at an ambient air temperature of -51 F (-46 C) with full load conditions during 4 hours of exposure.

3.5.5 Humidity. Reserved.

3.6 Electromagnetic Interference/Compatibility (EMI/EMC). The electromagnetic compatibility (EMC) requirements for the Power Supply shall be in accordance with MIL-

STD-464.

3.6.1 Conducted Emission Requirements. The Power Supply outputs and inhibit input shall meet or exceed the conducted emissions requirements of MIL-STD-461D, Fig. CE102-1, 28 V Basic Curve. The noise level on the power input shall be at least 6 dB below the basic curve.

3.6.2 Radiated Emission Requirements. The Power Supply shall meet the radiated emissions requirements of MIL-STD-461D, RE102, Figure RE102-3, Army.

3.6.3 Conducted Susceptibility Requirements. The Power Supply shall meet the following conducted susceptibility requirements of MIL-STD-461D:

a. CS101, Figure CS101-1,

b. CS114, Figure CS114-1, Curve #3 from 10 kHz to 2 MHz, and Curve #4 from

2 MHz to 400 MHz,

c. CS115, Figure CS115-1, at a 30 Hz rate for one minute.

3.6.4 Radiated Susceptibility Requirements. Reserved.

3.7. Nuclear Hardening. The Power Supply shall withstand the nuclear environments specified in classified USANCA document, “Nuclear Survivability Requirements for the Bradley A3”, dated 27 July 1993. The minimum acceptable hardening requirements are:

a. Gamma total Dose (Rad Si) 2500

b. Prompt (Rad Si/s) 3.0 E9

c. Neutron Fluence (n/cm2) 8.0 E11

A Nuclear Event Detector (NED) as shown in Figure 4 shall be incorporated into the power input section of the Power Supply. The NED, once tripped, shall cause the Power Supply to remain off until the power is recycled to the supply input.

4. QUALITY ASSURANCE PROVISIONS.

4.1 Responsibility for Inspection. Unless otherwise specified in the contract or purchase order, the supplier is responsible for the performance of all inspection requirements (examinations and tests) specified herein. Except as otherwise specified in the contract or purchase order, the supplier may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the procuring activity. The procuring activity reserves the right to perform any of the inspections set forth in this specification where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance. All items shall meet all requirements of Sections 3 and 5. The inspections set forth in this specification shall become a part of the supplier's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the supplier of the responsibility of ensuring that all products or supplies submitted to the procuring activity for acceptance comply with all contract requirements. Sampling inspection, as part of manufacturing operations, is an acceptable practice to determine conformance to requirements. However, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the procuring activity to accept defective material.

4.1.2 Materials and Manufacturing Processes. The supplier shall maintain, and make available for procuring activity review upon request, documentation verifying that materials and processes used in manufacture of the Power Supply conform to specified requirements. As a minimum, documentation shall confirm the following:

a. Materials as specified in Sections 3.2 through 3.2.2,

b. Design and construction as specified in 3.3,

c. ESS as specified in 3.3.3.5,

d. ESD as specified in 3.3.3.6,

e. Bonds and grounds as specified in 3.3.4, 3.4.2.3 and 3.4.2.4.

4.1.3 Automatic Test Equipment (ATE). When programmable ATE is used, the procuring activity shall review and approve the final test program(s) as well as the supplier's configuration control process for developing and controlling ATE software and hardware to ensure that the end item meets all requirements verified through ATE testing. The supplier shall notify the procuring activity of any changes to a previously approved ATE system or test program to determine whether a new review is required.

Disapproval of a system or program shall render each affected ATE unusable for acceptance of Power Supplies until the supplier has established and implemented a corrective action plan which includes either a correction or approved work-around acceptable to the procuring activity. An ATE configuration control process shall include the following, as applicable:

a. Design and coding standards,

b. Test program documentation,

c. Flow charts of program routines,

d. Test program source listings,

e. Configuration management of test programs,

f. Design and code reviews, quality assurance, and corrective action,

g. ATE hardware configuration identifiers, test configurations, and instrumentation procedures,

4.1.3.1 ATE Fault Insertion. Unless otherwise specified, ATE shall have fault insertion performed in accordance with the appendix upon completion of ATE development. The procuring activity shall be notified of any changes to the ATE to determine if fault insertion must be repeated. Fault insertion shall be approved by the procuring activity prior to ATE usage for acceptance of Power Supplies.

4.1.3.2 Failure. Inability of the ATE to detect any inserted fault shall constitute a failure. Such failure shall be cause for refusal to allow additional examinations or tests until the cause of failure has been corrected and the corrective action approved by the procuring activity. In the event of a failure or the need to reestablish a confidence level for ATE fault detection reliability, the procuring activity reserves the right to require additional faults be inserted and tested.

4.2 Classification of Inspections. The inspection requirements specified herein (see Table III) are classified as follows:

a. First-article inspection (see 4.4).

b. Quality conformance inspection (see 4.5).

4.3 Inspection Conditions. Unless otherwise specified, all inspections shall be conducted under the following standard (room) ambient conditions:

a. Temperature: 77 F 18 F

b. Relative humidity: uncontrolled room ambient

c. Atmospheric pressure: site pressure

4.4 First-article Inspection. When a first-article inspection is required, three Power Supplies shall be subjected to this inspection. Power Supplies subjected to first-article preproduction inspection need not be manufactured using production tooling. Power Supplies subjected to first-article initial production inspection shall be manufactured using production tooling.

4.4.1 Inspection Routine. The first-article sample shall be subjected to the inspections indicated in Table IV.

4.4.2 First-article Failure. Inability of a first-article sample to pass any examination or test shall constitute a failure. Such failure shall be cause for refusal to grant first-article approval. Such failure may, at the option of the procuring activity, be cause for refusal to allow additional examinations or tests until causes of faults have been corrected and the corrective action approved by the procuring activity.

Table IV. Inspection Requirements.

First Article (4.4) Quality Conformance (4.5)

Inspection Requirement Paragraph

Inspection Method

Samples 100% Inspection

Lot-by-lot Sampling

Control Tests

1 2 3 (4.5.1.1) (4.5.1.2) (4.5.2) Dimensions and Tolerances 3.3.1.1 Std. tools X X X X1/ Weight 3.3.1.2 Scale X X X Protective Finish 3.3.2 Visual X X X X2/ Product Marking 3.3.8 Visual X X X X2/ Workmanship 3.3.9 Visual X X X X2/ Interfaces 3.4.1 4.6.3.1 X X X X1/ Input Supply Voltage 3.4.2.1.1 4.6.3.2.1 X X X X Supply Inrush Current 3.4.2.2 4.6.3.2.1 X X X X Power Line to Case Isolation 3.4.2.3 4.6.3.2.2 X X X X2/ Power Input to Output Isolation

3.4.2.4 4.6.3.2.3 X X X X2/

Input Power 3.4.2.5 4.6.3.2.4 X X X X Transient Conditions 3.4.2.6 4.6.3.2.5 X X X Output Voltages 3.4.2.1.1, 3.4.5 4.6.3.5 X X X X Engine Starting Disturbance 3.4.2.1.2, 3.4.5 4.6.3.6 X X X X Reduced Voltage Operation 3.4.2.1.3 4.6.3.7 X X X X Power Supply Efficiency 3.4.6 4.6.1 X X X Over Voltage Protection 3.4.7 4.6.1 X Overload Protection 3.4.8 4.6.3.8 X X X X Output Inhibit Signal 3.4.9 4.6.3.9 X X X X Functional Shock 3.5.1 4.6.4.1 X X X Vibration 3.5.2 4.6.4.2 X X X X High Temperature Storage 3.5.3.1 4.6.4.3.1 X X X X High Temperature Operation 3.5.3.2 4.6.4.3.2 X X X X3/ Low Temperature Storage 3.5.4.1 4.6.4.4.1 X X X X Low Temperature Operation 3.5.4.2 4.6.4.4.2 X X X X3/

EMI/EMC 3.6 4.6.6 X X X

Nuclear Hardening 3.7 4.6.7 X X X Packaging 5. Visual X2/

1/ Major quality characteristics 2/ Minor quality characteristics 3/ Necessary only if 100% ESS testing is not performed

4.4.3 Retention of First-article Approval. Unless extended by the procuring activity to other contracts, first-article approval is valid only on the contract under which it is granted.

4.4.4 Disposition of Samples. Samples that have been subjected to first-article inspection shall be indelibly marked "Test Sample" and shall not be delivered as new equipment under the contract.

4.4.5 Changes to Design, Processes, Procedures, or Location. Whenever a change is made in the design, component manufacturer, or the manufacturing process, procedures, or facility location used in the production of Power Supplies, the procuring activity shall be notified. A determination will then be made whether or not Power Supplies produced under the new conditions will require reinspection of any of the requirements specified in 4.5.1 through 4.5.3.

4.5 Quality Conformance Inspection.

4.5.1 Inspection of Product for Delivery. Inspection of Power Supplies for delivery shall consist of 100 percent and lot-by-lot sampling inspections.

4.5.1.1 100 Percent Inspection. 100 percent inspection shall consist of the inspections so specified in Table IV.

4.5.1.2 Lot-by-Lot Sampling Inspection. Lot-by-lot sampling inspection shall consist of the inspections so specified in Table IV.

4.5.1.2.1 Lot-by-Lot Sampling Plan.

a. Basic method. Quality characteristics subject to lot-by-lot sampling inspection shall be inspected using the sampling plan shown in Table V. Alternate sampling plans are not allowed except under an approved statistical process control (SPC) system conforming to the requirements stated in 4.5.1.2.1 b.

Table V. Lot-by-Lot Sampling Plan.

Sample size

Lot size For major characteristics

For minor characteristics

2 to 13 14 to 25 26 to 50 51 to 90

91 to 150 151 to 280 281 to 500

501 to 1200 1201 to 3200

3201 to 10,000

Entire lot

NOTE: Accept lot on zero defects. Reject lot on one or more defects.

1. Tightened Inspection: Tightened inspection shall be introduced as soon as 2 out of 5 successive lots have been rejected. Rejection shall as a minimum, impose a 30 percent increase in sample size. Normal inspection sampling may be restored after 5 successive lots have been accepted under tightened inspection.

2. Reduced Inspection: Reduced inspection may be introduced when 10 successive lots have been accepted. Reduced inspection shall as a maximum, permit a 30 percent decrease in sample size. Normal inspection sampling shall be restored if a lot is not accepted under reduced inspection.

3. Lot: A lot is defined as a collection of units produced under essentially the same conditions and offered for inspection at one time.

4. Rejected Lot: A rejected lot may be 100 percent sorted (screened) to remove nonconforming parts and to determine acceptance of conforming parts.

b. Statistical Process Control (SPC) Sampling Method. Sampling plan requirements of 4.5.1.2.1a. may be satisfied through the use of SPC as an alternate control method. An SPC plan, detailing the methods for monitoring process control, shall be approved by the procuring activity or agent. The plan, developed by the supplier, shall include as a minimum:

1. Types of control charts and their uses.

2. Process capability (Cpk) studies.

3. Criteria for determining out-of-control conditions.

4. Corrective actions to be taken if an out-of-control or out-of-tolerance condition is detected.

5. Training programs and qualification requirements of personnel executing the plan.

6. Provisions for reduced inspection.

The plan shall contain the results of process capability studies for the process being controlled. For variable data, the minimum Cpk for statistical control should be 1.33.

For attribute data, a minimum process average of 99.73 percent is required.

4.5.2 Production Quality Control Tests. Production quality control testing is not required if ESS is performed. If ESS is not required (see Sections 3.3.3.5 and 6.2), control tests shall be performed and shall consist of the inspections so specified in Table IV. Delivery of Power Supplies that have passed 100 percent and lot-by-lot sampling inspections shall not be delayed pending control test results.

4.5.2.1 Control Test Sampling Plan. Unless otherwise specified (see 6.2), sample Power Supplies shall be selected at the rate of 1 per each 100 Power Supplies produced.

4.5.2.2 Noncompliance. If a sample fails to pass control testing, the supplier shall notify the procuring activity of such failure. Corrective action must be taken on the materials or processes, or both, as warranted, and on all units of product that were manufactured using essentially the same materials and processes, and are considered subject to the same failure. Acceptance and shipment of product shall be discontinued until acceptable corrective action is taken and retest of all failed requirements has shown that the corrective action was successful.

4.5.2.3 Disposition of Control Test Samples. Power Supplies that have been subjected to control testing may not be delivered as new equipment on the contract.

4.5.3 Nonconforming Parts. The supplier may rework or reprocess rejected Power Supplies to correct the nonconforming characteristics and resubmit it for inspection.

Reworking/reprocessing of Power Supplies shall be within the confines of drawing and specification requirements, and shall require 100 percent inspection of corrected characteristics.

4.6 Methods of Inspection.

4.6.1 Engineering Analysis. The purpose of engineering analysis is to provide objective evidence of the ability of the Power Supply to meet specific requirements.

This is needed where component level testing or inspection is either not required due to previous experience and/or testing, or, is not feasible due to unrealistic inspection conditions. Analysis may consist of evaluation of the data accumulated from inspection, demonstration, test and product design requirements, simulation, modeling, interpretation and/or parts similarity. Analysis may include engineering calculations, if applicable. The resultant analysis of these data shall be organized to provide evidence that a particular requirement has been met.

4.6.2 Design and Construction. Reserved.

4.6.3 Performance Tests.

4.6.3.1 Interfaces. Conformance to 3.4.1 shall be determined through performance testing and analysis.

4.6.3.2 Power Requirements.

4.6.3.2.1 Input Supply Voltage and Inrush Current. To determine conformance to 3.4.2.1.1-3 and 3.4.2.2, the tests described in Section 4.6.3.5 shall be performed. The tests shall be performed with the +28V supply voltage set at the three values specified in Table II.

4.6.3.2.2 Power Line-to-Case Isolation. To determine conformance to 3.4.2.3, verify that the internal DC resistance between +28V IN (pins 4, 5) and +28V RTN (pins 2, 3) of the unit under test (UUT) and its case is at least 1.0 M at 50VDC.

4.6.3.2.3 Power Input to Output Isolation. To determine conformance to 3.4.2.4, verify that the internal DC resistance between +28V IN (pins 4, 5) and +28V RTN (pins 2, 3) of the unit under test (UUT) and its output pins +5V (pin 9), +15V (pin 8), COMMON RTN (pin 7) and –15V (pin 6) is at least 100 M at 100VDC.

4.6.3.2.4 Input Power. To determine conformance to 3.4.2.5, monitor and verify that the UUT does not exceed the specified power limit.

4.6.3.2.5 Transient Conditions. To determine conformance to 3.4.2.6, spikes and surges will be measured between pins 5 and 2.

Surge testing will use MIL-STD-1275A section 6.2.4 paragraphs a, b, and d. Spike testing is in accordance with MIL-STD-1275A section 6.2.3. In both tests the power supply shall not be damaged. For surges the power supply will continue to operate within specified limits of section 3.4.5 during and after the test. For spikes the test setup shall be base lined prior to testing the power supply. The base line for acceptance will be the voltage coupled between the input and output signals for the test fixture. If the power supply measurements, during spike testing, exceed the voltage values of the baseline beyond values specified in section 3.4.5 then it constitutes a failure.

4.6.3.3 Built-in-Test. Not Applicable.

4.6.3.4 Reprogramming Capability. Not Applicable.

4.6.3.5 Output Voltages. The following procedure verifies conformance to 3.4.2.1.1 and 3.4.5.

a. With input power off, interconnect the test instrumentation to the UUT via pins 1 -

9. NOTE: The test instrumentation shall include resistive loads resulting in 3 A from the +5V output (pin 9), and 0.75 A each from the +15V (pin 8) and the -15V (pin 6) outputs with respect to the common return. Unless otherwise specified, all performance tests shall be performed with these loads in place.

b. While monitoring the voltage at pin 9, switch on power and verify that the startup transient does not exceed 0.5 V for +5 VDC line.

c. Verify that within 20 ms the output voltage at pin 9 has stabilized between 4.75 and 5.25 V.

d. Verify that ripple does not exceed 50 mV peak-to-peak.

e. Increase the load resistance for the +5V output so that the current drops to 0.5 A and verify that output voltage remains within the range specified in step c above.

f. Decrease the output load resistance to restore the current back to 3 A and verify that output voltage remains within the range specified in step c above.

g. Turn input power off and monitor the +15V output voltage (pin 8).

h. Switch on power and verify that the startup transient does not exceed +0.75V.

i. Verify that within 20 ms the output voltage has stabilized between +14.25 and +15.75 V

j. Verify that the +15V output voltage (8) is between +14.25 and +15.75 V.

k. Increase the load resistance for the +15V output so that the current drops to 0.1 A, and repeat step j above.

l. Turn input power off and monitor the -15V output voltage (pin 6).

m. Switch on power and verify that the startup transient does not exceed -0.75V.

n. Verify that within 20 ms the output voltage has stabilized between -14.25 and -

15.75 V.

o. Verify that the -15V output voltage is between -14.25 and -15.75 V.

p. Increase the load resistance for the -15V output so that the current drops to 0.1 A, and repeat step o above.

4.6.3.6 Engine Starting Disturbance. The following procedure verifies conformance to the temporary low input voltage requirement in 3.4.2.1 and 3.4.5. Remove load resistance from the +15V and –15V outputs.

a. Increase the load resistance for the +5V output (pin 9) so that the current decreases to 1 A.

b. While monitoring the voltage at pin 9, change the input supply voltage by starting at 28VDC and following Figure 1.

c. Verify that the +5V (pin 9) output remains within the range specified in 4.4.3.5 c.

d. Return the input supply voltage to its level prior to step b above.

4.6.3.7 Reduced Voltage Operation. The following procedure verifies conformance to the temporary low input voltage requirement in 3.4.2.1.3.

a. With input power off, connect resistive loads resulting in 3 A from the +5V output (9), and 0.38 A each from the +15V (pin 8) and the -15V (pin 6) outputs with respect to the common return.

b. Set the input power supply to 20VDC and switch on power. While monitoring the voltage at pin 9, switch on power and verify the output voltages meet 3.4.5 subparagraphs b for +5 VDC Output and for +15 VDC Outputs.

c. After 1 minute of operation reduce the input voltage to 16VDC. While monitoring the voltage at pin 9, verify the output voltages meet 3.4.5 subparagraphs b for +5 VDC Output and for +15 VDC Outputs for a period of at least 60 seconds.

d. Return power supply to 20VDC. While monitoring the voltage at pin 9, switch on power and verify the output voltages meet 3.4.5 subparagraphs b for +5 VDC Output and for +15 VDC Outputs.

4.6.3.8 Overload Protection. The following procedure verifies conformance to 3.4.6.

a. Decrease the load resistance for the +5V output to increase current to 6 A, and verify that the voltage at pin 9 drops at least 10% below its nominal level.

b. While monitoring voltages on pins 6, 8, and 9, increase the load for the +5V output so the current decreases to 3 A and verify that all outputs return to their respective ranges specified in 4.6.3.5 c within 20 ms.

c. While monitoring voltages on pins 9 and 6, short circuit the +15V output (pin 8 to pin 7). Remove the short circuit and verify that all outputs return to the respective ranges specified in 4.6.3.5 i within 20 ms.

d. While monitoring voltages on pins 8 and 9, short circuit the -15V output (pin 6 to pin 7). Remove the short circuit and verify that all outputs return to the respective ranges specified in 4.6.3.5 n within 20 ms.

4.6.3.9 Output Inhibit. The following procedure verifies conformance to 3.4.9.

a. Connect four NEDs (See Figure 3) to the Power Supply (connect V+ of the NEDs to pins 1, 7, 8 and 9, and V- of the NEDs to pins 2, 6, 7 and 7, respectively).

b. While monitoring the voltages on pins 6, 8, and 9, apply a 10 s pulse to ground simultaneously to the gates of all four NEDs.

c. Verify that the output on pin 9 declines to 1.85 V within 400 s and to 1.5 V within 2 ms.

d. Verify that the output on pin 8 declines to 5.55 V within 400 s and to 1.5 V within 2 ms.

e. Verify that the output on pin 6 increases to -5.55 V within 400 s and to -1.5 V within 2 ms.

f. Verify that pin 1 remains at 0.85 V after the pulse.

g. Remove input power and remove the NEDs from pins 6, 7, 8, and 9.

h. Connect resistive loads resulting in 3 A from the +5V output (pin 9), and 0.75 A each from the +15V (pin 8) and the -15V (pin 6) outputs with respect to the common return.

i. Monitor the +5VDC on pin 9 relative to Common Return pin 7.

j. Power up the power supply.

k. The voltage measured at pin 9 shall be less than 1.5V after applying a voltage of less than .7V to OUTPUT INHIBIT pin 1 relative to +28V RTN pin 2.

4.6.4 Environmental Tests. Unless otherwise specified herein, environmental testing (test condition tolerances, failure criteria, etc.) shall be conducted in accordance with the general requirements of MIL-STD-810. To verify that the performance of the UUTs have not been degraded beyond specification limits, carry out the performance prior to, during (when specified), and at the conclusion of each environmental test. After testing, the Power Supply shall show no evidence of damage or deformation. For purposes of this specification, "damage or deformation" is defined as visual evidence of cracking, loose hardware, and deformation that is beyond the dimensional requirements specified on Drawing 19200-12995064.

4.6.4.1 Functional Shock. To determine conformance to 3.5.1, the Power Supply shall be tested in accordance with MIL-STD-810, Method 516.4, Shock, Procedure I, Functional. Functional tests are completed after each axis of testing.

4.6.4.2 Vibration. To determine conformance to 3.5.2, the Power Supply shall be tested in accordance with MIL-STD-810, Method 514.4, Vibration, Procedure I.

Operational measurements shall be made under full load conditions during each vibration phase.

4.6.4.3 High Temperature.

4.6.4.3.1 Storage. To verify conformance to 3.5.3.1, the Power Supply shall be tested in accordance with MIL-STD-810, Method 501.3, High Temperature, Procedure I.

4.6.4.3.2 Operation. To verify conformance to 3.5.3.2, the Power Supply shall be tested in accordance with MIL-STD-810, Method 501.3, High Temperature, Procedure II. At the base plate temperature of 212 F (100 C) the operational measurements under full load conditions shall be performed at the end of 2,4,6 hour periods of the test.

During the time between the tests the power supply base plate temperature shall be maintained at 212 F (100 C).

4.6.4.4 Low Temperature.

4.6.4.4.1 Storage. To verify conformance to 3.5.4.1, the Power Supply shall be tested in accordance with MIL-STD-810, Method 502.3, Low Temperature, Procedure I.

4.6.4.4.2 Operation. To verify conformance to 3.5.4.2, the Power Supply shall be tested in accordance with MIL-STD-810, Method 502.3, Low Temperature, Procedure II.

At the base plate temperature of -51 F (-46 C) the operational measurements under full load conditions shall be performed at the end of 2,4,6 hour periods of the test. During the time between the tests the power supply shall not be powered and the power supply base plate temperature shall be maintained at -51 F (-46 C)

4.6.4.5 Humidity. Reserved.

4.6.6 Electromagnetic Compatibility. To verify conformance to 3.6.1 through 3.6.3, the Power Supply shall be tested in accordance with applicable MIL-STD-462D methods. EMI testing shall be conducted once with each power supply output resistively loaded to 25% specified capacity, and once at 85% of capacity.

4.6.7 Nuclear Hardening. Conformance to 3.7 shall be verified through engineering analysis and test, and shall be maintained and documented throughout the life cycle of the Power Supply.

5. PACKAGING

Preservation, packing and marking shall be in accordance with the applicable packaging standard or packaging data sheet specified by the procuring activity.

6. NOTES

This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.

6.1 Intended Use. Power Supplies manufactured in accordance with this specification are intended for use on military tracked vehicles in the BFV Family.

6.2 Acquisition Requirements. Acquisition documents must specify the following:

a. Title, number, revision, and date of this specification.

b. Title, number, revision, and date of part drawing.

c. Issue of DODISS to be cited in the solicitation, and if required, the specific issue of individual documents referenced (see 2.1).

d. First-article inspection, if required (see 3.1).

e. ESS, if other than as specified herein (see 3.3.3.5).

f. Responsibility for inspection, if other than as specified herein (see 4.1).

g. If fault insertion is not required (see 4.1.3.1).

h. Quality control test sampling plan if other than specified in 4.5.1.2.1.

i. Level of packaging (see Sec. 5).

j. Any deviation from this specification.

6.2.1 First Article. When first-article inspection is required (see 3.1), the contracting officer shall provide specific guidance to bidders regarding selection of sample Power Supplies from preproduction, initial production, or standard production from suppliers’ current inventory. The acquisition document should include specific instructions regarding the arrangements for examinations, approval of first-article test results and disposition of first articles. Invitations for bids should provide for the procuring activity to reserve the right to waive first-article inspection, or any portion thereof. Such waiver would be considered for those bidders offering a product that has been previously acquired or tested by the procuring activity or other responsible testing activity. Bidders offering such products should furnish evidence with the bid that prior first-article approval is presently appropriate for the pending contract, or that first-article inspection or any portion thereof, is inappropriate or unnecessary for the pending contract.

6.2.2 First-article Inspection. First-article inspection is applied when it is necessary to determine if a new supplier is qualified to produce Power Supplies in full compliance with this specification and all applicable documents. First-article inspection may also be applied when there is an interruption in production (normally one year or more), or when there is a change in the design or in the manufacturing methods or manufacturing facility location (see 4.4).

6.3 Definitions.

6.3.1 Environmental Stress Screening (ESS). Environmental stress screening (ESS) is a process that subjects devices to accelerated physical and/or climatic stress to precipitate hidden defects in design, workmanship or material that might otherwise result in premature failure of the device. Applied stresses usually include vibration, rapid temperature changes, power cycling and other techniques as appropriate. These stresses force flaws that are not ordinarily apparent into observable failures that can then be removed.

6.3.2 Abbreviations, Acronyms, and Symbols.

A3 A program for upgrading performance of the Bradley Fighting Vehicle A Ampere ATE Automatic Test Equipment AWG American Wire Gauge BFV Bradley Fighting Vehicle Cpk Process capability dB Decibel DC Direct Current DOD Department of Defense DODISS Department of Defense Index of Specifications and Standards EMC Electromagnetic Compatibility EMI Electromagnetic Interference ESD Electrostatic Discharge ESS Environmental Stress Screening g Gravitational acceleration Hz Hertz IPC Institute for Interconnecting and Packaging Electronic Circuits kHz Kilohertz LRU Line replaceable unit M Megohm mA Milliampere(s) max Maximum MHz Megahertz MIL-HDBK Military handbook MIL-STD Military Standard ms Millisecond(s) mV Millivolts(s) NED Nuclear Event Detector n/cm2 Neutrons per square centimeter PDT Product Development Team Rad (Si) Rad for Silicone RMS Root mean square

RTN Return s Second(s) SCR Silicon Controlled Rectifier SPC Statistical Process Control STD Standard USANCA United States Army Nuclear and Chemical Agency UUT Unit under test V Volt(s) VDC Volts DC C Degree(s) Celsius F Degree(s) Fahrenheit A Microampere(s) F Microfarad s Microsecond(s) Ohm(s)