Attachment 0005 3k STEP EMD PD_Updated 20220711.docx

PD 6115-0133

APPENDIX F

PD Revision Revision Date 11 Jul 2022

PURCHASE DESCRIPTION

ITEM SPECIFICATION

FOR THE

GENERATOR SET, SMALL TACTICAL ELECTRIC POWER: 3 < KILOWATTS < 5

Prepared for:

Project Manager Expeditionary Energy & Sustainment Systems (PM E2S2), 5850 Delafield Road, Building 324, Fort Belvoir, VA 22060

Prepared by:

Product Manager Mobile Electric Power Sources (PM MEPS), 5850 Delafield Road, Building 324, Fort Belvoir, VA 22060

SCOPE

Scope. This Purchase Description (PD) covers the greater than or equal to 3 kilowatt (kW) to less than 5kW Small Tactical Electric Power (STEP) generator set, hereinafter referred to as "set" or "sets". This PD also covers any accessories that are used with the set(s).

Requirement levels. This PD lists two values for certain performance parameters. The threshold (T) is the minimum acceptable level. The objective (O) is the desired level at which performance results in an operationally significant increase in capabilities. When only one requirement is stated, it is the threshold requirement. Within a single paragraph, if individual sentences are marked, the T or O applies to the sentence preceding the marking. If an (O) appears at the end of a paragraph, the entire paragraph is objective.

APPLICABLE DOCUMENTS

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

Government Documents.

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

COMMERCIAL ITEM DESCRIPTIONS

DEPARTMENT OF DEFENSE SPECIFICATIONS

DEPARTMENT OF DEFENSE STANDARDS

DEPARTMENT OF DEFENSE HANDBOOKS

(Copies of these documents are available online at http://quicksearch.dla.mil/) Other Government documents, drawings and publication. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ABERDEEN TEST CENTER (ATC)

TOP 01-1-011 - Test Operating Procedure: Vehicle Test Facilities at Aberdeen Test Center and Yuma Test Center (Copies of this documents are available online at http://quicksearch.dla.mil/)

ARMY PUBLISHING DIRECTORATE (APD)

(Copies of these documents are available from https://armypubs.army.mil/)

ENVIRONMENTAL PROTECTION AGENCY

40 CFR 1068.225 - Title 40 - Protection of Environment: Chapter I - Environmental Protection Agency: Subchapter U - Air Pollution Controls: Part 1068 - General Compliance Provisions For Highway, Stationary, and Nonroad Programs: Subpart C - Exemptions and Exclusions: Section § 1068.225 - Exempting engines/equipment for national security (Copies of this documents is available from https://www.govinfo.gov/ or https://www.ecfr.gov/) PRODUCT MANAGER SET, OUTFITS, & TOOLS (PdM-SKOT)

(Contents of these end items are available from https://www.peocscss.army.mil/pdmskot.html)

PROJECT MANAGER EXPEDITIONARY ENERGY & SUSTAINMENT SYSTEMS (PM E2S2)

(Copies of these drawings and document required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Officer.)

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

AMERICAN SOCIETY FOR QUALITY (ASQ)

ASQ/ANSI Z1.4 - Sampling Procedures and Tables for Inspections by Attributes (Copies of this document are available from https://www.asq.org/)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D975 - Standard Specification for Diesel Fuel Oils (Copies of this document are available from https://www.astm.org/)

ASSOCIATION OF AMERICAN RAILROADS (AAR)

(Copies of these documents are available from https://aarpublications.com/)

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

(Copies of these documents are available from https://www.ieee.org/)

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

(Copies of these documents are available from https://www.iec.ch/)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

(Copies of these documents are available from https://www.iso.org/)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

(Copies of these documents are available from https://www.nema.org/)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

(Copies of these documents are available from https://www.nfpa.org/)

NORTH ATLANTIC TREATY ORGANIZATION (NATO)

NATO STANAG 3747 - Guide Specifications (Minimum Quality Standards) for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, F-40 and F-44) (Copies of this document are available from https://nso.nato.int/nso/)

SOCIETY OF AUTOMOBILE ENGINEERS (SAE)

(Copies of these documents are available from https://www.sae.org/)

UNDERWRITERS LABORATORIES (UL)

(Copies of these documents are available from https://ulstandards.ul.com/) Order of Precedence. In the event of a conflict between the text of this document and the references cited herein (except for related PD sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained.

REQUIREMENTS

First article. When specified (6.2), the contractor shall furnish first article samples as specified in 3.2 in the quantities specified by the contracting officer for inspection (6.4.15) as specified in 4.1 for determination of conformance to this PD.

Description. The Tactical Microgrid Standard (TMS) compliant set (3.21) shall consist of an engine that can operate on the fuels specified in 3.10.1, permanent magnet or brushless generator, power converter (6.4.10) or excitation system if needed, governing system, fuel system, Direct Current (DC) cranking system, control system, protection system, starting battery, and other devices as required to achieve a complete set and to allow for the required performance. In addition, all sets used for first article inspection (4.4) shall include any accessories needed to meet required performance as stated herein. Sets used for production quality inspection (4.5) and production sets shall have the required accessories specified in the acquisition documentation (6.2).

Set rating. The set shall be rated at no less than 3kW, 0.8 Power Factor (PF) lagging, 60 Hertz (Hz), Alternating Current (AC) continuous at the AC load terminals and shall be reconnectable for the following voltages at the appropriate load terminals, as applicable, separately (not simultaneously):

a. 1 Phase (PH), 2-wire, 120 Volts (V) (double the current of 3.2.1.b) (T).

b. 1PH, 3-wire, 120/240V (T).

c. 28VDC nominal, integral to the AC power source, adjustable 23-35VDC (O).

d. 1PH 50Hz, with the same reconnectability as 60Hz (O).

e. All in one power source selectable to 28VDC, 120VAC 1PH 50/60Hz 2-wire, or 120/240 VAC 1PH 50/60Hz 3-wire, where AC has selectable frequencies as well (O).

Additional capabilities shall be considered (i.e. leading 0.8PF) if feasible given other performance constraints (O). Additional load terminals, circuit interrupters, and load receptacle rearrangement as well as control devices and indicators shall be provided, if applicable (T). If 50Hz is provided, power rating shall be no less than five sixths (5/6) of 60Hz continuous at the same PF (T). If DC is provided, current rating shall be no less than 64 Amperes (A) (T), 83A (O). As applicable, power quality shall be no less than utility in accordance with MIL-STD-1332 and as described herein (T).

Reliability. The minimum acceptable Mean Time Between Failure (MTBF) for the sets shall be 687 hours (T), 2290 hours (O) with a lower confidence of 80% under the conditions specified in 4.8.9.

Audio noise. Audio noise sound pressure levels (SPL) emanating from the set shall not exceed 72 dB(A) at 23.0 feet (7 meters) from the perimeter of the set when measured at 3.9 feet (1.2 meters) above the ground (T). In addition, audio noise SPL emanating from the set shall be less than 85 dB(A) at the operator's station, with the control panel doors open if used, defined to be a 2.3 feet (0.7 meters) hemisphere radiating outward from any point on the plane defined by the front of the control panel (T). Audio noise SPL emanating from the set shall be inaudible from the perimeter of the set 328 feet (100 meters) away (O). These requirements apply under all operating conditions specified herein with the set operating at all loads from the no-load to rated load (6.4.24) (T).

High-altitude electromagnetic pulse (HEMP). The sets and feeder boxes shall withstand the HEMP (6.4.14) nuclear environment specified in MIL-STD-2169 in both operating and non-operating conditions. The set and feeder box shall operate as specified herein after being subjected to the applicable nuclear environments without damage (6.4.5). The set and feeder box operating as a unit (not in parallel) shall meet operational requirements specified herein within 5 minutes (recover) after being subjected to the specified HEMP environment. The sets and feeder box operating in parallel (3 sets and one feeder box) shall meet operational requirements specified herein within the same time it takes to start, parallel remotely, and provide rated power at rated load (6.4.24) before and after being subjected to the specified HEMP environment. The recovery for each may include manual or automatic correction of HEMP induced changes in the set or feeder box, to include restart, but not the replacement of piece parts or components.

Chemical, biological, radiological and nuclear (CBRN) contamination survivability. The set and feeder box shall have a Chemical Agent Resistant Coating (CARC) painted as specified in 3.36 and shall be so designed for contamination survivability in accordance with MIL-STD-3056 Appendix A as applicable. The set and feeder box shall be capable of being decontaminated (T), operated (T), and serviced (O) (3.16) by personnel wearing Mission Oriented Protective Posture IV (MOPP IV) chemical, biological, and radiological clothing (6.4.20) without special tools or support equipment. The set shall not be damaged (6.4.5) and shall meet operational requirements specified herein within 60 minutes after being decontaminated according to the procedure specified in APPENDIX A.

Electrical performance. Set electrical performance shall be as specified herein. Set rating (3.2.1) shall be no less than 3kW at sea level (T), 1,000 feet (305 meters) (O) of altitude and with an ambient temperature of +120°F (+49°C). Components of the set shall not be damaged (6.4.5) when the set is operated continuously at all possible frequency and voltage adjustments. The set shall provide the applicable load rating (3.8.2) at the output terminals under all operating conditions specified herein.

Starting, operating, and stopping. The set, feeder box, and other accessories shall perform in the various environments herein as required, where applicable, and with the appropriate as applicable consumable (3.10), where each consumable is within their recommended use conditions and shall provide the operator, while adorned in artic mittens or MOPP IV clothing (6.4.20), the ability to control it. The planning guidance for realistic consideration of climatic conditions in the Research, Development, Test, and Evaluation (RDT&E) of material used in combat by the Army is described in AR 70-38.

Starting. The set shall start (6.4.32) within 5 minutes of the first user action in accordance with the startup procedures with and without the battery under any combination of the following conditions. The set shall start within 5 minutes of receipt of a remote signal, either dry contact closure or via a TMS command, with NATO slave power or a set battery connected:

a. At ambient temperatures from –25°F (–32°C) to +120°F (+49°C) using the electric start at any possible humidity; and from +20°F (–7°C) to +120°F (+49°C) using the manual start at any possible humidity.

b. At altitudes up to and including 8,000 feet (2,438 meters) above sea level.

c. With the base of the set in planes from level up to 15 degrees (0.27 radians) from level in any orientation.

d. With up to 5 inches (127 millimeters) of rain per hour impinging on the set at angles ranging from the vertical up to and including 90 degrees (1.571 radians) from the vertical.

e. With up to 355 British Thermal Units (BTUs) per square foot per hour (1,120 watts per square meter) of solar radiation.

f. With a sand/dust particle concentration of up to 1,400 mg per cubic meter. Particle sizes shall range from less than 74 micrometers in diameter to 1,000 micrometers, with the bulk of the particles ranging in size from 74 to 350 micrometers.

g. With a steady wind speed of up to 73 feet per second (22 meters per second) and gusts up to 95 feet per second (29 meters per second) at a height of 10 feet (3 meters) above ground level.

h. With accumulations of ice glaze, freezing rain and hoarfrost of up to 0.5 inch (13 millimeter) and up to a specific gravity of 0.9.

i. In a salt fog or sea-spray environment.

j. With fuels, lubricants, and coolants specified in 3.10.

Operating. Immediately after starting or with the remaining time left from startup while at no load operation, the set, feeder box, and all other accessories shall operate without damage (6.4.5 and 6.4.34) or failure (6.4.11) at all loads, continuous and intermittent, up to and including rated load (6.4.24) under any of the conditions or combinations of the conditions specified in 3.8.1, except that for the set rating as stated in 3.7:

a. At 4,000 feet (1,219 meters) altitude and +95°F (+35°C), set rated load (6.4.24) de-rating shall not exceed 10 percent (T), 5 percent (O).

b. At 8,000 feet (1,219 meters) altitude and +95°F (+35°C), set rated load de-rating shall not exceed 30 percent (T), 23.3 percent (O).

Stopping. The set shall stop (6.4.33) within 60 seconds after activation of any device intended to stop the set. Any cool down feature not requiring engine power can continue to draw power from the set battery(ies) but not to a point where the set battery(ies) cannot start the set (3.28.7.2.1).

Colder temperature. The set shall perform as prescribed in 3.8.1 through 3.8.3, inherently, or with an accessory, at an ambient temperature of –65°F (–54°C) where the set is electrically started and where the total time to start and operate is 10 minutes (O). If applicable and if in parts, parts of the accessory that requires removal of set components (longer than 5 minutes each to remove) in order to install (i.e. engine, harness, etc.) or installation at ambient conditions herein is impractical (i.e. adhesives used to attached the parts will not cure, etc.), those accessory parts shall come with every set, making it inherent to the set, and as such, included in the dry weigh of the set (T).

Endurance (life). The set shall operate for 2,150 hours without critical failure (6.4.11.1) at all loads, continuous and intermittent, up to and including rated load (6.4.24) under all of the conditions specified in 3.8.2.

Fuels, lubricants, and coolants.

Fuels. The set, while operating on F-24 fuel conforming to NATO STANAG 3747, Jet Propulsion (JP)-8 fuel conforming to MIL-DTL-83133, or diesel fuel conforming to ASTM D975, shall meet all the requirements specified herein. Diesel fuel shall be of grades very low or low sulfur (No. 1-D S15, No. 2-D S15 [also known as Ultra Low Sulfur Diesel (ULSD)] or 1-D S500, No. 2-D S500). The set, while operating on JP-5 conforming to MIL-DTL-5624, shall meet all requirements herein, except rated load (6.4.24) may be reduced up to 20 percent and a maximum of 300 hours of operation on JP-5 per 2,150 hours of set operation shall be required. Operation on JP-5 shall only be required at temperatures from 0°F (–18°C) to +100°F (+38°C) and at altitudes up to 1,000 feet (305 meters). No manual adjustment is allowed when changing between the above fuels.

Lubricants. The engine shall operate on lubricating oil conforming to MIL-PRF-2104 and MIL-PRF-46167, gear oil conforming to SAE J2360, grease conforming to MIL-PRF-10924, and preservative/break-in oils conforming to MIL-PRF-21260 as applicable.

Coolant. If a liquid cooled engine is used in the set, the engine shall be capable of operating with coolants conforming to A-A-52624.

Other set requirements.

Overspeed. The set shall withstand engine operation at 110 percent of rated speed (6.4.25) for 5 minutes without damage (6.4.5).

Flexural vibration and critical speeds. The set shall be free from dangerous flexural vibrations (6.4.6) and dangerous torsional critical speeds (6.4.7) between the minimum low idle speed and 115 percent of rated speed (6.4.25).

Vibration Stress. The set and feeder box shall be capable of withstanding vibrational stresses without damage (6.4.5) during transportation and operational modes.

Maximum power. The minimum acceptable maximum power shall be 110 percent of rated real power under all operating conditions specified herein, except that at altitudes above 1,000 feet (305 meters), the minimum maximum power shall be no less than the de-rating allowed at altitudes and temperatures above 1,000 feet (305 meters) (3.8.2). Production sets shall have a maximum power of not less than 2 percent below the average maximum power measured for the First Article Test (FAT) sets when corrected for the same conditions.

Fuel consumption. The set shall consume JP-8 fuel (6.56 pounds per gallon), F-24, and No, 2-D S15 at a rate less than 0.36 gallons per hour while operating at rated load (6.4.24) in ambient conditions; less than 0.40 gallons per hour for JP-5 under the same conditions except that load is at actual derated load if applicable.

Transportability.

Lifting and tiedown provisions. Mechanical lifting and tiedown provisions shall be provided in accordance with MIL-STD-209, except as specified herein. Slinging and multipurpose tiedown provisions shall have a minimum inside clearance of 1.969 inches, and a maximum inside clearance of 2.169 inches. Slinging and multipurpose tiedown provisions shall have a minimum clearance from the set surface to the farthest inside edge of 1.969 inches and a maximum clearance from the set surface to the farthest inside edge of 3.969 inches. The identification of slinging, tiedown, or multipurpose provisions shall be in letters not less than 0.375 inches in height. The set, with fuel tank 1/4 full to full, with or without the battery shall remain within 15 degrees of level when lifted. Lifting provisions shall be marked "LIFT HERE", and tiedown provisions shall be marked "TIE-DOWN".

Rail tiedown procedures. Procedures for mounting of the sets to a rail flat car for shipment (transportation) shall be provided. Mounting of the sets shall be in accordance with standard loading and bracing methods as shown in Section 1 “General Rules for Loading All Commodities” and Section 6 "Rules for Loading Military Equipment and Materiel" of Association of American Railroads (AAR) Open Top Loading Rules (OTRL) Manual.

Air transportability. The set and feeder box shall not be damaged (6.4.5) by aircraft and helicopter transportation (6.4.2), and shall be transportable while facing forward, aft and to either side.

Internal air transport. The lifting and tiedown provisions (3.12.1) shall meet the requirements of MIL-STD-209. The set and feeder box shall be capable of being transported in a C-130 or larger aircraft and inside utility rotary wing aircraft while facing forward, aft, or to either side.

Military airdrop. The sets and feeder boxes shall be capable of being platform mounted while facing forward, aft, or to either side. The set and feeder box shall meet the requirements of MIL-STD-814 for Low Velocity Airdrop (LVAD).

Rail transport. The set and feeder box while facing forward, aft and to either side shall be capable of being rail transported (6.4.23) on all open top railcars without damage (6.4.5).

Utility vehicle and trailer transport. The set and feeder box shall be capable of being transported by utility vehicle, truck, or trailer transportation (6.4.36) while facing forward, aft, or to either side without damage (6.4.5).

Inclined transportation. The set and feeder box shall be capable of being transported while in an operable condition but not operating, when inclined at any angle from horizontal to 25 degrees from horizontal in any direction, and with the set fuel tank at any possible level from empty to full, with no spillage or seepage from the set or any of its components.

Forklift openings. Openings shall be provided in the skid base to permit insertion of forklift tines. Each opening shall be not less than 8 inches long and 2.5 inches in height and the openings shall be located such that the center of gravity of the set falls between the centers of the forklift openings. The distance between the centers of the openings shall be a multiple of 2 inches but not more than 28 inches nor less than 18 inches. The openings shall be reinforced and equipped with guides such that the set will not be damaged (6.4.5) if it is lifted by a forklift, with the tines not extended completely through the base. Each opening shall be marked "FORKLIFT HERE" in 0.75 inch minimum letter height.

Handling. The set shall have provisions such that six soldiers can manually lift and transport the set. These provisions shall be located below the centerline of the set, and shall be suitable for use by personnel wearing arctic mittens and MOPP IV clothing (6.4.20). Handles shall be located such that soldiers can lift and carry the set without interfering with one another. The handling provisions shall be within the set maximum dimension (3.18) when not in use. If non-fixed handles are used, the handles must have a stop position perpendicular to the surface on which they are mounted, and be parallel to the ground when positioned for use. Any two opposing handles shall be capable of supporting the weight of the set.

Wheel and handle. If the set weights more than 100 pounds (45 kg), the set shall have a detachable wheel and handle accessory suitable for one solider to move (pull) the set over paved and unpaved firm or gravel surfaces; and packed dirt or sand. The accessory shall include any and all hardware required to install on the set. The force required to pull the set shall not exceed 45 pounds (200 Newtons) in accordance with MIL-STD-1472 (TABLE XLVIII with high traction) on a level surface. The set shall not be caused to have spilled liquids, fall over, or damage (6.4.5) by the install or usage (movement and stationary) when all fluids are at their full capacity. The accessory shall have the ability to prevent movement when the set is stationary on a 15 degree incline when installed and while operating without the need for tools. The accessory installation shall not require more than one solider to install properly.

Storage. The set and feeder box without packaging shall not be damaged (6.4.5 and 6.4.34) by exposure to:

a. Storage at –60°F (–51°C) to +160°F (+71°C).

b. Salt fog environment.

c. All possible relative humidities.

The set and feeder box shall be operational with minimal preparation after removal from storage consistent with standard DoD practice. Procedures for storage and preservation shall be incorporated in the technical manuals.

Safety. The set shall meet the provisions of MIL-STD-882, Warnings, hazards, and safety of MIL-STD-1472 (as specified in 3.25), and should use the guidelines of MIL-HDBK-454 for guidance, specifically guideline 1. Exposed parts of such nature as to be a hazard to personnel shall be insulated, enclosed or guarded without impairing the functioning of these parts.

Electromagnetic interference (EMI). EMI and susceptibility characteristics shall comply with the requirements of MIL-STD-461 for conducted emissions (CE102) (remote one and three receptacles), conducted susceptibility (CS101, CS114, CS115, CS116, and CS118), radiated emissions (RE102), and radiated susceptibility (RS103). A 5 meter (T), 3 meter (O) standoff distance is allowable in order to meet this requirement.

Servicing, operation and maintenance. The design and construction of the set shall permit routine service and maintenance under military field conditions. Any unscheduled maintenance which requires the removal of the set housing shall be validated before the set housing is replaced. The set shall be capable of being started and operated by one operator under all conditions. Starting or stopping the set shall not require manipulation of more than one control or switch, except for the activation of the engine starting aid control device (3.32.1.4). Hardware which requires torqueing shall be installed such that the nut, bolt or screw head is accessible for torque wrench application. In assemblies where both a bolt and nut are used, the nut shall be accessible for torque wrench application. When Test, Measurement and Diagnostic Equipment (TMDE) is required, TMDE shall be selected from the TMDE Preferred Items List (PIL) (See Appendix B). Requirements for any new TMDE shall be developed in accordance with AR 750-43, Army TMDE Program. The design shall maximize the use of existing tools available in the following tool kits: the General Mechanic's Tool Kit (GMTK) NSN 5180-01-605-5146 (SC 5180 95-B49), the Standard Automotive Tool Set (SATS) NSN 4910-01-490-6453 (SC 4910-95-A81), the Forward Repair System (FRS) NSN 4940-01-533-1621 (SC 4940-95-E42), and the Shop Equipment Contact Maintenance (SECM) NSN 4940-01-548-9064 (SC 4940-95-B36) for all set maintenance and service actions if not already tethered to the set. The design should avoid the need for a new special tool or new TMDE, and if required, the request shall be made as soon as the need is recognized in the design. Servicing, operation and maintenance requirements shall be met with the set on the ground. Design for maintainability shall comply with 3.25. Particular design attention shall be given to paragraph 5.9 (especially 5.9.11.3 - Captive fasteners) of MIL-STD-1472 as specified in 3.25. Fasteners used for scheduled maintenance shall be visible to the maintainer. Fluid indicators shall be easily and readily accessible.

Alternate clothing servicing. Parts that require adjustment or servicing shall be capable of being adjusted or serviced by personnel wearing arctic clothing, and/or MOPP IV (6.4.20) chemical, biological and radiological clothing (O).

Fuses. If any non-resettable fuses are use, a spare fuse shall be stored and properly marked close to the location of the fuse it is a spare for (T). Replacement of non-resettable fuses shall take no more than 5 minutes and not require tools (T). No non-resettable fuses shall be used (O).

Maintainability requirements. Maintainability requirements shall be applicable to the generator set while operating on the ground. The complete maintenance schedule, preventive and scheduled, shall be followed throughout the first article inspection (4.4).

Preventive maintenance. The minimum interval (hours of set operation) between scheduled preventive maintenance (checks, inspections, services), known as Preventative Maintenance Checks and Services (PMCS), shall be 24 hours (T), 36 hours (O). Preventive maintenance shall be simple enough for any Soldier (regardless of specialty) to perform in less than 15 minutes (T), 5 minutes (O). Preventive maintenance actions shall include but not be limited to the following:

a. Inspecting for loose connections, leaks, cracks, and making minor adjustments.

b. Checking and adding lubricating oil.

c. Draining of contaminants from fuel filters and water separators through drain valves.

d. Checking and servicing of the battery.

e. Checking and adding coolant if applicable.

f. Checking and servicing of air filters.

Oil level. The oil level shall be able to be checked while the set is in operation without causing damage (6.4.5) (O).

Scheduled maintenance. The minimum interval (hours of set operation) between scheduled maintenance services (adjustments, replacements, etc.) shall be not less than 100 hours (T), 150 hours (O). Scheduled maintenance service intervals for the set life (3.9) shall be as recommended by the contractor. The maximum time for all scheduled maintenance actions at each scheduled maintenance interval, performed at intervals less than 2,000 hours, shall be 2 hours when conducted by one person (MOS-91D). Without tools, one person shall be able to change the oil and replace the oil filter, or replace or clean the fuel and air filters, within 20 minutes (T), 10 minutes (O).

Unscheduled maintenance. The Median Time to Repair (MTTR) (6.4.19) for all unscheduled maintenance actions at the field level shall not exceed 1 hour (T), 0.5 hours (O). The Maximum Time to Repair (MAXTTR) (6.4.18) for 90 percent of all unscheduled maintenance actions shall not exceed 2 hours (T), 1 hour (O).

Maintenance Ratio. The maintenance ratio (6.4.17) of the set shall not exceed 0.028 (T), 0.020 (O) maintenance man-hours per operating hour for the combined organizational and direct support maintenance levels.

Diagnostic test points. The set shall include diagnostic test points as necessary to fully monitor and troubleshoot the set. All diagnostic test points shall be located in one easily accessible area inside the control panel. All test points shall be labeled and identified (3.38.3.1.10).

Self-diagnostics. In lieu of or in addition to the diagnostic test points, the set shall conduct and display to the operator or maintainer a self-diagnosis of all Line Replaceable Units (LRUs) during start-up and during operation to allow operators and maintainers to take corrective actions and to enhance troubleshooting of the set (O).

Prognostics. If self-diagnostics capable, the set shall monitor the internal health of the system and identify malfunctions and warn of performance anomalies before they become failures. It shall also store warnings, faults, and maintenance actions, and set operational data that may be displayed to the operator but shall be accessed through the remote one receptacle in accordance with the Tactical Microgrid Standard–Tactical Ground Power (TMS-TGP).

Engine/generator lifting attachments. A single lifting attachment shall be provided for removal of both the engine and generator. The lifting attachment shall withstand, without damage (6.4.5), a minimum of 3.5 times the weight of the lifted assembly. The inside dimensions of the lifting attachment shall permit passage of a 2-inch diameter lifting device.

Maintenance mode. The set shall have a mode for performing maintenance which is entered into by actuating a separate control device located on the control panel or within the set. The control device shall be protected from accidental actuation through code (i.e. actuate for 10 seconds, etc.) or through mechanical means (i.e. a protective cover, etc.), or both. This mode shall only be cancelled by the cycling (removal and reconnection) of DC control power. While in maintenance mode (6.4.16) the set shall not open the AC circuit interrupter (or DC circuit interrupter if equipped) in the event that the energized AC load terminals (or DC load terminals if equipped) become exposed. The control system shall report through the remote one receptacle the set state of this mode while in the remote TMS state (6.4.29). If a continuous display is provided, then the continuous display shall indicate the same mode state.

Interchangeability. Future sets realized from this PD or specification, shall use the same engine, governing system, skid base, housing, frame, wiring harness, mounts, battery, battery charging system, fuel system, air filter, oil filter, fuel filter, muffler and as many other common components as practical of sets initially realized from this PD unless otherwise stated elsewhere.

Physical configuration.

Shape. The shape of the set shall be rectangular to optimize the storage volume within tactical vehicles. The set housing shall inherently or with an ancillary accessory allow for stackability to further optimize the storage volume within tactical vehicles. This capability shall support at least the weight of the same set stacked on top. The set top shall also inherently have features to enable nesting into matching features in the skid base to further enhance the capability. (O) Size. The maximum dimensions of the set shall be no more than (O):

a. Length – 34.75 inches (882.65 millimeters).

b. Width – 27.80 inches (706.12 millimeters).

c. Height – 26.50 inches (673.10 millimeters)

d. Control panel location as shown in FIGURE 1 (the actual side of the set).

Weight. The set dry weight (6.4.9) shall not weigh more than 308 pounds (140 kilograms).

Skid base. The set shall have a skid base that extends horizontally beyond all components of the set. The skid base shall be provided with a method to drain spilled liquids from the interior of the set. There shall be at least a 1-inch clearance between the lowest projection of the set and the bottom of the skid base. The set shall not move or "walk" when operating unrestrained, on a level concrete surface, under all operating conditions specified herein. The skid base may be integral with the set housing.

Bolt pattern. A four (4) hole bolt pattern shall be provided in the skid base of the set (T). The bolt pattern shall be located such that that the longitudinal and lateral center of gravity of the set falls approximately between the centers of the bolt holes (T). The bolt holes shall be large enough to accommodate a half inch diameter bolt (T). The skid base bolt pattern shall match FIGURE 1 (O).

FIGURE 1. Objective skid base bolt pattern.

Housing. The set housing shall be removable to perform unscheduled maintenance actions including removal of engine, generator or other components. The housing shall provide for access to the interior of the set, without removal of panels, as necessary to perform all preventative and scheduled maintenance service (3.16.3.2) actions and also permit replacement of the set battery while setting on the ground. Hinged doors, if used, shall be self-supporting in the open position. The door swing for any hinged door shall not exceed 20 inches. The housing shall be permanently marked with a CAUTION against standing or storage of heavy objects on its top and/or specifics about its limits. The housing shall have drain holes to allow liquids to drain from within the housing. The set housing shall not cause injury to personnel as a result of increased temperatures from internal components. The set housing shall exclude wind-driven rain, snow and sand from the interior of the set to the extent necessary to meet all requirements herein. If a gasket is used, it shall be mechanically fastened to the housing.

Hinges and latches. Hinges or hinge pins shall be peened at the ends, or other means shall be provided to prevent workout of the pins. Hinges shall be removable. Latches shall require manual, not spring action, for closing. All parts of the latches having relative motion with each other shall be of corrosion-resistant metal. Access door latches (3.18.5) shall be flush mounted, non-key locking, dead bolt, and shall not require the use of tools for operation or require more than a half turn to latch or unlatch a door.

Grounding and Bonding. Grounding and bonding (6.4.13 and 6.4.3) of the set and accessories shall be in accordance with article 250 of the NFPA70 National Electric Code. The set shall be capable of being connected to earth to limit the affects imposed by HEMP, EMI, lightning, and static charges. All non-current-carrying metal parts that are accessible to users and are likely to become energized due to an electrical fault shall be bonded and grounded. Panels and doors shall be attached or hinged in such a manner as to ensure that they are at the same ground potential as the rest of the set in which they are mounted, whether in a closed or open position. Hinges or slides shall not be used for grounding paths. Ground connections to shields, hinges, and other mechanical parts shall not be used to complete electrical circuits. The impedance between the set ground (3.19.1.2) and to any bonded non-current carrying metal part shall be less than 0.1 ohms.

Set ground rod. A three-section ground rod and the ground rod accessories (grounding conductor, grounding conductor clamp, and ground rod section interconnects) conforming to A-A-55804-III-B shall be provided with each set (including both first article and production). Provisions for storage of the ground rod sections and its accessories, internal to the set, shall be provided, if the size of the set is large enough to allow for storage of ground rods and its accessories. If the ground rods and its accessories are stored within the set, door(s) through which ground rods are accessed shall be marked "GROUND ROD" on the outside.

Spacings. The minimum creepage and clearance (6.4.4) distances between uninsulated live parts of opposite polarity and between uninsulated live parts and non-current-carrying metal parts shall be no less than the spacing distances in TABLE I. The shortest distance between any output load terminals, including the ground terminal (3.19.1), shall be no less than 1.25 inches (31.8 millimeters).

TABLE I. Spacings.

Load terminals, load receptacles, and circuit interrupter. Load terminals, load receptacles, and circuit interrupters shall be protected from accidental contact and shall be protected from the environments while in use or not in use, attended or not attended, see section 406.9 “Receptacles in Damp or Wet Location” of NFPA 70 National Electrical Code. The AC load terminals (and DC load terminals, if equipped) shall not be energized if a protective door, lid, or cover has opened or has been removed. Exception is when the set is put into the maintenance mode (3.16.7) or in battle short mode (3.32.1.7). The control system shall monitor if this door, lid, or cover is exposing energized terminals to the user or not and report on its current state through the remote one receptacle in accordance with the TMS-TGP standard when in the remote TMS state (6.4.29) and illuminate the warning indicator or if a continuous display is provided, indicate the warning on the display.

Load terminals. Load terminals shall be sized to carry the full power of the set in all capable configurations (3.2 and 3.35). Load terminals shall conform to drawing 30554-69-692. Load terminals shall be rigidly mounted; studs shall not twist or turn in their mountings when hexagonal bar nuts are tightened. Terminals shall be readily accessible for connection of external output wires.

AC load terminals. The set shall be equipped with three (3) load terminals for AC power. The load terminals shall be conspicuously marked "L1", "L2", and "N"; terminal "N" being neutral. The load terminals shall be arranged in line in the sequence "L1", "L2", and "N" when reading from left to right or from top to bottom.

Ground terminal. The set shall be equipped with an appropriately sized ground terminal marked "GND". The ground plane shall contain the ground terminal and be permanently connected to the skid base by means of a low impedance, corrosion free connection. The ground terminal shall be provided next to the AC load terminals to serve as equipment ground (6.4.13) for the set with proper spacing (3.18.8). The set mounting arrangement shall permit a removable, low impedance connection between "N" and "GND" terminals. The connection shall be sized in accordance with the NFPA70 National Electrical Code. The control system shall monitor if the neutral ground (N-G) bond (6.4.3) is in place or not and report on its current state to the continuous display, if equipped, and through the remote one receptacle in accordance with the TMS-TGP standard when in the remote TMS state (6.4.29).

Load terminals AC (or DC if applicable) circuit interrupter. A dedicated AC circuit interrupter shall be connected between the voltage reconnection system and the AC load terminals. The AC circuit interrupter shall be electrically controlled from the DC control power by means of a dedicated switch on the control panel and the control system. The AC circuit interrupter shall be a device constructed such that the contacts close and open simultaneously. It shall not be possible for any of the contacts to remain closed while others are open. The main contacts shall open or close within 50 milliseconds when operating on the DC control voltage. Auxiliary contacts shall be provided that open and close with the main contacts. The control system shall monitor the state of the contactor (open or closed) from the auxiliary contacts. The control system shall monitor the voltage at the input side of the AC circuit interrupter main contacts (set voltage) and at the AC load terminals (bus voltage) for proper set operation. The AC circuit interrupter shall be connected so that it opens automatically when any of these conditions exist: 1. The AC circuit interrupter control device is placed in the “OPEN” state; 2. The set control device is placed in the "OFF" state; 3. The DC control circuit breaker is opened; 4. The emergency stop switch is actuated; 5. As required for remote control (3.34); or 6. As required by the protection system (3.33). This shall be accomplished independently from any protective device. Interrupting capacity of the main contacts shall be not less than 8 times rated current for the contacts.