ARMY MIL-PRF-32389-2013 LOAD BANK ELECTRICAL.pdf

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1、 MIL-PRF-32389 14 Aug 2013 PERFORMANCE SPECIFICATION LOAD BANK, ELECTRICAL This specification is approved for use by the Communication-Electronic Research and Development Center (CERDEC) and is available for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This d

2、ocument specifies the requirements for the design modification, fabrication, integration, test, and verification of a Load Bank, Electrical, hereinafter referred to as Load Bank. The Load Bank is intended to replace the TS-4216/G Load Bank (6625-01-220-2619), which is defined by military specificati

3、on MIL-L-52366. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While

4、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, 4, or 5 of this specification, whether or not they are listed. 2.2 Government Documents 2.2.1 Specifications, standards, a

5、nd handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. AMSC N/A FSC 6150 INCH-POUND Comments, suggestions, or question

6、s on this document should be addressed to Communication Electronic Research and Development Center (CERDEC), ATTN: RDER-PRO, Aberdeen Proving Ground, MD 21005 or emailed to us at army.apg.cerdec.mbx.standardization-crxmail.mil. Since contact information can change, you may want to verify the currenc

7、y of this address information using the ASSIST Online database at https:/assist.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-32389 2 DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-PRF-28800 Performance Specification, Test Equipment For

8、Use With Electrical and Electronic Equipment, General Specification (Copies of this document are available online at http:/quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) DEPARTMENT OF DEFENSE STANDARDS MIL-STD-1472

9、 Human Engineering MIL-STD-13231 Marking for Electronic Items (Copies of this document are available online at http:/quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Order of precedence. In the event of a conflic

10、t between the text of this document and the references cited herein, 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 Equipment sample requirements. When specif

11、ied (see 6.2), sample equipment shall be provided for inspections as specified in 3.1.1 and 3.1.2. 3.1.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection (see 4.2). 3.1.2 Conformance inspection. When specified (see 6.2), a sample shall be subjected to

12、conformance inspection (see 4.3). 3.2 Mode of Operation Requirements. The overall functional capability of the Load Bank shall be rated for continuous and operational performance providing reliable and safe conditions for testing and maintaining electrical generating equipment. 3.2.1 Load Power Capa

13、city. The Load Bank shall be specified for resistive standard load capacity consisting of single-phase and three-phase voltage ratings. The minimum load capacity ratings are provided in Table 1. Table I. Load Power Capacity MIN LOAD CAPACITY VOLTAGE RATING PHASE/FREQUENCY MIN LOAD STEP VALUES 60 kW

14、208 VAC 3-Phase/60 Hz 5 kW, 10 kW, 15 kW, 30 kW, 60 kW 3 kW 120 VAC 1-Phase/60 Hz 1 kW, 2 kW, 3 kW 3.2.2 Load Capacity. The Load Bank shall support single phase and three-phase load capacities. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-

15、32389 3 3.2.2.1 Three-Phase Load Capacity. The Load Bank shall provide at least 60 kW three-phase load capacity. 3.2.2.2 Single-Phase Load Capacity. The Load Bank shall provide at least 3 kW single-phase load capacity. 3.2.3 Voltage Rating. The Load Bank shall provide voltage rating for single phase

16、 and three phase configurations. 3.2.3.1 Three Phase Voltage Rating. The Load Bank shall provide 208 VAC voltage rating for three-phase load capacity. 3.2.3.2 Single Phase Voltage Rating. The Load Bank shall provide 120 VAC voltage rating for single-phase load capacity. 3.2.4 Phase/Frequency. The Lo

17、ad Bank shall provide operational functions for 60 Hz and 400 Hz generators. 3.2.4.1 60 Hz Generator. The Load Bank shall operate at 60 Hz for single phase and three-phase configurations generators. 3.2.4.2 400 Hz Generator. The Load Bank shall provide functional capability to support 400 Hz generat

18、ors. 3.2.5 Load Increments. The Load Bank shall provide the capability to adjust loads in step increments. 3.2.5.1 Three Phase Load Increments. The Load Bank while in three phase operation shall, at a minimum, provide adjustable loads in 5 kW steps. 3.2.5.2 Single Phase Load Increments. The Load Ban

19、k while in single phase operation shall, at a minimum, provide adjustable loads in 1 kW steps. 3.2.6 Control Power. The Load Bank shall operate from a generator under test with the exception that it may operate with an external 60 Hz source when testing a 400 Hz generator. 3.2.7 Operators Controls.

20、The Load Bank shall have a control panel with switches and devices capable of selection by the operator. 3.2.7.1 Control Panel. The Load Bank control panel shall provide a Master load on/off switch, a load step on/off switch consisting of a minimum of four load increments, power indicators, and test

21、 points to measure the voltage across the load. 3.2.7.2 Panel Orientation. The Load Bank panel shall be capable of being positioned in a face up orientation, as well as face front. The Load Bank shall be stable in both positions in accordance with MIL-PRF-28800. 3.2.8 Measurements. The Load Bank sha

22、ll be capable of measuring voltage, current, and frequency per phase to at least 3% accuracy. Accuracy verification shall be performed every twelve months. If calibration is a feature of the instrumentation, it shall be done at that time. Provided by IHSNot for ResaleNo reproduction or networking pe

23、rmitted without license from IHS-,-,-MIL-PRF-32389 4 3.3 External Interface Requirements. The Load Bank shall provide external AC power connections. 3.3.1 Connectors. The modified Load Bank shall support 175 Amp Powerpole type connectors. 3.3.2 Cables. The Load Bank shall include single and 3-phase

24、cable assemblies 8 to 10 feet in length with the generator end terminating in bare metal in a manner to provide size compatibility with all serviced generator lugs from 2 kW to 60 kW. 3.3.3 Cable Conductors. The Load Bank shall provide flexible conductors of an appropriate size (AWG) with insulation

25、, labels or makings colored in black, red, blue, white and green. 3.3.4 Test Points Accessibility. The Load Bank shall support panel-mounted test pins for connecting test leads. 3.3.5 Operators Interface. The Load Bank shall provide an easily accessible control panel for test instrumentation, load a

26、pplication switches, fan and control power switches, and operations illuminated indicators. 3.4 Safety Requirements. The Load Bank shall provide safety mechanisms and features to protect the user from electrical and physical hazards. 3.4.1 Personnel Hazards. When handling and working with the Load B

27、ank, personnel shall not be exposed to hazardous voltages or injury from mechanical components. Safety labels shall be placed in areas where a potential hazard can be encountered. 3.4.2 Edge Rounding Exposed. The Load Bank exposed edges shall be rounded to a minimum radius of 0.03 inch (0.75 mm), an

28、d exposed corners to a minimum of 0.05 inch (1.3 mm) in accordance with MIL-STD-1472. 3.4.3 Radioactive Material. The Load Bank shall not use radioactive materials (e.g. luminous dials/markings, electron tubes, surge arrestors and lenses). 3.4.4 Over Current Protection. Incoming power shall be fused

29、 to prevent over current input to the Load Bank. 3.4.5 Interlock Mechanism. Interlock mechanisms shall be implemented to prevent operation with insufficient cooling airflow to assure that the Load Bank does not overheat. 3.4.6 Flammable Material. The Load Bank shall not contain materials that ignite

30、 into flames at operating or storage temperatures. 3.5 Environmental Requirements. The Load Bank shall be classified as Class 2 test equipment in accordance with section 1.2.2 of MIL-PRF-28800 for a transit case protection. 3.5.1 Temperature. The Load Bank shall meet the temperature requirements for

31、 a Class 2 test equipment in accordance with MIL-PRF-28800. 3.5.1.1 Operating Temperature. The Load Bank shall operate in accordance with MIL-PRF-28800, Class 2 test equipment in the range of -10C (14F) to +55C (+131F). Provided by IHSNot for ResaleNo reproduction or networking permitted without lic

32、ense from IHS-,-,-MIL-PRF-32389 5 3.5.1.2 Storage Temperature. The Load Bank shall be in accordance with MIL-PRF-28800, storage temperature for a Class 2 test equipment, -51C (-60F) to +71C (+158F). 3.5.2 Relative Humidity. The Load Bank shall be subjected to conditions where the relative humidity i

33、s 5 to 955 percent in the temperature range of 10C (50F) to 30C (86F), conditions where the relative humidity is 5 to 755 percent in the temperature range of 30C (86F) to 40C (104F), and where the relative humidity is 5 to 455 percent in the temperature range above 40C (104F) to +55C (131F). 3.5.3 A

34、ltitude. The Load Bank shall meet the specified performance and accuracy requirements after returning from an altitude of 4600 meters in accordance with MIL-PRF-28800, Class 2 test equipment. The Load Bank is not used at altitudes beyond those specified for the generators. 3.5.4 Vibration. The Load

35、Bank shall be in accordance with the performance and accuracy requirements of MIL-PRF-28800, Class 2 test equipment after vibration tests. 3.5.4.1 Random Vibration. The Load Bank shall be subjected for 30 minutes per axis, to 10-500 Hz with a power spectral density of 0.03 g2/Hz. 3.5.4.2 Sinusoidal

36、Vibration. The Load Bank shall be subjected to sinusoidal vibration in accordance with MIL-PRF-28800, Class 2 test equipment. 3.5.5 Shock, Mechanical. The Load Bank shall meet the specified performance and accuracy requirements in accordance with MIL-PRF-28800, Class 2 test equipment aftershock test

37、s. 3.5.5.1 Shock, Functional. The Load Bank shall be subjected to 30g half-sine shock test in accordance with MIL-PRF-28800, Class 2 test equipment. 3.5.5.2 Transit Drop. The Load Bank shall be subjected to a drop test in accordance with MIL-PRF-28800, Class 2 test equipment. 3.5.6 Fungus. The Load

38、Bank shall not support fungal growth. 3.5.7 Salt Fog. The Load Bank shall meet the specified performance and accuracy requirements in accordance with MIL-PRF-28800, Class 2 test equipment, after exposure. 3.6 Electromagnetic Compatibility (EMC). The Load Bank shall be in accordance with MIL-PRF-2880

39、0, Class 2 test equipment. 3.7 Reliability. The design of the equipment shall be such that under normal use and operation the equipment does not fail within 1500 hours of operation with a statistical certainty of 95%. The manufacturer shall provide a summary of maintenance or warranty records to est

40、ablish the validity of the statistical assertion. Records of the actual equipment model shall be used, unless the Government authorizes the substitution of records from a similar model, due to the lack of sufficient supporting documentation on the offered equipment. The manufacturer shall be able to

41、 reasonably establish the claim that the offered equipment shall provide reliability similar to the model used to provide substitute records. 3.8 Maintainability. Maintainability shall be as specified in sections 3.8.1 to 3.8.3 Provided by IHSNot for ResaleNo reproduction or networking permitted wit

42、hout license from IHS-,-,-MIL-PRF-32389 6 3.8.1 Fault isolation. To whatever extent possible any required modification of the equipment shall permit isolation of faults, and repair down to the component item or lowest replaceable unit available. 3.8.2 Preventive maintenance. Preventive maintenance s

43、hall not require more than 15 minutes per a 30-day period. Preventive maintenance shall not require breaking of the equipment seams where calibration seals would normally be placed. 3.8.3 Maintenance provisions. Equipment shall be as specified in a. through d. to facilitate Maintenance. a. Accessibi

44、lity for maintenance. If required, the equipment shall be modified to ensure that maintenance access can be accomplished utilizing ordinary tools. The modifications shall be constructed so that no damage to any component shall occur and no permanent distortion to any structural member shall be cause

45、d during maintenance and calibration. b. Maintenance and calibration aids. When specified, circuit board extenders, special adapters, special tools (see 6.3), and patch cables required for maintenance or calibration shall be provided. They shall be identified as a set with a unique part number and n

46、ational stock number. Stowage shall be in a reusable pouch or container. c. Accessibility for repair. The modifications shall be designed so that subassemblies and chassis components can be removed without removing other hardwired subassemblies or components. Printed circuit cards shall be removable

47、 without the need to unsolder cables and interconnecting wiring. Printed circuit cards designed primarily to distribute power and signals to other printed cards are excluded from this requirement. When motherboards are used they shall be accessible from both sides to facilitate troubleshooting or re

48、pair. d. Accessibility for adjustment. The modification design shall permit adjustments to be made without removing any component, printed circuit cards, or subassembly. The use of extender cards is permitted. 3.9 Physical Characteristics of the System 3.9.1 Mechanical Parameters. The Load Bank shall have mechanical parameters not to exceed those specified below. 3.9.1.1 Weight. The weight of the Load Bank shall be lightweight, portable, not to exceed a one-man carry weight of 82 lbs in accordance with MIL-STD-1472. 3.9.1.2 Size. The Load Bank unit dimensions shall be in accordance with