ARMY MIL-PRF-81757 23-2011 WIRING HARNESS FOR BATTERY RECHARGEABLE REPAIRABLE NICKEL CADMIUM VENTED 24-VOLT BB-664 A.pdf

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1、AMSC N/A Page 1 of 11 FSC 6140 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited INCH-POUND MIL-PRF-81757/23(CR) 25 FEB 2011 PERFORMANCE SPECIFICATION SHEET WIRING HARNESS FOR BATTERY, RECHARGEABLE, REPAIRABLE, NICKEL CADMIUM, VENTED, 24-VOLT, BB-664/A This specificati

2、on is approved for use within Army CECOM Life Cycle Management Command, Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense. The requirements for acquiring the product herein shall consist of this specification and MIL-PRF-81757. REQUIREMENTS

3、 1. Part or identifying number. The part or identifying number (PIN) of the wiring harness shall be M81757/23-1. 2. Wiring harness assembly. The wiring harness shall fit inside a M81757/21-1 (BB-664/A) battery and shall provide over-temperature warning, over-temperature cut-outs, and have internal h

4、eating elements. The wiring harness shall consist of the following: a. One auxiliary receptacle (J2), conforming to the interface requirements of an MS27505E11E35S back panel box mounting receptacle to provide connection to battery sensing and control points. The receptacle shell shall be conductive

5、, corrosion resistant, and shall be capable of operation over a range of -65C to 200C. The J2 receptacle shall be connected as shown in Figure 2. Contacts shall be so designed that the sockets will not be damaged during repeated mating of counterpart connectors. The back of the connector shall be po

6、tted to prevent migration of electrolyte. b. One normally open temperature switch (S1) mounted as shown in Figure 1. The switch shall close when the battery temperature exceeds 57 3C (135F) and shall reopen when the battery temperature falls below 49 3C (120F). The temperature switch shall be certif

7、ied to withstand a minimum of 10,000 operating cycles at 30VDC and 1.0 ampere. The height of the thermoswitch, including the cell link, shall be no greater than 0.753 inches. c. One temperature transducer (TH1) shall be mounted as shown in Figure 1. Potting shall be employed to isolate the temperatu

8、re transducer from any unconnected battery voltage. Transducer temperature and resistance profile shall be as specified below. Copyright Communications - Electronics Command Provided by IHS under license with CRAINot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-

9、PRF-81757/23(CR) 2 Temperature Acceptable Resistance Range (ohms) 10oC (50oF) 2760-2860 16oC (60oF) 2840-2930 21oC (70oF) 2910-2990 27oC (80oF) 2990-3050 32oC (90oF) 3060-3125 38oC (100oF) 3130-3200 43oC (110oF) 3200-3280 d. One center tap voltage lead, having a ring terminal wire lug, shall be as s

10、hown in Figure 1. e. Three copper, ring terminal wire lugs, two of which can accommodate # 22 AWG wire (Ref. letter A and D) and one that can accommodate two # 22 AWG wires (same cross-sectional area as one # 19 AWG wire). All three shall accommodate #8-32 screws. f. The battery harness shall contai

11、n a heater assembly as shown in Figure 3. The three heater strips shall have the following properties: 1) The center heater shall have a total resistance of 76.7 2 ohms over the length of 10 7/8 inches and a resistance of not less than 3.4 ohms for a distance of not less than one inch starting from

12、the edge with the wire connections, connected in series with the 10 7/8 inches section. The resistance shall be uniformly distributed when contact is made with the cells at 6.74 ohms per inch. 2) The heater placed on the left (connector) side of the battery, in contact with nine cells, shall have a

13、total resistance of 162 2 ohms. This resistance shall be uniformly distributed where contact is made with the cells at 15.2 ohms per inch. 3) The heater placed on the right side, in contact with ten cells, shall have a total resistance of 145 2 ohms. This resistance shall be uniformly distributed wh

14、ere contact is made with the cells at 12.2 ohms per inch. g. Two (2) series connected single pole double throw (SPDT) thermoswitches (S3 breakdown of insulation; stripping of metal plating from connectors; corrosion of metal parts; nor cracking of potting compound. “c. The transducer shall meet the

15、requirements herein. “d. The thermoswitches shall close or open within the specified temperature ranges herein. “e. There shall be no mechanical failure of components. “f. There shall be no dimensional distortion beyond specified limits.” “3.10.32 Heater blanket. The M81757/21-1 (BB-664/A) battery s

16、hall have a heater blanket consisting of three heater strips as described elsewhere in this specification sheet. It shall have a total power of 342 15 watts of heat uniformly delivered to the battery cells. When tested as Copyright Communications - Electronics Command Provided by IHS under license w

17、ith CRAINot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-81757/23(CR) 5 specified in 4.5.34 installed in a M81757/21-1 (BB-664/A) battery, it shall be capable of raising the cell temperature from -54C (-65F) to -10C (+14F) in not less than one hour after the

18、 start of heating. Heater hot spot temperature shall not exceed 110C (230F). When tested as specified in 4.5.35, the heater shall demonstrate operation for 500 hours without deterioration or breakdown under visual examination or dielectric strength testing or change of resistance.” VERIFICATION 1. M

19、IL-PRF-81757 variance. The battery shall comply with MIL-PRF-81757 except as follows. 1.1 Modify the following paragraphs: 4.2.1 Inspection of batteries. Delete in its entirety and replace with: “For harness-only qualification, two harnesses shall be provided; one for the tests in Table IV of MIL-PR

20、F-81757 and the other for those tests added to table IV by the variance herein.” 4.5.3 Electrolyte resistance. Add the following at the end of the paragraph: “Functional testing shall consist of the connection continuity of harness test of 4.5.32.” 4.5.16 Vibration test. The wiring harness shall be

21、installed in a M81757/21-1 or similar configuration battery (i.e., BB-476/A) for vibration testing. No charge or discharge shall be performed before, during, or after vibration testing (i.e., the condition of the cells used will not impact test outcome). Following vibration testing, the wiring harne

22、ss shall be removed from the battery. Each harness shall be subject to the connection of continuity of harness test at 4.5.32. Visually examine each harness. Harnesses shall meet the requirements of 3.9 as modified herein and 3.10.31. 4.5.17 Temperature shock test. Subject wiring harnesses to the sa

23、me temperature shock method specified for batteries, except that all battery-specific steps (i.e., cover removal/replacement, charging, discharging) are not applicable. After the temperature shock test, perform the connection continuity of harness test of 4.5.32. Harnesses shall meet the requirement

24、s of 3.9 as modified herein and 3.10.31. 1.2 Add the following new paragraphs: “4.5.32 Connection continuity of harness. Continuity of the wiring harness terminations shall be checked with an ohmmeter between the points specified below. Continuity shall comply with 3.10.31. “a. J2 Socket 2 to Cell #

25、 10 Lug J2 Socket 3 to Power (-) Lug J2 Socket 4 to Power (+) Lug J2 Socket 10 to J2 Socket 11 “b. J2 Socket 6 to J2 Socket 7 (resistance of transducer; see 2c above) J2 Socket 9 to J2 Socket 12 (resistance of heater assembly) “c. J2 Socket 5 to J2 Socket 3 Copyright Communications - Electronics Com

26、mand Provided by IHS under license with CRAINot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-81757/23(CR) 6 J2 Socket 5 to Power (-) Lug J2 Socket 10 to J2 Socket 12 J2 Socket 10 to J2 Socket 9” “4.5.33 Wiring harness temperature test. The following test sha

27、ll be performed. After completion of testing, the wiring harnesses shall meet the requirements of 3.1 and 3.10.31. “a. Fixture the wiring harness so that an ohmmeter is connected across the terminals of the transducer and all thermoswitches. Note: Thermoswitches S3 and S3A require monitoring of dual

28、 output. “b. Place the harness into an environmental chamber. “c. Set the chamber to reach a temperature within a range of +3.4 1.1C (38F); allow the test sample to stabilize for not less than 1 hour. “d. Set the chamber to ramp down the temperature to not less than -5.0C (23F) at a rate not greater

29、 than 1C per five minutes while monitoring the continuity of thermoswitches S3 and S3A continuously. “e. Once thermoswitches S3 and S3A change status, record the temperature and stop the temperature decrease. “f. Set the chamber to reach a temperature within a range of 1.0 1.1C (34F). “g. Set the ch

30、amber to ramp up the temperature to not less than 11.2C (52F) at a rate not greater than 1C per five minutes while monitoring the continuity of thermoswitches S3 and S3A continuously. “h. Once thermoswitches S3 and S3A change status, record the temperature and proceed to the next step. “i. Set the c

31、hamber to reach the first temperature set point in the table below. Once the set temperature has been reached, allow the test sample to stabilize for not less than 1 hour. “j. Record resistance values for the thermistor. “k. Repeat steps i and j for the second set point in the table below. “l. Repea

32、t step k until readings have been obtained at all 4 set points. “m. Set the chamber to reach a temperature within a range of 52.8 1.1C (127F); allow the test sample to stabilize for not less than 1 hour. “n. Set the chamber to ramp up the temperature to not less than 60.0C (140F) at a rate not great

33、er than 1C per five minutes while monitoring the continuity of thermoswitch S1 continuously. “o. Once thermoswitch S1 closes, record the temperature and stop the temperature increase. “p. Set the chamber to reach a temperature within a range of 53.2 1.1C (127F). “q. Set the chamber to ramp down the

34、temperature to not greater than 46C (115F) at a rate not greater than 1C per five minutes while monitoring the continuity of thermoswitch S1 continuously. Copyright Communications - Electronics Command Provided by IHS under license with CRAINot for ResaleNo reproduction or networking permitted witho

35、ut license from IHS-,-,-MIL-PRF-81757/23(CR) 7 “r. Once thermoswitch S1 opens, record the temperature and proceed to the next step. “s. Return chamber to room ambient conditions. Allow the test sample to stabilize for not less than 1 hour. Remove the test sample and examine wiring harness for the re

36、quirements of 3.10.31. “Temperature Set Points, BB-664/A (1) 10.0 1.1C (50F) (2) 21.0 1.1C (70F) (3) 32.0 1.1C (90F) (4) 43.0 1.1C (110F)” “4.5.34 Heater blanket operation. The heater blanket shall be tested as follows. Install the full harness assembly into a M81757/21-1 (BB-664/A) battery. Charge

37、the battery in accordance with 4.4.3. Store the battery at -54C (-65F) for not less than 16 hours. Install temperature monitoring devices on all temperature switches and thermistors, and in not less than 3 cells to monitor electrolyte temperature. Apply 115 VAC 10%, 400 Hz 5% input power to the heat

38、er blanket. Continue testing at these parameters until battery electrolyte temperature exceeds -10C (+14F). Allow the entire battery to stabilize at room temperature for not less than 16 hours. Perform the dielectric strength test of 4.5.27. Heater blanket shall comply with 3.9, 3.10.27, and 3.10.32

39、.” “4.5.35 Heater blanket life test. The battery heater shall be tested for 500 hours under the following operating conditions. Insure the heater blanket is not installed in a battery; if connected to the harness, bypass the two heater thermoswitches. a. Test at 60 3C (140F), ambient humidity and at

40、mospheric pressure. b. Cycle the heater input power by applying 115 VAC 10%, 400 Hz 5% input power to the heater blanket for 30 5 seconds every 5 minutes. c. At the 250thand 499thhours, increase the input voltage to 190 volts, RMS, for not less than 0.1 second. At the completion of 500 hours, examin

41、e the heater for deterioration or damage. Conduct the dielectric strength test of 4.5.27. The heater blanket shall comply with 3.9, 3.10.27, and 3.10.32. Copyright Communications - Electronics Command Provided by IHS under license with CRAINot for ResaleNo reproduction or networking permitted withou

42、t license from IHS-,-,-MIL-PRF-81757/23(CR) 8 1.3 Modify the Tables of MIL-PRF-81757 as follows: Table IV. Qualification inspection of components and materials. Add the following: Part Examinations and tests Requirement paragraph Test paragraph Wiring harness Connection continuity of harness 3.10.31

43、 4.5.32 Wiring harness Vibration 3.9 4.5.16 Wiring harness Heater blanket operation 3.9, 3.10.32 4.5.34 Wiring harness Heater blanket life test 3.9, 3.10.32 4.5.35 Wiring harness Temperature shock 3.9, 3.10.31 4.5.17 Wiring harness Wiring harness temperature test 3.10.31 4.5.33 Table VII. Group B in

44、spection. Add the following: Test No. Examinations and tests Requirement paragraph Test paragraph I-4 Subgroup I Dielectric strength and insulation resistance 3.9, 3.10.27 4.5.27 Table VIII. Group C inspection. Add the following: Test No. Examinations and tests Requirement paragraph Test paragraph I

45、-10 I-11 Subgroup I Electrolyte resistance Temperature shock 3.9, 3.10.3 3.9, 3.10.31 4.5.3 4.5.17 I-12 Vibration 3.9 4.5.16 II-8 II-9 Subgroup II Wiring harness temperature test Heater blanket operation 3.10.31 3.9, 3.10.32 4.5.33 4.5.34 Copyright Communications - Electronics Command Provided by IH

46、S under license with CRAINot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-81757/23(CR) 9 Copyright Communications - Electronics Command Provided by IHS under license with CRAINot for ResaleNo reproduction or networking permitted without license from IHS-,-,-

47、MIL-PRF-81757/23(CR) 10 FIGURE 1 NOTES (internal paragraph reference): 1. All dimensions are in inches; tolerances are .25 inches unless otherwise stated 2. MS27505E11E35S connector (2a) 3. Thermoswitch S3A (2g) 4. Thermoswitch S3 (2g) 5. Thermoswitch S1 (2b) 6. Temperature transducer (2c) 7. Copper

48、 ring terminal wire lug (2e) 8. Heat shrink as needed 9. Heater assembly (Figure 3) FIGURE 2: Wiring Harness Connections Copyright Communications - Electronics Command Provided by IHS under license with CRAINot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-81757/23(CR) 11 WIRE O TO S3A THERMOSWITCHWIRE I TO J2 SOCKET 12WIRE M TO J2 SOCKET 9HEATER 3HEATER 2HEATER 1FIGURE 3: Heater Assembly FIGURE 3 NOTE: All dimensions are in inches Custodians: Preparing activity Army CR Army CR (Project Number 6140-2009-024) NOTE: T