DLA MIL-PRF-44259 E-2009 LIGHT SET PORTABLE FLUORESCENT.pdf

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1、Comments, suggestions, or questions on this document should be addressed to Defense Supply Center Richmond, ATTN: DSCR-VEB, 8000 Jefferson Davis Highway, Richmond, VA 23297-5616, or e-mailed to STDZNMGTdla.mil. Since contact information can change, you may want to verify the currency of this address

2、 information using the ASSIST database at http:/assist.daps.dla.mil/. AMSC N/A FSC 6230 INCH-POUND MIL-PRF-44259E 29 June 2009 SUPERSEDING MIL-PRF-44259D w/AMENDMENT 1 16 March 2004 PERFORMANCE SPECIFICATION LIGHT SET, PORTABLE, FLUORESCENT This specification is approved for use by all Departments a

3、nd Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers two types of portable fluorescent lights. 1.2 Classification. The light sets are of the following types, as specified (see 6.2): Type I - Set of four lights, with hard case, for Tent, Extendable, Modular, Personn

4、el (TEMPER) Type II - Set of two lights, no case, for Tent, Modular, Command Post, System (MCPS) Type III - Single light, no suspension strap 1.3 Part or identifying number (PIN). The PIN to be used for light sets acquired to this specification is created as follows: M 44259 - XX Type: I - Type I -

5、TEMPER II - Type II - MCPS III - Type III - Single light Specification number Prefix to indicate military specification Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-44259E 2 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this

6、 section are specified in sections 3 and 4 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 every effort has been made to ensure the completeness of this list, document users a

7、re cautioned that they must meet all specified requirements of the documents cited in sections 3 and 4 of this specification, whether or not they are listed. 2.2 Government documents. 2.2.1 Standards. The following standards form a part of this document to the extent specified herein. Unless otherwi

8、se specified, the issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE STANDARDS MIL-STD-202 - Electronic and Electrical Component Parts MIL-STD-461 - Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

9、MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests MIL-STD-1916 - DOD Preferred Methods for Acceptance of Product (Copies of these documents are available online at http:/assist.daps.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, P

10、hiladelphia, PA 19111-5094.) 2.2.2 Other government drawings. The following other government drawings form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation or contract. DRAWINGS ARMY 5-4-6721 - Strap, Light Support Ass

11、embly, Type II Light 5-4-6774 - Label, Wiring Diagram 5-4-6785 - Label, Date of MFG 5-4-6822 - Label, Caution threaded parts shall show no evidence of looseness, cross threading, or stripping; wire insulation shall show no evidence of burns, abrading, or pinch marks; and solder connections shall hav

12、e a smooth bright appearance with metallic luster and shall not have a chalky, gritty, or irregular surface nor exhibit any protrusions, pits, or voids. Finish shall be smooth and uniform without sags, pinholes, blisters, scratches, wrinkles, foreign matter imbedded in finish, or tackiness. The fini

13、shed light assembly shall conform to the quality of product established by this specification and the occurrence of defects shall not exceed the applicable quality levels. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. Fi

14、rst article inspection (see 4.2). b. Conformance inspection (see 4.3). 4.2 First article inspection. When first article is required (see 3.1 and 6.2), it shall be examined for the defects specified in 4.3.3 and 4.3.4 and shall be tested for the characteristics specified in tables I and IV. Provided

15、by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-44259E 8 TABLE I. First article tests. Requirement characteristic Test paragraph Test method Electromagnetic compatibility 3.4.8 4.4.1 Illumination 3.4.10 4.4.4 Light reduction 3.4.10.1 4.4.4.1 Cold star

16、ting at 60 Hz 3.5.6 4.4.2 Cold starting at 50 Hz 3.5.6 4.4.3 Thermal protector 3.4.5 4.4.6 Interconnection of lights 3.4.6 4.4.16 Dielectric strength 3.4.7 4.4.7 Insulation resistance 3.4.9 4.4.9 High and low temperature storage 3.5.1 4.4.10 High temperature operation 3.5.2 4.4.11 Resistance to humi

17、dity 3.5.3 4.4.12 Resistance to vibration 3.5.4 4.4.13 Noise levels 3.5.5 4.4.14 Interchangeability 3.6 4.4.15 4.3 Conformance inspection. Unless otherwise specified, sampling for inspection shall be performed in accordance with MIL-STD-1916. 4.3.1 Component and material inspection. Components and m

18、aterials shall be inspected in accordance with all the requirements of referenced documents, unless otherwise excluded, amended, modified, or qualified in this specification or applicable purchase document. 4.3.2 In-process inspection. Inspection of subassemblies shall be made to ascertain that cons

19、truction details, which cannot be examined in the finished product, are in accordance with specified requirements. The Government reserves the right to exclude from consideration for acceptance, any material or service for which in-process inspection has indicated nonconformance. Inspection shall be

20、 made of the following fabrication operations to establish conformance with specified requirements: a. That color coded wire is used throughout the wiring of the light assembly and is in agreement with the wiring schematic and that the wire is of the specified wire size. b. That all materials are pr

21、operly coated or protected from corrosion effects. c. That all electrical wires are properly routed and insulated to prevent abrasion from sharp edges. d. That all mounting hardware is properly secured. e. That all soldering is in accordance with specified requirements and soldered connections have

22、complete fusion, no excess solder, no porosity or inclusions, and all flux has been removed. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-44259E 9 f. That any crimp-type electrical fasteners are secure on the wires and that no wire strands

23、 are broken or not secured within the fastener. g. That wiring schematic is displayed in ballast chamber. Whenever nonconformance is noted, correction shall be made to the item affected and the process. Items, which cannot be corrected, shall be removed from production. 4.3.3 End item visual examina

24、tion. The end items shall be examined for the defects listed in table II. The lot size shall be expressed in units of complete light sets. The sample unit shall be one complete light set. The verification levels shall be IV for major defects and II for minor defects. TABLE II. End item visual defect

25、s. Classification Examine Defect Major MinorFinish Not adherent, e.g., blistered, peeled, or flaky 201 Coating not continuous or uniform i.e., not coated or area of no film 202 Scratch, dig, or abrasion exposing bare metal or primer 203 Color Not color specified 101 Electrical cable Not proper size

26、or type Cut or abrasion 102 103 Electrical connector Missing or not correct part number 104 Light straps Not as specified 105 Design and workmanship Sharp edge or burr 106 Puncture, fracture, or malformed 107 Design detail deviating from document 108 Evidence of rust or deposit of any foreign matter

27、 204 Light switch Missing, in-operable, or not correct switch 109 Light switch weather boot or covering Missing, ripped, torn or cracked 205 Markings or labels Omitted, incorrect, illegible, misplaced 206 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,

28、-,-MIL-PRF-44259E 10 4.3.4 End item dimensional examination. The light set shall be examined for dimensional defects listed in table III. The lot size shall be expressed in units of complete light sets. The sample unit shall be one complete light set. The verification levels shall be IV for major de

29、fects and II for minor defects. TABLE III. End item dimensional defects. Classification Examine Defect Major MinorSmaller than specified less applicable minus tolerance 101 Overall dimensions (individual light assemblies) Larger than specified dimensions and applicable plus tolerances 102 Overall di

30、mensions Dimensions not as specified 103 4.3.5 End item testing. The complete light set shall be tested for the characteristics listed in table IV. The lot size shall be expressed in terms of complete light sets. The sample unit shall be one complete light set. The verification level shall be IV. TA

31、BLE IV. End item tests. Characteristic Requirement paragraph Test method Current draw 3.4.3 4.4.5 Electrical continuity 3.4.9 4.4.8 4.3.6 Packaging examination. The fully packaged end items shall be examined for the defects listed in table V. The lot size shall be expressed in units of shipping cont

32、ainers. The sample unit shall be one shipping container fully packaged. The verification level shall be IV. TABLE V. End item examination. Examine Defect Marking (interior and exterior) Omitted; incorrect; illegible; of improper size, location, sequence or method of application Materials Any compone

33、nt missing, damaged, or not as specified Workmanship Inadequate application of components, such as: incomplete sealing or closure of flap, improper taping, loose strapping or inadequate stapling Content Number of light sets per shipping lot is more or less than required Provided by IHSNot for Resale

34、No reproduction or networking permitted without license from IHS-,-,-MIL-PRF-44259E 11 4.4 Methods of inspection. 4.4.1 Electromagnetic compatibility test. Each of the light assemblies from the sample light set shall be tested in accordance with test methods CE 102 and RE 102 of MIL-STD- 461. Failur

35、e of any light assembly to meet the limits specified in MIL-STD-461 (see 3.4.8) shall constitute a test failure. 4.4.2 Cold starting test at 60 Hz. Each of the light assemblies from the sample light set shall be cold soaked for 4 hours at a temperature of 0F. While maintaining a temperature of 0F, a

36、n electric power of 120 + 5 volts, 60 Hz shall be applied to each light assembly and the light operated for a minimum of 1 hour. Failure of any light assembly to properly operate or conform to the requirements of 3.5.6 shall constitute a test failure. 4.4.3 Cold starting test at 50 Hz. Each of the l

37、ight assemblies from the sample light set shall be cold soaked for 4 hours at a temperature of 0F. While maintaining a temperature of 0F, an electric power of 120 + 5 volts, 50 Hz shall be applied to each light assembly and the light operated for a minimum of 1 hour. Failure of any light assembly to

38、 properly operate or conform to the requirements of 3.5.6 shall constitute a test failure. 4.4.4 Illumination test. Each light assembly from the sample set shall be tested for illumination when operating at 120 5 volts, 60 Hz, and a maximum current of 0.7 amperes in an atmosphere of 77 5F. Failure t

39、o provide illumination as specified in 3.4.10 shall constitute a test failure. 4.4.4.1 Filter test. Each filter from the sample light set shall be tested for light reduction when the light assembly is operating under conditions specified in 4.4.4. Failure to provide the conditions specified in 3.4.1

40、0.1 shall constitute a failure. 4.4.5 Current draw test. Each light assembly from the sample light set shall be tested for current draw when operating at 120 5 volts, 60 Hz. Any light assembly exceeding 0.7 amp, as specified in 3.4.3, shall constitute a test failure. Repeat this test at 120 5 volts

41、and 50 Hz. 4.4.6 Thermal protector test. One ballast assembly (or a represented standard ballast circuit) shall be tested for thermal protection. Place ballast, which operates one external lamp at 120 V AC, 60 Hz inside an oven or similar chamber. Place a thermocouple on the ballast case. Soak the o

42、perating ballast for a minimum of 2 hours at 140 F and record stabilized case temperature and input current. Increase ambient temperature at 10 degree increments allowing case to stabilize at each increment until 160F has been reached. Record case and ambient temperatures and input current at each i

43、ncrement. Return chamber to 140F and observe normal operation. Record input current. Failure to conform to the requirements of 3.4.5 shall constitute a test failure. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-44259E 12 4.4.7 Dielectric p

44、rotector test. One light assembly from the sample light set shall be tested for a dielectric load for the period as specified in 3.4.7. Any inability to accept the specified voltage for this minimum time period without disruptive discharge or any current leakage shall constitute a test failure. 4.4.

45、8 Electrical continuity for light assemblies. Each conductor in the electrical light assembly shall be tested in accordance with Method 303 of MIL-STD-202. The test current shall not exceed 15 milliamperes and the test resistance shall not exceed 1 ohm. Measurement shall be made between each connect

46、or pin, which is mutually common to each other electrically. The continuity for each pin shall be checked for compliance with the continuity requirement of 3.4.9 and failure to conform to continuity requirement shall constitute a test failure. 4.4.9 Insulation resistance for light set assemblies. Wi

47、th the light switch “OFF“, the light set assembly shall be tested in accordance with Method 302 of MIL-STD-202. The test potential shall be 500 volts, test condition B. Insulation resistance measurement shall be made between the mutually insulated points and between insulated points and shell or gro

48、und. Each resistance measurement shall be checked for compliance with the insulation resistance requirement of 3.4.9. Failure to conform to the continuity requirement shall constitute a test failure. 4.4.10 High and low temperature storage test. The sample light assemblies in their packaged form sha

49、ll be tested for high temperature storage in accordance with Method 501, procedure I, of MIL-STD-810. The test temperature and cycle shall be as specified under hot induced conditions with a minimum of seven complete cycles. The sample light set shall then be tested for low temperature storage in accordance with Method 502, procedure I, of MIL-STD-810. The test temperature shall be severe cold (C3) (-