1、MIL-C-5 1542(EA) 29 September 1988 SUPERSEDING (See section 6) MILITARY SPECIFICATION CONVERTER, FREQUENCY, STATIC, XM5 (FOR M56, XM59, OR X?A62 FILTER UNITS) This specification is approved for use within the U.S. Army Chemical Research, Development and Engineering Center, Depart- ment of the Army,
2、and is available for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers a static frequency converter from a 208 volt (V), 3-phase, 60 Hertz (Hz) power source. 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Standards and handbooks.
3、 The following standards and handbooks form a part of this specification to the extent specified herein. Unless otherwise THIS DOCUMENT CONTAINS PAGES. specified, the issues of these documents shall be those listed in the issue of the Department of Defense Index of Specifications and Standards (DODI
4、SS) and supplement thereto, cited in the solicitation. STANDARDS FEDERAL FED. TEST METHOD STD. NO. 123 - Marking for Shipment (Civil Agencies). MILITARY MIL-STD-105 - Sampling Procedures and Tables for Inspection by MIL-STD-781 - Reliability Testing for Engineering Development, Attributes. Qualifica
5、tion, and Production. : Beneficial comments (recommendations, additions, deletions) and any perti- : : nent data which may be of use in improving this document should be addressed: : to: Commander, U.S. Army Chemical Research, Development and Engineering : : Center, ATTN: SMCCR-SPT-S, Aberdeen Provi
6、ng Ground, MD 21010-5423 by using: : the self-addressed Standardization Document Improvement Proposal (DD Form : : 1426) appearing at the end of this document or by letter. AMSC NIA FSC 4240 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Provided by IHSNot for Resa
7、leNo reproduction or networking permitted without license from IHS-,-,-MIL-C-51542 42 U 7799706 0235q38 4 MIL-C-51542(EA) HANDBOOKS MILITARY MIL-HDBK-781 - Reliability Test Methods, Plans, and Environments for Engineering Development, Qualification, and Produc- tion. 2.1.2 Drawings. The following dr
8、awings form a part of this specification to the extent specified herein. Unless otherwise specified, the issues shall be those in efEect on the date of the solicitation. DRANINGS IFoSo ARMY ARMAMENT, MUNITIONS AND CHEMICAL COMMAND CHEMICAL RESEARCH, DEVELOPMENT AND ENGIWERING CENTER 5-19-6425 - Conv
9、erter, Frequency, Static. SPECIAL PACKAGING INSTRUCTIONS (SPI) P5-19-6425 - Converter, Frequency, Static. I (Copies of standards, handbooks, and drawings required by contractors in con- nection with specific acquisition functions should be obtained from the con- tracting activity or as directed by t
10、he contracting activity.) 2&2 Order of precedence. In the event of a conflict between the text of this specification and the references cited herein, the text of this specifi- cation shall take precedence. Nothing in this specification, however, shall supersede applicable laws and regulations unless
11、 a specific exemption has been chta ned . 3 mQUIREMENTS 3.1: Materials and components. 3.1,1 Materials. All materials cited on Drawing 5-19-6425 and on the subsid- iary drawings shall conform to the specifications listed thereon, and to the specific characteristics set forth on the drawings. 3,1e2 C
12、omponents. All-components of the converter shall conform to the specifications and drawings listed on Drawing 5-19-6425 and subsidiary draw- fngs. 3.2 Manufacture and assembly. The converter shall be manufactured and assembled in accordance with Drawing 5-19-6425. 2 Provided by IHSNot for ResaleNo r
13、eproduction or networking permitted without license from IHS-,-,-MIL-C-515qZ q2 m 9999906 0235L139 b 3.3 Performance. 3.3.1 Cycling burn-in. burn-in which shall consist of 3 hours continuous operation under no load con- ditions and 3 hours on-off operation in accordance with 4.4.4.1. The converter s
14、hall be subjected to a cycling 3.3.2 Operational characteristics. The converter shall conform to the sche- matic representations specified in Drawings 5-19-6492 and 5-19-6437 and shall perform as specified in 3.3.2.1 through 3.3.2.6 when the applicable voltages, voltage phases, and load-are applied
15、to the specific junctions on the static frequency converter. 3.3.2.1 DC voltage. The test point DC voltages from test points 1, 2, and 3 to test point 4 shall be between 10.75 and 13.25 when tested as specified in 4.4.4.2(b) 3.3.2.2 AC voltage. The test point AC voltage between test points 5 and 6 -
16、 shall be greater than 2 volts when tested in accordance with 4.4.4.2(C). 3.3.2.3 Phasing. The phasing of the output shall be phase 1 on pin A, phase 2 on pin B and phase 3 on pin C of connector 58, when tested in accordance with 4.4.4.2(d). 3.3.2.4 Output voltage (line to line). The output line to
17、line voltage with load applied (see 6.3) shall be 208 + 15 Volts, root-mean-square (VRMS), when tested in accordance with 4.4.4.2(e)y 3.3.2.5 Output voltage (line to neutral). The output line to neutral volt- age with load applied (see 6.3) shall be 120 - + 10 VRMS when tested in actor- dance with 4
18、.4.4.2(f). 33.2.6 Output frequency. The output frequency of each-phase shall be 400 - + 10 Hz when tested in accordance with 4.4.4.2(g). 3.4. Reliability. 3.4.1 Preproduction reliability qualification. Prior to the start of regu- lar production, the preproduction sample converters shall demonstrate
19、accept- able reliability when tested in the configuration specified in 4.4.4.1 in accor- dance with task 302 of MIL-STD-781, using test plan IV of MIL-HDBK-781 with minimum test mean time between failures (01) equal to 934 hours. able failure shall be defined as any deviation from the requirements s
20、pecified in 3.3.2.1 through 3.3.2.6. An account- 3.4.2 Production reliability. The production reliability acceptance sample for each lot shall demonstrate acceptable reliability when tested in the con- figuration specified in 4.4.4.1 in accordance with task 302 of MIL-STD-781, using test plan IV of
21、MIL-HDBK-781 with a minimum test mean-time-between- failures (el), equal to 934 hours. any deviation from the requirements specified in 3.3.2.1 through 3.3.2.6. An accountable failure shall be defined as 3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-
22、,-,-MIL-C-51542 42 799470b 0235440 2 m 3.5 Workmanship. The converter shall be free from chipped or bent metal sec- tions, and foreign matter (dirt, oil, or viscous materials). 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for inspection. Unless otherwise specified in the con- tract or purchase
23、 order, the contractor is responsible for the performance of all inspection requirements as specified herein. in the contract or purchase order, the contractor may use his own or any other facilities suitable for the performance of the inspection requirements speci- fied herein, unless disapproved b
24、y the Government. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. Except as otherwise specified 4.1.1 Responsibility for compliance. All
25、items must meet all requirements o sections 3 and 5. become a part of the contractors overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitt
26、ed to the Government for acceptance comply with all require- ments of the contract. mission of known defective material, either indicated or actual, nor does it commit the Government to acceptance of defective material. The inspection set forth in this specification shall Sampling in quality conform
27、ance does not authorize sub- 4.1.2 Objective evidence. Packaged sample converters shall be examined in After completion accordance with the classification of defects (4.4.3.4(b), of the packaging inspection, the sample converters shall then be unpackaged and examined in accordance with the classific
28、ation of defects (4.4.3.4(a). 4.2 Classification of inspection. The inspection requirements specified herein are classified as follows: (a) Preproduction inspection (4.3) (b) Quality conformance inspection (4.4) 4.3 Preproduction inspection. 4.3.1 Sample. manufactured using the same methods, materia
29、ls, equipment, and processes as will be used durng regular production. A preproduction packaged sample of four converters shall be 4,3.2 Inspection procedures. 4.3.2.1 For examination. The packaged preproduction inspection sample of converters shall be inspected for all the requirements of the drawi
30、ngs and this specification. 4 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-I- C a a a MIL-C-53542 q2 7977706 0235443 4.3.2.2 For test. The unpackaged preproduction sample of converters shall be tested in accordance with 4.4.4.1 and 4.4.4.2 for con
31、formance to 3.3. Then the converters shall be tested in the configuration specified in 4.4.4.1 for conformance to 3.4.1. 4.3.3 Acceptance/rejection criteria. Each converter in the packaged pre- production sample shall meet the examination specified in 4.4.3.4. When tested in accordance with 4.3.2.2
32、the unpackaged preproduction inspection sample shall meet the requirements of 3.4.1 and the criteria of Test Plan IV of MIL-HDBK-781 to be acceptable. 4.4 Quality conformance inspection. 4.4.1 Lotting. A lot shall consist of the converters of one type produced by one manufacturer, from the same mate
33、rials, at the same locations, under essentially the same manufacturing conditions, and at essentially the same time . 4.4.2 Sampling . 4.4.2.1 For examination. The unpackaged sample converter for examination shall be conducted in accordance with MIL-STD-105. tion, the packaged converter for examinat
34、ion shall be conducted in accordance with MIL-STD-105. For the repair part acquisi- 4.4.2.2 For test. Each converter shall be tested. 4.4.2.3 For reliability production acceptance. A sample of four converters shall be taken randomly from each production lot for reliability production acceptance test
35、ing. 4.4.3 Inspection procedure. 4.4.3.1 For examination. The sample converters shall be examined in accor- dance with 4.4.3.4(a) of the classification of defects. acquisition only, the packaging inspection (4.4.3.4(b) shall also be con- ducted. For the repair part 4.4.3.2 For test. Each converter s
36、hall be tested for cycling burn-in and performance prior to packaging. Any converter failing any of the performance requirements shall be rejected. 4.4.3.3 For reliability production acceptance test. The reliability pro- duction acceptance test sample of unpackaged converters shall be tested in acco
37、rdance with 4.4.4.1 and 4.4.4.2 for conformance to 3.3. Then the convert- ers shall be tested in the configuration specified in 4.4.4.1 for conformance to 3.4.2. 5 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-4.4.3.4 Classification of defects. (a)
38、 Converter, frequency, static (Dwg 5-19-6425). Categories * Defects Critical: None defined Major: AQL 1.0 percent defective 101 Component missing, incorrect or incorrectly assembled 102 Damaged wires 103 Improper soldering 104 Workmanship (3.5) (b) Packaging inspection (SPI P5-19-6425) (see section
39、5). Categories Defects Critical: None defined Major: AQL 2.5 percent defective 101 Item not completely cleanedldried 102 103 104 105 106 Cushioning pads missing or not as specified Wrap missing or not as specified Unit or shipping container marking incorrect, missing or Unit or shipping container an
40、d closure not as specified Unit or shipping container damaged il legible 4.4.4 Tests. Cycling burn-in and performance tests shall be conducted as follows : 4.4.4.1 Cycling burn-in test. (a) Position the converter on a work bench so that the electrical connectors are readily accessible. breaker and f
41、ault isolation test points. the converter to a 208 V, 60 Hz, 3-phase power source through a three pole relay as follows: Open the protective cover on the circuit Open the circuit breaker. Connect Phase 1 to pin A of 57 Phase 2 to pin B of 57 Phase 3 to pin C of 57 CAUTION: Pin H of 57 must be ground
42、ed. (b) Connect the coil of the relay to a timer so that it may be energized at the rate of once every minute. 6 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-b- MIL-C-51542 92 7777706 0235LI43 W MIL-C-51542(EA) (c) Close the circuit breaker on the
43、 converter and energize the relay. After approximately 5 seconds, the converter will start as indicated by a high-frequency buzzing sound. Operate the converter in this configuration (no load) for 3 hours. Then actuate the timer so that the converter cycles, on reliability testing, the cycling shall
44、 continue until the reliability is demon- s trat ed. .- and off, and operate the converter in this configuration for 3 hours. For 4.4.4.2 Performance. After the cycling burn-in test, the converter shall be inspected to assure that it-is still cycling properly and that the circuit breaker is set. The
45、n: -c (a) With the power applied as specified in 4.4.4.l(a) operate the converter and make the following measurements using standard voltmeters and frequency counters. The voltmeter used in 4.4.4.2(e) and 4.4.4.2(f) must be a true root-mean-square reading meter. An average responding meter with a ro
46、ot- mean-square compensated scale is not acceptable because of the pseudo square wave output of the converter. (b) DC voltage. Measure in turn the DC voltage from test points 1, 2, and 3 to test point 4. This voltage shall be as specified. This test is run with no load on the converter. (c) AC volta
47、ge. Measure the AC voltage between test points 5 and 6. This voltage shall be as specified. This test is run with no load on the converter . (d) Phasing. output of the converter as follows: Connect a 7 to 8 amp per phase load (see 6.3) to the Phase 1 to pin A of 58 Phase 2 to pin B of 58 Phase 3 to
48、pin C of 58 Neutral to pin D of 58 CAUTION: The output neutral of the converter must be isolated from ground (see 6.3). Test the output phasing of the converter by observing that the applied load rotates in the proper direction when possible, or by displaying the phases in pairs on a dual trace osci
49、lloscope for conformance with specified requirements. (e) Output voltage. With the load applied (4.4.4.2(d), measure the output voltage of the converter from line to line, i.e. A to B, B to C, and A to C on connector 58. This voltage shall be as specified. (f) Output voltage. With the load applied (4.4.4.2(d) measure the output voltage of the converter from line to neutral, i.e. A to D, B to D, and C to D on connector 58. This voltage shall be as specifie
