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Ministry of Defence Defence Standard 61-5 Part 6 Issue 6 Publication Date 6 th February 2009 Nominal 12V and 24V DC Electrical Systems in Military Platforms

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Def Stan 61-5 Part 6

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  • Ministry of Defence Defence Standard 61-5 Part 6

    Issue 6 Publication Date 6th February 2009

    Nominal 12V and 24V DC

    Electrical Systems in Military Platforms

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified ii

    Contents

    Foreword ........................................................................................................................................................xiii Introduction....................................................................................................................................................xiv 1 Scope ..................................................................................................................................................1 2 Warning ..............................................................................................................................................1 3 Related Documents ...........................................................................................................................2 4 Abbreviations and Definitions..........................................................................................................2 4.1 Abbreviations ...................................................................................................................................2 4.2 Definitions.........................................................................................................................................2 5 Format.................................................................................................................................................7 6 Power Critical Design Review ..........................................................................................................7 6.1 Purpose.............................................................................................................................................7 6.2 Platform Power Critical Design Review Requirements................................................................7 6.3 Platform and Terminal Equipment Power Critical Design Review Requirements ....................8 7 Capacity..............................................................................................................................................9 7.1 Capacity Requirements ...................................................................................................................9 7.1.1 Generator / Source........................................................................................................................9 7.1.2 Terminal Equipment Battery Power Capacity ............................................................................9 7.1.3 Cabling / DCDU..............................................................................................................................9 7.2 Environmental Cable De-Rating ...................................................................................................10 7.2.1 Environmental Conditions .........................................................................................................10 8 Batteries ...........................................................................................................................................10 8.1 Battery Requirements....................................................................................................................10 9 Circuit Protection.............................................................................................................................10 9.1 Circuit Protection Requirements..................................................................................................10 10 Wiring Configuration.......................................................................................................................11 10.1 Cable Requirements ......................................................................................................................11 10.2 Example Wiring Configuration .....................................................................................................11 10.3 Bespoke Platform Guidance .........................................................................................................12 10.4 Wiring Configuration Requirements ............................................................................................12 11 Connections .....................................................................................................................................13 11.1 Connectors Recommendations....................................................................................................13 11.1.1 Connector Selection ...................................................................................................................14 11.1.1.1 Higher Corrosion Resistance ..................................................................................................14 11.1.1.2 Connections for 12V Systems.................................................................................................14 11.1.1.3 High Current Connections .......................................................................................................14 11.1.2 Physical Protection and Installation Considerations..............................................................15 12 Earthing ............................................................................................................................................16

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified iii

    12.1 Earthing Requirements .................................................................................................................16 13 Platform ............................................................................................................................................17 13.1 Platform Requirements .................................................................................................................17 14 Platform and Terminal Equipment.................................................................................................18 14.1 Platform and Terminal Equipment Requirements ......................................................................18 15 Environmental..................................................................................................................................18 15.1 Environmental Requirements.......................................................................................................18 15.2 Power Supply LRU/Component/Terminal Equipment Location and Test Temperature.........19 16 Quality Standard..............................................................................................................................19 16.1 Quality Management System (QMS) ............................................................................................19 16.2 UKAS Requirement........................................................................................................................20 17 Test Equipment................................................................................................................................20 17.1 Test Equipment Requirements.....................................................................................................20 17.2 Tolerances ......................................................................................................................................21 18 Electromagnetic Compatibility Legislation...................................................................................21 19 Management and Planning.............................................................................................................21 19.1 Management and Planning Requirements ..................................................................................21 19.2 Control and Management..............................................................................................................21 19.2.1 Test Plan ......................................................................................................................................21 19.2.2 Test Report ..................................................................................................................................22 19.2.3 Test Certificate (Optional) ..........................................................................................................23 19.3 Pass/Fail Criteria............................................................................................................................23 19.3.1 Susceptibility Criteria .................................................................................................................23 Annex A Platform Power Distribution Tests................................................................................................25 A.1 General Requirements...................................................................................................................25 A.1.1 Requirements ..............................................................................................................................25 A.2 DET01.A Steady State Voltage .....................................................................................................27 A.2.1 Purpose........................................................................................................................................27 A.2.2 Applicability.................................................................................................................................27 A.2.3 Test Layout ..................................................................................................................................27 A.2.4 Test Limits ...................................................................................................................................27 A.2.5 Test Conditions...........................................................................................................................27 A.2.6 Test Method.................................................................................................................................28 A.2.6.1 Test Condition 1........................................................................................................................28 A.2.6.2 Test Condition 2........................................................................................................................28 A.3 DET02.A Ripple Voltage ................................................................................................................29 A.3.1 Purpose........................................................................................................................................29 A.3.2 Applicability.................................................................................................................................29 A.3.3 Test Layout ..................................................................................................................................29 A.3.4 Test Limits ...................................................................................................................................29 A.3.4.1 Time Domain Test Limits .........................................................................................................29

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified iv

    A.3.4.2 Frequency Domain Test Limits ...............................................................................................29 A.3.5 Test Conditions ...........................................................................................................................29 A.3.6 Test Method .................................................................................................................................30 A.3.6.1 Time Domain .............................................................................................................................30 A.3.6.2 Frequency Domain ...................................................................................................................30 A.4 DET03.A Long Transients .............................................................................................................31 A.4.1 Purpose........................................................................................................................................31 A.4.2 Applicability.................................................................................................................................31 A.4.3 Test Layout ..................................................................................................................................31 A.4.4 Test Limits ...................................................................................................................................31 A.4.5 Test Conditions ...........................................................................................................................33 A.4.6 Test Method .................................................................................................................................33 A.5 DET04.A Short Transients.............................................................................................................35 A.5.1 Purpose........................................................................................................................................35 A.5.2 Applicability.................................................................................................................................35 A.5.3 Test Layout ..................................................................................................................................35 A.5.4 Test Limits ...................................................................................................................................35 A.5.5 Test Conditions ...........................................................................................................................35 A.5.6 Test Method .................................................................................................................................36 A.6 DET05.A Circuit Protection ...........................................................................................................37 A.6.1 Purpose........................................................................................................................................37 A.6.2 Applicability.................................................................................................................................37 A.6.3 Test Layout ..................................................................................................................................37 A.6.4 Test Limits ...................................................................................................................................37 A.6.5 Test Conditions ...........................................................................................................................37 A.6.6 Test Method .................................................................................................................................38 A.7 DET06.A Power Distribution Voltage Drop..................................................................................39 A.7.1 Purpose........................................................................................................................................39 A.7.2 Applicability.................................................................................................................................39 A.7.3 Test Layout ..................................................................................................................................39 A.7.4 Test Limits ...................................................................................................................................39 A.7.5 Test Conditions ...........................................................................................................................39 A.7.6 Test Method .................................................................................................................................40 A.7.6.1 Power Distribution System in Series (Figure 13) ..................................................................40 A.7.6.2 Power Distribution System in Parallel (Figure 14) ................................................................40 A.8 DET07.A Cranking..........................................................................................................................43 A.8.1 Purpose........................................................................................................................................43 A.8.2 Applicability.................................................................................................................................43 A.8.3 Test Layout ..................................................................................................................................43 A.8.4 Test Limits ...................................................................................................................................43 A.8.5 Test Conditions ...........................................................................................................................43

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified v

    A.8.6 Test Method.................................................................................................................................43 A.9 DET08.A Terminal Equipment Battery Capacity Test ................................................................44 A.9.1 Purpose........................................................................................................................................44 A.9.2 Applicability.................................................................................................................................44 A.9.3 Test Layout ..................................................................................................................................44 A.9.4 Test Limits ...................................................................................................................................44 A.9.5 Test Conditions...........................................................................................................................44 A.9.6 Test Method.................................................................................................................................45 A.10 DIT01.A Platform/Terminal Earth Bond .......................................................................................46 A.10.1 Purpose........................................................................................................................................46 A.10.2 Applicability.................................................................................................................................46 A.10.3 Test Layout ..................................................................................................................................46 A.10.3.1 Standard Test Layout ...............................................................................................................46 A.10.3.2 Alternative Test Layout ............................................................................................................47 A.10.4 Test Limits ...................................................................................................................................47 A.10.5 Test Conditions...........................................................................................................................47 A.10.6 Test Method.................................................................................................................................47 A.10.6.1 Standard Method ......................................................................................................................47 A.10.6.2 Alternative Method ...................................................................................................................47 A.11 DIT02.A Platform Over Voltage / Regulator Failure....................................................................49 A.11.1 Purpose........................................................................................................................................49 A.11.2 Applicability.................................................................................................................................49 A.11.3 Test Layout ..................................................................................................................................49 A.11.4 Test Limits ...................................................................................................................................49 A.11.5 Test Conditions...........................................................................................................................49 A.11.6 Test Method.................................................................................................................................49 A.12 DIT03.A Platform Imported Ripple (20Hz - 150kHz)....................................................................51 A.12.1 Purpose........................................................................................................................................51 A.12.2 Applicability.................................................................................................................................51 A.12.3 Test Layout ..................................................................................................................................51 A.12.4 Test Limits ...................................................................................................................................51 A.12.5 Test Conditions...........................................................................................................................51 A.12.6 Test Method.................................................................................................................................52 A.12.6.1 Calibration .................................................................................................................................52 A.12.6.2 Test.............................................................................................................................................52 A.13 DIT04.A Platform Load Dump .......................................................................................................54 A.13.1 Purpose........................................................................................................................................54 A.13.2 Applicability.................................................................................................................................54 A.13.3 Test Layout ..................................................................................................................................54 A.13.4 Test Limits ...................................................................................................................................54 A.13.5 Test Conditions...........................................................................................................................54

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified vi

    A.13.6 Test Method .................................................................................................................................55 Annex B Platform and Terminal Equipment Tests......................................................................................57 B.1 General Requirements...................................................................................................................57 B.1.1 Requirements ..............................................................................................................................57 B.2 DET01.B Ripple ..............................................................................................................................59 B.2.1 Purpose........................................................................................................................................59 B.2.2 Applicability.................................................................................................................................59 B.2.3 Test Layout ..................................................................................................................................59 B.2.4 Test Limits ...................................................................................................................................59 B.2.5 Equipment Mode .........................................................................................................................59 B.2.6 Test Method .................................................................................................................................59 B.3 DET02.B Exported Transients ......................................................................................................61 B.3.1 Test Method .................................................................................................................................61 B.3.2 Applicability.................................................................................................................................61 B.3.3 Test Layout ..................................................................................................................................61 B.3.4 Test Limits ...................................................................................................................................61 B.3.5 Equipment Mode .........................................................................................................................62 B.3.6 Test Method .................................................................................................................................62 B.4 DET03.B Maximum Inrush Current...............................................................................................64 B.4.1 Purpose........................................................................................................................................64 B.4.2 Applicability.................................................................................................................................64 B.4.3 Test Layout ..................................................................................................................................64 B.4.4 Test Limits ...................................................................................................................................64 B.4.5 Equipment Mode .........................................................................................................................65 B.4.6 Test Method .................................................................................................................................65 B.5 DIT01.B Positive Supply Isolation Test .......................................................................................66 B.5.1 Purpose........................................................................................................................................66 B.5.2 Applicability.................................................................................................................................66 B.5.3 Test Layout ..................................................................................................................................66 B.5.4 Test Limits ...................................................................................................................................66 B.5.5 Equipment Mode .........................................................................................................................66 B.5.6 Test Method .................................................................................................................................66 B.6 DIT02.B Earth Bonding..................................................................................................................68 B.6.1 Purpose........................................................................................................................................68 B.6.2 Applicability.................................................................................................................................68 B.6.3 Test Layout ..................................................................................................................................68 B.6.3.1 Standard Test Layout ...............................................................................................................68 B.6.3.2 Alternative Test Layout ............................................................................................................68 B.6.4 Test Limits ...................................................................................................................................68 B.6.5 Equipment Mode .........................................................................................................................68 B.6.6 Test Method .................................................................................................................................69

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified vii

    B.6.6.1 Standard Method ......................................................................................................................69 B.6.6.2 Alternative Method ...................................................................................................................69 B.7 DIT03.B Negative/Earth Bond Isolation .......................................................................................70 B.7.1 Purpose........................................................................................................................................70 B.7.2 Applicability.................................................................................................................................70 B.7.3 Test Layout ..................................................................................................................................70 B.7.4 Test Limits ...................................................................................................................................70 B.7.5 Equipment Mode .........................................................................................................................70 B.7.6 Test Method.................................................................................................................................70 B.8 DIT04.B Cranking ...........................................................................................................................71 B.8.1 Purpose........................................................................................................................................71 B.8.2 Applicability.................................................................................................................................71 B.8.3 Test Layout ..................................................................................................................................71 B.8.4 Test Limits ...................................................................................................................................71 B.8.5 Equipment Mode .........................................................................................................................71 B.8.6 Test Method.................................................................................................................................71 B.9 DIT05.B Reverse Voltage...............................................................................................................74 B.9.1 Purpose........................................................................................................................................74 B.9.2 Applicability.................................................................................................................................74 B.9.3 Test Layout ..................................................................................................................................74 B.9.4 Test Limits ...................................................................................................................................74 B.9.5 Equipment Mode .........................................................................................................................74 B.9.6 Test Method.................................................................................................................................74 B.10 DIT06.B Under & Over-Voltage .....................................................................................................75 B.10.1 Purpose........................................................................................................................................75 B.10.2 Applicability.................................................................................................................................75 B.10.3 Test Layout ..................................................................................................................................75 B.10.4 Test Limits ...................................................................................................................................75 B.10.5 Equipment Mode .........................................................................................................................75 B.10.6 Test Method.................................................................................................................................75 B.11 DIT07.B Short Transients..............................................................................................................77 B.11.1 Purpose........................................................................................................................................77 B.11.2 Applicability.................................................................................................................................77 B.11.3 Test Layout ..................................................................................................................................77 B.11.4 Test Limits ...................................................................................................................................77 B.11.5 Equipment Mode .........................................................................................................................77 B.11.6 Test Method.................................................................................................................................77 B.12 DIT08.B Load Dump.......................................................................................................................80 B.12.1 Purpose........................................................................................................................................80 B.12.2 Applicability.................................................................................................................................80 B.12.3 Test Layout ..................................................................................................................................80

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified viii

    B.12.4 Test Limits ...................................................................................................................................80 B.12.5 Equipment Mode .........................................................................................................................80 B.12.6 Test Method .................................................................................................................................80 Annex C Related Documents ........................................................................................................................82 C.1 Related Documents .......................................................................................................................82 Annex D Abbreviations ..................................................................................................................................84 D.1 Abbreviations .................................................................................................................................84 Annex E Cable Capacity De-Rating Factors ................................................................................................87 E.1 De-Rating Factors ..........................................................................................................................87 E.1.1 Example Cable Calculations ......................................................................................................87 E.1.1.1 Example 1 ..................................................................................................................................87 E.1.1.2 Example 2 ..................................................................................................................................87 E.1.1.3 Example 3 ..................................................................................................................................87 E.1.1.4 Example 4 ..................................................................................................................................87 E.1.2 Cable Calculation Method ..........................................................................................................87 E.1.3 Graphs Used To Determine De-Rating Factors .......................................................................88 Annex F Power Critical Design Review - Example Forms..........................................................................91 F.1 Amendment Status ........................................................................................................................93 F.2 Document History ..........................................................................................................................93 F.3 Distribution List..............................................................................................................................93 F.4 PROJECT INFORMATION..............................................................................................................94 F.4.1 Introduction .................................................................................................................................94 F.4.2 Review Outline/Summary...........................................................................................................94 F.4.3 Contact Details ............................................................................................................................94 F.5 Documents......................................................................................................................................95 F.5.1 Reference Documents ................................................................................................................95 F.5.2 Platform Power Critical Design Review Document .................................................................95 F.6 Platform Details..............................................................................................................................95 F.7 Platform Working Environment ....................................................................................................96 F.8 Platform and Terminal Equipment Power Distribution Systems Requirements .....................96 F.8.1 Platform Battery Requirements .................................................................................................96 F.8.2 Wiring Configuration ..................................................................................................................97 F.8.3 Cable De-Rating ..........................................................................................................................97 F.8.4 Platform and Terminal Equipment Power Distribution System Capacity .............................98 F.9 Earthing Strategy ...........................................................................................................................99 F.9.1 Earth Points .................................................................................................................................99 F.10 Circuit Protection.........................................................................................................................100 F.10.1 Mandatory Circuit Protection Requirements .........................................................................100 F.10.2 Circuit Protection Devices .......................................................................................................100 F.11 Connections .................................................................................................................................101 F.12 Installed Equipment.....................................................................................................................101

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified ix

    F.12.1 Installed Equipment Classification and Power Budget ........................................................101 F.13 Test Requirements.......................................................................................................................102 F.13.1 Test Positions............................................................................................................................102 F.14 Test Applicability .........................................................................................................................103 F.14.1 Modes of Operation ..................................................................................................................103 F.14.2 DET04.A Short Transients........................................................................................................104 F.14.3 Platform/Terminal Earth Bond Path ........................................................................................104 Annex G Platform and Terminal Equipment Power Critical Design Review - Example Documents ...107 G.1 Equipment Details........................................................................................................................107 G.2 Amendment Status ......................................................................................................................108 G.3 Document History ........................................................................................................................108 G.4 Distribution List ...........................................................................................................................108 G.5 Introduction ..................................................................................................................................109 G.6 Contact Details.............................................................................................................................109 G.7 Documents ...................................................................................................................................109 G.7.1 Reference Documents ..............................................................................................................109 G.7.2 Platform and Terminal Equipment Power Critical Design Review Documents..................110 G.8 Platform or Terminal Equipment Details ...................................................................................110 G.9 Platform and Terminal Equipment Working Environment.......................................................111 G.10 Platform and Terminal Equipment Design Requirements .......................................................111 G.10.1 Platform and Terminal Equipment Design Requirements ....................................................111 G.10.2 Isolation Switch.........................................................................................................................111 G.11 Connectors ...................................................................................................................................112 G.12 Test Requirements.......................................................................................................................112 G.12.1 Test Applicability ......................................................................................................................112 G.12.2 Modes of Operation ..................................................................................................................113 G.12.3 Harness and Connection Details.............................................................................................114 Figures

    Figure 1 Illustrative Long Transient with recovery time ............................................................................3 Figure 2 Ripple ...............................................................................................................................................5 Figure 3 Starting Disturbance.......................................................................................................................6 Figure 4 Typical Power Distribution System.............................................................................................12 Figure 5 Wiring Configuration showing Two Wire System......................................................................13 Figure 6 Wiring Configuration showing Two Wire System (where there is a separate DC to DC

    Converter or Power Management Unit from the Terminal Equipment) ...................................13 Figure 7 Typical Platform and Terminal Equipment Earthing Arrangements and Reference

    Points .............................................................................................................................................17 Figure 8 DET03.A 12V Limits ...................................................................................................................32 Figure 9 DET03.A - 24V Limits ....................................................................................................................32 Figure 10 DET03.A Typical Test Configuration........................................................................................34 Figure 11 DET04.A - Example Test Configuration ......................................................................................36

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified x

    Figure 12 DET05.A Typical Test Configuration for Terminal Equipment Distribution Protection ......38 Figure 13 DET06.A Typical Test Configuration Power Distribution System in Series......................41 Figure 14 DET06.A Typical Test Configuration Power Distribution System in Parallel....................42 Figure 15 DIT01.A - Typical Test Configuration ..........................................................................................48 Figure 16 DIT01.A Typical Test Configuration (APU to Terminal Earth Reference) using

    alternative test method.................................................................................................................48 Figure 17 DIT02.A Typical Test Configuration .........................................................................................50 Figure 18 DIT03.A Limits ............................................................................................................................51 Figure 19 DIT03.A Calibration Typical Configuration..............................................................................53 Figure 20 DIT03.A - Typical Test Configuration ..........................................................................................53 Figure 21 DIT04.A Typical Test Configuration .........................................................................................56 Figure 22 DET01.B - Typical Test Configuration.........................................................................................60 Figure 23 DET02.B - Typical Test Configuration.........................................................................................62 Figure 24 DET02.B - Test Configuration using External Switch................................................................63 Figure 25 DET03.B - Typical Test Configuration.........................................................................................65 Figure 26 DIT01.B - Typical Test Configuration ..........................................................................................67 Figure 27 DIT02.B - Typical Test Configuration ..........................................................................................69 Figure 28 DIT02.B - Typical Alternative Test Configuration using a Power Supply................................69 Figure 29 DIT03.B - Typical Test Configuration ..........................................................................................70 Figure 30 DIT04.B - Typical Test Configuration ..........................................................................................72 Figure 31 DIT04.B - Test Pulse......................................................................................................................72 Figure 32 DIT05.B - Typical Test Configuration ..........................................................................................74 Figure 33 DIT06.B - Limits (12V Systems) ...................................................................................................76 Figure 34 DIT06.B - Limits (24V Systems) ...................................................................................................76 Figure 35 DIT06.B - Typical Test Configuration ..........................................................................................76 Figure 36 DIT07.B - Typical Test Configuration ..........................................................................................78 Figure 37 DIT07.B - Negative Test Pulse A..................................................................................................78 Figure 38 DIT07.B - Negative Test Pulse - Pulse Train A ...........................................................................78 Figure 39 DIT07.B - Positive Test Pulse B ...................................................................................................79 Figure 40 DIT07.B - Positive Test Pulse - Pulse Train B ............................................................................79 Figure 41 DIT08.B - Typical Test Configuration ..........................................................................................81 Figure 42 DIT08.B - Test Pulse......................................................................................................................81 Figure 43 Temperature De-Rating Graph.....................................................................................................89 Figure 44 Temperature De-Rating Graph.....................................................................................................89 Figure 45 Altitude De-Rating Graph .............................................................................................................90 Figure 46 Number of Cores De-Rating Graph .............................................................................................90

    Tables

    Table 1 Connector Selection .....................................................................................................................15 Table 2 Platform and Terminal Equipment Operating Voltages ............................................................18 Table 3 Platform Power Distribution - Test Applicability .......................................................................26

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified xi

    Table 4 DET01.A - Test Applicability ........................................................................................................27 Table 5 DET01.A - Test Limits ...................................................................................................................27 Table 6 DET01.A - Test Conditions ...........................................................................................................27 Table 7 DET02.A - Test Applicability ........................................................................................................29 Table 8 DET02.A - Time Domain Test Limits ...........................................................................................29 Table 9 DET02.A - Test Conditions ...........................................................................................................30 Table 10 DET03.A - Test Applicability ........................................................................................................31 Table 11 DET03.A - Test Conditions ...........................................................................................................33 Table 12 DET04.A - Test Applicability ........................................................................................................35 Table 13 DET04.A - Test Limits ...................................................................................................................35 Table 14 DET04.A - Test Conditions ...........................................................................................................36 Table 15 DET05.A - Test Applicability ........................................................................................................37 Table 16 DET05.A - Test Limits ...................................................................................................................37 Table 17 DET05.A - Test Conditions ...........................................................................................................38 Table 18 DET06.A - Test Applicability ........................................................................................................39 Table 19 DET06.A - Test Conditions ...........................................................................................................39 Table 20 DET07.A - Test Applicability ........................................................................................................43 Table 21 DET07.A - Test Conditions ...........................................................................................................43 Table 22 DET08.A - Test Applicability ........................................................................................................44 Table 23 DET08.A - Test Limits ...................................................................................................................44 Table 24 DET08.A - Test Conditions ...........................................................................................................45 Table 25 DIT01.A Test Applicability .........................................................................................................46 Table 26 DIT01.A - Test Limits.....................................................................................................................47 Table 27 DIT01.A - Test Conditions ............................................................................................................47 Table 28 DIT02.A - Test Applicability..........................................................................................................49 Table 29 DIT02.A - Test Conditions ............................................................................................................49 Table 30 DIT02.A - Upper Test Voltage Limits ...........................................................................................50 Table 31 DIT03.A - Test Applicability..........................................................................................................51 Table 32 DIT03.A - Test Conditions ............................................................................................................52 Table 33 DIT04.A - Test Applicability..........................................................................................................54 Table 34 DIT04.A - Load Dump Limits ........................................................................................................54 Table 35 DIT04.A - Test Conditions ............................................................................................................55 Table 36 Platform and Terminal Equipment - Test Supply Voltages.......................................................57 Table 37 Platform and Terminal Equipment - Test Applicability .............................................................58 Table 38 DET01.B - Test Limits ...................................................................................................................59 Table 39 DET01.B - Voltage Source Ripple Limit ......................................................................................60 Table 40 DET02.B Test Limits - 12V System..............................................................................................61 Table 41 DET02.B Test Limits - 24V Systems............................................................................................62 Table 42 DET03.B Test Limits .....................................................................................................................64 Table 43 DIT02.B - Test Limits.....................................................................................................................68 Table 44 DIT04.B - Parameters for Test Pulse ...........................................................................................73

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified xii

    Table 45 DIT06.B - Operating Voltage Range.............................................................................................75 Table 46 DIT07.B - Parameters for Test Pulse A........................................................................................78 Table 47 DIT07.B - Parameters for Test Pulse B........................................................................................79 Table 48 DIT08.B - Parameters for Test Pulse ...........................................................................................81 Table 49 Related Documents.......................................................................................................................82 Table 50 Abbreviations ................................................................................................................................84 Table 51 Example of Cable De-Rating with Temperature, Altitude and Number of Cores....................88 Table 52 Platform Power Details .................................................................................................................91 Table 53 Reference Documents ..................................................................................................................95 Table 54 Platform Power Critical Design Review Documents .................................................................95 Table 55 Platform Description.....................................................................................................................96 Table 56 Platform Working Environment ...................................................................................................96 Table 57 Platform Battery Requirements ...................................................................................................97 Table 58 Two Wire System Compliance .....................................................................................................97 Table 59 Cable De-Rating.............................................................................................................................98 Table 60 Platform and Terminal Equipment Power Distribution System ...............................................98 Table 61 Mandatory Earthing Requirements .............................................................................................99 Table 62 Reference Earth Points.................................................................................................................99 Table 63 Designated Earth Points...............................................................................................................99 Table 64 Mandatory Circuit Protection Requirements............................................................................100 Table 65 Circuit Protection Devices .........................................................................................................100 Table 66 Platform Connector Details........................................................................................................101 Table 67 Installed Equipment Classification and Power Budget...........................................................102 Table 68 Test Positions..............................................................................................................................102 Table 69 Test Applicability.........................................................................................................................103 Table 70 Modes of Operation.....................................................................................................................104 Table 71 Short Transient for Test .............................................................................................................104 Table 72 Earth Bond Paths ........................................................................................................................105 Table 73 Platform and Terminal Equipment Power Critical Design Review - Equipment Details ......107 Table 74 Platform and Terminal Equipment Power Critical Design Review - Reference

    Documents...................................................................................................................................110 Table 75 Platform and Terminal Equipment Power Critical Design Review Documents ....................110 Table 76 Platform and Terminal Equipment Power Critical Design Review - Platform

    Description...................................................................................................................................110 Table 77 Platform and Terminal Equipment Working Environment......................................................111 Table 78 Design Requirements .................................................................................................................111 Table 79 Connectors ..................................................................................................................................112 Table 80 Test Applicability.........................................................................................................................113 Table 81 Modes of Operation.....................................................................................................................113 Table 82 Test Earth Bond Paths................................................................................................................114

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified xiii

    Foreword

    AMENDMENT RECORD

    Amd No Date Text Affected Signature and Date

    REVISION NOTE

    This standard is raised to Issue 6 to update its content.

    HISTORICAL RECORD

    This standard supersedes the following:

    This Standard supersedes Def Stan 61-5 Part 6 Issue 5 1990 and Amendment 1 in 1994. This document is a complete revision to meet current technologies in both platform power supply systems and Terminal Equipments since 1990.

    a) This standard provides requirements for the electrical interoperability between military (ground) vehicular power supplies and installed Platform and Terminal Equipment requiring a DC supply for nominal 12V and 24 V systems.

    b) This standard has been produced on behalf of the Defence Material Standardization Committee (DMSC) by the 61-5 Pt 6 Review committee.

    c) This standard has been agreed by the authorities concerned with its use and is intended to be used whenever relevant in all future designs, contracts, orders etc. and whenever practicable by amendment to those already in existence. If any difficulty arises which prevents application of the Defence Standard, UK Defence Standardization (DStan) shall be informed so that a remedy may be sought.

    d) Any enquiries regarding this standard in relation to an invitation to tender or a contract in which it is incorporated are to be addressed to the responsible technical or supervising authority named in the invitation to tender or contract.

    e) Compliance with this Defence Standard shall not in itself relieve any person from any legal obligations imposed upon them.

    f) This standard has been devised solely for the use of the Ministry of Defence (MOD) and its contractors in the execution of contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all liability whatsoever and howsoever arising (including, but without limitation, liability resulting from negligence) for any loss or damage however caused when the standard is used for any other purpose.

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified xiv

    Introduction

    The purpose of this Defence Standard is to ensure electrical interoperability between military (ground) vehicular power supplies and installed Platform and Terminal Equipment requiring a DC supply for nominal 12V and 24 V systems.

  • DEF STAN 61-5 Part 6 Issue 6

    Unclassified 1

    Standards for Defence - Nominal 12V and 24V DC Electrical Systems in Military Platforms

    1 Scope

    This standard defines the characteristics for all military (ground) platform DC power distribution systems, platform and terminal equipment within the military, bespoke, military off the shelf (MOTS) and commercial off the shelf (COTS) vehicular environment. It covers supply sources with a nominal voltage of 12 V and 24 V, supplying up to 1000A, irrespective of whether these are derived from an on-board engine driven generator, a separate auxiliary power unit (APU), converter, conditioner, battery or combinations thereof.

    The standard includes a main section, which covers Scope, Warnings, Definitions, Format, Power Critical Design Review, Capacity, Batteries, Circuit Protection, Wiring Configurations, Connections, Earthing, Platform Requirements, Platform and Terminal Equipment Requirements, Environmental, Quality Standard, Test Equipment and Management and Planning.

    Detailed technical requirements are included in the following annexes:

    a) Annex A defines the power distribution system and its required characteristics to be provided at the electrical distribution socket outlets;

    b) Annex B defines the constraints that the Platform and Terminal Equipment shall meet, including its added cabling to the distribution socket outlets;

    c) Annex C defines the Related Documents;

    d) Annex D defines the Abbreviations;

    e) Annex E defines Cable Capacity De-Rating Factors and includes example cable calculations;

    f) Annex F and Annex G includes Power Critical Design Review example forms.

    By application of these tests and compliance with the defined limits, the electrical interoperability of Platform and Terminal Equipment, including communications and other non-platform electronic/electrical systems, with the platform power systems should be ensured.

    NOTE For Land Platforms, the following tests may be considered for inclusion in Def Stan 59-411 Parts 3 and 4, in the next issue:

    a) DET02.A Ripple Voltage (DCE02 Requirement);

    b) DIT03.A Imported Ripple;

    c) DET01.B Exported Ripple;

    d) DET02.B Exported Transients;

    e) DIT07.B Short Transients.

    2 Warning

    The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws regarding Health and Safety at Work. All Defence Standards either directly or indirectly invoke the use of processes and procedures that could be injurious to health if adequate precautions are not taken. Defence

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    Standards or their use in no way absolves users from complying with statutory and legal requirements relating to Health and Safety at Work.

    3 Related Documents

    3.1 Related publications referred to in the text of this standard are detailed in Annex C of this standard.

    3.2 Reference in this standard to any related document means in any invitation to tender or contract the edition and all amendments current at the date of such tender or contract unless a specific edition is indicated.

    3.3 In consideration of Clause 3.2 above, users shall be fully aware of the issue and amendment status of all related documents, particularly when forming part of an invitation to tender or contract. Responsibility for the correct application of standards rests with users.

    3.4 DStan can advise regarding where related documents are obtained from. Requests for such information can be made to the DStan Helpdesk. How to contact the helpdesk is shown on the outside rear cover of Def Stan documents.

    4 Abbreviations and Definitions

    4.1 Abbreviations

    To assist readers of this Part of the Defence Standard and other publications related to Defence, a list of abbreviations is included at Annex D.

    4.2 Definitions

    AOF: Acquisition Operating Framework. The AOF is an authoritative source of policy and good practice for all members of the UK Ministry of Defence (MoD) and its Industry partners concerned with acquisition.

    Auxiliary Power Unit (APU): This is an auxiliary (non-propulsive) power unit or Generating Unit, Electric (GUE), which is used to provide electric power for non-automotive systems.

    Battery: A battery is a device that stores chemical energy and makes it available in an electrical form. Batteries consist of electrochemical devices such as two or more galvanic cells, electrolytic cells, lithium cells, fuel cells, or flow cells etc.

    Bespoke Platform: A platform originally designed and built specifically for a military role or purpose, (i.e. Challenger, Engineer Tank System (ETS), and Warrior).

    Bonding: The process of connecting together metal parts so that they make low resistance electrical contact for direct current and low frequency alternating current.

    Circuit Protection: Circuit protection devices are used to protect wires and connectors from being damaged by excess current flow caused by either an over current or short-circuit. Excess current causes excess heat, which causes circuit protection to "open circuit.

    Commercial off the Shelf (COTS): Commercial equipment procured for military purposes without modification.

    COTS Platform: A platform designed and built for commercial use which will be modified for a military purpose (i.e. logistics and covert platforms).

    Crank (Cranking): Starting an engine.

    DC Load Banks: DC passive resistive loads to simulate Platform and Terminal Equipment.

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    Design Authority: The Supplier or Contractor providing the Platform or Platform/Terminal Equipment.

    Designated Earth Point (DEP): Multiple electrical terminals directly bonded to the platform chassis, designated by the manufacturer, which have a low resistance with respect to the Platform and Terminal Earth References.

    Dual Voltage System: A Platform Power Distribution System comprising of two nominal operating voltages, normally 12V and 24V.

    Earth Terminal: A specific terminal used for earthing.

    Earthing: The process of making a satisfactory electrical connection between the structure or metal skin of an object and the mass of the earth. As platforms are not usually connected to the mass of the Earth, this standard uses earthing to define and ensure a common potential between the Platform and Terminal battery sources, and Platform / Terminal Equipment, see Figure 7.

    External DC Distribution: A point on the Platform which provides DC power to adjacent systems, i.e. trailer. This is part of the Platform Power Distribution System (PPDS).

    External DC Distribution Designated Load Requirement: The maximum output current of the External DC Distribution.

    Fall Time: The fall time is the difference between the times when the signal or voltage transient crosses a high threshold (90% of peak) to the time when the signal or voltage transient crosses the low threshold (10% of peak).

    Generator: Electrical machine rotated by a shaft driven from a prime mover. It generates electrical power, (Watts), that can be either AC or DC.

    Isolation (Isolated): Electrical separation between two contacts, for both positive and negative feeds, e.g. DC to DC converters.

    LISN: A Line Impedance Stabilisation Network is used as a reference standard in the laboratory in place of the impedance of the platform wiring harness, in order to determine the behaviour of equipment and electrical/electronic devices.

    Long Transients: A long transient is a variation from the controlled steady-state limits of a characteristic that usually has a duration 1ms. Usually long transients are a result of inherent regulation of the electrical power supply system see Figure 1.

    Long Transient Peak

    VoltageUndershoot

    Long Transient

    PeakVoltage

    Overshoot

    Recovery Time

    SteadyStateLimit

    Time

    Volts

    0

    Figure 1 Illustrative Long Transient with recovery time

    Maximum Rated Current: The maximum current level of a Platform or Terminal Equipment, i.e. radio in transmit mode.

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    Military off the Shelf (MOTS): refers to equipment that has been developed for specific military application and is available for use.

    Military Platform: For the purposes of this standard a Military Platform is one intended for service with the Armed Forces whose electrical distribution system has been designed for the installation of non-platform electrical/electronic equipment, e.g. Communications Equipment, ECM.

    Minimum Battery Discharge Voltage: The lowest voltage the battery can sustain without damage during the loaded condition (closed circuit).

    Mission Related: A characteristic or function of an equipment or system in which a failure can cause the task or operation demanded from the materiel to be abandoned or severely impaired.

    NOTE The classification of equipments shall be decided at the Power Critical Design Review.

    MOTS Platform: A platform designed and built for military role which requires modification to achieve its purpose (i.e. Panther, Mastiff and Supacat).

    Outlet Point: An output from a DCDU, protected by a circuit protection device, which provides power to the Platform or Terminal Equipment.

    Platform Battery: The batteries that supply the Platform. In the case of COTS Platforms, the Platform Battery may be required to power Terminal Equipment.

    Platform DCDU: The platform installed power distribution outlet for the interface to Platform systems.

    Platform DCDU Protection: Circuit protection of the cabling to the Platform DCDU.

    Platform Earth Reference: The chassis connection point/terminal that is connected to the platform battery negative terminal.

    Platform Equipment: The original equipment fitted to COTS and MOTS platforms at procurement. These systems are permanent and connected to the Platform Power Distribution System. The classification, Platform or Terminal Equipment, shall be decided at the Power Critical Design Review, with guidance taken from Clause 10.3 Wiring Configuration.

    Platform Equipment Designated Load Requirement: The electrical load (current) required to power all the Platform Equipment.

    Platform Inductive Load: Loads such as air conditioning pumps, motors, clutches.

    Platform Power Distribution System (PPDS): Supplies power to the Platform Equipment and the External DC Distribution Point. This consists of the Power Generation Source, batteries, cabling and circuit protection and the platform DCDU.

    Platform Test Condition Current: The current required by the platform under the stipulated Test Condition.

    Power Generation Source: Source of electrical power on the platform, normally consisting of engine driven generator, alternator or Auxiliary Power Unit (APU).

    Recovery Time: The interval between the time a characteristic deviates from the steady-state limits and the time it returns and remains within the same range (see Figure 1).

    Ripple: Regular and/or irregular peak to peak alternating voltage variations. It should be noted that these variations are about the steady state voltage, but are not necessarily symmetrical, (see Figure 2).

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    Peak to Peak Ripple

    Upper Ripple Limit

    Lower Ripple Limit

    SteadyState DC

    Level

    Time

    Volts

    Figure 2 Ripple

    Rise Time: The rise time is the difference between the times when the signal or voltage transient crosses a low threshold (10% of peak) to the time when the signal or voltage transient crosses the high threshold (90% of peak).

    RoHS: Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2008 (the RoHS Regulations). These Regulations implement EU Directive 2002/95 which bans the placing on the EU market of new electrical and electronic equipment containing more than agreed levels of lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyl (PBB) and polybrominated diphenyl ether (PBDE) flame retardants.

    Safety Related: A characteristic or function of an equipment or system whose correct operation contributes to safety or material.

    NOTE The classification of equipments shall be decided at the Power Critical Design Review.

    Short Transient: A short transient is a variation from the controlled steady-state limits of a characteristic that usually has a duration

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    Volts Duration of IELT

    Cranking Level

    Cranking Level

    Voltage

    0

    InitialEngagement

    LongTransient

    Time

    VBVS

    KeyVB = Voltage Supply (battery only)VS = Voltage Supply (with alternator)

    Figure 3 Starting Disturbance

    Steady State: The operating voltage or current level when connected to a constant Platform or Terminal load.

    Terminal Earth Reference: The chassis connection point/terminal that is connected to the Terminal Equipment battery negative terminal.

    Terminal Equipment: Equipment that is fitted to COTS and MOTS platforms to make them fit for purpose. These systems can be permanent or temporary, and are connected to the platform or APU using the Terminal Equipment Power Distribution System. The classification, Platform or Terminal Equipment, shall be decided at the Power Critical Design Review, with guidance taken from the Clause 10.4 Wiring Configuration.

    Terminal Equipment Battery: The batteries that supply the Terminal Equipment only.

    Terminal Equipment Battery Capacity: The length of time that the Terminal Equipment batteries can supply the Terminal Equipment Designated Load Requirement.

    Terminal Equipment DCDU: The platform installed power distribution outlet for the interface to Terminal Equipments.

    Terminal Equipment DCDU Protection: Circuit protection of the connectors and cabling to the Terminal Equipment DCDU.

    Terminal Equipment Designated Load Requirement: The electrical load (current) of the Terminal Equipment, as stipulated in the SRD. This does not include the load required to operate the Platform Equipment. The load requirement in the SRD does not include the capacity requirements stipulated in this standard.

    Terminal Equipment Power Distribution System (TEPDS): Supplies power to the Terminal Equipment. This consists of the Power Generation Source, batteries, cabling and circuit protection and the Terminal Equipment DCDU.

    Terminal Equipment Protection: Circuit protection of the cabling to the Terminal Equipment, i.e. circuit breaker on the outlet of the Terminal Equipment DCDU.

    Transients: Voltage changes with time (V/t). Transients are the changing voltage levels with time. These usually go beyond the steady-state limits, return to and remain within the steady-state limits within a specified time.

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    Worst Case Mode: The operating condition requiring maximum electrical loading (current) and will be defined in the Power Critical Design Review.

    5 Format

    The test methods specified in this standard are designated by an alpha-numeric identification scheme:

    a) DET0x Defence Exported Transients;

    b) DIT0x Defence Imported Transients.

    Each method has subsections of Purpose, Applicability, Test Layout, Test Limits, Test Conditions or Equipment Mode, and Test Method together with illustrations as necessary.

    NOTE An additional letter is placed after each test method in Annex A and Annex B to signify that the test is only applicable to that particular annex of DEF STAN 61-5 and not to any other annex, e.g. DET0x.A or DET0x.B.

    6 Power Critical Design Review

    6.1 Purpose

    The purpose of the Power Critical Design Review is to document the parameters and subsequent test methods required to validate the Platform and equipments against the requirements of this standard. This document shall evolve throughout its design and validation period.

    When the Power Critical Design Review is initially completed, a Test Plan shall be generated using the information it contains.

    Examples of Power Critical Design Review documents can be found in Annex F.

    6.2 Platform Power Critical Design Review Requirements

    The Design Authority is responsible for holding the Power Critical Design Review and ensuring approval for the appropriate MoD Authority. This shall form part of the Design Process.

    The following documents shall be provided by the Design Authority and kept with Power Critical Design Review for future reference:

    a) Platform wiring schematics including current ratings of cables and DCDUs;

    b) Platform earthing strategy;

    c) Platform circuit protection strategy.

    The Power Critical Design Review shall contain the following information:

    a) Nominal voltage of the platform (12V, 24V, Multiple i.e.12V and 24V);

    b) Terminal Equipment Designated Load Requirement;

    c) Platform Equipment Designated Load Requirement;

    d) Working environment details (expected working locations);

    e) Documentation and evidence of:

    1) Platform Power and Terminal Equipment Power Distribution System cable environmental de-rating;

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    2) Platform and Terminal Equipment Power Distribution System capacity;

    3) Terminal Equipment Battery type, capacity (Ah) and Minimum Battery Discharge Voltage;

    4) Two wire systems;

    5) Exported DC power requirement (e.g. trailer);

    6) Mandatory earthing requirements;

    7) Mandatory circuit protection requirements;

    8) Circuit Protection types and disconnection times.

    f) Classification of installed equipments:

    1) Platform Equipment or Terminal Equipment;

    2) Safety Related or Mission Related.

    g) Test Modes for Platform (to include DIT dwell times);

    h) Test applicability;

    i) Test positions.

    6.3 Platform and Terminal Equipment Power Critical Design Review Requirements

    The equipment manufacturer is responsible for the Power Critical Design Review and shall form part of the Design Process.

    The following documents shall be provided by the Design Authority and kept with Power Critical Design Review for future reference:

    a) Wiring Schematics;

    b) Earthing Strategy;

    c) Circuit Protection Strategy;

    d) Installation Instructions.

    The Power Critical Design Review shall contain the following information:

    a) Equipment description and function

    b) Equipment Type (Platform or Terminal);

    c) Nominal voltage of the equipment (12V, 24V);

    d) Working environment details (expected working locations);

    e) Intended platform of operation;

    f) Maximum Rated Current;

    g) Mode of operation which requires Maximum Rated Current (worst case mode).

    Documentation and evidence of:

    a) Two wire systems compatible (Terminal Equipment only);

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    b) Mandatory earthing requirements;

    c) Mandatory circuit protection requirements;

    d) Upper and lower working voltages;

    e) Earth bond position (Terminal Equipment only);

    f) Isolation switch (Terminal Equipment only);

    g) Connectors.

    Test applicability;

    Test Modes (to include Mode of Operation, Pass/Fail criteria, support equipment, DIT dwell times);

    Harness details (to include, cable type, size and connections).

    7 Capacity

    The fundamental design of the platform power supply system may not allow for future expansion, unless extra capacity is designed and manufactured for all aspects of the platform power supply system. This strategy will avoid later extensive modification that would otherwise be structural and expensive.

    The Design Authority shall submit full details of construction, parts, environmental capacity and designed future proofing used in the Platform Power Supply System, for MoD agreement, and included in the Power Critical Design Review.

    7.1 Capacity Requirements

    Platforms shall be procured and designed with spare capacity, for future proofing.

    Capacity requirements are mandatory for all bespoke military platforms (i.e. Challenger, Warrior), for both Platform and Terminal Equipment Power Distribution Systems. For COTS and MOTs Platforms, only the Terminal Equipment Power Distribution Systems are required to meet capacity requirements.

    The load requirement detailed in the SRD does not include the capacity requirements stipulated in this standard.

    Capacity can also be affected by a change in environmental conditions; therefore an analysis of cable capacity against temperature shall be performed.

    7.1.1 Generator / Source

    The Power Generation Source and/or Terminal Equipment batteries shall be capable of continuously delivering 110 % of the Designated Load Requirement under all environmental conditions e.g. 10 % spare capacity.

    7.1.2 Terminal Equipment Battery Power Capacity

    The Terminal Equipment shall be able to operate from batteries when either the platform generator or APU are not functioning, for greater than 1 hour, under all environmental conditions.

    The Terminal Equipment load requirement shall be specified in the Power Critical Design Review.

    7.1.3 Cabling / DCDU

    Cabling shall be assessed for capacity after environmentally de-rated, see Clause 7.2.

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    The following shall apply:

    a) The power distribution shall be rated at 150 % operating current e.g. greater than 50 % spare capacity for systems of 200A;

    b) The power distribution shall be rated at 125 % operating current e.g. greater than 25 % spare capacity for systems of > 200A;

    c) The Terminal Equipment DCDU shall allow for a 50 % increase in connection positions, to include the associated circuit protection devices;

    d) The Terminal Equipment DCDU will be provided with termination positions to allow for safe access to carry out testing under full load conditions.

    7.2 Environmental Cable De-Rating

    7.2.1 Environmental Conditions

    Cables are to be de-rated in capacity depending on the following conditions:

    a) Installation in platform, (conduit);

    b) Working air temperature;

    c) Number of simultaneous loaded cores;

    d) Alt