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dticasdsbirsbir031n086cdoc - PRELIMINARY SPECIFICATION ONLY

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									     VARIABLE SPEED DRIVE
                                         Newport News Shipbuilding
                                       4101 Washington Avenue
                                       Newport News, Virginia 23607-2770
                                       Phone: 757 688-8088




Newport News Shipbuilding




    VARIABLE SPEED DRIVE
               FOR
      PERMANENT MAGNET MOTOR


   GENERAL REQUIREMENTS




                     Prepared by:
                     Jack A. Clark
                      Craig Currie
                    Stephen J. Smith
               VARIABLE SPEED DRIVE                      Newport News Shipbuilding




                                             Draft:
                                             Final:
                                             Revision:

[TOC UNFINISHED & NOT YET COORDINATED WITH SPECIFICATION]

Variable Speed Drives

2.     SCOPE
2.1    Scope

3.     APPLICABLE DOCUMENTS
3.1    Order of Precedence
3.2    Background Design Guidance
3.3    Reference Specifications

4.     REQUIREMENTS

3.1    Basic requirements
3.2    Power
3.3    Circuit arrangement
3.4    Wiring
3.5    Assembly
3.6    Motor Type and Duty
3.7    Enclosure
3.8    Overload protection
3.9    Ambient temperature ratings
3.10   Mounting
3.11   EMI
3.12   Vibration
3.13   Relays
3.14   Switches
3.15   Cooling
3.16   Detail requirements
       3.16.1         Control
       3.16.2         Basic Requirements
       3.16.3         Programming
       3.16.4         Parameter Adjustment
       3.16.5         Display
       3.16.6         Interconnecting
       3.16.7         Carrier Frequency
       3.16.8         Speed Control
       3.16.9         Dynamic Braking
       3.16.10        Running Start


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                   NNS PRELIMINARY SPECIFICATION ONLY
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       3.16.11         Restart Circuit
       3.16.12         Frequency Skip
       3.16.13         Preset Speeds
       3.16.14         Analog Control
       3.16.15         Ramp Adjustment
       3.16.16         Flux Vector Control
       3.16.17         Self Diagnostics
       3.16.18         Relay Contacts
       3.16.19         Standard Display
       3.16.20         Built In Diagnostics
       3.16.21         Emergency Start/Stop
       3.16.22         Control During Power Loss
       3.16.23         Remote/Local Operation

3.17   Protective Controls
       3.17.1        Overload
       3.17.2        Overcurrent
       3.17.3        Overvoltage/Undervoltage
       3.17.4        Overfrequency/Underfrequency
       3.17.5        Overload
       3.17.6        Controlled Shutdown
       3.17.7        Thermal Overload
       3.17.8        Phase Loss
       3.17.9        Adjustable Current Limit
       3.17.10       Ground Fault
       3.17.11       Ride Through
       3.17.12       External Cable Connections
       3.17.13       Transformer
       3.17.14       Input Circuit Breaker
       3.17.15       Output Circuit Breaker
       3.17.16       Software
       3.17.17       Power Line Harmonic Reduction
       3.17.18       Built in Test Equipment


4      VERIFICATION
                 X. Table: Testing Requirements
4.1    Factory Testing
4.2    Instruments
4.3 Follow on Testing
        4.3.1         Preliminary requirements
        4.3.2         Load testing
        4.3.3         Input short circuit test


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       4.3.4          Output short circuit test
       4.3.5          Input total harmonic distortion
       4.3.6          Transient recover test
       4.3.7          Acoustical noise
       4.3.8          Control and protective device check
       4.3.9          Endurance test
       4.3.10         Insulation resistance
       4.3.11         High impact shock
       4.3.12         Compliance with shock test
       4.3.13         Location of shock test
       4.3.14         Correction and disposal of shock test equipment
       4.3.15         Post-shock test evaluation criteria
       4.3.16         Vibration test
       4.3.17         Overvoltage limiting test
       4.3.18         Test preparation
       4.3.19         Test agenda
       4.3.20         Test report
       4.3.21         Nameplates
       4.3.22         Terminal marking
       4.3.23         Maintainability
       4.3.24         Drawings


Quality conformance inspection
Table: Quality conformance inspection
Table: Routine inspection
   4.4     TESTS
       4.4.1 Failures
       4.4.2 Routine inspection
       4.4.3 Examination and general operation
       4.4.4 Temperature rise
       4.4.5 Endurance
       4.4.6 Overload protection
       4.4.7 Vibration
       4.4.8 Shock
       4.4.9 Inclination
       4.4.10 Insulation resistance
       4.4.11 Dielectric
       4.4.12 Effectiveness of enclosure
       4.4.13 Noise, ac contactors and relays (if applicable)
       4.4.14 Pickup and dropout voltage
       4.4.15 Voltage variation
       4.4.16 Terminal strength
       4.4.17 EMI


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       4.4.18   Time delay setpoint repeatability
       4.4.19   Recycle time of time delay relay
       4.4.20   Transient voltage and frequency tolerance and recovery test for solid-state devices
       4.4.21   Spike voltage
       4.4.22   Power interruption
       4.4.23   Leakage current
       4.4.24   Output leakage current
       4.4.25   Output voltage drop
       4.4.26   Pressure and temperature switch setpoint repeatability
       4.4.27   Mechanical interlock
       4.4.28   Position sensing switch operational performance


5.      PACKAGING
Packaging
Inspection of packaging

NOTES

      Intended use
      Acquisition requirements
6.3   Technical manuals
6.4          Qualification
6.5          Definitions
6.6   Special information concerning shock testing
6.6.1 Limits on shock testing
6.7   Provisioning

APPENDICES:

A  ENGINEERING DRAWINGS TECHNICAL CONTENT REQUIREMENTS
      A1. SCOPE
      A2. APPLICABLE DOCUMENTS
      A3. Drawings
B TECHNICAL CONTENT REQUIREMENTS FOR CERTIFICATION DATA
      B1. SCOPE
      B2. APPLICABLE DOCUMENTS
      B3. PROCEDURE




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SECTION 1: GENERAL INFORMATION
Introduction. This specification applies to variable speed drives
intended for powering and controlling a range of permanent magnet
“brushless DC” (PMB) type motors. It includes all associated sensors,
switching devices, semiconductor (solid-state) devices, display,
diagnostics, and interconnecting cable required to make a complete
system. The power conditioning system described herein shall be a
standardized modular power conversion and control system for military
shipboard applications suitable for driving PMD motors.

Order of precedence. In the event of a conflict between the text of
this document and the references cited herein, the text of this
document takes precedence. Nothing in this document, however,
supersedes applicable laws and regulations unless a specific
exemption has been obtained.

Background design guidance. It is the intent of this specification
is to reduce logistics infrastructure for VSDs in future military
applications. The VSD will power a class of PM motors within a range
of torques utilizing one basic frame size (i.e., constant diameter,
and variable length). A modular rack mounting configuration will be
used such that components of various sizes and functions can be
mounted interchangeably without significant modification of the
basic system. VSD shall be a [Form FC, from NEMA?] type controller
with AC input power, intermediate DC bus and variable frequency
output.

SECTION 2: STANDARDS / CODES / REFERENCES
Reference specifications. The variable speed drive shall meet the
requirements of the following specifications:


              Type                            Reference
Electric Power Equipment           MIL-E-917
Interface Standard for Shipboard   MIL-STD-1399, SECTION 300A
Systems, Electric Power,
Alternating Current
Enclosure for Electric and         NEMA 250, Type 2 and 4
Electronic Equipment
High Impact Shock                  MIL-S-901D, Grade A, Class II,
                                   Type A
Vibration                          MIL-STD-167-1
Electro-magnetic Interference      MIL-STD-461 and MIL-STD-462




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SECTION 3:                POWER ELECTRONICS FEATURES

Basic requirements. The drive shall be microprocessor-based and
provide four quadrant operation of continuously variable speed and
torque control over the entire speed range of the motor. Controller,
rectifier, inverter and other main VSD components shall be industry
standard and interchangeable to the greatest extent possible.
Modules and parts shall be standard industrial design and interface,
versus designed for a unique application. VSD shall be a modular
design that allows troubleshooting and repair without disturbing
other modules and parts to the greatest extent possible, with a
minimum of internal disassembly.

Control inputs. VSD shall be capable of receiving control signals
from any of three modes: (1) remote operator control station (OCS),
(2) VSD console, and (3) a laptop personal computer. Provide user
configurable motor control unless otherwise specified herein. The
VSD shall conform to the requirements of MIL-E-917 for the following
items.

1)   Materials (parts shall not be cadmium plated)
2)   Electrical shock hazard
3)   Electrical creepage and clearance distances
4)   Threaded parts and fastening devices
5)   Electrical insulation
6)   Insulating procedures
7)   Wire, wiring methods and marking
8)   Parts
9)   Processes

Power. The VSD components shall not require external power separate
from the main three-phase power feeding the main rectifier unit. All
VSD power conditioning equipment shall be contained within the
enclosure. Power up, power down, and power interrupt characteristics
shall be predictable, repeatable, and fully defined by application
information prepared by the manufacturer. VSD shall be designed to
operate on input power in accordance with the MIL-STD-1399, Section
300A, Type I, ungrounded systems. Current transformer secondaries
shall be grounded to the VSD enclosure. Provide main line disconnects
as part of the VSD. It shall not be possible for the motor to be in
a different mode of operation than indicated by VSD display and alarm
circuits. VSD shall use electrical or mechanical interlocks in its
operations to preclude any short circuit condition.

Power line harmonic reduction. VSD shall meet IEEE 519 current and
voltage standards for harmonic levels on the input line.




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EMI. The VSD shall meet the electromagnetic interference (EMI)
emission and susceptibility requirements of MIL-STD-461. Switching
functions and internally generated EMI shall not be propagated
outside the VSD enclosure by way of input or output interface signals
or cause inadvertent alarms or perturb surrounding equipment. The
VSD shall not be susceptible to damage or control errors due to
transients and excursions of voltage, current, or frequency common
to the shipboard environment.

Circuit arrangement. Each VSD shall be supplied with installation
instructions, operation manuals, wiring diagram, schematic diagram,
and description of operation. Wiring diagrams, schematic diagrams,
and description of operation shall be secured internal to the
enclosure and printed with a process that is nonfading, protected by
transparent plastic, and secured inside of the enclosure.

Wiring. Permanent internal wiring shall be copper wire or bus bar.
The size, stranding, and insulation of wire and the dimensions,
insulation, and spacing of bus bars shall be mechanically and
electrically suited to the application. PVC insulation shall not be
used. The minimum wire size shall be AWG 14, except that AWG 16 may
be used for connections to local switches and that at a minimum, AWG
22 may be used for all logic VSD connections.

Assembly. Open lugs are prohibited. Design shall permit removal of
functional sub-assemblies, parts or modules without disturbing other
parts to the greatest extent possible.

Motor type and duty. Variable speed drive will be used to power a
PMB synchronous machine. Unless otherwise specified, VSDs shall be
constructed for continuous duty and military-marine service.

Enclosure. Provide a NEMA 250 Type 2/4 with heat sink
through-the-back mounting type configuration to contain all primary
components of the VSD. Enclosures shall be constructed such that all
necessary cables can be brought into either the top or bottom. All
dust and humidity sensitive logic and power electronics shall be
enclosed in a sealed and non-ventilated NEMA 4 compartment accessible
from the front. All other components not considered sensitive to
moisture laden cooling air or heat sink surfaces may be located in
a ventilated or fan cooled NEMA 2 compartment. Mounting flanges shall
have machined mounting surfaces and be provided with round holes for
mounting bolts. Enclosures shall be equipped for deck mounting on
shock mounts in the vertical upright position with lifting eyelets
and provision for sway bracing if necessary. Parts mounted on
enclosure panels shall be replaceable without removing the panel. All
hinges and hardware shall be stainless steel. Arrange to provide
required louvers, cooling air, entry and exit provisions for
equipment within enclosures. Construct unit so that all components,


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with the exception of control and monitoring components, are totally
enclosed within the enclosure. Electronic circuits including power
circuits shall be modular construction readily accessible for
maintenance, repair and module replacement from the exterior of the
enclosure. Unit shall not require rear access for maintenance. All
accessibility shall be from the front or sides. Provide permanent
identification tags for wiring. Uniquely identify each wire. Use
the same identification system in the wiring diagrams in the Operation
and Maintenance Manual. Provide each enclosure with a marine grade
finish coat over a substrate, which has been provided with a rust
inhibiting treatment.

Ambient temperature rating. The VSD shall be rated for operation from
no load to rated full continuous load without exceeding the design
limitations under the following environmental conditions:

1.     From 0C to 50C ambient operating temperature
2.     From 0C to 70C ambient storage temperature
3.     Relative humidity from 0 to 95 percent, non-condensing

Noise. VSD and motor shall meet the requirements for shipboard noise
limitations specified for Grade D noise levels in MIL-STD-1474D,
Requirement 5, Shipboard Equipment Noise. [mil-spec SUPERCEDED: When
specified in purchase order VSD for low noise applications shall meet
the structure borne noise requirements for type III equipment of
MIL-STD-740B or, if specified, MIL-STD-740-2, and airborne noise
requirements for grade A3 and A12 equipment of MIL-STD-740-1. ]

Shock. Equipment shall withstand the high-impact shock test
specified in MIL-S-901D without change of operational state,
mechanical or electrical damage, or electrical malfunction.
Equipment shall not fail to function in any operational mode or
capacity due to the shock test. Pre- and post-test examination and
general operation test shall verify equipment performance. Enclosure
may be mounted on shock mitigating mounts as approved by NNS.

Vibration. Equipment shall withstand the vibration test specified
in MIL-STD-167-1 without mechanical damage, contact chatter,
transfer, or other electrical malfunctioning. Vibration test
frequency shall be 4 to 33 Hz. Equipment which will be exposed to
frequencies above 33 Hz shall be vibrated up through 50 Hz. Equipment
shall not fail to function in any operational mode, including
energized and deenergized conditions, during the vibration. Pre- and
post-test examination criteria for the H.I. shock test and general
operation test shall verify equipment performance.

Relays. Relays shall conform to this specification except that
control relays shall be solid state [commercial spec#?] [MIL-R-19523,



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endurance class A or B, shock class I or II]. [Relay position shall
be clearly indicated on … the front panel?]

Switches. Switches shall conform to the applicable specifications
MIL-S-15291, MIL-S-18396, and MIL-S-21604 or applicable requirements
of this specification. Endurance requirements of switches shall be
50,000 operations at 100% of rated current. Switch operation status
of open or closed shall be clearly indicated.

Cooling. Natural interior and exterior convection cooling is
preferred over fan cooling. If required, provision shall be made to
vent the exhaust air to any specified location. The NEMA 2 compartment
may be cooled with an internally mounted fan if necessary. Air supply
and exhaust shall be filtered to minimize dust accumulation.

SECTION 3.3 CONTROL
Control functions. The VSD shall have provisions for remote/local
control and programming of motor operation. Provide circuits for
analog control and sensor inputs, PID process control and Profibus
communications protocol. Operator controls shall be mounted on the
door of the cabinet and consist of a membrane command center which
allows manual stop/start, speed control, local/remote status
indication, manual or automatic speed control selection, and run/jog
selection. In addition, the command center will serve as a means to
configure controller parameters such as minimum speed, maximum speed,
acceleration and deceleration times, volts/Hz ratio, torque boost,
over-frequency limit, and current limit. Potentiometers will not be
allowed for these settings. It shall not be necessary to use any
expansion cards or other hardware mounted internal to the
microcomputer to perform programming functions. The controller shall
have an internal means of deactivating keypad parameter adjustments
to eliminate unauthorized data entry. Indication of the processor's
health and troubleshooting parameters shall also be available via the
digital display.

Basic requirements. Provide user configurable speed control, torque
control, and flux vector control. Whenever life of parts is
predictable and can be controlled through design, the equipment shall
be designed and applied such that equipment can be expected to operate
for a 40,000 hour life expectancy and a mean time between failures
exceeding 25,000 hours, assuming regular maintenance. Provide the
following features:

1.     Drive efficiency rating of at least 95 percent at full load.
2.     Microprocessor based adjustable frequency drive with sinusoidal
       or trapezoidal PWM control.
3.     Provide automatic voltage adjustment within the power range.



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4.     Digital user interface panel [is graphical feasible?] with full
       function LED display for operating parameter control and status.
5.     Two analog outputs (+/- 10 VDC or 4-20 mA)
6.     Two analog inputs (+/- 10 VDC or 4-20 mA)
7.     Four programmable contact inputs or outputs
8.     2 separately addressable serial interface ports 1 for RS232/485.
9.     Comprehensive warning and fault protection message processing
       and display.

Programming. The VSD shall be fully programmable via the front panel
or remote PC. A digital display shall be provided for viewing
operational parameters. Programming software shall alert the user
to programming errors such as illegal reference and improper
instruction. The software shall provide continuous status of motor
operation. Password protection shall be available to lock out
different levels of operation to protect the motor from untrained
users. Provide capability for displaying and manipulating
operational history data in graphical format from remote personal
computer [i.e. with LabView or …]

Software. A non-proprietary standard software suite of control and
communications functions shall be implemented that will be executable
on industry accepted CPU configurations. Vendor shall advise NNS of
proposed software prior to final approval.

Parameter adjustments. Controller shall be user programmable for the
following functions from local, remote, serial control ports:
1.   Access authorization to controller functions [password
     protection]
2.   Motor operating modes
3.   Minimum and maximum switching frequency
4.   Minimum and maximum motor speed
5.   Voltage boost/current boost
6.   Motor overload current
7.   Overload time before shutdown
8.   Analog scaling and range settings
9.   Ramp up waiting time
10. Acceleration/deceleration time
11. 4 independent preset speeds
12. Speed control feedback gain
13. Integration time of frequency/speed regulator
14. Torque limiting
15. DC link regulator
16. Space vector regulator method for IGBTs [optional?]
17. Tension control
18. Pressure / flow control
19. Arithmetic functions (logic control)
20. Open/closed loop control blocks
21. 3 frequency skips


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Standard displays. The VSD enclosure shall have a front panel to
display system operational status, adjustment parameters and trouble
conditions. A high intensity digital LED display on the door of the
cabinet shall be provided for viewing operational parameters and
shall be clearly visible in a dark or bright environment. Provide
the option to select any display parameter as analog output via
terminals. The digital display shall be viewable in a dark
environment. Following displays shall be user selectable:

1.     DC link voltage
2.     Motor torque
3.     Motor/drive utilization
4.     Elapsed operating time
5.     Time stamped fault indication
6.     DC bus voltage
7.     Motor speed
8.     Output frequency (Hz)
9.     Output current
10.    Output torque
11.    Output voltage
12.    Output power

Interconnecting cable. Provide all interconnecting cable and
terminal connections and sensor wires between motor and drive
required to complete the system.

Current rating. The VSD general class shall be current rated as
sufficient to drive a PMB motor from 50-200 HP. No derating of the
drive shall be required due to increasing this switching frequency
for motor noise reduction. Drive shall not automatically reduce the
carrier frequency as load is increased [necessary?].

Speed control. Speed regulation accuracy of +/-1% is required.
Controller shall be capable of driving all motors in class at speeds
from 0 to 3000 rpm in both directions without damage to motor or VSD.

Dynamic braking. Provide full torque, sustained regenerative
braking, with power dissipated into an air-cooled resistor load bank.
Load bank shall be capable of sustaining rated load energy dissipation
for a minimum of 10 minutes. Provide adjustable braking that is
programmable from the front panel in amplitude. Provisions for smooth
brake torque transfer from electro-mechanical brake to mechanical
shaft brake after the motor has stopped may be required.

Running start. Provide the capability of starting into a rotating
load regardless of direction without the need of a time delay upon
a start command.



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Restart circuit. An automatic restart circuit which is settable by
number of restart attempts and time interval between restarts.

Frequency skip. Three critical frequency avoidance bands, which can
be programmed in the field, enable the controller to avoid resonant
frequencies of the driven equipment. Each critical frequency
avoidance band shall have a bandwidth adjustable via keypad entry of
+/- 5 Hz.

Preset speeds. Provide programmable speeds which will ramp the motor
to a preset speed upon a user contact closure. This feature shall
be set digitally by entering data via the door mounted membrane
command center for up to four separate speeds.

Analog control. An isolated electrical follower capability shall
enable the VSD to follow a 0-20mA, 4-20mA or 0-4, 0-8, or 0-10 volt
DC speed signal. An isolated 0-10 volt or 4-20 ma output signal for
computer controlled feedback signals shall be selectable for speed
or current.

Ramp adjustment. For smooth and continuous acceleration and
deceleration capabilities, the drive shall have a pre-programmed ramp
adjustment that can be activated locally.

Flux vector control. Flux vector control shall be available for
control of motor current and voltage independently. Vector control
shall have the capability to be closed loop or open loop.

Relay contacts for remote operation/indication. [need advice on this
para] Provide relay contacts for remote operation, indication of
drive fault and motor running status for interconnection to other user
supplied devices. Variable speed capabilities shall be available for
both local and remote units. The drive contact output ratings shall
be 115V AC/30V DC, 5.0 Amp resistive, 2.0 Amp inductive. The four
(4) contacts provided shall be as follows:
Form A Run Contact         [what is Form A, C? etc.]
Form C Fault Contact
Form C Alarm Contact
Form A Programmable Contact for at speed, at frequency, at current
or at torque.

Built-in diagnostics. VSD circuitry shall include built-in
diagnostics to monitor the primary controller, rectifier, inverter
and associated protective circuits. Built-in diagnostics equipment
shall troubleshoot and isolate any VSD malfunction to the lowest
replaceable element. Diagnostics shall be accessible without causing
system interference while VSD is in normal operation. Provide visual
indications to assist diagnosis of unit failures to a component level
as necessary. VSD shall be of a modular design that allows


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troubleshooting and module replacement without disturbing other
parts to the greatest extent possible, with a minimum of internal
disassembly. Isolation and replacement of hardware failures shall
require not more than (15) minutes.

Emergency start/stop. Terminals shall be provided for remote
emergency start/stop operation. VSD shall be provided with a means
of defeating the overload protection for emergency operation. After
a total input power outage the VSD shall be capable of automatically
restarting and re-energizing the load upon restoration of normal
power. Manual restart shall also be available. Manual/automatic
restart shall be selectable in the VSD’s software.

Control during power loss. Upon loss of power to the VSD for longer
than one second, VSD shall do emergency motor shutdown,
simultaneously applying the shaft mounted brake (if used), and shall
maintain full control functionality until the motor has been safely
shut down and the mechanical brake engaged. After emergency shutdown,
the VSD shall have the capability to either automatically restart the
motor upon restoration of power or to require a manual restart command
prior to restoration of power.

Local/remote operation. When specified, the VSD shall have
provisions for remote/local control of motor operation. Variable
speed capabilities shall be available for both local and remote units.

Protective controls and status indicators. The following controls
and indicators (menu selectable) shall be available as standard with
the VSD. Additional protective features may be required with each
individual application.

1.     Input overcurrent /undercurrent
2.     Input overvoltage / undervoltage
3.     Overfrequency / underfrequency
4.     Output phase loss
5.     Thermal overload
6.     Adjustable output current limit
7.     Ground fault short circuit
8.     Dynamic braking indicator
9.     Air flow pressure indicator

Overcurrent protection. Provide speed dependent overcurrent sensing
circuitry, using two level alarm and shutdown modes, to protect VSD
and motor based on current sensors in the VSD during starting and
running conditions. Overcurrent protection circuit shall sound an
alarm to indicate motor is drawing abnormally high current. Provision
shall be made for selection of automatic and/or manual resetting of
protective circuit on the front panel of the enclosure. The
overcurrent protection system shall be fail safe without any bypass


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or automatic reset capability. Provide solid state overload devices
calibrated for operation at maximum ambient temperature. Overload
rating shall be based on motor speed on an inverse time basis. This
overload shall be UL and NEC recognized as adequate motor protection.

Overvoltage/undervoltage protection. The VSD shall operate in plus
or minus 10 percent of rated voltage with rated frequency. In case
of an emergency situation not to exceed 5 minutes duration, VSD shall
withstand without damage any under- or over-voltage supply power
which is 25 percent below or above rated voltage. [Power off
automatically upon sensing unacceptable supply voltage.]

Overfrequency/underfrequency protection. The VSD shall operate
within plus or minus 5 percent of rated frequency at rated voltage.
In case of an emergency situation not to exceed 5 minutes duration,
VSD shall withstand without damage any under or over-frequency supply
power which is 25 percent below or above rated frequency.

Fault protection. VSD shall be capable of carrying the fault current
from a bolted line-to-line or three-phase fault until the integral
system protective devices interrupt the fault without damage to the
VSD or PMB motor. Indication of and protection against ground faults
shall be provided.

Controlled shutdown. Upon sensing power quality, fault or power
interruption conditions, VSD shall exhibit controlled shutdown of the
motor, and automatic application of the mechanical brake without harm
to VSD or PMB motor.

Thermal overload protection. The VSD shall provide thermal overload
protection for each motor. Motor temperature will be provided as
sensor inputs to the VSD. Standard drive shall accept [thermister,
4–20 mA, or … ] inputs for motor thermal protection. If specified,
two levels of alarm outputs may be required for warning and maximum
temperature. Sensing accuracy shall be within +/- 2C. This overload
shall be UL and NEC recognized as adequate motor protection.

Phase loss protection. Provisions shall be made to detect any loss
of phase currents to the motor and initiate an alarm condition and
shut down action. Protective function activates when any one of the
phase currents are 60 percent less than normal phase current.




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Adjustable current limit. The current limits shall be user adjustable
to provide optimum protection of the motor under different service
conditions.

Cooling fan indication. Provide indication of cooling system status
(on/off).

Ride through. VSD shall store sufficient energy in the DC link to
provide a minimum of 1 second voltage dip (momentary complete power
outage) ride through without interruption of normal operation at
rated power output.

External connections. External power circuit conductors may be wired
directly to the internal connection points. Terminal boards and
direct connection points shall be accessible from the front of the
enclosure. Provide power cable and control wires suitable for
connecting associated motor in accordance with […] Maximum cable run
between motor and controller shall be 200 [500?] feet.

Fasteners. Bolts and screws used for mechanical connections shall
be secured with locknuts [or lockwashers? 917E: 3.3.16.8]. [Drilled
and tapped connections need locknut?] Fasteners shall be made of
corrosion-resisting material or shall be treated to resist corrosion
without paint. Precipitation hardened semi-austenitic
corrosion–resisting steel fasteners do not require additional
protection against corrosion.

Control transformers. Control circuit transformers shall conform to
[commercial spec #?] [MIL-T-16315] and shall be rated accordingly.
Components powered by the transformer shall operate satisfactorily
from type I power and shall meet the operational requirements of this
specification. [necessary? Probably better left out]

Input circuit breaker. NNS shall provide a dedicated UL listed input
circuit breaker of appropriate rating external to the VSD to protect
the feeder lines. Vendor shall provide an internal input circuit
breaker to protect the VSD and motor from overload. Internal breaker
shall be manually operable from the front exterior of the enclosure.

Fused components.         [necessary?]

Output circuit breaker. Provide VSD output with a non-automatic
manual circuit breaker with appropriate frame size and shunt trip
coil. Circuit breaker shall be tripped by the unit’s OFF circuit local
or remotely activated and when any circuit identified in “Protective
Control” causes the system to shut down. Breaker shall be operable
from the front of the VSD.




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SECTION 4.0 TESTING.
Test preparation. The manufacturer shall make, previous to tests to
be witnessed by the purchaser sufficient tests to insure that the
design of the PMB motor & VSD system conforms in all respects to this
specification. To prevent delays and the additional cost of repeated
tests, not more than two tests shall be made, the second test to be
made within such time after the first test as stipulated by the
inspector. Failure to make the necessary repairs or remedy defects
within that time shall be considered sufficient cause for final
rejection of the VSD. All tests shall be conducted with the VSD
operated as a complete unit and loaded with the motor and all system
parts. Any equipment or services, which the Vendor considers should
be supplied by the Purchaser or Government to conduct the required
VSD tests, must be listed in the Vendor’s Proposal and approved as
a contract requirement.

Test agenda. Detailed test agenda and procedures for all VSD tests
shall be submitted for NNS for approval 30 days prior to test. [submit
to NAVSEA for 901D and 461?]

Instruments. The test plan shall list make and model and provide
functional description of the test instruments and accessories and
shall describe the setup of the tests to be conducted. Provide test
instruments capable of measuring and recording or displaying tests
data at a higher resolution and greater accuracy than specified for
the VSD’s performance. The test instruments used in the field tests
shall have current and valid calibration stickers issued by an
approved calibration laboratory. Verify calibration and adjustments
of VSD instruments provided prior to field tests.

Test reports. In addition to distribution of test reports required
by MIL-STD-167-1, MIL-STD-461, MIL-STD-462, and MIL-STD-901D, six
copies of test records and additional information as required shall
be forwarded to Newport News Shipbuilding, Department 051.

Factory testing. Conduct VSD performance tests under the supervision
of the manufacturer's representative. Successfully complete the
preliminary operation, control and protective devices check prior to
performing load and transient tests. If the VSD fails to operate
within the specified limits during any of the performance tests the
Contractor shall discontinue the test and shall make necessary
repairs to correct the failure and retest the VSD.

The factory and shipboard tests in the evaluation of this variable
speed drive unit shall be conducted while connected to the associated
PMB motor.


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                        NOT A PURCHASE ORDER
1.     Full load endurance
2.     Cycling through forward and reverse operation
3.     Thermal overload
4.     Interlock coordination between motor and VSD


TEST ELEMENT                 Factory     Qualifi-c   Specification     Notes
                                           ation
Preliminary Operation
High impact shock                            X         MIL-S-901D
(mitigated)
Vibration                                    X       MIL-STD-167-1
Airborne noise                               X
Structure borne noise           X
Full load endurance             X
Cycling forward & reverse       X
Input short circuit             X
Output short circuit            X
Brake operation                 X
Load                            X
EMI                                          X
Thermal overload                X



Brake and motor
coordination
Enclosures for Electrical
Equipment, NEMA 250
Control and Protective
Device Check
Input Total Harmonic
Distortion
Insulation resistance           X
Heat run                        X
Transient recovery              X
Dielectric                      X
Maintainability                              X

Preliminary operation. Inspect the VSD and make adjustments
necessary to assure proper operation in accordance with the
manufacturer's instructions. Operate VSD at 0, 25, 50, 75 and 100
percent of rated full load at 25, 50, 75 and 100 percent rated speed
for each. Measure and record the output voltage, current and
frequency at each load. Verify VSD is operating within specified
limits at each load level.




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Load. Run VSD and motor continuously a minimum of 4 hours at 100
percent rated load. Measure and record the critical VSD component
(controller, DC link, rectifier, IGBT inverter) temperatures and the
motor stator winding temperatures in 10 minute increments. Motor and
controller shall not thermally overload […] Monitor output to confirm
there is no power interruption.

Overload/Over-current: Operate at nominal input voltage with loads
listed below: [add more wording here…]

   Percent    of Full Load   Minimum Operating Time
       110    percent              60 minutes
       125    percent              10 minutes
       150    percent               1 minutes

Input short circuit. Apply a bolted line-to-ground, bolted
line-to-line, and bolted three-phase fault directly to the input
terminals of the VSD. Monitor operation of the motor to ensure
controlled shutdown and braking operation. Conduct a minimum of three
consecutive successful tests on each VSD. Provide recordings or
display of short circuit current during short circuit tests. Repeat
each short-circuit overload test [4] times to ensure consistent
protection.

Output short circuit. Apply a bolted line-to-ground, bolted
line-to-line and bolted three-phase fault directly to the output
terminals of the unit. Conduct a minimum of three consecutive
successful tests on each unit. Provide VSD components capable of
carrying the fault current until the integral system protective
devices interrupts the fault with no damage to the VSD. Provide
recordings or display of short circuit current during short circuit
tests. Repeat each short-circuit overload test [4] times to ensure
consistent protection.

Overvoltage limiting. An analysis shall be made of the VSD system,
to determine that no single failure will result in stator temperatures
in excess of the temperature limits specified in [x.xx]. With the
motor operating at full load, rated voltage, and rated frequency, a
failure in the … to cause over speed/torque shall be simulated. The
overvoltage limit shall be set at the minimum and maximum limits and
then approximately three equally spaced points, to determine
satisfactory operation. The following minimum readings shall be
taken before, during, and after the simulated failure: the three
line-to-line voltages, frequency, field current, and field voltage.

Surge protection. Apply input surges in accordance with IEEE C62.41,
Category B and monitor output. Conduct a minimum of three consecutive
successful tests on each unit listed. Confirm there is no



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                        NOT A PURCHASE ORDER
interruption to output power and voltage stays within specified
regulation tolerances.

Input total harmonic distortion (THD). Operate at nominal input
voltage at no load and full load with balanced and 15% percent
unbalanced load. Measure and record the THD for the line-to-line
voltage of each phase current. A 15 percent unbalanced load is defined
as follows:
Phase A at full rated single-phase load.
Phase B at 90 percent of Phase A.
Phase C at 85 percent of Phase A.

Transient recovery. Operate at steady-state conditions at 100
percent rated load. Conduct transient load shed tests on each VSD
by instantaneously removing 50 percent of rated load and then 100
percent of rated load. Provide recordings or displays of voltage,
current and frequency during each transient test, and display on the
recordings the time intervals and acceptable limits for voltage,
current and frequency. Conduct transient load gain tests on each VSD
by operating at 50 percent rated load and instantaneously adding 50
percent of rated load and then 75 percent of rated load. Repeat and
record each transient test three times. Measure and record recovery
time and output voltage deviation limits. Provide recordings or
display of output voltage during transient tests. Verify VSD is
operating within specified limits.

Acoustical noise. Operate at no load, 50 percent and 100 percent of
full load. Measure continuous steady sound pressure level 5 feet
horizontally from the center of each side of the VSD at a point 5 feet
above the deck. Continuous airborne sound level shall be a maximum
of 70 dBA. [airborne, structure borne] Decibels (dB) are referenced
to 20 micro-pascals.

Control and protective device checks. Operate each control, switch,
input/output device that is capable of being operated manually a
minimum of three times, demonstrating satisfactory operation each
time. Perform operation test on each protective device to ensure that
devices functions properly. After each operation measure and record
the VSD output frequency, voltage and current. Verify VSD is
operating within specified limits.

Endurance. A device will have failed the endurance test if at any
point during the test specified in […] the device fails to function
mechanically or electrically by failure to make, carry, or break the
load, there is welding of contacts, or at the conclusion thereof, the
device fails to operate as required to pass the examination and
general operation test specified in [incl table listing requirements
Table I?]



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Efficiency. Operate at nominal input voltage at half load and full
load. Measure and record input voltage, input current, input power
factor, output voltage, output current, and output power factor.
Calculate the unit efficiency.

Brake and motor coordination. Test coordination between mechanical
brake and motor including transition from regenerative mode and shaft
mounted brake mechanisms. [add specifics here …] Apply the brake
while operating system at 100 fpm and 50 fpm line speed in both
directions to ensure motor becomes inactivated while brake is
applied.

Insulation resistance. The insulation resistance test shall be
conducted before the dielectric test. Prior to the application of
the test voltage, all circuits shall be thoroughly discharged. The
test voltage shall be applied between all electrically isolated
circuits and between each circuit and frame (or chassis). Circuit
diagrams shall be carefully studied prior to conducting this test,
to ascertain that circuits which may be damaged by acceptable leakage
current are grounded. When testing between the circuits and frame
(or chassis), all circuits may be tied together so that only one test
voltage need be applied, providing that the insulation resistance
when tested in this manner meets the minimum value of 5 meg-ohms
specified in 3.5.4. Resistance shall be measured with an insulation
resistance indicating instrument. The time of test voltage
application shall not be less than 60 seconds. The temperature of
the circuits at the time of the test shall be measured and readings
taken. Insulation resistance measurements shall be corrected to
25°C. Corrections shall be made on the basis of insulation resistance
doubling for each 15°C decrease in temperature. The relative humidity
at the time of the test shall be determined and recorded.

Dielectric. A dielectric strength test as specified in ASTM D149-81
[MIL-E-917 and method 301 of MIL-STD-202]. The RMS test voltage shall
be twice rated circuit voltage plus 1000V. Duration of test shall
not be less than 60 seconds for each measurement. Test voltage shall
be applied between each electrically isolated circuit [input
terminals only?] and ground with all other circuits grounded.

High impact shock. The test shall be as specified for high impact
Grade A, Type A, Class II of Specification MIL-S-901D and as specified
herein. After first article tests a shock test will be required only
where there are any significant changes made in the design, materials
or manufacturing procedures.

General. The Variable Speed Drive components may be mounted on shock
mounts. Shock mounts are available from NNS which will reduce levels
to less than 15 g’s. The VSD & PMB motor system & components thereof
shall be energized during the shock test. All equipment or parts shall


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be mounted on the shock machine in a manner simulating the actual
installation onboard ship. The weight designation of the shock test
shall be as required by the combined weight of the equipment or
components thereof being tested. The output readings of the equipment
shall be taken before and after the test, to determine compliance with
4.16.2.

Shock test compliance criteria. Equipment which has been subjected
to the shock test and has successfully performed all the principal
functions specified herein will be acceptable, provided the following
are satisfactorily met:

1.     Visual inspection. Inspected without disassembly for breakage,
       distortion deformation and dislocation of any parts.
2.     Heat run. Operate at full load and 25%, 50%, 75% and 100 rated
       speed for not less than 4 hours. Any unusual motor symptoms shall
       be noted.
3.     Dielectric strength. The applied voltage shall be 65% of the
       values specified for the dielectric test.
4.     Internal inspection. Disassemble and inspect thoroughly for
       damage (breakage, distortion, deformation, or dislocation of
       parts). The extent of disassembly shall be sufficient to observe
       the condition of all parts including the enclosure, inverter,
       rectifier, controller, heat sinks, fan, contacts, display, and
       major supporting components.
5.     No breakage of any parts, including mounting bolts. Cracking
       or signs of cracking in parts vital to operation shall be
       considered breakage.
6.     No appreciable distortion or dislocation of any parts such as
       mounting feet, coils, or conducting terminals.
7.     No values of insulation resistance (corrected to 25° Celsius)
       less than that permitted by […].
8.     Ability to withstand dielectric test voltage equal to 65 percent
       of that specified in […]
9.     Failure to meet
10.    Shift in the value of maximum torque of more than 2 percent.
11.    Failure of any of the protective circuits which may be provided
       to meet the requirements for thermal capacity limiting and …
       operation.

The compliance requirements above need not hold during the shock test,
but shall be maintained after the shock test without adjustment.

Location of shock test. Shock tests shall be performed at Newport
News Shipbuilding facilities in Newport News, Virginia or the
contractor’s plant, commercial laboratory, or Government laboratory
which is equipped to perform these tests. Copies of all master
drawings shall accompany the equipment for shock testing.



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Correction and disposal of shock tested equipment. Equipment which
has been subjected to the shock test and has failed to perform any
of the principal functions specified herein shall not be acceptable,
either in whole or any of the parts, until it has been modified and
successfully passed the shock test, or until the design modifications
have been approved by the contracting activity.

Vibration. The VSD shall be tested to demonstrate that the equipment
can withstand externally excited vibration in accordance with
MIL-STD-167-1. The method of energizing and loading during the test
and the readings taken before, during, and after the test, shall
conform to [X.XX], Shock test. Criteria for compliance shall be as
specified in [x.xx, Shock test].

Nameplates. The nameplates shall be attached to a part of the
equipment which will not ordinarily be renewed during its normal
service life. These plates shall be located in a readily accessible
position where they can be read at all times without danger to
personnel. The markings shall done in such a manner as to produce
permanent and durable markings to last the anticipated life of the
equipment.

The data marked on each nameplate shall include the following items:

(1)    Manufacturer's name, identification symbols, serial number,
       Government contract or shipbuilder's order number, and date of
       manufacture.
(2)    Salient design characteristics of the VSD component, for
       example, type, frequency, voltage, and capacity.
(3)    Blank space for Government inspector’s official stamping.
(4)    Standard Navy stock number.

Terminal marking. Terminals shall be marked with original terminal
numbers to facilitate hook-up of existing wiring.

Maintainability. Equipment repair time in accordance with
MIL-STD-471 shall be less than 3 hours. No repair shall require more
than 10 hours. Prediction shall be in accordance with MIL-HDBK-472
procedure II . Failure Mode and Effects Analysis shall be in
accordance with MIL-STD-1629. Critical items shall be identified.

Drawings. Drawings shall conform to ASME Y14.24M and as specified
herein. Drawings shall be presented on sheets of the same size and
shall not be smaller than 17 by 22 inches. Sheet sizes smaller than
28 by 40 inches shall be used only when all of the required drawing
data for each designated category is furnished complete as one sheet.

FROM HERE ON NEEDS LOTS OF WORK …

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Assembly Drawings.        Assembly drawings shall contain the following
minimum data:

1.    List of material.
2.    List of onboard repair parts and tools in table form.
3.    A table of insulation indicating the location, class of
      insulation, insulation material and applicable specifications
      and remarks.
4.    A table or list of units such as transformers, rectifier stacks,
      resistors, capacitors, and similar items giving piece number,
      type, and rating of each. This data is a supplement to the list
      of material where space normally does not permit complete noting
      of part rating. Ratings shall include both manufacturer's rating
      and the specific application rating.
5.    Outline dimensional drawings of units such as transformers,
      reactors, transformers, reactor cores, rectifier stacks,
      capacitors and similar items except for those parts which have
      received separate qualification approval under applicable part
      specifications in which case the parts shall be identified by
      making reference to the letter of agency approval and the test
      report number.
6.    Sectional views describing provisions for mounting of power
      transformers, reactors and semiconductors heat sinks internal
      to the VSD enclosure, such as brackets and channels, adequate
      to illustrate the mechanical relationship between part mounting
      and overall cabinet structure.

Transformer data.
1.   Core material and core or lamination Form and size (including
     stack height) if core boxes are used, the material and size of
     the box should be given.
2.   Winding data including number of turns, tape, wire size and
     specification type designation, insulation, method of
     impregnation and treatment, and DC resistance at a specified
     temperature.
3.   If potted, the method of potting and potting compound should be
     identified.
4.   Identification as to where used.

Semiconductor data
1)   General information including the name of semiconductor
manufacturer, manufacturer's identification number, salient
ratings, circuit application, number of semiconductor per VSD.
Describe physical mounting and heat sinking of power semiconductors
and voltage reference diodes.

Schematic diagram of test circuit.



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Installation Drawings

Installation drawings shall contain the following information:

Manufacturer's name and catalog number or equivalent identification
of the VSD.

B.   List of descriptive data of the VSD including:
     1)   Applicable specification and exceptions.
2)   Complete rating showing (a) input voltage, frequency,
regulation, and number of phases, (b) output voltage, regulation and
current from zero to full load, (c) efficiency at one-half and full
load, (d) degree of output voltage compensation.
     3)   Duty.
     4)   Shock classification.
     5)   Enclosure classification.
     6)   Ventilation.
     7)   Type of load.
     8)   Ambient temperature.
     9)   Temperature limits (when specified).
     10) Weight of VSD.
     11) Notation of the corrosion-resistant treatment of all
hardware.
Special features.
Clearances for ventilation and maintenance

C.   Finish, including method of treatment of enclosure for
paintings, color, and applicable specification of paint.

Sketch showing method of mounting of VSD enclosure, indicating size
and location of mounting holes and position of brackets or mounting
supports, and illustrating significant structural members of
enclosure.

Detailed dimensioned sketch, with terminal markings, of all terminal
boards for input and output connections.

Location of center of gravity of VSD shown in at least two views of
the enclosure.

Outline of VSD showing overall and principal dimensions of front view,
side view, top view, and sectional-views as necessary to show
approximate mounting arrangement and location of parts of the list
of material. Parts shall be flagged by item or piece number. Views
shall show identification and information plates with data to appear
thereon.

Cable entrances provisions.



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                        NOT A PURCHASE ORDER
Air intake and discharge openings with statement of minimum
ventilation clearances.

Wiring compartment. Showing provisions for cable access and position
of output voltage compensation adjustments.

       K.     Required interconnections and cabling.

Maintenance Drawings

Maintenance drawings shall contain the following minimum data:

Schematic electrical diagram arranged in simplified form. Magnetic
amplifier circuits shall show all windings in location with their
respective cores but with circuitry to the control windings shown
remote from the cores to avoid long and indirect runs. Control
windings in the circuit schematic shall be shown in symbols or
notation designating the direction of magnetic effect All parts and
windings shall be identified by appropriate symbols corresponding to
their identification in the description of operation.

Wiring diagram indicating markings of all terminals, leads, and all
parts with wire sizes shown for all connections. Each lead shall be
shown by number designation. The wiring diagram shall show parts and
wiring in the approximate same physical location with respect to one
another as mounted in the VSD.

Description of operation, description of all adjustments and a
general theory of operation.

Technical Manuals. Technical manuals shall be furnished and shall
conform to MIL-M-24784. The text of technical manual shall be
specific for the VSD. General information may be added in supplement
to required specific information (that is, general theory of
operation) when considered desirable by the manufacturer and when
approved by NAVSEA.

Arrangement of the text shall be as follows:

       A.     Cover
       B.     Title page
       C.     General data
              1)    Title description of VSD.
              2)    Navy type designation.
              3)    Federal stock number.
              4)    Dimensions.
              5)    Weight (without packing).
              6)    Salient design characteristics.
              7)    Manufacturers type and catalog number.


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           8)   Safety notices.
     D.    Table of contents, listing all divisions and primary and
secondary subdivisions (such as chapters, sections, and others) with
corresponding page numbers.
     E.    List of illustrations, photographs, and drawings.
     F.    Introduction.
     1)    General description.
     2)    Input requirements and output rating.
     G.    Operating instructions.
     H.    Principles of operation.
           1 ) Explanation of basic theory governing the functions
performed by power regulating parts and control circuits which define
buck-boost effects within VSD.
           2)   Block diagram showing necessary signal flow to
achieve voltage regulated operation of power stage.
           3)   Simplified illustrations and schematic diagrams to
supplement explanation text.
           4)   Significant operational characteristic curves, such
as transfer curves for magnetic amplifiers; and power magnetics of
specialized design.
           5)   Voltage and current signal waveforms internal to
regulator control circuitry; correct phase relationship of trigger
pulses and gating signals with respect to AC line voltage, indicating
instantaneous excursions, reference levels and time base.
     I.    Installation instructions.
           1)   Precautions.
           2)   Preparation for use after storage.
           3)   Mounting.
           4)   Electrical connections.
           5)   Tests, including insulation resistance measurements,
necessary to verify suitability for shipboard installation.
     J.    Maintenance, corrective.
           1)   Proper adjustment of resistive and reactive voltage
compensation potentiometers.
           2)   Simple voltage regulation toots requiring
measurement of and RMS output voltage.
           3)   Resistance measurements and continuity checks.
           4)   Troubleshooting techniques; involving observation of
symptoms diagnosis of faults and corrective action sequence of stops
required to isolate faults.
Signal tracing and measurement of significant voltages, currents, and
waveforms necessary trimming adjustments.
           7)   Removal of replaceable trays or modules to facilitate
troubleshooting and repair.
           8)   Description of test instruments required to
troubleshoot VSD, and admonitions or precautions on proper use of
instruments.
     K.    Maintenance, preventive



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          1)   Visual inspection For broken leads, heat damaged
parts, dirt, and contaminants.
          2)   Proper procedure For cleaning interior of VSD to
accomplish safe and nondestructive removal of dirt and deposits;
precautions on use and handling of cleaning solvents.
     L.   Parts identification in form of list-based on provisioning
technical documentation defining recommended complement of onboard
repair parts.
     M.   Reduced size master drawings of line voltage regulator.
     N.   Photographs (Include a sufficient number of photographs of
both external and internal views of the VSD to show construction
details and location of parts. Parts shall be flagged.)
     O.   Definitive list of test VSD, indicating instrument,
manufacturer and model designation, necessary to troubleshoot
shipboard installed VSD and to reproduce test data.

Manual Validation Plan

The manufacturer shall prepare, revise as appropriate, and follow a
validation plan for the technical manual as specified in MIL-M-24784.
The validation plan shall provide for Government verification.
Validation of maintenance procedures shall be accomplished in
accordance with MIL-M-85337 prior to VSD delivery.


Factory Tests. The manufacturer shall test every VSD to assure
compliance with the specification. Tests shall include the
following:

No Load Losses: Operate at no load and nominal input voltage. Measure
and record input voltage, input current, input power, input power
factor, and output voltage.

Special Factory Tests. The manufacturer shall test one unit of VSD
to assure compliance with the specification. Conduct tests on
production model of VSDs of the same design, construction and KVA
rating provided. The tests shall include the following:

5.0    SUBMITTALS

Submit the following documents:

5.1    Manufacturer’s Catalog Data

A. VSD
B. PMD motor

5.2    Drawings



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A. VSD
B. PMD motor

5.3    Statements

A.   Work plan
B.   Routine factory test procedures
C.   Special factory test procedures
D.   Qualifications of manufacturer
E.   Field test procedures

5.3.1         Work Plan

Submit a written schedule of dates of factory tests, installation,
and field tests of VSD.

5.3.2         Routine Factory Test Procedures

Submit 7 copies of test plans and procedures at least 21 calendar days
prior to the test being conducted. Provide detailed description of
test procedures, including test equipment and setups, to be used to
ensure the VSD meets the performance specification and explain the
test methods to be used. As a minimum, the test procedures shall
include the tests required under the paragraph entitled “Routine
Factory Tests”.

5.3.3         Special Factory Test Procedures

Submit 7 copies of test plans and procedures. Provide detailed
description of test procedures, including test equipment and setups,
used to ensure the VSD meets the performance specification and explain
the test methods to be used. As a minimum, the tests procedures shall
include the tests required under the paragraph entitled “Routine
Factory Tests".

5.3.4         Qualifications of Manufacturer

Submit a certification that the manufacturer has a minimum of five
(5) years experience in the design, manufacturing and testing of VSDs.

5.3.5         Field Test Procedures

Submit 7 copies of test plans and procedures at least 10 calendar days
prior to the field tests. Provide detailed description of test
procedures, including test equipment and setups, used to ensure the
VSD meets the performance specification and explain the test methods
to be used. As a minimum, the test procedures shall include the tests
required under the paragraph entitled “Field Tests and Inspections”.



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5.4    Factory Test Reports

A.     Routine Factory tests report
B.     Special factory tests report
C.     Burn-in test

5.4.1         Routine Factory Tests Report

Submit within 15 calendar days after completion of tests. Certify
tests were conducted on each VSD in accordance with the requirements
set forth in paragraph entitled “Routine Factory Tests” and certify
VSD satisfactorily operated within specified limits. Report shall
include copies of the test procedures and test data and results.

5.4.2         Special Factory Tests Report

Certify tests were conducted on a VSD of the same design, construction
and KVA rating to be provided and in accordance with the requirements
set forth in paragraph entitled “Special Factory Test” and certify
VSD operated within specified limits. Report shall include copies
of the test procedures and test data and results.

5.5    Field Test Reports

A. VSD

Submit within 15 calendar days after completion of tests. Provide
in accordance with the requirements set forth in paragraph entitled
“Field Tests and Inspections”. Certify tests were conducted on each
VSD in accordance with the paragraph entitled “Field Tests and
Inspections” and certify VSD satisfactorily operated within
specified limits. Report shall include copies of the test procedures
and test data and results.

Factory Test Certification

Submit certification that routine and special factory tests were
conducted on VSD of the same design, construction, and power rating
stating that test results are within specified limits.

5.7    Operation and Maintenance Manuals

A. VSD
B. PMD motor

6.0    EXTRA MATERIALS




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                 NNS PRELIMINARY SPECIFICATION ONLY
                        NOT A PURCHASE ORDER
Furnish recommended manufacturer’s spare parts list and schedule of
prices for each type of VSD and other equipment specified in this
section. They shall include the following:

A.     Power semi-conductors
B.     Power filter capacitors
C.     Plug-in logic cards
D.     Output switching modules
E.     Fuses

Indicator lamp/LED

7.0    INSTALLATIONS

Manufacturer's Representative

The manufacturer’s representative shall place the system in operation
and make necessary adjustments to ensure optimum operation of the
equipment. The manufacturer’s representative shall have practical
experience in the installation and testing of VSDs.

Field tests and inspections

Perform field tests and conduct inspections. Provide labor,
equipment tests instruments, and incidentals required for the tests
including load banks, except the Government will furnish electricity.
Give the Contracting Officer 7 days notice in writing of the dates
and times scheduled for performance tests and submit written copies
of test results.

QUALITY ASSURANCE PROVISIONS
Quality System. Provide and maintain a quality control system
compliant with ISO 9001. Notwithstanding the provisions of this
clause, the contractor is in no way relieved of the final
responsibility to furnish supplies and services as specified herein.
All quality control requirements including material testing,
fabrication, and inspection as listed in any of the governing
specifications shall be strictly adhered to unless specifically
waived by the purchaser.

Responsibility for inspection. Unless otherwise specified in the
contract or purchase order, the contractor is responsible for the
performance of all inspection requirements (examinations and tests)
as specified herein. Except as otherwise specified in the contract
or purchase order, the contractor may use his own or any other
facilities suitable for the performance of the inspection
requirements specified herein, unless disapproved by the Government.
The Government reserves the right to perform any of the inspections


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                 NNS PRELIMINARY SPECIFICATION ONLY
                        NOT A PURCHASE ORDER
set forth in this specification where such inspections are deemed
necessary to ensure supplies and services conform to prescribed
requirements.

Responsibility for compliance. All items shall meet all requirements
of this appendix. The inspection set forth in this appendix shall
become a part of the contractor’s overall inspection system or quality
program. The absence of any inspection requirements in the
specification shall not relieve the contractor of the responsibility
of ensuring that all products or supplies submitted to the Government
for acceptance comply with all requirements of the contract.

Inspection and test requirements. Inspection and test requirements
specifically required by this contract are for the convenience of the
Buyer and do not relieve the Seller of his responsibility to provide
a high quality product and one which meets all applicable contract
specifications. If during the Buyer’s own test or inspection of the
equipment after its delivery, any condition is uncovered which fails
to meet all the applicable contract specifications, the Seller is
financially responsible for correcting these conditions. This
requirement applies irrespective of the extent of test or inspection
specifically required of the seller by the contract.

Inspection at place of manufacture. Each VSD may be subjected by the
Government inspector to a thorough examination at the place of
manufacture to ascertain that the material, workmanship and design
are in conformance with this specification.

Burn-in. Before delivery, burn-in all units by cycling units 8 hours
“ON” under full load conditions and 3 hours “OFF” at no load conditions
for at least 4 complete “ON” cycles.

Instructing Government Personnel. Provide field training to
Government personnel on the operation and maintenance of the VSD
provided. As a minimum the training shall include 8 hours of
instruction on the theory of operation and 16 hours on the repair and
maintenance of the VSDs. The manufacturer of the unit provided shall
approve the instructor. The Contracting Officer shall approve
training at least 2 weeks in advance. The Government may record video
and audio from the training sessions and use these recordings to train
personnel on the operation and maintenance of the VSD system. Provide
two copies of video or audio tapes, if used, in the training sessions
to the Contracting Officer.
Provide field training to Government personnel on the operation and
maintenance of the VSD and PM motor provided. As a minimum the
training shall include 8 hours of instruction on the theory of
operation and 16 hours on the repair and maintenance of the VSD and
motor. Training shall be approved by NNS Code E63 at least 2 weeks
in advance. The Government may record (audio/video) the training


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                 NNS PRELIMINARY SPECIFICATION ONLY
                        NOT A PURCHASE ORDER
sessions and use these recordings to train personnel, on the operation
and maintenance of the VSD and motor system. Provide two copies of
video or audio tapes, if used, in the training sessions to the NNS
Contracting Officer. [ for inclusion in specific PO vice general
spec? ]

Assembly. To facilitate troubleshooting and repair insofar as
practical, the VSD modules shall be packaged into functional
assemblies including power supply, 60 Hz to DC Rectifier, DC to DC
conversion unit (if used) Output inverter, Controller, Built-In-Test
(BIT) and Built-In-Diagnostic (BID) functions. Those assemblies that
are not plug-in shall be wired to associated devices with screw
terminal connections. Open lugs are prohibited. Screw terminals
shall permit use of crimp lugs conforming to MIL-T-7928 Type 2 or
MIL-E-16366. PC Boards shall be provided with conformal coating,
keyed plugs, guides for insertion, restrainers, extender boards for
troubleshooting and require no special tools required for insertion
or removal. Design shall permit removal of functional sub-assemblies
or the entire inactive module without disturbing other parts of the
VSD.

Packaging and Transportation. Use of yellow or green wrapping
material and attached yellow or green protection devices such as caps
and plugs are strictly prohibited (nuclear related colors). The
purchase order number shall not, under any circumstances, appear on
the outside of any containers shipped as part of this order, but shall
be plainly marked on the inside of every container.

Material shall be shipped directly to the following destination:
Newport News Shipbuilding
4101 Washington Avenue
Attn:                             Phone: 757/688-1736
Bldg: 160 or Rouse Tower
Newport News, VA 23607

The supplier shall provide two copies of a detailed packing list that
identifies all components and their associated loose piece parts
which are included in this shipment.

-- End of Specification --




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                 NNS PRELIMINARY SPECIFICATION ONLY
                        NOT A PURCHASE ORDER
Technical questions can be addressed to:
Stephen J. Smith, E63, at (757) 688-1736
Email: smith_steve@nns.com
Newport News Shipbuilding, Dept E63
Rouse Tower, Room 4013-B
6060 Jefferson Avenue
Newport News, VA 23605




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