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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

Contents
Foreword ........................................................................................................................................................xiii
Introduction....................................................................................................................................................xiv
1

Scope ..................................................................................................................................................1

Warning ..............................................................................................................................................1

Related Documents ...........................................................................................................................2

Abbreviations and Definitions..........................................................................................................2

4.1

Abbreviations ...................................................................................................................................2

4.2

Definitions.........................................................................................................................................2

Format.................................................................................................................................................7

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
7.1

Capacity..............................................................................................................................................9
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
7.2.1
8
8.1
9

Environmental Cable De-Rating ...................................................................................................10


Environmental Conditions .........................................................................................................10
Batteries ...........................................................................................................................................10
Battery Requirements....................................................................................................................10
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
11.1
11.1.1

Connections .....................................................................................................................................13
Connectors Recommendations....................................................................................................13
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
12
ii

Physical Protection and Installation Considerations..............................................................15


Earthing ............................................................................................................................................16
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12.1
13
13.1
14
14.1
15

Earthing Requirements .................................................................................................................16


Platform ............................................................................................................................................17
Platform Requirements .................................................................................................................17
Platform and Terminal Equipment.................................................................................................18
Platform and Terminal Equipment Requirements ......................................................................18
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
19.3.1

Pass/Fail Criteria............................................................................................................................23
Susceptibility Criteria .................................................................................................................23

Annex A Platform Power Distribution Tests................................................................................................25


A.1
A.1.1
A.2

General Requirements...................................................................................................................25
Requirements ..............................................................................................................................25
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


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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


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A.8.6
A.9

Test Method .................................................................................................................................43


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


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A.13.6

Test Method .................................................................................................................................55

Annex B Platform and Terminal Equipment Tests......................................................................................57


B.1
B.1.1
B.2

General Requirements...................................................................................................................57
Requirements ..............................................................................................................................57
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


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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


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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
E.1.1

De-Rating Factors ..........................................................................................................................87


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
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F.12.1
F.13
F.13.1
F.14

Installed Equipment Classification and Power Budget ........................................................101


Test Requirements.......................................................................................................................102
Test Positions............................................................................................................................102
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
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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


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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
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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

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DEF STAN 61-5 Part 6 Issue 6

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.

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DEF STAN 61-5 Part 6 Issue 6

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.

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DEF STAN 61-5 Part 6 Issue 6

Standards for Defence - Nominal 12V and 24V DC Electrical


Systems in Military Platforms

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.

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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DEF STAN 61-5 Part 6 Issue 6


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

3
3.1

Related Documents
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
4.1

Abbreviations and Definitions


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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DEF STAN 61-5 Part 6 Issue 6


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.

Volts

Long
Transient
Peak
Voltage
Overshoot

Recovery Time

Steady
State
Limit
Long Transient
Peak
Voltage
Undershoot
0

Time

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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DEF STAN 61-5 Part 6 Issue 6


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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DEF STAN 61-5 Part 6 Issue 6


Volts

Upper Ripple Limit

Steady
State
DC
Level

Peak to Peak
Ripple

Lower Ripple Limit


Time

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 <1ms. It results from very high frequency currents of complex waveforms produced
when reactive loads are switched. An individual short transient generally has an interval lasting less than
50 microseconds (s) but may take up to one millisecond (ms) to decay to the steady-state level.
Slave Position: Position where the platform receives DC power from an adjacent platform during cranking.
Starting Disturbances: These are under voltage variations from the steady-state level and are caused by
engine starter engagement and cranking. A typical profile showing Initial Engagement Long Transient
(IELT) and Cranking Level is given in Figure 3. The duration of the initial engagement long transients is
measured from the instant at which it departs from the steady-state value to the instant at which it reaches
and remains at the cranking level.

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DEF STAN 61-5 Part 6 Issue 6

Volts

Duration of

Cranking Level

IELT

VS
VB

Initial
Engagement
Long
Transient
Cranking
Level
Voltage
Key
VB = Voltage Supply (battery only)
VS = Voltage Supply (with alternator)
0
Time

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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DEF STAN 61-5 Part 6 Issue 6


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

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.

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 derating;
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DEF STAN 61-5 Part 6 Issue 6

f)

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.

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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DEF STAN 61-5 Part 6 Issue 6


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).

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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DEF STAN 61-5 Part 6 Issue 6


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)

Altitude of platform operation.

The Design Authority shall provide details of the cable load commitment, maximum working temperature,
and capacity when de-rated against the maximum working temperature (using the guidance provided in this
standard, Clause 15.1), installation details and the number of simultaneous loaded cores.
For Bespoke Platforms, both Platform and Terminal Equipment Power Distribution System cables shall be
de-rated against environmental conditions.
For COTS and MOTS Platforms, only Terminal Equipment Power Distribution System cables shall be derated against environmental conditions.
If de-rating factors are available from the cable manufacturer, then these shall be used. In the absence of
manufacturers' data, guidance shall be taken from Clause 15 and Annex E of this standard.

8
8.1

Batteries
Battery Requirements

All batteries shall meet the requirements stated in the appropriate Defence Standard 61-21 series.

9
9.1

Circuit Protection
Circuit Protection Requirements

The following shall apply:


a)

All DCDU outlets shall be protected with circuit protection devices;

b)

The circuit protection devices shall be appropriately rated under all environmental conditions, inclusive
of storage, and evidence shall be provided at the Power Critical Design Review;
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DEF STAN 61-5 Part 6 Issue 6


c)

The Terminal Equipment DCDU shall be capable of incorporating higher (current) ratings of circuit
protection equipment for any outlet up to the rating of the Terminal Equipment DCDU;

d)

Bespoke Platform Batteries shall be protected from short circuit by a protection device, such as a fusible
link;

e)

COTS, MOTS and Bespoke Terminal Equipment batteries shall be protected from short circuit by a
protection device, such as a fusible link;

f)

Taps from multiple voltage systems, (i.e. 12/24V systems), shall be protected from short circuit by a
protection device, such as a fusible link;

g)

Bespoke Platform Power Distribution Systems shall have an isolation switch/breaker to isolate the power
generation source and batteries;

NOTE
It is recommended that MOTS Platforms have an isolation switch/breaker to isolate the power generation
source and batteries.

h)

Bespoke, MOTS and COTS Platform Terminal Equipment Power Distribution Systems shall have an
isolation switch/breaker to isolate the power generation source and batteries;

i)

The positive output of the isolation, feeding the Terminal Equipment, shall be fitted with a circuit
protection device, see Figure 5;

j)

Generators shall be protected from short circuit by a protection device, such as a fusible link or thermal
overload switch.

10
10.1

Wiring Configuration
Cable Requirements

All Power Distribution System cabling (including earth cables) shall meet the requirements stated in the
appropriate Defence Standard 61-12 Series.

10.2

Example Wiring Configuration

Figure 4 shows an example of a typical Power Distribution System.

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DEF STAN 61-5 Part 6 Issue 6


Power
Distribution

Power Source/Generation

PE / TE

Platform
Battery

Platform Power
Distribution System

Circuit
Protection

Platform
DCDU

PE / TE
PE / TE
External DC

Platform
Generator

Platform
Regulator

Terminal Equipment Power


Distribution System

Platform Power Distribution System and Terminal


Equipment Power Distribution System

Charging
Switching

Terminal
Equipment
Batteries

Terminal
Equipment
DCDU

TE
TE
TE

APU

Figure 4

10.3

Typical Power Distribution System

Bespoke Platform Guidance

Bespoke platforms are designed from scratch and therefore can have a fully integrated power supply
distribution system that is usually two wire and allows for Platform and Terminal Equipment to be connected
to the same Power Distribution System. The Power Distribution System shall meet Clauses 7, 8, 9, 10, 11,
12, 13, & 14 and the requirements of Annex A. The Platform or Terminal Equipments are required to meet
the appropriate parts of this standard. The Design Authority is required to classify each Platform or Terminal
Equipment at the Power Critical Design Review for applicable requirements, Test Plans and Test Reports.

10.4

Wiring Configuration Requirements

The following shall apply:


a)

The TEPDS shall be a two-wire system. To maintain a two-wire system, the Terminal Equipment shall
be isolated at the input, (e.g. using a DC to DC Converter), as shown in Figure 5 and Figure 6;

b)

The negative input to the Terminal Equipment shall only be referenced to Earth at the Terminal
Equipment battery;

c)

The Terminal Equipment negative input, after isolation, shall be made common to a Designated Earth
Point or Terminal Earth Reference;

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DEF STAN 61-5 Part 6 Issue 6


Terminal
Equipment
Battery

Terminal
Equipment
DCDU

Terminal Equipment

Terminal
Equipment
(isolated from
TE DCDU)

Isolation

Circuit
Protection

Figure 5

Wiring Configuration showing Two Wire System


Non-integral DC to DC
converter or a Power
Management Unit

Terminal
Equipment
Battery

Terminal
Equipment
DCDU

Isolation

DC - DC

Figure 6

Circuit
Protection

Terminal
Equipment
Terminal
Equipment
(isolated from
TE DCDU)

Wiring Configuration showing Two Wire System (where there is a separate DC to DC


Converter or Power Management Unit from the Terminal Equipment)

d)

For COTS and MOTS platforms, it is acceptable for the Platform Power Distribution System to use a
chassis return system. A label shall be displayed at the distribution point stating that this type of system
has been used;

e)

For COTS and MOTS platforms, the TEPDS shall contain batteries. For bespoke platforms, the Power
Critical Design Review shall determine the requirement for Terminal Equipment batteries;

f)

Terminal Equipment Batteries shall not be used to supplement platform power requirements. (It is
acceptable for a switch to be installed to the platform that allows Terminal Equipment batteries to supply
platform loads in emergency);

g)

Platforms that cannot comply with the foregoing shall be considered on a case by case basis e.g. Fuel
Tankers, Recovery Platforms, etc and Design Authority shall document their designs for MoD Authority
agreement at the preliminary and critical design reviews.

11
11.1

Connections
Connectors Recommendations

This Standard recommends a discrete number of connectors to be adopted for use by Platform and Terminal
Equipment manufacturers to ensure compatibility and inter-changeability of equipment between platforms.

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DEF STAN 61-5 Part 6 Issue 6


This has been achieved using a mixture of Military Standard ranges and commercial types because some of
the military connectors do not meet the entire standards recommended requirements but commercial types
do meet these requirements.
It is anticipated that the military connector standards will be updated and that future issues of this standard
will recommend military types only.
In all cases, socket contacts should be used for connectors supplying power, including those attached to
DCDUs. Pin contacts should be used on connectors for Terminal Equipments.
For applications where technical compliance with the widest range of factors is required, connectors
compliant to CECC 75201-002 shall be specified. This is a range of connectors, mechanically and electrically
identical to MIL DTL 38999 Series 1, but manufactured from Aluminium Bronze, and hence achieving the
best levels of corrosion resistance available.
11.1.1

Connector Selection

Connectors should be selected as shown in Table 1, Connector IDs 3 and 4:


11.1.1.1

Higher Corrosion Resistance

For applications where the higher corrosion resistances are not required, the following connectors may be
substituted:
MIL-DTL-26482 Series 1 Style connectors, fitted with EMC grounding fingers, Rough grip coupling nuts and
Black Zinc-Nickel (RoHS compliant) plating. Crimp contacts should be specified in preference to solder
buckets.
Connectors should be selected as shown in Table 1, Connector IDs 5 and 6.
11.1.1.2

Connections for 12V Systems

For 12V systems, alternative connector planforms should be used to avoid mis-mating between 12V and 24V
systems. As 12V Terminal Equipments are typically used for relatively low current applications, only
connectors for low currents are specified. If higher current connections are required, connectors should be
chosen not to be compatible with those of 24V systems, and should otherwise chosen to follow the technical
requirements of this section. Such connectors should be agreed at the Power Critical Design Review.
Connectors should be MIL-DTL-26482 Series 1 Style connectors, fitted with EMC grounding fingers, Rough
grip coupling nuts and Black Zinc-Nickel (RoHS compliant) plating. Crimp contacts should be specified in
preference to solder buckets.
Connectors should be selected as shown in Table 1, Connector IDs 1 and 2.
11.1.1.3

High Current Connections

For applications where a higher current connection is required, connections should be made by direct
connection to a suitable bus-bar within the DCDU. Cables should exit via suitable glands or feed-throughs to
provide strain relief, abrasion resistance and screening.
Alternative connectors are type VG 95 234, reverse bayonet (derivative of MIL-DTL-5015H), style connectors
with rough grip coupling nuts and Black Zinc-Nickel (RoHS compliant) plating. Crimp contacts should be
specified in preference to solder buckets.
Connectors should be selected as shown in Table 1, Connector IDs 7 and 8.
NOTE
This range of connectors is not available with grounding fingers, and hence is unlikely to be suitable for
applications requiring a high degree of EMC integrity.

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DEF STAN 61-5 Part 6 Issue 6


Table 1

Connector Selection
Pin Assignment

Number
of
Poles

Contacts
Size

Total
Current
Capacity

12-03

3 pole

16

10A

+ve

-ve

Not
Used

12V

14-02

2 pole

12

20A

+ve

-ve

24V

11-2

2 pole

16

10A

+ve

-ve

+ve

-ve

10A

+ve

-ve

12

20A

+ve

-ve

2 pole

135A

+ve

-ve

2 pole

245A

+ve

-ve

Connector
ID

Connector
Style

Connector
Voltage

Insert

MIL-DTL26482
Series 1

12V

MIL-DTL26482
Series 1

CECC
75201-002

CECC
75201-002

24V

15-04

4 pole

12

MIL-DTL26482
Series 1

24V

10-02

2 pole

16

MIL-DTL26482
Series 1

24V

14-04

4 pole

VG95 234

24V

24-9

VG95 234

24V

32-5

40A

11.1.2

(20A per
pair)

+ve

-ve

+ve

-ve

Physical Protection and Installation Considerations

Refer to Clause 9 for guidance on Circuit Protection.


Spare power outlet sockets should be protected to the full current capability of the socket and should be
provided with a suitable protective cap and stowage for the protective cap.
Any socket outlet requiring disconnection of cables under normal usage should be provided with a suitable
protective cap, and stowage for the protective cap.
Where mis-connection protection of DCDU outlet points is required, alternative keying arrangements of
standard connectors should be used as the first preference over alternative insert orientations or connector
sizes. In all other cases normal keying and orientation should be selected.
Although exemptions to certain legislations are possible for military equipment, best practice is to procure
new components compliant to RoHS legislation. Zinc-Nickel plating has therefore been specified as this
gives the best combination of conductivity and corrosion resistance available at the time of publication of this
standard. Other platings may be substituted, but should be assessed by the equipment manufacturer for
suitability in the application.
Where additional contacts are required in a connector to perform another function such as power interlock or
capacitor pre-charge, an appropriate connector meeting the above physical requirements should be chosen.
No recommendation is made as to the specification of backshells / endbells or other accessories to be used
with the connectors specified as there is a very wide range of these parts available, and selection will need
to be made dependent on the needs of the installation. It is recommended that they be procured to an
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DEF STAN 61-5 Part 6 Issue 6


applicable UK Defence Standard or Military standard and due consideration given particularly to material and
plating compatibility with the connector, as well as the EMC requirements.
Proposals for alternatives to the connectors provided for by this standard shall be submitted to the MoD
Authority, as part of the Power Critical Design Review.

12

Earthing

12.1

Earthing Requirements

The Design Authority shall be responsible for providing the Platform and Terminal Earth Reference points,
Designated Earth Points along with their characteristics (current capacity, size) to the Power Critical Design
Review. The safety earth bonds shall meet the requirements of this Section and Test Requirements in
Annex A and Annex B of this standard.
A typical Platform and Terminal Equipment earthing arrangements are shown in Figure 7;
The following shall be provided:
a)

Platform and Terminal Reference Earth Terminals shall be bonded together;

b)

All earth terminals shall be accessible;

c)

All earth terminals shall be passivated;

d)

An earth terminal shall be provided at each DCDU;

e)

All earth terminals shall be labelled clearly;

f)

All earth bonding positions are to be detailed with design, position, size, material used, termination type,
paint clearance technique used;

g)

All earth bonds shall be designed to operate over the life of the platform, without degradation, i.e. harsh
environments and corrosion;

h)

All Terminal Equipment DCDU and Terminal Equipments shall have a test earth bonding position
required for initial earth bond measurements and future scheduled maintenance measurements;

i)

The negative input to the Terminal Equipment shall only be referenced to Earth at the Terminal
Equipment battery;

j)

The negative output, after isolation, of the Terminal Equipment shall be referenced to a Designated
Earth Point or Terminal Earth Reference;

k)

To ensure harmony with EMC Standards, the length of any Earth Bond used shall be kept as short as
possible;

l)

All earthing components, i.e. cables and connections shall be sized to ensure conduction of fault
current.

NOTE
Figure 7 represents a configuration that is regarded as best practice. In some platforms, Platform and
Terminal Equipment batteries are all connected to the same DCDU via switches, used to isolate the Platform batteries
during reduced signature operation

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DEF STAN 61-5 Part 6 Issue 6


Power Source/Generation

Power Distribution

Circuit
Protection

Equipments

Earth Return
for COTS/
MOTS

PE
Platform Battery

PE

Platform DCDU

PE
Earth Return can
be via chassis

Platform Earth Reference


Designated Earth Point

Terminal Earth Reference


Platform
Chassis

Platform
Generation
Source

Platform
Regulator

Charging /
Switching
Equipment
Rack

TE
APU

Terminal
Equipment
Batteries

Terminal
Equipment
DCDU

TE
TE

Key
Platform and Terminal Earth Reference
Designated Earth Point
Positive Terminal
Negative Terminal

Figure 7

13

TE = Terminal Equipment
PE = Platform Equipment
Circuit Protection

Typical Platform and Terminal Equipment Earthing Arrangements and Reference Points

Platform

13.1

Platform Requirements

Ideally the platform power generation source is capable of providing the full Platform and Terminal
Equipment Designated Load Requirement when the engine is at idle.
This standard recognises that this is not easily achieved, but expects the Design Authority to take measures
to ensure that, when the engine is at idle, the Designated Load is not supplied from the batteries.
This may be solved using one of several methods:
a)

Automatic monitoring of alternator charging and management of engine idle speeds;

b)

Manual hand throttle with instructions to the user;

c)

A higher capacity alternator providing more current at lower engine revolutions;

d)

Adjustment of the gearing of the generator to increase the speed of the generator at low engine
revolutions, ensuring the engine revolutions do not exceed the alternators manufactures maximum
recommended running speed.

Tests to ensure the Designated Load is provided by the power generation source and not the batteries,
whilst at engine idle, are detailed in Clause A.2 DET01.A Steady-State Voltage of the standard.

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DEF STAN 61-5 Part 6 Issue 6

14

Platform and Terminal Equipment

14.1

Platform and Terminal Equipment Requirements

a)

All Platform and Terminal Equipment shall meet the meet requirements stipulated in Annex B of this
standard;

b)

Platform and Terminal Equipment shall operate over the voltage range shown in Table 2;
Table 2

Platform and Terminal Equipment Operating Voltages


Nominal 12V

Nominal 24V

Terminal
Equipment

Platform
Equipment

Terminal
Equipment

Platform
Equipment

Lower Voltage

9V

9V

18V

18V

Upper Voltage

16V

19V

32V

38V

c)

All Terminal Equipment shall have a power isolation switch that isolates the positive line from the power
supply. In some cases, it is necessary for a constant power feed to ensure correct operation. The
rationale for this shall be provided in the Power Critical Design Review;

d)

Terminal Equipment shall have a test earth bonding position required for initial earth bond
measurements and future scheduled maintenance measurements;

e)

To ensure the Terminal Equipment maintains a two wire system, the Terminal Equipment positive and
negative power input shall be isolated from the earth bond as shown in Figure 6;

f)

Platform and Terminal Equipment manufacturers shall provide installation instructions to include
earthing and circuit protection requirements.

15
15.1

Environmental
Environmental Requirements

Extreme temperatures can cause changes in the response of power supply components with respect to their
resistive, capacitive and inductive properties. This in turn could affect the frequency response and voltage
characteristics and in turn the transient response e.g. circuit breaker performance, changes in filter
characteristics and electrical durability.
Climatic factors such as humidity, wind, ozone, hail, sand, rain, ice and snow shall not be considered as
these will be considered during environmental trials. Temperature change and altitude shall only be
considered when assessing cable current carrying capacity and circuit protection devices.
Def Stan 00-35 Pt4 identifies eleven climatic categories that have been chosen to represent distinctive types
of climate found on the land surfaces of the world.
The eight categories, A1 to A3 and C0 to C4, relating to the land surface are defined with temperature as the
principal consideration, while the remaining three, B1 to B3, represent climates in which high humidity
accompanied by a warm temperature is the outstanding characteristic. Humidity is not considered in this
standard and will reference the eight categories, A1 to A3 and C0 to C4 only.
The geographical locations to which these climatic categories apply are illustrated approximately in the maps
in Def Stan 00-35 Pt4.
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DEF STAN 61-5 Part 6 Issue 6


For simplicity, the hot and cold temperature requirements required for assessing power cable de-rating in
Annex A and Terminal Equipment testing in Annex B shall be based on the extremes categories found in
Def Stan 00-35 Pt4 (A1 = 58C and C4 = -68C).
For simplicity, the hot and cold temperature requirements required for assessing circuit protection devices
shall be based on the extremes categories found in Def Stan 00-35 Pt4 (A1 = 58C and C4 = -68C),
environmentally modified for their location within the platform, see Clause 15.2. The required operating
temperature range shall be defined by the Design Authority at the Power Critical Design Review and
evidence of component compliance shall be provided and agreed at the Power Critical Design Review.
During the Power Critical Design Review, rationale may be provided to change the climate category. For
example a platform may only be required to operate in Central Europe therefore the climatic categories can
be justified as A3 (42C) and C2 (-56C).
Platform and Terminal Equipment designed for specific platforms shall have the same climatic category as
the platform. Specific installation factors (for example an air conditioned cabinet) shall be included in the
Power Critical Design Review as rationale to adjust the environmental categories. If the Platform or Terminal
Equipment has been designed for different platforms, then the extreme climatic categories shall apply (A1
and C4).

15.2

Power Supply LRU/Component/Terminal Equipment Location and Test Temperature

As a general rule the internal temperatures in a platform will increase with, in proportion to, the amount of
energy generated by all equipments and occupants. This condition is further increased by the addition of
solar radiation. Therefore, for key components, such as Circuit Protection devices and Terminal Equipments
in non air conditioned environments, an increase of 30 C is considered appropriate to the external
categories. Engine compartments normally achieve internal ambient temperatures of in excess of 100 C. Air
conditioners can reduce the temperature by between 15 and 20 C.

16
16.1

Quality Standard
Quality Management System (QMS)

The Design Authority shall establish, document, implement, assess and improve an effective and economical
system, which includes the requirements of ISO 9001:2000, AQAP 2100 series, Defence Standard 05-61
and DEFCON's 602A or 602B as necessary to satisfy the contract requirements.
The MoD Authority shall be provided with objective evidence to show this system is compliant with those
documents referenced above and effective. The MoD Authority reserves the right to reject this system as it
applies to the contract.
Unless invoked in the contract, the Design Authority shall determine the test methods required and perform
the tests to demonstrate conformity with the corresponding requirements at appropriate stages up to and
including the final product. The Design Authority shall provide a Certificate of Conformity at release of
product to the MoD Authority.
The MoD Authority reserves the right to reject the Test Regimes proposed.
Where it is desirable, or necessary, that conformity to the specified contract requirement has been achieved,
the MoD Authority shall invoke ISO/IEC 17050 series. This declaration of conformity shall be based on
results of an appropriate type of conformity assessment activity (e.g. testing, measurement, auditing,
inspection or examination) carried out by one or more first, second or third parties. Conformity assessment
bodies involved, where applicable, should consult relevant International Standards, Guides and other
normative documents.
The Design Authority shall issue and implement documented procedures which identify, control and
segregate non-conforming products. The Design Authority shall notify the MoD Authority of non-conformities
and corrective actions required. The MoD Authority will only consider the acceptance of non-conforming
product where there is clear and demonstrable benefit to the MoD. Application for a Concession, in
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DEF STAN 61-5 Part 6 Issue 6


accordance with Defence Standard 05-61 Pt 1, to deliver or embody a non-conforming product shall be
made, without delay, by the Design Authority.

16.2

UKAS Requirement

Testing to prove contractual compliance shall be carried out by a UKAS Accredited Test Facility, whose
schedule includes this standard.

17

Test Equipment

17.1

Test Equipment Requirements

The following test equipment shall be utilised unless indicated otherwise:


a)

The Environmental Chamber shall meet the requirements stipulated in the Power Critical Design
Review;

b)

LISNs shall meet the requirements of ISO7637-2 2004;

c)

Clause B.11 (DIT07.B) - Transient Generator shall meet the requirements of ISO7637-2 2004;

d)

Clause A.12 (DIT03.A) Function / Signal Generator capable of providing a sinusoidal wave over the
frequency range of 20 Hz to 150 kHz;

e)

Clause A.12 (DIT03.A) Broadband amplifier capable of amplifying a sinusoidal wave to the required
test levels;

f)

Digital Storage Oscilloscope (DSO) capable of data acquisition and data sample storage shall meet the
following requirements: input impedance of not less than 0.1 M, bandwidth of DC to not less than 400
MHz, a minimum sampling rate of 500MS/s and a minimum input sensitivity of 5mV/div;

g)

A high impedance oscilloscope probe shall meet the following requirements: input impedance of not less
than 0.1 M, bandwidth of DC to 400 MHz and a minimum input sensitivity of 5mV/div. Care should be
taken to ensure measured voltage does not exceed the maximum input voltage of the oscilloscope
probe (for validation of fast transients, DIT07.B, only);

h)

Differential oscilloscope probe with a bandwidth of >100MHz and a differential input voltage rating of
>500V;

i)

DC passive, non inductive load banks for simulating Platform and Terminal Equipment;

j)

Clause A.4 (DET03.A) - Test Switch/Contactor, as rated for the maximum current, shall meet the
requirements stipulated in Def Stan 59-411 Part 3 DCE03.B;

k)

Clause A.6 (DET05.A) - Test Switch/Contactor, rated for three times the circuit protection device current
and shall meet the requirements stipulated in Def Stan 59-411 Part 3 DCE03.B. It shall provide a trigger
signal to the DSO upon application of load;

l)

Clause B.3 (DET02.B) External Test Switch/Contactor shall meet the requirements stipulated in
ISO7637-2 2004;

m) Earth Bond Meter with a sensitivity of 500 , with an applied measurement current of 10A;
n)

Current Clamp that covers the current range of the Platform or Terminal Equipment being measured;

o)

Current Shunt that meets the current rating of the Terminal Equipment being measured;

p)

DVM. Digital Voltmeter capable of measuring DC and AC voltages 150kHz, current, continuity and
resistance;
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DEF STAN 61-5 Part 6 Issue 6


q)

Batteries or power supplies.

All equipment used for quantitative measurement shall be calibrated by a UKAS accredited calibration
laboratory with the required parameters traceable to national or international standard.

17.2

Tolerances

The Laboratory shall, for all tests performed, produce a Test Uncertainty of its measurements, in accordance
with UKAS Documents M3003 - The Expression of Uncertainties and Confidence in Measurements and
LAB12 The Expression of Uncertainty in Testing.
Unless otherwise stated, the following accuracy/tolerance shall be applied:
1)

Resistance 10%;

2)

Voltage 1%;

3)

Current 1%;

4)

Time 1%.

Reference to Clause 16 of this standard is also required for Quality Assurance.

18

Electromagnetic Compatibility Legislation

Without prejudice to any other provision of this Def Stan, the Contractor shall comply with all legislation as
regards the electromagnetic compatibility of vehicles, systems, components and separate technical units to
which this Def Stan applies and shall not be permitted to rely on any exemption which disapplies that
legislation or any part thereof to such military vehicles, systems, components and separate technical units
without the express prior written consent of the Authority.

19

Management and Planning

19.1

Management and Planning Requirements

The Management and Planning aspects shall be documented by the Design Authority and include the
following items:
a)

Control and Management requirement for Power Critical Design Review;

b)

Test plan;

c)

Test report;

d)

Test Certificate;

e)

Pass/Fail Criteria;

f)

Maintenance Requirements e.g. bonding and earthing.

19.2
19.2.1

Control and Management


Test Plan

A Test Plan shall be produced before the commencement of testing.


The Test Plan shall be signed by the Design Authority and appropriate MoD Authority.
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DEF STAN 61-5 Part 6 Issue 6


The Test Plan shall follow this standard, and contain any deviations and special requirements from the
Power Critical Design Review.
a)

Amendment Status;

b)

Document History;

c)

Distribution List;

d)

Sign off;

e)

Introduction;

f)

Test Outline / Summary;

g)

Test Objectives;

h)

Test Applicability, referenced to standard and/or deviations;

i)

Platform Conditions or Equipment Modes;

j)

Order of Tests;

k)

Platform Systems and Terminal Equipment Pass/Fail Criteria;

l)

References;

m) Personnel in Attendance (as appropriate);


n)

Release of Data (as appropriate);

o)

Security Classification (as appropriate).

19.2.2

Test Report

The Test Report shall meet the requirements of UKAS and include the following:
a)

Amendment Status;

b)

Document History;

c)

Distribution List;

d)

Sign off;

e)

Test Objectives, as per Test Plan and any deviations;

f)

Test Results, summarising the following:

g)

1)

Test Applicability;

2)

Test Layout;

3)

Test Limits;

4)

Platform Conditions or Equipment Modes;

5)

Test Method.

Test Results, detailing the following;


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22

DEF STAN 61-5 Part 6 Issue 6


1)

Details of pass/fail and waveforms or measurements as appropriate;

2)

Test and Equipment Pass/Fail Criteria;

3)

Test Exceptions.

h)

Test and support equipment List, including calibration status;

i)

Supplied Drawings;

j)

Platform or Equipment Description and identifications;

k)

Support Equipment Used/Supplied;

l)

Photographs;

m) References;
n)

Personnel in Attendance;

o)

Security Classification (as appropriate).

19.2.3

Test Certificate (Optional)

A Test Certificate stating compliance or non-compliance with this standard.

19.3
19.3.1

Pass/Fail Criteria
Susceptibility Criteria

In order that the test engineer can determine the threshold during DIT tests, the criteria for malfunction must
be stated in the Power Critical Design Review and the subsequent Test Plan agreed in writing prior to
testing, based on the following performance criteria.
The main performances that need to be assessed for failure criteria are safety related and mission
assurance functions. For safety related systems, reference should be made to Def Stan 00-56, whilst for
mission assurance, reference should be made to the Systems Requirement Document (SRD) to identity the
degree of upset and recovery allowable for the Platform and Platform/Terminal Equipment.
Performance Criterion A:
The equipment shall continue to operate as intended during and after each test. No degradation of
performance or loss of function or unwanted operation is allowed, when the equipment is used as intended.
Performance Criterion B:
The equipment shall continue to operate as intended after the disturbance is removed. After the test, no
degradation of performance or loss of function or unwanted operation is allowed, when the apparatus is used
as intended. During each test, degradation of performance is allowed. However, there shall be no change to
the actual operating state or to stored data (memory) at the end of test. Any such loss of performance during
testing shall be recorded in the Test Report together with the conditions of test under which the degradation
occurred.
Performance Criterion C:
Temporary loss of function is allowed during each test, provided the function is recoverable, by manual
intervention, at the end of the test within an acceptable timescale, e.g. re-boot or reset. The allowable loss of
function and timescale shall be stated in the Test Plan. Any such loss of function during testing shall be
recorded in the Test Report.
Performance Criterion D:
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DEF STAN 61-5 Part 6 Issue 6


Loss of function is allowed during each test provided the function can be restored by manual intervention at
the end of the test, and no permanent damage occurs, e.g. fuse replacement. The allowable loss of function
shall be stated in the Test Plan. Any such loss of function during testing shall be recorded in the Test Report.
These types of failures and recovery are usually reserved for unlikely events e.g. lightning strikes or reverse
polarity, where damage protection is usually specified in the SRD.

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DEF STAN 61-5 Part 6 Issue 6

Annex A
Platform Power Distribution Tests

A.1

General Requirements

A.1.1

Requirements

a)

All battery sets shall be as new. Prior to test, the charging current shall be less than 5 A;

b)

Unless otherwise stated, the Platform and Terminal Equipment DCDU Isolation switches shall be on, i.e.
the Platform and Terminal Equipment DCDUs are connected to the Power Generation Source and
batteries;

c)

For all tests, ensure all Terminal Equipments are disconnected;

d)

Measurements shall be made at a sufficient number of positions to ensure that the results obtained are
fully representative of both the Platform and Terminal Equipment Power Distribution Systems. Unless
otherwise stipulated in the individual test requirements, measurement points shall include:
1)

The main distribution point for Platform Equipment (i.e. Platform DCDU or the point where the
power generation source and platform battery are connected);

2)

Every Terminal Equipment DCDU;

3)

Any external DC distribution points, e.g. trailer. This does not include slave positions.

NOTE 1

The external DC distribution points are not applicable for all tests, see individual Test Applicability.

NOTE 2
If the platform has a Dual Voltage System, then measurements shall be performed on both 12V and 24V
Platform Power Distribution Systems.

e)

Measurement Points shall be stipulated in the Power Critical Design Review;

f)

Load requirements are determined from the Power Diagram provided from the Power Critical Design
Review;

g)

If the Platform has provision to provide exported DC power (e.g. trailer), then this shall be loaded at 90%
of full rated load during all tests as defined in the Power Critical Design Review;

h)

Perform a full functionality check before and after all DIT tests, for example on-board diagnostic fault
codes, circuit breaker activation, manual physical checks;

i)

Test Applicability shall be determined using Table 3.

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DEF STAN 61-5 Part 6 Issue 6


Table 3

Platform Power Distribution - Test Applicability


Power Distribution Applicability

Test Ref.

Test Description

Clause
COTS

MOTS

Bespoke

DET01.A

Steady State Voltage

PPDS and TEPDS

A.2

DET02.A

Ripple Voltage

PPDS and TEPDS

A.3

DET03.A

Long Transients

PPDS and TEPDS

A.4

DET04.A

Short Transients

PPDS and TEPDS

A.5

DET05.A

Circuit Protection

DET06.A

Power Distribution Voltage Drop

DET07.A

Cranking

TEPDS

DET08.A

Terminal Equipment Battery


Capacity Test

TEPDS

DIT01.A

Platform/Terminal Earth Bond

DIT02.A

Platform Over Voltage /


Regulator Failure

PPDS

DIT03.A

Platform Imported Ripple


(20Hz - 150kHz)

PPDS

DIT04.A

Platform Load Dump

PPDS

NOTE 1
test.

TEPDS

TEPDS

TEPDS

TEPDS

TEPDS

TEPDS

PPDS and
TEPDS

A.6

PPDS and
TEPDS

A.7

A.8
A.9

PPDS and
TEPDS

A.10

A.11

A.12

A.13

In all figures, shaded elements indicate Test Equipment. Un-shaded elements indicate the Platform under

NOTE 2
For bespoke platforms, applicability is for guidance only and shall depend on a case by case basis, and
established during the Power Critical Design Review.

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DEF STAN 61-5 Part 6 Issue 6

A.2
A.2.1

DET01.A Steady State Voltage


Purpose

The purpose of this test is to measure the steady state voltage with the generator or APU under different
load conditions. This is to ensure generators and/or the APU regulators hold the output voltage steady when
the load is fixed for a period of one hour. This test ensures that the batteries have sufficient capacity and are
appropriately charged when the Platform engine or APU is at idle.
The test shall be made at 90% of full load to reduce the risk of the circuit protection device operating during
the test.

A.2.2

Applicability

Power Distribution Systems Types applicable are shown in Table 4.


Table 4

DET01.A - Test Applicability


COTS

Platform Type

MOTS

Applicable Power
Distribution System

Bespoke

PPDS and TEPDS

This test is also applicable to external DC distribution points.

A.2.3

Test Layout

Measurement positions shall be stipulated in the Platform Power Critical Design Review with guidance from
Annex A - General Requirements.

A.2.4

Test Limits

The steady state voltage, including ripple peaks shall remain within the limits, as shown in Table 5:
Table 5

DET01.A - Test Limits

Nominal Voltage

A.2.5

Steady State Voltage

12V System

12.5 Vpk

15 Vpk

24V System

25 Vpk

30 Vpk

Test Conditions

The Test Conditions are detailed in Table 6.

Table 6
Test Condition

DET01.A - Test Conditions

Engine Condition

Load Requirements (% of
rated maximum load

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DEF STAN 61-5 Part 6 Issue 6


conditions)
1

Engine at tick over

90% of Platform and


Terminal Equipment
Designated Load
Requirement (includes
External DC Distribution)

Minimum engine speed to ensure maximum load.

90% of Platform and


Terminal Equipment
Designated Load
Requirement (includes
External DC Distribution)

Nominal fixed speed engines shall be run at their designed on-line speed only

A.2.6
A.2.6.1

Test Method
Test Condition 1

Connect the DSO as close as physically possible to the measurement point. This ensures the calibrated
differential scope probe can reach without any extensions. This also reduces the risk of any radiated noise
being measured.
Connect DC load banks across the Platform and Terminal Equipment DCDU bus bars and load in
accordance to the Test Condition 1.
NOTE
In the case of COTS or MOTS platforms which do not have an accessible DCDU, loading may take place
across the Platform Battery terminals.

Leave the platform for 1 hour in Test Condition 1 prior to measurement.


Measure and record 15 seconds of steady state voltage.
During measurement, ensure that the system operates normally and only inherent and natural changes
occur i.e. do not deliberately change any part of the system which will change the load requirements of the
platform.
A.2.6.2

Test Condition 2

Connect the DSO as close as physically possible to the measurement point. This ensures the calibrated
differential scope probe can reach without any extensions. This also reduces the risk of any radiated noise
being measured.
Connect DC load banks across the Platform and Terminal Equipment DCDU bus bars and apply Test
Condition 2.
NOTE
In the case of COTS or MOTS platforms which do not have an accessible DCDU, loading may take place
across the Platform Battery terminals.

Measure and record 15 seconds of steady state voltage.


During measurement, ensure that the system operates normally and only inherent and natural changes
occur i.e. do not deliberately change any part of the system which will change the load requirements of the
platform.

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A.3

DET02.A Ripple Voltage

A.3.1

Purpose

The purpose of this test is to measure the ripple voltage with the generator or APU under different load
conditions.
Ripple is a test of the power source regulator, quality of the battery and the construction quality of the Power
Distribution System.
Ripple frequency is dependant on the power generator RPM, number of poles and number of phases. Ripple
amplitude is directly proportional to the impedance of the power distribution system.

A.3.2

Applicability

Power Distribution Systems Types applicable are shown in Table 7.


Table 7

DET02.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System

MOTS

Bespoke

PPDS and TEPDS

This test is also applicable to external DC distribution points.

A.3.3

Test Layout

Measurement positions shall be stipulated in the Platform Power Critical Design Review with guidance from
Annex A General Requirements.

A.3.4
A.3.4.1

Test Limits
Time Domain Test Limits

The Test Limits are shown in Table 8.


Table 8

A.3.4.2

DET02.A - Time Domain Test Limits

Nominal Voltage

Ripple Voltage

12V System

< 2V pk to pk

24V System

< 4V pk to pk

Frequency Domain Test Limits

Def Stan 59-411 Pt 3 DCE02.B Class A Limits for both 12V and 24V systems.

A.3.5

Test Conditions

The Test Conditions are detailed in Table 9.


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DEF STAN 61-5 Part 6 Issue 6


Table 9

DET02.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Engine at tick over

0%

Minimum engine speed to ensure maximum load.

90% of Platform and


Terminal Equipment
Designated Load
Requirement (includes
External DC Distribution)

Nominal fixed speed engines shall be run at their designed on-line speed only

A.3.6
A.3.6.1

Test Method
Time Domain

Connect the DSO to the measurement point using differential scope probes as close as physically possible
to the measurement point. This ensures the calibrated scope probe can reach without any extensions. This
also reduces the risk of any radiated noise being measured.
Connect DC load banks across the Platform and Terminal Equipment DCDU bus bars and load in
accordance to the test conditions.
NOTE
In the case of COTS or MOTS platforms which do not have an accessible DCDU, loading may take place
across the Platform Battery terminals.

The DSO shall be adjusted to AC coupled and the time base adjusted to accurately capture the ripple
voltage.
During measurement ensure the system operates normally and only inherent and natural changes occur i.e.
do not deliberately change any part of the system which will change the load requirements of the platform.
Perform the measurements in both test conditions as stipulated in Clause A.3.5.
A.3.6.2

Frequency Domain

Perform test: Def Stan 59-411 Pt 3 DCE02.B.


Perform the measurements in both test conditions as stipulated in Clause A.3.5.

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DEF STAN 61-5 Part 6 Issue 6

A.4
A.4.1

DET03.A Long Transients


Purpose

The purpose of this test is to measure long transients when switched between different load conditions.
A long transient is a direct response from the power source and regulator to a change in load conditions.

A.4.2

Applicability

Power Distribution Systems Types applicable are shown in Table 10.


Table 10

DET03.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System

MOTS

Bespoke

PPDS and TEPDS

This test is also applicable to external DC distribution points.

A.4.3

Test Layout

Measurement positions shall be stipulated in the Platform Power Critical Design Review with guidance from
Annex A - General Requirements.
A typical test configuration is shown in Figure 10.

A.4.4

Test Limits

Test Limits are shown in Figure 8 and Figure 9.

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DEF STAN 61-5 Part 6 Issue 6


25

20V, 0.05s
20

15V, 1.0s

Peak Voltage (Volts)

16V, 0.1s
15

Steady State > 1s


11.5V, 0.5s
10

12.5V, 1.0s

0.01

Figure 8

0.1
Recovery Time (seconds)

1.0

0
0.001

Note:
Solid Line shows Limits for Long Transient.
Dashed Line shows Steady State Voltage.
Limits inclusive of ripple.

DET03.A 12V Limits

50

40V, 0.05s
40

30V, 1.0s

Peak Voltage (Volts)

32V, 0.1s
30

Steady State > 1s


23V, 0.5s
20

25V, 1.0s

10

0.01

Figure 9

0.1
Recovery Time (seconds)

DET03.A - 24V Limits

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1.0

0
0.001

Note:
Solid Line shows Limits for Long Transient.
Dashed Line shows Steady State Voltage.
Limits inclusive of ripple.

DEF STAN 61-5 Part 6 Issue 6


A.4.5

Test Conditions

The Test Conditions are detailed in Table 11.


Table 11

DET03.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Minimum engine speed to ensure maximum load.

Platform and Terminal


Equipment Designated Load
Requirement (includes
External DC Distribution)
Switched 0% - 90% - 0%

Nominal fixed speed engines shall be run at their designed on-line speed only

A.4.6

Test Method

Connect the DSO as close as physically possible to the measurement point. This ensures the calibrated
differential scope probe can reach without any extensions. This also reduces the risk of any radiated noise
being measured.
Load the Terminal Equipment DCDU, and external DC Distribution (if fitted), to 90% of full load.
Connect the DSO to the Platform DCDU.
Capture and record long transients when the Platform load is being switched between 0% to 90% load and
90% to 0% load conditions.
Perform each test with the following time bases configured on the DSO: 1ms, 10ms and 100ms per division.
If steady state is not achieved when using a time base of 100ms, then the time base shall be increased until
the voltage returns to steady state.
Repeat each operation 3 times for each time base, report the worst case amplitude for each time base, and
the steady state recovery time.
Load the Platform DCDU and external DC Distribution (if fitted) to 90% of full load. Repeat measurement
method at the Terminal Equipment DCDU.
Load the Platform and Terminal Equipment DCDU to 90% of full load. Repeat measurement method at the
external DC Distribution (if fitted).

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DEF STAN 61-5 Part 6 Issue 6


Terminal
Equipment
DCDU

Oscilloscope
Probes

Test
Switch/
Contactor

DC Load

Switch shown
open
(0% load
condition)
Bus bars

DSO

Figure 10

Test Switch/Contactor
Control

DET03.A Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

A.5
A.5.1

DET04.A Short Transients


Purpose

The purpose of this test is to measure short transients generated when long or short duration inductive
platform loads are switched on or off and between modes. Typical sources include wipers, air conditioning,
motors and pumps.

A.5.2

Applicability

Power Distribution Systems Types applicable are shown in Table 12.


Table 12

DET04.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System

MOTS

Bespoke

PPDS and TEPDS

This test is also applicable to external DC distribution points.

A.5.3

Test Layout

Measurement positions shall be stipulated in the Platform Power Critical Design Review with guidance from
Annex A - General Requirements. An example Test Configuration is shown in Figure 11.

A.5.4

Test Limits

The Test Limits are shown in Table 13.


Table 13

DET04.A - Test Limits

Short Transient Duration

A.5.5

12V System

24V System

<= 10s

+45V

-30V

+90V

-60V

>10s to 1ms

+35V

-20V

+70V

-40V

Test Conditions

The Test Conditions are detailed in Table 14.

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DEF STAN 61-5 Part 6 Issue 6

Table 14

DET04.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Minimum engine speed to ensure maximum load to


the Terminal Equipment DCDU.

0%

Nominal fixed speed engines shall be run at their designed on-line speed only

A.5.6

Test Method

Connect the DSO as close as physically possible to the measurement point. This ensures the calibrated
differential scope probe can reach without any extensions. This also reduces the risk of any radiated noise
being measured.
Measure individual platform inductive loads when switched between the off to on and on to off conditions
using the appropriate platform switch.
Perform each test with the following time bases configured on the DSO: 100ns, 500ns, 1s, 100s and 1ms
per division.
Repeat each operation 3 times for each time base, report the worst case amplitude for each time base, and
the steady state recovery time.
Differential
Oscilloscope
Probes

Terminal
Equipment
DCDU

Platform and Terminal


Equipment

Power Switch (for


Terminal Equipment)
Bus bars

DSO

Figure 11

DET04.A - Example Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

A.6

DET05.A Circuit Protection

A.6.1

Purpose

The purpose of this test is to ensure correct installation and operation of the circuit protection devices. This
test ensures the DCDUs and individual equipments are protected from over-current.

A.6.2

Applicability

Table 15 defines the circuit protection applicable for test.


Table 15

DET05.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System
Circuit Protection

NOTE

MOTS

TEPDS

Bespoke

PPDS and
TEPDS

Only a single circuit protection device of each value and type requires test on each DCDU.

This test is also applicable to external DC distribution points.

A.6.3

Test Layout

For Platform and Terminal Equipment DCDU protection, measurements shall be made across DCDU bus
bars.
For Platform and Terminal Equipment protection, measurements shall be made at the output of the
appropriate circuit protection device.
A typical test configuration is shown in Figure 12.

A.6.4

Test Limits

The Test Limits are shown in Table 16.


Table 16

DET05.A - Test Limits

Position

Time between activation of test switch to zero volts

Platform / Terminal Equipment DCDU


Protection

As identified in the Power Critical Design Review

Platform / Terminal Equipment Protection

As identified in the Power Critical Design Review

A.6.5

Test Conditions

The Test Conditions are detailed in Table 17.

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DEF STAN 61-5 Part 6 Issue 6


Table 17

DET05.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Minimum engine speed to ensure maximum load to


the outlet point.

Switched 300%

Nominal fixed speed engines shall be run at their designed on-line speed only

A.6.6

Test Method

Connect the DC load banks via the Test Switch/Contactor to the outlet point or DCDU bus bars under test.
Connect the DSO to the output of the protection device, connect the trigger signal from the Test
Switch/Contactor and adjust the DSO to trigger externally.
The DC load banks shall be set to 300% of the protection device being tested. For example a 100A circuit
breaker will be tested with the DC loads set to 300A.
Test the circuit protection device and report the protection device response and the disconnection time.
Measure and record all waveforms on the DSO, to be included in the final report.
Terminal
Equipment
DCDU

Circuit
Protection

Test Switch/
Contactor

DC Load

Switch shown
open
(0% load
condition)
Oscilloscope
Probes

DSO

Figure 12

Trigger
Signal

DET05.A Typical Test Configuration for Terminal Equipment Distribution Protection

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Test Switch/Contactor
Control

DEF STAN 61-5 Part 6 Issue 6

A.7
A.7.1

DET06.A Power Distribution Voltage Drop


Purpose

The purpose of this test is to determine that the capacity of the cables from the Power Generation Source
and batteries, to the Platform or Terminal Equipment DCDU, meets power requirements when fully loaded.

A.7.2

Applicability

Table 18 defines applicable Power Distribution Systems.


Table 18

DET06.A - Test Applicability

Platform Type

COTS

MOTS

Bespoke

Applicable Power
Distribution System

TEPDS

TEPDS

PPDS and
TEPDS

This test is also applicable to external DC distribution points.

A.7.3

Test Layout

Measurements are to be performed as shown in Figure 13 and Figure 14.

A.7.4

Test Limits

Test Condition 1: 2% of Power Generation Source Voltage in Test Condition 1 (Measurement 1).
Test Condition 2: 2% of Power Generation Source Voltage in Test Condition 2 (Measurement 1).

A.7.5

Test Conditions

The Test Conditions are detailed in Table 19.


Table 19

DET06.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Minimum engine speed to ensure maximum load to


the Platform or Terminal Equipment DCDU with the
battery negative disconnected.

95%

NOTE: Ensure negative cable remains common with


the Earth Reference
2

Ignition on (engine off). Battery negative connected.

95%

Nominal fixed speed engines shall be run at their designed on-line speed only

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DEF STAN 61-5 Part 6 Issue 6


A.7.6
A.7.6.1

Test Method
Power Distribution System in Series (Figure 13)

Measure and record Power Generation Source voltage, at the DCDU, in Test Condition 1 using
Measurement 1 detailed in Figure 13.
Measure and record the voltage between the Power Generation Source positive terminal and the positive
DCDU bus bar, (Measurement 2 in Figure 13), Test Condition 1.
Measure and record the voltage between the Power Generation Source negative terminal and the negative
DCDU bus bar, (Measurement 3 in Figure 13), Test Condition 1.
NOTE
The Power Generation Source negative terminal may be the mounting bolts connecting the Power
Generation Source to the Platform.

Add the absolute values of the positive and negative voltage drops (Measurements 2 and 3).
Ensure Test Condition 1 limit is achieved.
A.7.6.2

Power Distribution System in Parallel (Figure 14)

Measure and record Power Generation Source voltage in Test Condition 1 using Measurement 1, detailed in
Figure 14.
Measure and record the voltage between the Power Generation Source positive terminal and the positive
DCDU bus bar, (Measurement 2 in Figure 14), Test Condition 1.
Measure and record the voltage between the Power Generation Source negative terminal and the negative
DCDU bus bar, (Measurement 3 in Figure 14), Test Condition 1.
NOTE
The Power Generation Source negative terminal may be the mounting bolts connecting the Power
Generation Source to the Platform.

Add the absolute values of the positive and negative voltage drops (Measurements 2 and 3).
Ensure Test Condition 1 limit is achieved.
Measure and record the voltage between the battery positive terminal and the positive DCDU bus bar,
(Measurement 4 in Figure 14), Test Condition 2.
Measure and record the voltage between the battery negative connection and the negative DCDU bus bar,
(Measurement 5 in Figure 14), Test Condition 2.
Add the absolute values of the positive and negative voltage drops.
Ensure Test Condition 2 limit is achieved.

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DEF STAN 61-5 Part 6 Issue 6

Terminal
Equipment
DCDU

Terminal
Equipment
Battery
Power
Generation
Source

DC Load

Negative Battery
Terminal
(disconnected)

Figure 13

Measurement Number

Switch shown open


(prior to test)
Measured between these points

Test Condition 1,
Negative Battery Terminal
Disconnected

DET06.A Typical Test Configuration Power Distribution System in Series

Terminal
Equipment
DCDU
Power
Generation
Source

3
Terminal
Equipment
Battery

DC Load

Switch shown
open (prior to
test)

5
6

Negative Battery
Terminal

Measurement Number

Measured between these points

}
}

Test Condition 1, Negative


Battery Terminal
Disconnected

Test Condition 2, Negative


Battery Terminal Connected

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DEF STAN 61-5 Part 6 Issue 6


Figure 14

DET06.A Typical Test Configuration Power Distribution System in Parallel

NOTE
When measuring the voltage drop with multiple DCDU's in series, ensure all DCDU's are loaded to 95% of
their capacity.

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DEF STAN 61-5 Part 6 Issue 6

A.8
A.8.1

DET07.A Cranking
Purpose

The purpose of this test is to ensure Terminal Equipment batteries are not being used during the cranking
phase.

A.8.2

Applicability

Table 20 defines the Power Distribution System batteries required for test.
Table 20

DET07.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System
Battery

MOTS

Bespoke

TEPDS

If the platform has a switch that allows the Terminal Equipment batteries to be used in an emergency
situation (for platform systems) then this switch shall be open during this test.

A.8.3

Test Layout

Measurements are to be made across the Terminal Equipment DCDU bus bars.

A.8.4

Test Limits

Terminal Equipment batteries are to remain within steady state voltage levels, detailed in Clause A.2.4,
during the cranking phase.

A.8.5

Test Conditions

The Test Conditions are detailed in Table 21.


Table 21

DET07.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Measurements are to be made during the cranking


cycle.

0%

A.8.6

Test Method

Connect the DSO across the positive and negative terminals of the Terminal Equipment DCDU bus bars.
Crank the platform. Measure and record the Terminal Equipment battery response.

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DEF STAN 61-5 Part 6 Issue 6

A.9
A.9.1

DET08.A Terminal Equipment Battery Capacity Test


Purpose

The purpose of this test is to ensure Terminal Equipment batteries have the capacity to supply their
designated load requirement, as stipulated in the Power Critical Design Review, for 1 hour.

A.9.2

Applicability

Table 22 defines applicable Power Distribution Systems.


Table 22

A.9.3

DET08.A - Test Applicability

Platform Type

COTS

MOTS

Bespoke

Applicable Power
Distribution System

TEPDS

TEPDS

TEPDS (if
fitted)

Test Layout

Measurements are to be made across the Terminal Equipment DCDU bus bars.

A.9.4

Test Limits
Table 23

A.9.5

DET08.A - Test Limits

System

Minimum Terminal Equipment DCDU Voltage

Time

12V

Whichever the greater of 9V or minimum discharge


voltage as defined in the Power Critical Design
Review

1 hour

24V

Whichever the greater of 18V or minimum discharge


voltage as defined in the Power Critical Design
Review

1 hour

Test Conditions

The Test Conditions are detailed in Table 24.

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DEF STAN 61-5 Part 6 Issue 6

Table 24

DET08.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

All power generation sources shall be off during


testing.

Terminal Equipment
Designated Load
Requirement, as stipulated
in the Power Critical Design
Review

A.9.6

Test Method

Connect the DC load banks to the Terminal Equipment DCDU bus bars and adjust to meet the Terminal
Equipment Designated Load Requirements, as stipulated from the Power Critical Design Review.
Monitor the Terminal Equipment DCDU bus bar voltage for 1 hour and ensure it stays within the test limits.
Record the elapsed time if voltage exceeds limits within 1 hour.
Visually inspect the exterior of the battery for signs of damage, cracks and corrosion. Report observations.
NOTE

The initial DC load bank settings shall remain unchanged throughout the test.

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DEF STAN 61-5 Part 6 Issue 6

A.10
A.10.1

DIT01.A Platform/Terminal Earth Bond


Purpose

The purpose is to test the electrical bonds of Platform and Terminal Equipment. This is to ensure the fault
current is sufficient to activate circuit protection within limits set in Clause A.6 - DET05.A.
NOTE

If RF bond measurements are scheduled, RF bonds shall be measured first.

A.10.2

Applicability

Table 25 defines the Power Distribution System earth bonds applicable.


Table 25

DIT01.A Test Applicability

Platform Type

COTS

MOTS

Bespoke

Applicable Power
Distribution System Earth
Bonds

TEPDS

TEPDS

PPDS &
TEPDS

Measurements shall be identified in the Power Critical Design Review. The following paths shall be used as
guidance and are dependent on Power Distribution System type:
a)

Platform Earth Reference to Terminal Earth Reference;

b)

Platform Battery to Platform Earth Reference;

c)

Platform DCDUs to Platform Earth Reference;

d)

Terminal Equipment batteries to Terminal Earth Reference;

e)

Terminal Equipment DCDUs to Terminal Earth Reference;

f)

Terminal Equipment to Terminal Earth Reference;

g)

APU to Terminal Earth Reference (see Figure 15);

h)

Equipment Racks to Terminal Earth Reference;

i)

External DC distribution points to Platform Earth Reference.

Measurements shall be performed between all Designated Earth Points and the Terminal Earth Reference.
NOTE
The Power Critical Deign Review shall identify any parallel paths that will need to be disconnected during
measurement.

A.10.3

Test Layout

Measurements shall be made at the test earth bonding position where available.
A.10.3.1

Standard Test Layout

Measurements shall be made using an Earth Bond Meter, as shown in Figure 15.

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DEF STAN 61-5 Part 6 Issue 6


A.10.3.2

Alternative Test Layout

A typical alternative test configuration, using the power supply method, is shown in Figure 16.
The power supply positive shall be connected via a resistor across the bond path.
The resistor should be of the appropriate value and power rating to ensure the power supply can provide
10A to the circuit.
The resistor is necessary to avoid applying a virtual short circuit across the power supply.
A current clamp shall be positioned around the output of the power supply as shown in Figure 16.

A.10.4

Test Limits

The Test Limits are shown in Table 26.


Table 26

A.10.5

DIT01.A - Test Limits

Power Distribution System Type


Current Capacity

Bond Resistance

< 500A

10 m

500A to 1000A

2 m

Test Conditions

The Test Conditions are detailed in Table 27.


Table 27

DIT01.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

All power generation sources shall be off during


testing.

0%

A.10.6

Test Method

Isolate power generation sources and all batteries.


Remove any potential cabling that could create a parallel path to the reference earth, for example negative
terminals, signal cables, coaxes and remote controls, as stipulated in the Power Critical Design Review.
A.10.6.1

Standard Method

Using an Earth Bond Meter with the current output set to 10A, carry out measurements of the bonds.
A.10.6.2

Alternative Method

It is acceptable to use the power supply method as shown below, if the measurement positions exceed the
cable lengths of the earth bond meter.
Connect power supply as shown in Figure 16, to either end of the bond path being measured.
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DEF STAN 61-5 Part 6 Issue 6


A current clamp shall be positioned around the output of the power supply as shown in Figure 16.
Adjust output voltage of power supply to provide 10A measured on the current clamp.
Measure the voltage across the bond path using a DVM.
Determine resistance of bond path by using Ohms Law.
Terminal Earth Reference

Designated Earth Point


Platform Chassis

Earth Bond
Meter

Removed
during
bond
check
Terminal
Equipment
Battery

APU

Figure 15

DIT01.A - Typical Test Configuration


Terminal Earth Reference

Designated Earth Point


Platform Chassis

Resistor

DVM

Test Power
Supply

Current Clamp
DVM

Terminal
Equipment
Battery

APU

Removed during
bond check

Figure 16

DIT01.A Typical Test Configuration (APU to Terminal Earth Reference) using alternative
test method

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DEF STAN 61-5 Part 6 Issue 6

A.11
A.11.1

DIT02.A Platform Over Voltage / Regulator Failure


Purpose

The purpose of this test is to ensure the platform system can withstand an increase in voltage if the power
generator regulator fails.

A.11.2

Applicability

Table 28 defines the Power Distribution System applicability.


Table 28

DIT02.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System

A.11.3

MOTS

Bespoke

PPDS

Test Layout

A typical test configuration is shown in Figure 17.

A.11.4

Test Limits

Ensure all platform systems meet Performance Criteria A detailed in the Test Plan, in accordance with
Clause 19.3.

A.11.5

Test Conditions

The Test Conditions are detailed in Table 29.


Table 29

DIT02.A - Test Conditions

Test Condition

Engine Condition

Load Requirements

Minimum engine speed to ensure maximum load to


the platform.

All Platform Equipments in


the modes as stipulated in
the Power Critical Design
Review.

Nominal fixed speed engines shall be run at their designed on-line speed only

A.11.6

Test Method

Install the test fixture (as per Figure 17).


Place the platform in the Test Condition as stipulated in Clause A.11.5.
Switch the test fixture so the power supply is supporting the platform.
Increment the power supply in 0.5 V steps to the upper test voltages as shown in Table 30:

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DEF STAN 61-5 Part 6 Issue 6


Table 30

DIT02.A - Upper Test Voltage Limits

Nominal Voltage

Upper Test Voltage

12V

19V

24V

38V

Report any deviations from the functionality of Platform Equipments stipulated in the Power Critical Design
Review.
NOTE 1
The power generator shall be disconnected from the platform battery, using the switch, to prevent damage to
the battery from overcharging.
NOTE 2
If the test power supply does not have the capacity to supply the platform with all Platform Equipments
switched on, it is acceptable to switch on a subset of equipments to perform the test, and then repeat, ensuring all
equipments are exposed to the Platform Over-Voltage Test.
Terminal
Equipment
DCDU

Test Fixture
Platform Battery

Battery Isolator Switch


(open during test)
Power Generation
Source Isolator Switch
(open during test)

Test
Power
Supply

Power
Generation
Source

Platform Earth
Reference

Figure 17

DIT02.A Typical Test Configuration

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Platform
DCDU

DEF STAN 61-5 Part 6 Issue 6

A.12
A.12.1

DIT03.A Platform Imported Ripple (20Hz - 150kHz)


Purpose

The purpose of this test is to ensure the platforms system can withstand ripple voltage generated from
Terminal Equipment.

A.12.2

Applicability

Table 31 defines the Power Distribution System applicable.


Table 31

DIT03.A - Test Applicability


COTS

Platform Type

MOTS

Applicable Power
Distribution System

A.12.3

Bespoke

PPDS

Test Layout

Measurements are to be made across the Terminal Equipment DCDU positive and negative bus bars. A
typical test configuration is shown in Figure 20.

A.12.4

Test Limits

Ensure all platform systems meet Performance Criteria A detailed in the Test Plan, in accordance with
Clause 19.3.

Limit (dBuV) RMS

160

140
136

24V Systems
12V Systems

126
120

106.5
100

96.5

80
10

20

100

1K

5K

10K

100K 150K

1M

Frequency (Hz)

Figure 18
NOTE

Limits are shown in dBV RMS.

A.12.5

Test Conditions

DIT03.A Limits

The Test Conditions are detailed in Table 32.

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DEF STAN 61-5 Part 6 Issue 6


Table 32

DIT03.A - Test Conditions

Test Condition

Engine Condition

Load Requirements

Minimum engine speed to ensure maximum load to


the platform.

All Platform Equipments in


the modes as stipulated in
the Power Critical Design
Review

Nominal fixed speed engines shall be run at their designed on-line speed only

A.12.6

Test Method

A.12.6.1

Calibration

Configure test equipment as shown in Figure 19.


Set the signal generator to the lowest test frequency.
Apply the test signal and then increase the amplitude until the voltage level (as indicated by the AC
voltmeter) corresponds with the specified test limit.
The sinusoidal form factor shall be measured at the start, middle and end of the frequency range across the
0.5 ohm calibrated load.
The sinusoidal form factor is the ratio of the RMS (Root Mean Square) value to the average value.
The tolerance of the sinusoidal form factor shall be 1.11, with a tolerance of 20%.
Record the setting of the signal source.
Step through the frequency range using 100 points per decade increments, recoding the signal source level
at each frequency.
A.12.6.2

Test

Connect test equipment to the platform, as shown in Figure 20.


With the platform in its Test Condition, step through the test frequencies at 100 points per decade applying
the signal source recorded during the calibration.
Monitor and record induced ripple levels using an AC Voltmeter across the Terminal Equipment DCDU.
Report any deviations from the functionality of Platform Equipments stipulated in the Power Critical Design
Review.
If deviations are observed, reduce signal source level to determine the threshold of deviation, and record in
terms of ripple voltage.

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DEF STAN 61-5 Part 6 Issue 6


Signal
Source

Power
Amplifier

0.5 Ohms

AC
Voltmeter

30000F

Figure 19

DIT03.A Calibration Typical Configuration


Signal
Source
Ripple Generator
representing
Terminal Equipment

AC Voltmeter
measuring
representative
ripple imported to
the Platform

Power
Amplifier

Terminal
Equipment
DCDU

AC
Voltmeter
30000F

Figure 20

DIT03.A - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

A.13
A.13.1

DIT04.A Platform Load Dump


Purpose

When a power generator is charging a fully or nearly discharged battery, a large amount of current is flowing
into the battery. When the battery cables become corroded or frayed or otherwise disconnected from the
charging battery, a very high-energy pulse is impressed upon the platform DC system. This high-energy
pulse is called "Load Dump". A load dump can also be generated by switching off large loads.
The load dump pulse has the energy to destroy an unprotected electronic system.
NOTE

This test could cause damage to the Platform under test.

A.13.2

Applicability

Table 33 defines the Power Distribution System applicable.


Table 33

DIT04.A - Test Applicability


COTS

Platform Type
Applicable Power
Distribution System

A.13.3

MOTS

Bespoke

PPDS

Test Layout

A typical test configuration is shown in Figure 21.

A.13.4

Test Limits

Ensure all platform systems meet Performance Criteria D detailed in the Test Plan, in accordance with
Clause 19.3.
The load dump waveform shall not exceed limits shown in Table 34.
Table 34

DIT04.A - Load Dump Limits


Nominal Voltage

Pulse Parameter

Peak Amplitude

12V

24V

55V

110V

Duration

A.13.5

300ms

Test Conditions

The Test Conditions are detailed in Table 35.

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DEF STAN 61-5 Part 6 Issue 6


Table 35

DIT04.A - Test Conditions

Test Condition

Engine Condition

Load Requirements (% of
rated maximum load
conditions)

Minimum engine speed to ensure maximum load to


the platform.

Safety Related Equipments in


the modes as stipulated in the
Power Critical Design Review

Minimum engine speed to ensure maximum load to


the platform.

Safety Related and Mission


Related Equipments in the
modes as stipulated in the
Power Critical Design Review

Nominal fixed speed engines shall be run at their designed on-line speed only

A.13.6

Test Method

Install the test fixture (as per Figure 21).


Close the Battery Isolation Switch and open the Load Dump Switch.
Place the platform in the Test Condition 1 as stipulated in Clause A.13.5.
Record the peak current supplying the platform in its Test Condition.
With the load dump switch closed, adjust the DC load to achieve a 100% of the power generators capacity
by calculating the difference between the power generators maximum rated output and the platform test
condition current.
For example: DC Load = Power Generator Maximum Rated Output Platform Test Condition Current.
Open the battery isolation switch so the platform is running from the power generator only.
Increase the engine speed for 1 minute prior to the test to ensure the power generator is supplying the
maximum current.
Open the load dump switch. Capture and record the load dump transient waveform across the Terminal
Equipment DCDU on the DSO and include in the final report.
NOTE
In the event that no Terminal Equipment DCDU is fitted, the load dump waveform measurement shall be
captured and recorded across the Platform Equipment DCDU.

Repeat procedure for Test Condition 2 in Clause A.13.5.


Report any deviations from the functionality of Platform Equipments stipulated in the Power Critical Design
Review.

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DEF STAN 61-5 Part 6 Issue 6


Test Fixture
Platform Battery
Current
Clamp
Battery Isolator
Switch (closed at
start of test)

Terminal
Equipment
DCDU

Current
Clamp

DSO
DVM

Load Dump
Switch
(open at
start of test)

Load
Platform
DCDU

Power
Generation
Source

DVM

Platform Earth
Reference

Figure 21

DIT04.A Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

Annex B
Platform and Terminal Equipment Tests

B.1

General Requirements

B.1.1
a)

Requirements

Unless otherwise stated, all tests shall be performed using the Supply Voltage (VS) and Battery Voltage
(VB), where appropriate. Table 36 stipulates the voltages during test:
Table 36

Platform and Terminal Equipment - Test Supply Voltages

Test Voltages

12V Systems

24V Systems

VS

13.5V 0.5V

27V 1.0V

VB

12V 0.2V

24V 0.4V

b)

The ambient temperature during tests shall be 23 5 C;

c)

Care shall be taken to ensure that the surrounding electromagnetic environment does not interfere with
the measurement set-up;

d)

Ideally actual cable-forms shall be used for test;

e)

In the absence of actual cable-forms, interconnecting cable-forms shall whenever possible be of length,
type and layout representative of the practical installation;

f)

If details of the cable-form are unknown, power, control and signal cable lengths shall be 1000mm 100
mm;

g)

Platform and Terminal Equipment shall be bonded in accordance with the manufacturers specification
and details shall be included in the report;

h)

Unless otherwise stipulated, the Platform and Terminal Equipment and all harnesses shall be supported
above a ground conducting bench on 50mm (+10/-0) insulated stand-offs. It is acceptable for Platform
and Terminal Equipment not to require a ground conducting bench when in an environmental chamber;

i)

The ground conducting bench shall have a flat conductive surface whose potential shall be used as a
common reference for all test equipment, batteries, power supplies and Platform and Terminal
Equipments under test. The ground conducting bench shall have a low impedance connection to mains
earth for safety purposes when using transient generators;

j)

Large equipment mounted in a metal rack or cabinet shall be considered as a part of the ground
conducting bench for testing purposes and shall be bonded to the ground conducting bench by the rack
or cabinet bonding arrangements;

k)

All connections to the ground conducting bench shall have a low frequency AC impedance of 2m;

l)

Classification of equipment type (Platform or Terminal) shall be stipulated in the Power Critical Design
Review;

m) Platform and Terminal Equipment test mode(s), fault criteria and environmental aspects shall be defined
at the Power Critical Design Review;
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DEF STAN 61-5 Part 6 Issue 6


n)

Platform or Terminal Equipment may be required to be tested in more than one mode of operation to
ensure all functions of the equipment are fully tested. This shall be defined at the Power Critical Design
Review;

o)

Test Applicability shall be determined using Table 37.


Table 37

Platform and Terminal Equipment - Test Applicability

Test Ref.

Test Description

Test Applicability

Clause

DET01.B

Ripple

All Platform and Terminal


Equipment

B.2

DET02.B

Exported Transients

All Platform and Terminal


Equipment

B.3

DET03.B

Maximum Inrush Current

All Terminal Equipment

B.4

DIT01.B

Positive Supply Isolation


Test

All Terminal Equipment

B.5

DIT02.B

Earth Bonding

All Terminal Equipment


designed with an earth bond

B.6

DIT03.B

Negative/Earth Bond
Isolation

All Terminal Equipment

B.7

DIT04.B

Cranking

All Platform and Terminal


Equipment

B.8

DIT05.B

Reverse Voltage

All Platform and Terminal


Equipment

B.9

DIT06.B

Under and Over-Voltage

All Platform and Terminal


Equipment

B.10

DIT07.B

Short Transients

All Platform and Terminal


Equipment

B.11

DIT08.B

Load Dump

All Platform and Terminal


Equipment

B.12

NOTE
In all figures, shaded elements indicate Test Equipment. Un-shaded elements indicate Platform or Terminal
Equipment under test.

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B.2
B.2.1

DET01.B Ripple
Purpose

The purpose of this test is to measure the ripple voltage generated from Platform Equipments and Terminal
Equipment power supplies containing DC-to-DC Converters and regulation circuits.

B.2.2

Applicability

All Platform and Terminal Equipment types.

B.2.3

Test Layout

A typical test configuration is shown in Figure 22.


The Platform and Terminal Equipment shall be connected via LISNs positioned on both positive and
negative feeds, using the supplied harness or a test harness of length 1000mm 100mm, where the harness
to be used in the installation is not available. The measurements shall be taken at 50mm 10mm from the
Platform or Terminal Equipment under test.

B.2.4

Test Limits

The Test Limits are shown in Table 38.


Table 38

B.2.5

DET01.B - Test Limits

Nominal Voltage

Ripple Voltage Limit

24V

<2V pk-pk

12V

<1V pk-pk

Equipment Mode

Measurements shall be taken on the worst case mode as stipulated in the Power Critical Design Review.

B.2.6

Test Method

Connect the DSO using differential scope probes across the positive and negative feeds at 50mm 10mm
from the Platform or Terminal Equipment under test.
Connect an equivalent resistive load that represents the load of the Platform or Terminal Equipment in its
worst case mode.
The DSO shall be adjusted to AC coupled and the time base adjusted to accurately capture the ripple
voltage.
Perform an ambient measurement to ensure the voltage source ripple is as shown in Table 39.

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Table 39

DET01.B - Voltage Source Ripple Limit

Nominal Voltage

Voltage Source Limit

24V

<200mV pk-pk

12V

<100mV pk-pk

Replace the resistive load with the Platform or Terminal Equipment and repeat.
During measurement ensure the Platform or Terminal Equipment operates normally and only inherent and
natural changes occur i.e. do not deliberately change or operate any part of the system.
NOTE

If testing DC to DC converters or battery conditioning units, tests should be applied to both input and outputs.

Supplied harness or 1000mm 100

50mm 10
A

LISN

B
DSO

Oscilloscope Probes

Common Link
A

LISN

Power Switch
Key
A
B
P

Power Supply Terminal


Common Terminal
Output Terminal

Figure 22

DET01.B - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

B.3
B.3.1

DET02.B Exported Transients


Test Method

The purpose of this test is to measure the amplitude and duration of transients appearing on positive and
negative feeds. This is caused by the Platform and Terminal Equipment being switched on and off, or
between modes of operation (functional switching).
These transient emissions may couple via conduction and radiation from the positive and negative feeds to
the platform or other equipments in the installation.
It should be noted that short transients are attenuated in the Platform Power Distribution System, and
therefore Clause B.3 DET02.B limits do not exactly match those of Clause A.4 DET03.A.

B.3.2

Applicability

All Platform and Terminal Equipment positive and negative feeds.

B.3.3

Test Layout

A typical test configuration is shown in Figure 23, and test configuration using an external switch in Figure
24.
The Platform and Terminal Equipment shall be connected via LISNs positioned on both positive and
negative feeds, using the supplied harness or a test harness of length 1000mm 100mm, where the harness
to be used in the installation is not available. The measurements shall be taken at 50mm 10mm from the
Platform or Terminal Equipment under test.
For Terminal Equipment, the power isolation switch shall be used during this test.
For Platform Equipment, the power isolation switch shall be used where fitted. In the absence of the power
isolation switch, an external switch as stipulated in the Clause 17 Test Equipment shall be used.

B.3.4

Test Limits

The Test Limits are shown in Table 40 and Table 41.


Table 40

DET02.B Test Limits - 12V System

Time

Upper Limit

Lower Limit

0 to 10s

25V

-75V

10s to 10ms

25V

-20V

> 10ms

Steady State Voltage

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Table 41

DET02.B Test Limits - 24V Systems

Time

Upper Limit

Lower Limit

0 to 10s

50V

-150V

10s to 10ms

50V

-40V

> 10ms

B.3.5

Steady State Voltage

Equipment Mode

Measurements shall be made on Platform and Terminal Equipment when cycled between off/on/worst case
mode/on/off, as stipulated in the Power Critical Design Review.
For example a radio, from off to receive to transmit to receive to off.

B.3.6

Test Method

Connect the DSO using differential scope probes across the positive and negative feeds at 50mm 10mm
from the Platform or Terminal Equipment under test.
Perform each test with the following time bases configured on the DSO: 100ns, 500ns, 1s, 100s and 1ms
per division.
If voltage has returned to steady state when using a time base of 1ms, then the time base shall be increased
until the voltage returns to steady state.
Repeat each operation 3 times for each time base, report the worst case amplitude for each time base, and
the steady state recovery time.

Supplied harness or 1000mm 100

50mm 10
A

LISN

B
DSO

Oscilloscope Probes

Common Link
A

LISN

Power Switch
Key
A
B
P

Power Supply Terminal


Common Terminal
Output Terminal

Figure 23

DET02.B - Typical Test Configuration

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Equipment

DEF STAN 61-5 Part 6 Issue 6

Supplied harness or 1000mm 100


Test Switch/
Contactor
A

LISN

50mm 10

B
DSO

Oscilloscope Probes

Common Link
A

LISN

Platform / Terminal
Equipment

B
Test Switch/
Contactor
Control

Key
A
B
P

Power Switch

Power Supply Terminal


Common Terminal
Output Terminal

Figure 24

DET02.B - Test Configuration using External Switch

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DEF STAN 61-5 Part 6 Issue 6

B.4
B.4.1

DET03.B Maximum Inrush Current


Purpose

The purpose of this test is to measure the amplitude and the duration of peak inrush currents required by the
Terminal Equipment under test, on initial switch on and when changing between modes of operation.
These tests shall be performed in hot and cold environmental conditions determined, by the Power Critical
Design Review.

B.4.2

Applicability

All Terminal Equipment types.

B.4.3

Test Layout

A typical test configuration is shown in Figure 25.


The Terminal Equipment shall be positioned in the environmental chamber, using the supplied harness or a
test harness of length 1000mm 100mm where the harness to be used in the installation is not available. A
battery source, (VB), shall supply the Terminal Equipment. No LISNs shall be fitted. The measurements shall
be taken, using differential scope probes connected to the DSO measuring across a current shunt.
NOTE
DSO.

Ensure the battery negative is isolated from the ground conducting bench, to prevent a short circuit of the

The Terminal Equipment switch shall be used during this test.


Measurements shall be made in both hot and cold environmental conditions, stipulated by the Power Critical
Design Review.

B.4.4

Test Limits

The Test Limits for Terminal Equipments are shown in Table 42.
Table 42

DET03.B Test Limits

Inrush Current Limit (A pk)


(Multiple of Maximum Rated
Current)

Time from Terminal Equipment Initial Switch On / Change of Modes

7 times

< 100ms

2 times

100 ms 1s

Steady State

> 1s

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DEF STAN 61-5 Part 6 Issue 6

B.4.5

Equipment Mode

Measurements shall be made on Terminal Equipment when cycled between off/on/worst case mode, as
stipulated in the Power Critical Design Review.

B.4.6

Test Method

The Terminal Equipment shall be left switched off in its stipulated test mode and each environmental
condition, for 1 hour prior to test.
LISNs are to be removed for this test.
Attach the DSO across the current shunt in series with the positive line of the Terminal Equipment.
Perform each test with the following time bases configured on the DSO: 100ns, 500ns, 1s, 100s and 1ms
per division.
If current has not returned to steady state when using a time base of 1ms, then the time base shall be
increased until the current returns to steady state.
Repeat each operation 3 times for each time base, report the worst case amplitude for each time base, and
the steady state recovery time.
The DSO shall be adjusted to measure and record amplitude and duration of the inrush current, while
operating in its stipulated environmental condition.

Supplied harness or 1000mm 100

Current
Shunt
Battery/Batteries

Terminal Equipment

DSO
Power Switch

Figure 25

DET03.B - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

B.5
B.5.1

DIT01.B Positive Supply Isolation Test


Purpose

The purpose of this test is to ensure when Terminal Equipment is switched off, it is fully isolated from the
positive supply. This will ensure the platforms quiescent current is limited to the equipment designated to
have a continuous positive supply.

B.5.2

Applicability

All Terminal Equipment types, unless designated to have a constant positive feed.

B.5.3

Test Layout

A typical test configuration is shown in Figure 26.


Using the supplied harness or a test harness of length 1000mm 100mm, where the harness to be used in
the installation is not available, connect the Terminal Equipment on both positive and negative feeds. The
measurements shall be taken, on the positive line only using a current shunt and DVM, with a measurement
sensitivity of less than 1mA.

B.5.4

Test Limits

Current shall be less than 1mA pk for both 12V and 24V nominal systems.

B.5.5

Equipment Mode

The Terminal Equipment isolation switch shall be in the off position.

B.5.6

Test Method

Disconnect Terminal Equipment from power source.


Ensure that the Terminal Equipment isolation switch has been made (ON).
Briefly connect the positive and negative supply cables across a 1k ohm resistor to dissipate any residual
charge that may be present within the Terminal Equipment circuitry.
Ensure that the Terminal Equipment isolation switch has been made (OFF).
Position the current shunt in series with the positive feed of the power source.
Re-connect the positive supply cable to the power source, ensuring that the Terminal Equipment isolation
switch remains switched off.
Monitor for any levels of current. All current levels to be recorded.

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DEF STAN 61-5 Part 6 Issue 6

Supplied harness or 1000mm 100

LISN

Current
Shunt

B
Terminal Equipment
Common Link
A

LISN

DVM
Power Switch

Key
A
B
P

Power Supply Terminal


Common Terminal
Output Terminal

Figure 26

DIT01.B - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

B.6

DIT02.B Earth Bonding

B.6.1

Purpose

The purpose of this test is to ensure that the earth bond supplied or stipulated in the installation instructions
is sufficient to carry safety currents to the Terminal Designated Earth Reference.

B.6.2

Applicability

All Terminal Equipment designed with an earth bond.

B.6.3
B.6.3.1

Test Layout
Standard Test Layout

Measurements shall be made between the earth bond test position and the end of the supplied earth cable
as stipulated in the manufacturers installation guide, using an Earth Bond Meter with a test current of at least
10A, as shown in Figure 27.
B.6.3.2

Alternative Test Layout

A typical alternative test configuration, using the power supply method, is shown in Figure 28.
The Terminal Equipment is to be fitted with the supplied earth cable as stipulated in the manufacturers
installation guide, to the earth bond point, as Figure 28.
The test power supply positive shall be connected to the Terminal Equipment earth bond test position and
the negative shall be connected to the earth cable, via a resistor.
The resistor should be of the appropriate value and power rating to ensure the test power supply can provide
10A to the circuit.
The resistor is necessary to avoid applying a virtual short circuit across the test power supply.
A current clamp shall be positioned around the output of the test power supply as shown in Figure 28.

B.6.4

Test Limits

The Test Limits are shown in Table 43.


Table 43

B.6.5

DIT02.B - Test Limits

Total System Current Capacity

Bond Resistance

< 500A

10 m

500A < 1000A

2 m

Equipment Mode

Terminal Equipment switched off.

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DEF STAN 61-5 Part 6 Issue 6


B.6.6
B.6.6.1

Test Method
Standard Method

Using an Earth Bond Meter with current output set to at least 10A, measure the resistance between the
Terminal Equipment earth bond test position and the end of the earth cable.
B.6.6.2

Alternative Method

Connect power supply as per Figure 28.


Adjust output voltage of power supply to provide 10A measured on the current clamp.
Measure the voltage across the Terminal Equipment earth bond test position and the end of the earth cable,
as shown in Figure 28.
Determine the resistance from Ohms Law.
If the earth bond is rated at less than 10A, the appropriate test current shall be reduced accordingly.

Earth Bond
Meter

Terminal Equipment

Supplied Earth Cable


Earth Bond
Test Position

Earth Bond

Figure 27

DIT02.B - Typical Test Configuration

Current Clamp (10A)


Test Power Supply

Terminal Equipment

DVM

Resistor

NOTE

Supplied Earth Cable


Earth Bond
Test Position

Figure 28

Earth Bond

DVM

DIT02.B - Typical Alternative Test Configuration using a Power Supply

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DEF STAN 61-5 Part 6 Issue 6

B.7
B.7.1

DIT03.B Negative/Earth Bond Isolation


Purpose

The purpose of this test is to check the isolation between the Terminal Equipment earth and the negative
input. This is to ensure the current supplying the Terminal Equipment is maintained as a two wire system.

B.7.2

Applicability

All Terminal Equipment.

B.7.3

Test Layout

DVM to measure the resistance between the earth bond test position and negative input line.

B.7.4

Test Limits

Bond resistance shall be 1M between the earth bond test position and negative input line.

B.7.5

Equipment Mode

Terminal Equipment shall be switched on, but not powered.

B.7.6

Test Method

DVM to measure between the earth bond test position and negative input line, as shown in Figure 29.
Record measured result.

Earth Bond Test Position

Terminal Equipment
DVM

Power Switch (ON)


Figure 29

DIT03.B - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

B.8
B.8.1

DIT04.B Cranking
Purpose

The purpose of this test is to ensure Platform and Terminal Equipment assumes normal operation with no
loss of functionality after the platform cranking phase.
NOTE
Platform and Terminal Equipment is not expected to function correctly during the cranking phase as the
cranking waveform voltage drops below the Platform and Terminal Equipment working voltage as stipulated in this
document.

B.8.2

Applicability

All Platform and Terminal Equipment types.

B.8.3

Test Layout

A typical test configuration is shown in Figure 30.


The Platform and Terminal Equipment shall be connected to the transient generator using the supplied
harness or a test harness of length 1000mm 100mm, where the harness to be used in the installation is not
available.

B.8.4

Test Limits

Ensure Platform and Terminal Equipment meets Performance Criteria B detailed in the Test Plan, in
accordance with Clause 19.3.

B.8.5

Equipment Mode

The Platform and Terminal Equipment shall be tested in the modes as stipulated in the Power Critical Design
Review.

B.8.6

Test Method

No LISNs present; direct injection of a single pulse onto Platform or Terminal Equipment power supply lines,
as shown in Figure 30, with parameters in Table 44.
Report any deviations of functionality to the Platform or Terminal Equipment.
Measure and record all test waveforms on the DSO, to be included in the final report.

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DEF STAN 61-5 Part 6 Issue 6


Supplied harness or 1000mm 100

DSO

Transient Generator

Platform and Terminal


Equipment

Power Switch (for


Terminal Equipment)

Figure 30

DIT04.B - Typical Test Configuration

VS

V1

V2

V3

VB

0
t
t1

t2

t3

Figure 31
NOTE

t4

DIT04.B - Test Pulse

The test pulse commencement voltage is VB and the final voltage is VS.

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t5

DEF STAN 61-5 Part 6 Issue 6

Table 44

DIT04.B - Parameters for Test Pulse

Parameter

12V System

24V System

V1

3V

8V

V2

5V

15V

V3 (pk-pk)

2V

2V

t1

5 ms

10 ms

t2

15 ms

50 ms

t3

50 ms

t4

10 s

20 s

t5

100 ms

40 ms

Frequency of ripple

2 Hz

2 Hz
0 to 0.02

Transient Generator Output


Impedance

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DEF STAN 61-5 Part 6 Issue 6

B.9
B.9.1

DIT05.B Reverse Voltage


Purpose

The purpose of this test is to ensure the Platform and Terminal Equipment assumes normal operation with
no loss of functionality once correct polarity is restored.
NOTE

B.9.2

It is acceptable to reset or replace Platform or Terminal Equipment circuit protection devices post-test.

Applicability

All Platform and Terminal Equipment types.

B.9.3

Test Layout

A typical test configuration is shown in Figure 32.

B.9.4

Test Limits

Ensure Platform and Terminal Equipment meets Performance Criteria D detailed in the Test Plan, in
accordance with Clause 19.3.

B.9.5

Equipment Mode

The Platform or Terminal Equipment isolation switch (where fitted) shall be set to on during test.

B.9.6

Test Method

Ensure Platform or Terminal Equipment operates correctly.


Disconnect power supply cables to Platform or Terminal Equipment; ensure the bond cable is removed from
the Platform or Terminal Equipment, to isolate it from the battery source (preventing short circuit).
Connect to cross-polarity test fixture as shown in Figure 31.
Perform test for a period of one minute.
Restore Platform or Terminal Equipment to correct polarity. Ensure normal operation and functionality, as
stipulated in the Power Critical Design Review.

Platform or
Terminal
Equipment

Battery Source

1 min

Figure 32

DIT05.B - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

B.10
B.10.1

DIT06.B Under & Over-Voltage


Purpose

To ensure that Platform or Terminal Equipment operates correctly at the voltage extremes as designated by
this standard. This test simulates a gradual discharging and re-charge of a battery.

B.10.2

Applicability

For all Platform or Terminal Equipments.

B.10.3

Test Layout

A typical test configuration is shown in Figure 35, with the Platform or Terminal Equipment connected
directly to a variable DC power supply.

B.10.4

Test Limits

Ensure Platform and Terminal Equipment meets Performance Criteria A detailed in the Test Plan, in
accordance with Clause 19.3.

B.10.5

Equipment Mode

The Platform or Terminal Equipment shall be tested in the modes as stipulated in the Power Critical Design
Review.

B.10.6

Test Method

In one complete cycle, apply the following voltage changes according to Table 45 and Figure 33 and Figure
34:
Table 45

DIT06.B - Operating Voltage Range


Nominal 12V

Nominal 24V

Terminal
Equipment

Platform
Equipment

Terminal
Equipment

Platform
Equipment

Lower Voltage

9V

9V

18V

18V

Upper Voltage

16V

19V

32V

38V

Decrease the supply voltage from the nominal voltage to the lower voltage, maintain lower voltage for 5
minutes.
Increase to the upper voltage; maintain upper voltage for 5 minutes.
Decrease to the nominal voltage.
Apply a change rate of 0.5 V/min for all tests, as shown in Figure 33 and Figure 34.

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DEF STAN 61-5 Part 6 Issue 6


5 Mins
16 V / 19V

VS

VS
0.5 V

1 Min
0.5 V

1 Min

9V
5 Mins

Figure 33

DIT06.B - Limits (12V Systems)


5 Mins
32 V / 38V

VS

VS
0.5 V

1 Min
0.5 V

1 Min

18 V
5 Mins

Figure 34

DIT06.B - Limits (24V Systems)

Supplied harness or 1000mm 100

Transient Generator

DSO

Platform and Terminal


Equipment

For validation of
waveforms only
Power Switch (for
Terminal Equipment)

Figure 35

DIT06.B - Typical Test Configuration

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DEF STAN 61-5 Part 6 Issue 6

B.11
B.11.1

DIT07.B Short Transients


Purpose

The purpose of this test is to ensure the Platform and Terminal Equipment can withstand electrical short
transients caused by arcing of contact points in mechanical switches and relays.

B.11.2

Applicability

All Platform and Terminal Equipment types.

B.11.3

Test Layout

A typical test configuration is shown in Figure 36.


The Platform or Terminal Equipment shall be connected to the transient generator using the supplied
harness or a test harness of length 1000mm 100mm, where the harness to be used in the installation is not
available. Pulse shapes shall be as shown in Figure 37 through Figure 40, and parameters in Table 46 and
Table 47.

B.11.4

Test Limits

Ensure Platform and Terminal Equipment meets Performance Criteria A detailed in the Power Critical Design
Review, in accordance with Clause 19.3.

B.11.5

Equipment Mode

The Platform or Terminal Equipment shall be tested in the modes as stipulated in the Power Critical Design
Review.

B.11.6

Test Method

With the Platform or Terminal Equipment disconnected, validate and record the waveform of the transient
generator and include in the final report.
NOTE
When validating the transient waveform, the use of high speed scope probes as stipulated in Clause 17.1
are recommended to ensure accurate validation.

No LISNs present; direct injection of negative pulse and positive pulse waveform onto Platform or Terminal
Equipment power supply lines, for a period of 30 minutes per pulse type, in each mode.

Supplied harness or 1000mm 100

Transient Generator

DSO

Platform and Terminal


Equipment

For validation of
waveforms only
Power Switch (for
Terminal Equipment)

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DEF STAN 61-5 Part 6 Issue 6


Figure 36

DIT07.B - Typical Test Configuration


td
tr

VS
0.1VA

0.9VA
VA

Figure 37

DIT07.B - Negative Test Pulse A

t2

t3

VS
0
VA

t1

Figure 38

DIT07.B - Negative Test Pulse - Pulse Train A

Table 46

DIT07.B - Parameters for Test Pulse A

Parameter

12V System

24V System

VA

-150V

-200V

td

0.1 s +0.1 s

tr

5 ns 1.5 ns

t1

100 s

t2

10 ms

t3

90 ms

Transient Generator Output


Impedance

50

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DEF STAN 61-5 Part 6 Issue 6


VA
0.9VA

0.1VA

VS
tr
td

Figure 39

DIT07.B - Positive Test Pulse B

VA

t1

VS
0

t2

Figure 40

t3

DIT07.B - Positive Test Pulse - Pulse Train B

Table 47

DIT07.B - Parameters for Test Pulse B

Parameter

12V System

24V System

VA

100V

200V

td

0.1 s +0.1 s

tr

5 ns 1.5 ns

t1

100 s

t2

10 ms

t3

90 ms

Transient Generator Output


Impedance

50

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DEF STAN 61-5 Part 6 Issue 6

B.12
B.12.1

DIT08.B Load Dump


Purpose

The purpose of this test is to ensure the Platform and Terminal Equipment is protected from high-energy
pulses that could be seen on the platform power supply.
NOTE 1

It is acceptable to reset or replace Platform or Terminal Equipment circuit protection devices post test.

NOTE 2

This test could cause damage to the equipments under test.

B.12.2

Applicability

All Platform and Terminal Equipment types.

B.12.3

Test Layout

A typical test configuration is shown in Figure 41.


The Platform or Terminal Equipment shall be connected to the transient generator using the supplied
harness or a test harness of length 1000mm 100mm, where the harness to be used in the installation is not
available. Pulse shape shall be as shown in Figure 42 and parameters in Table 48.

B.12.4

Test Limits

Ensure Platform and Terminal Equipment meets Performance Criteria D detailed in the Power Critical Design
Review, in accordance with Clause 19.3.

B.12.5

Equipment Mode

The Platform or Terminal Equipment shall be operated in its normal operating mode as stipulated in the
Power Critical Design Review.

B.12.6

Test Method

With the Platform or Terminal Equipment disconnected, validate and record the waveform of the transient
generator and include in the final report.
No LISNs present; direct injection of single pulse onto Platform or Terminal Equipment power supply lines, in
each mode.

Supplied harness or 1000mm 100

Transient Generator

DSO

Platform and Terminal


Equipment

For validation of
waveforms only
Power Switch (for
Terminal Equipment)

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DEF STAN 61-5 Part 6 Issue 6


Figure 41

DIT08.B - Typical Test Configuration

Key
VPK= Peak pulse voltage
td = Pulse duration
tr = Pulse rise time

td
tr

VPK
0.9VPK

0.1VPK
VS

Figure 42
Table 48

DIT08.B - Test Pulse

DIT08.B - Parameters for Test Pulse

Parameter

12V System

24V System

VPK

87V

174V

td

400ms

350ms

tr
Transient Generator Output
Impedance

10 ms
0.5

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DEF STAN 61-5 Part 6 Issue 6

Annex C
Related Documents

C.1

Related Documents
Table 49
AQAP 2000 series

Acquisition
(AOF)

Operating

Related Documents

NATO policy on an integrated systems approach to


quality through the life cycle
Framework

UK Ministry of Defence (MOD) Acquisition Operating


Framework (AOF)
http://www.aof.mod.uk/index.htm

DEFCON 602A

Quality Assurance - Deliverable Quality Plan

DEFCON 602B

Quality Assurance - Without Deliverable Quality Plan

Defence Standard 00-35 (Part 3)

Environmental Handbook for Defence Materiel


Environmental Test Methods.

Defence Standard 00-35 (Part 4)

Environmental Handbook for Defence Materiel Natural


Environments.

Defence Standard 00-35 (Part 6)

Environmental Handbook for Defence Materiel Induced


Climatic, Chemical and Biological Environments.

Defence Standard 00-56

Safety Management Requirements for Defence Systems.

Defence Standard 05-61

Quality Assurance Procedural Requirements.

Defence Standard 23-06

Technology Guidance for Military Logistics Vehicles.

Defence Standard 59-411 Part 1

Electromagnetic Compatibility Management and


Planning.

Defence Standard 59-411 Part 3

Electromagnetic Compatibility Test Methods and Limits


for Equipment and Sub Systems.

Defence Standard 59-411 Part 4

Electromagnetic Compatibility Platform and System


Test and Trials.

Defence Standard 61-12 Series

Wires, Cords and Cables, Electrical.

Defence Standard 61-21 Series

General Specification for batteries.

ISO 7637 Parts 1

Road Vehicles Electrical disturbances from conduction


and coupling Definitions and general considerations.

ISO 7637 Parts 2

Road Vehicles Electrical disturbances from conduction


and coupling Electrical transient conduction along
supply lines only.

ISO 7637 Parts 3

Road Vehicles Electrical disturbances from conduction


and coupling Vehicles with nominal 12V and 24V supply
Unclassified

82

DEF STAN 61-5 Part 6 Issue 6


voltage.
ISO 9001:2000

Quality Management Systems Requirements.

ISO/IEC 17025

General Requirements for the Competence of Calibration


and Testing Laboratories.

ISO/IEC 17050

Conformity assessment. Suppliers declaration of


conformity.

ISO/IEC Guide 2

Standardizations and Related Activities

LAB12

The Expression of Uncertainty in Testing

M3003

The Expression of Uncertainties and Confidence in


Measurements

SAE AS50881

Wiring Aerospace Vehicle

STANAG 2601

Standardisation of Electrical Systems in Tactical Land


Vehicles

VG95218-5

Electrical cables and insulated wires Part 5 Current


rating

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DEF STAN 61-5 Part 6 Issue 6

Annex D
Abbreviations

D.1

Abbreviations

The following abbreviations, in Table 50, are in addition to those appearing in the text of this part of the
standard. They also include, for reference purposes, other abbreviations that are in general use and may
appear in other standardisation documents.
Table 50

Abbreviations

AC

Alternating Current

ACSM

Assemblies, Components, Spare Parts and Materials

Ah

Amp Hour

ANSI

American National Standards Institute

AP

Allied Publication

APU

Auxiliary Power Unit

AQAP

Allied Quality Assurance Publication

BS

British Standard

BSI

British Standards Institution

CDR

Critical Design Review

CIS

Communications and Information Systems

COSHH

Control of Substances Hazardous to Health

COTS

Commercial Off The Shelf

DC

Direct Current

DCDU

Direct Current Distribution Unit

DP

Distribution Point

DEF STAN

Defence Standard

Dstl

Defence Science and Technology Laboratory

DStan

UK Defence Standardisation

DEP

Designated Earth Point

DET

Defence Exported Transients

DIT

Defence Imported Transients

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DEF STAN 61-5 Part 6 Issue 6


DSO

Digital Storage Oscilloscope

DTI

Department of Trade and Industry

DVM

Digital Voltmeter

EC

European Commission

ECM

Electronic Counter Measures

EEC

European Economic Community

EN

European Standard (European Normalization)

EU

European Union

GOTS

Government Off The Shelf

GUE

Generating Unit, Electric

IELT

Initial Engagement Long Transient

ISO

International Organization for Standardization

ITU

International Telecommunications Union

LISN

Line Impedance Stabilisation Network

LRU

Line Replaceable Unit

MoD

Ministry of Defence

MOTS

Military Off the Shelf

PDR

Preliminary Design Review

PE

Platform Equipment

PER

Platform Earth Reference

pk

Peak

PPDS

Platform Power Distribution System

RoHS

Restriction of Hazardous Substances

SAE

Society of Automotive Engineers

SATNAV

Satellite Navigation

SRD

Systems Requirement Document

TE

Terminal Equipment

TEPDS

Terminal Equipment Power Distribution System

TER

Terminal Earth Reference

UKAS

United Kingdom Accreditation Service


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85

DEF STAN 61-5 Part 6 Issue 6


VB

Voltage Battery

VS

Voltage Supply

Unclassified
86

DEF STAN 61-5 Part 6 Issue 6

Annex E
Cable Capacity De-Rating Factors

E.1
E.1.1
E.1.1.1

De-Rating Factors
Example Cable Calculations
Example 1

A 16mm2 cable, unbundled, with a maximum operating temperature of 150 C working at 25 C at sea level,
feeding a DCDU on a platform.
E.1.1.2

Example 2

A 16mm2 cable, unbundled, with a maximum operating temperature of 150 C working at 55 C at an altitude
of 1000m above sea level, feeding a DCDU on a platform.
E.1.1.3

Example 3

A 6mm2 cable, bundled with 6 cores, with a maximum operating temperature of 100 C working at 25 C at
sea level, feeding a DCDU on a platform.
E.1.1.4

Example 4

A 6mm2 cable, bundled with 8 cores, with a maximum operating temperature of 100 C working at 70 C at
an altitude of 3000m above sea level, feeding a DCDU on a platform.

E.1.2

Cable Calculation Method

Calculate t by subtracting the cable operating temperature from the maximum cable operating temperature.
Using the graphs in Figure 43 and Figure 44 in Annex E, the cable size and t, calculate the maximum
operating current.
Using the graph in Figure 45 in Annex E, the altitude de-rating factor can be found.
Using the graph in Figure 46 in Annex E, the number of cores de-rating factor can be found. This will
depend on the percentage loading of the cable. For the examples, 100% loading has been assumed.
The cable rating, taking into account operating temperature, altitude, number of cores de-rating is calculated
by multiplying the cable maximum operating current by the altitude and number of cores de-rating factors.
The worked examples are shown in Table 51.

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DEF STAN 61-5 Part 6 Issue 6

Table 51

Example of Cable De-Rating with Temperature, Altitude and Number of Cores

Cable Factor
Parameters

Example 1

Example 2

Example 3

Example 4

150 25

150 55

100 25

100 70

= 125 C

= 95 C

= 75 C

= 30 C

16mm2 cable and


t of 125 C =

16mm2 cable and


t of 95 C =

6mm2 cable and


t of 75 C =

6mm2 cable and


t of 30 C =

175A

150A

67A

43A

Sea Level gives a


de-rating factor =

1000m above sea


level gives a derating factor =

Sea Level gives a


de-rating factor =

3000m above sea


level gives a derating factor =

1.0 (not de-rated)

0.98

1.0 (not de-rated)

0.95

Number of cores
= 1, gives a derating factor =

Number of cores
= 1, gives a derating factor =

Number of cores
= 6, gives a derating factor =

Number of cores
= 8, gives a derating factor =

1.0 (not de-rated)

1.0 (not de-rated)

0.575

0.52

175A * 1.0 * 1.0

150A * 0.98 * 1.0

67A * 1.0 * 0.575

43A * 0.95 * 0.52

38.525A each
core

21.242A each
core

(231.15A total)

(169.936A total)

From Figure 43
or Figure 44,
cable operating
current using t

From Figure 45,


altitude de-rating
factor

From Figure 46,


number of cores
de-rating factor

Cable rating
175A

E.1.3

147A

Graphs Used To Determine De-Rating Factors

The following graphs are used to de-rate the current carrying capacity of each cable, according to these
factors:
a)

Temperature;

b)

Altitude;

c)

Number of Cores.

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88

DEF STAN 61-5 Part 6 Issue 6


0.75
K
250

0.15 0.25

0.4

0.5 0.6

1.2
1.0

1.5

2.0 2.5

5 6

Cross section of
conductor in mm2

200

Temperature Difference

150
120
100
90
80
70
60
50
40

30
25

30

35 40 45 50

60 70 80 90 100 120
Current I

150 A

240

185

150

95
107
120

85

70

50

Temperature De-Rating Graph

42

K
250

20

35

9
10

Figure 43

15

400

12

25

9 10

350

22

16

13
14

4 4.5 5

Cross section of conductor


in mm2

200

120
100
90
80
70
60
50
40

Current

Figure 44

2000

1500

1200

1000

900

800

700

600

500

450

300

250

200

150

120

90
100

80

70

60

30
50

Temperature Difference

150

Temperature De-Rating Graph

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89

DEF STAN 61-5 Part 6 Issue 6


1.0

Factor f2

0.9

0.8

0.7
5

15

10

20

30

25

Altitude m (10 )

Figure 45

Altitude De-Rating Graph

1.0

0.9

0.8

Factor f1

0.7

0.6

Percent
Loading

20

0.5

0.4
40
60
0.3
80
100
0.2
1

10

15

Figure 46

20

25
30
Number of cores in bundles

Number of Cores De-Rating Graph

Unclassified
90

35

40

45

DEF STAN 61-5 Part 6 Issue 6

Annex F
Power Critical Design Review - Example Forms

Defence Standard 61-5, Part 6, Issue 6


Platform Power Critical Design Review
Table 52

Platform Power Details

Platform Under Test:

Platform Power Critical Design Review No.:

Copy Number:

Version:

Carried Out By:

On Behalf Of:

Review Location:

Date Of Review:

Control Plan Reference:

Contract / SRD Reference:

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91

DEF STAN 61-5 Part 6 Issue 6

Originated By: ____________________________________________Date: ______________________

Concurred By (optional): ____________________________________Date: ______________________


(Signed on behalf of Test Laboratory)

Reviewed By: ____________________________________________ Date: ______________________


(Signed on behalf of Design Authority)

Authorised By: ___________________________________________ Date: ______________________


(Signed on behalf of IPT or Representative)

Unclassified
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DEF STAN 61-5 Part 6 Issue 6


Amendment & Tracking Record

F.1

Amendment Status
Amendment List

Revision
Number

F.2

Dated

Reason For
Change

Pages
Affected

Signature of
Originator

Date

Document History
Issue

F.3

Incorporated By

Dated

History

Recipient

Location / Company

Distribution List
Copy No.

Unclassified
93

DEF STAN 61-5 Part 6 Issue 6

F.4

PROJECT INFORMATION

F.4.1

Introduction

The purpose of this Platform Power Critical Design Review document is to document the parameters and
subsequent test methods required to validate the compatibility of the Platform Name against the
requirements of Defence Standard 61-5 Part 6, Issue 6 (2008).
When the Platform Power Critical Design Review is fully completed a test plan can be generated using the
information collated.

F.4.2

Review Outline/Summary

The aim of this Platform Power Critical Design Review document is to ensure that the Platform Name is
electrically fit for purpose, where it is fully capable of delivering the SRD requirements as stipulated and has
been designed with adequate capacity allowing for future equipment fitments during its active service role(s).
The overall testing strategy to be followed is detailed in the Control Plan Reference shown on the front page
of this document.

F.4.3

Contact Details

Document Originator supplied contact details are as follows:


Originator
Tel
Mobile

Test Laboratory for the programme is as follows:


Test Laboratory (optional)
Contact Name
Tel
Mobile

Design Authority for the programme is as follows:


Design Authority
Contact Name
Tel
Mobile

IPT or Representative for the programme is as follows:


IPT or Representative
Unclassified
94

DEF STAN 61-5 Part 6 Issue 6


Contact Name
Tel
Mobile

F.5
F.5.1

Documents
Reference Documents
Table 53

Reference Documents

Title

Document Reference

System Requirements Document (SRD)


Platform Control Plan
Environmental Reference

F.5.2

Defence Standard 00-35 Pt 4 Natural Environments

Platform Power Critical Design Review Document

All documents to be included within the Power Critical Design Review document:
Table 54

Platform Power Critical Design Review Documents

Title

Document Reference

Platform Wiring Schematics (Appendix A)


Platform Earthing Strategy (Appendix B)
Terminal Equipment Circuit Protection Strategy
(Appendix C)

F.6

Platform Details

The details of the type of platform to be assessed:

Unclassified
95

DEF STAN 61-5 Part 6 Issue 6

Table 55

Platform Description

Vehicle Manufacturer:

Fuel Type:

Type:

Gearbox:

Drive Type:

Body Style:

Build Level:
Platform Type (COTS, MOTS, Bespoke):
Nominal Voltage of platform (12V, 24V, Dual Voltage Systems):
Terminal Equipment Designated Load Requirement as stipulated in the SRD:
Platform Equipment Designated Load Requirement:
Exported DC Power Requirement (e.g. trailer):

F.7

Platform Working Environment

The working environment as determined from the supplied documentation and using Clause 15 of Def Stan
61-5 Part 6 for guidance:
Table 56

Platform Working Environment

Extreme Temperature

Climatic Category

Highest Temperatures
Lowest Temperatures

F.8
F.8.1

Platform and Terminal Equipment Power Distribution Systems Requirements


Platform Battery Requirements

Unclassified
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DEF STAN 61-5 Part 6 Issue 6

Table 57
Platform
Location /
Supplied
DCDU

F.8.2

Number of
Batteries
Supplying
DCDU

Platform Battery Requirements

Battery Type

Battery
Manufacturer

Capacity (Ah)

Meets the
Requirements
of Def Stan
61-25 Series

Wiring Configuration

Def Stan 61-5 Part 6 mandates the Terminal Equipment Power Distribution System to be a two wire system
(Def Stan 61-5 Part 6 Clause 10) for COTS and MOTS Platforms and permits the Platform Power
Distribution System to have a chassis return configuration. Wiring configuration guidance for Bespoke
Platforms can be found in Def Stan 61- 5 Part 6 Clause 10.3.
All components of the Terminal Equipment Power Distribution System shall be entered in to a table and
evidence provided to ensure a two wire system is maintained.
Table 58
Component

F.8.3

Two Wire System Compliance


Compliant
(Yes/No)

Comments

Cable De-Rating

Both Platform and Terminal Equipment Power Distributions system cables shall be de-rated against
environmental conditions for all types of platforms. If de-rating factors are available from the cable
manufacturer then these shall be used. In the absence of manufacturers data guidance shall be taken from
Annex E of this standard.

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97

DEF STAN 61-5 Part 6 Issue 6

Table 59

Cable De-Rating

Cable De-Rating
Cable
Type/Manufacturer

F.8.4

Purpose

Cross
Section
(mm2)

Location

Number of
Cores

Maximum
Temperature
Rating C)

Cable
Rating (A)

Platform and Terminal Equipment Power Distribution System Capacity

All parts of the PPDS (Bespoke Platforms only) and TEPDS shall be entered into Table 60 and assessed
against capacity requirements of Def Stan 61-5 Pt 6.
Table 60

Component
Capability

Platform and Terminal Equipment Power Distribution System

Capability (A)

Terminal Load
Requirement
(as stipulated
in the SRD)

Actual
Capacity

Def Stan 61-5


Pt6 Capacity
Requirement

Compliant
(Yes/No)

(A)
Example
APU

150A

75A

200%

110%

Yes

Generator

100A

100A

100%

110%

No

Generator / Source

Distribution

Earthing

NOTE 1
If the platform has only one power generation source, then the terminal load requirement shall also include
the platform load (see Clause 6.2 Platform Power Critical Design Review).
NOTE 2
When calculating cable capacity, the environmentally de-rated value of the cable shall be used. See Def
Stan 61-5 Pt6 Clause 15 for guidance.

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DEF STAN 61-5 Part 6 Issue 6

F.9

Earthing Strategy

Details of compliance and a copy of the Platform Earthing Strategy shall be stored in Appendix B for future
reference.
Table 61

Mandatory Earthing Requirements


Compliant

Requirement

Comments
(Yes/No)

Platform and the Terminal Earth Reference shall be


bonded together.
An earth terminal shall be provided on every DCDU
All earth terminals shall be labelled
Design, position, size, material, termination type
and paint clearance shall be included in the
Platform earthing Strategy Document.
Detail of protection in extreme environmental
conditions
All Terminal Equipment DCDUs have earth test
positions fitted

F.9.1

Earth Points
Table 62

Reference
Earth

Location

Size

Reference Earth Points


Material

Connection
Type

Passivated
(Yes/No)

Fault
Current
Capacity

Passivated
(Yes/No)

Fault
Current
Capacity

Platform
Terminal

Table 63
Designated
Earth Points

Location

Size

Designated Earth Points


Material

Connection
Type

Unclassified
99

DEF STAN 61-5 Part 6 Issue 6

F.10

Circuit Protection

Details of compliance and a copy of the Terminal Equipment Circuit Protection Strategy shall be stored in
Appendix C for future reference.

F.10.1

Mandatory Circuit Protection Requirements


Table 64

Mandatory Circuit Protection Requirements


Compliant
Comments

Requirement
(Yes/No)
All DCDU outlets shall be protected with circuit protection
devices.
Circuit protection devices meet environmental requirements
stipulated in section 14, i.e. required operating temperature
range as appropriate for location on the platform.
Terminal Equipment circuit protection devices can be
interchanged to incorporate higher value (current) protection.
All batteries and power generation sources are protected from
short circuit.
Multiple voltage systems (12V/24V) shall be protected from
short circuit.
All DCDU outlets shall be protected with circuit protection
devices.

F.10.2

Circuit Protection Devices


Table 65

Circuit Protection Devices

Platform Circuit Protection

Type /
Manufacture

Location

Maximum
Temperature
Of Operation
(C)

Minimum
Temperature
Of Operation
(C)

Disconnection
Time @ Fault
Current

Terminal Equipment Circuit Protection

Unclassified
100

Disconnection
Time @ 3
Times Fault
Current

DEF STAN 61-5 Part 6 Issue 6

F.11

Connections

Def Stan 61-5 recommends the use of specific connectors in Clause 11. All connectors used on the platform
and their location and technical details shall be entered into Table 66 to ensure Def Stan 61-5 requirements
are met.
Table 66

Platform Connector Details

Connection Location / DCDU


CECC 75201-002 Compliant (Yes/No)
Socket (Yes/No)
61-5 Approved Recommended (Yes/No)
Connector Identification
Protective Cap (Yes/No)
Storage For Protective Cap (Yes/No)
RoHS Compliant (Yes/No)
Deviation/Comments

F.12

Installed Equipment

All electrical / electronic equipment fitted to the platform shall be listed in Table 67 and be categorised in
accordance with Def Stan 61-5 Pt6 definitions.

F.12.1

Installed Equipment Classification and Power Budget

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DEF STAN 61-5 Part 6 Issue 6

Table 67

Installed Equipment Classification and Power Budget


Classification of Equipment Fitted

Name of
Equipment

Equipment
Nominal
Voltage

Equipment Type

Worst Case
Current
Consumption

Platform
Equipment

Equipment Status

Terminal
Equipment

Safety
Related

Mission
Related

Example
Instrument
Cluster

12V

4A

Communications
Equipment

24V

40A

F.13

Test Requirements

Guidance for deciding applicable test positions can be found in Def Stan 61-5 Pt 6 Annex A General
Requirements and in each individual test requirement.

F.13.1

Test Positions
Table 68

Test Positions

Test Position

Locations
1)

Platform Power Distribution System

2)
3)
1)

Terminal Equipment Power Distribution System

2)
3)
1)

DC Export Distribution Points

2)
3)

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DEF STAN 61-5 Part 6 Issue 6

F.14

Test Applicability
Table 69

Test Ref

Test Description

Test Applicability

Test
Applicability

Rationale If Test Is
Not Applicable

Applicable Test
Positions

(Yes/No)
DET01.A

Steady State Voltage

DET02.A

Ripple Voltage

DET03.A

Long Transients

DET04.A

Short Transients

DET05.A

Terminal Equipment Circuit


Protection

DET06.A

Terminal Equipment Voltage


Drop

DET07.A

Cranking

DET08.A

Terminal Equipment Battery


Capacity Test

DIT01.A

Platform/Terminal Earth Bond

DIT02.A

Over Voltage/Regulator
Failure

DIT03.A

Imported Ripple (20Hz


150kHz)

DIT04.A

Load Dump

F.14.1

As Earth Bond
Paths

Modes of Operation

All Platform Equipment modes of operation, fault criteria and cycle times shall be entered into the Table 70
below. The modes of operation are used during DIT02.A Over Voltage/Regulator Failure, DIT03.A Imported
Ripple (20 Hz 150 kHz) and DIT04.A Load Dump.

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DEF STAN 61-5 Part 6 Issue 6

Table 70

Modes of Operation
Mode Status

Platform
Equipment

Mode Of
Operation

Fault Criteria

Cycle Time
Safety Related

Mission
Related

Example

Turret

F.14.2

Turret shall
rotate 1
complete
rotation every
30 seconds
with barrel
elevation
remaining static

The turret shall


not increase or
decrease
rotation speed
and the barrel
shall remain
static

30 seconds

DET04.A Short Transients

Platform Equipment which has a potential of generating a Short Transient shall be entered into Table 71.
Guidance to be taken from DET04.A Short Transients found in Def Stan 61-5 Pt6 Annex A.
Table 71
Platform Equipment

Short Transient for Test

Switch To Be Used/Location

Functional Switching

Example
Wiper Motor

F.14.3

Stalk On Steering Column

Off to Full Speed

Platform/Terminal Earth Bond Path

All Earth Reference and Designated Earth points are applicable for test in DIT01.A. All earth points shall be
entered into Table 72 along with the path to its Earth Reference.

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DEF STAN 61-5 Part 6 Issue 6


Table 72
Earth Path

Earth Bond Paths


Path Route

Identified Parallel Path to be


Disconnected During Test

Example
APU to Terminal Earth Reference

Earth Cable Chassis


Terminal Earth Reference

APU negative output

Equipment Racks to Terminal


Earth Reference

Equipment Rack Chassis


Terminal Earth Reference

N/A No parallel paths identified

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DEF STAN 61-5 Part 6 Issue 6

APPENDIX A
Platform Wiring Schematics

APPENDIX B
Earthing Compliance Data Platform Earthing Strategy

APPENDIX C
Terminal Equipment Protection Compliance Data Platform Circuit Protection Strategy

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DEF STAN 61-5 Part 6 Issue 6

Annex G
Platform and Terminal Equipment Power Critical Design Review Example Documents

G.1

Equipment Details

Table 73

Platform and Terminal Equipment Power Critical Design Review - Equipment Details

Equipment Under Test:

Platform and Terminal Equipment Power Critical


Design Review No.:

Copy Number:

Version:

Carried Out By:

Equipment Manufacturer:

Review Location:

Date Of Review:

Originated By: ___________________________________________________Date: ______________

Concurred By (optional): ___________________________________________Date: ______________


(Signed on behalf of Test Laboratory)
Reviewed By: ___________________________________________________Date: ______________
(Signed on behalf of Equipment Manufacturer)

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DEF STAN 61-5 Part 6 Issue 6

G.2

Amendment Status
Amendment List

Revision
Number

G.3

Dated

Reason For
Change

Pages
Affected

Date

Dated

History

Recipient

Location / Company

Distribution List
Copy No.

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Signature of
Originator

Document History
Issue

G.4

Incorporated By

DEF STAN 61-5 Part 6 Issue 6

G.5

Introduction

The purpose of this Power Critical Design Review document is to document the parameters and subsequent
test methods required to validate the compatibility of the Equipment Name against the requirements of
Defence Standard 61-5 Part 6, Issue 6 (2008).
When the Platform and Terminal Equipment Power Critical Design Review is fully completed, a Test Plan
can be generated using the information collated.

G.6

Contact Details

Document Originator supplied contact details are as follows:


Originator
Tel
Mobile

Test Laboratory for the programme is as follows:


Test Laboratory (optional)
Contact Name
Tel
Mobile

Equipment Manufacturer for the programme is as follows:


Equipment Manufacturer
Contact Name
Tel
Mobile

G.7
G.7.1

Documents
Reference Documents

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DEF STAN 61-5 Part 6 Issue 6

Table 74

Platform and Terminal Equipment Power Critical Design Review - Reference Documents
Title

Document Reference

Environmental Reference

Defence Standard 00-35 Pt 4 Natural Environments

Test Equipment

ISO 7637-2 2004 Electrical Transient Conduction


Along Supply Lines Only

G.7.2

Platform and Terminal Equipment Power Critical Design Review Documents

All documents to be included within the Power Critical Design Review document.
Table 75

Platform and Terminal Equipment Power Critical Design Review Documents


Title

Document Reference

Wiring Schematics (Appendix A)


Earthing Strategy (Appendix B)
Circuit Protection Strategy (Appendix C)
Installation Instructions (Appendix D)

G.8

Platform or Terminal Equipment Details

The details of the type of platform to be assessed:


Table 76

Platform and Terminal Equipment Power Critical Design Review - Platform Description

Equipment Manufacturer:
Equipment Description and Function:
Build Level:
Intended Platform of Operation:
Equipment Type (Platform or Terminal):
Nominal Voltage of Equipment (12V, 24V):
Maximum Rated Current:
Mode of Operation Which Requires Maximum Rated Current (worst case mode):

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DEF STAN 61-5 Part 6 Issue 6

G.9

Platform and Terminal Equipment Working Environment

The working environment as determined from the supplied documentation and using Clause 15 of Def Stan
61-5 Pt 6 for guidance:

Table 77

Platform and Terminal Equipment Working Environment

Extreme Temperature

Climatic Category

Highest Temperatures
Lowest Temperatures

NOTE
If the Platform or Terminal Equipment has been designed for different platforms then worst case
environmental categories shall apply (A1 and C4).

G.10
G.10.1

Platform and Terminal Equipment Design Requirements


Platform and Terminal Equipment Design Requirements
Table 78

Equipment
Maximum
Working
Voltage (V)

Equipment
Minimum
Working
Voltage (V)

Design Requirements

Isolation Switch
Fitted

Earth Bond
Position

Earth Bond
Current
Capacity

Two Wire
System
Compatible

NOTE

* indicates this requirement is only applicable to Terminal Equipment only.

G.10.2

Isolation Switch

Def Stan 61-5 Pt6 will accept Terminal Equipment without an isolation switch with approved rationale. Enter
rationale in the area provided.

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DEF STAN 61-5 Part 6 Issue 6

G.11

Connectors

Def Stan 61-5 recommends the use of specific connectors. All connectors used for the equipments primary
power and technical details shall be entered into Table 79, to ensure Def Stan 61-5 requirements are met.
Table 79

Connectors

Connection Location / DCDU


CECC 75201-002 Compliant (Yes/No)
Socket (Yes/No)
61-5 Approved Connector (Yes/No)
Connector Identification
Protective Cap (Yes/No)
Storage for protective cap (Yes/No)
RoHS Compliant (Yes/No)
Deviation / Comments

G.12

Test Requirements

Guidance for deciding applicable test positions can be found in Def Stan 61-5 Pt 6 Annex B General
Requirements and in each individual test requirement.

G.12.1

Test Applicability

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DEF STAN 61-5 Part 6 Issue 6

Table 80

Test Applicability
Test Applicability

Test Ref

Test Description
(Yes/No)

DET01.B

Ripple (20Hz 150kHz)

DET02.B

Exported Transients

DET03.B

Maximum Inrush Current

DIT01.B

Positive Supply Isolation Test

DIT02.B

Earth Bonding

DIT03.B

Negative/Earth Bond Isolation

DIT04.B

Cranking

DIT05.B

Reverse Voltage

DIT06.B

Under and Over Voltage

DIT07.B

Short Transients

DIT08.B

Load Dump

G.12.2

Rationale if Test is not


applicable

Modes of Operation

Equipment modes of operation, fault criteria and cycle times shall be entered into the Table 81 below. The
modes of operation are used during DIT03.B Negative/Earth Bond Isolation, DIT04.B Cranking, DIT06.B
Under and Over Voltage and DIT07.B Load Dump.
Table 81
Mode of Operation

Modes of Operation

Pass/Fail Criteria

Cycle Time

Support Equipment
Description and Function

Example
Radio shall transmit a
carrier wave of 34MHz

The carrier wave shall


not deviate by 1kHz and
0.5dBm

2 seconds

10W 50 Load to simulate


antenna

NOTE
Some equipment may require to be tested in more than one mode of operation to ensure all functions of the
equipment are fully tested.

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DEF STAN 61-5 Part 6 Issue 6


G.12.3

Harness and Connection Details

Ideally actual cable-forms shall be used for test but in the absence of actual cable-forms, interconnecting
cable-forms shall whenever possible be of length, type and layout representative of the practical installation;
Table 82

Test Earth Bond Paths

Cable Form Specifics

Cable Form Requirement

Connector Type
Cable Size
Cable Maximum Working Temperature
Cable Layout (twisted pair)
Earth Bond Size and Length

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DEF STAN 61-5 Part 6 Issue 6

APPENDIX A
Wiring Schematics

APPENDIX B
Earthing Strategy

APPENDIX C
Terminal Equipment Protection Compliance Data Circuit Protection Strategy

Appendix D
Installation Instructions

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Crown Copyright 2009

Copying Only as Agreed with DStan

Defence Standards are Published by and Obtainable from:

Defence Equipment & Support


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GLASGOW G2 8EX

DStan Helpdesk

Tel 0141 224 2531/2


Fax 0141 224 2503
Internet e-mail enquiries@dstan.mod.uk

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The DStan file reference relating to work on this standard is D/DSTAN/61/5.
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application and for complying with contractual and statutory requirements. Compliance with a Defence
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Defence Standards are revised as necessary by an up issue or amendment. It is important that users
of Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk,
updated weekly and supplemented regularly by Standards in Defence News (SID News). Any person
who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to
notify UK Defence Standardization (DStan) without delay in order that the matter may be investigated
and appropriate action taken.