Mobile Electric Power Distribution - Replacement (MEPDIS-R) And Related .

PROGRAM MANAGEREXPEDITIONARY POWER SYSTEMSMARINE CORPS SYSTEMS COMMANDMobile Electric PowerDistribution – Replacement(MEPDIS-R)and Related SystemsMSgt Fred McCueProject Officer - Mobile Power Teamfred.mccue@usmc.mil1

Somewhere in Iraq .2

Agenda Overview of projects– MEPDIS-R– Field Wiring Harness– Tent Lights– Field Food Service Buss Duct Future roadmap Questions3

Current USMC MEPDIS Fielded in early 1980’s / Fabricated by FPI 3 size panels 4 15 kW – TAMCN B59530 kW – TAMCN B600100 KW – TAMCN B605Single power inputs60 & 400 Hz compatible10 wire sets issued with systemAmphenol military connectors

Field Wiring Harness5Used for Tent lighting and general electrical hook-ups12 different wire assemblies light bulbsWeight: 764 lbs. / Cube: 32 ft3TAMCN: B0608

MEPDIS-RMEPDIS-R will replace current MEPDIS (B0595, B0600, B0605)and Field Wiring Harness (B0608)6

MEPDIS-R Replaces functionality of MEPDIS and the Field WiringHarness (FWH) when used with new tent lights. System composed of six different types of powerdistribution panels, each with associated cables andaccessories. Compatible with MEPDIS and existing equipment Based on commercial components and technology7

System RoadmapMEPDISMEPDIS-RFWHFFSBDTENTLIGHTSNote that MEPDIS, FWH, and FFSBD are interoperable with MEPDIS-Rand will remain in service for the near future.8

MEPDIS-R Evaluation Competed to industry based on performancespecifications and established interfaces – 2005 Lex Products selected – 2005 System extensively tested – 2005/06– Environmental testing (Aberdeen)– Electrical performance testing (Aberdeen, MET)– Durability testing (Aberdeen)– Field user evaluation (CLNC)9

MEPDIS-R Compatibility (LUE)100 kW15 kW30 kW10

MEPDIS-R Power Panels5 kW Indoor5 kWOutdoor30 kW11100 kW15 kW300 kW100 kW

5 Kilowatt Power Panels5 Kilowatt Outdoor Non-GFCI Protected Power Panel Input:– 5 wire, 3-phase, 30 amp IEC 309 Pin & Sleeve Output:– 6 each: 3 wire, 1-phase, 20 amps IEC 309– 3 each: 3 wire, 1-phase, 30 amps IEC 309 Cords:– 6 each: cord sets, 50 ft. each in length with 4 each, 5-15R receptacles Connectors:– (3) HBL330P4W 30A 1ø 2P 3W 120 VAC IEC309 Pin & Sleeve Plugs5 Kilowatt Indoor GFCI Protected Power Panel Input:– 5 wire, 3-phase, 30 amp IEC 309 Pin & Sleeve Output:– 9 each: 3 wire, 1-phase, 120 VAC 20A GFCI Duplex Receptacles Cords:– 6 each: cord sets, 50 ft. each in length with 4 each, 15R receptacles12

15/30 Kilowatt Power Panels15 Kilowatt Power Panel Input:– Circuit Breaker Protection– 2 each: 5 wire, 3-phase, 60 amp IEC 309 Pin & Sleeve Output:– 4 each: 5 wire, 3-phase, 30 amp IEC 309 Pin & Sleeve– 4 each: 3 wire, 1-phase, 20 amp IEC 309 Pin & Sleeve– 1 each: 3 wire, 1-phase, 120 VAC 20A GFCI Duplex Receptacle30 Kilowatt Power Panel Input:– Circuit Breaker Protection– 2 each: 5 wire, 3-phase, 100 amp IEC 309 Pin & Sleeve Output:– 4 each: 5 wire, 3-phase, 60 amp IEC 309 Pin & Sleeve– 2 each: 5 wire, 3-phase, 30 amp IEC 309 Pin & Sleeve– 2 each: 5 wire, 3-phase, 20 amp IEC 309 Pin & Sleeve– 2 each: 3 wire, 1-phase, 20 amp IEC 309 Pin & Sleeve– 1 each: 3 wire, 1-phase, 120 VAC 20A GFCI Duplex Receptacle13

100 Kilowatt Power Panel Input:– 400 Amp Switch Protection, 2 each,– Cam Style, 5 wire Output:– 1 each: Cam Type, 200 Amp, 5 wire connection– 4 each: 5 wire, 3-phase, 100 amp IEC 309 Pin & Sleeve– 2 each: 5 wire, 3-phase, 60 amp IEC 309 Pin & Sleeve– 2 each: 5 wire, 3-phase, 30 amp IEC 309 Pin & Sleeve– 2 each: 5 wire, 3-phase, 20 amp IEC 309 Pin & Sleeve– 2 each: 3 wire, 1-phase, 20 amp IEC 309 Pin & Sleeve– 1 each: 3 wire, 1-phase, 120 VAC 20A GFCI Duplex Receptacle14

300 Kilowatt Power Panel Input:– 400 Switch Protection– 3 each Cam Style, 5 wire Output:– 2 each: Cam Style, 400 Amp, 5 wire connection– 2 each: 5 wire, 3-phase, 100 amp IEC 309 Pin & Sleeve– 1 each: 3 wire, 1-phase, 120 VAC 20A GFCI DuplexReceptacle15

MEPDIS-R Cabling50' 60A INPUT CABLEPIGTAIL 15KWNSN: 6150-01-529-73681650' 100A CABLE JUMP100KW-30KWNSN: 6150-01-529-880650' 100A INPUT CABLEPIGTAIL 30KWNSN: 6150-01-529-88035KW OUTDOOR CORDSET ONLYNSN: 6150-01-530-735250' 30A CABLE JUMP15KW-5KWNSN: 6150-01-529-84285KW INDOOR CORD SETONLYNSN: 6150-01-530-1960

MEPDIS-R Cabling50' 60A CABLE JUMP30KW-15KWNSN: 6150-01-529-7674Adapter, 100ACommercial - Mil StdNSN: 6150-01-529-84241725' 400A (5) Wire Feeder SetNSN: 6150-01-529-7900Adapter, 100A Mil Std CommercialNSN: 6150-01-529-7698Y-cable with 50 foot extensionNSN: 6150-01-540-3519Adapter, 60A Mil Std CommercialNSN: 6150-01-529-8063

USMC Future Direction USMC is moving away from Military Style connectors:– High Cost– Long Lead time– Cables for backward compatibility are part of MEPDIS-R family Commercial Connectors:––––––Fully meet electrical and environmental requirementsReadily available from industrial supply stores worldwideMuch cheaper than current Mil ConnectorsRapid assembly and repairWaterproof connection for wet locationsSeparate Ground from Neutral, 3-wire 1-phase, 5-wire 3-phase Industry standards based on voltage and current18– IEC 309 is standard being followed– Recently renamed to IEC 60309

AC Connectors AC connectors are of two types– Large power Single Pole– Small power Multi Pole (3 to 5 wire) Less than 125 AMPS Pin & Sleeve Connectors19

IEC “P” & “S” Features Provides maximum protection from abuse andenvironment Heavy-wall molding resists impact, heat, flame andchemicals Superior performance in low-to-high ambienttemperatures (-40oC to 60oC) Excellent UV stability for outdoor performance(UL 1682)20 V-O flammability rating Fully insulated Color coded by voltage for easy identification

Cam Loc Connectors21

Cam Loc Type 16 Connectors These are single conductor connectors Come in two sizes– 2-0 cables– 4-0 to 1-0 cablesTheThe connectorconnector mustmust bebe twistedtwisted 180180degreesdegrees uponupon insertion,insertion, oror theythey cancanoverheatoverheat22

Cam Loc Benefits & Features23 Inter-mateable and compatible with competitive cam-type products – can beretrofitted to existing locations and power distribution systems Locking and reinforcing ring won’t melt, break, or crack Shatter and crack-proof – high durometer thermoplastic elastomer (TPE) orneoprene rubber Color coded insulating sleeves – fast and easy phase ID Prevents arching or burning – no movement of contact surfaces Self-compensating for wear – slit and cam in male contact provides springaction for longer usage Quick connect/disconnect – twist and pull provided by double cam male andcam-button in female High conductivity, positive, vibration proof connection Meet most NEC requirements, are UL listed, NEMA 3R rated (rainproof) foroutdoor use

Form Factors24

Tent Lights New tent systems will include florescent tent lights (C3409) aspart of the tent. Lights are available to retrofit older tents. Power distribution systems (5 kW indoor) will power the tentlights, and will provide the power outlets inside the tent.25

Field Food Service Buss Duct FFSBD (C0200) is a 300 KW power distribution panelthat allows paralleling of up to three 60 kW or 100 kWgenerators Fielded as part of the Field Food Service Kitchen (FFSK)26 Will remain in service, but new purchases will be ofMEPDIS-R 300 kW panel (B0032)

PROGRAM MANAGEREXPEDITIONARY POWER SYSTEMSMARINE CORPS SYSTEMS COMMANDQuestions ?27

PROGRAM MANAGEREXPEDITIONARY POWER SYSTEMSMARINE CORPS SYSTEMS COMMANDBackup Slides28

3 phaseUSMC stdconnectors29Single phase

Key Design Elements30

ReceptaclePart #Inlet Part #PlugPart #ConnectorPart #1P 3W15Yellow316R4W316B4W316P4W316C4W1P 3W20Yellow320R4W320B4W320P4W320C4W1P e5100R9W5100B9W5100P9W5100C9W1Phase 3 wire100-130V3 Phase 5 wire120/208 V31

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Cam Type Specs33

Male and Female Designs34

DC Connectors Types of DC power distribution connectors– High Power Cam Loc Same as AC Different Color Code– Medium power - NATO Slave– Low Power 5-40 VDC, up to 30 Amps Efforts still in progress to continue defining models / classes PM EPS is working to standardize for commonalityacross future items to be fielded35

NATO Connector - Medium36

DC Power - LowPossible Power Sources Vehicle PowerSolar Power AdaptorsBatteriesFuel CellsPower SuppliesDC generatorInputOutput (multiple)Possible Power Consumers37 RadiosSensorsComputersBattery ChargersPersonal items

Cabling Moving to standardize on SEOOW Cable– S – 600 Volt Thermoset service cord– E – Elastomer compound– O – Oil resistant inner conductor insulation– O – Oil resistant outer jacket– W – Outdoor, harsh, industrial environment Balance between the weight concerns and performanceneeds Suitable for full spectrum environmental profile Description sheet provided on conference CD38

Sample Cabling Specification39

MEPDIS-R NomenclatureTAMCNNOMENCLATUREB00275 kW Indoor MEPDIS-R panelB00285 kW Outdoor MEPDIS-R panelB002915 kW MEPDIS-R panelB003030 kW MEPDIS-R panelB0031100 kW MEPDIS-R panelB0032300 kW MEPDIS-R panelPanels include input and output cables, cable reels, and other items.40

MEPDIS-R Cable ReelsLarge and Small model41Stackable (anti-slip lugs welded)

Fielding Plan MEPDIS-R panels are not a one-to-one replacement forMEPDIS panels. Allowances appear by MEPDIS-R panel TAMCN. Unit allowances determined by capability. Plan is to field to individual units, vice MEF IIP. MEPDIS and Field Wiring Harness (FWH) will remain inservice for near future.42

Fielding Schedule3RD QTR FY07 FIELDINGMEFUNIT5 KW O5 KW I15 KW30 KW100 KW300 KWI MEF7TH ESB502512842I MEF9TH COMM30157882BICMPS-180401628844TH QTR FY07 FIELDING5 KW O435 KW I15 KW30 KW100 KW300 KWIII MEF9TH ESB502512842III MEF7TH COMM20105842IV MEF6TH ESB502512842IV MEF6TH COMM30157882

Fielding Schedule1ST QTR FY08 FIELDING5 KW O445 KW I15 KW30 KW100 KW300 KWII MEF8TH ESB502512842II MEF8TH COMM30157842II MEFMWSS 27132168642II MEFMWSS 27232168642II MEFMWSS 27332168642II MEFMWSS 27432168642I MEFMWSS 37132168642I MEFMWSS 37232168642I MEFMWSS 37332168642I MEFMWSS 37432168642III MEFMWSS 17132168642III MEFMWSS 17232168642IV MEFMWSS 47132168642IV MEFMWSS 47232168642IV MEFMWSS 47332168642

Fielding Schedule2ND QTR FY08 FIELDING5 KW O455 KW I15 KW30 KW100 KW300 KWI MEF1ST CEB20105420II MEF2ND CEB20105420III MEF3RD CAB402010420IV MEF4TH CEB20105420

Fielding Issues MEPDIS-R is a significant improvement over MEPDIS and isfully compatible with it. 7th ESBn & 9th CommBn will receive MEPDIS-R in June 2007 MWSSs will receive MEPDIS-R Oct 2007. 1st CEB will receive MEPDIS-R Feb 2008. All shipments will be direct to unit, not IIP, Retain MEPDIS until no longer serviceable. NET to be conducted by Talmadge Jackson, FSR.46

IF NOTHING ELSE,REMEMBER THIS: MEPDIS-R will complement MEPDIS. Retain MEPDIS until no longer serviceable. Call the Project Officer or FSR if you need help.47

2 each: 5 wire, 3-phase, 100 amp IEC 309 Pin & Sleeve Output: - 4 each: 5 wire, 3-phase, 60 amp IEC 309 Pin & Sleeve - 2 each: 5 wire, 3-phase, 30 amp IEC 309 Pin & Sleeve - 2 each: 5 wire, 3-phase, 20 amp IEC 309 Pin & Sleeve - . Cam Loc Benefits & Features Inter-mateable and compatible with competitive cam-type products .