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MILSPEC Alternators
Starting out with just one client, our first product was our 100A alternator. From there we have worked hard to become the premier designer and manufacturer of brushless alternators and portable power systems for defence forces across the world, offering an extensive range of alternators from 120 - 900 amps. With over 15,000 Milspec alternators in the Australian Defence Force alone, this is a testament to our ability to consistently delivery quality, on-time products, with a commitment to continuous development.
History & Quality
Welding Technology Institute of Australia
ISO 3834 Part 2Certifi cate No. AU 024
THA
LES Bushm
aster
NAVISTA
R Husky
Contents
Permanent Magnet Alternators............................................................................................4 450A Water Cooled Alternator.................................................................................................. 6 900A Water Cooled Alternator.................................................................................................. 8
Inductor Alternators.............................................................................................................10 120A Air Cooled Alternator...................................................................................... .................12 300A Air Cooled Alternator Case Study.................................................................................13 300A Air Cooled Alternator..................................................................................................... 14 360A Water Cooled Alternator..................................................................................................15 360A Air Cooled Alternator...................................................................................................... 16
Portable Power................................................................................................................... 17
BAE M
113
44
Permanent Magnet vs Inductor Inductor alternator technology is a synchronous arrangement in which the output windings and field windings both reside within the stator. The Magnetic flux is produced by introducing a DC voltage into the static field coils. An AC voltage is then generated within the output windings as the toothed rotor periodically passes through the magnetic field. Inductor alternators are a staple in military power generation due to the conformance to EMC standards and high reliability achieved by having no electrical connections to the rotor.
However, the technology has performance limitations in efficiency and power output response. A typical output graph shows a relationship between the engine RPM and output. The trend shows minimal output at idle and maximum current output is only achieved with a significantly increased RPM. Often modifications are required to elevate the engine idle to boost the alternator output level to reach the minimum requirement.
This limitation in performance has driven the need for better technology, where maximum electrical output can be attained at engine idle. Technology that supports the need for an ever increasing demand for power and zero compromise for safety with the ability to run all electrical systems, all the time.
Permanent magnet power generation is the technology that excels and future proofs the electrical supply demand.
The power in this instance is created as the rotor’s permanent magnetic fields transfer through the static output windings. The fixed magnetic field strength does not require excitement and thus a superior output can be achieved at a lower RPM. Milspec Engineering and university lead research has developed patent pending technology to solve the variable speed AC regulation where other have failed. The high reliability of the system is sustained by maintaining no electrical connections to the rotor and through the expertise of 30 years of Alternator development.
Milspec’s range of 28V Permanent Magnet Alternators generate in excess of 450A (12kW) at engine idle.
Engine Idle
900A
450A
300A
RPM
Am
ps
55
900A Inductor Alternator
900A Permanent MagnetAlternator22
0mm45
0mm
450A Inductor Alternator
450A Permanent MagnetAlternator
380m
m
220m
m
300A Inductor Alternator20
0mm
Specifications Units Alternators
Model 300A Air Cooled 450A Water Cooled 900A Water Cooled
Type Brushless Brushless Brushless
Cut in Speed (rpm) RPM 1700 1500 1500
Max Output Amps 300 450 900
Max Continuous Output #1 Amps 285 450 900
Weight KG 24 38 76
Voltage Regulation Volts 28.3 14-30 Programmable 14-30 Programmable
Ambient Operating Temp Celsius -15°C to +92°C -40°C to +105°C
Maximum Rotor Speed RPM 13000 10000 10000
Mounting Specific SAE J 180 Custom Custom#1 Coolant Temperature Dependent
6
450A Water Cooled Alternator
Brushless design.
Meets military standards Mil STD 461, Mil STD 810 and Mil STD 1275.
Compact and reliable, weighing 38kg.
Long service life 11,000+ hours.
Designed for the harshest environments from sub-zero temperatures to desert climates.
Alternator output available from 1500RPM.
Maximum current output 450 Amps.
Factory configurable voltage and current limits.
Maximum operating speed - 10,000RPM.
Engine idle output of 450 Amps.
CAN J-1939 interface.
Specifications
Part Number: 450A-000-001
Type Brushless Permanent Magnet
Cut in Speed 1500 RPM (Alternator)
Maximum Output 450 Amps
Weight 38 Kg
Voltage Regulator Programmable, typical 28.3 Volts
Voltage Range 14 - 30 Volts DC
Operating Ambient Temperature -40° to 105 °C
Maximum Rotor Speed 10,000 RPM
Regulator Unit Integrated, Solid State.
Max Continuous Output #1 450A
Mounting Custom
Ignition Warning Light Yes
Electrical Connection M16 (+ve), M12 (-ve)
Cooling Water Cooled
Coolant Temperature -40° to +85 °C
Coolant Flow Rate >3 litres /min#1 Coolant Temperature Dependent
7
308
150
187275
Alternator Performance Curve
0
50
100
150
200
250
300
350
400
450
500
1500 2000 2500 3000 3500 4000 4500+
Amps
RPM
450A
450A
Customisable mounting and form factor
8
3°
6x 9
105
60.2°
6X 60°Ø200 pcd
A
B
2 x 8.5 24.5M10 - 6H 20 10.1 X 90°, Near Side
100
VIEW B
277
551
87 87
68.
5
4 x 14.5 36.5M16x1.5 - 6H 32
22
0
329
VIEW A3.0°
OUTLET 2INLET 2OUTLET 1INLET 1
284
558
85
24
.6
56
6
16
0 H9
/f8
DIN 5480 - W25X2X11X7K
M16 POSITIVE TERMINAL 1 M16 POSITIVE TERMINAL 2
M12 NEGATIVE TERMINAL 1 M12 NEGATIVE TERMINAL 2
GROUND CONNECTION: 5 12
M6 - 6H 10
87.
8
100
150
30
214
R112.5
26°
145
X2 - CANVG95912 B 10-35SN
X1 - SENSEVG95234 B1 14S-6SN
TECHNICAL DATAVOLTAGE: CURRENT MAX : SPEED MAX: COOLANT TEMPERATURE:COOLANT FLOW RATE:
28V900A10000 RPM85° MAX6 L/MIN (2 *3 L/MIN) MINIMUM
2X
A - AWIC - SENSE
X1
1 - CAN H2 - CAN L3 - CAN GND.X2
(+)
(-)
REG
SCHEMATIC
900A Water Cooled Alternator
Brushless design.
Meets military standards Mil STD 461, Mil STD 810 and Mil STD 1275.
Compact and reliable, weighing 76kg.
Long service life 11,000+ hours.
Designed for the harshest environments from sub-zero temperatures to desert climates.
Alternator output available from 1500RPM.
Maximum current output 900 Amps.
Factory configurable voltage and current limits.
Maximum operating speed 10,000RPM.
Engine idle output of 900 amps.
CAN J-1939 interface.
900A Water Cooled Alternator
Specifications
Part Number: 900A-000-001
Type Brushless Permanent Magnet
Cut in Speed 1500 RPM (Alternator)
Maximum Output 900 Amps
Weight 76 Kg
Voltage Regulator Programmable, typical 28.8 Volts
Voltage Range 14 - 30 Volts DC
Operating Ambient Temperature -40° to 105 °C
Maximum Rotor Speed 10,000 RPM
Regulator Unit Integrated, Solid State.
Max Continuous Output #1 900A
Mounting Custom
Ignition Warning Light Yes
Electrical Connection 2x M16 (+), 2x M12 (-)
Cooling Water Cooled
Coolant Temperature -40° to +85 °C
Coolant Flow Rate >6 litres /min (2x 3 litres / min)
900A Water Cooled Alternator
#1 Coolant Temperature Dependent
9
3°
6x 9
105
60.2°
6X 60°Ø200 pcd
A
B
2 x 8.5 24.5M10 - 6H 20 10.1 X 90°, Near Side
100
VIEW B
277
551
87 87
68.
5
4 x 14.5 36.5M16x1.5 - 6H 32
22
0
329
VIEW A3.0°
OUTLET 2INLET 2OUTLET 1INLET 1
284
558
85
24
.6
56
6
16
0 H9
/f8
DIN 5480 - W25X2X11X7K
M16 POSITIVE TERMINAL 1 M16 POSITIVE TERMINAL 2
M12 NEGATIVE TERMINAL 1 M12 NEGATIVE TERMINAL 2
GROUND CONNECTION: 5 12
M6 - 6H 10
87.
8
100
150
30
214
R112.5
26°
145
X2 - CANVG95912 B 10-35SN
X1 - SENSEVG95234 B1 14S-6SN
TECHNICAL DATAVOLTAGE: CURRENT MAX : SPEED MAX: COOLANT TEMPERATURE:COOLANT FLOW RATE:
28V900A10000 RPM85° MAX6 L/MIN (2 *3 L/MIN) MINIMUM
2X
A - AWIC - SENSE
X1
1 - CAN H2 - CAN L3 - CAN GND.X2
(+)
(-)
REG
SCHEMATIC
Alternator Performance Curve
0
100
200
300
400
500
600
700
800
900
1000
1500 2000 2500 3000 3500 4000 4500+
Amps
RPM
900A
900A
Customisable mounting and form factor
1010
Inductor Alternators
Milspec formed in April 2002 as a result of a management buyout of Australian Defence Industries Live Fire Target Systems design & manufacturing capability. As part of this management buyout Milspec gained the IP for a number of military grade alternators that were developed in conjunction with the US, Canadian and UK defence forces as part of a collaborative partnership to minimise vehicle component variations. Australia has been involved in the seamless production of military grade alternators since the 1970’s.
From those early days Milspec have taken that base line technology and developed a full range of alternators for military vehicles. Today Milspec offers a range of inductor alternators from 120 amps to 360 amps.
The development of stator winding technology and electro-magnet strength has allowed Milspec to create market leading alternators delivering world class output/kg and output/cubic meter. This performance from our inductor alternator range is replicated and enhanced through our complete range of permanent magnet alternators.
Compliant to:
• Mil STD 461: electro-magnetic defence capability standard.• Mil STD 810: environmental military standard.• Mil STD 1275: voltage capability standard for military vehicles.
If you require 120-360 amps at vehicle idle Milspec has the solution!
1111
Specifications Units Alternators
Model 120A Air Cooled 300A Air Cooled 360A Air Cooled 360A Water Cooled
Type Brushless Brushless Brushless Brushless
Cut in Speed (rpm) RPM 1665 1650 1600 1600
Max Output Amps 120 300 360 360
Max Continuous Output Amps 120 280 320 340 #1
Weight KG 24 24 32 27
Voltage Regulation Volts 28.4 28.3 28.6 28.6
Ambient Operating Temp Celsius -15°C to +92°C
Maximum Rotor Speed RPM 13000 13000 13000 12000
Mounting Specific SAE J 180 SAE J 180 SAE J 180 Clamp
#1 Coolant Temperature Dependent
0
50
100
150
200
250
300
350
400
2000 3000 4000 5000 6000 7000 7500+
Amps
RPM
120A
300A
360A WC & AC
Alternator Performance Curves
12
120A Air Cooled Alternator
Milspec’s most successful alternator with over 15,000 in service. Commissioned on the Unimog and Landrover vehicles, this unit remains available for replacement parts. This air cooled alternator has been modified from its original 100 amp output to now deliver 120 amps while maintaining its original diameter. Milspec’s engineers will work with you and your team to configure your engine in 3D CAD to align the unit to your vehicle requirements.
Specifications
Part Number: 120A-AC-001
Type Inductor Alternator
Cut in Speed 1665
Maximum Output 120A
Weight 24kg
Voltage Regulator 28.4 V
Voltage Range 26 - 30 V
Operating Ambient Temperature -40 - 93 C
Maximum Rotor Speed 13000 RPM
Regulator Unit Integrated, Solid State.
Max Continuous Output 120 A
Mounting SAE J 180
Ignition Warning Light Optional
Electrical Connection M12 +ve, M10 -ve
Cooling Air Cooled
13
In 2004 Milspec was approached by Thales to develop a 300A alternator for the Bushmaster vehicle to replace the current 100A unit.
Working closely with Thales, our alternator was designed and developed around exact requirements. Trials were conducted in the vehicle for EMC, temperature and reliability, proving that we were able to design and develop an alternator that fit into the confines available, our alternator was selected for the highly successful Bushmaster vehicle.
Given the success of our alternator in the Bushmaster, Navistar assessed our unit during the process of identifying a suitable alternator for their Husky vehicle. Navistar found that our unit was the worlds smallest military spec alternator in their capacity range. Our 300A alternator was selected by Navistar to be installed in their Husky vehicle.
Our 300A alternator is now in service with at least a dozen armed forces worldwide, with more than 1000 units of different variants in service in the Australian Defence Force.
The success of our 300A alternator has allowed us to develop our range of permanent magnet and inductor alternators to extend up to a 900A alternator. Contact Milspec today to see how we can work with you to develop an alternator to suit your needs.
300A Alternator Case Study
14
300A Air Cooled Alternator
The Milspec 300A alternator has been in use in both Australian and International Defence Forces, and is currently installed and in service on the highly successful Thales Bushmaster and Navistar Husky vehicles. Manufactured and tested in-house to meet standards Mil STD 461, Mil STD 810, and Mil STD 1275, our alternators are lighter than competitors and feature a double seal on the ball bearing, increasing the life span to 11,000hrs.
Specifications
Part Number: 930213-300
Type Inductor Alternator
Cut in Speed 1700
Maximum Output 300A
Weight 24kg
Voltage Regulator 28.6 V
Voltage Range 26 - 30 V
Operating Ambient Temperature -40 - 93 C
Maximum Rotor Speed 13,000 RPM
Regulator Unit Integrated, Solid State.
Max Continuous Output 280 A
Mounting J-180
Ignition Warning Light Optional
Electrical Connection M12 +ve, M10 -ve
Cooling Air Cooled
15
Our 360A water cooled alternator allows the retrofit of an existing water-cooled system to the high output Milspec 360 amp unit. The technology has evolved from our highly reliable 300A air cooled unit. The fully sealed water jacket allows this unit to run up to 360 Amps with a maximum water inlet temperature of 95 degrees celsius. Using SAE J180 vehicle mount system this unit is compatible with multiple military vehicle applications. Milspec will work with you and your team to configure your Engine in 3D CAD models to align the unit to your vehicle requirements.
360A Water Cooled Alternator
3RD ANGLE PROJECTION
203.20
157 PCD
68.60 339.80
30.70
8
M10
M12
VG95234
REV. DESCRIPTION EN DATE AUTHOR APPROVED01 *** FIRST DRAFT - DO NOT USE FOR PRODUCTION *** -
A
B
D
E
F
C
1 2 4 5 63
F
D
E
C
B
A
UNLESS OTHERWISE SPECIFIED:TOLERANCES
LINEAR HOLE ANGULAR ±0.4 +0.2\-0.0 ±1.0°
SHEETSIZEA3
SCALE 1:2
Milspec Manufacturing Pty Ltd.161-169 Fallon Street, Albury, NSW 2640, Australia.Telephone: (02) 6022 7100. Facsimile:(02)6040 9866.www.milspec-manufacturing.comACN 100 161 582.
© 5.5.05 MILSPEC MANUFACTURING PTY LTD OWNS THE COPYRIGHT TO THISDRAWING WHICH IS ITS EXCLUSIVE PROPERTY AND WHICH IS SUPPLIEDIN CONFIDENCE AND WHICH MUST NOT BE USED FOR ANY PURPOSEOTHER THAN THAT EXPRESSLY PERMITTED IN WRITING BY THE OWNERSAND MUST NOT BE DISCLOSED OR PRODUCED WITHOUT PERMISSION FROMTHE OWNERS IN WRITING. THIS DRAWING MUST BE RETURNED TO THEOWNERS WHEN THE PURPOSE FOR WHICH IT IS SUPPLIED HAS CEASED.
CAT No.360A Water CooledSHEET 1 OF 1
DRAWN TO AS1100. IF IN DOUBT-ASK.DO NOT SCALE.
REMOVE BURRS AND BREAK SHARP EDGES.
DR: REQ 18/04/2016CK: 25/09/2013
MANUFACTURINGMilspec
TITLE:
Specifications
Part Number: 360A-WC-001
Type Inductor Alternator
Cut in Speed 1600
Maximum Output 360A
Weight 26kg
Voltage Regulator 28.4 V
Voltage Range 26 - 30 V
Operating Ambient Temperature -40 - 93 C
Maximum Rotor Speed 13000 RPM
Regulator Unit Integrated, Solid State.
Max Continuous Output 340A #1
Mounting Clamp
Ignition Warning Light Optional
Electrical Connection M12 +ve, M10 -ve
Cooling Fluid
Coolant Temperature -40 - 85 C
Coolant Flow rate 3l/min #1 Coolant Temperature Dependent
16
As vehicle manufacturers struggle to meet military requirements for power at vehicle idle in a finite space, Milspec developed the 360A air cooled unit. This unit offers maximum capacity by volume over all of our inductor alternators. It uses the SAE J180 vehicle mount system which makes it compatible with multiple military vehicle applications. Milspec will work with you and your team to configure your engine in 3D CAD models to align the unit to your vehicle requirements.
360A Air Cooled Alternator
Specifications
Part Number: 360A-AC-001
Type Inductor Alternator
Cut in Speed 1600
Maximum Output 360A
Weight 28kg
Voltage Regulator 28.4 V
Voltage Range 26 - 30 V
Operating Ambient Temperature -40 - 93 C
Maximum Rotor Speed 13000 RPM
Regulator Unit Integrated, Solid State.
Max Continuous Output 320A
Mounting J-180
Ignition Warning Light Optional
Electrical Connection M12 +ve, M10 -ve
Cooling Air Cooled
17
Milspec’s Portable Power product range has developed as a result of our experience in
designing and manufacturing military grade alternator products. This alternator technology
was leveraged to produce a high performance, low weight range of units designed to meet
MIL STD 461 and tailored to meet numerous applications. Milspec is working with world
leading diesel and hydraulic technology companies to deliver a state of the art product to
our customers. Contact Milspec today to see how we can meet your Portable Power needs.
MILSPEC Portable Power
C4I KITS
AUXILIA
RY POW
ER UN
ITS
PORTA
BLE D
ISTRIBUTIO
N U
NITS
18
Hydraulic DieselLength 700mm 700mm
Width 280mm 400mm
Height 280mm 600mm
Weight 38kg 166kg
Output Voltage 28Vdc 28Vdc
Output Current 300A 300A
Output Power 8.4kW 8.4kW
Fuel Consumption N/A 265g/kWh
Length 720mm
Width 490mm
Height 620mm
Weight 145kg
Output Voltage 28Vdc
Output Current 430A
Output Power 12kW
Fuel Consumption 212g/kWh
Length 1650mm
Width 650mm
Height 800mm
Weight 380kg
Output Voltage 28Vdc
Output Current 800A
Output Power 22.4kW
Fuel Consumption 212g/kWh
MILSPEC APU-H-8.4/D-8.4
MILSPEC APU-D-12
MILSPEC APU-D-22
Fuel Consumption
MILSPEC
Visitwww.milspecmanufacturing.com
Milspec Manufacturing874 Knight Road,Albury NSW 2640Telephone +61 2 6022 7100Facsimile +61 2 6040 9866
Length 330mm
Width 200mm
Height 100mm
Weight 5kg
Input Voltage 20-36Vdc
Output Power 100W @ 12V
THALES PDU
MILSPEC 120 kVA PDU
MILSPEC 60 kVA PDULength 940mm
Width 450mm
Height 555mm
Weight 70kg
Input Voltage 415V
Output Voltage 415V
Length 1152mm
Width 550mm
Height 600mm
Weight 80kg
Input Voltage 415V
Output Voltage 415V
