VA ENVIRONMENTAL

HANDBOOK FOR
INC ALEXANDRIA P A JORDAN - /3
D-Ri28 632 INTEGRATION RADIAN
CONTROL(U) ENGINEERING

UNOSFEhhhhhh0/E hI
UNCLSSIFED02 MAY 83 83-5-525-8805 DAAK7-Si-D-9i2 G i/ I
 .0 -

gj4

12.
*lO 111120

111.2 111L

MICROCOPY RESOLUTION TEST CHART

1963-A
BUREAUOF STANDARDS-
NATIONAL
 Report No. 83-5-525-0015

INTEGRATION ENGINhEERING HANDBOOK FOR ENVIRONMENTAL CONTROL

-*" RADIAN INC.

20-30 South Quaker Lane
Alexandria, VA 22314-4585
U

2 May 1983

DISTRIBUTION STATEMENT A
Final Approved for public releaum
Distribution Unlimited I

Distribution of this document is unlimited.

" DTIC
ELECTE
Prepared for 271983
SHELTER MANAGEMENT OFFICE
Headquarters, Electronics Systems Division (AFSC)
Hanscom Air Force Base, MA 01731 .

.
- Through
ELECTROMECHANICAL DIVISION, ENGINEER SERVICE SUPPORT LABORATORY
U.S. Army Mobility Equipment Research and Development Command
Fort Belvoir, VA 22060

~FILE COPY
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83-5-525-0015 1P
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TITLE (and Subtitle) 5. TYPE OF REPORT A PERIOD COVERED

S Integration Engineering Handbook for Final

Environmental Control
6. PERFORMING ORO. REPORT NUMBER

7. AUTHOR(q) S. CONTRACT OR GRANT NUMUER(.)

P.A. Jordan, III

1 RADIAN INC. 9O 0
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AREA A WORK UNIT NUMBERS
RADIAN INC.
20-30 South Quaker Lane Program Element 64708F
Alexandria, VA 22314-4585 Project No. 2674
11. CONTROLLING OFFICE NAME AND AOORESS 12. REPORT OATS
Shelter Management Office 2 May 1983
Headquarters, Electronics Systems Division (AFSC) tS. NUMmER OF PAGES

Hanscom Air Force Base, MA 01731 143

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Electromechanical Div., Engineer Service Spt Lab.,

U.S. Army Mobility Equipment Research and Unclassified
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SCHEDULE
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I.. SUPPLEMENTARY NOTES

[.4

IS. KEY WORDS (Centin.e an rere, adds If neay amd Identify by block matber)
Air conditioning, Blast and thermal effects, Chemical and biological effects,
Cooling and heating load, Environmental control unit mounting methods, Electro-
magnetic pulse (EMP) effects on ECU, Environmental control unit (ECU), Heating,
Mobile tactical shelters, System integration.

ATRACr one . a. N ... eW -d MN*lfr by block ammber)

This handbook offers those who are not heating and air conditioning engineers
guidance and procedures for meeting uncomplicated cooling and heating require-
ments in standard, mobile, military shelters. The handbook addresses the selec-
tion and mounting of environmental control units, introduction of conditioned air
into the shelter and its distribution, chemical and biological warfare equipment
application, and steps that might help the environmental control system to
survive in a nuclear environment. The handbook is intended as a simplified guide
it recognizes that expert help from technical documents and qualified engineers
may be required in complicated situations./4\

WO 1473 aTLON OFI? NOV g5S OUSOLETk Unclassified

75
Ji",. SECURITY CLASSIFICATION OF THIS PAGE (When Date Entred)
 Nq

TABLE OF CONTENTS

Section Title

I Introduction

II Selection of Environmental Control Units (ECU)

. III Mounting the ECU

IV Distributing Air in the Shelter

V Protecting Against Chemical, Biological (CB), and

Radioactive Fallout Contamination

VI Protection Against Electromagnetic Pulse (EMP)

VII Blast and Thermal Protection

i Appendix I-I Explanations and Illustrations of Terms

1-2 Bibliographical References

Appendix Il-I Estimating Shelter Cooling and Heating Requirements

11-2 Reducing Cooling Load by Shading

Appendix III-1 Retractible Mounting Design

111-2 Sample Calculation: Wall Mounting Frame for the

18,000 Btuh ECU on S280 Shelter

111-3 Wall Mounting Designs

07. 111-4 Sample Calculations: Remote Ground Mount for

18,000 Btuh Vertical ECU

111-5 Remote Ground Mounting Design

Appendix VI-l EMP Shielding Consultants and Manufacturers

'°"Accession For

DTIC TAB [
• Urarunounced [

4 Distribution/
Availability Codes
Avail and/or
Dist spmelal
 - . . -7 . 7. ....--

LI

SECTION I - INTRODUCTION

"U - Introduction

This handbook offers those of you who are not heating and air
conditioning engineers, guidance and procedures for meeting uncomplicated
cooling and heating requirements in standard, small, military shelters.

1-2. -

The handbook addresses:

e The selection and mounting of standard military environmental

control units (ECU) 1 .

* Introduction of conditioned air into the shelter and its

distribution.

* Chemical and biological (CB) warfare protective equipment and

- its use with the ECU.

* Steps that might help the ECU to survive and function in a

nuclear-CB (NBC) environment.

1-3. General Parameters

The extent and boundaries of the handbook are defined in large part by
the shelters considered, the ECU's available and the climatic extremes of
potential operational areas.

o Shelters Considered. The shelters which are considered are

taken from the Standard Family of Tactical Shelters (Reference 25 of Appendix
1-2). The total list was culled to leave a fully representative range of size
and structural types, all of which should be readily procurable. You will
find these tabulated at Figure I-1.

o ECU's Considered. Only standard military compact ECU's and

four Navy adaptations of commercial models are considered for the applications
4of this handbook. The military units are all included in Military
Specification MIL-A-52767B (Reference 27) and Military Standard 1408A
(Reference 32); the Navy units are in Navy Technical Manual NAVAIR 19-60-83
(Reference 35). Descriptive data extracted from MIL-A-52767B and NAVAIR
19-60-83 are tabulated in Figure 1-2.

o Climatic Conditions and Categories. Figure 1-3 tabulates the

world temperatures and humidities by the climatic categories agreed to in
-. QSTAG 360 (Reference 15). The locations of the world in which these
conditions are found are shown on Figure 1-4. These data are necessary in
*determining the required ECU capacity. You will note that in regions where
heat is the principal consideration the highest temperatures are given and the
lowest temperatures where cold is the main consideration.
1
See definition in Appendix I-1.

I-1
 1-4. Use of Handbook

3
-.
. This is a guide. You may find that it is all you need in most
situations. However, you may occassionally encounter more complicated
problems which will require professional assistance or reference to
appropriate technical publications. The handbook attempts to highlight where
these instances might arise. When you do need help, one of the first places
to look is Reference 4, Appendix 1-2.

* The handbook is organized so that back-up information is

included in appendices at the rear. For speed of reference, each appendix has
been numbered to correspond with the section it supports; for example, the
II-series of appendices supports Section II. Appendix I-I is an explanation
and illustration of terms. You should find it helpful to become aware of
these terms before beginning the use of this handbook.

I-5. Coordinated Planninx

e Your job will be much easier if you can approach the

environmental control aspects in conjunction with the planning for all other
*equipment to be installed in a shelter. If you can treat these as a system, a
better product should result. Two examples of areas in which coordinated
planning would pay dividends are the utilization of shelter space that the ECU
"" and its ducting must share with operational equipment and the compatibility of
power requirements for the ECU and other equipment in terms of voltage, phase,
and frequency.

.-

p I-2
 Service Nominal Outside Inside Dimensions
Designation Service Dimensions (HxWxL) (HxWxL)
Sponsor (ft) (ft/in.)

Nonexpandable
S$250 Army 6x6 x7 H: 5'4" in aisle
: 3'10" at side wall
W: 6'3" at top
3'8" at floor
L: 6'6"

S280 Army 7 x 7 x 12 6'5" x 6'10" x 11'6"

ISO GP I Army 8 x 8 x 20 7'1" x 7'7" x 19'1"

1
MF ISO Navy 8 x 8 x 20 7'18" x 7'6" x 19'4"

Expandable

S-530 A/G Air Force 7 x 7 x 12 Unexpanded:

(unexpanded) 6'9" x 6'7" x 11'5"
Expanded: '
6'9" x 19'9" x 11 5 2
ISO, one Army 8 x 8 x 20 Unexpanded:
side expandable (Unexpanded) 7'1" x 6'5" x 19'1"
Expanded:
U7'1" x 14'6" x 18'4"

ISO, two sides Army 8 x 8 x 20 Unexpanded:

expandable (Unexpanded) 7'16" x 6'0" x 19'1"
Expanded:
7'1" x 21'6" x 18'4"

IThe Navy MF ISO has three configurations:

1. Single unit basic mobile facility.
2. Side joining units A and B which join into a double unit.
3. Integration unit to which up to six single basic units can be
attached, end on: one to each end and two to each side.
All HF ISO units have the same dimensions and the same thermal
characteristics.

2Two shelters joined.

, Figure I-I. STANDARD SMALL MILITARY SHELTERS

CONSIDERED IN THIS HANDBOOK

*' 1-3
 Power
Requirement
Nominal Rating (Btuh) Dieson Voltage Phase Freq. (He) Wires Consumption (KW)
Capacity Hx W x L weight
2
S (Btub) Cooling Heating (Inches) (ib) 115 208 230 1 3T 50/60 400 3 4 50/60 Hz 400 Hz

Horizontal Configuration (Army)

1 1 x 23;7 x 2 1
6
9,000 10,000 7,000 200 X x x X 3.2
x X x X 3.2
x x x x 3.0
x X x x 3.1
18,000 18,500 14,300 20 x 30 x 28 290 x X X X 6.5
x x x X 6.5
I x X x 6.5
36,000 41,000 31,200 29=x 3 8 ,:- x 35f-, 435 x x X x 13.5
x 16x x 13.5
. 60,000 62,000 45,000 272 x 44-i . 41t 600 x x X x 14.0
8 8 i X
x x 18.0
Vertical ConfLiguration(Army)

6,000 6,300 4,500 21,, 17 17 180 X x X X 2.2

aI Z I 2.6
9,000 9,350 6,000 32 x 17 x 17 200 X X x X 3.6
X X X X 3.4
X I X X 3.4
x I x x 3.6
18,000 19,300 12,000 4 x 172 x 20 270 x I x I 5.0
4x x x 5. 7
36,000 17,800 28,600 , 460 x 8.5
5 x x 18.6
I IC X X 10.5

60,000 60,000 47,000 65N x 34- x 23,- 620 x x 1

1 x x 18.6

Vertical Configuration (Navy) 18.6

* 22,000 22,000 21,004 14 x 31t x 270 208/ x 60

* (HB022) 230
34,000 33,400 35,0004 71' 31 115 432 208/ x 60 16.0 N/A
(1B036) 7 240
3
Sleeve Moutd Cofigrion (Navy)
11 1I
22,000 22,000 21,0004 24 x 31f x 22= 275 208/ X 60 10.6 N/A
(B1022R 230

34,000 33,400 35,0004 44 z 394 X 28. 423 208/ 1 60 16.0 N/A

(130361 240

1
Sources of data are Reference 27 in Appendix 1-2 for Army ECU's and Reference 35 for Navy units.
2
CoolinS ratings for the Amy horizontal ECU's were determined at 125F7 dry bulb (db) outside temperature and 90"7 db
inside temperature. For the Army vertical units, except the 18,000 Btuh unit. the outside temperature was 120"F db
and the inside temperature was 9007 db; for the 18,000 Btuh unit, it was 125"F db and 900? db. The Navy units were
rated at 95'? db outside and 80a db inside.
3
See "Heat Pump" in Appendix I-1.
* "For installed supplementary heaters, see Reference 35.

Figure 1-2. STANDARD MILITARY ENVIRONMENTAL CONTROL UNITS

* 1-4
 3
Climatic Ambient Air Temperatures, OF (oC)
Category 2 Highest/Lowest Relative Humidity
C gHigh Low Ever Recorded 4

Al
• "i"Hot dry 120 (49) 90 (32) 136 (58) 3% - 8%

A2
Intermediate l1 (44) 86 (30) 127 (53) 8% - 40%
hot dry

Nearly constant at
75 (24) throughout 95% - 100%
Wet warm
the 24 hours

D2 74% @ 95* (1500 hrs)

95 (35) 79 (26) 100% @ 790
Wet hot (2400 - 0600 hrs)

B3 60% @ 1068 (1500 hrs)

Humid hot 106 (41) 88 (31) 88% @ 880
coastal desert (2400 - 0600 hrs)
CO Tending to
Mild cold 21 (-6) -2 (-19) -11 (-24) saturation

Cl Tending to
Intermediate cold-6 (-21) -24 (-31) -44 (-42) tndin
saturation
cold

C2 Tending to
Cold -35 (-37) -51 (-46) -69 (-56) saturation

•C3 CNearly constant

-60 (-51) at
through- Tending to
. Severe cold -
out (5 th24 hours
the ough saturation

C4 Nearly constant at Tending to

Extreme cold -71 (-57) through- -96 (-71) saturation
out the 24 hours s

1
-" From Reference 15.
2
See Figure 1-4.
3
For categories Al, A2, and CO through C4, temperature is the principal
consideration. For categories BI, B2, and B3, humidity is the principal
* consideration. All temperatures are dry bulb readings.
4
Highest temperature where heat is principal consideration and lowest
where cold is principal consideration.

Figure 1-3. HIGH AND LOW TEMPERATURES AND RELATIVE HUMIDITIES FROM
CHARACTERISTIC DIURNAL CYCLE DURING HOTTEST OR COLDEST
1
MONTH OF THE YEAR

1-5
 lse 1650 150 135' 1200 105' led 7 is'o. 450 30' 0
of

ARCTIC OCEAN

ALASKAS

QKF wATLANTIC OCEAN

% 02

Is.I

5'

50' 5111 lip 133' 121'9 6 is' Ms 45' 30' 15' 0

us6 50 as 15 316 456 1111 756 HE6 1050 1206 135' 5ose Si' 6

Foom lamp LA

ARCT IC OCEAN ~ .; m ~ AEAST SIBERIANSEA

KINEGAT ANTE SEARY43ZELN

ISOASTKHDESSR
HUMD HOT

PAC INTFEIICTOCCAL

E5TEM
C4Q COLD

OCEA. FigureI LOAINOFCIAISCTGRE

(IcWIeNacngpae

1-7p

.. .. . ..
a

SECTION II- SELECTION OF ENVIRONMENTAL CONTROL UNITS (ECU)

II-1. Introduction

This section gives you simple and easily followed steps for selecting
environmental control units (ECU) for standard, small, military shelters.
These steps do not get into ECU design; rather, they guide you in the
selection of suitable standard units from those already available for military
use. To make a selection, you will need to know:

o How to estimate the sumer cooling requirement.

o How to estimate the winter heating requirement.
o How to select an adequate ECU.
o How to select an auxiliary heater, if one is needed.

This easy method provided here will give you acceptable results for mo
" military systems. If your system needs special conditions such as pre, -1
humidity control, then you may need special engineering help. To see the
.. method described in this section was developed, look in Appendix II-1.

A 8 C E F G H
STAJAJ. SEL TERtSIZE SUN=R SOLAI WINT= CLIMATIC SMNER WINTER
S(WIWxL) 4 CONDUCION CONDUCO VrNTIIATO VENTILATION
H4EAT
GAIN NEAT LOSS COOLING MATING CATEGORIES HEAT GAIN MEAT LOSS
DMSIGRATION (FT. (m) (8TUM) FACTOR FACTO (BTURI/CI) (ITUI/CFM)

Nom-Exandable:
S 1.49 1.00 -Al HOTDRY 44 76

Army 5-250 6X61X 7 3.750 6,200

Ary 3-280 7h5u1,12 7,060 11.580 1.31 1.00 A2 MO0 HOT DRY 34 76

1
Navy Mr ISO 8u~x20 8.272 13,440 NA 1.00 ,.1S WETWASN NA 76
(Sing"e)
MNavy
R ISO 83.L6x20 12.984 21.280 1.00 1.00 82 WETHOT 100 76
Cnoble)

IS A2 8z8x20 11.630 18.820 1.24 1.00 53 HUMIDHOT 1.24 76

Expendable: 1.31 1.00 CO MILD COLD 39 76

Alt Force 7lp22x12 15,830 25.430

S-520 1.00 1.36 C1 MOD COLD 39 104
IOAW1.00
ISO Azu 1.71 C2 COLD , 39 L31
I side expand- 8xl5z20 17,580 28,420
able
LW*l 1.00 1.84 C3 SEVERE COLD 39 141
2 sides expand- 8x22x20 23,640 38,020
able 1.00 2.00 4 EM. NS COLD 39 152

Usellne Emperatures Inside shelter: Summer, 78*F; Winter, 70*F.

Figure I-i. ESTIMATING DATA FOR COOLING AND HEATING REQUIREMENTS

IWhen single MF shelters are attached to the integration unit (see footnote to
Figure I-I), each shelter, including the integration unit, is treated as a
separate unit for determination of cooling and heating requirements.
 ....

11-2. How to Estimate the Summer Cooling Requirement

Reproduce the worksheet shown on page 11-13. Fill in the data at the
top of the sheet and then follow steps I through 5 of the instructions. If
you are planning for a Bl region (see Figure 1-4), anticipate a worldwide, as
opposed to a regional, application or plan that CB collective protection
K" equipment will be required, you should read paragraphs 11-3, 11-4, and 11-5
before starting on the worksheet.

I-3. Precise Humidity Control (PHC)

Military ECU's are generally not very satisfactory as dehumidifiers

* under conditions of high humidity. When confronted with a situation of very
high humidity and not much cooling to be done, such as Climatic Category B1
with a nearly constant temperature of 750 F, they cannot handle the problem.
*. This is reflected in Figure II-1.

. Military ECU's are designed not for PHC but primarily for sensible
(dry) cooling. They cannot dehumidify unless they are also cooling. What
dehumidification is accomplished is only incidental to the cooling process
and, in high humidity, the ECU evaporator coils, especially on some vertical
configurations, experience water carryover problems and tend to throw water
" out of the return air louvers.

e PHC needs humidistat control of cooling, a reheat capability roughly

equal to cooling, and a reheat temperature control. Military ECU's do not
have these. They would have to be provided by the user a. add-ons, as
required, and adding them to military ECU's is a difficult job. It requires
extensive knowledge of psychrometrics, a familiarity with the internal
circuitry of the equipment, precise load evaluation, and design experience
with the necessary add-on features. All this is well beyond the scope of this
handbook to cover. The job should be undertaken only by someone with the
necessary expertise and a full and proven capability, ideally, the ECU's
original manufacturer. If you need PHC, it is recommended that you contact
one or more of the leading manufacturers of air conditioners to discuss in
specific terms any problems and requirements you may have with regard to PHC.

A major consideration in using PEC is the power requirement. Because

of the need for full constant cooling plus about equal reheat, PHC imposes a
high power demand which must be met. This could result in as much as twice
the normal cooling power consumption.

11-4. Worldwide Application

The cooling requirement determination of Worksheet Part I and as
illustrated in the sample problem of paragraph 11-8 is for a specific climatic
category applying to a certain region of the world. You may have need for
systems capable of worldwide use. In such cases, complete two worksheets
using the climatic categories which provide the most extreme conditions: Al
and B3. Using the Column E and G values of 1.49 and 46 for Al and 1.26 and
124 for B3, compute the total cooling requirement. Use the one which gives
the larger requirement.

11-2
S

11-5. If CB Collective Protection Equipment is to be Used

* Collective protection equipment will add to the cooling load of the

ECU. The CB filter-blower unit blows air into the shelter at 10OF to 15OF
above outside temperature. You must take this into consideration since it may
require an increase in the size of the ECU you would normally select.
Paragraph V-10, Section V, explains how to do this.

11-6. How to Estimate the Winter Heating Requirement

Reproduce Worksheet Part II shown on page 11-14. Fill in the data at

the top of the sheet and then follow Steps 6 through 12 of the instructions.

11-7. How to Select an Adequate ECU

You are now ready to make a preliminary selection of an ECU. Final

selection will depend on several additional considerations explained in
paragraphs 11-9 through 11-12. For now, the requirement is to narrow the
field of possible ECU's by selecting a unit which is adequate but not
unnecessarily oversized. MIL-A-52767B and MIL-STD-1408, from which you will
select the ECU, lists (as does Figure 1-2 of this Handbook) a number of
categories of units available. Normally, you should limit your selection to
horizontal compact and vertical compact units; the Worksheet Part II addresses
these two types. You need to explore the others only if there is a special
requirement for which a conventional or developmental type is particularly
suited; the procedure will be the same regardless of the type. Reproduce
Worksheet Part I1, shown on pages 11-15 and 11-16, fill in the top portion
and then follow Steps 13 and 14 of the instructions and, if appropriate, Steps
*: 15, 16, and 17.

" 11-8. Sample Problem

This provides you with an illustration of how the procedures offered

in Paragraphs 11-2, 11-6, and 11-7 will work.

o Assume:

so Shelter: Navy MF ISO (single)

eo Location: Ramstein, Germany
so Occupants: 3 people
so Design inside temperature: 750 F (desired inside
temperature)
.e Electrical equipment/lights: Maximum at any one time -
6,000 watts; minimum - 0 watts
* Available power: AC 208 volts, 3 phase, 50/60 Hz, 4 wires

* From the completed Worksheet Part I (Figure 11-2), the cooling

requirement is 33,091 Btuh. Note that the solar/conduction heat gain was
adjusted for the fact that your desired interior temperature is different from
7. the 780F on which the values in Column C of Figure II-I are based. Figure
11-5 was used to determine the correction factor, in this case 1.07.

11-3
 i

WORKSHEET PART I - COOLING REQUIREMENT ESTIMATE

Shelter Designat ion _AIVY104P0 [S '(//4.

7
*Shelter Location _ -?4AVS W,'Al 4--;pjvf4VK~#
Shelter occupanta (Avg. No. of Persons) 13
m Required (Design) Inside Temperature _ _ _ _ _

(If only heating is required, skip steps I through S and go to Worksheet I1)

* STEP

• Solar/conduction heat gain:

1. V272
(i) stub x A(lb)- F-
(1) stub

Hot gain from electrical equipment/lights:

~~(la)
2. 6 00c watts a 3.4 Stub/watt 052l 0 stub

3. Heat gain from personnel: 13' ersooa rstron =LO etue /s 5C' Stub

(4a) (4b) (4)

5. Total cooling requirement: (!) + (2) + (3) + (4) 3 3. O / stub

(5)

here to find (la): Figure 11-1. Colum C (3a): Top of workoeet

-
(lb): Figure I-1. Column (4a): Figure II-I, Colum G
(Ic): Figure 11-5 (I4b): Top of workshot
*(2a): gquilpni and lights in shelter

INSTRUCTIONS FOR COMPLETING WOOKSHEET

STEPI - SOLAK/COiNDCTI0N NEATGAIN

a Find the shelter you want to cool in Colum A of Figure li-1.

. For this type of shlter pick out the sumer cooling load rom Colum C and put It in wrkaheat space (.).
a Find the location of the shelter on the emp, figure 1-4, and note the pattern.
a Hatch the pattern with Colum . Pick out the proper cooling factor and put it In worksheet space (lb).
a With your design inside temperature, turn to figure I-S and, using the Solar Conduction Het Gail Curve,
find the correction factor and put it in space (1c).
' a Perform multiplicatl and put the result in space (1).

STEP 2 - HEAT GAIN FROM ELETRICAL EMIPHENT/LICTS

a Add the power rating (watts) of all electrical equipment and lights to be uaed in the shelter.
a Put the sun in apace (2a) end multiply it by 3.4.
a Put the result.Li space (2).
STEP 3 - HEUT GAIN F3) PEAOHUL

• Put the nmber of people to occupy the shelter In specs (3s).

a Multiply by 500 and put the result in space (3).
STEP 4 - HEAT GAIN FROMVINTILATION

a With the same climatic category pattern usd in Step 1, find the suir heat gain factor from Column C.
and put it in worksheet space (4s).
a Put the number of people in the shelter in space (4b).
a Perform the multiplication indicated on the worksheet and write the result in space (4).
STEP 5 - TOTAL COOLING IREM rENT

a Perform the addition and put the sun in space (5). This is the cooling requirement for selecting the ECU.

Figure 11-2. SAMPLE PROBLEM-WORKSHEET PART I

i 11-4
 • From the completed Worksheet Part II (Figure 11-3), the heating
. -requirement is 24,548 Btuh.

e From the completed Worksheet Part III (Figure 11-4):

ee Steps 13 and 14 show that adequate cooling requires a

* standard ECU with a nominal capacity of 36,000 Btuh. The actual rating of the
horizontal unit is 38,335 Btuh and the vertical unit is 35,343. Both units
are well above the requirement so you may select the configuration best suited
to your needs. You should have noticed that the final ECU ratings were
adjusted (de-rated). This de-rating is done because in Figure 1-2 the ECU is
rated for an interior temperature of 80°F at outdoor temperatures up to 105 0 F.
At lower indoor temperatures, in this case 750 F, it is necessary to de-rate
* the air conditioner. Had you been selecting a system for a climatic area with
outdoor design temperatures above 1050F, the de-rating factor would have been
*0.805. You use Figure 11-5 to obtain these factors.

Before proceeding, read paragraphs 11-9 and 11-10.

*a Step 17 determined that a pair of horizontal units with a

combined capacity of 34,596 Btuh or a pair of vertical ECU's at 36,092 Btuh
will be adequate and reasonably sized. It also shows that the combined
heating capacities are close enough to the requirement to be acceptable in
view of the fact that heat generated by personnel and electrical equipment
were not considered in the Worksheet Part II computations.

* You have now made your preliminary selection. Final selection

will depend upon any adjustments you make after considering paragraphs 11-9
through 11-12 and the mounting method required.
V 11-9. Proper Sizing

The ECU you finally select should be adequate but not oversized for
the cooling load you calculated on Worksheet Part I. Sizing the cooling unit
as closely as possible to the requirement is important because of the
dehumidification process. An oversize ECU will cool the shelter quickly,
*switch to a non-cooling mode and remain in a non-cooling mode until it is
needed to cool again. While in the non-cooling mode, it is not dehumidifying
the shelter. A smaller ECU will cool more slowly and, because its capacity is
close to the requirement, will cool almost constantly; it therefore will be
also constantly dehumidifying the shelter. By contrast, oversize of the
heating capacity does not create a similar problem. Actually, heating
V. oversize may be beneficial in overcoming heat loss because of doors opening
and also for bringing an unused shelter up to the desired temperature more
quickly before sensitive equipment is turned on.

11-10. Multiple Units

The use of two or more ECU's to satisfy a single requirement offers

" several potential advantages:

* It may be possible to size closer to the requirement.

4 11-5
 WO1/SNEZT PART 1I - HEATING REQUIREHENT ESTIMATE

Shelte..r
Loctio ar / f

Shelter Occupanta (Avg. No. of Persons) ,.3

STEP
6. Conduction heat lose . t ub z _ - _ , /. 2 5 t u

(6a) (6b) (6)

7. Vast heat le: tub/cf.a %3 per a o c.,l-e. - ',, 270 stub
(7a) (7b) (7)

S. Hosting requirement- (6) + (7) . " ,,,tsr, 7 V. , 24' 5' ' Stb

9. Heat gain from elec equip/lights: watts x 3.4 Stub/watt - Stub

(9.) (9)
10. Neat gain from personnel: _ prs x 500 Stub/pere - stub
(10e) (10)

1" . Total beat gain: (9) + (10) - stub

12. Hot hoting requirement: (8) - (11) - stub

(12)

Whare to find (6a): Figure 11-1, Coil 0 (7b)i Top of workebeet

(6b): Figure 1-2, Colum F (9a)l Equipment and lights in shelter
(7a): Figure 11-2. Colm 8 (10m): Top of waksheet

tusTRtCIioms FOE coHPI.ZFING w0UNE

STEP 6 - CONDUCTION HEAT LOSS

* Find the shelter you want to cool in Coluen A of Figure 11-1.

a For this type of shelter, pick out the winter heating load from ColIm. D and put It isn worksbet space (6a).
a Find the location of the shelter on the mep, Figure 1-4. and mote the patter .
9 match the pattern with Column F, Figure 11-. Pick out the proper CoiLng fsctor sad put it In worutnet
space (6b).
a Perform the mlcipllcation and put the result in space (6).

ST1P 7 - VUITILATION HEAT LOSS

a With the climatic castegory pattern ueed In Stop 6, find the winter heat ls8 factor in Colum H, Figure I-1.
sad put It in space (7s).
a Put the amber of people In the shelter in space (7b).
a Perform the multiplication and put the result in apace (7).
STEP 8 - HEATING aCONIUDfIF

a Add (6) and (7) ad put the sum In worksheet space (8). This i your heating requirmat if your operational
equipment must be warmed before it cia be safely started. In this case, wee this figure In Worksheet arct 11.
If you do ot require preheating for the equipmet, your energy requiremnts cam be reduced by recognizing
the heat gained from electrical equipmn and peruonnel in the shelter eid following Steps 9 through 12.

STE 9 - HET GAIN FRO EL CTRICA. EQUIPMU/LIQTS

a Add b*. power rating (watts) of mini electrical equipment sad lights to be used during shelter operation.
a Put the sue in space (9a) and multiply it by 3.4.
a Put the results in space(9).

STEP 10 -SAT GAIN FSON PESOSUEL

* Put the number of people in space (10e) and multiply by SOC.

0 Put the result in space (10).

STEP 11 - TTAL NEAT GAIN

a Add (9) and (10) and put the um in spaea (11).

$TV 12 - NET MUTING 1I=UIIDUT

a Subtract (11) from (8) and put the difference in apace (12). This is the hosting requirement for
selecting the ECU.

Figure 11-3. SAMPLE PROBLEM-WORKSHEET PART II

11-6
 AORKSHM PAR? III AUELCTION OF ECU tPag. I ot 2)

Shelter Designation: NA411y #,4 (__5ci________________Location:

Cooling Requirement: 33 ~Btuh; Heating Requirement: 2 *.5~&stun

Design Inaids, Temperature: 75...................~.
climatic Category: C'/
*?;

Power Source Available: 4C 2O9 voice, phase. 0 Hertz, wires

Wat eece figuare 1-2 ad KIL-4-527671 for ECU data.

STEP HORIZONTAL CONACT VERTICAL COMPACT

SINGIE ECU

13. 4ominal capacity (Btub): &361~ C.6 0

(13s) (13b)
14.. Actual rating (Itub):

(144) (14b) Cd)

(14) (14a.) (14f)

Seating: 31120 100

(14g) (14h)

WIUMTOfS MR cCffl.EUNC WDSUU1

STEP Q3 - NOHNAL ECUCAPACITY

a From Figure 1-2. select a horizontal and a vertical U each with a noelnal capacity equal to the next size larger than
the cooling requrin. Put these sizes in spacee (13a) and (13b).

STEP 1' - ACTUAL RATING AND SUECIOU

a From figure 1-2. find the cooling and heatlng 'Ring Stub" for theme two EU's. Put these ino spacaes (14a.) and (14%)
* for the horizoetal ECU =W (l4d) and (14h) for the vertical EW9.
a With rour climtic catsg or~ad desired interior toperatre (deaign inside, temerature), turn to Figure 11-5. Using
Curve A or Curve 5. as datesmined by your climatic category, find the correction factor and put it into spaces (14b)
ad (14a). Multiply to d"tersine the WU actual rating.
a If cooling raring of either or both of them* in equal to or slightly larger than the cooling requirement. you have
completed tha preliinary selection process snd Steps L3 aid 16 my be skipped.
* If the hearing raring in equal to or larger than the requiremet. no suppltary heater will be required and para-
* graphm 11-U my be skipped. If the hestari reting to smaller then the requiremnt, go to paragraph 11-13.
9 You should complete Step. 1S and 16 if the units in Step 14 are smller or such larger than the requirement.

Figure II-4a. SAMPLE PROBLEM-WORKSHEET PART 111 (1 OF 2)

11-7
 mmzug PART III SEL=TIO OF ECU (Page 2 of 2)

DUAL WS HORIZONTAL COMPACT VERTICAL COMPACT

15. 01amIn caepcities (Stub):

(1Sa) (15b) (15) (15d)

L6. ActuaL ratings (5tub).:

(16.) (16b) (16) (1d) (16.) (16)

meating:&001, 0
(16) (16h)

17. Closest combinaion.:

CooL(n: Z X (1() or (16t -97

Neacstai 21 (16g) or (ib) - o OR 000

(17.) (17d)

l5TRUMT1 mR COMMIT I EOIS3T

S DUAL =13'

SV 13 - MMUIAL CADCrM

SFree FViga" -2, aeleet the amleet pair at nmoisn caacities that satisfies the cooling requirement. Put theae
*, racingl in apaces (Ws) and (153). ftitply thee by 2 and put the cesUm.s in spaces (15b) amid(15d). It the pair
loks claoe. preceed with Step L6; if sme. select mcher pair.

STV 16 - ACTUAL SATIMS

OPFree Figure 1-2. tind the Cooling a heating ring. fee the verticaL and horizontal ECU' picked to Step 13. enter
htae in seca (164). (16d). (16s) mad (16h). Eace in spaces (16b) sad (l6e) the cotection factor used in (14b)
and (le). Haltiply and put the results in spwas (16c) ad (16).

San 17 - 06131r =~lsuwmC of wCs

, e It a p ir of NXU' Sceties and in cloaer to the cooling requirement than the singLe units of Step 14, the pair.
shelter $pS pelmi t ng. should be your preiinimary aeLection. Heating consideration is the seen an for Step 14.

Figure II-4b. SAMPLE PROBLEM-WORKSHEET PART I1 (2 OF 2)

H1-8
- .....
.........
. . . . ;. -

The flexibility of mounting at two or more points on the

"

shelter might permit a solution to the distribution problem without the need
for ducting.

" The calculated cooling requirement is based on the anticipated

* worst case. During times that the worst case does not exist, the cooling
*. requirement would be reduced.

*. Use of a single oversized unit could result in the problem

discussed in paragraph 11-9. Multiple units provide a flexibility which might
avoid this problem.

ee Much of the time when the load is less than the maximum
. computed, one of the pair of ECU's may meet the cooling requirement. Less
power would then be consumed. Further, with two or more units, there would
* exist the desirable situation in which there would be a back-up ECU during the
periods of lower requirements.

As a rule, when two or more ECU's are used, it is a good idea to make
them all the same. This will not only ease the logistical support burden but
will also improve the back-up flexibility. In a technical sense, however,
there is no significant drawback to mixing types and capacities (as long as
power requirements are compatible) and there may be an occassional good reason
for doing so. For example, there could be a case in which normally operating
mission equipment generates a moderate amount of heat but where installed
-" special mission equipment, which operates only infrequently, is a big heat
producer. In this case, a small ECU may cool adequately for normal operations
but a larger ECU may be a necessity when the special equipment is in use.

II-11. Reducins Oversize

The ECU size and power usage increase significantly as rated cooling
capacity increases. Since shelters are usually cramped for space and power is
often at a premium, consideration should be given to using the lowest capacity
ECU that reasonable comfort and equipment requirements will permit. For
example, if:

e An inside temperature of 850 F, instead of 780 F, is tolerable,

considering the benefits to comfort that the dehumidification effected by the
ECU will provide, and

* A reduced ventilation requirement is acceptable, considering

that since the onset of the energy shortage a more conservative value of 5 cfm
per person has been established by Reference 4, Appendix 1-2, then --

The selection process of Section II (and the criteria of Appendix II-1) would
include the following adjustments:

* Reduce the solar/conduction cooling load (Figure II-1, Column

C). Select from Figure 11-5 the solar/conduction correction factor for 850 F
(0.835). Recompute Worksheet Step 1 by multiplying the value in Worksheet
space (1) by the correction factor, 0.835.

11-9
 . ° :- -L . - - *,-. • .. " " " ' - " " " -" " . - . . . . "

* Reduce the ventilation requirement from 20 cfm per person to 5

* cfm per person and recompute worksheet Step 4.

o Retotal spaces (1) through (4) to obtain an adjusted cooling

requirement.

o Increase the rated cooling capacity of the next smaller ECU.

Using Curve B of Figure 11-5 (if outside temperature were over 105 0 F, you
*would use Curve A), select the ECU rating correction factor (1.064 or 1.06).
Multiply the rated cooling capacity of the ECU by the factor 1.06 to obtain
the adjusted cooling rating. Compare the adjusted rating with the adjusted
requirement. If the smaller ECU now meets the cooling requirement, it may be
selected. This procedure may be used in the same manner for other interior
shelter temperatures within the range of Figure 11-5.

1 2.O

1.10

- CURVE A FOR DESIGN OUTSIDE

. TEmPERATURES OVER 105F.
(CLZMATE CATEGORIES Al,A2,

V - AMD B3; SEE FIGURE 1-3.)

2
CURVE B FOR DESIGN OUTSIDE
"0.9 ME EATURES UP TO lo5"F.
(ALL CLrMAT CA TGORIES OTHER
I THAN Al, A2 AND B3; SEE

U FIGURE 1-3.)

•.80

0. 70
70 75 80 85 90
SHELTER INTERIOR TEMPERATURE (*F)

Figure I-5. CORRECTION FACTORS FOR ADJUSTING FROM

SHELTER INTERIOR DESIGN TEMPERATURE

"- 11-12. The Value of Shading the Shelter

As you may have noted in completing Worksheet Part I, a significant

source of heat which the ECU must handle is solar radiation subsequently
* conducted through the shelter walls and roof. You can reduce the heat gain
from this source by approximately 45% if you shade the shelter. To reach this
reduction, the shade should be complete, that is, no sun filtering through.

IThe method used for estimating the 45% is explained in Appendix 11-2.

".-10
Adequate shade can be provided by dense tree foliage if such is available. If
not, you may erect a canvas rectangle, perhaps combined with your camouflage
scheme. The canvas should be as shown in Figure 11-6. The overhang should be
the same on all four sides of the shelter. The distance of the canvas above
the shelter should always be at least one foot. There is no noticeable
advantage to making it higher than this; but, if some consideration requires
that it be, the overhang distance should then become the height of the shelter
plus the distance between the canvas and the shelter roof.

C AN A OVER HNG D ISTANCE , 0 0 (Do h + ).

-. h + I - - - Ift--

SHELTER h ft

Figure 11-6. SHADING THE SHELTER

11-13. How to Select a Supplementary Heater

Cooling is the primary concern in selecting an ECU. In most of the

cases you will encounter, it is probable that the ECU which was sized for
cooling will be adequate also for heating. However, if the net heating
requirement which you determined in Step 12 exceeds the rated heating capacity
of the selected ECU (or ECU's), then you will require a supplemental heater.
You will find heiters applicable to shelters listed in MIL-STD-1407 under the
heading: "Heater, Space, Blower Type". The heater you select will depend on
the specifics of your situation. For example:

* If you need to keep the temperature in the entire shelter at a

fairly uniform level, a fuel burning space heater with a blower may be
required. The heating requirement would be that determined on Worksheet Part
Ii.

e If you want to heat just the space around an individual

occupant, you may need only a small portable electric space heater or a small
fuel burning heater.

e If floor space is at a premium, outside mounting of a duct type

heater may be needed.

e Electric heaters increase power consumption but all fuel

burning heaters require an exhaust to the outside.

f II-1I
 In short, identifying potential heaters from MIL-STD-1407 is a
e

relatively simple matter but selecting one depends upon the definition of your
requirement.

11-14. A Caution on Ventilation

Instructions should be included in the operating procedures for the

shelter not to exceed the ventilation specified in Steps 4 and 7. When the
fresh air damper is manually adjusted open to provide additional fresh air for
ventilation to exceed 20 cfm, there results a substantial penalty in air
conditioner cooling load in hot and humid conditions and in heater load in
colder climatic conditions.

- - - - - - - - - - - - - -

11-12
 WORKSHEET PART I - COOLING REQUIREMENT ESTIMATE

Shelter Designation

Shelter Location

Shelter Occupants (Avg. No. of Persons)

Required (Design) Inside Temperature °F

(If only heating is required, skip steps 1 through S and go to Worksheet 1I)

STEP

1. Solar/conduction heat gain: Stub x x Btuh

(is) (1b) (i1) (1)

2. Heat gain from electrical equipment/lights: _ watts x 3.4 Btuh/watt - Stub

(2a) (2)

3. Het gain from personnel: person@ z 500 Btuh/person * Stub

(3a) (3)

4. Heat gain from ventilation: Stub/cfm x persons x 20 cfm/person - Stub

(4a) (4b) (4)

5. Total cooling requirement: (1) + (2) + (3) + (4) Stub

S
(5)

Where to find (is): Figure lI-1, Column C (3a): Top of worksheet

(lb): Figure I-i, Column E (4a): Figure I-1, Column G
" (ic): Figure 11-5 (4b): Top of vorksheet
(2a): Equipment and lights in shelter

INSTRUCTIONS FOR COMPLETING WORKSHEET

STEP 1 - SOLAR/CONDUCTION HEAT GAIN

n Find the shelter you went to cool in Column A of Figure II-1.

9 For this type of shelter pick out the surier cooling load from Column C and put It In worksheet apace (la).
• Find the location of the shelter on the map, Figure 1-4, and note the pattern.
a Hatch the pattern with Column E. Pick out the proper cooling factor and put It in worksheet space (lb).
n With your design inside temperature, turn to Figure 11-S and, using the Solar Conduction Heat Gain Curve,
find the correction factor end put it in space (1c).
9 Perform multiplication and put the result in space (1).

STEP 2 - HEAT GAIN FROM ELECTRICAL EQUIPHENT/LIGHTS

a Add the power rating (watts) of all electrical equipment and lights to be used in the shelter.
a Put the sum in space (2s) and multiply it by 3.4.
• Put the result. in space (2).

STEP 3 - HEAT GAIN FROM PERSONNEL

* Put the number of people to occupy the shelter in space (3s).

a Multiply by 500 and put the result in space (3).
STEP 4 - HEAT GAIN FROMVENTILATION

- With the ea= climatic category pattern used In Step 1. find the sumr heat gain factor from Column G.
end put it in worksheet space (4e).

e Put the number of people in the shelter in space (4b).

e Perform the multiplication indicated on the worksheet and write the result In space (4).

STEP S - TOTAL COOLING REQUIREMENT

* Perform the addition and put the sum in space (5). This is the cooling requirement for selecting the ECU.

11-13

-4
 WORKSHEET PART 11 HEATING REQUIREM4ENT ESTIMATE

Shelter Deaignation________________________

Shelter Location _________________________

Shelter Occupants (Avg. No. of Persons) ______________

STEP
6. Conduction heat lose: _________ tub x _____*_______ Stub
(6a) (6b) (6)

7. Vent heat lose: ___T7__&_ Stub/cfa a (7b)__ pars x Iq cfm/pera (7)_______ Stub

S. Heating requirement: (6) + (7) Btuh

9. Heat gain from eLac equip/lights: _________watts x 3.4 Stub/watt - tub

B______
(9a) (9)

10. Reat gain from personnel: _ pers z 500 Stub/pers - B______

tub
(10a) (0

11. Total heat gain; (9) + (10) - _______Btuh

12. Net heating requirement; (6) -(11) _______ B tub

(12)

WhIere to find (Ga): Figure 11-1, Column D (Tb): Top of workahoot

(6b): Figure 11-2, Colum P (9a); Equipment ad lights In shelter
(?a): Figure 11-2, Coluemn 9 (10a): Top of workshoet

INSTRUCTIOINS FOR COMPLETING WORKSHEET

* STEP 6 -CONDUCTION HEAT LOSS

a Find the shelter you want to cool in Column A of Figure Il-I.

a For this type of shelter, pick out the winter heating load from Colun D and put It in workaheet space (Ga).
a Find the location of the *belter on the mep, Figure t-4, end note the pattern.
9 NoHtch the pattern with Column F, Figure 11-1. Pick out the proper cooling factor end put It in worksheet
*Perform the multiplication and put the result In apace (6).

STEP 7 - VENTILATION lWA LOSS

a With the climetic category pattern used In Step 6v find the winter heat Loss factor in Column H, Figure 11-1.
ad put It in space (7a).
a Put the number of people In the shelter in space (7b).
a Perform the multiplication end put the result in space (7).
STEP 8 - HEATING IEOVIflIEfl

5Add (6) and (7) and put the @s in workaheet apace (6). This is your heating requirement if your operational
equipment must he warmed before it can he safely started. In this case, use this figure in Workaheat Part Ill.
If you do not require preheating for the equipment, your energy requirements can he reduced by recognizing
the heat gained from electrical equipment and personnel in the ahelter and following Steps 9 through 12.
STEP 9 - HEAT CAIN FROM ELECTRICAL EQIPHET/IGHTS
a Add the power rating (watts) of minimum electrical equipment and lights to be used during shelter operation.
0 Put the $sm In apace (96) and mltiply it by 3.4,.
0 Put the results in space (9).

STUP 10 - H1EATGAIN FROM PERSONNL

a Put the number of people in space (10a) and mltiply by 500.

0 Put the result in space (10).

STEP 11 - TOTAL NEAT CAIN

* 5a Add (9) end (10) and put the sum in space (11).
$TEP 12 - NET HEATING SEQUIRWWT

eSubtract (11) from (8)and put the difference in space (12). This is the heating requirement for
selecting the ECU.

11-14
 'ORA.SHFET PART III- SELECTION OF ECU kPage I oi 2)

Shelter Designation: ; Location:

Cooling Requirement: _tuh; Heating Requirement: scun

Deslgn Inside Temperature: _F; Climatic Category:

Poner Source Available: _ volts, _ phase. tartz, wires

Reference Figure 1-2 and NIL-A-527675 for ECU data.

U
STEP HORIZONTAL COMPACT VERTICAL COMPACT

SINGLE ECU

13. Nominal capacity (Ituh):

(13a) (L3b)

14. Actual rating (Itub):

Cooling: _______ I_______*______ ______ X_______

(14a) (14b) (14c) (14d) (14a) (14f)

(14g)
(14h)

INTrVUCTIONS FOR COIEPLING WORKSHEET

SINGLZ ECU

S STEP L3 - NOMAL CCUCAPACITY

* From Figure 1-2, selact a horizontal and a vertical ECU each with a nominal capacity equal to the next size larger than
the cooling requirement. Put these siee in spaces (13a) and (13b).

,-. STEP 14 - ACTUAL RATING AID SELECTION

. 9 From Figure 1-2, find the cooling and heating "Rating Btuh" for these tvo ECU's. Put these into spaces (la) and (14%)
for the horizontal ECU and (l4d) and (14h) for the vertical ECU.
a With your climatic category and desired interior cemrerure (design tiside temperature), turn to Figure 11-5. Using
Curve A or Cure B, as detezuined by your climatic category, find the correction factor and put it into spaces (lb)
and (14e). Multiply to determine the MCU actual rating.
" If cooling rating of either or both of thea is equal to or slightly larger than the cooling requirement, you have
completed the preliminary selection proceas and Steps 15 and 16 may be skipped.
. If the hoting rating Is equal to or larger than the requirement, no supple- tary heater will be required and para-
graph 1l-13 may be skipped. If the heating rating is smaller than the requirement, go to paragraph 11-13.

a You should complete Steps 15 and 16 if the units in Step 14 are smaller or much larger than the requirement.

11-15
 IJORESSER? PART III -SELECTION Of ECU (Page 2 of 2)

DULNECUIS HORIZON1TAL COMPACT VERTICAL COMPACT

1S. NominaL capacities (stbl):

(5)(15b) (15c) (15d)

* 16. Actual racing* (Stuh):

Colig: (16.) (16b) (16c) (16d)(1)(6)

Heating:
(l6g) (16h)
17. Closest combinationl:

Cooling: 2 X (16a) or (161) - (l_______ OR (17b)____

Resting: 2 X (16g) or (161a) * _____ OR ______

(17c) (17d)

MTRU~CrxauS MR CONFUETING WORKSHET

Fro fiure1-2
slec th sul.Latpair of nominal capacities that satisfies the cooling requireent. Put these
* ratings in spaces (15a) and (13c). Multiply them by 2 and pat the results in spaces (15b) and (15d). If the pair
look. clos., proceed wt tp1;i oslc nte ar

SME 16 - ACTUAL RATINGS

e. From Figure 1-2, find the cooling and heating ratings for Cho vertical and horizontal ECU's picked in Step 1S; enter
these in spaces (16a). (16d). (16g) and (16h). Enter in spaces (16b) and (16e) the correction factor used in (14b)
and (14.). Multiply and put the results in spaces (16c) and (161).

*- STEP 17 -CLOSEST COMDBIOUY Of ECU'S

a If a pair of EU'. satisf ie and in closer to the cooling requirement than the single units of Stop 14,. the pair,
Ape sheliter space permitting,. should be your preliminary selection. Heating consideration is the same as for Step 14.

11-16
 SECTION III - MOUNTING THE ECU

Ill-1. Introduction

- This section suggests means for mounting the ECU's which you
. selected in Section II. The mountings presented here are structurally sound
and fit a variety of applications.
U * You will find that no single mounting concept is ideal for all
aspects of an operational requirement; each has its good points and each has
its drawbacks. As a consequence, you must clearly define your operational
environment, establish your priorities, and then select the concept which
comes closest to meeting your need or, conversely, creates the fewest
problems. Further, your consideration of mounting concepts must be done in
* full coordination with all other equipment to be mounted or emplaced in the
shelter.

111-2. Limiting Factors in Developing the Range of Mountinits

There are a number of practical considerations which affect mounting

options and narrow the range of possibilities.

e Side walls of all shelters are excluded from permanent exterior

mounting. The maximum envelope dimensions that you must stay within for
shipment preclude permanent exterior projections from the sides.

* Exterior permanent mountings on the end walls of all shelters,

except the S250 and S280, also are precluded by the shipping envelope
constraints.

e Permanent fixtures must be limited in expandable shelters. In

one-side expandables, the expandable side and a portion of each end wall are
excluded from any permanent fixture by the very narrow spacing between folded
panels. Because of center of gravity considerations during lifting and
moving, there should be restrictions also on the weight of equipment
permanently installed on the nonexpandable side unless the shelter is
permanently mounted on a truck or trailer. Both side walls and portions of
both end walls in two-side expandables are excluded from use for permanently
mounted equipment.

e Exterior mounting of the ECU on the entrance end of the S280 is

to be avoided because of the potential requirement for a protective entrance
(PE). (There are instances, however, where both the PE and ECU have been
accommodated on the entrance end, but this requires a special design for the
end panel to move the door from the middle to one side.)

* Permanent end-wall mounting of any ECU heavier than the 36,000

Btuh units is risky because of the limited strength of the shelter wall panel,
which could fail during road or rail movement.
S
e All mountings, when in shipping configuration, must withstand
railroad humping loads (up to 6 G's in the vertical and lateral directions and
10 G's in the longitudinal direction (from Reference 6)) and survive in the

.-
 nuclear conditions described in Section VII. These requirements have resulted
in much heavier mountings than would be required for a shelter which can
* remain static and not be subjected to tactical requirements.

9 The requirement for setup or takedown-packup to be accomplished

within 30 minutes by two men with little or no mechanical lifting assistance
" dictates:

ee Permanent mountings where practicable: slide-in/slide-out

and inside-fixed or exterior-fixed wall mountings.

e* The exclusion of mountings which require manual lifting of

*the ECU more than a few inches off the ground in order to mount it.

ee That remote mountings be designed as self-contained units.

The ECU should be transported on its mounting pallet so that only positioning
relative to the shelter, connecting, and turning on are all that are required
upon arrival at the operating site. All hardware necessary for putting the
unit into operation must accompany the ECU and be readily available and
accessible. The possibility of separation or loss during storage, shipment,
and use must be at a minimum.

9 The mounting should permit ready access for routine servicing

* and minor maintenance without removal of the ECU from its position. If slight
shifting must be done, it should be possible without the need for mechanical
lift assistance. This requires that both sides, front, back, and top be
exposed or easily exposable.
. 111-3. Recommended Match-Ups

To assist you in narrowing your considerations, a table of recommended

shelter-ECU match-ups is shown in Figure III-1. Types of mounts suitable for
these match-ups are discussed in paragraphs 111-4 through 111-7, below.

111-4. Retractable Mounting

o Description. The distinguishing feature of the retractable

mounting is its ability to move out of and back into the shelter through a
hole in the shelter wall. In the design presented here, this movement is made
possible by the commercially available supporting ball bearing slides, or
tracks. The recomended position of the mount is at floor level where it
requires the least amount of space-consuming bracing and reinforcing to
withstand the dynamic loading of rail shipment. A type of retractable mount
*. is illustrated at Figure 111-2; a design drawing is at Appendix II-1.

• Benefits.

*e In concept, the retractable mount is the best system for the

shelters of this handbook in non-CB and non-nuclear environments. It permits
you to keep the noise and heat outside the shelter during operation while
allowing for rapid deployment. In non-CB and non-nuclear environments, the
ECU can be retracted for redeployment with little time and effort and then
pushed out again into operating position upon arrival at the new site.

* 111-2
 SHELTER HORIZONTAL ECU VERTICAL EC; j MOUNTING POSITION OPTIONS

VONEXPANDABLE

S250 6,000 1 Rear 2 exterior wall

9,000 Rear exterior wall
2
S280 6,000 Front or rear exterior wall

9,000 Front or rear exterior wall

900Frontora exterior wall
3
9,000 (Single or Double) Front exterior wall
3
18,000 (Single or Double) Front exterior wall
18,000 Front exterior wall
3
36,000 36,000 Front exterior wall
All above, plus 60,000 All above, Ground: remote or flush;
plus 60,000 entry through any wall
Retractable: any wall

ISO, Army, GP Same as S280 Any wall: mount should be

retractable, fixed interior
or ground type

Navy Same as S280 Any wall: mount should be

retractable, fixed interior
or ground type

EXPANDABLE

All 36,000 and 60,000 6,000, 9,000 Remote ground mount with
(Below 36,000, vertical and 18,000 flexible ducting
ECU's present a more (Above 18,000,
suitable matchup) horizontal ECU's Flush ground mount with boot
present a more to eliminate flexible
stable package and ducting
a smaller envelope)

ISee Figures 1-1 and 1-2

2
Rear - shelter entrance end
Front - end opposite from shelter entrance
3
Fixed or retractable mount

• .1
Figure III-1. RECOMMENDED SHELTER-ECU MATCHUPS

111-3
C-, ' . -.-- - > .- . . - .- - .. . . "- .. - .

HASKETING REQUIRED
AROUND SIDES AND TOP

PROPER GASKETING ESSENTIAL

AT ALL NONWELDED JOINTS
TOP REMOVABLE FOR
RETRACTING ECU

T B
SALL EARING TACKS

SIEES AF IXEDTO
PERMANENTLY
. SHELTER FLOOR

SEALING OPTION: ALUMINUM BOX OVER

TRACKS SEALS OPENING AGINST C5 CON-
TAMINATION AND EMP.

FLOOR STIFFENERS

Im MOUNT IN EXTENDED POSITION

• " WEDGES

SINCE TRACKS WILL NOT SUPPORT MAXIMUM DYNAMIC AND BOLTED

LOADS, MOUNTING WEDGES LIFT WEIGHT OFF TRACKS
WHEN IN RETRACTED POSITION. BOLTS LOCK MATING
WEDGES TOGETHER AND RESIST DYNAMIC LOADS.

Major actions to place into operation: Remove plug from wall opening; push ECU into operating
position; attach bracing as required; place cover plate over tracks inside shelter (for sealing);
* attach power and control cables; attach any ducting required; start ECU.

CHARACTERISTICS OF RETRACTABLE MOUNTING

* . ECU mounted on ball-bearing slides, For shipping, ECU locked in retracted position inside the
shelter (sketch illustrates concept). For humping, ECU also requires bracing at top. Boithole
in
in upper rear of ECU provided for this purpose. For operation, ECU pushed through opening
shelter wall into extended position.

. • To withstand nuclear overpressure in extended position mount and ECU require removable
external bracing against movement in all three planes (not shown on sketch).
mounting is
a Mounting shown uses vertical ECU which generally is a more suitable configuration.
adaptable to a horizontal ECU.

Figure 111-2. MOUNT FOR RETRACTABLE ECU

111-4
 go When retracted, this mounting method leaves no significant
exterior projections to violate the shipping envelope. This benefit is most
notable with the shelters larger than the S250 and S280. (The S250 and S280
can fit into a shipping container with their ECU's still mounted on the front
end).
e The ECU is protected during shipment since it is inside the
shelter.

9 Problems.

oo The stringent sealing requirements for an NBC (including

EMP) environment are very difficult to meet and to maintain with a retractable
mount. The irregular surfaces around the tracks supporting the ECU constitute
an exceptionally difficult interface joint to seal. A concept for this is
shown on Figure 111-2. Reference 35 shows a concept for closure used with the
Navy ECU's. Further, when seals must be repeatedly broken and re-established,
there is a serious doubt that they will continue to be effective in:

- Maintaining the positive air pressure necessary for CB

4 protection without an undue loss of air from leakage and the resultant
increased demand on the ECU and the gas particulate filter unit (see Section
V).
- Sealing against CB and radioactive contaminants during
|
6. brief moments when outside pressure may be greater than inside pressure. Such
m reverses in pressure may be from a number of causes to include a gust of wind
or a passing truck.

- Maintaining the seal against EMP, which is critical if

solid-state equipment is to survive.

os The best ball bearing tracks available are strong and

durable but, when extended, cannot be relied upon to withstand significant
dynamic loading while supporting the weight of the ECU. Therefore, to survive
significant nuclear overpressure (see paragraphs VII-2 and -3), the mounting
would need reinforcing with outside bracing comparable to the wall mount
designs presented in paragraph 111-6. Since projections outside the shipment
_- envelope are unacceptable, the bracing would have to be removed for transit,
stowed during transit and reinstalled upon setup. This would detract from the
quick setup and takedown benefits of the retractable mount. Further, there
would be little gain, if any, in survivability since the current shelter,
. itself, is rather weak in this respect (see paragraph VII-2).

go There is no gain in interior space when the mount is in the

extended position. The area vacated by the ECU when it is extended (and into
which it retracts) is not available for other uses since this area must remain
clear to prevent blocking the air passage (unless detachable ducting is
provided, which would further complicate the takedown and setup process by
.adding to the number of pieces to be disconnected, stowed, and reconnected).

* 111-5
 so Structurally, the best position to place the retractable
mounting is on the floor. The best position from an air distribution
viewpoint is near the ceiling. 1 The dynamic loading of railroad humping would
make a structure for putting the ECU near the ceiling rather space-consuming.
(Note comment on use of equipment racks in paragraph 111-5, below.) The
problem could be overcome by use of a riser duct from the air supply outlet of
the ECU to a point near the ceiling. But this would require space (up to 8
inches from the wall and as wide as the ECU air supply discharge). Also, as
* noted above, ducting would complicate the takedown and setup process.
so The ECU should not be retracted into the shelter following a
CB attack until it is decontaminated.

111-5. Tnside Fixed Mounting

e Description.

*o For floor mounting, the ECU is fixed into its place firmly
enough to withstand the rail shipmenL dynamic loadings and is insulated to
reduce both heat and noise (the heat being that which radiates from the ECU
housing). The rear of the ECU faces outbide through a hole in the shelter
wall so that air used for cooling the condenser is discharged directly outside
without entering the shelter compartment.

so Since the mounting bolt spacing of the ECU probably will not
coincide with the floor stiffener spacing, a plate or beams will have to be
used to span and be bolted to the stiffeners. The ECU can then be bolted to
the plate or beams. It is adviseable also to use a reinforcing back plate
beneath the floor, on the outside, which can be connected to the base plate or
beams by bolts through the shelter floor. The Base Civil Engineer should be
able to provide the engineering for this relatively uncomplicated requirement.
One way to deal with the problem of noise and heat from the inside-mounted
5 ECU, and at the same time provide the vertical ECU with the necessary bracing
against overturning, is to fabricate a rigid, insulated enclosure for the ECU
(note Figure 111-3). The enclosure would attach to the shelter floor and wall
* and be removable to permit access to the ECU for repair and maintenance.

so Mounts near the ceiling would require structure inside the

shelter which, depending upon its design, may reduce space for other purposes.
" A supporting structure, such as equipment racks of the type provided by
shelter manufacturers, if adequately anchored, can support the ECU near the
ceiling and might permit better space utilization by allowing the space
beneath the ECU to be used for other purposes.

'Provided there are no obstructions to block the air flow (see Section IV),
cooling can probably be accomplished in the shelters addressed by this

* handbook with a
effectively. floor-mounted
Because of their ECU, although
height, somewhat ECU's
the vertical less efficiently and to
are more suited
floor mounting than are the horizontal models and can probably be used
satisfactorily without ducting. A floor-mounted horizontal ECU, on the other
hand, should probably have its supply ducted to near the ceiling.

111-6
 VERTICAL ECU WITH DUCTING TO SEPARATE AIR SUPPLY AND AIR RETURN

AIR SUPPLY OUTLET

18,000 BTUH ECU IN SOUND

AND HEAT INSULATED COMPARTMENT

VERTICAL ECU WITH AIR SUPPLY DUCTED TO CEILING LEVEL OUTLETS

-SPACE WITH
•AIR SUPPLY OUTE DIFFICULT ACCESS

AIR RTURN18,000 BTUH ECU IN SOUND

AND HEAT INSULATED COMPARTMENT

AIR SUPPLY
RISER DUCT

Figure 111-3. INSIDE MOUNTED ECU'S ILLUSTRATING

CHARACTERISTIC SPACE REQUIREMENTS

m 111-7
 o Benefits

ee The ECU is fixed and braced in place and ready to turn on

almost immediately upon arrival at the operating site. Further, there are no
requirements for you to remove hardware in preparation for a move, to stow it
during transit, and to replace it upon arrival, so takedown and setup times
are practically nil.

eo Sealing is comparatively easy since gaskets are compressed

between the relatively even surfaces of the rim of the ECU's rear face and the
frame around the hole in the wall panel. Additionally, the seals should be
more effective than with most other mounts since there is no requirement to
* break them for moves; the floor mounting should permit maintaining a rigid
joint with a constant pressure on the seals.

so The ECU is protected at all times to the same degree as

other interior-mounted equipment.

eo This is a less expensive and more quickly installed mounting

' than all others considered.

o Problems

*o Military ECU's are designed primarily for outside

installation, so the condenser sections of the ECU's are not insulated. As a
consequence, they are heat producers in suer and cold producers in winter.
Further, they are noisy, especially the vertical configurations, although,
newer models have been improved somewhat in this respect. Adequate insulation
can reduce the heat problem to a manageable level but may help less
* effectively with noise. A good, solid job of mounting should be some help
" with vibration and noise.

o For structural reasons, the shelter floor is the best place

to mount the ECU, but this position is not the best for air distribution.,
Addequate bracing inside the shelter, to support the ECU near the ceiling and
meet the railroad humping load requirement, would be very space consuming and
is not recomended unless standard equipment racks can be made suitable. The
ducting necessary to raise the air supply outlet from the floor to the ceiling
would also consume space. To rise vertically from the ECU air supply
-" discharge, the ducting would be 20 to 30 inches from the wall (a little more
than the distance from front to back of the ECU) and, unless adjacent
equipment can lend support, would be free standing and require special
bracing. Some appreciation of the space requirement may be gained from the
sketches in Figure 111-3.

so Access for maintenance and repair can become a problem

unless care is taken in locating adjoining equipment. There must be clearance
for hands and the use of appropriate wrenches in demounting and remounting the
ECU.

1Ib1id.

11 -

.i. . . . .
 111-6. Outside Wall Mounting

e Description. The ECU is wall-mounted outside the shelter on a

frame affixed to the end panel of the shelter. The conditioned air supply and
return face into the shelter through a hole in the wall. The mountings are
"* designed to withstand railroad humping; an incidental benefit is an ability to
"- survive an estimated nuclear free field overpressure of 4 psi. Since the
structural design of shelter wall panels, according to the leading
* manufacturers, varies widely even within the same shelter type, the design
. cannot rely solely on end panel strength. Instead, it transfers a major
portion of the load from the end panel to the corners and into shear stresses
in the side and roof panels. (The thin-skinned sandwich panels are much
-stronger in shear than in moment.) Sample design computations are included in
*Appendix 111-2; design drawings are at Appendix 111-3. You can find wall
mountings illustrated in Figures 111-4 and 111-5.

* Benefits

ee There is no requirement for setup and takedown for

relocations.

so Noise and radiated heat are outside the shelter.

e There is a space saving by not having the ECU and its

mounting structures inside the shelter. This saving is reduced somewhat,
i however, by the need to keep the area in front of the ECU open and permit
proper air flow.

9 Problems

eo The use of the outside fixed mounting is limited to the S250

and S280 shelters. These mounts would be applicable also to other shelters of
* similar width if their use were not precluded by the shipping envelope
constraints.

so Because of their exposed position, the outside mounted ECU's

- are subject to damage by flying fragments as well as nuclear blast and thermal
effects.

so The outside wall mounts assume that the shelter will be

truck-mounted and therefore are designed to overhang the truck cab. The
designs are intended to allow adequate clearance between the mounting frame
and the truck cab. However, the height of the cab top above the truck bed can
vary several inches not only between truck types but also within the same
type. Therefore, the vertical distance between the cab top to the bed level
must be determined and checked against the mounting design for each truck used
to see whether the mount will clear the cab or whether the shelter should be
raised by blocking.

III-7. Ground Mounting

o Description. The two types of mountings described below should

- satisfy nearly all ground mounting requirements.

S111-9
 - I.- .---.

-OUTLINE OF ECU,
OFRAME
r-SHELTER OPENING

ECU TRANSVERSE
SUPPORT MEMBERS

OPENING
ECU SEALING COLLAR ECUFE

U • MOUNT ING-, GASKET ING

G ECU GRILLES
MOUUNTINRGLE
GASKETING
//
REINSTALLED
GRILLES

S I" -- OPENING FRAME

U S -IM SHELTER WALL

MOUNTING METHOD "A" MOUNTING METHOD "B"

ECU fits through opening into shelter. This is ECU is completely outside shelter. Supply and
- simpler of two methods but it is a little more return grilles and control panel are removed and
difficult to seal. reinstalled onto a grille support frame which
must be fabricated. Grille support frame must
include ducts to keep supply and return air
separated in space between ECU and remounted
N% grilles.

CHARACTERISTICS OF FIXED MOUNTINGS

. Permanently attached to shelter; permits shipping shelter with ECU in place (ECU mounted
using normal boltholes in bottom of unit).
e Designed for rail humping loadings of 6G in vertical and transverse directions and lOG in
longitudinal direction.
* Designed for nuclear overpressures up to 4 psi.
e Fabricated from standard aluminum extruded shapes or from shapes built up from aluminum
sheets. Welded construction.

Figure 111-4. TYPICAL WALL MOUNTING

III-10

LN .- . ~ - - ft 1
 ------ WALL MOUNT #1
"4-' Applicable
ECU: 900Btuh
I 18,000 Btuh
* Approximate
*Weight: 113 pounds

*Drawing: Appendix 111-2

Figure 111-2-1

WALL MOUNT #2
Applicable
ECU: (2) 9,000 Btuh
(2) 18,000 Btuh
Approximate
Weight: 118 pounds

*Drawing: Appendix 111-2

* Figure 111-2-2

WALL MOUNT #3
Applicable
ECU: 36,000 Btuh
Approximate
Weight: 133 pounds
Design
oilDrawing: Appendix 111-2
_ Figure 111-2-3

Figure 111-5. WALL MOUNTINGS FOR HORIZONTAL ECU

 oe Remote mounting. The ECU is mounted and braced on an
aluminum frame pallet, see Figure 111-6. Also on the pallet is space for
stowing the hardware necessary to put the ECU into operation. The ECU is
shipped on its mount, separate from the shelter. When tied down to prevent
tipping, the mount is designed to survive rail hump loadings as well as the
nuclear overpressure up to 4 psi. (Sample design computations are included in
Appendix 111-4 and a design drawing is at Appendix 111-5.) In operation, the
mount is located 4 to 8 feet from the shelter and the conditioned air is
carried to the shelter by flexible ducting.

9o Flush mounting. The main conceptual difference between this

and the remote mount is that the flush mounting is almost touching the shelter
* as illustrated in Figure 111-7. Shelter and ECU are connected by a short,
*heavy-duty boot made of high-heat-resistant material. The boot is accordioned
to absorb a small amount of independent movement between the shelter and ECU.
It is strong enough to provide a degree of support to the ECU so that it can
*- use a simpler mounting than that required of the remote concept. The mounting
illustrated in Figure 111-7 is a suggested type but any mounting which would
hold the ECU at the desired level and prevent its tipping over should be
*acceptable.

e Benefits

so Remote mounting.

-- Since the conditioned air supply and return are carried

in 10-foot-long flexible ducts, this mounting method offers the most
flexibility of all the mounts for locating the supply and return opening(s) in
the shelter wall. You may locate them separately or together, select a
position to avoid obstructions and prevent a short circuit (see definition in
Appendix A-l), and place the openings to make most effective use of available
air passages inside the shelter, thus reducing the space that must be
*dedicated solely to this purpose.

-- The sealing of the interface between the ECU and the

shelter is comparatively simple to achieve and maintain.

-- There is practically no stress on the wall panel from the

mounting.

-- The remote mounting can be used with any size ECU and
with any shelter.

-- There is full accessibility for maintenance and repair of

the ECU.

-- The shelter is isolated from the vibration and noise of

- the ECU.

o Flush mounting.

-- Sealing the ECU-shelter interface is a comparatively easy

task since fairly even surfaces meet each other and gaskets can be uniformly
compressed.

' 111-12
 ~-MOUNTING

PROVISION FOR

NUTS, BOLTS ADAPTERS

SMALL PARTS 'QUICK RELEASE CLAMPS

CONTROL PANEL SOX

REMOTE MOUNTED ECU WITH ESSENTIAL ACCOMPANYING PARTS

major actions to place into operation: locate and level mount, remove supply
and return grilles from ECU and install on grille support frame (permanently
nstalled on inside of shelter), mount control box in shelter, install
adapters and flexible ducting, connect power cables.

CHARACTERISTICS OF REMOTE MOUNTINGS

* LocaL d away from shelter.
e ECU bolted to skid-mounted pallet, using normal ECU boltholes, for shipment
and operation.
* includes stowage for all necessary hardware.
a-* Designed for rail humping loadings of 6G vertically and transversely and
00Glongitudinally.
a Designed for nuclear overpressures up to 4 psi.
a Fabricated from standard al w'rium sheets and extruded shapes. Welded
construction.

Figure 111-6. TYPICAL REMOTE GROUND-MOUNTED ECU

111-13
F

" F PLEXIBLE DUCTING B00T *

i'! --- ILLES HAVE BEEN• ECU SHELTER

REMOVED FOR INSTAL-

LING OVER OPENINGS

CONTROL PANEL REMOVED AND RELATIONSHIP OF ECU TO SHELTER

INSTALLED INSIDE SHELTER

PALLET: ALUMINUM CHANNELS

FOR FRAME AND J-INCH
ALUIINUM PLATE FOR TOP.

---A----CONTROL CABLE
"'" POWER CABLE

ROLLING CRANK JACKS P A *A SOURCE FOR THIS KIND

OF BOOT IS:
THERMOIO DIVISION
H.K. RTER COMPANY, INC.
I.il PORTER BUILDING
PITTSBURGH, PA 15219

" ajo7 actions to place into operation: Remove grilles from ECU; attach boot to ECU; attach power
cables; push ECU into position close to shelter; attach necessary gasketing; attach boot to shelter;
gattach necessary filters; attach grilles to opening inside shelter; attach necessary ciedowns.

CHARACTERISTICS OF FLUSH MOUNTING

o ECU mounted on simple pallet to provide stability for shipment and operation. For railroad
shipment and when nuclear overpressure loadings are expected, tiedowns, from the top, should also
be provided. Pallet has light duty, rolling crank jack (several types are commercially available)
bon each corner for adjusting height up to 12 inches and for leveling. Wheels on jacks permit
short moves at very slow speeds and manually shifting position of unit.

ECU located approximateiy 6 inches from shelter and attached to shelter by custom made, commercial
heavy, flexible, high heat ducting, or boot. Boot has metal flanges bonded to ducting. Small
access space between ECU and shelter dictates that flange and bolt holes be accessible from the
inside of boot. Boot is connected to ECU first. ECU is then pushed against shelter. Access to
bolts is from inside of shelter through hole in wall panel to inside of boot.

* Suggested means of transporting boots, bolts, and wrench is canvas pouch, or pouches, which can
be strapped to ECU.

o Vertical ECU is shown in illustration but concept is adaptable to horizontal units.

Figure 111-7. TYPICAL FLUSH GROUND MOUNTING

111-14
 -- The short boot which connects the ECU and the shelter is
relatively hard. It is much shorter and much tougher than the long flexible
ducting of the remote mount. Also, it is between the ECU and the shelter and
thereby somewhat shielded from thermal radiation.

-- There is no constraint on matching ECU's and shelters.

-- During normal operation, there is little stress on the

*shelter panel from the mounting.

-- The shelter is separated from the ECU by the length of

the boot (approximately 6 inches). This serves to isolate the shelter from
the vibration and noise of the ECU.

e Problems

-o Remote mounting.

-- The ECU and ducting are vulnerable to fragments, blast

pressures, and thermal radiation; the ducting should not be expected to
Isurvive.

-- The weight of the ECU and the mount requires mechanical

lifting equipment and transporting equipment to move the system to the site
and to place it where it will be used. If materials handling equipment,
cranes, or wreckers are available, this is no problem. A system shipped by
sea would require transport to move it to its site and plans would probably be
in place for this. One shipped by air may require a dolly or other means of
short-range transport to move it from the aircraft to its on-base site. Long
distances would require major transport means in any event.

e Flush mounting.
Although less vulnerable than the remote mounting, the
--

fact that the ECU is in the open renders the flush mount, also, susceptible to
- damage by fragments, blast pressures, and thermal radiation. However, the
boot duct should survive in cases in which the ECU and shelter survive.

-- The weight of the ECU presents the same requirement for

moving and handling as does the remote mounting.

oe Because of their height, both mounts are subject to tipping

when hit by the blase wave or subjected to railroad humping. They should
therefore be tied down during both movement and operation.

111-8. Frames

For all mounts, the necessary holes or openings in the walls must be
adequately framed both to restore and reinforce the strength and rigidity of
*the panel and to protect the edges of the hole. A framing concept which is
*commonly used and which has proved to be satisfactory is illustrated on Figure
111-8. The frame can be modified in size and strength to accommodate having
, other structural members bolted to it.

111-15
 7

ANGLES (SEE NOTE I

THERMAL BARRIER
(SEE NOTE 2)

SHELTER INTERIOR SHELTER EXTERIOR

SHELTER WALL
BLIND RIVETS
A (SEE NOTE 3)

3 ASSEMBLED FRAME SECTION A-A

NOTES:
I. ALUMINUM ALLOY 6061-T6: EXTRUDED OR FABRICATED
ANGLES, MINIMUM 1/8 IN. THICK. LEG LENGTHS TO
ACCOMMODATE SHELTER WALL THICKNESS AND ANY
STRUCTURAL ATTACHMENTS (E.G., MOUNTING FRAMES).

2. THERMAL BARRIER, 1/8 IN. THICK:

- LAMINATED PLASTIC - MIL-P-15035, TYPE FBM QA

- TEFLON STRIP - MIL-P-22242 Qj
- PLYWOOD, EXTERIOR TYPE, COMMERCIAL STANDARD
PS-I-74

3. RIVETS SHOULD BE DIPPED IN CONDUCTIVE SEALANT

PRIOR TO INSERTING INTO HOLES.

Figure 111-8. SHELTER OPENING FRAME

111-16
 111-9. Summary

RFor Mountings,
-
convenience, a Table of Considerations for Selecting ECU
which summarizes the discussions of paragraphs 111-2 and 111-4 to
111-7, is included at Figure 111-9.

11-1

. L- . --
 CONSIDERATION EXTERIOR FIXED RETRACTABLE & FIXED GROUD MOUNTINGS
WALL MOUNTINGS INSIDE MOUNTING (REMOTE & FLUSH)

U ,icn shelters are

applicable?
S250 and S280 only (all
others precluded by ship-
All nonexpandable sheltersI All shelters.
(no permanent fixtures in
ping constraints). walls of expandable
shelters).

"hat ECU sizes can be Up to: Two 18,000 Btuh, or Up to one 36,000 Btuh per No restrictions. (But
mounted? One 18,000 Btuh mounting. Vertical ECU's for ECU's of 36,000 Btuh
plus 1 GPFU, or present betrer space and above, horizontals
One 36,000 Btuh utilization in most cases, present a smaller enve-
ilope. Verticals are pre-
ferred below 36,000 Btuh.)

Any restrictions on e Restricted to: a Should be restricted to No restrictions.

mounting locations? - Rear end wall of S280. floor level only.
Front (entrance) end
F All two-side expandable
precluded by need to
preserve option to use mounts which are not
CB protective dismantled before
entrance. shelter is prepared
for
- Front (entrance) end movement.
of S250.

* Shipping considerations
preclude use of:
- All side walls of all
shelters.
- All shelters larger
than S280.
- All expandable
shelters.

What clearances are Sufficient to prevent Requires space for entire Sufficient to prevent
required inside blocking of air supply and ECU, plus riser air duct; blocking of air supply
shelters? return flow. Refer to also space sufficient to and return flow (see
Section IV of this hand- prevent blocking of air Section IV). Supply and
book. supply and return flow return can be close
(see Section IV). together or separated
when flexible ducting is
used for carrying air to
shelter.

Any exterior ducting None required. None required. Normal remote mounting
required? requires flexible duct-
ing. The ground flush
mounting uses a boot
which allows ECU virtual-
ly to be attached to
shelter yet permits small
independent movement and
isolates shelter from ECU
vibration.
What set-up tasks are None. Retractable: Unplug wall Minor leveling of ECU
required at the opening; remove bolts, pallet, unplug wall open-
operational site? emplace ECU in out ing(s), connect adapters
position; affix external and ducting, connect con-
bracing, install air duct trol cables, and connect
connections, seal around power cables. (Assumes
opening. pallet-mounted ECU was
satisfactorily located
Fixed Inside: Unplug wall when delivered. ECU and
opening. pallet can be manhandled
for small adjustments in
position.)

Figure II-9a. TABLE OF CONSIDERATIONS FOR SELECTING ECU MOUNTINGS

(Continued on next page)

111-18
 EXTERIOR FIXED RETRACTABLE & FIXED GROUND MOUNTINGS
N EWALL MOUNTINGS INSIDE MOUNTING (REMOTE & FLUSH)

How is the access for Good. Retractable: Good. Excellent.

servicing and minor Fixed Inside: Good to
repairs?por
affied, ithsandpoor.

Can mounting, with ECU Designed to withstand rail Retractable: When in Mounting pallet is
affixed, withstand humping loadings (6 G in retracted position only. designed to withstand
shipping? vertical and transverse Fixed Inside: Proper rail humping loadings
directions and 10 G in fixed mnie Proper with ECU in mounted
longitudinal direction). floor mounting should position. NO TESTING
NO TESTING HAS BEEN DONE. stand up to hump loads. HAS BEEN DONE.

'hat is extent of Overpessure up to 7.3 psi. Retractable: Can with- Mounting will take 7.3
nuclear hardening? ECU may be vulnerable to stand only in retracted psi with ECU on it but
fragments. NO TESTING HAS position (if shelter has will need anchoring to
BEEN DONE. been hardened). NO TEST- 1 prevent moving or tip-
ING HAS BEEN DONE. ping over. Flexible
as ducting is extremely
Fixe Ivulnerable. Boot used
above, with flush mounting is
expected to be equal to
mounting. NO TESTING
HAS BEEN DONE.

What is difficulty of Moderate. Retractable: High. Minimal.

sealing the ECU Fixed Inside: Moderate.I
openings in the shelter F
against air loss and
NBC contamination?

Is transportation No. ECU and mount are No. ECU and mount are Yes. ECU is separately
separate from shelter permanently attached to permanently attached to mounted and transporta-
required? shelter, shelter. tion arrangements for it
are required. This
includes long distance
and short distance moves.
Also, mechanical help for
loading and unloading
from transporting vehicle
is required.

Figure III-9b. TABLE OF CONSIDERATIONS FOR SELECTING ECU MOUNTINGS

111-19
1
 SECTION IV - DISTRIBUTING AIR IN THE SHELTER

IV-1. Introduction

e You will find that most heating and air conditioning manuals
are aimed at buildings requiring considerably more complex air distribution
systems than do tactical shelters. Fortunately, most of the factors which
impact heavily on air flow in long, complex systems have drastically less
impact on the types of short, compact systems of concern here. Therefore, for
these small systems, simplifications can be introduced to permit easier and
quicker design without appreciably degrading either the design or the
effuctiveness of the system.

a If you encounter more complex problems than the ones addressed

here, you should consult appropriate handbooks (References 4, 7, and 19, for
.* example) or an air conditioning engineer for the needed assistance.

IV-2. Free-Flow or Ducted Distribution?

e There are two ways in which you can distribute the air within a
shelter. One is free-flow, that is, direct discharge of the conditioned
"
-supply air into the shelter with sufficient velocity and direction so that the
air, in effect, distributes itself. The other way is to carry the air through
ducts directly to the point or points where it is needed. In a combination of
* these two methods, you may duct the supply, only. It is very unlikely that
5you would need to duct the return in small shelters.

* Free-flow distribution will be adequate in most cases covered

by this handbook and you should use it wherever possible. It has the
advantages of being cheaper, quicker, and easier to install than ducted
distribution and it takes up less space inside the shelter.

IV-3. Plannina the Distribution System

e Obtain scale drawings of the plan and elevation of the shelter

interior. Then follow the planning steps on the Air Distribution System
Planning Instructions, pages IV-2 through IV-4.

e In one system or another, you will certainly encounter the need

o-to change the duct's cross-sectional dimensions, change direction, or direct
some of the air to intermediate points, and maybe all of these. These changes
need not have a great impact on your system effectiveness if they are handled
properly. If and when you encounter these needs, refer to paragraphs IV-4
through IV-7 for advice.

* When ducting is to be used for both cooling and heating, it is

* normally designed for cooling with the knowledge that it will work also for
heating. Auxiliary heaters in a shelter will probably be unducted or, if
ducting is necessary, separately ducted.

IV-1
 AIR DISTRIBUTION SYSTEM PLANNING INSTRUCTIONS

STEP

3 NO. STEP DESCRIPTION AND EXPLANATION COMPLETED

Steps 1 thru 17 are in Section II - Selecting the ECU

18 Determine what needs cooling:

* Personnel

* Equipment

e Both

19 Accurately locate on the scale drawings personnel stations and all

installed equipment, cabinets, or other objects which might cause
an obstacle to straight air flow. Identify the position of
electrical equipment.
20 Determine where the ECU supply and return will be. You may not
have much choice in this; the location of a wall-mounted ECU is
dictated largely by the shelter wall structure and the mounting
structure design. The ducted supply and return from an ECU on a
remote mount provide more flexibility for locating the entry into
the shelter. But even here, you may find yourself restricted by
the arrangement of interior-mounted mission equipment. If you
have a choice:

* Position the supply and return to avoid a short circuit1 .

• Locate the supply so that the air stream is afforded a

straight path to the primary area to be cooled.

e Locate the supply so that the conditioned air reaches

personnel stations first and electrical equipment second.

* For horizontal ECU's, locate the supply entry into the

shelter in the upper part of the wall. If the ceiling is
free of obstructions, a location near the ceiling should
be selected. If there is an obstruction on the ceiling,
;he supply should be lowered to where a straight air
stream will miss the obstruction. In most cases the
supply air outlet of a vertical ECU mounted at floor
level will be high enough to permit free flow
distribution without ducting unless there is an
obstruction to proper flow. The location of the return
is less critical but should not be blocked or positioned
to cause a short circuit (see Figure IV-I). It is
desirable that the return be in the lower part of the
wall, even near the floor if this is an easy option.

ISee definition in Appendix I-I. A short circuit can defeat your

system so avoiding it is important.

IV-2
 Clearance for Air Return

The following is a rule of thumb and AIR SUPPLY OUTLET

not a hard-and-fast requirement. You
may vary from it if the equipment in the
shelter cannot be arranged to permit the AIR RETURN OUTLET
recommended clearances. But you must
keep in mind that the more you squeeze
the air flow clearances, the greater the
risk to the effectiveness of the I
environmental control system.

The clearance (dc) in front of

return intake of the ECU should be at
-' least 2 inches or that necessary to pro-
vide a cross-section of air flow equal
to twice the area of the ECU return dc
intake opening, whichever is greater.

Example:

A - Area of ECU air return intake

- opening
- 15 in. x 16 in. - 240 sq in. ECU SUPPLY AIR
Wc - Width of clearance - 16 in. SIDE
hc -Height of clearance - 30 in.
RETURN AIR
FIND: Required depth of clearance, dc

2A dc (2hc + wc) dc

Notice that since obstruction is sitting

on the floor, air flow is around three
sides only.

d 2 x 240 - 6.3 inches

c 2(30) + 16

NOTE: If the air flow from the sides of p- RETURN AIR

the ECU is lessened by reducing the
clearance or adding more obstructions,
the more will be the air that must come
over the top of the obstruction. This ECU
path will impinge on the flow space of dd
the air from the supply outlet and A Wc
create conditions that could result in TO
a short circuit. If this becomes a
problem, the supply air outlet should be A
relocated by ducting.
-CRETURN AI R

Figure IV-1. RETURN AIR CLEARANCE

IV-3
 AIR DISTRIBUTION SYSTEM PLANNING INSTRUCTIONS

STEP
NO. STEP DESCRIPTION AND EXPLANATION COMPLETED

21 Accurately locate on the drawings the conditioned air supply and

return outlets.

22 Determine by using the drawings if there is a direct, unobstructed

view, at least as wide as the supply outlet, from the air supply
U to points to be cooled. If not, an unsatisfactory condition for
free-flow distribution exists. See Step 25.

23 Determine by using the drawings if a short circuit condition

exists or is likely to exist. A good rule of thumb to follow is:
if it seems likely that there will be a short circuit, assume
there will be. If there seems to be a short circuit condition, an
unsatisfactory condition for free-flow distribution exists. See
Step 25.

24 Determine if free-flow air will pass heat generating electrical

equipment enroute to personnel. If so, multiply the wattage of
the equipment by 3.4 Btuh per watt. If the result is 35%1 or more
of the ECU rated cooling capacity, an unsatisfactory condition
exists for free-flow distribution. See Step 25.

25 If all conditions examined in Steps 22, 23, and 24 are

satisfactory, ducting is not required; you may use free-flow air
distribution, and the remainder of this step and all of Step 26
may be omitted. If any condition is unsatisfactory, ducting is
necessary.

* If more than one condition is unsatisfactory, any ducting

planned must satisfy all conditions.

e On the drawings, sketch the route of the ducting and the

location(s) of outlet(s) to overcome the problem(s).
Keep in mind that:

eo Only the supply needs to be ducted except in unusual

circumstances.

*e The duct should be as short as the requirement will

allow.

ae Changes in direction and size or cross-sectional shape

of ducts should be minimized and curves should be as
gentle as space will permit.

1The 35% is another rule of thumb and is based upon considered

judgement; it is believed close enough for your purposes in this
handbook.

IV-4

I --
 AIR DISTRIBUTION SYSTEM PLANNING INSTRUCTIONS

STEP
NO. STEP DESCRIPTION AND EXPLANATION COMPLETED

oe High velocity air (50 fps or higher) blowing directly

on a person will be uncomfortable. The best approach
for air at acceptable1 velocities is directly from the
front. The next best is from the side or from
overhead. The lease desirable, from the viewpoint of
comfort, is from behind the person. 1

*o While comfort is not to be ignored, these systems are

for use under field conditions where comfort must take
second place to operational and logistical
considerations. If in extreme weather conditions the
temperature occassionally becomes a little warmer or a
little cooler than desired, the occupants can dress
accordingly. If there are times when the breeze from
the ECU is blowing directly on an occupant and is
either too strong or too cool, the occupant can change
the louver setting to deflect the airflow.

26 Once you have decided upon the location of the duct and the
outlets, the size and cross-sectional shape of the duct should be
determined. These may be controlled to some extent by the space
available but you should try to keep them as close as you can to
the dimensions of the supply discharge. The aspect ratio, that
is, the ratio of the cross-sectional long dimension to the short
should be as close to that of the supplj discharge as practicable
or else as close to 1:1 as practicable.1 If the duct must be over
walkways, there may be some constraint on the depth of the duct so
that there will be sufficient head room. In this case, the
vertical dimension will be the short one and the aspect ratio will
be considerably more than 1:1. On the other hand, if the duct
passes over cabinets, there may be room to make the aspect ratio
approach 1:1. In any event, you should try to avoid an aspect
ratio over 5:1. Determine the controlling dimension and, using
the cross-sectional area of the supply discharge, determine the
other dimension. You must accept that adequate may have to be
good enough. Shelters are usually cramped for space with a number
of valid needs competing for that which is available. Also, the
small spaces sometimes dictate practices that would not be
followed if more room were available. So, you do the best you can
and take what you get.

1Reference 7, p 2-65. Acceptable velocities are between 18 psi

and 50 psi; most favorable is around 25 psi.
2 See "Aspect Ratio" in Appendix I-1.

IV-5
 IV-4. Reductions and Expansions

As long as the volume of air being conducted remains the same (no
takeoffs or outlets and no significant leaks), the cross-sectional dimensions
should remain the same for the length of the duct. If space does not permit
this, then a reduction in size or a change in shape becomes unavoidable. Any
change should be made in a straight stretch of duct, if possible, and made
with a thought to keeping the aspect ratio as low as possible. When a
dimension must decrease or increase, the gentler the rate of change, the less
the loss of efficiency.

• You should try to limit the angle of increase or decrease to

not more than that shown in Figure IV-2.

MAXIMUM DESIRABLE CONTRACTION AND EXPANSION ANGLES

15* OR LESS 10* OR LESS\

AlR C> AIR C>

CONTRACT ION EXPANSION

Figure IV-2. MAXIMUM DESIRABLE CONTRACTION AND EXPANSION ANGLES

* If you cannot stay within the limits shown above, the

disadvantages of the wider angles can be lessened somewhat by the use of
splitters to guide the flow generally along a less angular path (see Figure
* IV-3).

SPLITTERS IN EXPANSION AND CONTRACTION FITTINGS

EXPANSION CONTRACTION

Figure IV-3. SPLITTERS IN EXPANSION AND CONTRACTING FITTINGS

IV-5. Bends

There are several types of bends, or elbows, for which you may have
use. These are illustrated on the next page. Elbows for only rectangular
ducting are shown since rectangular shapes are more adaptable to your needs.

IV-6
 r r-r . C -4

CURVED ELBOWS

CENTERLINE RADIUS

ZEROTRADIUS VAN EBO

SHORT~~~~~UL RADIUS EALBLBWOW ~ ~ e hidvnea O~o

~VRE RADIUS
SHORT ELBOWSW EO AIU ANDELO

AIR)

ELBOW WITH ELBOW WITH

SINGLE THICKNESS VANES DOUBLE THICKNESS VANES

Figure IV-4. ELBOWS FOR RECTANGULAR DUCTING

IV-7
 o The full radius elbow, which by definition has an R/D ratio of
1.25, is considered optimum.

o Because of the limited space available in shelters, the chances

are that you will be using mostly short radius (anything with Rt less than
3/4D, including Rt equal to zero) or square elbows. In order of efficiency
and reverse order of overall cost, elbows rank: full radius, short radius,
and square.

so To improve their lower efficiency, short radius and square

elbows normally require turning vanes. For curved elbows, the vanes should
run the full length of the curvature and only two or three will be necessary
for your applications.

so The square plbow requires numerous small vanes, the number

* depending upon the size of tile elbows. There are two types of these: single
thickness, which are the thickness of the sheet metal used to fabricate them,
and double thickness configured to an aerodynamic shape as shown in Figure
IV-3. The double thickness vanes are considerably more efficient and are
preferable. A local heating and air conditioning contractor can probably
bb prefabricate these for you.

* so Figure IV-4 shows the location and spacing of vanes for both
* types of elbows.

IV-6. Takeoffs

Takeoffs are needed to channel some of the air from the main stream to
a second destination. Two types should be considered for your applications:
the diverging wye, which is the preferred takeoff, and the diverging tee for
use where space prevents the use of a wye (see Figure IV-5). When you divert
air from the main flow, you will need to know how much air you take off and
how much remains in the main duct for other destinations. For the small
systems dealt with here, an acceptably accurate way to estimate flow of air in
the main and branch ducts is by direct proportion to the duct cross-sectional
areas. For example, the flow of air in the main duct beyond the takeoff plus
the flow in the branch must equal the flow approaching the takeoff. The lower
part of Figure IV-5 provides a graphic means of making these estimations.

IV-7. Outlets

o Outlets are important elements of the distribution system even

though they are at the end of the line. Their primary functions are to:

oe Direct the air in desired directions.

so Regulate the spread of the conditioned air stream and the

resultant entrainment of air already in the room.

o Achieve entrainment at the desired rate; the higher the

entrainment rate, the shorter the throw and the more quickly objectionable air
velocities are reduced.

4IV-8
 DIVERGING 90 CURVED WYE DIVERGING 45* ANGULAR WYE

DIVERGING TEE INTERIOR OF DIVERGING TEE

SHOWING NECESSARY DAMPER

CURVE FOR ESTIMATING TAKEOFF AND MAIN DUCT SIZES

AND AIR VOLUMES
100

90

70

* 60

50

04. V

al vi 3-C~

20- a1 1 V1 3

a2

0 01 20 30 40 50 60 70 20 90 100
* PERCENT OF AIR VOLUME (CFM)
V V
2 3
X 100 and - X 100
Vi V1

Figure IV-5. TAKEOFFS

Iv- 9
 0 Wall Outlets.

e Grilles with individually adjustable louvers, such as those

with the ECU, are the most desirable type of wall outlet. They can satisfy
the above three points in most cases. Louvered grilles are available
*commercially in a variety of sizes.

so In some instances, however, the air can enter the

compartment with such a velocity that it creates a high level of noise and
draws complaints about uncomfortable breezes. In these cases, you may need a
long, narrow outlet as illustrated in Figure IV-6 (as close to the width of
the shelter as available space will allow and only 2 or 3 inches high). With
this, the velocity will be reduced, cutting down the noise and the breeze.

SUPPLY AIR OUTLET

SHELTER
. END WALL RETURN AIR INLET SHELTER SIDE WALL
(ECU ON OUTSIDE WALL MOUNT)

Figure IV-6. OUTLET FOR REDUCING AIR VELOCITY AND NOISE

o Ceiling Outlets. The two types of ceiling outlets that you

should be concerned with are diffusers and perforated ceilings.

so As their name implies, diffusers disperse the air into the

compartment. The approach of the air to the diffuser is a factor in its
effectiveness. Two methods of aOhieving a satisfactory approach are
illustrated in Figure IV-7.

* The perforated ceiling is a form of plenum and will probably

find only rare usage for your purposes. If you think a plenum would be
appropriate, consult an air distribution expert.

IV-8. Material

Weight and safety considerations lead to the recommendation that ducts

be fabricated from 22-gage aluminum1 and that all joints, seams, and
connections be made airtight.

IlReference 7, Table 14.

IV-10
 APPROACHES TO DIFFUSERS

FigureIV-7. PPROACES - IFFSE

L
 SECTION V- PROTECTING AGAINST CHEMICAL, BIOLOGICAL,
AND RADIOACTIVE FALLOUT CONTAMINATION

V-1. Introduction

Previous sections of this handbook were based on a peacetime

situation, that is, no threat of an attack of any type. When the threat of
*attack is foreseeable, you must take into account some additional
considerations. These relate to protecting yourself and your mission
equipment while continuing to function effectively. This section looks at
available means of protection against exposure to hazardous concentrations of
CB agents and radioactive particulate fallout. (Thermal radiation, blast, and
electromagnetic pulse are addressed in later sections.) Additionally,
directions are included for adjusting the size of the ECU to handle the
* increased cooling load resulting from the use of CB collective protection
equipment.

V-2. Threat

*The threat of CB attack is most serious to personnel.' Therefore, for

our purposes here, the threat can be narrowed to the potential entry into the
shelter of CB agents and radioactive particles. The means of delivery is
immaterial. The threat to equipment by CB agents is not serious.

* Contamination of the outside-mounted ECU does not cause

significant problems. Even if contaminated the function of the ECU will not
be affected and it can operate for long periods without requiring maintenance.

• Chemical agents are mildly acidic but should do little or no

short-term damage to military equipment. Decontamination agents are another
matter, hovwver. They are highly corrosive and should be used with great
care; there is further discussion of this problem in paragraph V-li.

* CB agents and radioactive fallout, themselves, have no major

destructive effect on materiel and facilities. Possible damage from other
* types of attack, preceding or simultaneous with the release of CB agents, are
considered in Sections VI and VII.

V-3. Protection of Personnel

You can protect personnel in one of two general ways.

• Individual Protection. This is essentially a mask and special

clothing. It is primarily for the individual who must work in an outdoor
toxic environment. It is cumbersome, relatively uncomfortable, and inhibits
*the manual dexterity and mental concentration important for operating the
complex equipment likely to be in most shelters. While it does not protect
sensitive equipment, it could enable personnel within a shelter to survive and
*possibly work if collective protection should be disrupted. But while

1
Reference 8, Appendix 11-2, contains a useful summary of chemical agent
* characteristics and effects.

V-1
-- individual protection has an emergency back-up place in your planning, it is
not within the scope of this handbook so it will be dropped at this point. If
you have need for information on individual protection equipment, Reference 8
of Appendix 1-2 is a good source.

* . * Collective Protection. You can provide protection for one or

more individuals by use of a contamination-free enclosure, such as a mobile
shelter, or by ventilated facepieces. By pumping clean, filtered air into the
shelter or facepieces, sufficient positive pressure is maintained to prevent
infiltration of contaminants. Within an adequately sealed shelter, the
shirt-sleeve environment important for mission effectiveness can thus be
achieved. The collective protection system most suited to your needs, the
MCPE, is discussed in the next paragraph. Other types and developmental
systems are addressed in paragraph V-7.

. V-4. Modular Collective Protection Equipment (MCPE)

" The MCPE provides sufficient, clean, filtered air to maintain a

small positive pressure of 1.2 to 1.7 inches of water inside the shelter or
enclosure to prevent penetration of contaminants from the outside.

e The system includes a gas particulate filter unit (GPFU), a

- protective entrance (PE), a static frequency converter (if 400 cycle power is
not otherwise available), a power distribution unit, a compartment control
module, and necessary flexible ducting and electrical cables (see Figure V-1).
These are discussed below in the context of the interfaces between the GPFU,
ECU, PE, and shelter.
£ Protective Entrance
Control Module
2 8000 Stuh/
" CU , uctino..

Poe -Protective
Distributionn Entrance
Uni t

I
Gas-Particulate - !/ -
Filter Unit ' "", " . ..

GPU Ine nut

i ,'I Compar tment

.. 'll
.. " "Control Module

"" GPFU Input inlet. 15

,

to ECU Transitio "

Cable

•_Figure V-I. MCPE APPLICATION TO PATRIOT SYSTEM

,Illustration from Reference 22, Appendix 1-2. Note that the GPFU input to
the ECU is through the fresh air intake which is on the side of the PATRIOT
ECU. This is unusual and differs from Figure I-1-1 in Appendix I, which is
the more common arrangement.

V-2
 V-5. Interfaces

5 * MCPE-Shelter. You should consider the following:

es GPFU. The filter unit is the heaviest element of the MCPE.

Three sizes (capacities) of GPFU are available: 200 cfm, 400 cfm, and 600
. cfm. (See Figure V-2.) Paragraph V-9 explains how to select the size suited
to your need.
U
GAS FILTER
P&ARTCULAFF
MAIN FAN FILTER

TBNS ITION

DUSt
SEPARATOR

DUST EXHAUST AINFLOw

BLO14RVAE

OUST EXHAUST POUEA DISTRIBUTIONl

i$[ KOER OUTLET
SR UNIT

Dimensions in Inches Power

Unit Weight (ib) Consumption
Height Width Length (KW)
M56, 200 cfm 32.9 35.5 34.6 212.5 1.1
- XM59, 400 cfm 32.9 35.5 44.8 271.2 1.6
XM62, 600 cfm 32.9 35.5 55.0 336.5 2.6

Figure V-2. GAS PARTICULATE FILTER UNIT 1

- In most cases, the GPFU should be mounted on the ground

-- using the stand available for this purpose (see Reference 22). In cases where
wall mounting is required, you must be careful not to overload the shelter
wall. ECU Wall Mount Number 2 (see Figure 111-5, Section III) with some
adaptation can accommodate the GPFU and one 18,000 Btuh ECU within the limits

5 llllustration from Reference 22.

V-3
 of the wall capability. If an individual wall mounting option is required,

the Physical Protection Division, U.S. Army Chemical Systems Laboratory1 has a
1design which you should examine before expending effort on designing your own.

- Air from the GPFU is carried to the shelter (or to the ECU
when one is used) through flexible ducting. This is very vulnerable to blast
and fragments but there is not a good alternative at present. An aluminum
duct, for example, might be almost as vulnerable because of its exposed
location connecting the two units. Integration of the GPFU and ECU into a
single package might help but efforts to date toward the end have not shown
great promise (see paragraph V-6).

- To deliver the required volume of air, the GPFU blower

requirep 400 Hz power. Because power of this type is often not readily
available, the MCPE includes a frequency converter for converting 50-60 Hz,
208 Vac, 3 phase power to the required 400 Hz, 208 Vac, 3 phase power. It
will not work with single phase input power. The converter weighs 62 pounds
and is 19.8 inches long, 8.5 inches wide and 8 inches high. It should be
mounted vertically, to facilitate cooling, and may be mounted on the GPFU
stand or mount, or directly on the shelter wall or floor. Since the converter
uses solid-state devices, when EMP is a threat you should consider mounting it
inside the shelter or, if outside, providing adequate shielding.

- The GPFU may prove useful in non-NBC situations where an

effective capability to remove dust and supply a quantity of clean, fresh air
is required. Conversely, in situations where dust will not be a problem, the
GPFU may be used without the dust separator.
so Compartment Control Module. This automatically regulates
the compartment air pressure relative to ambient and must be mounted on the
inside of the shelter. It is connected to the power distribution on the GPFU
by an electrical cable which will require an entry provision in the shelter
wall. (Note that all MCPE cables are unique to the system. You may obtain
information on cables and connections from the Chemical Systems Laboratory.)
When pressure falls below a safe level, a horn in the module sounds to warn
personnel to don protective masks and equipment. At the same time, an
indicator on the control module labeled "MASK" lights.

eo Protective Entrance.

- The PE is a pressurized transitional compartment. In it,

personnel coming in from a contaminated atmosphere can be subjected to a
recommended 5-minute air wash and can perform personal decontaminating
operations before entering the shelter itself. Space inside the PE limits
occupancy to one person at a time.

1
Telephone Number: AV 584-4222, Commercial (301) 671-4222.
Mailing Address: Commander/Director
U.S. Army Armament Research and Development Command
Chemical Systems Laboratory
ATTN: DRDAR-CLW-E
Aberdeen Proving Ground, MD 21010

4 v-4
 - Positive air pressure within the PE assures an outward
leakage to prevent entry of contamination. The PE pressure is slightly lower
than that in the shelter, but the difference is low enough to minimize loss of
5 shelter pressure when people enter or leave. The required pressure level is
maintained in the PE by means of a protective entrance control module (PECM)
which automatically adjusts air flow from the GPFU. The PECM is located in the
." air duct between the GPFU and PE.

- The PE is collapsible for transport. In use, it is 85

inches high, 44.1 inches wide, and 50.1 inches deep. Collapsed into its
carrying package, it is only 12.5 inches high. It weighs 145 pounds and can be
carried and erected by 3 men in 30 minutes.

- The standard PE is the M12 model. The M10 is almost the

* same, but has a longer skirt for the interface between the PE and the shelter.
Although all PE's are unhardened and very vulnerable to fragments and blast
waves, the XM14 model has a PECM which has been modified to meet nuclear
*hardness requirements, primarily from EMP. Since it is accepted that the PE
will be lost to blast and fragments, you should plan to have replacements
available. Because of this, as an alternative, you may want to consider
establishing a protective vestibule within the larger shelters or perhaps a
small, connected hardened shelter as a protective entrance to be used with
smaller shelters. Their functions would be the same as the current collapsible
PE. If there seem to be advantages in a more rigid and durable PE such as
these, you should contact the Chemical Systems Laboratory 1 for advice and
assistance.

- Standard kits are available for interfacing with the S250

and S280 shelters. The modular design of the PE and its interfacing is intended
to provide ready adaptability, nevertheless, you should examine the application
to other shelters on a case-by-case basis to determine whether modifications are
*required. For truck-mounted shelters, the truck tailgate may have to be
modified to handle the PE, and any shelter supported above the ground will
*require a platform to support the PE at the same level.

- When standard hardware is used, the air from the GPFU to the
PE is carried by a flexible duct passing atop the roof of the shelter. This is
very vulnerable to blast and fragments and spare ducting should be carried. But
a better, more protected arrangement which you should consider is conveying the
air from the GPFU to the PE through permanent ducting inside the shelter.

* MCPE - ECU.

ce In one application, the MCPE-ECU interface is provided by a

flexible duct which conveys air from the GPFU to the ECU make-up air (fresh air)
channel (note Figure V-3). This is only a portion of the GPFU output. In some
applications, the remainder of the air goes all to the PE. In others, it goes
partly to the PE and partly directly into the shelter. In yet another
arrangement, the air is pumped into the shelter, which acts as a plenum with the
air from the shelter to the PE, as in the other cases being automatically
regulated by a PECM. In this arrangement, the ECU gets all its make-up air from
the shelter. Supplying the PE with conditioned air from the shelter greatly
increases the load on the ECU; therefore, this application is not recommended.

-* llbid.

V-5

~A. * . ~
_ * - * - - --
S

INTERFACE WITH ECU

U
'g IS WITH DC
• . .FROM GPFU

(a) (b)
, Transition (a) is more efficient than transition (b) and
is to be preferred.

Figure V-3. TYPICAL TRANSITIONS FROM FLEXIBLE DUCT

TO ECU MAKE-UP AIR INTAKE

so In the Army AN/TSQ-73 application, where the GPFU provides

fresh air to the ECU, there is a valve between the GPFU and the ECU which
allows the air to by-pass the GPFU and go directly to the ECU when the GPFU is
not working. When the filter unit is operating, the valve is held closed by
air duct pressure to prevent contaminated air from entering. In all of the
above cases, the ECU make-up air inlet must be closed when the GPFU is working
in a CB environment or air leakage will prevent adequate pressurization.

• Summary of Concerns Regarding the MCPE.

*e Although the basic MCPE System has passed several nuclear

hardening, EHI, and EMP tests, the unhardened shelter, the flexible ducting,
and the PE are very vulnerable to blast and fragments. As a matter of fact,
it is contemplated that the ducting and the PE will require replacement
following a conventional or nuclear attack; for this reason, spares should be
carried.
*e Exterior ducting is also subject to heat transfer from
ambient conditions to filtered air. Because of this and the vulnerability of
exterior ducting to blast and fragments, you should give consideration to
interior shelter ducting to carry the air from the GPFU to the PE. For design
guidance on efficient ducting, refer to Section IV.

so You must seal the ECU-GPFU interface against entry of

.. contaminants.

V-6
 so You must reassess your ECU selection. Guidance for this is
provided in paragraph V-10.

- The additional heat load caused by the GPFU may exceed the
cooling capacity of the ECU which was initially selected in Section II.

- Filtered air from the GPFU comes out 10OF to 150F warmer
than it goes in; this adds to the cooling load of the ECU and may require a
I larger unit.

*. You must seal the shelter well enough to permit the GPFU and
ECU to maintain the necessary positive pressure without undue loss of air.
Good sealing is necessary also to prevent a momentary reverse flow of air due
to greater outside pressure, such as can be created by a blast wave or a
passing truck. These problems and their regulation are discussed in Reference
22.

ee Sealing material used to reduce air leakage and protect

against CB agent infiltration must be impermeable to air; resistant to CB
agents, environmental extremes, and decontamination fluids; be easy to
install; and be compatible with requirements for protection against EMP (see
Section VI).

*' . More detailed information on the MCPE may be found in

References 8, 13, and 22, Appendix 1-2.

S V-6. Integration of GPFU and ECU

In current applications, the MCPE and the ECU are not integrated into
a single unit; they are not compatible to that extent.

e Although there may be components of similar purpose (e.g.,

blowers) in each, the components cannot perform each other's functions in
their present configurations. Further, there are so many components dedicated
to each unit's specific function that little could be eliminated through
integration of the two units into a single package.
9 The few attempts at a single, integrated system that have been
noted are bulky and cumbersome to the extent that they required their own
dedicated trailers for transport. Also, it is not clear how successful they
are since no performance or test data have been seen, if, in fact, any have
been collected.

e The separate units offer you certain advantages:

so There is more flexibility in mounting arrangements.

so The ECU can function alone when CB attacks are not imminent,
thus saving power.

so The demand for 400 Hz power can be held to a minimum (the

GPFU requires it but the ECU can be in 50/60 cycle configurations).

V-7
 In the event of a breakdown, one can be replaced without
so
having to replace the other as well.

* If you find that an integrated GPFU-ECU system is an

operational requirement, it is suggested that you contact the Physical
Protection Division of the U.S. Army Chemical Systems Laboratory. 1 They
should be able to advise you of the status of any integration efforts.

V-7. Other Collective Protection Equipment.

* Ventilated Facepiece Equipment. This is primarily to provide

protection for crewmembers of a vehicle. It consists of a central GPFU
connected to a facemask at each crew station. The system maintains a slight
positive pressure and can provide adequate air (up to 20 cfm) for five crew
stations. Since air is provided only at each crew station, it limits the
mobility of the users.

*. A variation now in development provides for a compact,

self-contained individual GPFU which can be carried by the user while it is in
operation. By permitting the user to connect to either the central system or
the individual GPFU, the mobility restraint of the multiple station is largely
overcome.

so In cases where use of ventilated facepiece equipment would

be necessary, one would also have to wear protective clothing to prevent entry
of CB agents into the body system through the skin. This leads to the same
problems of encumbered movement that individual protection has.

so If you want more information on this item, it may be found

in Reference 8.

o Hybrid Collective Protection Equipment (HCPE), XM23, XM24, and

XM25. Three sizes of the HCPE are currently in development: 100 cfm, 200
cfm, and 300 cfm. The HCPE is a combination of the positive pressure
compartment and the ventilated facepiece systems. It is designed primarily
for situations where closed compartment operation is possible part of the time
and open hatch operation is necessary for the remainder.

so The HCPE offers the advantages of both systems. But when

facepieces are required, protective clothing should also be worn.
* The variety of system components available and becoming
available offer the flexibility of modular adaption to fit your need.

so You may refer to page 47, Reference 8, for more information.

V-8. Caution

None of the filters in the equipment discussed above or in the GPFU

will protect against carbon monoxide or ammonia fumes.

1bid

v-8
 V-9. Selection of GPFU Capacity

.N The selection of GPFU size is based upon the air flow requirement.
There are several components of this requirement.

o Shelter Leakage. This is incidental leakage as opposed to

deliberate venting. It can be determined only by test since it is largely
dependent on how well the shelter is sealed against leaks. It should be
measured at the positive pressure under which you will want the system to
function. Some leakage, either incidental or deliberate, is required if
ventilation requirements are to be met.

• Ventilation. Personnel health and comfort require ventilation.

Multiply the average number of people occupying the shelter at any one time by
20 cfm per occupant to determine the ventilation air requirement. If in
Section II you used a smaller figure than 20 cfm per person, then that figure
should be used. If incidental leakage is insufficient to provide for the
required ventilation, a means of deliberate venting must be provided. (The
GPFU and ECU, after a certain pressure is reached, can input only as much air
as can be leaked or vented.) Adjustable dampers are available for this
purpose; two are illustrated on pages 235 and 237 of Reference 24. Also, most
* shelter manufacturers have workable dampers for this purpose.

s Protective Entrance. The PE must exhaust contaminated air

after air-washing people who are entering the shelter. It therefore has a
* deliberate leakage of 125 to 150 cfm, depending upon the positive pressure to
be maintained. This pressure, and the air flow to sustain it, incidentally,
are automatically controlled by a pressure regulation network which is part of
the PE system.

o ECU Make-up Air. Thia requirement is not a factor in

determining the GPFU capacity. When the shelter and MCPE are used in a CB
environment, one of two situations exists relative to the ECU make-up air
(fresh air) intake (see Figure I-1-1). In one case, part of the GPFU output
is passed through the ECU for conditioning before entering the shelter; in
this case, it is ducted directly to the ECU make-up air intake. In the other
case, the GPFU air enters the shelter first and then is taken into the ECU,
through the return air inlet, for conditioning. In this latter case, the ECU
fresh air inlet damper must be closed to prevent loss of shelter air pressure.
* In either case, the make-up air is not an air flow requirement for the GPFU.

* Air Flow Requirement Determination. This can best be explained

with the following illustrative example.

Shelter Leakae. For the purpose of the example,

it is assumed that the shelter test showed a
leakage of: 140 cfm

Ventilation. Two people are assumed to be in the

shelter. At 20 cfm/person, the requirement is: 40 cfm

Protective Entrance. The PE is assumed to be at

1.5 cfm and requires: 125 cfm

V-9

* . o. -
 Analysis.

*o The shelter leakage (140 cfm) exceeds the ventilation requirement

(40 cfm), so ventilation is satisfied through incidental leakage; deliberate
venting will not be required.

-o The total of the leakage to be made up plus the PE requirement is

265 cfm (140 cfm plus 125 cfm). This is too large for the 200 cfm filter size
and the 400 cfm unit will be required.

oo If the leakage can be reduced by better sealing, to where the

loss is only 75 cfm, then the total would be 200 cfm and the smallest GPFU
filter size can be used. This is an advantage if it will prevent having to go
to a larger ECU. Besides the drawback of an oversized ECU mentioned in
Section II, paragraph 11-9, a larger ECU would use more power as also would
the larger GPFU.

9 If a GPFU is added to the air system of the shelter, regardless of

size, the ECU size determination must be re-evaluated as explained in the next
paragraph.

V-10. Reassessment of ECU Size Based Upon Use of the GPFU

As mentioned in paragraph 11-5, ambient (outside) air temperature is

raised by 10OF to 150F when it passes through the GPFU. This makes it
necessary that you recompute Step 4, Worksheet, Part I, and Step 7, Worksheet,
Part II, to determine the increased load on the ECU. The values in spaces 4a
and 7a of the worksheets are taken normally from Columns G and H of Figure
II-1. When the GPFU is to be used, these values should be taken instead from
Columns I and J of Figure V-4 (next page). For worksheets which have already
been completed without consideration of the GPFU, the Figure V-4 values should
replace those in spaces 4a and 7a and the heat gain or loss for ventilation
recomputed. The total cooling requirements or net heating requirement should
then be re-determined.

V-li. Decontamination

Once NBC contaminants have been deposited on equipment, sooner or

later they must be removed or neutralized. As mentioned in paragraph V-i,
decontaminating agents are highly corrosive and can damage rubber, certain
plastics, and metal. For this reason, you should avoid the use of the
standard decontaminating agents on the ECU and shelter seals if less stringent
means are available. If they must be used, these agents should be applied as
prescribed but should be washed off, as soon as instructions for use permit,
with soapy water and a clean water rinse which, themselves, are effective in
removing contaminants. Also, if you use decontaminating agents, you should
avoid applying them to areas not touched during maintenance, closed
compartments not contaminated, and areas where it will be difficult to rinse
after decontamination. The following subparagraphs discuss the standard
agents for decontaminating equipment and alternatives which might be available
to you.

V-10
 IJ
CLIMATIC SL'74ER WINTER

VENTILATION VENTILATION
CATEGORIES HEAT GAIN HEAT CAIN
(BTUH/CFM) (STUH/CFM)

- Al HOT DRY 62 66

A2 MOD HOT DRY 50 66

1 BI WETWARM NA 66

,*B2 WET HOT 116 66

B3 HUMID HOT 140 66

CO MILD COLD 55 66

C1 HOD COLD 55 94

C2 COLD 55 120

C3 SEVERE COLD 55 130

-=" C4 EXTREME COLD' 55 141

Figure V-4. VENTILATION FACTORS WHEN GPFU IS USED

. Decontaminating Agent, STB (Supertropical Bleach). STB is a

mixture of chlorinated lime and calcium oxide that can be used against all
liquid chemical agents and some biological agents. It is available in powder
form in 8-gallon drums. It is applied as a powder or as a slurry.

e* It is recommended that you not use STB on equipment covered

in this handbook. It is highly corrosive to most metals and injurious to most
fabrics. It is toxic and flammable.

eo Under development is the XD14, Truck-Mounted, Power-Driven

Decontaminating Apparatus which includes a capability to dispense STE as well
as capabilities for steam cleaning and vehicle washing. This would permit you
to decontaminate with STE and follow with a good cleaning; thus, overcoming
some of the objectionable features of STE.

so For further information, refer to pages 103 and 131 of

Reference 8.

V-1l
r7_.

• Decontaminating Agent, DS2. DS2 is 70 percent active agent

(diethylenetriamine), 28 percent solvent (ethylene glycol monomethyl ether),
and 2 percent active agent booster (sodium hydroxide). It is available in
liquid form in either 1-1/3-quart cans or 5-gallon drums.

0. DS2 is effective against all known toxic chemical agents if

" allowed to remain in contact to a maximum of 30 minutes. It is effective
against the nerve agent GB and mustard gas HD within 5 minutes.

'e As with STB, you should avoid use of DS2 on the ECU and its
ancillary equipment if you can. But, if a choice between STB and DS 2 must be
made, DS2 would be preferrable in most cases.

- DS 2 has a low flashpoint and can be a fire hazard if used

on heated equipment.

- It is irritating to the eyes and skin and the vapor is

harmful if inhaled.

- DS2 removes and softens new paint, except polyurethane

paint, and can discolor old paint and polyurethane. It will also soften
leather and rubber products.
es You may find further information on page 111 of Reference 8.

* Alternatives to STB and DS2. The following alternatives are

b primarily means of removing the contamination from the equipment rather than
neutralizing it. An exception is the heat method which can neutralize most
chemical and biological agents. You must remember that if an agent is just
removed, as in washing, it still remains a potential danger even in the waste
water.

fl *o Heat will vaporize most chemical agents and permit them to

be dispersed by evaporation into the air in non-injurious concentrations. The
temperature necessary for hest alone to do the job is a minimum of 180 0 F. How
this might be achieved is a question which greatly limits its application at
* present. However, there are two items of equipment under development which
you might find applicable.
r4 - The XMI6, Truck-Mounted, Jet Exhaust Decontaminating
Apparatus is basically a jet engine. This item is operated in pairs. A
contaminated vehicle is driven slowly between the two with the hot jet
exhausts being directed at it from both sides, raising surface temperatures to
between 212OF and 2340F. For more information, see page 137 of Reference 8.
- The D415, interior surface decontaminating system is being
developed for use inside vehicles and shelters. The system as presently
configured is too large for its intended use and effort is underway to reduce
the size to about 1 cubic foot. It is expected that it will generate
- temperatures up to 1940F. More information may be found on page 139 of
hReference 8.

LV-12
 *o Washing with a strong alkaline soap (e.g., GI soap) and hot
water will likely remove CB decontamination as well as radioactive particles
and achieve a small degree of decontamination. This is fairly easy for small,
outside surfaces but it may be difficult to reach some interior sections of
the ECU.

'e Rinsing with plain water may not neutralize the agents but
it Vill probably remove enough to reduce their chances of causing injury. An
item being readied for adoption by the U.S. Army is the XM17, Lightweight, Hot
Water Dispensing, Decontaminating System. This, called the NBC Sanator, is
standard equipment for the Norwegian and Swedish forces. It provides a hot
.- water rinse for shelters, vehicles, and equipment. It draws water from any
source, heats it, and delivers it at 100 psi at controlled temperatures up to
248 0 F. Additional information is on page 135 of Reference 8.

*e Steam cleaning is a very effective means of removing and

perhaps neutralizing contaminants without damage to the ECU or protective
equipment. A mobile steam generator would be a very handy piece of equipment
to have for this. As mentioned above, the developmental XH14 decontaminating
apparatus includes a steam generator and, if available, would provide a means
of steam cleaning the ECU.

~V-13
 °
.,.. ,.. - . . :. - . -' . -i . : i p : b i ' "

SECTION VI - PROTECTION AGAINST ELECTROMAGNETIC PULSE (EMP)

" VI-1. Introduction

EMP is an intense burst of electromagnetic energy resulting from a

nuclear explosion. The energy released can disrupt communications and burn
out electronics, especially solid state components which are extremely
susceptible to EMP, hundreds of miles from the blast. Any conductor, a
telephone line, a powerline, or a grounding line, for example, can pick up the
pulse and carry it for miles into equipment which might otherwise be shielded.
Because of EMP, control of the environment within the shelter raises three
* problems with which you must deal.

o One is the restoration of the electrical continuity of the

' shelter enclosure which was interrupted by the holes cut into the walls. But
these holes are no different than the holes required by other types of
equipment which you already know how to handle.

- The second is the vulnerability of the ECU and the MCPE.

o The third is the ECU-shelter interface.

This section offers you guidance on the second and third of these
problems.

3 VI-2. Anticipated Threat

It seems generally accepted that the assumed threat, which is

classified, requires an attenuation of 60 dB over the range of 0.15 MHz to 10
G~z and 80 dB over the range of 0.20 MHz to 1 MHz.

VI-3. ECU and MCPE Vulnerabilities

o ECU. The ECU has a number of componev.- which are particularly

vulnerable to EMP.1

*o The two chief causes of concern are the solid-state

rectifier and the solid-state time delay relay. EMP can cause damage and even
- total failure in both of these.

so Other elements which may also be weak links in the chain are
the capacitors, the filters for DC current, and the starters. While these are
not solid-state, the very high currents and voltages induced by the EMP could
cause component upset even if they do not cause permanent damage.

o0Additionally, EMP-induced currents and voltages may cause

circuit breakers to open or fuses to blow.

1
12 The only exception at present is the 18,000 Btuh Split-Pack ECU developed for
the PATRIOT System. This is believed to be protected to an adequate EMP
*attenuation level although this is yet to be confirmed by testing.

VI-1

- *.*-
U

a MCPE. The MCPE has passed basic EMP testing and the version
being used for the PATRIOT system has been modified to provide even greater
resistance to EMP. The modifications include part of what will also have to
be done with the ECU: the elimination of all solid-state circuitry and the
provision of shielding and filtering in the electrical cables. The MCPE is
not considered a problem.

VI-4. Remedy for ECU Weaknesses

There are two courses which you can follow in overcoming the ECU's
vulnerabilities.

o The best course is to request the DOD proponent agency' to

furnish you with ECU's which have the requisite protection. The advantages of
this:

so It would provide a basis in demand for the establishment of

a program to develop protected ECU's over the range of unit sizes which you
need.

so It would eventually place into the DOD procurement system

EMP-protected ECU's and make future acquisition of these units simpler and
* quicker.

* The other alternative is to retrofit existing ECU's. This may

possibly produce quicker short-term results and might warrant your
consideration in conjunction with the above course. Retrofit is sufficiently
complicated so that you should have it done at the factory and have it done
*, against performance specifications, to include required EMP attenuation (see
paragraph VI-2, above), rather than an enumeration of work to be done. 2 The
work should include at least the following and might include other items if
the retrofit facility believes them necessary to meet the required
performance:

ao Replacement of solid-state components with vacuum tubes or

mechanical components or the placement of solid-state circuitry in
EMP-shielded and sealed enclosures.

"Commanding General
U.S. Army Troop Support and Aviation Materiel Readiness Command
Attention: DRSTS-WX
* 4300 Goodfellow Boulevard
St. Louis, MO 63120
*. (Procedures for placing a development requirement are contained in DARCOM
Regulation 700-5).
2 The
requirement for all EMP protective materials to withstand CB agents,
thermal radiation, temperature extremes, corrosive effects of the atmosphere,
galvanic erosion, and air pressures (from within the shelter as well as
external nuclear overpressure) also should be spelled out in some detail in
" the performance specification.

VI-2
 r- - . . . . . ...

eo The shielding of all other sensitive components (e.g.,

capacitors, circuit breakers) perhaps by placing them also in sealed
- enclosures. You might consider the possibility of remote mounting the circuit
breakers inside the shelter. This would provide shielding as well as safe
* "access for resetting.

eo Conductive sealant at all seams.

eo Conductive gasketing on all doors and access panel

enclosures.

See Filtering at control and power cable entries.

eo Conductive honeycomb barriers on all uncovered openings.

oeShielded cables.

eo All bolts and rivets solidly seated with clean

- metal-to-metal contact or installed after dipping in conductive sealant and
sealed against the environment.

" VI-5. ECU-Shelter Interface

The interface should restore the conductivity and shielding of the

unbroken aluminum skin of the shelter. It should also seal well enough to
3 maintain the positive air pressure necessary for CB protection within the
compartment. Achievement of these two objectives is basically a matter of
gasketing.

e There are a number of types of EMI/EMP gasketing on the market

which can provide the shielding effectiveness (EMP attenuation, air pressure
3 seal, and resistance to chemicals and temperature extremes) you require.
Examples of some which may be suited to your need are:

ee A metal mesh of knitted, springy, resilient, interlocking

wire loops (see Figure VI-l(a), (b), and (c)). Metal mesh cannot, by itself,
provide a pressure or environmental seal; it must be used in conjunction with
an elastomer as illustrated in Figure VI-I(a). A type of gasket not shown is
an elastomer core surrounded by wire mesh. This can provide an environmental
as well as an EMP seal but is of questionable reliability as a pressure seal.

0e A solid or sponge silicone elastomer with embedded,

conductive shielding wires oriented perpendicular to the mating surfaces
(Figure VI-l(d)).

ee A solid silicone elastomer with continuous metal conductive

paths throughout the gasket with many surface contact points (Figure VI-l(e)).

• The oriented wires and the contact points of the conductive

L paths protrude from the surface of the gasket and, under compression, cut
through any buildup of nonconductive oxidation to establish good electrical
contact with the mating surfaces. The solid elastomer will probably provide
you with a better pressure seal than will the sponge but achieving and

* VI-3
 KNITTED WIRE MESH

Two formed or compressed mesh strips in parallel

with sponge elastomer strip. Affixed with bolt
through bolthole. Can be affixed also with
(a) adhesive. Thicknesses available: 0.062 to
0.375 inch.

Formed mesh strip in parallel with mesh attaching

strip. Affixed with conductive or nonconductive
- (b) adhesive. May be obtained with boltholes in
attaching strip. Thicknesses available: 0.04 to
0.375 inch.

Round mesh strip with extruded metal attaching

fin. Affixed with conductive or nonconductive
- (c) adhesive. May be obtained with boltholes in fin.
Thicknesses available: 0.062 to 0.500 inch.

METAL CONDUCTORS EMBEDDED IN ELASTOMER

Shielding wires in matrix of solid or sponge

silicone elastomer. Wires oriented perpendicular
(to mating surfaces. Affixed with conducting
d) elastomer. Provides composite EMP and pressure
seal. Thicknesses available: 0.030 to 0.500
inch.

Multiple layers of solid copper conductive paths

in solid or sponge elastomer. Contact points
(e) " . coated with special tin alloy. Thicknesses
available: 0.125 to 0.625 inch.

Figure VI-l. SOME EXAMPLES OF EMP GASKET MATERIALS

VI-4
 T . .

maintaining adequate compression pressure will be more difficult than with the
-' sponge elastomer. In designing a gasket, you should understand that a sponge
eleastomer compresses into a smaller space while the solid elastomer does not
compress but rather deforms and flows while maintaining a constant volume.
Space must be allowed in your joint design for this.

• The oriented wires and metal conductive paths should have

galvanic compatibility with the mating surfaces to reduce galvanic erosion and
corrosion. Since both the shelter and, in most cases, the ECU enclosures are
aluminum, aluminum in the gasketing would be appropriate. You might find it
desirable insurance to apply a chromate conversion coat to both mating
surfaces to retard oxidation. Within 3 miles of the sea (saltwater) you
should also apply a 0.003 inch (0.0766 mn) coating of silver-filled epoxy.

• The service life of the gasket is another factor you should

*- keep in mind. The gasket material should be resistant to or protected from
abrasion, moisture, chemicals, and thermal radiation. Also, close attention
should be paid to manufacturers' specifications since some elastomers change
.* under temperature extremes, becoming hard and brittle in extreme cold and soft
and foamy in extreme heat. In either case, a loss of seal can result.

e Compression pressure (to compress the seal between the mating

surfaces) is important in developing the full EMP shielding and
pressure/environmental seal effectiveness of the gasket.

e* The sponge or solid elastomer must be compressed or deformed

sufficiently to fill all the uneveness between the two mating surfaces and to
force the wire tips or contact points through any oxidation buildup.
Depending upon the situation and the material, you will need to obtain a
compression pressure of 20 to 100 psi.

*o The concern in this respect is primarily with wall

*; mountings, since the seal between the heavy ECU and the shelter might be
broken if the mounting should flex during transport.

e Reference 14 offers a thorough discussion of EMI/EMP gasket

" design theory and a design procedure.

e The flexible ducting, or connecting boot, of the ground mounts

is unshielded; therefore, an EMP gasket at the interface of the duct and the
shelter would give you no benefit (CB sealing is still vital, however). In
the case of ground mounts, EMP protection for the shelter interior must be
provided by conductive honeycomb barriers in the air passages through the
shelter wall. An illustration of a honeycomb barrier is at Figure VI-2(a).

poiiv e Pressure sealing is essential to the maintenance of the

positive shelter pressure necessary for CB operations. When properly
installed, both the solid and sponge silicone elastomer gaskets already
mentioned are rated very highly in this respect: up to 30 psi. This should
also withstand the overpressures generated by a nuclear blast at a level which
the shelter, itself, would survive.

VI-5
 m~

e A useful non-gasket type of shield for doors which are

repeatedly opened and closed is the metallic spring finger strip, an example
of which is illustrated in Figure VI-2(b). This type of shield provides no
pressure or environmental seal and must be used with environmental and
pressure seals such as elastomer gaskets. Careful and proper installation of
the spring finger strips is necessary to reduce damage from normal use and
* traffic. A type of damage that often occurs is that in which a finger is
snagged on a passing object, a person's clothing for example, and broken.
This would likely negate the effectiveness of the shield. For best effect,
installation should be so that the fingers scrape the contact surface during
closing to assure that non-conductive oxides, which may have formed, are wiped
off.

0
0

(a) HONEYCOMB AIR (b) SPRING FINGER DOOR

PASSAGE SHIELD CLOSURE SHIELD

Figure VI-2. EXAMPLES OF EMP SHIELDING FOR

AIR PASSAGES AND DOOR CLOSURES

e This handbook does not attempt to designate the specific

shielding you should use. But the foregoing has highlighted considerations
that must bear on your selection. It is strongly suggested that you consult
with several of the leading manufacturers of EMP shielding materials for their
recommendations on the best materials for your need and the most effective
procedures for installation. When presented with specific requirements, a
manufacturer may be able to propose combinations of sealing materials and
methods tailored to your need and to guarantee the required results. Appendix
VI-1 contains a list of randomly selected but representative firms which
manufacture EMP shielding materials or which can provide engineering and
design assistance for solving shielding problems.

VI-6

*. . o-.-. . . . ...... .... .. *

 SECTION VII - BLAST AND THERMAL PROTECTION

VI-1. Introduction

This section addresses actions that you might take to reduce the
vulnerability of ECU's, MCPE's, and related equipment to nuclear blast and
thermal radiation.

o For the purposes of this section, blast effects include those

resulting from overpressure (the excess pressure over atmospheric pressure
caused by the shock front) and the dynamic pressure resulting from the strong
winds immediately behind the shock front. Thermal effects result from the
*! short duration, intense heat generated by the blast. The thermal pulse
arrives two to three seconds before the shock front.

* There are current efforts to perfect techniques for hardening

mobile shelters (see References 16 and 17, Appendix 1-2). If and when these
techniques are perfected and can be applied to all shelters, the best
protection for vulnerable equipment would be to mount it inside the shelter.
While this may not be practical with the smaller shelters (5280 and below), it
becomes more inviting with the larger shelters where there may be sufficient
space to partition off a section for the ECU and GPFU. (Soundproof and
insulated partitioning can reduce the noise and heat problems mentioned in
Section III.) But with the present unhardened, indeed, soft, shelters,
interior mounting offers little gain in protection against blast. There
should, however, be one-time (see paragraph VII-2, below) protection from the
thermal pulse for interior mounted equipment simply because it would be shaded
from direct radiant exposure.

VII-2. Assumed Threat

* References 16 and 17 address nuclear hardened shelters in the

context of the RATS (Hardened Tactical Shelter) program and for this purpose
work with the following nuclear threat:

so Peak free-field overpressure of 7.3 psi with a pressure

positive phase of 1.0 second.

so Thermal pulse with a fluence of 65 calories per square

centimeter, deposited in 2 seconds.

o The EATS threat is well beyond what an unhardened shelter can

* be expected to survive.

o This level of overpressure with the accompanying dynamic

pressures would cause crushing and displacement of the shelter and a tearing
away of the CB protective entrance and any exposed flexible ducting.

so The temperatures associated with the HATS level of thermal

pulse might well, in the worst case, reach 2000 0 F, oi. above in the shelter's
directly exposed aluminum skin. This is approaching twice the melting
temperature of aluminum. Even in cases in which the duration of the pulse
should be too short to cause melting, there would in all likelihood be almost

VII-1
 a complete and permanent loss of strength in the skin. The aluminum members
of the ECU wall mounting frame would fare better. They are thicker and
heavier than the skin and therefore, those directly exposed to the thermal
pulse would experience internal temperatures not much over 300 0 F. But even at
this temperature, these members also could suffer a drastic, although
temporary, loss of strength, possibly up to one-half. They should recover
almost completely when returned to normal temperature, however. These thermal
effects will probably be the same for the exposed elements of the ECU.

*o The thermal radiation temperatures can also cause burning or

blistering of paint and ignition or charring of exposed parts of gaskets,
flexible ducting, protective entrance material, and other materials sensitive
to the short duration, intense heat. Exposed portions of materials which
depend upon flexibility for their effectiveness could lose their effectiveness
by becoming brittle or too soft.
Until the hardened shelters become available, the present unhardened

* versions are the ones you must be concerned with. It is estimated that the
current unhardened S280 shelter, as an example, can withstand approximately
0.3 psi nuclear peak, free-field overpressure or 1.3 psi static equivalent
overpressure loading. There appears little payoff from deliberately hardening
ancillary components beyond this level. However, much equipment is already
*beyond that level and designing the ECU mounts for railroad humping has given
them a degree of nuclear hardness as well. This and reasonable protective
measures, if deemed necessary, are addressed in the following two paragraphs.

VII-3. Current Hardening Status

o ECU Mountings. The mountings for the ECU's (with the exception
of the retractable mounting in its extended position) are all designed to
withstand railroad hump loadings (see paragraph 111-2). A side benefit of
this is the capability to survive an estimated nuclear free-field peak
overpressure of 4 psi with the following caveat: those members of the
mounting frame which are directly exposed to the unattenuated thermal pulse
may have a reduced strength at the time the shock front arrives. The ground
mounts, too, have this built-in hardness but they must also be well anchored
with guy lines at top and bottom to reduce shifting and to prevent the taller
mounts for vertical ECU's from tipping.
o ECU. The military ECU, itself, is a fairly sturdy piece of
equipment.

so Blast.

- The 18,000 Btuh PATRIOT horizontal ECU, a unit designed

for added durability, has demonstrated in blast tube tests the ability to
stand up to approximately 7.3 psi overpressure and continue to function.
(Other units have not been so tested and their durability is questionable.)
But the PATRIOT ECU did suffer some deformation to its enclosure which, if
seams were opened or panels sprung, could cause problems if it is subsequently
subjected to DMP. Further, the overpressure load which pushed in the side of
the enclosure could have compromised the air-tight seals necessary for CB

VII-2
 protection, internally, between the compressor and the evaporator and,
externally, in the ECU-shelter interface. What actually happened to such
seals, if in fact they were in place for the test, is unknown since no data on
this were collected.

- The blast tube test resulted in failure of the enclosure

panels of the standard 18,000 Btuh vertical unit. Since then, the panels have
been reinforced against this type of failure but the ECU has not been
re-tested. Nevertheless, these units manufactured subsequent to 1981
incorporate the additional hardening.

*? eo Fragments. The enclosure which houses the ECU is for

protection from the elements, not from an attack. High velocity fragments
from either a nuclear blast or a conventional attack can be expected to
penetrate it and to cause internal damage to the ECU. Also, for the remote
ground mountings, the flexible ducting in all likelihood would be damaged or
destroyed.

ee Thermal Radiation. The exposed sections of the ECU's

aluminum enclosure will probably suffer to some degree from any direct thermal
radiation received. But the enclosure will provide adequate thermal shielding
for the internal works. Any exposed gasketing or sealing would be subject to
damage unless a high heat-resistant material is used. This applies also to
any exposed flexible ducting.

o Modular Collective Protection Equipment. The basic MCPE (see

Section V) has passed several nuclear hardening tests.1 However, the flexible
ducting and the protective entrance are soft, completely exposed elements.
(It should be noted that most current concepts envision that the interface
between the ECU and the GPFU be a flexible duct.) They would certainly be
damaged beyond their ability to continue their function by any attack causing
flying fragments. Also, the projected nuclear overpressure and dynamic
pressure would tear them away. Either of these situations would be critical
if the conventional or nuclear attack were accompanied or followed by a CB
attack. Unless the duct and PE could be replaced prior to the CB attack,
contamination within the shelter would be almost unavoidable. Anyone leaving
* the shelter to put up replacements would open the door to contamination and
the MCPE could not provide the necessary positive pressure in the shelter with
no ducts for delivering the air.

VII-4. Protective Steps

. ECU.

e Wall-mounted ECU's. Other than using heat-resistant

gasketing and sealants, there is not a whole lot more that you can do directly
to the ECU; it cannot be changed substantially without a major redesign or
retrofit. External to the ECU, armor plate (steel, aluminum, Kevlar) can be
added to the top, bottom, and both sides. The rear (condenser intake and

1
Reference 22, Appendix 1-2.

VII-3
 discharge end) must remain largely exposed, except for EMP shielding, to
prevent inhibiting the air flow necessary for the ECU's proper functioning.
The vulnerability of the rear can be reduced by the use of a baffle plate but
great care should be taken to assure ample passage of air. The method of
determining clearance described in Figure IV-1 should be useful in this
respect. The armor will also provide adequate shielding against thermal
radiation for those areas that it shields.

so Ground Mounts. Remote ground mounts are particularly

vulnerable because of the flexible ducting. In situations where there is
risk, you can significantly reduce the risk by flush-mounting the ECU as
illustrated in Figure 111-6. Protection of the ECU, itself, can be
accomplished in the same manner as discussed imediately above.

e MCPE.

*- Flexible Ducting. The first thing that you should do is to

eliminate the flexible ducting. There are two ways you can do this.

- The first is to run the air duct for the PE through the
shelter (see Section IV). You should give consideration to insulating this
duct since the GPFU raises the temperature of the air it pumps through it by
as much as 150 F above ambient. This added heat will increase the load on the
ECU.

- The second way is to use the shelter interior as a plenum

5 which conducts the air to the P2. The flow to the P! must be regulated by an
automatic valve which can operate at the same time to maintain the necessary
positive pressure in the shelter. When the PE is blown away during an attack,
the valve must stop the flow of air; it must also accommodate to sudden,
"- momentary high pressures outside the shelter which might reverse the leakage
flow and force contaminants into the shelter. (A valve to regulate flow and
pressure is essential to the method described immediately above, as well.)
This second method can put a large burden on the ECU since it uses conditioned
air for the PE air wash function.

VII-5. Protective Siting and Protective Construction

In the period before hardened shelters become available, it seems

-almost futile to harden ECU's and MCPE's. But hardening these ancillary items
may give an edge to survival, albeit a very slight one. However, the shelter
can also be given improved protection which will at the same time enhance the
survival prospects of the ECU.

e Siting. Operational considerations permitting, you should look

for places to put the shelter which are away from likely targets. Further,
you should strive to take advantage of terrain features to place the shelter
in defilade from likely directions of blast and thermal effects as well as
from conventional attack. You might orient the shelter so that the smallest
dimensions face the likely location of blast and that the most vulnerable
apurtanances are on the away side of the shelter.

VII-4
 0 Construction. You can use protective construction to
substitute for protection afforded by the terrain or in conjunction with the
terrain to enhance protection. Protective construction would be limited to
protecting the shelter (bunkers could replace the shelter). It would probably
take the form of revetments and berms (similar to those which protect aircraft
in parking areas at forward airfields). Entrenching is another form of
construction that offers possibilities.

* Without overhead protection, such as offered by hardened

aircraft shelters, the electronics shelters remain rather vulnerable. But the
siting and construction suggested above may shield against direct thermal
radiation, intercept fragments, or deflect a shock wave just enough to permit
,.4 survival which might otherwise not be possible. In other words, you should
take advantage of every opportunity to give yourself an edge.

. -'.-

VII-5
 APPENDIX I-1. EXPLANATIONS AND ILLUSTRATIONS OF TERMS

Aspect ratio - In the cross-section of a duct, the ratio of the long side
dimension to the short side dimension. The most efficient (least
pressure loss) and least expensive duct (materials, fabrication, and
installation) is round with a given aspect ratio of 1:1. The next most
efficient and next least expensive is square, with an aspect ratio of
1:1. As the aspect ratio increases, the cost increases and the
efficiency decreases. For the small systems dealt with here, these
factors have relatively small impact as long as the aspect ratio stays
below 5:1.

*.: Btuh (British thermal units per hour) - The English system unit of heat
transfer rate in which all heat loads and capacities discussed in this
Handbook are expressed. 1 Btu - amount of heat required to raise 1 lb
of water 16F.
Cooling capacity - The measure of the ability of an ECU or air conditioner
to remove heat from an enclosed space.

Cooling load - The rate at which heat must be removed from an enclosed
space to maintain a given inside air temperature.

Environmental Control Unit (ECU) (See Figure 1-1-1) - Any device which
processes air (cooling, heating, ventilating, dehumidifying, filtering,
or a combination) to control environmental conditions within an
enclosed space. Specifics on military ECU's may be found in References
27 and 32.

* Horizontal ECU - An ECU designed so that its maximum dimension

is horizontal.

* Vertical ECU - An ECU designed so that its maximum dimension is

vertical.

Equivalent diameter of a duct - One of the factors in determining pressure

losses and resultant reductions in air flow is the circular equivalent
of a rectangular duct. This is expressed in terms of the equivalent
diameter of the rectangular section and can be computed using this
formula:

Equivalent diameter = 1.38 (ab)

2
(a+b)

Where: a and b are the dimensions of two adjacent sides of the

rectangle.

" .Gas Particulate Filter Unit (GPFU) - See Figure 1-1-2.

Beat gain - The rate at which heat enters into or is generated within an
enclosed space.

Neat loss - The rate at which heat is transferred (lost) from an enclosed
space.

AI-1-1

_ . - .-
- . - ,. ; - - ,- . ,- . , -. : - -, .- +: .. . , _ . ., .: .- .: , . . _ , . : . " . ., . " -,
 HORIZONTAL ECU

POWER SUPPLY CONNECTION

U
C -EVAPORATOR AIR DISCHARGE CONDENSER AIR DISCHARGE
CNTRL PNELINTO SHELTER (SUPPLY AIR) CANVAS COVER
FRESH AIR DAMPER CONTROL

- mEVAPORATOR AIR RETURN

M0"
INDIVIDUALLY ADJUSTABLE LOUVERS
ALTERNATE POWER
LIFTING HANDLES SUPPLY CONNECTION CONDENSER AIR INTAKE
FRONT FRESH AIR INTAKE REAR
';2,CONDENSATE
CONNECTION DRAIN

VERTICAL ECU
4 CAV COFRESH AIR INTAKE

-EVAPORATOR AIR DISCHARGE

INTO SHELTER (SUPPLY AIR)

INDIVIDUALLY ADJUSTABLE LOUVERS

.,--EVAPORATOR AIR RETURN

CONDENSER AIR DISCHARGE-

POWER SUPPLY CONNECTION

%-FRESH AIR DAMPER CONTROL

LIFTING HANDLE---
"--CONTROL PANEL
CONDENSATE DRAIN CONNECTION
-ALTERNATE
( PLACES - I SIDE EACH)
POWER
SUPPLY CONNECTION CONDENSER AIR INTAKE
FRONT REAR

NOTE:

o AIR ENTERING THE CONDENSER AIR INTAKE COOLS THE CONDENSER AND LEAVES THROUGH THE CONDENSER
AIR DISCHARGE. SINCE IT DOES NOT ENTER THE SHELTER, FILTERING IS NOT REQUIRED IN CB
SITUATIONS.

* AIR (SUPPLY AIR) ENTERS THE SHELTER THROUGH THE EVAPORATOR AIR DISCHARGE. THERE ARE TWO
SOURCES FOR SUPPLY AIR: AIR ALREADY IN THE SHELTER, WHICH IS TAKEN INTO THE ECU THROUGH
THE EVAPORATOR AIR RETURN FOR RECONDITIONING, AND OUTDOOR AIR THROUGH THE FRESH AIR
(MAKE-UP AIR) INTAKE. IN CB SITUATIONS THE FRESH AIR INTAKE IS OFTEN CONNECTED BY DUJCT-
ING TO THE GPFU AND ONLY FILTERED AIR IS PROVIDED. IF THIS IS NOT THE CASE, THE FRESH
AIR INTAKE MUST W CLOSED TO PREVENT LOSS OF SHELTER AIR PRESSURE. SEE THE DESCRIPTION
OF THE 14CPE-ECU INTERFACE ON PAGE V-5.

Figure 1-1-1. TYPICAL MILITARY ENVIRONMENTAL CONTROL UNITS

* 1-1-2
 1--

GAS-PARTICULATE FILTER UNIT (GPFU) -A DEVICE WHICH PROVIDES CLEAN, FILTERED

AIR AT SUFFICIENT RATE TO PERMIT THE BUILDUP AND MAINTENANCE OF A POSITIVE
- AIR PRESSURE IN A SHELTER. (ALSO SEE FIGURE V-2.) THE AIR ENTERS THROUGH
THE PROTECTCO AND IS ROUTED TO THE DUST SEPARATORQ2 WHICH REMOVES
AND EXHAUSTSQ) 90 PERCENT OF THE DUST. THE AIR THEN PASSES THROUGH THE
PARTICULATE FILTER&, WHICH REMOVES PARTICULATE MATTER AND AEROSOLS, AND
THEN THROUGH THE G.'J FILTER®5 FOR REMOVAL OF GASEOUS TOXIC AGENTS. FROM
THE FILTERS IT PASSES ITO A PLENUM®SURROUNDING THE FILTERS AND OUT
THROUGH THE AIR OUTLET(7T THE ECU, SHELTER, AND PROTECTIVE ENTRANCE.
THIS PROCESS RAISES THE AMBIENT AXR TEMPERATURE BY 10* TO 15*F. WHEN THE
GPFU IS IN A DUST-FREPE ENVIRONMENT OR WHEN M4OUNTED 5 FEET OFF THE GROUND OR
HIGHER IN A NORMAL ENVIRONMENT, IT MAY BE OPERATED WITHOUT THE DUST
SEPARATOR.

Figure 1-1-2. GAS PARTICULATE FILTER UNIT

 Heat pump - To cite from Reference 35: "The heat pump is a mechanism that
can either remove heat from an indoor area and discharge this heat to the
3outside, or it can be used to pick up heat from the outside and discharge
-it into the indoor area for heating." For details, see Reference 35.

• For heating, if the outdoor (evaporator) coil is operated at 0OF,

for example, the refrigerant in the coil can pick up heat from ambient air
at temperatures as low as 100 or 150 F. When compressed to 1200 to
*J 1400, the refrigerant will then release heat to cooler surrounding air
being circulated to the shelter interior. Since the heat pump loses
efficiency at lower temperatures, supplementary heaters are required to
provide adequate heating capacity and are normal components of the unit.

e For cooling, the heating process is reversed by the use of a system

of valves (e.g., the outside evaporator becomes the condenser) and the
heat pump then functions basically as a normal air conditioner.

- The Navy heat pumps as now available are adaptations of Westinghouse

commercial models and were not designed with tactical environments in
mind. (See Figure 1-1-3.) They lack the ruggedness and durability under
N field conditions of the ECU's designed for military applications. When
they are transported, it should be on smooth roads with the avoidance of
shocks. The compressor of a wall-mounted unit failed in a recent road
test which was less severe than railroad humping. Therefore, if subjected
to cross-country road conditions or railroad humping, experience has shown
that they can be expected to fail internally unless carefully packed and
braced externally and internally. However, in peacetime, static situa-
tions they offer an additional range of options for environmental control.

Heating capacity - The measure of the ability of an ECU or heater to add

heat to an enclosed space.

Heating load - The rate at which heat must be added to an enclosed space
to maintain a given inside temperature.

Modular Collective Protection Equipment (MCPE) - A system of interacting

modules necessary in a CBR environment to provide clean, filtered air to a
shelter, to maintain a small positive air pressure in the shelter to
prevent outside-to-inside leakage of contaminants, and to permit entry and
exit of personnel without contaminating the shelter interior. The MCPE
probably will operate in conjunction with an ECU. More description and
illustration may be found in paragraph V-4 and Figure V-i, Section V.

Plenum - Basically, a large duct. One use is similar to an automotive

engine manifold, that is, to collect air from more than one source
before distributing it to one or more outlets. In another use, it is a
wide duct with many small openings for air passage. It might cover an
entire ceiling and distribute the air through the many outlets over the
area. Plenums distribute air usually more gently and more quietly than
more finite outlets but lack ability for precise regulation of flow and
direction. A plenum may also be used for return air.

1-1-4
 WALL-MOUNTED UNIT, HB036 AND HB022

AIR SUPPLY DISCHARGE

SUPPLEMENTARY HEATER

AIR RETURN INTAKE 'jTHERMOSTAT

FRESH AIR INTAKE
cm

0 UDO

OUTDOURDAIR

FRONT

SLEEVE (THROUGH-WALL)-MOUNTED UNIT, HEO36R&S AND HEO22R&S

WIRING INLETS:

SUPPLEMENTARY HEATERS

AIR SPPLYOUTDOOR AIR

-AIR RETURN
INTAKE

OUTDOOR

rVDOR (SZZMIOUTDOOR SECTIO0N

NVOTEP:

*UNITS ARE TO BE USED) P/ITH DUCTIN1G THERE~tFORE fiAvr NO ATTACNErD GtRLLS FOR 7HE INDOORt
SUPPLY AND RETURtN.

*UNITS AREr CONTRtOLLED BY THERMOSTAT MCUNTED ON SHEL2TR INTERIOR WALL.

Figure 1-1-3. NAVY HEAT PUMPS

Short circuit - A term used to describe the condition in which the supply
air goes directly back into the return almost as soon as it is discharged.
This is caused most often when an obstacle is too close in front of the
supply and return outlets, retarding the proper flow of air. This might
also occur when the obstacle blocks the return, leaving the return air
no path other than across or through the supply flow. Remedies include
relocating the obstacle, relocating the obstruction, or ducting the
supply to where it is clear of the obstruction.

Throw - The horizontal distance that air will travel after it leaves the
supply discharge before a specified reduced velocity, usually 50 feet
per minute, is reached.

Ventilation - The process of introducing ambient air into an enclosed

space by an ECU.

1-1-6
A.- :. . . - - -. - . . o. . . / ' . -o . - .- - . -

f
" APPENDIX I-2. BIBLIOGRAPHICAL REFERENCES

1. Aluminum Association, The, Aluminum Construction Manual, Section 3.

Engineering Data for Aluminum Structures, third edition, 1975.

2. Aluminum Company of America, ALCOA Structural Handbook, Pittsburgh,

Pennsylvania: ALCOA, 1960.

3. American Society of Heating, Refrigerating and Air-Conditioning

Engineers, Inc., ASHRAE Handbook and Product Directory, 1979 Equipment,
New York, N.Y.: ASHRAE, 1979.

4. , ASHRAE Handbook, 1981 Fundamentals, Atlanta, Ga.: ASHRAE,

1981.

5. Anonymous, Installation Manual for Adaptor Kit, Remote Control

Conversion, 18K Vertical Air Conditioner for AN/TSC-26 System, 1970.

6. , Methods for Installing the 18,000 Btuh Total Environmental

Control System in Trailers and Shelters, 1974.

7. Carrier Air Conditioning Company, Carrier System Design Manual. Part 2.

Air Distribution, Seventh Printing, Syracuse, N.Y.: Carrier Air
Conditioning Company, 1966.

8. Engineering Laboratory, Computer Sciences Corporation, National Space

and Technology Laboratories, NSTL Station, Mississippi, Chemical and
Biolouical Protective Equiment Guidelines for Modular Collective
Protection Equipment User Systems, Chemical Systems Laboratory
Contractor Report, 1981. (Requests for document should be made to:
Commander/Director, Chemical Systems Laboratory, ATTN: DRDAR-CLJ-R,
Aberdeen Proving Ground, Maryland 21010.)

9. Glasstone, Samuel and Philip J. Dolan, ed, The Effects of Nuclear

Weapons, U.S. Department of Defense and the Energy Research and
Development Administration, Washington, D.C.: U.S. Govermn.ent Printing
Office, 1977.

10. ITEM 1978 (Interference Technology Engineers Master) Directory and

Design Guide, Plymouth Meeting, PA, R&B Enterprises, 1978.

11. Krisko, William J., Study on Sealing and Leakage Reduction Measures for
CB Protective Shelters, Corad Division, Donaldson Company, Inc. for
Physi:al Protection Laboratory, Edgevood Arsenal, MD, 1970.

12. Baumeister, Theodore, ed, Marks' Mechanical Engineers' Handbook, sixth

edition, New York: McGraw-Hill Book Company, 1964.

13. Mears, Merton D., Special Publication ARCSL-SP-79003, Handbook on

Collective Protection, Aberdeen Proving Ground, MD: Chemical Systems
Laboratory, U.S. Army Armament Research and Development Command, 1979.
(Requests for document should be made to: Comander/Director, Chemical
Systemp Laboratory, ATTN: DRDAR-CLJ-R, Aberdeen Proving Ground,
Maryland 21010.)

1-2-1

,, . . . - . - ,.-°...
.. . . ' . - . .. . ... - . . - - .- .-
-"° . i. - - . ' i i .
 14. Metex Electronic Shielding Group, EMI/RFI Shielding Handbook and
Catalog, Edison, N.J.: Metex Corporation, 1977.

15. Quadripartite Standardization Agreement-360. Climatic Environmental

Conditions Affecting the Design of Military Materiel, Armies of the
United States, United Kingdom, Australia, and Canadian Forces, 1979.

16. Schuman, William J., Jr., E. James Gaul, David F. Bassett, Robert K.
Warner; U.S. Army Harry Diamond Laboratories, Hardened NBC Protection
for C3 Shelters (undated).

17. Schuman, William J., Jr., U.S. Army Harry Diamond Laboratories; Garabed
Zartarian and Raffi P. Yeghiayan, Kaman AviDyne; W. Don Allison, U.S.
Army Ballistics Research Laboratory, C3 Shelter Designs for the Tactical
Battlefield (undated).

18. Spectrum Control, Inc., Spectrum Control Catalog (a catalog of products

and services related to electromagnetic compatibility), Fairview, PA,
undated.

19. Trane Company, Trane Refridgeration Manual (Manual 2), LaCrosse,

Wisconsin: Trane Company.

20. U.S. Department of the Army, Army Materiel Command, AMC Pamphlet No.
706-120. Ensineering Design Handbook. Criteria for Environmental Control
of Mobile Systems, Washington, D.C.: U.S. Government Printing Office,
1971.

21. , Army Regulation No. 70-38, Research, Development,

Ijst and Evaluation of Materiel for Extreme Climatic Conditions, 1
August 1979 with Change 1, 15 September 1979.

5 22. , Chemical Systems Laboratory, Aberdeen Proving

Ground, Maryland 21010, Air Filtration by Modular Collective Protection
Eauivment, Aberdeen Proving Ground, MD, 1981.

23. , Technical Manual, TM 5-3610-250-14, Operator,

Organizational. Direct Support and General Support Maintenance Manual
for Map Layout Section. Topographic Suvyort System Semi-Trailer Mounted
(Gichner Mobile Systems Model 10536-1), Jan 1981.

24. , Technical Manual, TM 750-5-15, Army Equipment Data

Sheets, Chemical Weapons and Defense Equipment, August 1972.

25. U.S. Department of Defense, DOD Brochure: Standard Family of Tactical

Shelters, Natick, MA: U.S. Army Natick Research and Development
Laboratories, 1981.

26. , DOD Military Handbook, MIL-RDBK-23A, Structural

Sandwich Composites, U.S. Air Force, Dec 1968 with changes through Jun
1974.

1-2-2

.' .,...'
,., -..'.... .- -
........-.-...- . . . .. . .. . . ,. .. . ...- , . -.... . -. . . .
 27. _____,_____,Military Specification, MIL-A-52767B, Air
Conditioners: Vertical and Horizontal. Compact, 4 Sep 1979 with interim
U Amendment, 8 Jul 1981.
28. ___________,__________,MIL-S-55286D, Shelter,
Electrical Equipment S-280( )/G, 5 Dec 1979.
29. ______,______ MIL-M-81957A(A.S), Mobile Facility. General
* Specification 'For, 9 Oct 1975.

30. ___________,__________,MIL-C-83400A, Core Material

for Metal Sandwich Panels for Shelter Construction (Polyurethane Foam),
19 Aug 1980.

31. __________,Military Standard, MIL-STD-1407, Heaters,

Vehicular Compartment: Heaters. Coolant. Engine; Heaters. Space;
* Heaters. Duct-Type, 16 Jul 1975.

* 32. _________________ Air

_,MIL-STD-1408A,

* Conditioners, Family of Enviropmenital Control Units. General Application

Characteristics, 9 Apr 1975.
33. ____________________,MIL-STD-1472C, Human
Ennineerina Design Criteria for Military Systems. Equipment and
Facilities, 2 May 1981.

34. _____ Military Standardization Handbook, NIL-HDBK 5C, Metallic

Materials and Elements for Aerospace Vehicle Structures, Vol 1, 15 Sep
1976.

35. U.S. Navy Technical Manual, NAVAI. 19-60-83, Air Conditioner/Heat Pumps.
Models H3B036. HE036. RB022 and RE022 (Westinghouse Air Conditioning,
Sturtevant Division), Naval Air Systems Comnd, 1980.

1-2-3
 APPENDIX II-1. ESTIMATING SHELTER COOLING AND HEATING REQUIREMENTS

- I-1-1. Purpose

* This appendix explains how the methods you used in Worksheet Parts I
and Il were developed.

wWORKSHEET PART I
11-1-2. Cooling Requirement Estimate

* You determine the total cooling load for a shelter by suming the
heat gains from solar radiation and conduction (Step 1), electrical equipment
and lights (Step 2), personnel occupying the shelter (Step 3), and the
ventilation air drawn in from outside (Step 4).

* Step 1: Summer Heat Gain From Solar Radiation and Conduction.

This part of the total cooling load is the Btuh to be gained under the design
conditions (Figure II-1, Column C) adjusted to a specific climate using the
*multiplier of Column E. This is how these are derived:

*' .e Column C. Compute the shelter summer heat gain from solar
.* radiation and conduction, Column C, using the cooling load temperature
difference (CLTD) method described in Chapter 26 of the 1981 ASHRAE Handbook
(Reference 4). This method applies the following relationship:

q - U x A x CLTD

Where: q = Cooling load (heat gain) in British thermal units

(Btu) per hour.

r U - Heat transfer coefficient of the shelter in Btu per

hour (Btuh) per square foot (SF) per degree Fahrenheit
(OF). For the Navy MF shelters it is taken as 0.25 Btuh/
-SF/°F and for all other shelters it is taken as 0.35
Btuh/SF/OF.

A - Area in SF of the surface (wall, roof, floor) of the

shelter for which the q is being computed.

CITD - Cooling load temperature difference in oI from Chapter

26 of the 1981 ASHRAE Handbook:

- Roof 1, without suspended ceiling, Table 5A, worst

case.

II-1-1
 -- Wall, Group G, Table 7A, worst case.

(Both tables based upon an inside design temperature

of 780F I and minimum outside temperature of 950F 2 ).

Note: For the floor, because the sun never reaches

the floor, the CLTD is:
950 - 780 - 170F

An example of the above relationship using the S-280

shelter:

A 90 5

A.5.ZSTOTAL A * S72.5 SF SUN

f2
DIRECTION.\>

SHELTER DIMENSIONS (EXTERIOR) - SUN

/ ' WORST CASE 0r INTATION

Computations:

Element U-Factor x Area x CLTD -

J;lls - NE 0.35 x 90 x 26 M 819.0

- SE 0.35 x 56.25 x 30 0 590.6
- SW 0.35 x 90 x 63 - 1,984.5
- NW 0.35 x 56.25 x 47 M 925.3
" Roof 0.35 x 90 x 70 - 2,205.0
Floor 0.35 x 90 x 17 M 535.5
Total - 7,059.9 Btuh

*o Column E. The summer cooling load in Column C, Figure II-1,

was based on areas where the maximum summer temperature is 950 F. For other
areas the adjustment factors of Column E are needed. Develop the Column E
factors as follows:

* 178OF (dry bulb) is the neutral point between sensations of being warm and
cool in the ASHRAR Comfort-Health Index (Reference 4, Chapter 8). This is
also the inside temperature used in the ASHRAE CLTD tables (Reference 4,
* Chapter 26) upon which the data in Columns C through F of Figure 11-.1 are
based.
2
The ASHAE CLTD tables and, consequently, the values in Columns C and D of
Figure II-1, are based upon an outside design temperature of 95°F (DB).

11-1-2

/-,,:,-,
... . .,.
....-
..-., ...-.
.. . . .• . . •,. 2,-,... ,.
 The ASHRAE Handbook (Chapter 26) provides a formula for a
corrected CLTD:

CLTDcorr - [(CLTD + LM) x K + (7 8 -TR) + (To-85)] x f

Where: CLTD is the same as previously used.

LM is a latitude-month correction which is not

required here.

K is a color correction factor which equals 1 since

there is no color change.

(78-TR) is the indoor design correction which is not

required here since indoor design temperature remains
the same.

(To-85) is the outdoor correction factor. To is the

average outside temperature from Figure 1-3. The
85F is the mean outdoor temperature upon which the
tables in Chapter 26, 1981 ASHRA! Handbook, are based.

f is a factor for an attic fan and is not applicable.

The resulting formula is:

CLTDcorr - CLTD + (To-85)

eUsing climatic category Al and the S280 figures from above for the
examp le:

Element

NE 0.35 x 90 x :(26 + (105-85) - 1,449

SE 0.35 x 56.25 x (30 + (105-85) - 984.38
SW 0.35 x 90 x (63 + (105-85) - 2,614.5
NW 0.35 x 56.25 x (47 + (105-85) - 1,319.06
Roof 0.35 x 90 x (70 + (105-85) - 2,835
Floor 0.35 x 90 x (120- 78) = 1,323

Total a 10,524.94 Btuh

(Use: 10,525 Btuh)

11-1-3
 The adjustment factor for Column E is the ratio of the adjusted
cooling load (heat gain) to the design conditions cooling load
- 10.525 Btuh - 1.49
7,050 Btuh

o Step 2: Heat Gain from Electrical Equipment and Lights.

Operating electrical equipment, electrical motors, and lights are sources of
shelter heat gain. Reference 12 (Appendix 1-2) offers the figure 3.4 Btuh per
Watt for converting the total electric power to heat. So add the power rating
of all electrical equipment in the shelter and multiply by 3.4 to obtain the
estimated heat gain from this source.

o Step 3: Heat Gain from Personnel Occupying the Shelter.

People are sources of both sensible heat and latent heat (moisture). The heat
gain to the shelter depends upon the level of activity and sex of the
occupants. Table 18 in Chapter 26 of the 1981 ASHRAE Handbook (Reference 4)
shows that for a seated male doing very light work the heat gain is 480 Btuh.
For purposes of this handbook, this value is rounded to 500 Btuh. Therefore,
the number of people occupying the shelter is multiplied by 500 to determine
the total heat gain from personnel.

o Step 4: Heat Gain from Ventilation. This part of the total

heat gain depends upon the volume of air introduced into the shelter, inside
and outside temperature, and inside and outside humidity.

*e The total heat gain from ventilation is found when you

multiply the total cfm of air brought into the shelter by the climatic area
factor from Column G (summer) or H (winter) of Figure II-1. This factor is a
function of temperature and humidity and is developed from formula (33) on
page 26.30 of Reference 4:

Qt - 4.5 x cfm x Ah

Where: Qt - heat gain in Btuh per cfm

4.5 - 60 min/hr x 0.075 lb of dry air/cu ft. This converts

cfm to lb of dry air/hour.

cfm - the quantity of outside air introduced into the shelter/

min.
Ah = difference between iaside enthalpy (hi) and outside
enthalpy (ho ) :.n Btu/lb - (hi - ho).

*e Reference 33 established a military design requirement for

*ventilation of 20 cfs outside air pet person. You multiply this by the number
of occupants in. the shelter to determine the total volume (cfm) of air to be
brought into the shelter per minute. This is the cfm to be used in the above
formula. The 4.5 x ^h then becomes the formula for the factors, q, of Columns
G and H, Figure 11-1.

11-1-4
S

Or: q - 4.5 (hi - ho )

U
e* To determine hi and ho:

FOR SU1ER COOLING

p (For the summer cooling example, Climatic Category Al is used.)

o -Toutside temperature = 120OF DB (see Figure 1-3)

*Ti = inside temperature = 78oF DB (see footnote 1, page 11-1-2)

RHO - outside relative humidity - 3% (see Figure 1-3)

* - Using To and RHO, enter the ASHRAE Psychometric Chart No. 1 and find:

ho 31.2 Btu/lb dry air

w o = 0.002 lb water/lb dry air

Assume no change in air moisture content between outside and inside.1

-
. Therefore:

wi - wo - 0.002 lb water/lb dry air

Using Ti and wi, enter the psychometric chart and find:

hi - 21 Btu/lb dry air

Then:

q 4.5 (31.2 - 21)

- 45.9 Btuh/cfm

Use: 46 Btuh/cfM (see Figure II-1)

FOR WINTER HEATING

(For the winter heating example, Climatic Category CO is used.)

To 0 F (see Figure 1-3; round (-)20 F to 0OF for this purpose)

Ti - 70OF (see Figure II-1 and Reference 4, Chapter 25)

RHO - 100% (see Figure 1-3)

1
This is a safe assumption under low humidity conditions. In higher humidity
areas (e.g., B2), it is assumed that the ECU will remove half the moisture
from the outside air; therefore, wi - 0.Swo.

11-1-5
 Using To and RHO, enter ASHRAE Psychometric Chart No. 2 and find:

ho - 0.85 Btu/lb dry air

W o - 0.0008 lb water/lb dry air

Assume: w i " wo - 0.0008 lb water/lb dry air, enter

ASHRAE Psychometric Chart No. I with wi and
Ti and find:

hi - 17.8 Btu/lb dry air

Then: q - 4.5 (17.8 - 0.85)

- 76.3 Btuh/cfm

Use.: 76 Btuh/cfm (see Figure III-i)

WORKSHEET PART II

11-1-3. Heating Requirements Estimate

Determine the total heating requirements in the same way that you
found the cooling requirement. The methods as well as the multipliers for
computing heat gains from electrical equipment and personnel in the shelter
(Steps 9 and 10) and the heat loss from ventilation (Step 7) are identical to
the corresponding functions in the cooling estimate. Therefore, the bases for
Worksheet Part II Steps 7, 9, and 10 do not need to be explained again. The
conduction heat loss requires slight modifications to the Part I formula; this
"* is addressed below.

. Conduction Heat Loss (Load), Figure II-1, Column D. The

relationship used in paragraph 11-1-2 applies here also but with a
modification:
q - U xA x T

Where: q, U, and A are the same as in paragraph 11-1-2.

T represents the difference between the design inside

temperature (700F) and the outside ambient temperature (0°F). This is used
instead of CLTD, which includes solar radiation transfer, since maximum heat
loss occurs at night when there is no solar radiation. Further, since there
is not sun at night, orientation is inmaterial and A equals the entire shelter
outside area.

Still using the S-280 Shelter for the example computation:

q- 0.35 x 472.5 x (70 - 0) - 11,576 Btuh

(Use: 11,580 Btuh)

. I1-1-6

*. . . . .
 " Winter Heating Factor, Figure III-I, Column F

q - U x A x Tcorrected for Cl condition

- 0.35 x 472.5 x (70 - (-25))

- 15,711 Btuh

11-1-4. Verification. To verify the validity of broad application of the

adjustment factor in both Columns E and F, computations were done individually
-" for each shelter and all were found to agree.

di

111-
 RD-A2B ~2~NINERINGHANBOO
ITEGATIN FORENVRONMNTA 120
CONTROL(U) RADIAN INC ALEXANDRIA YR P A JORDANIRL 2/.
7UNCRSSIIED82 MAY83 83-5-525-8805 DARK7-8i-D-MS /G0/ N

CSFIDF*Gi/
 .L.

*W6

~~.8

1111 .05 1;4

ICROOP REOUTINTETCHR
NTIONA 336A
OFSANADS 96-
 APPENDIX 11-2. REDUCING COOLING LOAD BY SHADING
K
11-2-16 Introduction

Solar radiation is a significant source of heat gain for a shelter.

This appendix presents the method which was used to estimate how much
reduction in heat gain, and resultant cooling load, from this source can be
*achieved by shading the shelter. The example presented is for the S280
shelter. The method will work for other shelters, as well. In fact, the 45
percent approximate reduction given in paragraph 11-12, Section II, is an
approximation derived from the estimated reductions using several
representative types of shelters.

11-2-2. Starting Point

e 5280 shelter, with same orientation relative to the sun as was

used in Appendix II-1. Dimensions and orientation are shown on page 11-1-2.

e Since all shelter surfaces will be shaded, the CLTD will be

260 F; this is the same as for the NE wall in Appendix II-1, which is away from
the sun (see page 11-1-2).

e The cooling load for the unshaded shelter does not exceed the
load for the shaded shelter until after 0900 to 1000 hours.

* The sun altitude is below 450 from vertical only two or three
hours before 0900 to 1000 hours. Therefore, a shading angle of 450 is
adequate. See Figure 11-6.

S11-2-3. Computations

* For S280 Shelter:

Element U-Factor X Areal X CLTD -

Walls - NE 0.35 90 26 - 819.0

- SE 0.35 56.25 26 - 511.9

- SW 0.35 90 26 - 819.0

- NW 0.35 56.25 26 - 511.9

Roof 0.35 90 26 - 819.0

Floor 0.35 90 17 535.5

Shaded Total 4016.3 BTUH

II1-2-1
, ,o ,,'
-.
-. ,.- . . ",, .'-' . ' ., ' .. 'o .' 3 . . ; .. ' . 3 -:.. . . ". . . .- -- " "• -

Unshaded Total: 7,059.91

S Shaded Total: 4,016.3

Difference: 3,043.6 BTUH

3,043.6 x 100 43% Reduction

7,059.9

• By the same method, heat gain reductions for other

representative shelters were estimated at approximately 45% plus or minus 3%.
. Since consistent precision and constant conditions are not possible when
working with matters of this nature, the figure of 45% for reduction in solar
heat gain from shading is taken as a valid and useful standard reduction for
application to all shelters.

1
"- From page 11-1-2.

L II-Z- 2
 APPENDIX III-1. RETRACTABLE MOUNT DESIGN

Content

This appendix contains a design for a retractable mount for one 18,000
Btuh military vertical ECU. The design was drawn with the S280 shelter in
mind but is adaptable to other shelters as well as to other ECU's. If heavier
ECU's are contemplated, heavier duty tracks will be required. (Check the
* weight of ECU against track manufacturer's claims for track carrying
capacity.) Also, the provisions for anchoring the ECU for transit should be
re-evaluated. As for all designs in this Ill-series of appendices, shop
drawings must be provided before the mount can be fabricated.

1111-
 z .n 0

z. oz z 0

1 wm z
-Z Zw
cJ CIO m z

u z

. m0 .0 1) x "t

t. 0 CL.

a~O ~ I( IC .0~Z a7 C

T~ T 0x4 -- w0

ar Z E 0'E'*- r

IC~~ i 0Cu

4m
4C u .0

m m ..
2J 0

.C -C
Ca
'0. I.

aL
-0z
C-4 0L

uNOG

0- J

a eg
z 040

________ ______ E4

uJ
.JI
-j ---
CL LLI
L I.-
uj PI
IIIJ
CL%- 7i

uuJ

111-1-

. . .N
 7- 7, T V7 W7

APPENDIX 111-2. SAMPLE CALCULATIONS: STRESS ANALYSIS

FOR WALL MOUNTING FRAME FOR 36,000 ETUII
ECU ON S280 SHELTER

* 111-2-1. Introduction.

The task here is to develop mounting frames which allow the

*standard, compact, horizontal 9000, 18000, and 36000 Btuh ECU's to be
attached, singly or in pairs to small, transportable shelters. The frames
must be simple yet sufficiently strong to support the units during railroad
transportation and when subjected to limited nuclear overpressures (up to 4
-: psi). The task includes only horizontal ECU's. The horizontal configuration
is more suited to fixed mounting on the front end of a truck-mounted shelter,
such as the S280, and can fit above a truck cab. The sample calculations
presented in later paragraphs are for the 36,000 Btuh horizontal ECU and are
representative and illustrative of the method employed for all sizes of units.

I: e The Shelter
- The design considers only the Army 5280 shelter, which is similar
in end dimensions and construction features to most other unhardened and
non-expandible shelters. You should, therefore, be able to adapt mountings
designed for the S280 to other shelters of similar dimensions fairly easily.

es The S280 has outside dimensions of 7-1/2 feet in height x 7-1/2

* feet in width x 12 feet in length. It weighs about 1400 pounds and uses
sandwich construction for the wall, roof, and floor panels.

es The wall panels, to which the ECU's must be attached, consist

of a 2-inch thick urethane foam core (density 2 pcf) to which 0.040-inch thick
sheets of 5052-H34 aluminum alloy have been cemented on both inside and
3outside surfaces. Although the panels are formed with aluminum extrusions on
the edges and are stiffened with aluminum extrusions placed inside the panel,
exploratory calculations indicated that it would not be feasible to transfer
the dynamic loads due to railroad humping directly to the composite wall. The
P lack of compressive and shear strength of the low-density urethane foam core
is the limiting factor. Discussions with a representative of a firm 1 which
manufacturers urethane foam disclosed that the foam would have to be much
denser, about 16 pcf, to have the shear and compressive strengths necessary
for a structural component in a composite wall. Material with the density of
only 2 pcf is primarily a thermal insulation, according to the manufacturer.

". Two leading shelter manufacturers 2 advised that the shelter end
panel probably would not stand up to the design loadings (see next
single-bullet paragraph), especially for the heavier ECU's, unless the panel
*l were specifically constructed for the loads. They further said that it would
be risky to fit a standard mounting frame to an end panel without the aid of
the structural drawings for the particular shelter being used since the
- structural design of shelters is not uniform; the size, placement, and number

IPlastics Manufacturing Company, Philadelphia, Pennsylvania.

2
Craig Systems and Gichner Mobile Systems.

' 111-2-1
 of stiffeners is not assured even within a given shelter type and model. They
therefore recomended transferring some of the loads to the side and roof
panels which, in shear, can take them better than the end panel can be
expected to take them in moment. The fact that the mount designs do not rely
specifically on the panel stiffeners for strength or bolted attachments makes
it easier to adapt the mounts to a variety of end panel designs.

so Paper honeycomb is a much stronger core material than 2 pcf

urethane. For this reason, shelter panels with paper honeycomb cores 3 do not
* have internal stiffeners. The result is that the panel strength is comparable
to urethane panels, and the ECU mounting frame attachment and load transfer
are also comparable. The same mounting frame designs are adaptable to both
urethane and paper honeycomb panels and no design was made specifically for
either one.

*o As mentioned above, the mounting frames are designed to survive

limited nuclear overpressures. To exploit this capability, they must be
attached to shelters hardened to a comparable degree. When attached to an
*- unhardened shelter, the frame would survive only as long as the shelters does.
Nevertheless, the mounting frames have been designed to be adaptable to either
the hardened or unhardened shelter. The HATS program is supposed to include
designs for mountings hardened to the same level as the shelter.

. Dynamic Loads.
e Transportation Shocks. In addition to the weight of the units,
the frames must be capable of supporting the ECU's when subjected to the
following acceleration forces caused by railroad humping:

Longitudinal direction - lOg's acceleration

Transverse direction - 6g's acceleration
Vertical direction - 6's acceleration

These figures were used in the calculation set of Reference 6.

*o Nuclear Overpressure. The criteria presented in References 16

and 17 indicate that a shelter should be able to withstand a peak free-field
overpressure of 7.3 psig, which translates to an amplified peak reflected
overpressure of 35 psig equivalent static load. An unhardened shelter would
not hold up to this (nor would the mounts presented in this handbook.) For
more discussion of this, see paragraph VII-2.

so No test data are available to show whether the ECU, itself, can
withstand the dynamic loads described above. This is a source of some
concern. Design criteria specify that ECU's be able to withstand railroad
humping and it is assumed that they are being manufactured in accordance with
the specifications. However, the nuclear overpressure loading at 7.3 psi is
worse than the humping loads and it is highly unlikely that the ECU's, without
extensive protective measures, would survive it.

3Brunswick Shelters, for example.

1 -

II11-2-2
 • Allowable Stresses. To facilitate the design, we decided to apply
a minimum factor of safety of 2.5 on the appropriate yield properties of the
material, using the railroad humping loads. This would provide ample
protection for the humping loads (factor of safety - 2.5 on yield stress) and
limited resistance to nuclear blast pressure.

9 Concept of Design. These designs are for securing: a single

18,000 Btuh horizontal ECU to the shelter front end (adaptable for a 9,000
Btuh unit); two 18,000 Btuh horizontal ECU's (adaptable for two 9,000 Btuh
units); and a 36,000 Btuh unit. Two of the designs, for the single 18,000
Btuh unit and for two 18,000 Btuh units, use structural elements secured to
the corners of the shelters. The vertical location of the two mounts can be
shifted up or down to meet the needs of the application. The design for the
36,000 Btuh has its location fixed near the top of the end panel by the two
diagonal struts used to transfer some of the loads to the roof panel of the
shelter. This concept is sketched below. This design for the 36,000 Btuh ECU
mounting is the one used in the following paragraphs to illustrate the stress
analysis method employed for all designs.

111-2-3
 :! • Dimensions and Weight.

II

8orri

90 L Weight, W = 435 lb. _ _ -

,:-3 * ECU Mounting Bolt: Spacing.

Six 3/8-inch diameter bolts are

"" used in the bottom of the ECU to secure the tI
.. unit to the mounting frame. '

ECU MonigROtSaig 0e

4; 2 44 &*v

481

111-2-4

. ° . . . . . .-. - , • •.,
 9 Stress Analysis Approach and Sequence of Broad Steps.

With the design concept decided (see the sketch on page 111-2-4),
we then determine the shape and size of each member of the mounting frame
based upon the stresses expected in each member. Aluminum is used throughout
" to save weight; section characteristics and allowable stresses are taken from
Reference 1.

*o We assume that the frame is weightless and exerts no forces

Aupon itself. This eases the computations and is made acceptable by the factor
of safety which is applied.

eo Our first broad step determines the reactions to the design

loadings at the connections of the mounting frame to the shelter and
establishes the design conditions for these connections (paragraph 111-2-2).

so The next broad step (paragraph 111-2-3) determines the ECU

mounting bolt reactions to the design loadings.

*o In the last broad step, we use the reactions previously

determined, to find the forces and moments acting on the members of the
mounting frame (paragraph 111-2-4). We then select each member from the
- standard shapes of Reference I to withstand these forces and moments.

111-2-2. Frame-to-Shelter Attachment Bolt Reactions at Points A. B. C. and G.

These are reactions to the humping loads (shocks) in the three primary
(I directions. The maximum values identify the design conditions.

\ lOW 5/-- -1 -- #

2-, -62

S.28. .
p,4AA "L
o>

II11-2-5
 * Loads (F) Applied to Frame by ECU Due to Weight and Humping Loads

Fz - (6 + )W - 7W

Fx = W + loW

.y W + 6W

NOTE: Addition is of vector quantities.

e Vertical Shock Caused by ECU

*e Take summation of moments about line CG to permit calculation

of reactions Ax and Bx, which are equal.

EMCG - 2Ax x 36 - -7W x 19

-7 x 1 x 435
Ax=2 x 36

Ax - Bx - -803.5. - -804 lb

•o Take summation of moments about line AB to permit calculation

of the reactions Cx and Fx, which are equal.

EMAB - 2 Cx x 36 = +7W x 19

Cx - Fx - +803.5 - 804 lb

*. This determines the vertical components of the reactions at

A, B, C, and G, which are equal.

SEF z 7W
Az Bz Cz Gz 7w 7(435)
.' o.4 4

NOTE: If shock direction is reversed:

Ax - Bx 5 x P(435) -- 574 lb
2 x 36

Cx - Gx - +574
~~~5(435) 54I
Az - Bz - Cz - Gz 545 544lb

thus the bolt reactions would be smaller than in the shock

direction selected.

111-2-6
 • Transverse Shock Caused by ECU

. Reactions due to deadweight only:

EMCG - 2Ax x 36 - 19(-W) (Ax Bx .. Ax + Bx =

2Ax)
19 (-435)
Ax - B w 2x36

Ax - Bx - -114.8 lb - -115 lb

"MAB: Using same procedure as above:

Cx - Gx - +114.8 lb - 115 lb

ee Reactions due to impact of 6W only:

Assume that the frame is rigid and that bolt forces are
proportional to their distance from center of rotation.

Looking down on the shelter and frame permits the relationship

between the x-components of the bolt reactions to be
determined. By symmetry: Gx = Cx and Bx = Ax .

CA4

x
C- Ax
Using similar triangles:
- 45 20
20 20
Ax = Bx = 45FI; Neglecting signs, take summation of

moments about the center of rotation to enable Cx to be

determined.

Z, CR= 2 Cx 45 + 2 Ax 20 - 19 x 6W - 114W
Substituting for Ax, and solving for Cx

45
2 Cx 45 + 2(20 Cx)20 - 114W

Cz.- 114 . 114 (3) -460.1i

107.78" 107.78

111-2-7
 Use the relationship developed above to determine the other
components.

Cx - -460 lb -Gx
20
Ax - -- (460) - -204.5 lb = -Bx

Take smat ion of forces in the transverse direction to

enable the components of the reactions in that direction to
be determined.
Fy - 6W; Ay - By -i Cy M Gy .jW . 6x435 - 652.5 - 653
yF W;yB~Cy y 4 4

The summation of forces in the vertical direction allows the

z-components of the bolt reactions to be determined.

-Fz - 435; Az - Bz - Cz - Gz 44 4 - 109

35 b

ee The smmaation of forces in the x-direction is used to establish

the bolt reaction components in that direction.

*If shock reversed, change signs

Fx =0 Ax - -115 - 205* - -320
Bx - -115 + 205* - 90

Cx - 115 - 460* - -345

Gx - 115 + 460* - +575 Check ZFx - 0 OK

U
e Longitudinal Shock Caused by ECU

"e Reactions due to weight only, see first double bullet under
"Transverse Shock" paragraph, above.

Ax Bx -115

Cx -F x 115

-o Reactions due to the impact of 1OW only:

Take sumation of moments about CG to permit calculations of

the reactions Ax and Bx .

ZMCG " 2 x Ax x 36 - lOW x 13 " 130W

A B 130 W 130 (435) - 785.4 lb - 785 lb

2x36 2x36

111-2-8
 Take summation of moments about a line through A and B to
permit calculation of the reactions Cx and Fx, which are
equal.

ZMA= 2 x Cx x 36 10W x (36 13) =230W

'"C x M 2x36
23 (435) =1389.6

Cx - Gx - 1390

Take summation of forces in the longitudinal direction to

enable the components of the reactions in that direction to
be determined.

ZFx - 1OW

*If shock direction is

reversed, change signs:
Ax - -115 + 785* - 670 Ax - -900

Bx - -115 + 785* - 670 Bx - -900

Cx - +115 + 1390* - 1505 Cx - -1275

Gx - +115 + 1390* - 1505 Gx - -1275

2 (670 + 1505) - 4350 - 1W OK

The summation of the forces in the vertical direction allows

the four z-components of the bolt reactions to be determined;
these are assumed to be equal.

-F z 435
-- W- 19 l
BzCzFz Alb
44

111-2-9
 • Summary - Mounting bolt reactions at Points A, B, C, and G for
humping loads.

ae Vertical Shock

76/
A?..604 '*4AT7

Ay-76/
CZ,. 76/ 0
C Cx80,

*e Transverse Shock Az - /09

AN -- SZO, a C3 4,r90 rs /09

=~ ~C
C- I09 - c/r

Cx- 3da Fy.K61 :575

Cy:653

ee Longitudinal Shock

B 70

A
Ax r 670 15

-CAO~
/5 059

111-2-10
 a Design Conditions for Connections of Frame to Shelter (abstracted
from preceding aumary)

Max Shear in Y-Z Plane

Vertical Shock Fz 761 lb

Max Tension

Longitudinal Shock Fx -1275 lb

Max Compression

Longitudinal Shock Fx 1505 lb

111-2-3 ECU Mounting Bolt Reactions

* Vertical Shock
*s Take the uat ion of moments about the line PS and calculate
the Z-components of the bolt reactions.

EMPS
2Rz 23 + 2q 20 -7W (14.19)

Assume that the frame and ECU base are rigid. Use similar
triangles to establish relationship between Qz and Rz.
but . mz 20 Fj T
2U7. 23- 23

Rz (46 + 40 x 2 - (7 x 14. 19)(435) P. OT RZ

-2.3
Ili-2-11
 - Uz - 534.9 - 535
-Z

Qz " Tz " 2-0 (535) - 465.11 - 465

*o Take the summation of forces in the vertical direction and

calculate the two unknown bolt reactions in that direction
which are equal, Pz - Sz.
F z z"7W - 2 (535 + 465) . [7(435) - 20001 " 2 - 522.5 -523
ZFz 1'z = 2

Check - 2(523 + 465 + 535) - 3046 - 7W - 7(435)

3046 - 3045

9 Transverse Shock. Determine the vertical components of the bolt

reactions due to the weight of the ECU, W, and to the transverse shock, 6W.

so Due to Weight (divide quantities from "Vertical Shock"

paragraph, above, by 7):

- - - 76.4 - 76 lb

QzTz 465 . 66.4 - 66 lb

-Z - 523M- 74. - 75 lb

eo Due to Transverse Shock. 6W

Take summation of moments about line AC and solve for vertical
components of bolt reactions.

ZMAC

-, Ez = Gz a6W x 13 6(435)x13 .327.8-328 lb

(3)34.5 34.5(3)

Take summation of vertical forces, note that Az Bz - Cz

Pz Qz - Rz - -328 lb

Due to both weight and transverse shock

Pz = -328 + 75 - -253 lb Sz - +328 + 75 - 403 lb

Qz -328 + 66 - -262 lb Ez - +328 + 66 - 394 lb

Rz -328 + 76 - -252 lb Uz - +328 + 76 - 404 lb

111-2-12
 SL-

*e Determine the transverse components of the bolt reactions due

to the transverse shock, 6W, these are assumed as being equal.

EFy M 6W
:-.Py -=Qy- Ry - Sy - Ty - Uy 6W 6(435) 435 lb-
435 lb
P~iQ
7 1wS~nT~n~ 6 6

9 Longitudinal Shock. Determine the vertical components of the bolt

reactions due to the veight of the ECU, W, and to the longitudinal shock, 10W.

ee Due to Weight. W (Same as above)

Rz U z - 76 lb

Q z - Tz - 66 lb

Pz - Sz - 75 lb

oo Due to Transverse Shock. 1OW

Take the summation of moments about line QT and determine the

vertical components of the bolt reactions at P,S and R,U.

EMBF - 0 -M= 13x IOW-%30W

/
t RU
2 x20xP z +2 x3 x mM -130 xW PS 20

But - =- Rz - Pz, because frame is rigid

20 3 20

Pz (40 + 6 L) =
130 x 435

.130 x 435 =18 b=S

Pz 40.9 133 lb -

Rz x 1383 - -207 lb - Uz Negative sign used to

20 indicate tension.
eo Take the summation of forces in the vertical direction to

determine the vertical components of the reactions Q and S.

z -- 0 (Due to moment only)

Pz +Qz +z - 0
Tz Qz -(Pz + Rz) -(1383 - 207) -1176 lb

111-2-13
 0o Summary of forces in z-direction due to both weight and
longitudinal shock.
SPz - 75 + 1383 - 1458 Sz - 75 + 1383 - 1458
- Q - 66 - 1176 - -1110 Tz - 66 - 1176 - -1110

Rz -76 - 207 - -131 Uz -76 - 207 - -131

ee Determine the longitudinal components of the bolt reactions due
to the longitudinal shock of loW. These reactions are equal.

.lOW EFx " lOW

10x435_ 72 5 b
Px Qx Rx Sx Tx " FUx
- 6lb
6 6

111-2-14
 0 Suary ECU Mounting Bolt Reactions

so Vertical Shock

*o Transverse Shock S~-

.~ ~~ y
hc LoStdna

$r

5. q

- (Ir

17-1-2-15
 .,I - . .- .'. . . . -.-. °-

111-2-4. Forces and Moments Acting on Members of Frame, (see paragraph

111-2-2 for sketch.

0 Member DR (and E.), Base Beams

-e Vertical Shock. (Forces from previous subparagraph

"Summary - ECU Mounting Bolt Reactions.")
MD: Rz = (523x4. 81) + (465x24. 81) + (535x27. 81)
ZMD: I~-36

Ez - 803.6 - 804 lbi4 O 316&-q

" Fz" z - 523 + 4 535 - 804

Dz - 719 lb Deg

Since shear geos through zero at 79

point B, the bending moment will be
bD
a maximum there, in vertical plane. ( "9 -269 8 N

MB - 719 x 24. 81 - 523 x 20

MB - 7378 in lb $.e'At DIAG*AA4

oe Transverse Shock, Forces from paragraph: "Summary - ECU

Mounting Bolt Reactions", above.

Vertical Forces
MD: Hz l(03 x 4. 81) + (394 x 24. 81) + 404(27.81)
36

Hz - 637 lb

ZFz: Dz - 403 + 394 + 404 - 637 - 564 lb

Since shear goes through zero at

point B, max moment is there. .
= o4
Moment at B in vertical plane MB.V

MBV 564 x 24.81 - 403 x 20

MB-V - 5933 in lb

Horizontal Forces
EMD: Hy = 435(4. 81 + 24. 81 + 27.81) - 694 lb

36 64l

EFy: Dy = 3 x 435 - 694 - 611 lb

111-2-16

* " -" . . . ' ." " " . * '- . " . " - • " o . .I"• • ,.- •... , , . . . " . . "
-.-. . . --- . . . . .

Max Mom Horiz is at point B (MB H );

shear goes through zero.

MB-H = 611 x 24. 81 - 435 x 20

MB- H = 6459 in lb

So, beam must withstand moments in:

Vertical plane, MBV - 5933 in lb

Horizontal plane, MBH - 6459 in lb

so Longitudinal Shock, Forces from paragraph: "Summary - ECU

Mounting Bolt Reactions."
EMD H2 (-1458 x 4. 81 + 1110 x 24. 81 + 131 x 27.81-)
. 36 Ax 3,rj"r//o CgSS/$3

Hz - -671 lb 1"07-1 srz ./ae

ZFz: Dz - 1458 - 1110 - 131 + 671 . -D, ,

Dz- 888 lb

Moments in vertical plane

MA - 888 x 4. 81 = 4271

MB - 888(24. 81) - 1458 x 20 = -7129 lb Max

(top of beam in tension)

so Allowable Stresses

Allow stress - Min Stress + Factor of Safety of 2.5

Material: Alum Alloy Extrusion 6061-T6

Allow
Strength Stress (Sa)
Min psi psi

Ultimate 38,000 15,200

Tens ion
Yield 35,000 14,000

Ultimate 24,000 9,600

Shear
Yield 20,000 8,000

Compression Yield 35,000 14,000

111-2-17
 es Member DR - Select Structural Shape

3. Requirements
=
Bending Moment, Vertical Plane, Mv 7378 in lb (from above)

Bending Moment, Horizontal Plane, MH = 6459 in lb (from above)

Section Modulus

Vertical Plane - Mv Sa - 7378 in lb L 14000 lb-2 - 0.527 in3

in

Horizontal Plane - MH + Sa - 6459 14000 - 0.461 in3

Selection: AA STD Channel 4.0 D x 2.25 W x 2.331 lb/ft.

Sxx - 2.60 in3 (Horizontal) OK, > 0.461

+-
SYY- 0.69 in3 (Vertical) OK, > .527

• Member GF

This member would be subjected to bending moments in the vertical

plane due to the effects of vertical shock, which is represented by the two
719 lb forces, applied at points D and E. These forces are developed earlier
in paragraph 111-2-4. The effect of longitudinal shock would be to apply two
loads of 1088 pounds each in the horizontal direction of points D and E.
These forces can be developed by dividing the sum of the three horizontal
forces, 725 lb each shown in the sketch of paragraph 111-2-4 e, third *o, by
two. While the structure supporting the ECU could be analyzed as a truss in
the horizontal plane, it was felt that it should be designed as though the
structural elements CG acted as a beam in the horizontal plane as it does in
the vertical plane. This would maintain structure strength in the horizontal
plane even though the comparatively light diagonal members CH and FJ might be
damaged.

(-)7/9 7/9

111-2-18
 Maximum Moments

In vertical plane M)
v - 719 x 25 17,975 in lb

In horizontal plane MR - 1088 x 25 - 27,200 in lb

Section Modulus, Req'd (For Factor of Safety of 2.5 based on yield)

In vertical plane Sv - = 75 1.28 in3

sac 14000
In horizontal plane SE - 27200 = 1.94 in3
sac 14000

Selection
.06_X
Alum Assoc Std I-Beam

6D x 4W x 4.03 lb/ft Yq__ Y

- Sv
-yy - 1.55 in3 OK, > 1.28

Sxx - SH - 7.33 in3 OK, > 1.94

. Member H

The two forces acting in the vertical plane (804 lb) and the two
seperately in the horizontal plane (1088 lb) were developed
earlier in this numbered paragraph.

804 JZI:8V4f
.>7 ~~-o42.75',= -3..

4 - llo

.. -ZZ

Maximum Moments

In vertical plane

SM v, -804 x 2.75 2211 in lb

In horizontal plane

M11 - 1088 x 2.75 = 2992 in lb

Section Modulus. Req'd

In vertical plane S Mu_ . 2211 = 0.16

sac 14000

t In horizontal plane S, = VK. = 2992 = 0.214

sac 14000

111-2-19
 Select ion

Alum Assoc Std I-Beam

3D x 2-1/2W x 1.637 lb/ft

Sv .SOyy = 0.42 > 0.16 OK 2Y2

SSH - Sxx - 1.4 9 > 0.214 OK x
9 Member Ah (and BJ)

Force in AR can be either tension or compression. Use compression

*for design purposes.

AE -V-2 x804 -11371lbA

For column in compression see

Reference 2, page 48 for 6061-T6,
buckling formula constants:
B - 39.9, D - 0.263, C - 68
Trial Selection
2 inches OD x 1/4 inches wall round tubing

Metal area Z (22 - 1.52) -

- 1.3744 in2

Radius of gyration, r 0.625

* •1 - 51_- 81.6
r .625

Ultimate strength, since - > 68

r

fc 102000 102000 = 15.32 i 15,320 psi

.(1)2 (81.5)2 in2 1

Fc = 1.3744 in2 x 15,320 lb..= 21,054 lb

, . - in2

Factor of Safety FS
FS - 21.054 1&5 OK since FS > 2.5
*- 1137

111-2-20
 o Member CH

The maximum compressive load in this member can be calculated

using the maximum value of the reaction at mounting bolt "C" as summarized
near the end of paragraph 111-2-2. This is a load of 1505 lb. in the
longitudinal direction,-caused by the shock of 10 g's in that direction.

c 2

C-4 fX =/5 15 5

Take summation of forces in the x-drection at the bolt joint "C" to allow

calculation of the maximum compressive load in members CH.

CH Cos e =Cx

CH . C . 1505 lb - 1505 lb (43.3- - 1832 lb

Cose 36/43.83 36

Trial Selection of Structural Element

2 inches OD x 1/4 inch wall round tubing

Metal cross-sectional area - Am - 1.3744 in2

radius of gyration - r = 0.625 in.

1 43.83 in = 70.128
r 0.625 in

since > 68, determine allowable compressive stress fc using:

r

fc 02.000 = X02,000 = 20.74 = 20,740 psi

-
(1)2 (70. 128)2 in2
r

111-2-21
 Allowable compressive load, Fc

Fc f c x Am 20. 740 lb-2 x 1.3744 in 2

- = 28,506 lb
in

Factor of Safety, FS

FS L_.c . 28.506 lb =
CG 1832 lb 15.56

OK Since FS > 2.5

111-2-22
 e General Arrangement

MEMBER

AB Aluminum Association Standard Angle, 6D x 6W x 1/2 x 6.75 lb/ft

CG Aluminum Association Standard I-Beam, 6D x 4W x 4.03 lb/ft
DEJ Aluminum Association Standard Channel, 4D x 2.25W x 2,331 lb/ft
Hi Aluminum Association Standard I-Beam, 3D x 2-1/2W x 1.637 lb/ft
AE,CH,&J,GJ Round Tube, 2 in OD x 1/4 in Wall x 1.62 lb/ft
*C,G Rectangular bar, 4W x 1/4

NOTE: Material: Aluminum Alloy 6061-T6

111-2-23
 APPENDIX 111-3. WALL MOUNTING DESIGNS

Contents

- Figure 111-3-1: Mounting design for single 18,000 Btuh horizontal ECU
(adaptable for 9,000 Btuh horizontal ECU).

o Figure 111-3-2: Mounting design for two 18,000 Btuh horizontal ECU's
(adaptable for two 9,000 Btuh horizontal ECU's or one 18,000 Btuh horizontal
ECU and one GPFU).

o Figure 111-3-3: Mounting for single 36,000 Btuh horizontal ECU.

111-3-1
 0 Z

- um.I

o to

MA ~ usZq
33 z
I-o

c -8
(De w

UC
* C.. 0

1-

IL-

111-3-
 5 >

WA - I, -I-u,

-a -6 '-
ma
0

'Cu~-a
- - -. di

I-=3

IL

1113-
 UA'

- - -- -

- w

K -z
CL

A -~

L.%w0 dc

A A l 0I
z c A
t.* t e I

~4111 s g 43-4
 APPENDIX 111-4. SAMPLE CLCULATIONS: REMOTE GROUND
FOR 18,000 BTUE VERTICAL ECU

1. Description of Problem
Design a simple aluminum mounting for an 18,000 Btuh ECU which will be
remote from the shelter and rest on the ground. The mounting must be strong
*l enough to support the ECU during rail movement1 and withstand nuclear
overpressure up to 7.3 psi. The mounting should be adaptable to other,
smaller ECU's by adjusting the lengths of structural members.
2. Key Data for ECU

e Weight: 260 pounds

•. * Design load: 10 x 260 2600 pounds
9 Dimensions: See Sketch

C+.
C, 4 S J.,,,&,r'-
51 DE76

7/ /0,.

74O CCUd 20'-.~ 4~PA7r~

3. Concept

- .eSee Sketch

* Dimensions: , ,.oo

AB DE GH 18.5 in.

CD. EF in.
o22.25 '+ I

"CD---BE¥
AD - 2.2
45.625 in.-- I -.
DG E - 26 in.T

lDynamic loadings caused by acceleration due to rail humping are 6g in

transverse and vertical directions and lOg in the longitudial direction.

111-4-1
 AG - BE =45625 . 52.44 in.
SIN 0

AC - BF - 50.76 in.

4. Member A-B

RI x 45.625 - 2600 x 20

SR I - 1140 lb.

e Maximum bending moment

i:.r10-9.25" 20

/8.5 -40
MM" xi=570 x 9.25 - 5273 lb in

.*Try: Aluminum 6061-T6 angle (Fcy - 35,000 psi).

2 Section Modulus S - 0.38 in3
,"
T(NOTE: All section data and
allovable loads used in these
computations are from Reference
- - 1.)

fb - 5273 lb. in. - 13,876 psi

s .38 in3
M.S X-Y" 3.5.000
- 2.52, OK

fb 13,876

5. Members AG and BE

* Compression load
570 570 1178 lb

fcomp = Cose .494

111-4-2
. -I6-

v.-... ... . .- . --. -. . -. . -".:--- . :- .". , - ./ ;. - ,--- --- - -,- -

 e Try: Aluminum 6063-T52, 1-1/2-in. square tubing

Area - 0.663 in2 , r =

0.565, Fcy 21,000 psi

Length - 52.44 in

L/r L 52.44 -9.

0.565

e Member is critical in buckling

Allowable fcom- 21,000 - 24.5 x L (C 1.5)
C r

- 21,000 - x 92.8 = 2440 psi

1.5

Actual compressive stress

Fcomp - 1178 - 1777 psi

.663

M.S. _ 2440 _ 1.37 OK

1777

6. Members AC and BF

R 1 R2 2600 x 20 .825 lb.B

63
II
B
50.75 x 825 - 918 lb.
= 45.625

Members AC and BF are same aluminum C . "

sections as AG and B but design loads
are lover by the ratio of 918. Therefore, P O3"
AC and BF are OK. 1178

7. Members DG and EH

* Assume worst case: total moment load carried by DG and ER; ECU not
connected to AB.

M = 2600 x 20 - 52,000 lb-in

R2 2000 lb M 2 b0.

26 a

111-4-3
i
e Maximum bending moment per member:

Load will be divided equally between DG and EH.

=R x A - 2000 x 26 - 13,000 lb-ft

2 2 2x2

= 35000 psi
Try: Aluminum 6061-T6 Channel, S 0.452, Fcy -

.b 13000 28,760 psi

S .452

M.S. 35,000 = 1.22,

L -
28,760

111-4-4
 .
Ir-

r APPENDIX 111-5. REMOTE GROUND MOUNTING DESIGN

U4

p6

.. ROVISION FOR FORKLIFT

NOMINAL LENGTHS
6000 BTUl 9000 STUH 18000 STU.
VERTICAL VERTICAL VERTICAL
FIND 4O. QTY DESCRIPTION ECU ECU ECU

3 1 2 Wide Flange Bas

Army-Navy Series
74-It2" 74-LIZ" 74-1I2"

4" x 3" - 1.788 Lbs/Ft

- 2 2 Channel, Form From 1/8" Thick Sheet 27-3/8" 27-3/8" 27-3/8"

3 2 Channel - Army-Nav7 30" 30" 30"

4" x 2" - 2.205 Lbs/Ft

2 Tubing, Square, 1-1/2" x 1/8" Thick 40-3/4" 43-5/8" 55"

5 2 Tubing, Square, 1-1/2" x 1/8" Thick 30-1/2" 34-1/4" 47-7/8"

6 2 Tubing, Square, 1-1/2" x 1/8" Thick 37-15/16" 41" 53"

7 4 Angle, 3" x Z" x 1/4" 30" 30" 30"

8 1 Angle, 3-1/2" x 2-1/2" x 1/4" 21" 21" 21"

Material: Find Numbers I , 3 7 8 Aluminum 6061-T6.

Find Numbers 9 , 5 , 6 Aluminum 6063-T52.

Figure 111-5-1. GROUND MOUNT FOR VERTICAL ECU

e I1i-5-I
 V.- Ole .

FF
UZ

19w

-- - - -- - -
~ IIs

N,-

Li 00

~111-5-
 APPENDIX VI-1. EMP SHIELDING CONSULTANTS AND MANUFACTURERS

VI-l-1. Introduction

e This appendix contains two lists, both consisting of firms selected

at random and generally representative of the types of services and products
available. These are not comprehensive lists of firms doing business in this
pfield.
e The first list, in paragraph VI-l-2, contains firms offering
consulting services. The second list, in paragraph VI-1-3, contains firms
which manufacture products which may be useful in protecting against EMP.

VI-l-2. Design and Engineering Services

* Atlantic Research Corporation

5390 Cherokee Avenue
Alexandria, Virginia 22312
(703) 642-4000

* Elite Electronic Engineering Company

1516 Centre Circle
Downers Grove, Illinois 60515
(312) 495-9770

. IRT Corporation
P.O. Box 80817
San Diego, California 92138
(714) 565-7171

9 Mission Research Corporation

1720 Randolph Road
Albuqueque, New Mexico 87106
(505) 843-7200

e R&B Enterprises
P.O. Box 510
Plymouth Meeting, Pennsylvania 19462
(215) 828-6236

* TRW Defense and Space Systems Group

One Space Park
Redondo Beach, California 90278
(213) 535-0126

VI-1-3. Shielding and Protection Materials Manufacturers

e All-tronics, Inc. Power Line Filters

45 Bond Street
Westbury, New York 11590
(516) 333-3090

VI-1-1
 *
. Breeze-Illinois, Incorporated Cable Shielding
Main Street at Agard Street
Wyoming, Illinois 61491
(309) 695-2511

* Chomerics, Inc.
77 Dragon Court
Woburn, Massachusetts 01801
(617) 935-4850

" Enclosure Corporation Shielded Cabinets

4529 Adams Circle
Cornwells Heights, Pennsylvania 19020
(215) 638-9550

" Flexible Metal Hose Mfg Co Cable Shielding

777 W. 16 Street
Costa Mesa, California 92627
(714) 631-3030

* General Semiconductor Industries, Inc. EMP Suppressors

P.O. Box 3078
Tempe, Arizona 85281
(602) 968-3101

* Hopkins Engineering Co. EM Filters

12900 Foothill Boulevard
San Fernando, California 91342
(213) 361-8691

e Instrument Specialties Company "Finger" Contact Strips

P.O. Box A
Delaware Water Gap, Pennsylvania 18327
(717) 424-8510

• ITT Cannon Flectric Electronic Filters

2801 Air Lane
Phoenix, Arizona 85034
(602) 275-4792

* METUX Electronic Shielding Group Gasketing and Shielding;

970 New Durham Road Engineering and Design
Edison, New Jersey 08817 Service
(201) 287-0800

e Spectrum Control, Inc. Gasketing, Shielding,

8061 Avonia Road Electronic Filters, Air
Fairview, Pennsylvania 16415 Vent Shields
(814) 474-1571
.Sprague Electric Company Electronic Filters;
87 Marshal Street Consulting Services
* "North (413) Adams,
664-4411Massachusettes 01247

VI-1-2
 e Tecknit, Eastern Division Gaskets, Gasket Material,
129 Dermody Street Conduction Paints and
Cranford, New Jersey 07016 Adhesives, Shielded
(201) 272-5500 Windows, Air Vent
Shields, Conductive
Caulking
* Versitron, Inc. Isolators and Enclosures
*6310 Chillum Place, N.W.
Washington, D.C. 20011
(408) 244-7370

-.- .

vi-1-3
4.4.

IlkI

It
I -.

61-

jF .,

or;

Ake
 F3
,0A2 '
RAr NNFI
ANFRTO Itm o FO [VRflNMFNlAi

I I11 A I f /I Nl
 1.0 L511.
JjW5
112.

1 12 1111411111.

MICROCOPY RESOLUTION TEST CHART

BUREAU OF STNOARDS 1963-A
NATIONAL
.SUPPLEMENTARY

INFORMATI ON
 DEPARTMENT OF THE ARMY
US ARMY SELVOIR RESEARCH ft
DEVELOPMENT CENTER
FORT BELVOIR, VIRGINIA 2206

~Y STRBE-E4E
18 JAN
S SUBJECT: AD Number A128632, Title:
Integration Enqineering
for Environmental Control Handbook

~k DTIC
Cameron Station
(Z~ Alexandria, VA 22314

1. Request that enclosed

attached to and made a (two page) Errata
part of the subject Sheets
all future distribution. document (Endl 1) be
and included wt
wt
2. Point of contact for
additional information
Good, AV 354-6031 or Comm is Mr. Franklyn P.
(703) 664-6031.
FOR THE COMMANDER

1Encl
as HARD E
hie ,Engineer
Sevice SuprE abrtr

S'a v g
 AD Number A128632
Integration Engineering Handbook for Environmental Control

Errata Sheets (Page 1 of 2)

Page 1-3. Footnote 1, line 3. Change "...six single basic units..."

to "...five single basic units...". Change "...two to each
side." to "...one or two to each side."
Page 1-4 Figure 1-2, Vertical and Sleeve Mounted Configuration
(Navy) power consumption 50/60 Hz. Change 10.6 and 16.0 to
2.9 (5) and 5.0 (6), respectively. Add footnotes (5) 2.9 is
cooling pow -. Heating power varies from 2.6 to 10.6. (6)
5.0 is cooling power. Heating power varies from 4.0 to 16.
Page 111-5 Last paragraph, first sentence. Change "...is no gain..."
to "...may be a gain..." Last paragraph, second sentence.
Change to "The area vacated by the ECU when it is extended
may be used for fold out tables or benches to perform
administrative and/or technical work.
Page 111-6 Paragraph 4. Delete sentence "The Base Civil Engineer
should..."
Page 111-8 Paragraph 6. Second sentence. Change "Addequate" to
"Adequate".
Page 111-9 Third double dot paragraph. Add "Mounting method "B"
shown in Figure 111-4 is better suited for CB and EMI
protection". I
Page 111-18 Figure III-9a, column "EXTERIOR FIXED WALL MOUNTINGS", row
"What ECU sizes can be mounted?" change "GPFU" to "GPFU(l)"
Add footnote "(l)See Figure 1-1-2, page 1-1-3".
Page V-I Section V-2, first paragraph. Replace second, third, and
fourth sentences by "However, for our purposes here,
discussion of the threat will be restricted to the effects
of CB agents on ECRs and other equipment".
Page V-4 Last paragraph. Replace middle sentence with "This com-
partment permits entry of essentially clean personnel into
a shelter. The compartment's air wash provides only a
limited decontamination capability".
Page VI-1 Section VI-2, first paragraph. Replace "...60dB over the
range... to 1 MHz". with "...at least 60 dB over the fre-
quency range from approximately .15 MHz to 450 MHz".

4
 AD Number A128632
Integration Engineering Handbook for Environmental Control
Errata Sheets (Page 2 of 2)

Page VI-2 Section VI-4, second paragraph. Replace "DOD" with

"appropriate military" Add in footnote 1,

Department of the Air Force Department of the Navy

San Antonio Air Logistics Center HQ US Marine Corps
SA-ALC/PMDM ATTN: LME
Kelly AFB TX 78241 Washington DC 20380
AV 945 7762 AV 227 3664
Page VI-3 Section VI-5, first paragraph, last sentence. Change
"...a matter of gasketing". to "...a matter of gasketing
and welding".
Page VI-5 Paragraph 7. Change "Reference 14 offers..." to
"References 14 and 36 offer..."
Page VII-I Section VI-1. Change "VI-l" to "VII-l". Second
paragraph, last sentence. Delete "two or three seconds".
Page VII-5 First paragraph. Delete "(bunkers could replace the
shelter)".
Page I-1-1 Add "Accustat - A fixed setting, non-adjustable
thermostat".
Page 1-1-4 Paragraph 4. Delete.
Page 1-1-5 Figure 1-1-3, first note. Change to "Units to be used
with ducting may be supplied without attached supply and
return grilles". Second note. Change "thermostat" to
"thermostat or accustat".
Page 1-2-3 Add 36. Cain, Bruce L., EMI/RFI Gasketing for Tacticl
Shelter Door Seam Applications. US Army Construction
Engineering Research Laboratory. To be published.
ml
: 7 kATE
I

,,ILMED