Portable Generatorsfor Military Applications

Telephone: +44 (0)1629 824 284 Fax: +44 (0)1629 824 613 Email: info@HGIgenerators.com

www.HGIgenerators.com

HGI deliver tailored integrated powersolutions to full defence standards orstand alone derivatives.

Contents:HGI-DEF-01 ASTOR

HGI-DEF-02 CORMORANT

HGI-DEF-03 MILITARY PLATFORM/DC

HGI-DEF-04 LFG

HGI-DEF-05 PPRF

HGI-DEF-06 PTARMIGAN

HGI-DEF-07 RAPIER

HGI-DEF-08 REACHER

HGI-DEF-09 SAAB

Specialist generators for the most demanding conditions

IntroductionAt the heart of any defence system is power. Without it command andcontrol computers would not function, radars not operate, satellitecommunications remain silent and systems using re-chargeable batteriesdegrade to become just extra weight.

Modern technology demands power. Though low down in the ‘food chain’ it is one of the key essentials on today’s battlefield.

Harrington Generators International (HGI), are a leading provider of military-specification generators using either conventional fuels or green alternatives.

HGI has over 30 years experience of designing, developing and producinghigh quality generator sets which deliver what you what, where you want itno matter how challenging.

This experience means that HGI can provide you with the right unit toachieve maximum efficiency and cost effectiveness for the task at hand.The solution could be a one-off or a bespoke fleet. By combining ourunparalleled design, project management and world class manufacturingskills HGI can meet or exceed target deadlines and provide long termreliability for every project.

Military SolutionsHGI is a leading military generator supplier to the UK’s Ministry of Defenceand the largest UK generator manufacturer in the military field.

We are committed to providing professional and economic solutions tailored to your power requirements whatever they may be or wherever theymay be needed.

Where you need strict EMC performance and Defence Standard construction,HGI has the experience and capability to meet your requirements.

Through-Life SupportHGI is dedicated to providing you with through-life support to ensure that your generators keep running to maximum efficiency and effectivenesswherever you maybe in the world. This includes providing engineers underCONDO conditions, a full range of PDS services and full refurbishments at our Wirksworth factory in the Derbyshire Dales.

Our product range includes:

• Small rugged, man-portable generatorswith very low ripple DC output.

• The advanced 2kW Lightweight FieldGenerator (LFG) in service with the UK’s Armed Forces, now the standardgenerator in its class.

• Trailer mounted generators with poweroutputs from 5kW to in excess of 25kW and used on equipment such asthe Rapier air defence system or the ASTOR airborne stand off radar groundcontrol station.

• On board sets requiring specialist design skills and often fitted into tightspace envelopes such as on the SaabArthur weapons locating system and the Reacher satellite communications ground terminal.

• The SKD range of super silent canopieddiesel generators producing from 2.6kVA up to 120kVA based on COTSequipment, to shorten delivery times and reduce costs.

ASTORAirborne Stand-off RadarAirborne Stand-Off Radar (ASTOR) is a ground surveillance system designed to provide information about the deployment and movement of enemy forces.

It uses state-of-the-art radar technology to obtain high resolution imagery of staticfeatures and, operating in an alternatemode, it is capable of identifying andtracking moving vehicles. Imagery gatheredis transmitted in near-real-time to a networkof distributed ground stations deployedwith the front-line forces. Facilities withinthe ground stations will permit the displayand analysis of imagery, thus ensuring thatthe tactical commanders are aware of thelatest developments on the ground.

HGI provide the generators that power theground station network. Each generatorconsists of a John Deere 3029D engine,running at 1500rpm, close coupled to aNewage, AVR controlled alternator.

The sets are mounted in an extremelyrugged, acoustic canopy which is in turnmounted on a specially adapted version ofan in-service trailer.

The units are 3-phase, 415V and provide28.7kVA of power at 25°C, 30% RH at sea level.

The generator is capable of running on both F54 Dieso and F34 AVTUR and has an onboard fuel tank with enough capacityto give 12hrs running at full load.

The generator sets conform to Class C ofDef Stan 59-41 for EMC, Category level 3of Def Stan 08-6 Part 2 for noise as wellas other standards for NEMP, LEMP andenvironmental conditions (sand, dust,snow, ice, rain, wind, etc).

The canopies are coated in an infra-redreflective powder-coating and the set isable to run in blackout conditions.

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Cormorant

The CORMORANT power solution consists of either a pair of 20.0kVA(16.0kW) generators or three 4.0kVA (3.2kW) generators designed toprovide power for the army's new digital communications systems.

The CORMORANT generator utilisescommercial off-the-shelf (COTS) technology adapted for the military todeliver a high tech solution to theirequipment requirements.

Providing power for two primary components:

• A local access component, based on an ATM switch, which will providedigital voice subscriber facilities and a high speed data LAN for over 20 Headquarters.

• A wide area component will allow the interconnections network across alarge geographical area as well as themeans to interconnect with single service and multinational systems.Interconnection of components will bepossible using microwave radio relay,satellite communications, commercialcable bearers and a new Tropo-Scatter 'over the horizon' capability.

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Cormorant

The 20kVA sets consist of Isuzu 4LE1water-cooled engines close coupled toNewage BCI182J alternators and are dualmounted on a specially designed trailer.The 20kVA generators provide power for thewide area component. These sets are fittedin a lightweight (steel/aluminium) canopythat is strong enough to cope with thedemands of military use. The units can beremotely controlled via the inbuilt enginemanagement module and come completewith military spec control gear, meters and gauges.

The 4kVA sets consist of Yanmar L100 aircooled engines, fitted into strong, tubularsteel frames. They also have fittings forconnection to standard Jerry cans toextend the running time of the generators.

As with the 20kVA sets, the 4kVAgenerators can be remotely controlled viathe inbuilt engine management module.

The 4kVA generators are mounted in sets of three on a Bucher Duro vehicle and provide power for the local access component.

Both sets have the ability to start and runat temperatures as low as -32°C and ashigh as +49°C.

The RAF 90 signal unit (formerly known as Tactical CommunicationsWing) Ruggedised Tactical Telephone System was withdrawn fromservice in 2008. The CORMORANT was chosen to replace it with EADSDS assisting the Theatre and Formation Communications Systemsintegrated project team in the transition.

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Military Platform Generator

Rating : 6.5kW continuous at 1000mabove sea level at +55°C

Engine : Air cooled Hatz 2G40

Overload Capability : 10% overloadavailable for one hour in every 10 hours of continuous operation

Output Voltage : 28Vdc

Electrical Performance : Def Stan 61-5Part 2, Section 1

Starting : 24Vdc via internal batteries orNATO compatible inter-vehicle connector

Cold Starting : At temperatures down to -32°C

Dimensions : (LxWxH) 920mm x 570mm x 845mm

Weight : 235Kg approx

Fuel Supply : Integral 24 hour diesel tank and Jerry can connectors and pumpfor refuelling from jerry cans or platformmounted fuel tank

DC GeneratorsA small rugged man-portable generatorwith very low ripple DC output. Suitablefor battery charging and communicationequipment application.

• Portable, diesel engined 12 Volt / 24 Volt 60 Amp DC

• Yanmar L48 engine, Hatz 1B20

• Manual start

• Single cylinder

• Air cooled diesel

• Inter vehicle connector - electric start or battery electric start

• Integral fuel tank or NATO Jerry can fuel system

• Temperate Zone -40°C to +50°C Available

• Stud terminal, dinse sockets or built to customer specification

• Supplied worldwide

Applications :

• Field catering

• LAN telecom

6.5kW DC Platform Generator

LFGLightweight Field Generator

Over 4000 units in service in harsh militaryenvironments. The main power source inIraq and Afghanistan.

This advanced, lightweight 2kW generatorhas been selected by the Ministry ofDefence as the standard British Army 2kWgenerator for service throughout the worldover the next 15 years.

Designed and built to a very demandingspecification, the LFG has manyadvantages over conventional machines.

Testing & Trials

As is standard with equipment enteringMOD service, the LFG was subjected to the most exhaustive tests, ensuring thatthe set would excel in any conceivableenvironment. Tests included :

• Severe vibration and bump programmes

• Extreme temperature tests at maximum output

• Exhaustive reliability qualification testing over 48 battlefield missioncycles, equating to 8800 hours runtime

• EMC testing to Defstan 59-41 Class C,and no radio interference at 15 metres

• Electrical performance to Defstan 61-5 (Part 2)

PMG : Permanent Magnet Generator

• The LFG utilises a PMG type alternatorand inverter, allowing significantlyreduced weight, and vastly increased fuelefficiency over a standard alternator

• Multi-output 28V DC/110V AC/230V AC– Supplies any combination of either AC voltage and 28V DC at the same timeup to 2.2kW on 10% overload

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HGI's 2kW Lightweight Field Generator, currently in use and in production for the British MOD.

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LFGLightweight Field Generator

Vari-Speed operation: Hatz 1B20 enginewith acoustic enclosure

• Single cylinder air-cooled engine-hand or24V electric start from power through theintervehicle connector

• Vari-speed : 2650 and 3200rpm settings

• Run at a lower rpm when full output isn’t required, for increased efficiencyand noise reduction

MDPE engine enclosure

• Medium density polyethylene acousticenclosure, with rigid-foam liner for sound insulation, significantly reducesengine noise for operation in sensitiveenvironments, and situations where low noise is preferable

• Runs on diesel or AVTUR fuel

• Fuelled from adjacent standard 25 litreJerry can allowing 25 hours running timeat full load

• Easily fitted and removed 2 metre exhaust extension

Additional Information :

• -40°C to +49°C operation

• 76Kg Total Weight

• L x 600mm W x 500mm H x 550mm

HGI's 2kW Lightweight Field Generator, currently in use and in production for the British MOD.

LFGLightweight Field Generator

Performance

• Electrical performance parametersexceed requirements of Def Stan 61-5(part 2)

• Excellent voltage regulation

• Perfect sine wave output

• Rapid response to load changes

Summary

• Whole life costs significantly reduced by dual speed inverter technology

• Low cost of ownership

• Multi output capabilities of LFG allow forrationalising of an existing generator fleet

• Significantly reduced weight

• Vastly increased fuel efficiency

• Reduced engine noise

• Highly robust

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HGI's 2kW Lightweight Field Generator, currently in use and in production for the British MOD.

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PPRFPower Pack Repair Facility

In service with the British MOD since1998, this HGI designed and built setprovides crucial power support forChallenger Mk2 Main Battle Tank mobilerepair. Five sets work together to powerinflatable workshops where the tank enginecan be stripped down and repaired, even in the middle of a battle zone. This set isperfectly featured to operate in even themost arduous conditions for any length of time.

HGI provide the generators that supply the power for the repair facility.

Each generator consists of a John Deere3029D engine, running at 1500rpm, close coupled to a Newage, AVR controlled alternator.

The sets are mounted in an extremelyrugged, acoustic canopy finished in aninfra-red reflective powder-coat.

The units are 3-phase, 415V and provide27.0kVA of power. The generator is capableof running on both F54 Dieso and F34AVTUR and has an onboard fuel tank withenough capacity to give 12hrs running atfull load.

To ensure sustainability of an operation, the timely replacement ofarmoured fighting vehicle power packs at the place on the battlefieldwhere they failed is now commonplace.

Ptarmigan

The 4kW ORP EDGS designed to operate in a military environment as part of amobile communications facility. It isdesigned to meet the most stringent EMCrequirements and to produce full outputpower at altitudes up to 3000 metresabove sea level.

HGI were awarded the contract to design,develop, and install the ORP EDGSincluding military qualification testing andthe provision of a complete ILS package.

HGI successfully completed the contractincluding development, ILS package andinstallation of the generators into thearmy's fleet of Ptarmigan radio relayvehicles in just over 12 months from initial contract award.

Rating : 5kVA, 4kW, 0.8pf

Speed : 3000rpm

Operating Temperature : -32°C to +49°C

Altitude : 3000 metres above sea level

Fuel : Diesel or AVTUR F34Self Priming Jerry can fuelling system

EMC performance is tested to Def Stan 411, Land Class A

Engine : Hatz 1B40

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4kW generator (ORP EDGS) for the Ptarmigan radio relay vehicle.

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RAPIER

The DG 18-30 is a highly developed and test-proven 18kVA 3000 rpm liquidcooled Diesel, super silenced mobilegenerator set.

Designed for ease of operation, andmaintenance, the machine has proveditself both durable and reliable with nowmany hundreds of operating hours recordedon operational service in high ambienttemperatures and desert deployments with no recorded problems to date.

Originally developed in collaboration with a major UK supplier of defence equipmentand first-hand input from the customer (a middle east air force). The unit wasspecifically designed to power legacyRapier SAM systems, but can easily beadapted to provide more conventionalpower requirements.

The trailer is a bespoke design intended for use with Land Rover/Land Cruiser typevehicles in desert conditions and isequipped with a 76mm NATO hitch andlighting equipment including convoy light.

The fully loaded trailer has been testedboth on and off-road and proved to bestable at speeds of up to 60mph (100kph)in all conditions.

The unit shown carries many role specific features 200V, 400Hz Rapier electronic controls, optional cablereel carriers and stowage trunk.

REACHERSatellite Ground Terminal

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Reacher is designated as the replacement for the VSC 501,Land Rover-based, mobile satellite ground terminal and will beprovided in 3 types.

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Reacher Medium

A fully ruggedised next generation landterminal specifically designed for XBandmilitary satellite communications.Designed to operate with a forwardoperating headquarters unit, it is mountedon a MOWAG Duro 6 x 6 vehicle and has adetachable intermediate group cabin andassociated trailer with a 2.4m Antenna.

Reacher Large

Mounted on the same vehicle as theReacher Medium with a 4.5m Antenna.

Reacher All Terrain

This Reacher terminal is mounted on BV206 vehicles and associated trailers.

All Reacher terminals are transportableusing Chinook helicopters, C130 aircraft,sea and rail.

HGI provide the unit to supply power for all three types of terminal.

A derivative of the CORMORANT generatorset, the REACHER unit comprises of theYanmar 4TNV84T turbo engine closecoupled to Newage BCI182K alternator.

The set is capable of providing 25kVA(20kW) of 1-phase, 230V power constantlyup to altitudes of 3000m a.s.l, andsimultaneous temperatures of +28°C.

In addition to this the REACHER generatorwill operate in temperatures as low as -46°C and as high as +49°C.

The REACHER generator utilises Webasto air heaters and Kim Hotstart oil sump heaters to achieve these starting parameters.

As with all of HGI's generators supplied tothe MoD, the REACHER set is subject to arigorous testing programme before beingput into service. Environmental, mobility,electrical and acoustic testing programmesare used to ensure that a safe, reliableproduct is achieved.

HGI's ISO9001:2008 QA system is alsoemployed to ensure consistency throughoutthe life of the project.

The REACHER generators have been inservice since 2006.

SAAB

Over the last 12 months HGI have been working with Saab MicrowaveSystems (SMW) to develop very compact military APU systems to beinstalled in the technical compartments of mobile radar shelters.

The latest version of ARTHUR from SaabAB provides accurate location of artilleryweapons within a 60km long and up to120° wide search arc, enabling timely andaccurate counter-battery fire even in a highintensity, mass fire environment.

ARTHUR is a vital instrument in the currentstatic or asymmetric operations. It providesprotection against incoming rounds bycalculating the impact point well in advanceand sending out a warning to the units inthe impact area.

The emplacement time of ARTHUR is only 2 minutes, providing a unique capability tosupport a high tempo operation.

Power for both ARTHUR and the AMBvariant systems is provided by HGI using a totally-enclosed generator system having a power density unparalleled indiesel equipment and fully supporting the SAAB rapid deployment and availability philosophy.

These super-compact 30kW units are fullyintegrated into the complex vehicleinstallation by virtue of bespoke ancillariesaround a common core plant and providefull output power under a wide range ofenvironmental extremes from -40°C to+55°C and at altitudes up to 3000m abovesea level.

SAAB

Over the last 12 months HGI have been working with Saab MicrowaveSystems (SMW) to develop very compact military APU systems to beinstalled in the technical compartments of mobile radar shelters.

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Both model options are fully tested and validated against the highest military standards.

HGI were commissioned to develop twobasic variants for the AMB Giraffe and the Arthur systems.

The power plants have undergoneextensive military compliance testingincluding the most demanding Mil-Std EMC testing and environmental trials. Both variants produce approx 30kW, 3-phase, 400V in environments from -40°C to +55°C and at altitudes up to3000m above sea level.

HGI and SMW worked closely toaccommodate the power plants into thevery restricted space envelope while stillensuring that full access is available for all maintenance procedures.

The power plant for the Arthur system is fitted with slides so that the mainassembly can be slid-out of the vehicle for maintenance.

The power plant design has been optimisedby FEA techniques to minimise weightwhilst ensuring compliance with the shock,vibration and acoustic specifications.

Notes :