4) AL-1823-1141 - SOW D.pdf

SR BPC Procurement_SOW

Release Date: Nov 17 2025 4:30:59 PM PST

Document Number: AL-1823-1141 Revision: D

Document Status: Released

Document Type: STANDARD

Category Code: LS229502

ALS-U STORAGE RING

Power Supply Systems Bipolar Power Supply

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

Table of Contents

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

1.1 Project Overview

1.2 Description of Items

1.3 Roles and Responsibilities

2 Scope of Work

3 Deliverables and Schedule

3.1 Deliverables

3.2 First article

3.3 Production

3.4 Add sub-number as needed (N/A)

3.5 Verification summary

4 Management

4.1 Reporting/Communication requirements

4.2 Documentation requirements

4.3 Reviews

4.4 Hold points and what’s required

5 Fabrication / Assembly (as applicable)

5.1 Packaging

5.2 Serialization

6 Quality Assurance

6.1 Quality reporting requirements

6.1.1 Subcontractor Quality program

6.1.2 Deviation requests

6.1.3 Nonconformance reports

6.2 Work Instructions (N/A)

6.3 Required Factory Inspections and Tests

6.4 ACL upon receipt

7 Applicable Documents

8 References ci al ly R el ea se d

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REVISION HISTORY

Rev. CM Number Description of Change A Initial Release B Per TPRR recommendations - Added and updated information in Sections 4.1, 4.3, 4.4, 6.1.3 and 6.4.

Renamed Section 6.3

C Per TPRR recommendations - Updated information in Sections 3.0

D Per PRR recommendations – Removed lead times in “Deliverables and Schedule” table, and replaced with a sentence referring to subcontract documentation.

APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Approver Name Project Role (ex. Project Manager) Alessandro Ratti Accelerator Electrical Eng. Systems Lead Alessandro Morato ALS-U PS CAM/Tech Lead Danny Padrazo BNL Technical Representative William Waldron Accel. Electr. Eng. Systems Tech Deputy Jiani Niu ALS-U QA Manager Kelly Hanzel ALS-U Procurement Manager Windchill Approved / Concurred By khanzel,al_padrazo,wlwaldron,aratti,jianiniu,amorato

ABBREVIATIONS AND ACRONYMS

Short list of acronyms that are applicable to the SOW only (Thinking for example UHV, or component specific items)

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade BNL Brookhaven National Laboratory LBNL Lawrence Berkeley National Laboratory University

ACL

The Regents of the University of California Acceptance Criteria List ci al ly R el ea se d

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1 INTRODUCTION

1.1 Project Overview

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS is a 1.9

GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system that is capable of providing the foundations for an upgrade that will achieve world-leading soft x-ray coherent flux. The existing ALS provides a ready-made foundation, including conventional facilities and also includes extensive beamlines (up to

40 simultaneously operating beamlines) and instrumentation, an experimental hall, computing resources, ancillary laboratories, offices, and related infrastructure that will be heavily utilized in an upgrade scenario.

The ALS will be upgraded with a multibend achromat (MBA) lattice design that will provide a soft x-ray source that is orders of magnitudes brighter — an up to 100-1000 times increase in brightness and will provide a significantly higher fraction of coherent light in the soft x-ray region than is currently available at ALS.

1.2 Description of Items

The purpose of this statement of work is to define the production work required to provide completed assemblies for five (5) custom models of the Bipolar Power Converter, critical to the ALS-U Power Supply system. In accordance with the referenced documents as defined in this document, the subcontractor must manufacture, assemble and deliver the

Bipolar Power Converters as set forth in this document, including:

• Model #1: BPC-2CH-S-18V-24A

First Article QTY 1

First Production QTY 27

• Model #2: BPC-4CH-S-18V-10A

First Article QTY 1

First Production QTY 153

• Model #3: BPC-2CH-S-16V-35A

First Article QTY 1

First Production QTY 48 ci al ly R el ea se d

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• Model #4: BPC-1CH-F-16V-70A

First Production QTY 103

• Model #5: BPC-1CH-S-16V-200A

First Production QTY 27

1.3 Roles and Responsibilities

The subcontract will name two University specialists to oversee the contractual and technical aspects of the procurement:

• The University Procurement Specialist is responsible for contract administration from solicitation to subcontract award, and any contractual issues that arise thereafter.

• The University Technical Representative is responsible for the technical aspects, beginning with the subcontract award through receipt and acceptance of deliverables.

The selected subcontractor must identify a project manager who will act as the single point of contact for the University representatives. The project manager must be available for the duration of the subcontract to resolve issues and provide technical, programmatic, and schedule updates as specified in this SOW and in the subcontract.

2 SCOPE OF WORK

Provide completed chassis assemblies for each of 5 custom models of the Bipolar Power

Converters, including all components as specified in each sub-assembly drawing, respectively. Design documentation package was prepared by Brookhaven National

Laboratory on behalf of Lawrence Berkeley National Laboratory (LBNL) for the U.S.

Department of Energy (DOE) Advance Light Source Upgrade (ALS-U) Project.

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3 DELIVERABLES AND SCHEDULE

Item No. Name Qty Delivery Schedule

01 BPC-2CH-S-18V-24A First Article 1

Delivery date requirements are specified in subcontract documentation.

BPC-2CH-S-18V-24A 27

02 BPC-4CH-S-18V-10A First Article 1

BPC-4CH-S-18V-10A 153

03 BPC-2CH-S-16V-35A First Article 1

BPC-2CH-S-16V-35A 48

04 BPC-1CH-F-16V-70A First Article 1

BPC-1CH-F-16V-70A 103

05 BPC-1CH-S-16V-200A First Article 1

BPC-1CH-S-16V-200A 27

3.1 Deliverables

Description of product deliverables:

BPC-1CH-F-16V-70A: 1 Channel Fast 16V-70A (Bi-Polar Power Converter), P/N LT-EL-SR-PS-CRR-6102-10

BPC-1CH-S-16V-200A: 1 Channel Slow 16V-200A (Bi-Polar Power Converter), P/N LT-EL-SR-PS-CRR-6103-10

BPC-2CH-S-18V-24A: 2 Channel Slow 18V-24A (Bi-Polar Power Converter), P/N LT-EL-SR-PS-CRR-6201-10

BPC-2CH-S-16V-35A: 2 Channel Slow 16V-35A (Bi-Polar Power Converter), P/N LT-EL-SR-PS-CRR-6203-10

BPC-4CH-S-18V-10A: 4 Channel Slow 18V-10A (Bi-Polar Power Converter), P/N LT-EL-SR-PS-CRR-6201-10 ci al ly R el ea se d

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3.2 First article

In accordance with the schedule in the subcontract, the subcontractor must provide one

(1) first article assembly for each of the five types of assemblies.

The First Article units must be a 100% representation (Form, Fit, and Function) of the anticipated production unit. First article units must not be considered prototypes and will be installed in the ALS-U.

Compliance to the specification, to which each assembly is built, must be verified using the Acceptance Test Procedure (ATP) generated as a document by BNL.

3.3 Production

The subcontractor must not commence fabrication of any production units until receiving notification of first article acceptance for each of the 5 model assemblies, and authorization in writing by an authorized representative of the University.

3.4 Add sub-number as needed (N/A)

3.5 Verification summary

At the time of delivery, the subcontractor must provide a dated, and numbered receipt indicating the unit model and Serial numbers.

4 MANAGEMENT

Within two (2) weeks after award of subcontract, the subcontractor must deliver a detailed program plan for each phase which includes a milestone schedule defining manufacturing, assembly, QA inspection in sufficient detail to allow regularly scheduled progress monitoring.

4.1 Reporting/Communication requirements

Upon award of the subcontract, the University Technical Representative will contact the selected subcontractor to set up a Project Kick-off meeting. This meeting will establish ci al ly R el ea se d

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Visits by LBNL personnel or selected designee, including access to the factory where the manufacturing and assembly work is performed may be required. Visits are at the discretion of LBNL with reasonable notice to the subcontractor.

Action item tracking is recommended and may be required based upon LBNL’s discretion.

Throughout the life of the contract, the subcontractor must supply a written report by the fifth of every month to the project technical lead, and LBNL Technical Representative and clearly detailing the progress through the prior month with respect to the program.

This mustinclude detailed progress with photos, planned work for the upcoming month, open actions, problems, recommended solutions, and risk mitigation.

Within two (2) weeks after award of contract, bi-weekly program technical and progress teleconferences and/or meetings between the subcontractor and an authorized representative of the University must be held at a mutually scheduled time. The discussions must include the subcontractor’s progress, technical and contractual questions, presentations of analysis or inspection results, material status, tooling status, resources, and manufacturing issues. The frequency of these meetings may be adjusted at the discretion of the University, based on project needs or by mutual agreement.

4.2 Documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and/or

BNL. Windchill will be used as the repository for all documentation, QA data, certificates of conformance, test results, models, and drawings.

An electronic copy of all required documentation as noted in this document is required and must be transmitted to LBNL via the designated Windchill portal.

Acceptable document formats include .docx, .xlsx, and other editable Office file formats or as noted in this document.

All engineering drawings provided by BNL must include:

▪ PDF and native file format where applicable

▪ Document Control List

▪ Parts list

▪ Assembly Drawing

▪ Pick and Place

▪ Gerber Data for PCB Fabrication ci al ly R el ea se d

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▪ Part number syntax in accordance with format as LT-EL-SR-PS-xxx

4.3 Reviews

Designs and specifications have previously been reviewed by an authorized representative of the University. This is a build to print procurement, the subcontractor has manufactured the same assemblies in the recent past.

A Production Readiness Review (PRR) is required prior to the start of production. The

PRR must review the production plan and include a summary/documentation of the manufacturing process (key manufacturing steps, assembly or work instructions, and QC checks), the status of production tooling, testing equipment and components, and updated production schedule including shipments. The subcontractor will develop a PRR presentation. The form and content of the PRR must be acceptable to the University

Technical Representative.

4.4 Hold points and what’s required

Written approval from an authorized representative of the University is required to proceed beyond any identified hold points.

Start of production is contingent upon approval of first article acceptance testing.

The completed assemblies must not be shipped until the University provides written authorization to ship. The Subcontractor must first provide relevant QC data detailed in

Section 6.3 and the subcontractor production plan for University review and approval prior to any production item shipment.

5 FABRICATION / ASSEMBLY (AS APPLICABLE)

IPC / J-Std Class 2 – Printed Circuit Assembly Materials

All fabrication and assembly must meet IPC 610 Class 2

Lead solder must be used for component to printed circuit board soldering.

Every printed circuit board will undergo Automated Optical Inspection (AOI): Printed circuit board assemblies must be inspected using 3-D AOI process for top and bottom component layers.

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5.1 Packaging

After completion of each assembly at the subcontractor’s facility, assemblies must be packaged individually using adequate ESD compliant packing material by the subcontractor. Assemblies must be hand-delivered to BNL in boxes which are durable enough to facilitate subsequent storage at BNL after completion of the incoming inspection.

5.2 Serialization

Where labeling is required, the position of serialization and/or labeling of the identification number/nameplate as per assembly drawing for each unit.

6 QUALITY ASSURANCE

6.1 Quality reporting requirements

The subcontractor must retain objective evidence, including records, of the inspections and tests performed in the course of manufacturing, testing, inspecting, preserving, packaging, and preparation for shipment of procured items. These records must be made available to LBNL's representative for review upon request. These records must be maintained for a minimum of three (3) years, unless otherwise specified in the procurement documentation, after the completion of the contract.

6.1.1 Subcontractor Quality program

Supplier must maintain a quality system that meets the requirements of the ISO 9001 standard: "Quality Management Systems - Requirements" (Latest revision as of the date of issuing the procurement documentation).

6.1.2 Deviation requests

Any deviations from the dictating LBNL documents must be requested by the subcontractor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form; however, a subcontractor’s existing or internal document may be utilized with prior written LBNL approval.

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Deviation requests apply to requests to modify processes or documented drawings.

Deviation requests DO NOT apply to hardware that is built and does not conform to the specification.

6.1.3 Nonconformance reports

The authorized University representative must be notified in writing, of all non-conformance within 48 hours of their occurrence.

A nonconformance report (NCR) provides a written summary that describes how a particular product does not conform to defined specifications or how a procedure does not conform to defined requirements. A nonconformance may be determined and reported by either the Subcontractor or the University.

The University uses their standard NCR form that the Subcontractor can request. Or, with prior University approval, the Subcontractor can use their own customary NCR documentation.

The University will provide a written dispensation establishing a path forward for each nonconformance. However, once a nonconformance has been identified, no further operation may be performed on the nonconforming item without the University’s written approval to proceed. Additionally, if any process is found to produce nonconforming components, all work utilizing that process must immediately cease upon discovery until the process can be reviewed with input from the University. Resumption of the process is at the discretion of the University.

6.2 Work Instructions (N/A)

6.3 Required Factory Inspections and Tests

The subcontractor must be responsible for performing the following inspections and tests prior to delivery.

1. Install jumpers on PWM-Regulator board assembly (LT-EL-SR-PS-CRR-6x0x-

01) according to BNL furnished data table.

2. Install jumper into screw terminal block J13 (J26) on PWM-Regulator board.

3. Install blank SD card into controller board (card capacity TBD).

4. Determined ID code of each 1-wire sensor, and add readable tag on 1-wire cable.

5. Install rear-panel ground jumper plugs.

6. Pre-shipment QA inspection of the following:

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a. Common mode choke plus to minus not shorted (standalone test with just choke, not installed on pcb).

b. Common mode chokes installed correctly on power amp pcb.

c. Visual verification that PWM-Regulator Power daughterboard (-CRR-

6301-11) U1 has part number RS6-2415D.

d. Visual verification of correct value of snubber resistor R1 (R23) on power amp board assembly (LT-EL-SR-PS-CRR-6x0x-11).

e. Visual verification of ‘C’ suffix in P/N ADUM5400CRWZ for U1 and U19 on PWM-Regulator board assembly (LT-EL-SR-PS-CRR-6x0x-01).

f. Visual verification that either U3 (U37) or U4 (U38) but not both are installed on PWM-Regulator board assembly (LT-EL-SR-PS-CRR-6x0x- 01).

g. Visual inspection of z-bracket sheet metal workmanship in chassis under controller board to ensure no shorts to chassis.

h. Visual inspection that AC input green ground wiring is correct for AC input module and Delta power converter.

i. Electrical continuity test of cable assemblies LT-EL-SR-PS-CRR-6201-81, LT-EL-SR-PS-CRR-6102-80, LT-EL-SR-PS-CRR-6102-81, and LT-EL-SR-

PS-CRR-6401-81.

j. Electrical verification that resistance between pins 3 and 4 of Q2-Q9 on power amplifier board reads 10 kΩ.

k. Every printed circuit board will undergo Automated Optical Inspection

(AOI) for top and bottom component layers, and saved electronically by subcontractor.

6.4 ACL upon receipt

Each assembly delivered to the University must undergo a visual inspection and a functional electrical acceptance test upon receipt. Acceptance of the assemblies is contingent upon successful completion of these evaluations.

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7 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document must be valid to the full extent, unless specifically noted within this document. Applicable documents must be obtained from the LBNL Document Control Center (DCC).

Document Number Title AL-1823-0962 BPC-2CH-S-18V-24A ALS-U Tech Note Document AL-1823-0963 BPC-4CH-S-18V-10A ALS-U Tech Note Document AL-1823-0961 BPC-2CH-S-16V-35A ALS-U Tech Note Document AL-1823-0958 BPC-1CH-F-16V-70A ALS-U Tech Note Document AL-1823-0959 BPC-1CH-S-16V-200A ALS-U Tech Note Document

8 REFERENCES

Documents listed in this section are considered reference documents that can be used to better describe, clarify intent, or provide information where the information was obtained from.

IPC standards for printed circuit board fabrication, assembly and chassis construction including quality meeting the requirements of ISO-9001 standards, as well as the IPC/J-

Std Class 2 standards for printed circuit assembly material, and IPC 610 Class 2 for fabrication and assembly.

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