SOW - ARSR-4TCS - Rev E - 10-03-2018.pdf

STATEMENT OF WORK

for the

ARSR-4 TRANSMITTER COOLING SYSTEM (TCS)

October 03, 2018

Federal Aviation Administration Mike Monroney Aeronautical Center

6500 S. MacArthur Blvd.

Oklahoma City, OK 73169

October 03, 2018 ARSR-4 TCS SOW Rev E i

TABLE OF CONTENTS

1.0 INTRODUCTION

1.1 Background

1.2 Purpose

1.3 Scope

1.4 Definitions

1.5 Quantities

2.0 APPLICABLE DOCUMENTS

2.1 FAA Specifications

2.2 FAA Standards

2.3 Military Standards

2.4 Other FAA Documents

2.5 Non-Government Documents

3.0 SYSTEM REQUIREMENTS

3.1 Program Management

3.1.1 Project Control

3.1.2 Meetings, Reviews, and Conferences

3.1.2.1 Post Award Conference (PAC) / Preliminary Design Review (PDR)

3.1.2.2 Final Design Review (FDR)

3.1.2.3 Formal Test Readiness Review (TRR) Prior to Commencing Formal Testing . 7

3.1.2.4 Post-Test Reviews

3.1.2.5 Technical Interchange Meetings (TIMs)

3.1.2.6 Physical Configuration Audit (PCA)

3.1.3 Schedule Planning and Control

3.1.4 Configuration Management (CM)

3.2 Systems Engineering and Modification Kit Production

3.2.1 System Requirements

3.2.1.1 Modification Kit Contents

3.2.1.1.1 Low Ambient Configuration

3.2.1.1.2 High Ambient Configuration

3.2.1.2 Individual Component Requirements

3.3 Test and Evaluation

3.3.1 Test Program Description

3.3.2 Test Equipment

3.3.3 Test Management and Conduct

3.3.4 Test Readiness Reviews (TRRs)

3.3.5 Limited Production Test (LP Test)

3.3.6 Operational Test (OT Test)

3.3.7 Production Acceptance Test (PAT)

3.3.8 Test Conditions

3.3.9 Immediate Formal Test Rejection Criteria

3.3.10 Test Rejection and Retest

3.3.11 Post-Test Reviews

3.3.12 Development Test (DT) Support

3.3.13 Site Acceptance Test (SAT) Support

ii

3.3.14 On-site System Startup

4.0 SUPPORT

4.1 COTS Manuals and Documentation

4.2 Packaging, Handling, Storage, and Transportation

4.3 Nameplates

APPENDIX A ACRONYMS AND ABBREVIATIONS

APPENDIX B ARSR-4 SITE LIST

APPENDIX C SYSTEM PARTS LIST

APPENDIX D SYSTEM DRAWING PACKAGE

APPENDIX E SITE ACCEPTANCE TEST (SAT) PLAN

APPENDIX F VARIABLE FREQUENCY DRIVE (VFD) SETUP

APPENDIX G WIRE LIST

APPENDIX H PLC SOFTWARE

1.0 INTRODUCTION

1.1 Background

The ARSR-4 radar system is the United States’ newest long range radar system and completed deployment in year 2000. This system provides radar coverage for the Federal Aviation Administration (FAA), the Department of Defense (DoD), and the Department of Homeland Security (DHS). The radar transmitter used in the ARSR-4 system is located in a room on the upper portion of the radar tower just below the antenna. The method that was employed to cool the transmitter is comprised of a high pressure blower that draws unconditioned air from the outside of the structure, forces it across cooling coils in the transmitter, and then exhausts the heated air back outside the structure. This method resulted in the accelerated deterioration and reduced life of components in the transmitter, as well as other equipment in the transmitter room.

To fix this situation, the FAA created a design that no longer re-circulates unconditioned air through the transmitter. The primary component of this design is a special-purpose refrigerant-based cooling system. This system draws air through the transmitter, cools the heated air, and then exhausts the air back into the room. FAA engineers have completed the design of the cooling system, and the design package is ready for manufacture and production.

1.2 Purpose

This Statement of Work (SOW) describes the tasks the Contractor shall perform for the manufacturing, production, test, and delivery of the ARSR-4 Transmitter Cooling System (TCS) for these radars according to the design, form, and intent of the design package attached in appendix A.

1.3 Scope

This SOW defines the tasks involved for producing the ARSR-4 TCS. These include:

a) Procure and/or manufacture all individual parts, materials, and equipment needed to produce the design;

b) Assemble, manufacture, and produce the design;

c) Test each system produced;

d) Provide spare parts and assemblies in order to support the design;

e) Ship completed units;

f) Perform startup of completed units at radar sites (refer to paragraph 3.3.14);

g) Support operational testing by the Government.

The radar sites that shall have a modification kit produced and delivered are listed in appendix B.

The remaining ARSR-4 systems have either already been modified, will be modified under a separate contract, or will require a non-standard configuration, which is beyond the scope of this

SOW.

The FAA national engineering office Air Route Radar Division, AJW-142, in Oklahoma City, OK, designed this modification. Three prototype systems have been deployed, assembled, installed, and tested at operational facilities in different climate conditions. The scope of this

SOW does not include or allow for any design or engineering changes to the existing design without the express written permission and approval of the Government.

All deliverable documentation, including Contract Data Requirements List (CDRL) items, briefing packages, and meeting minutes, shall be in editable form. Formats shall include, but are not limited to, Microsoft Office products, Hypertext Markup Language (HTML), and Extensible Markup Language (XML). There shall not be links to documents in Portable Document Format (PDF) without Government approval.

1.4 Definitions

All reference to the “Government” in this SOW shall mean by authority of the Contracting Officer or designee. Reference to Government approval shall be limited to the Contracting Officer and his/her Technical Representative. The term software, as used in this SOW, refers to any code developed or otherwise used, including the code for firmware and all support files (e.g., library files, project files, test development software, etc.) needed for editing/making changes for future modifications.

Any reference to the acronym TCS in this SOW shall mean all systems, components, wiring, and cabling that comprise a modification kit for one radar site installation.

For the purposes of this SOW, any item manufactured or modified by the Contractor is defined to be non-COTS if there are no commercial customers other than the U.S. Government.

1.5 Quantities

This contract is to provide one first article and eight (8) additional complete TCS units. The first article shall be of a low ambient configuration. The additional eight (8) TCS units shall be ordered incrementally, with an anticipated rate of no less than 1 and no more than 3 systems per year until all the systems have been delivered. The remaining eight (8) systems will be of the low ambient configuration. Including the first article, this contract will be for a total of nine (9) low ambient configurations.

Additionally, there is anticipation that individual condenser towers separate from a TCS as a whole modification kit, would need to be procured to continue to support existing systems already installed within the FAA National Airway System (NAS). The condenser towers would be procured on an as needed basis, with no minimum purchase of units. Both the low ambient and high ambient condenser towers could be procured.

2.0 APPLICABLE DOCUMENTS

The following specifications, handbooks, orders, standards, and drawings form a part of this SOW and are applicable to the extent specified herein. The design presented was designed according to these specifications and as delivered conforms to all applicable sections and regulations.

2.1 FAA Specifications

None

2.2 FAA Standards

FAA-C-1217F Electric Work, Interior standards (February 26, 1996) FAA-G-2100H FAA Electronic Equipment Specification FAA-STD-019E Lightning and Surge Protection, Grounding, Bonding and

Shielding Requirements for Facilities and Electronic Equipment

2.3 Military Standards

MIL-PRF-28000B Initial Graphic Exchange Specification (IGES) MIL-HDBK-454A General Guidelines for Electronic Equipment MIL-W-5088 Wiring, Aerospace MIL-W-16878/4 & /5 Wiring for Aerospace Applications

2.4 Other FAA Documents

FAA Order 4650.30 Management of NAS F&E Project / Material

2.5 Non-Government Documents

ASTM-D-3951 Standard Practice for Commercial Packaging

3.0 SYSTEM REQUIREMENTS

The Contractor shall produce a single modification kit consisting of all systems and components needed to install a complete configuration at an operational ARSR-4 facility. The Contractor shall not make any changes to the design of these systems without the express written approval of the Government. The Contractor shall acquire Government approval of any variation in the new design that may be necessary throughout the development of these systems due to parts obsolescence or equipment unavailability. The Contractor shall ensure that the TCS units are developed, documented, integrated, tested, and delivered in accordance with (IAW) the requirements in this SOW.

In performance of the above, the Contractor shall provide qualified personnel, management, administrative materials, and facilities including assembly and manufacturing space. The Contractor’s assembly and manufacturing practices shall adhere to all of the elements in this SOW. The Contractor shall provide all plans, procedures, reports, and testing documentation.

The term Limited Production (LP) applies to the first production article kit. The Contractor shall manufacture and deliver the LP kit to the ARSR-4 installation at the Mike Monroney Aeronautical Center (MMAC) for installation and site acceptance test.

Subsequent to the successful conclusion of development and testing of the LP kit, the Contractor shall refurbish and maintain the LP modification to the production article configuration baseline throughout the lifecycle of this SOW.

The Contractor shall perform IAW all plans developed in response to this SOW and as approved by the Government. The Contractor shall interpret this SOW as taking precedence over any conflicts with said plans. Throughout this SOW, the Contractor shall interpret the requirements to “record” information or data to mean ‘set down in a manner that can be retrieved and viewed’, unless otherwise specified. The result may take many forms, including, but not limited to, hand-written notes, hard copy, electronic documents, and data recorded in Computer Aided System Engineering (CASE) and project management tools. The Contractor shall provide to the Government any software required to read or use the documents and data (as identified in this contract). All documentation, data, hardware, firmware, software, and CASE tools delivered by the Contractor as part of this contract, shall become the property of the Government.

The Contractor shall grant to the Government unlimited rights to all documentation (including, but not limited to, Contractor-developed depot level manuals of Commercial-Off-The-Shelf (COTS) parts and Contractor-proprietary parts, test equipment, and software for organic repair capabilities), data, hardware, firmware, and software developed under this contract. In addition to documentation, the Contractor shall grant to the Government unlimited rights and licenses to all data, hardware, firmware, and software (including, but not limited to, all library and project files) developed under this and other Government-funded efforts that are used under this contract.

The Contractor shall accompany all non-COTS software (including code, firmware, and project and library files), hardware, components, systems, and information with Government rights to distribute and have manufactured. The Contractor shall deem any item manufactured or modified by the Contractor to be non-COTS if there are no commercial customers other than the U.S. Government.

3.1 Program Management

The Contractor shall submit for Government approval a Program Management Plan (PMP), and shall revise such plan as necessary. Upon approval of the PMP, the Contractor shall apply this plan. The Contractor shall identify in the PMP the Contractor’s management, organization, authority, responsibility, controls, and the extent to which these apply to the TCS. The Contractor shall detail in the PMP the Contractor’s methodology to ensure the program management requirements set forth in this SOW are met. At a minimum, the Contractor shall perform the following tasks in managing this Contract:

a) Produce the schedules of work that reflect and track the delivery of products as specified by this SOW;

b) Use methods and metrics for assessing the schedule, technical performance of the work, cost, and risks of this program;

c) Identify risks and develop and implement mitigation plans for those risks;

d) Designate a Contractor’s Program Manager (PM) who is responsible for integrating and maintaining the total Contractor effort as described in this SOW and the Program Management Plan (PMP).

The Contractor’s PM shall be prepared at all times, given reasonable notice, to present and discuss with the Government the status of contract activities.

The Contractor shall conduct ongoing risk management activities during the period of the contract. The Contractor shall ensure that the risk management activities are an integral part of the Contractor’s management process, as described in the PMP.

3.1.1 Project Control

To control the contract activities as well as subcontractor and vendor activities, the Contractor shall continuously monitor the technical performance of this contract, and of all subcontracts, and provide the Government with an assessment of program progress or problems at Technical Interchange Meetings (TIMs).

3.1.2 Meetings, Reviews, and Conferences

The Contractor shall provide an agenda for each management review and formal meeting for review and approval by the Government at least 2 working days prior to the meeting. At each management review or audit, the Contractor shall provide backup data regarding assumptions made and methodologies used in arriving at specific recommendations or conclusions. The Contractor shall propose an overall strategy for conducting each set of reviews.

The Contractor shall submit minutes accompanied by a summary of action items and all presentation materials used, for Government approval. The Contractor shall consider management and formal reviews and audits not complete until approval of the final minutes by the Government is granted in writing.

3.1.2.1 Post Award Conference (PAC) / Preliminary Design Review (PDR) The Contractor shall plan for, host, support, and participate in a combined Post Award Conference (PAC) and Preliminary Design Review (PDR) of not less than one work day, to be held at the Contractor’s site within six weeks of contract award. The PAC and PDR have been combined in this SOW because the TCS has been designed by the Government, and the intent of the PDR is to communicate the design to the Contractor. The design baseline is included with this SOW. Any deviations from this baseline shall require the written approval of the Government. The Government will determine the actual date of the PAC/PDR within two weeks after contract award. At this conference, it is assumed by the Government that the Contractor’s overall knowledge of the operation of the system will be limited. However, the Contractor shall make every effort to address the plans, schedules, and work efforts for this contract. The Contractor shall provide preliminary details of its plans for acquiring and developing the required materials, components, hardware, and equipment to meet contract requirements. The Contractor shall discuss the production and manufacturing strategies, sequence of events, and resources.

At this conference, the Government shall:

a) Work with the Contractor to develop an effective meeting plan and minutes for the

PAC/PDR;

b) Provide an engineering level briefing on the function, operation, and design of the TCS;

c) Provide engineering level expertise on all systems of the TCS;

d) Discuss methods, procedures, and resources needed for system testing;

e) Provide any information on possible sources for parts and materials requested by the contractor;

f) Take Action Items to provide information needed in order for the Contractor to manufacture, produce, and deliver the TCS unit;

g) Deliver the operational system software for the Programmable Logic Controller (PLC) and the Human Interface Touch Panel (HITP) to the Contractor;

h) Deliver the blower and condenser fan Variable Frequency Drive (VFD) configurations;

i) Deliver the circuit card data.

To successfully complete the PAC/PDR, the Contractor shall:

a) Obtain Government approval of the conference and meeting minutes for this meeting;

b) Identify COTS and non-COTS items and the manufacturing approach for each item in the parts list;

c) Identify commercial COTS documentation, any licensing agreements, and any usage limitations;

d) Identify any production issues in the design including, but not limited to, manufacturing risks or methods, assembly risks or issues, or procurement issues that present risk to the manufacturing and delivery of the TCS kits according to the requirements of this SOW;

e) Identify any resources needed for system testing;

f) Review overall program risks on a technical, cost, and schedule basis.

3.1.2.2 Final Design Review (FDR)

The Contractor shall conduct a Final Design Review (FDR). The Government will support this review by providing engineering knowledge needed in order to manufacture, assemble, operate, check-out, and fully test the proposed design in addition to the presentation in the PAC/PDR.

All open items or issues shall be addressed. The intent of this meeting shall be to remove as much risk as possible and begin manufacturing of the first article LP kit.

The Contractor shall not conduct a FDR before obtaining Government approval of the PDR, and all PDR action items for both the Contractor and the Government shall be closed prior to conducting the FDR, unless the Government has given permission to proceed.

In the FDR, the Government shall:

a) Work with the Contractor to develop an effective meeting plan and minutes for the FDR;

b) Provide engineering level expertise on all systems of the TCS;

c) Take Action Items to provide any additional information needed in order for the

Contractor to manufacture, produce, and deliver the TCS unit.

In the FDR, the Contractor shall present sufficiently detailed information to permit the Government to evaluate risk areas on a technical, cost, and schedule basis.

The Contractor shall provide further details of its acquisition and development of the required components and materials needed to meet contract requirements.

As part of the FDR, the Contractor shall present and review in detail the following items with the Government:

a) Manufacturing schedule;

b) Production ability analysis;

c) Testing schedule;

d) Delivery schedule.

To successfully complete the FDR, the Contractor shall:

a) Obtain Government approval of the conference and meeting minutes for this meeting;

b) Establish an initial allocated baseline based on the detailed design;

c) Obtain Government approval of the Factory Acceptance Test for LP kit 1.

3.1.2.3 Formal Test Readiness Review (TRR) Prior to Commencing Formal Testing The Contractor shall schedule and conduct a TRR to ensure readiness to begin formal testing.

Also, see SOW section 3.3.4 for requirements for TRRs to be held prior to the formal LP test and first formal Production Acceptance Test (PAT) on the first production system.

To successfully complete the TRR held prior to commencing formal testing, the Contractor shall:

a) Provide a schedule for the testing of the capabilities and applicable requirements;

b) Obtain Government approval of the conference and meeting minutes for this meeting;

c) Present a review of all configuration items applicable to the test and include all applicable test documentation (which includes, but is not limited to, plans, procedures, test tool certification results, test bed configuration diagrams, and any proposed changes from the approved documentation of these items), the availability of Contractor/Government resources and personnel, the configuration control/validation of test tools and test items (both hardware and software), test limitations, and any other items deemed necessary to the successful conduct of testing;

d) Present the problems found in any informal lower level or dry run tests conducted prior to the TRR.

3.1.2.4 Post-Test Reviews

The Contractor shall hold post-test reviews following the completion of each formal test to review test data and preliminary results. The Contractor shall include minutes of the reviews, (including Action Items and Deficiencies identified during the review by the Government and Contractor), and a plan and schedule for resolution of Action Items and Deficiencies (including any necessary re-testing results). See SOW section 3.3.11 for requirements for post-test reviews.

3.1.2.5 Technical Interchange Meetings (TIMs)

The Contractor shall plan, host, and take part in TIMs between the Contractor, the Contracting Officer’s Technical Representative (COTR) and other Government representatives, including but not limited to Government engineers. The Contractor shall plan for up to 3 TIMs each year. At the Government’s discretion, the Contractor shall conduct TIMs, alternating between the Contractor’s facility and sites selected by the Government. The Contractor shall discuss at the TIMs the status of all meeting action items, specific technical activities (including studies), test plans, test results, design issues, schedule, technical performance, implementation (including schematics and electronic software listings), and technical guidance to ensure continued Government involvement into the technical progress of the contract. Special purpose TIMs may be requested by either the Contractor or Government to discuss a specific issue that would not lend itself to a general TIM.

3.1.2.6 Physical Configuration Audit (PCA)

The Contractor shall support configuration audits. The Contractor shall be responsible for determining the extent that subcontractors, vendors, and suppliers participate in Government configuration audits. The Contractor shall support a PCA of the first production article kit prior to the shipment of equipment at the start of Operational Test (OT). The Contractor shall perform subcontractor, vendor, and supplier PCAs for all parts listed in appendix C developed for the procurement or modified for use by other than the prime Contractor. To successfully complete the PCA, the Contractor shall:

a) Obtain written Government acceptance that the first production article kit meets performance criteria;

b) Obtain written Government acceptance that any inconsistencies between the design presented in this SOW and the produced equipment are mutually acceptable variations and configuration management tools are updated.

3.1.3 Schedule Planning and Control

The Contractor shall establish a schedule based on a logical and efficient sequence of events designed to accomplish the tasks described in the contract, including all options. The Contractor shall include both planned dates and actual completion dates, and measured progress of individual schedule elements.

3.1.4 Configuration Management (CM)

The Contractor shall use an internal CM system for the control of all configuration documentation, software, physical media, and physical parts representing or comprising the ARSR-4 TCS modification. The Contractor shall maintain this system and related procedures throughout this contract. The Contractor shall use and maintain configuration baselines and their documentation. Incremental product baselines may be permitted if proposed and approved by the Government.

3.2 Systems Engineering and Modification Kit Production

The Contractor shall execute a systems engineering program for fulfilling, verifying, integrating, and testing the requirements. The Contractor shall designate and purchase (after Government approval) long lead-time hardware items (those that would impact the schedule if not ordered prior to production turn-on) necessary to implement the design.

The Contractor shall provide a modification kit that meets all requirements in this SOW.

The Contractor shall maintain effective control over the system engineering process, including subcontract items and services, to ensure that cost, performance, and schedule are met, to provide early detection and resolution of problems, and to reduce risk. The Contractor shall specify a single authority that will serve as a Point of Contact (POC) for systems engineering issues.

The Contractor shall establish an initial hardware and software baseline for a LP kit prior to the completion of the FDR. The Contractor shall document all changes from FDR through the last production article to traceable hardware or software baselines.

3.2.1 System Requirements

The Contractor shall procure, manufacture, assemble, factory test, deliver, and perform on-site start-up (which includes, but is not limited to, soldering copper pipe, evacuating, charging, leak testing, and setting superheat) of complete TCS modification kits. There are two types of modification kits with different configurations. One configuration is for operation at a radar site that is exposed to no more than 115 ºF outside ambient temperature and is designated as a Low Ambient (LA) configuration. The other configuration, to be exposed to no more than 125 ºF outside ambient temperature, is designated as a High Ambient (HA) configuration. The only differences between the two configurations are the number of condensing units, the coil configuration of each condensing unit, the number and size of receivers in each condensing unit, and the strapping of the control unit enclosures. There are also differences in the field installed piping and condenser fan wiring between the two configurations that affect testing.

3.2.1.1 Modification Kit Contents

The Contractor shall include all of the system and materials listed in either section 3.2.1.1.1 or section 3.2.1.1.2 in a TCS kit depending on the site configuration listed in appendix B.

3.2.1.1.1 Low Ambient Configuration

A Low Ambient configuration TCS modification kit shall include the following contents:

a) Two Control Enclosure cabinets manufactured, assembled, and tested according to the design package in appendix D. One unit will be labeled and setup as Air Handler Unit 1 (AHU-1) and the other unit will be labeled and setup as AHU-2. These units shall be strapped for Low Ambient (LA) operation;

b) Two Condensing Unit cabinets in the Low Ambient (LA) configuration manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

c) Two Cooling Stack Units (Compressor/Evaporator/Blower) manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

d) Two Harmonic Suppression Junction Boxes (HSJB) manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

e) One Cooling System Interface Box (CSIB) manufactured, assembled, and tested according to appendix D;

f) Three Transmitter Air Intake Filter Cages (TAFC) manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as filter cage A, one unit will be labeled and setup as filter cage B, and one unit will be labeled, and setup as filter cage C;

g) Two Transmitter Exhaust Ducts manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

h) One Transmitter Plenum Pressure Box (TPPB) manufactured, assembled, and tested according to appendix D. Additional items required for the TPPB are:

1. 2 A-302/H25-600 static pressure tip pitot tubes;

2. 1 pitot tube mounting bracket, as shown in LRR-000022-0031;

i) Cable kit manufactured, assembled, and tested according to appendix D;

j) Two Isolation Transformers, consisting of:

1. Two Evans Electric Enterprises Part Number ET3H30S;

i. Input Voltage: 208 Delta / 60 Hz / 3 Phase;

ii. Output Voltage: 208 WYE / 120V;

iii. Power: 30 KVA;

iv. Enclosure: NEMA 1;

v. Weight: 243 lbs;

k) One Refrigeration Line Kit, consisting of:

1. 175 ft. 5/8” Type K ACR Copper tubing in 25 ft. lengths;

2. 175 ft. 7/8” Type K ACR Copper tubing in 25 ft. lengths;

3. 35 - 90 degree 5/8” Copper elbows;

4. 20 - 90 degree 5/8” Copper street elbows;

5. 35 - 90 degree 7/8” Copper elbows;

6. 20 - 90 degree 7/8” Copper street elbows;

7. 20 - 45 degree 5/8” Copper elbows;

8. 20 - 45 degree 7/8” Copper elbows;

9. 20 - 5/8” Copper couplings;

10. 20 - 7/8” Copper couplings;

11. 8 - 5/8” vibrasorbers Y/P Products Model #VIB-5 or Packless VAF-5;

12. 8 - 7/8” vibrasorbers Y/P Products Model #VIB-8 or Packless VAF-8;

13. 25 - 5/8” stainless steel cushioned line clamps for unistrut (padded);

14. 25 - 7/8” stainless steel cushioned line clamps for unistrut (padded);

15. 1 lb. - Stay Silv 15% (0.050 x 1/8” x 20”);

l) 450 lbs. R-407c refrigerant (DuPont SUVA Blend);

m) 4 Gallons Polyol Ester Refrigerant Oil;

n) One Cabinet Vibration Isolation kit, consisting of:

1. Three Vibration isolation pads;

i. Mason Industries Super W Waffle Pad 18” x 18” x 3/4” AASHRO Bridge

Bearing Neoprene;

o) One Documentation kit;

1. All COTS literature for every COTS component in kit, bound in a three-ring binder;

p) One spare Cooling System Interface Board circuit board, sealed in an Electrostatic Sensitive Device (ESD) safe bag, and stored in reusable fast pack (13” x 13” x 3-1/2”);

National Stock Number (NSN) 8115-01-057-1243;

q) One Condensing Drain Installation Kit, consisting of:

1. 100 ft SCH 80 2” PVC pipe Grey UV resistant;

2. 5 - 45 degree SCH 80 Grey UV resistant 2” elbows;

3. 8 SCH 80 Grey UV resistant 2” couplings;

4. 20 ft SCH 80 1” PVC pipe Grey UV resistant;

5. 10 - 90 degree SCH 80 Grey UV resistant 1” elbows;

6. 4 SCH 80 Grey UV resistant 1” unions;

7. 2 SCH 80 Grey UV resistant 1” tees.

3.2.1.1.2 High Ambient Configuration

A High Ambient (HA) Configuration TCS modification kit shall include the following contents:

a) Two Control Enclosure cabinets manufactured, assembled, and tested according to the design package in appendix D. One unit will be labeled and setup as Air Handler Unit 1 (AHU-1) and the other unit will be labeled and setup as AHU-2. These units shall be strapped for High Ambient (HA) operation;

b) Four Condensing Unit cabinets in the High Ambient (HA) configuration manufactured, assembled, and tested according to appendix D. Two units will be labeled and setup as

AHU-1 (one as circuit one and the other as circuit two) and the other two units will be labeled and setup as AHU-2 (one as circuit one and the other as circuit two);

c) Two Cooling Stack Units (Compressor/Evaporator/Blower) manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

d) Two Harmonic Suppression Junction Boxes (HSJB) manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

e) One Cooling System Interface Box (CSIB) manufactured, assembled, and tested according to appendix D;

f) Three Transmitter Air Intake Filter Cages (TAFC) manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as filter cage A, one unit will be labeled and setup as filter cage B, and one unit will be labeled and setup as filter cage C;

g) Two Transmitter Exhaust Ducts manufactured, assembled, and tested according to appendix D. One unit will be labeled and setup as AHU-1 and the other unit will be labeled and setup as AHU-2;

h) One Transmitter Plenum Pressure Box (TPPB) manufactured, assembled, and tested according to appendix D. Additional items required for the TPPB are:

1. 2 A-302/H25-600 static pressure tip pitot tubes;

2. 1 pitot tube mounting bracket, as shown in LRR-000022-0031;

i) Cable kit manufactured, assembled, and tested according to appendix D;

j) Two Isolation Transformers, consisting of:

1. Two Evans Electric Enterprises Part Number ET3H30S;

i. Input Voltage: 208 Delta / 60 Hz / 3 Phase;

ii. Output Voltage: 208 WYE / 120V;

iii. Power: 30 KVA;

iv. Enclosure: NEMA 1;

v. Weight: 243 lbs;

k) One Refrigeration Line Kit, consisting of:

1. 200 ft. 5/8” Type K ACR Copper tubing in 25 ft. lengths;

2. 200 ft. 7/8” Type K ACR Copper tubing in 25 ft. lengths;

3. 35 - 90 degree 5/8” Copper elbows;

4. 20 - 90 degree 5/8” Copper street elbows;

5. 35 - 90 degree 7/8” Copper elbows;

6. 20 - 90 degree 7/8” Copper street elbows;

7. 20 - 45 degree 5/8” Copper elbows;

8. 20 - 45 degree 7/8” Copper elbows;

9. 20 - 5/8” Copper couplings;

10. 20 - 7/8” Copper couplings;

11. 8 - 5/8” vibrasorbers Y/P Products Model #VIB-5 or Packless VAF-5;

12. 8 - 7/8” vibrasorbers Y/P Products Model #VIB-8 or Packless VAF-8;

13. 25 - 5/8” stainless steel cushioned line clamps for unistrut (padded);

14. 25 - 7/8” stainless steel cushioned line clamps for unistrut (padded);

15. 1 lb. - Stay Silv 15% (0.050 x 1/8” x 20”);

l) 700 lbs. R-407c refrigerant (DuPont SUVA Blend);

m) 4 Gallons Polyol Ester Refrigerant Oil;

n) One Cabinet Vibration Isolation kit, consisting of:

1. Three Vibration isolation pads;

i. Mason Industries Super W Waffle Pad 18” x 18” x 3/4” AASHRO Bridge

Bearing Neoprene;

o) One Documentation kit;

1. All COTS literature for every COTS component in kit, bound in a three-ring binder;

p) One spare Cooling System Interface Board circuit board, sealed in an Electrostatic Sensitive Device (ESD) safe bag, and stored in reusable fast back (13” x 13” x 3-1/2”);

National Stock Number (NSN) 8115-01-057-1243;

q) One Condensing Drain Installation Kit, consisting of:

1. 100 ft SCH 80 2” PVC pipe Grey UV resistant;

2. 5 - 45 degree SCH 80 Grey UV resistant 2” elbows;

3. 8 SCH 80 Grey UV resistant 2” couplings;

4. 20 ft SCH 80 1” PVC pipe Grey UV resistant;

5. 10 - 90 degree SCH 80 Grey UV resistant 1” elbows;

6. 4 SCH 80 Grey UV resistant 1” unions;

7. 2 SCH 80 Grey UV resistant 1” tees.

3.2.1.2 Individual Component Requirements

The Contractor shall follow the manufacturing specifications and directions on the drawings for parts and assemblies without exception. In addition to the requirements identified in the drawing package, the Contractor shall ensure that the ARSR-4 TCS units comply with the following general requirements:

a) Condensing Units:

1. All parts, materials, and hardware with the exception of refrigeration plumbing, electrical conduit (rigid and flexible), the condensing coil, and refrigeration valves and sensors, shall be constructed of 316 alloy stainless steel;

2. All surfaces exposed outside of the unit after assembly shall be electropolished after all forming, tooling, and rivnut insertion has been completed;

3. All edges of sheet metal material that have been sheared shall be deburred to remove sharp edges that may be hazardous to the technician;

4. All other surfaces shall be passivated after deburring, forming, and tooling has been completed;

5. Units shall be free of cutting chips, shavings, oils, or other fluids used during the manufacturing process, or any errant debris;

6. All hardware shall be installed correctly with no cross-threaded bolts, nuts, or other fasteners. Incorrectly installed fasteners must be removed and repaired to original correctly installed condition or replaced;

7. All hardware that is installed on electropolished surfaces shall have flat nylon washers that are 1994 UL UV rated installed between the metal flat washer and the electropolished surface;

8. All electrical wiring internal to the condenser shall be sealed against moisture or contamination. The Contractor shall not use EMT electrical conduit for any purpose. Connections to electrical junction boxes shall be performed with liquid tight connections;

9. All electrical conduit shall have ground bushings with abrasion resistant inserts attached to all ends;

10. All electrical conduit ground bushings shall have a ground wire attached and connected to a ground bar installed in the lower electrical enclosure;

11. Ground bar shall be installed in accordance with FAA-STD-019E;

12. All hinged doors shall have a braided ground strap attached to the door and an inner surface of the enclosure using ring terminals;

13. All hook-up wire shall conform to MIL-W-16878/4 or MIL-W-16878/5;

14. The wire harness shall conform to wiring practices set forth in MIL-STD-454N and FAA-G-2100H;

15. All installed refrigeration plumbing and tubing shall be braced and protected from damage due to vibrations/abrasions;

16. All installed refrigeration plumbing and tubing shall be coated after assembly with Ameron PSX 700 corrosion coating according to the following schedule:

i. Wipe and dry with solvent designed for wax and grease removal (e.g.

DuPont 3901S or equivalent);

ii. Scotch-Brite (3M Hand Pad #7447 or equivalent) all copper surfaces to be painted until oxides have been removed;

iii. Wipe and dry again with wax and grease remover to remove abrasion residue;

iv. Mask all valve and component labels;

v. Apply PSX 700 coating per data sheet and manufacturers instructions;

vi. Remove mask from valve and component labels;

17. All warning and identification labels shall be installed according to the drawings in appendix D;

18. Condensers shall be constructed according to drawings in appendix D.

b) Cooling Stack Units (Compressor/Evaporator/Blower):

1. All parts, materials, and hardware with the exception of the refrigeration line, the evaporator coil, refrigeration valves, sensors, PVC plumbing, and slide assembly shall be constructed of 316 alloy stainless steel;

2. All structural steel used in the blower cabinet shall be constructed of hot dipped galvanized steel, with all tooling marks coated with cold galvanized spray;

3. All edges of sheet metal material that have been sheared shall be deburred to remove sharp edges that may be hazardous to the technician;

4. All surfaces shall be passivated after deburring, forming, and tooling have been completed;

5. All exposed surfaces outside of the unit shall be painted after passivation according to the following paint schedule:

i. Parts shall be painted separately prior to assembly;

ii. Reverse side surfaces shall show no signs of overspray after coating completion;

iii. Prior to painting, all surfaces to be painted shall be prepared by wiping with wax and grease remover (DuPont 3901S or equivalent) and rubbed with abrasive (3M Scotch-Brite Hand Pad #7447 or equivalent) until uniform scratch pattern is achieved;

iv. Prime all surfaces to be painted with Sherwin Williams Industrial Wash Primer Part No. P60G2;

v. Paint shall be Sherwin Williams Coating Product:

1. Part No. #F63 Polane T;

2. Color: 30372, Federal Color Chart #595B;

vi. Paint shall have uniform texture and appearance with no visible runs, sags, or drips;

vii. The Contractor shall follow Application Note CC-D5 “Polane T Polyurethane Enamel” for all other application directions other than those specifically designated in this SOW;

6. All installed refrigeration plumbing and tubing shall be braced and protected from damage due to vibrations/abrasions;

7. All installed refrigeration plumbing and tubing shall be coated after assembly with Ameron PSX 700 corrosion coating according to the following schedule:

i. Wipe and dry with solvent designated for wax and grease removal (e.g.

DuPont 3901S or equivalent);

ii. Abrasively clean (3M Scotch-Brite Hand Pad #7447 or equivalent) all copper surfaces to be painted until oxides have been removed;

iii. Wipe and dry again with wax and grease remover to remove abrasion residue;

iv. Mask all valve and component labels;

v. Apply PSX 700 coating per data sheet and manufacturers instructions;

vi. Remove mask from all valve and component labels;

8. Units shall be free of cutting chips, shavings, oils or other fluids used during the manufacturing process, or any errant debris;

9. All electrical wiring internal to the cooling stack shall be protected from rubbing against abrasive surfaces. All electrical wiring external to liquid tight conduit shall be protected in conformance to MIL-HDBK-454A guideline 69;

10. The Contractor shall not use EMT electrical conduit for any purpose;

11. All electrical conduit shall have ground bushings with abrasion resistant inserts attached to all ends;

12. All electrical conduit ground bushings shall have a ground wire attached and connected to a ground bar installed in the electrical enclosure;

13. Ground bar shall be installed in accordance with FAA-STD-019E;

14. All hinged doors shall have a braided ground strap attached to the door and an inner surface of the enclosure using ring terminals;

15. All hook-up wire shall conform to either MIL-W-16878/4 or MIL-W-16878/5;

16. The wire harness shall conform to wiring practices set forth in MIL-HDBK-454A and FAA-G-2100H;

17. All hardware shall be installed correctly with no cross-threaded bolts, nuts or other fasteners. Incorrectly installed fasteners must be removed and repaired to original correctly installed condition or replaced;

18. All warning and identification labels shall be installed according to the drawings

19. Cooling stacks shall be constructed according to drawings in appendix D.

c) Control Enclosure Units:

1. All parts, materials, and hardware shall be constructed of galvanized steel;

2. All edges of sheet metal material that have been sheared shall be deburred to remove sharp edges that may be hazardous to the technician;

3. All exposed surfaces outside of the unit shall be painted following deburring, tooling, and forming according to the following paint schedule:

i. Parts shall be painted separately prior to assembly;

ii. Reverse side surfaces shall show no signs of overspray after coating completion;

iii. Prior to painting, all surfaces to be painted shall be prepared by wiping with wax and grease remover (DuPont 3901S or equivalent) and rubbed with abrasive (3M Scotch-Brite Hand Pad #7447 or equivalent) until uniform scratch pattern is achieved;

iv. Prime all surfaces to be painted with Sherwin Williams Industrial Wash Primer Part No. P60G2;

v. Paint shall be Sherwin Williams Coating Product:

1. Part No. #F63 Polane T;

2. Color: 30372, Federal Color Chart #595B;

vi. Paint shall have uniform texture and appearance with no visible runs, sags, or drips;

vii. The Contractor shall follow Application Note CC-D5 “Polane T Polyurethane Enamel” for all other application directions other than those specifically designated in this SOW;

4. All wiring internal to the cabinet shall be protected from rubbing against abrasive surfaces. Wiring that goes over an edge or attaches to a door shall have spiral wrap protection that conforms to MIL-HDBK-454A guideline 69;

5. All wiring internal to the cabinet shall conform to either MIL-W-16878/4 or MIL- W-16878/5;

6. All hinged doors shall have a braided ground strap attached to the door and an inner surface of the enclosure using ring terminals;

7. The wire harness shall conform to wiring practices set forth in MIL-HDBK-454A and FAA-G-2100H;

8. Ground bar shall be installed in accordance with FAA-STD-019E;

9. Units shall be free of cutting chips, shavings, oils or other fluids used during the manufacturing process, or any errant debris;

10. All hardware shall be installed correctly with no cross-threaded bolts, nuts or other fasteners. Incorrectly installed fasteners must be removed and repaired to original correctly installed condition or replaced;

11. All warning and identification labels shall be installed according to the drawings

12. Control enclosures shall be constructed according to drawings in appendix D.

d) HSJB Units:

1. All hardware shall be constructed of 316 alloy stainless steel;

2. All surfaces shall be painted following deburring, tooling, and forming according to the following paint schedule:

i. Parts shall be painted separately prior to assembly;

ii. Reverse side surfaces shall be masked off and show no signs of overspray after coating completion;

iii. Prior to painting, all surfaces to be painted shall be prepared by wiping with wax and grease remover (DuPont 3901S or equivalent) and rubbed with abrasive (3M Scotch-Brite Hand Pad #7447 or equivalent) until uniform scratch pattern is achieved;

iv. All aluminum parts shall be clear anodized;

v. Prime all surfaces to be painted with Sherwin Williams Industrial Wash

Primer Part No. P60G2;

vi. Paint shall be Sherwin Williams Coating Product:

1. Part No. #F63 Polane T;

2. Color: 30372, Federal Color Chart #595B;

vii. Paint shall have uniform texture and appearance with no visible runs, sags, or drips;

viii. The Contractor shall follow Application Note CC-D5 “Polane T Polyurethane Enamel” for all other application directions other than those specifically designated in this SOW;

3. All wiring internal to the cabinet shall be protected from rubbing against abrasive surfaces. Wiring that goes over an edge or attaches to a door shall have spiral wrap protection that conforms to MIL-HDBK-454A guideline 69;

4. All wiring internal to the cabinet shall conform to either MIL-W-16878/4 or MIL- W-16878/5;

5. The wire harness shall conform to wiring practices set forth in MIL-HDBK-454A and FAA-G-2100H;

6. Units shall be free of cutting chips, shavings, oils or other fluids used during the manufacturing process, or any errant debris;

7. All hardware shall be installed correctly with no cross threaded bolts, nuts, or other fasteners. Incorrectly installed fasteners must be removed and repaired to original correctly installed condition or replaced;

8. All electrical wiring connecting the VFDs and the HSJB shall be sealed against moisture or contamination. The Contractor shall not use EMT electrical conduit for any purpose. Connections to HSJB shall be performed with liquid tight connections;

9. All electrical conduit shall have ground bushings with abrasion resistant inserts attached to all ends;

10. All electrical conduit ground bushings shall have a ground wire attached and connected to a ground bar installed in the HSJB;

11. Ground bar shall be installed in accordance with FAA-STD-019E;

12. All hinged doors shall have a braided ground strap attached to the door and an inner surface of the enclosure using ring terminals;

13. All warning and identification labels shall be installed according to the drawings

14. HSJB units shall be constructed according to drawings in appendix D.

e) CSIB Units:

2. All surfaces shall be painted following deburring, tooling, and forming according to the following paint schedule:

i. Parts shall be painted separately prior to assembly;

ii. Reverse side surfaces shall be masked off and show no signs of overspray after coating completion;

iii. Prior to painting, all surfaces to be painted shall be prepared by wiping with wax and grease remover (DuPont 3901S or equivalent) and rubbed with abrasive (3M Scotch-Brite Hand Pad #7447 or equivalent) until uniform scratch pattern is achieved;

iv. Prime all surfaces to be painted with Sherwin Williams Industrial Wash Primer Part No. P60G2;

v. Paint shall be Sherwin Williams Coating Product:

1. Part No. #F63 Polane T;

2. Color: 30372, Federal Color Chart #595B;

vi. Paint shall have uniform texture and appearance with no visible runs, sags, or drips;

vii. The Contractor shall follow Application Note CC-D5 “Polane T Polyurethane Enamel” for all other application directions other than those specifically designated in this SOW;

3. All internal wiring to the cabinet shall be protected from rubbing against abrasive surfaces. Wiring that goes over an edge or attaches to a door shall have spiral wrap protection that conforms to MIL-HDBK-454A guideline 69;

4. All wiring internal to the cabinet shall conform to either MIL-W-16878/4 or MIL- W-16878/5;

5. The wire harness shall conform to wiring practices set forth in MIL-HDBK-454A and FAA-G-2100H;

6. Units shall be free of cutting chips, shavings, oils or other fluids used during the manufacturing process, or any errant debris;

7. All hardware shall be installed correctly with no cross threaded bolts, nuts, or other fasteners. Incorrectly installed fasteners must be removed and repaired to original correctly installed condition or replaced;

8. Ground bar shall be installed in accordance with FAA-STD-019E;

9. All hinged doors shall have a braided ground strap attached to the door and an inner surface of the enclosure using ring terminals;

10. All warning and identification labels shall be installed according to the drawings

11. CSIB units shall be constructed according to drawings in appendix D.

f) TPPB Units:

2. All surfaces shall be painted following deburring, tooling, and forming according to the following paint schedule:

i. Parts shall be painted separately prior to assembly;

ii. Reverse side surfaces shall be masked off and show no signs of overspray after coating completion;

iii. Prior to painting, all surfaces to be painted shall be prepared by wiping with wax and grease remover (DuPont 3901S or equivalent) and rubbed with abrasive (3M Scotch-Brite Hand Pad #7447 or equivalent) until uniform scratch pattern is achieved;

iv. Prime all surfaces to be painted with Sherwin Williams Industrial Wash Primer Part No. P60G2;

v. Paint shall be Sherwin Williams Coating Product:

1. Part No. #F63 Polane T;

2. Color: 30372, Federal Color Chart #595B;

vi. Paint shall have uniform texture and appearance with no visible runs, sags, or drips;

vii. The Contractor shall follow Application Note CC-D5 “Polane T Polyurethane Enamel” for all other application directions other than those specifically designated in this SOW;

3. All internal wiring to the cabinet shall be protected from rubbing against abrasive surfaces. Wiring that goes over an edge or attaches to a door shall have spiral wrap protection that conforms to MIL-HDBK-454A guideline 69;

4. All wiring internal to the cabinet shall conform to either MIL-W-16878/4 or MIL- W-16878/5;

5. The wire harness shall conform to wiring practices set forth in MIL-HDBK-454A and FAA-G-2100H;

6. Units shall be free of cutting chips, shavings, oils or other fluids used during the manufacturing process, or any errant debris;

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