AL-1747-5370A.pdf

Slow MPS SR Production SOW

Release Date: Jul 9 2024 11:27:11 AM PDT

Document Number: AL-1747-5370 Revision: A

Document Status: Released

Document Type: PROJECT MANAGEMENT

Category Code: LS180000

ALS-U GENERAL

GENERAL

O ffi ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

Downloaded by: Martha Gamarano Grausz at July 09, 2024 15:40:54

AL-1747-5370 Rev. A Doc. Status: Released Page 2 of 28

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

2.1 LBNL Provided Components

2.2 Groups A thru E: Fabrication of 1st Article and Production Chassis

2.3 Subcontractor Additional Responsibilities

3 Deliverables and Schedule

3.1 First Article Units

3.2 Production Units

3.3 Substitute Parts List

4 Management

4.1 Reporting/Communication requirements

5 Engineering and Assembly

5.1 Model A Chassis Design

5.1.1 M12 Flying Lead Wire Sleeve

5.2 Model B Chassis Design

5.3 Model C Chassis Design

5.4 Model D Chassis Design

5.5 Model E Chassis Design

6 Build Standard

6.1.1 Cable/Wire Identification

6.1.2 Special Tools

6.1.3 Wire Ferrules

6.1.4 Special Wiring Supplies

6.1.5 Wire Ties and Terminal Block Identification

6.1.6 Wire Tie Post

6.1.7 Cable/Wire Stripping and Routing

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 3 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

6.1.8 Spade or Ring Terminal Crimping

6.1.9 Wire Butt Splicing

7 Shipping and Handling

8 Quality Assurance

8.1 Quality reporting requirements

8.1.1 Subcontractor Quality program

8.1.2 Deviation requests

8.1.3 Nonconformance reports

8.2 Work Instructions

8.3 Test and Inspection Plan

9 Applicable Documents

10 Support Documents ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 4 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

REVISION HISTORY

Rev. CM Number Description of Change A Initial Release

APPROVALS

The following individual(s) must approve this document:

Approver Project Role Jeong Han Lee ALS-U Controls Tech Lead Ernesto Paiser ALS-U Controls and Instrumentation CAM

Windchill Approved / Concurred By jeonglee,paiser

ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source

ALS-U

SR

ARO

ATC

BOM

CPU

I/O

Advanced Light Source Upgrade Storage Ring After Receipt of Order Auto Tester Chassis Bill of Material Central Processing Unit Inputs and Outputs

LBNL

mm

MPS

NRTL

PG

PLC

QA

QTY

RIO

RTB

SOW

TIP

VDC

Lawrence Berkeley National Laboratory Millimeter Machine Protection System Nationally Recognized Testing Laboratory Prefix for Connector Identification Programmable Logic Controller Quality Assurance Quantities Remote Inputs & Outputs Removable Terminal Block Statement of Work Test and Inspection Plan Voltage Direct Current ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 5 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

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 capable of providing the foundations for an upgrade to 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 to be heavily utilized in an upgrade scenario.

1.2 Description of Items

The five PLC chassis designs (Model A through Model E) are based on Allen-Bradley 5380 series CPU and 5000 series I/O modules. All chassis are of a modular three-piece design and each sub-assembly can be assembled independently. The front panel contains all PLC components, and the rear panel includes interface connectors. When assembled together, these three sub-assemblies make up one PLC chassis.

Group Part # 1st Article Quantity

Production Quantity

Description

A AL-1380-4560 1 14 Model E Chassis

B AL-1445-6303 1 7 Model D Chassis

C AL-1440-6511 1 14 Model A Chassis

D AL-1445-5609 1 0 Model C Chassis

E AL-1445-5606 1 0 Model B Chassis

Table 1.1 Deliverables Groups in terms of 1st Article and Production

1.3 Roles and Responsibilities

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

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 6 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

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 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

The purpose of the statement of work is to define the assembly and schedule of the PLC chassis for the Storage Ring (SR) Machine Protection System based on design information provided by LBNL.

The deliverables are defined in Table 1.1. The schedule of deliverables is defined in Table

1.2. All work must adhere to LBNL Electrical Equipment Build Standard V6, Engineering Division Electronic Equipment Build Standard and Section 6 of SOW.

2.1 LBNL Provided Components

LBNL will provide the Subcontractor with long lead time items such as Allen-Bradley PLC components, including CPUs, I/O modules, associated RTBs. These parts are listed in AL-

1747-5362.

Any remaining component(s) must be returned to the University Technical

Representative.

2.2 Groups A thru E: Fabrication of 1st Article and Production Chassis

The scope of work must consist of:

Procuring parts not supplied by LBNL

Assembly, wiring, and wire check of work performed

LBNL design files include BOM, schematics, assembly, Front Panel Express files, TIP, and

Work Instructions.

After the first article approval is received from LBNL, procurement of production unit parts and then assembly of remaining units can commence.

2.3 Subcontractor Additional Responsibilities

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 7 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Supply of wire, wire label, and other wiring supplies

Supply of items listed in sections 6.1.1 thru 6.1.4

Packaging of finished units for shipping

3 DELIVERABLES AND SCHEDULE

To ensure deliverables defined in Table 1.2 are met, Subcontractor must define resource allocation in proposal. Due to possible supply chain issues, due dates are negotiable.

Due to limited LBNL storage space, Subcontractor must work with LBNL to schedule build and delivery of finished production units per specific group in Table 1.2. A staggered delivery schedule must be used rather than all at once delivery.

Group Item Type Work Scope Type Due Date (weeks)

A 1st Article Unit Fabricate one of each unit ~ 6 after ARO and receiving section

2.1 parts

A Production Units Fabrication production qty ~ 6 after 1st Article approval

B 1st Article Unit Fabricate one of each unit ~ 6 before/after Group A 1st Article and receiving section 2.1 parts

B Production Units Fabrication production qty ~ 6 after 1st Article approval

C 1st Article Unit Fabricate one of each unit ~ 10 before/after Group B 1st Article and receiving section 2.1 parts

C Production Units Fabrication production qty ~ 10 after 1st Article approval

D and E 1st Article Unit Fabricate one of each unit ~ 10 before/after Group C production and receiving section 2.1 parts

A thru E 1st Article Unit TIP Documentation ~ 1 after item 2

A thru C Production Units

TIP

Documentation ~ 1 after item 4

Table 1.2 Schedule for each deliverable

3.1 First Article Units

The fabrication of Group A thru E 1st Article units listed in Table 1.2 is required and is subject to LBNL inspection and testing. Approval of the 1st Article unit(s) for each Group will be given following successful testing and agreement on any remedial or improvement actions.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 8 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

The Subcontractor must provide detailed pictures of each finished unit to be reviewed by

LBNL, and must obtain LBNL approval before shipping.

3.2 Production Units

The assembly of Groups A thru C production units listed in Table 1.2 must commence once each corresponding Group 1st Article unit is approved.

3.3 Substitute Parts List

The Subcontractor may substitute parts for any build unit with parts listed in AL-1593-

3824. Notice of this change must be given to LBNL technical representative of which specific unit(s) is/are affected.

4 MANAGEMENT

4.1 Reporting/Communication requirements

Item No. Description Schedule Responsibility

1 Kick-off Meeting 14 days ARO LBNL

Groups A thru C Production Approval

~ 2 weeks after the final review of 1st Article

LBNL

3 Production Unit Updates As required or requested by LBNL Subcontractor

5 ENGINEERING AND ASSEMBLY

LBNL carried out the design of the five MPS PLC chassis. PLC components, terminal blocks, and connectors have been carefully selected for long trouble-free service. In addition, the modular three-piece design allows for easy assembly/disassembly and future upgrades.

Due to the closed box design, most internal connection connections are of spring clamp design. Electrical components are NRTL-rated and are carefully located for easy wiring and future maintenance.

5.1 Model A Chassis Design

The main chassis that contains the PLC CPU to communicate to Model B through Model

E. The chassis is a 9U form factor and is comprised of three sub-assemblies (Figure 5.1).

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 9 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 5.1 – Model A Chassis Assembly Layout

Figure 5.2 – Model A Front Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 10 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 5.3 – Model A Front Sub-Assembly (Rear)

Figure 5.4 – Model A Rear Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 11 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 5.5 – Model A Rear Sub-Assembly (Rear)

Figure 5.6 – Model A Full Assembly Top View ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 12 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

5.1.1 M12 Flying Lead Wire Sleeve

A flexible tubing or similar products should be used to hold loose M12 wires. In addition, the wire sleeve must be marked with a label.

5.2 Model B Chassis Design

RIO chassis that contains remote I/O adapter, I/O modules, fusing, and external rear-mounted 24 VDC power supply. The chassis is a 4U form factor and is comprised of three sub-assemblies (Figure 6.1).

Figure 6.1 – Model B Assembly Layout

Figure 6.2 – Model B Front Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 13 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 6.3 – Model B Front Sub-Assembly (Rear)

Figure 6.4 – Model B Rear Sub-Assembly (Rear) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 14 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 6.5 – Model B Full Assembly Top View

5.3 Model C Chassis Design

RIO chassis that contains remote I/O adapter, I/O modules, fusing, and two external rear-mounted 24 VDC power supplies. The chassis is a 5U form factor and is comprised of three sub-assemblies (Figure 7.1).

Figure 7.1 – Model C Assembly Layout ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 15 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 7.2 – Model C Front Sub-Assembly (Front)

Figure 7.3 – Model C Front Sub-Assembly (Rear) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 16 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 7.4 – Model C Rear Sub-Assembly (Rear)

Figure 7.5 – Model C Chassis Top View ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 17 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

5.4 Model D Chassis Design

RIO chassis that contains remote I/O adapter, I/O modules, fusing, and external rear-mounted 24 VDC power supply. The chassis is a 4U form factor and is comprised of three sub-assemblies (Figure 8.1).

Figure 8.1 – Model D Assembly Layout

Figure 8.2 – Model D Front Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 18 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 8.3 – Model D Front Sub-Assembly (Rear)

Figure 8.4 – Model D Rear Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 19 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 8.5 – Model D Rear Sub-Assembly (Rear)

Figure 8.6 – Model D Chassis Top View ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 20 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

5.5 Model E Chassis Design

RIO chassis that contains remote I/O adapter, I/O modules, fusing, and external rear-mounted 24 VDC power supply. The chassis is a 5U form factor and is comprised of three sub-assemblies (Figure 9.1).

Figure 9.1 – Model E Assembly Layout

Figure 9.2 – Model E Front Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 21 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 9.3 – Model E Front Sub-Assembly (Rear)

Figure 9.4 – Model E Rear Sub-Assembly (Front) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 22 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 9.5 – Model E Chassis Top View

6 BUILD STANDARD

LBNL designed these chassis to have a trouble-free service life for 30 years. Fabrication, assembly, and wiring must adhere to LBNL Electrical Equipment Build and Engineering

Division Electronic Equipment Build Standard.

Any deviation from the specified standards or specifications in this section must receive approval from the LBNL Technical Representative. The below sections are in addition to the previous two LBNL standards and must be applied to all builds.

6.1.1 Cable/Wire Identification

Cables and wires must have identification on both ends using printed heat shrink tubing marker label in black ink and legible three feet away. The exception is preprinted numbered or color coded wire. Black and red twisted pair wires or two conductor zip cord wires must use heat shrink tubing as a cable marker label.

6.1.2 Special Tools

To ensure a trouble-free service life of 30 years, special tools must be used during the installation of wire/cable. Below are recommended tools that may be substituted with tools with similar functionality with LBNL approval.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 23 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

Item No. Manufacturer Part # Where Used

1 Wago 210-719 Spring terminal block

2 IWISS HD-2612 Crimper for ILME pin/socket

3 ILME CCES ILME pin/socket removal tool

4 IWISS HSC8 6-4 Wire ferrules

5 Klein Tools 11063W 10-22 gauge wire stripper for general wiring

6 Molex 64016-0200 Mini-FIT Jr for Main and RIO auto testers

7 Panduit GS2B-E Wire tie gun for general use

8 Klein Tools 3005CR Ratcheting tool for crimping spade and ring terminals

Table 2.1 – Recommended Tools

6.1.3 Wire Ferrules

Listed below are recommended wire ferrules for all builds. Wire ferrules must not be used on any thermocouple connections.

Item No. Manufacturer Part # Where Used

1 Weidmuller 1076990000 5069 PLC CPU and I/O RTBs only

2 Weidmuller 0409500000 General wiring

3 Weidmuller 9028240000 Model B PG1 through PG4 and RIO Auto Tester PG1 through PG19

Table 2.2 – Recommended Wire Ferrules

6.1.4 Special Wiring Supplies

Suggested special wiring supplies are listed below, along with the application where each is used.

Item No. Manufacturer Part # Where Used

2 Hellermann Tyton 553-50004 Model B PG1 through PG7 and Model C PG1 through

PG3

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 24 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

3 Hellermann Tyton 553-50025 Twisted pair and two conductor zip cords.

4 Hellermann Tyton 553-50029 Model A PG10, PG20, PG30, PG40, and general use.

5 MIXC B079GSWTTL M12 flying lead wire sleeve

Table 2.3 – Special Wiring Supply

6.1.5 Wire Ties and Terminal Block Identification

High-quality wire ties must be used to create a neat appearance without stressing wire, cable, or connection points. Wire tie gun must be used on cable strain relief, and wire tie must not block more than 10 percent of the cable label. No wire ties are allowed inside wire ways.

Terminal blocks and Breakout Modules must have identification per schematic using manufacturer’s suggested labels, except for green ground terminal blocks.

Figure 9.1 – General Wiring Example 1

Figure 9.2 – General Wiring Example 2 ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 25 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

6.1.6 Wire Tie Post

Wire tie posts are provided near PG connectors behind rear panels to facilitate wire tie points. Cable from PG connectors must be tied with a wire tie gun. Wire tension must be checked to ensure no stress is applied to the wire connection on the PG connector after the wire tie is used.

Wire tie stop washers are installed to these wire tie posts to prevent wire tie slippage. Wire ties must be positioned no more than 50 mm from the wire tie stop washer to reduce stress on wire connections.

Figure 10.1 – Wire Tie Post

Figure 10.2 – Wire Tie Position and Stop ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 26 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

6.1.7 Cable/Wire Stripping and Routing

Due to the use of flexible cables in assembly, attention must be taken to avoid cutting or breaking fine-stranded wires during wire stripping process. An automatic wire stripper set to the proper wire gauge size must be used (see Section 6.1.2).

Cable and wire must be routed away from sharp metal edges or spiral wrap must be used to avoid chafing. Cable and wiring routing must be done in a clean and efficient manner.

6.1.8 Spade or Ring Terminal Crimping

A ratcheting crimper must be used to ensure secure and trouble-free crimping (see

Section 6.1.2).

6.1.9 Wire Butt Splicing

Wire butt splicing is not allowed, and all copper wire and shield drain wires must be one continuous run from source to destination.

7 SHIPPING AND HANDLING

The Subcontractor is responsible for packaging the finished PLC chassis to avoid environmental and physical damage to chassis housing and internal components during shipment. Due to limited storage space, the Subcontractor must work with LBNL to develop a delivery schedule of finished units.

The packaging must be compliant with the Toxics in Packaging Prevention Act, AB-455*.

8 QUALITY ASSURANCE

8.1 Quality reporting requirements

8.1.1 Subcontractor Quality program

The Subcontractor must complete the ALS-U Supplier Quality Evaluation Survey (AL-

1208-0209) during RFP process.

The Subcontractor must maintain and apply an effective QA program for the design, manufacture, and testing of all systems and equipment provided

Post-award surveys may be required and must be supported.

*Reference: https://dtsc.ca.gov/toxics-in-products/toxics-in-packaging-law/

This AB 455 act prohibits intentional introduction of cadmium, lead, mercury, or hexavalent chromium, and/or incidental presence of those metals above 100 parts per million (ppm) by the combined weight of all of the above metals.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 27 of 28

All officially released LBNL documents are watermarked and contain LBNL Document

8.1.2 Deviation requests

Any deviations from the dictating LBNL documents must be requested by the

Subcontractor and approved by LBNL before implementation. LBNL will provide a standard deviation request form. However, a subcontractor’s existing or internal document may be utilized with LBNL approval.

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.

8.1.3 Nonconformance reports

A nonconformance report provides a summary of products or procedures which do not conform to the defined requirements. Nonconformances may be determined and reported by either the Subcontractor or LBNL staff. LBNL will provide a standard nonconformance report form. However, a subcontractor’s existing or internal document may be utilized with LBNL approval. Nonconformance reports must be submitted to

LBNL within three business days of the identification.

Nonconformance reports apply to hardware that is built and does not conform to the specification(s). LBNL will provide a written disposition establishing a path forward for each nonconformance. No operations on the nonconforming item may be performed without LBNL’s written disposition or approval to proceed.

8.2 Work Instructions

LBNL will provide Work Instructions that must be followed for all the fabrication activities except Group A in Table 1.1. The Subcontractor must provide completed Work

Instructions for each unit.

8.3 Test and Inspection Plan

LBNL will provide Test and Inspection Plans. The Subcontractor must provide completed

TIP for each unit.

9 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered part of this document.

All information in an applicable document must be valid to the full extent unless noted ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU

AL-1747-5370 Rev. A Doc. Status: Released Page 28 of 28

All officially released LBNL documents are watermarked and contain LBNL Document explicitly within this document. Applicable documents must be obtained from the LBNL

Document Control Center (DCC).

Document Number Title AL-1497-6982 Model A – Assembly Work Instructions AL-1440-6511 Model A – Schematics, BOM, Assembly & Mechanical

AL-1440-6511-T Model A – Test and Inspection Plan AL-1499-1171 Model B – Assembly Work Instructions

AL-1445-5606-T Model B – Test and Inspection Plan AL-1445-5606 Model B – Schematics, BOM, Assembly & Mechanical AL-1499-1170 Model C – Assembly Work Instructions AL-1445-5609 Model C – Schematics, BOM, Assembly & Mechanical

AL-1445-5609-T Model C – Test and Inspection Plan AL-1505-6355 Model D – Assembly Work Instructions AL-1445-6303 Model D – Schematics, BOM, Assembly & Mechanical

AL-1445-6303-T Model D – Test and Inspection Plan AL-1499-1172 Model E – Assembly Work Instructions AL-1380-4560 Model E – Schematics, BOM, Assembly & Mechanical

AL-1380-4560-T Model E – Test and Inspection Plan AL-1747-5362 Slow MPS SR Production LBNL Provided Components AL-1593-3824 Slow MPS AR Production Substitute Parts List

10 SUPPORT DOCUMENTS

Document Number Title Electrical Equipment Build Standard V6 Engineering Division Electronic Equipment Build Standard ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: J ul y 9t h, D C

C A ut h

K ey

: Q K

SU

O

O X

EU