Attach 1-SOW - Gymnasticator Modernization 08032023.docx

REVISED 3 August 2023

SCOPE OF WORK WITH SPECIFICATION

GYMNASTICATOR MODERNIZATION

The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.

1. SCOPE

1.1 General. This specification establishes the requirement for the modernization of three (3) Mandus Group Model MG3000 gymnasticators, referred to in this document as the “gymnasticator” and the “test stand” and located at Anniston Army Depot, Anniston, Alabama. The modernization of the Gymnasticators shall eliminate obsolescence and improve upon existing capabilities. The Contractor shall provide all resources necessary to design, manufacture, deliver, install, demonstrate functional operation including verification of results, and provide operator and maintenance training as described in this document.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in section 2 form a part of this specification. The issues of these documents referenced shall be the most recent at the time of award, except when a specific document issue is cited in this specification. While every effort has been made to ensure the completeness of this section, all requirements of documents cited in this specification must be met.

2.2 Government Documents.

2.2.1 Specifications, standards and handbooks. The following specifications, standards, and handbooks are incorporated by reference into this specification.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-71172 - Cylinder, Recuperator, Recoil. M119A1/A2 Howitzer, Light, Towed: 105MM (Distribution Statement C)

MIL-DTL-70953 - Buffer, Recoil Mechanism Assembly, M119A1/A2 Howitzer, Light, Towed: 105MM (Distribution Statement C)

MIL-M-70821 - Mount, Howitzer, M182 (Distribution Statement A)

MIL-PRF-71229 - Mount, Gun, 120MM (Distribution Statement A)

MIL-A-70625 - Automated Acceptance Inspection Equipment Design, Testing and Approval, of (Distribution Statement A)

(Copies of these documents are available online at http://quicksearch.dla.mil)

2.2.2 Other government documents, drawings and publications. The following other government documents, drawings and publications form a part this specification.

DEPOT MAINTENANCE WORK REQUIREMENTS

DMWR 9-1015-252 - Howitzer, Light, Towed: 105-MM (Distribution Statement C)

NATIONAL MAINTENANCE WORK REQUIREMENTS

NMWR 9-2350-388-2-1 - M1A2 SEP Turret System Enhancement Package (SEP) (Distribution Statement C)

NMWR 9-2350-264-2-1 - Turret Tank, Combat Full-Tracked 120-MM Gun, M1A1 and M1A1 Abrams Integrated Management (AIM) and M1A1 Abrams Integrated Management Situational Awareness (Distribution Statement C)

(Requests for copies of these documents may be made to the Contract Officer. Distribution is controlled by distribution statement as noted and may not be available during the solicitation period.)

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR 1910 - Occupational Safety and Health Standards

(Requests for copies of these documents may be made directly publishers, society, or the association that authorized the standards.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI AS35411 - Fittings and Lubrication

ANSI B93.114 - Pneumatic Fluid Power Systems - Standard for Industrial Equipment and Machine Tool Applications

ANSI 14.2 - Ladders, Fixed – Safety Requirements

INSTITUTE OF ELECTRICAL AND ELECTRONICs ENGINEERS (IEEE)

IEEE C2 - National Electrical Safety Code

IEEE 142 - Recommended Practice for Grounding of Industrial and Commercial Power Systems

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4413 - Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components

ISO 4414 - Pneumatic Fluid Power - General Rules and Safety Requirements for Systems and Their Components

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 - Enclosures for Electrical Equipment (1,000 V Maximum)

NEMA MG1 - Motors and Generators

NEMA ICS 1 - Industrial Control Systems: General Requirements

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 - National Electrical Code

NFPA 79 - Electrical Standard for Industrial Machinery

TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)

TIA-1005 - Telecommunications Infrastructure Standard for Industrial Premises

OTHER DOCUMENTS

MG3000 O&M - MG3000 Mechanical Gymnasticator Operator Manual, 30 May 2014 Revision (Proprietary to Mandus Group)

(Requests for copies of these documents may be made directly publishers, society, or the association that authorized the standards.)

2.4 Order of precedence. Where conflicts exist within these documents, and between these documents and this specification, the contractor shall notify the government. The government will make the final determination on a document’s applicability to this specification. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Requirement for standard industry practice. This specification includes those requirements that are considered by the government to be standard industry practice. The contractor shall be responsible for possessing the knowledge and understanding of standard industry practice as it relates to design and construction of test and measurement systems, calibrated systems, automated test equipment, and industrial machinery, and all other areas of practice required to execute this specification. The contractor shall execute this specification per standard industry practice. Execution shall be the best available in the industry.

3.2 Design review. The contractor shall implement a formal design review process. The purpose of the design review process is to minimize rework and the associated costs. The process shall be based on that described in MIL-A-70625 include Government review of the design as a concept, Government review of the detailed design when ready for execution, Government approval of the detailed design prior to execution, and Government acceptance of the final design. The contractor shall submit all designs in the form of computer solid models, computer drawings, specifications, schematics and written descriptions. The timeline for the design review process will be established by the contractor. The Government shall be allowed a reasonable amount of time to review and respond to the submitted design. The Government approval a design shall extend only to that design information provided to the Government.

In addition to participation in formal design reviews, the Government will participate substantially throughout the design process leading up to the design reviews. This participation is informal and may inlude discussion of prelimary concepts and ideas, reviewing data sheets of candidate COTS components, and general participation in decisions that effect performance, usability, maintainability/serviceability and the requirements of this SOW.

The Government recommends but does not require that the detail design be reviewed and approved by the government prior to the contractor taking actions related to the design such as procurement and fabrication. The contractor shall be responsible for costs incurred as a result of design related actions taken by the contractor prior to Government approval of the detailed design.

3.2.1 Conceptual design. The conceptual design defines the basis for the detailed design.

3.2.2 Detailed design. The detailed design will be based on the accepted conceptual design and include sufficient detail for procurement, fabrication, assembly, installation, and verification to be completed.

3.2.3 Final design. The final design is the final revision of the detailed to represent the design as installed and verified onsite at ANAD. The final design is generally revised by the government as part of the equipment documentation.

3.3 Project plan. The contractor shall provide to the government a project plan within 30 business days after contract award. The plan format shall be a Gantt chart and include milestones for the deliverables as described in this specification.

3.4 Detailed requirements. The contractor shall modernization three (3) existing gymnasticators located at ANAD. The contractor shall be responsible for all engineering, selection, procurement, design, manufacture, assembly, testing, delivery, installation, calibration, documentation, training, and commissioning required to make a production ready system. The requirements of section 3.4 are specific to the modernization of gymnasticators at ANAD.

3.4.1 Modernization. The modernization shall eliminate all obsolescence, improve and expand existing capability, and provide updated documentation as described in this document.

3.4.2 Obsolescence. The modernization of the existing gymnasticators shall eliminate all obsolete components and replace them with the latest equivalent component. Components include electrical, electro-mechanical, mechanical and firmware/software components, including but not limited to switches, buttons, lamps, motors, valves, motor starters, pumps, signal conditioners, transducers, logic controllers, touch panel displays, operating system software, printers and variable frequency drives. Obsolete components include all commercial off-the-shelf (COTS) components which are no longer available from the manufacture and/or the manufacturer has designated the components as “obsolete”, “legacy” or with a similar designation indicating a planned end of life and subsequent end of support of the component. Equivalent components are those that are identified as equivalent by the manufacturer of the obsolete component. When no equivalent component is available, a suitable replacement which maintains the existing form and function of the gymnasticator shall be substituted.

3.4.3 Existing capability. Modernization of the gymnasticators shall retain all existing capabilities except as stated herein. Existing capability includes gymnasticating the following items.

M119 Recoil System per MIL-DTL-71172 and DMWR 9-1015-252

M182 Gun Mount (for M109) per MIL-M-70821 and DMWR 9-1025-213

M256 Gun Mount (for M1) per MIL-PRF-71229, NMWR 9-2350-388-2-1 and NMWR 9-2350-264-2-1

3.4.4 New capability. Modernization of the gymnasticators shall add all capability included in the contractor’s most recent model MG3000 gymnasticator design . In addition, new capabilities shall be added including test report storage, recall and printing. These capabilities shall be both local at gymnasticator and remote at new host computer. Existing capabilities shall be improved as stated in this specification.

3.4.4.1 Host computer and printer. The contractor shall supply a host computer and network-capable laser printer. The computer and printer shall be installed on a government supplied desk located within the same building as the gymnasticators. The contractor shall install a system for wired communication between the host computer, laser printer and the three (3) gymnasticators. The computer shall be configured for each gymnasticator to store data remotely on the computer hard disk drive. The computer shall have Adobe Acrobat Reader installed for viewing and printing test reports stored locally on the computer. The laser printer shall receive and execute print jobs from the gymnasticators independently of the host computer.

3.4.4.1.1 Computer requirements. Computers shall meet the following minimum requirements:

a. Business-class computer assembled by a major computer OEM (i.e. Hewlett Packard, Dell)

b. Tower computer case

c. Windows 11 Pro operating system

d. Intel Core i5 processor

e. 16 GB RAM

f. Two (2) identical internal data storage drives with a minimum capacity of 1 TB each installed in a RAID 1 mirrored array and configuration for automatic real-time backup

g. Internal DVD writer optical disc drive

h. English-language QWERTY type USB wired extended keyboard

i. USB wired optical mouse with mouse pad

j. Integrated graphics and a 24-inch FHD (1920 x 1080) monitor

k. Business-class network laser printer with enclosed paper tray built by a major printer OEM such as Hewlett Packard

3.4.4.1.2 Printer requirements. All printers shall be the same make and model. Printers shall be business-class network laser printers with enclosed paper tray and built by a major printer OEM such as Hewlett Packard.

3.4.4.1.3 Communication devices and cabling. The Contractor shall provide all materials, labor, and any other resources to design, install and configure cabling and devices used to facilitate communication between the host computer, printer and three (3) gymnasticators for the purpose of transferring test report data for printing and storage. The installation shall meet the requirements of TIA-1005-A, specifically the requirements related to protection and support of installed cabling and devices and the suitability of the cabling and devices for the application.

3.4.4.2 Test report format, printing, and storage. Test reports shall use the existing format. Currently at the conclusion of a test, the gymnasticator automatically generates, displays, and prints the test report to a printer connected to the gymnasticator via USB. In addition to these actions, the gymnasticator shall automatically save the test report as a PDF file in non-volatile memory both locally at the gymnasticator and remotely on the host computer.

3.4.4.3 Test report filenames. The filenames of saved test reports shall include the test type, serial number, and the date and time of test in MMDDYYYY_HHMMSS format. The filename shall be unique and when necessary, a number (_####) shall be appended to all filenames to make them unique. The number appended shall be consecutive for that specific duplicate filename (i.e., M1_M1A1_SN23J56_05262023_142343_0001, M1_M1A1_SN23J56_05262023_142343_0002, etc.).

3.4.4.4 Revised gymnasticator graphical operator interface (GUI). The existing gymnasticator GUI shall be revised to accommodate changes required by this specification. The changes shall include those needed for the operator to perform test report related tasks.

3.4.4.4.1 The GUI shall include a screen to allow the operator to select between performing new tests and report related tasks for viewing, printing, and copying existing test reports.

3.4.4.4.2 The GUI shall include a screen for the operator to list, filter, sort, select, view, print and copy all test reports stored locally at the gymnasticator. For each test report, the list shall display the following criteria for each report: test type, serial number, the result (PASS or FAIL), and the date and the time the report was generated. The GUI shall filter the list to display only reports that meet operator selected criteria. The GUI shall sort the list in both ascending and descending order as selected by the operator. The operator shall select from a list, the test report to view, print and copy. The operator shall choose to view, print or copy the report. When the operator chooses to view a test report, the test report will display as is does currently after a test is completed. When an operator chooses to print a test report, they shall select either the local printer at the gymnasticator or remote network printer. When the operator chooses to copy a test report, the test report file shall be copied to local removable media at the gymnasticator.

3.4.4.5 Gymnasticator support for removable media. The gymnasticator shall support reading and writing data to locally connected removable media including CDs, DVDs and USB drives. A DVD Writer shall be provided for each gymnasticator. The gymnasticator operator console shall be provided with an externally located 120VAC 15A electrical outlet and a USB port for powering and connecting these devices. The USB port shall be protected when not in use. When a USB connected DVD Writer is provided and it is in use, it shall be connected to the operator console using the externally located power outlet and USB port. When not in use, the DVD writer shall be stored inside the operator cabinet.

3.4.4.6 Error handling. Additional error handling shall be added to the control logic and GUI. Errors shall be handled including but not limited to the following errors. Errors shall be handled in a way that will minimize test time, minimize the amount of retesting, and provide information to direct the operator to the cause of the error.

3.4.4.6.1 Local printer unavailable, not found, etc. This may occur when the printer is powered off, the printer cable is disconnected or damaged, or the printer is not installed in the operating system.

3.4.4.6.2 Local printer general errors. This may occur when the printer has paper jammed, is out of paper, is out of ink, or requires other maintenance.

3.4.4.6.3 Local or remote file storage location is unavailable. This may occur when local storage is removed or disconnected, local storage is full, remote storage is powered off, or communication is unavailable.

3.4.4.7 Other changes and improvements. The following changes and improvements shall be made.

3.4.4.7.1 Trigger position beyond sensor range. When moving the trigger to the required position, the trigger position moves beyond the range of the linear position sensor rod and stops at its mechanical limit. If the cause of the problem is not related to wear or damage to gymnasticator components, the contractor shall make changes to the gymnasticator software to fix this problem. The current solution is the installation washers to offset the linear position sensor rod approximately ¾ inches toward the gun breech.

3.4.4.7.2 Mount position changes when elevating gun mount. The mount position changes when the gun mount elevation changes. This causes significant error in the total recoil time in the first pull following an increase in elevation. The contractor shall modify the gymnasticator software so that the in-battery position is determined after the elevation has occurred and in other ways as required to fix this problem. The return to in-battery offset that defines how close the mount position needs to be from the mount position at the start of the pull shall be added as a user-defined constant located on the existing Supervisor Manual Screen. The constant shall be in units of inches.

3.4.4.7.3 Live test results. The gymnasticator software shall be modified to allow the operator to view the results of previous pulls on a summary screen while continuing to run the test in the foreground if there is sufficient space on the display, otherwise in the background accessible via a soft-button. The summary screen shall be the same as the test report screen.

3.4.4.7.4 Latching failure. The gymnasticator software shall be modified to eliminate the repeating of previous pulls when the latch fails to engage or disengages due to operator error, fixture wear or misalignment. The government requires the gymnasticator software to detect that latching has likely failed and in response pause the test, give the operator the control required to either stop the test or remedy the cause latching failure, re-engage the latch, repeat the last pull when failure the failure occurred, and then continue the test to completion.

3.4.4.7.5 Cannon and breech serial numbers. The gymnasticator software shall be modified to add cannon serial number and breech serial number fields on the existing Test Selection Screen and allow the operator to enter these serial numbers as alphanumeric values (reference MG3000 O&M Manual, page 10). The default value for each shall be a blank field and entering a value into the field shall be optional.

3.4.4.7.6 Repeat cycle. The gymnasticator software shall be modified to allow a failed cycle to be repeated by the operator. For instance, if cycle 8 fails requirements, the operator will have the option to repeat cycle 8 again. Only the results from the most recent cycle 8 will be reported. The purpose of this feature is to prevent repeating the entire test when a failure is due to reasons not related to the gun mount under test. This feature shall be enabled or disabled via a setting on the existing Supervisor Manual Screen. Once enabled, the feature shall be available to the operator until it is disabled on the Supervisor Manual Screen.

3.4.4.8 Operator console. A new operator console shall be assembled offsite, delivered to ANAD and installed on the gymnasticators replacing the existing control panels.

3.4.4.8.1 Programmable logic controllers (PLC). PLCs shall be Allen Bradley or equivalent that are compatible with Allen Bradley programming software and communication cables.

3.4.4.9 Installation location. The gymnasticators are currently located at Anniston Army Depot, Anniston, AL in Building 423.

3.4.4.10 Utilities and dimensional requirements. The modernized Gymnasticators shall utilize existing utilities and floor space except for equipment shared by all three (3) Gymnasticators for which standard 20 A, 120VAC, single phase outlets and floor space will be provided by the Government within the same building where the Gymnasticators are currently located.

3.4.5 Parts Allowance. The contractor shall provide an allowance to be used to provide parts to the government as required to replace those existing parts that are identified by the contractor based on experience and/or inspection as worn beyond beyond design limits. These parts are in addition to those provided under any other requirement of this specification. The allowance shall be equal to the cost of the parts listed below in the total quantities stated. The parts listed are for the purpose of establishing an allowance only, and theses parts may or may not be required. Prior to contract award as part of the response to solicitation, the contractor shall provide to the government a list of recommened replacement parts and quanites of each part. The list of parts shall include pricing in the quanties needed for all three (3) gymnasticators. The government will make the final determination on the parts to be provided by the contractor against the allowance established. The government shall install these parts on the gymnasticators. The contractor shall ship the parts to the arrive at ANAD with sufficient time for installation such that the gymnasticators will be operational when needed for the contractor to perform. Shipping shall be at no direct cost to the government.

1. CAM 1K0188, 1 EA, TOTAL QUANTITY OF 3 (Trigger sliding cam)

2. COUPLING 1K0104, 1 EA, TOTAL QUANTITY OF 3 (Motor to Acme screw coupling)

3. SCREW 1K0100, 1 EA, TOTAL QUANTITY OF 3 (Acme screw)

4. CAMFOLLOWER, 1K0101, 5 EA, TOTAL QUANTITY OF 15 (Horizontal plane + one for trigger bracket)

5. CAMFOLLOWER, 1K0102, 4 EA, TOTAL QUANTITY OF 20 (Vertical plane)

6. BEARING, 1K0105, 2 EA, TOTAL QUANTITY OF 6 (Bearing on each end of Acme screw)

7. BRACKET ASSEMBLY, 1K0190, 1 EA, TOTAL QUANTITY OF 3 (Holder for gun tube position magnet)

8. SPRING, 1K0010, 1 EA, TOTAL QUANTITY OF 3 (Spring for pull bar assembly)

9. PLUNGER ASSEMBLY, 1 EA, TOTAL QUANTITY OF 3 (Plunger for pull bar assembly)

10. YOKE, 1K0187, 1 EA, TOTAL QUANTITY OF 3 (Trigger bracket - Acme nut)

11. SPRING, MS24586-789, 1 EA, TOTAL QUANTITY OF 3 (Jaw spring for latch box assembly)

12. LATCH, 1K0005, 2 EA, TOTAL QUANTITY OF 6 (Jaw for latch box assembly)

13. TRIP, 1K0097, 1 EA, TOTAL QUANTITY OF 3 (Trip rotary cam for latch box assembly)

14. SPRING, 1K0010, 1 EA, TOTAL QUANTITY OF 3 (Spring for trip cam)

15. PLUNGER, 1K0096, 1 EA, TOTAL QUANTITY OF 3 (Plunger for trip cam)

16. BUSHING, 1K0095, 1 EA, TOTAL QUANTITY OF 3 (Bushing for trip cam plunger)

17. LEVER, 1K0098, 1 EA (Lever for trip cam)

18. LINK, 1K0006, 1 EA, TOTAL QUANTITY OF 3 (Y-link for latch box assembly)

19. LINK, 1K0007, 1 EA, TOTAL QUANTITY OF 3 (H-link for latch box assembly)

20. PIN, 1K0009, 2 EA, TOTAL QUANTITY OF 6 (Latch to link pin)

21. PIN, 1K0209, 1 EA, TOTAL QUANTITY OF 3 (Link to link pin in latch box assembly)

22. PIN, 1K0008, 2 EA, TOTAL QUANTITY OF 6 (Latch retaining pin in latch box assembly)

3.5 General requirements. The following requirements shall be met by the contractor. The contractor shall request that government provide additional explanation for any requirement for which applicability is unclear. The government will make the final determination on the applicability of the following requirements.

3.5.1 Source code. The contractor shall provide to the government all source code for any application developed by the contractor that is executed on the test stand PC, PLC, or other programmable device. The source code shall be in a format that is ready for compiling into an executable and be fully accessible by the Government and not password protected. Source code shall be fully documented using programming best practices. The Contractor shall identify code in the which was developed outside this or another Government contract. The Contractor shall grant the Government the right to modify the source code for the purpose of fixing bugs, adding capability and maintaining compatibility with replacement hardware.

3.5.2 Original equipment manufacturer’s part numbers. Original Equipment Manufacturer's part numbers referenced herein are intended to be descriptive and not restrictive; and are not intended to preclude the use of any item otherwise conforming to this specification.

3.5.3 Components. Components shall be standard unmodified products of an Original Equipment Manufacturer regularly engaged in the manufacturing of such products. Components of the same type and purpose shall be identical and supplied by the same manufacturer.

3.5.4 Electrical requirements.

3.5.4.1 Electrical materials and workmanship. All electrical work shall comply with IEEE C2, NFPA 70, and, unless outdoors or in an electrically hazardous classified area, shall be installed to meet NEMA 13 rating. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings. Workmanship shall be in accordance with standard commercial practices. All wire shall be copper; no aluminum wire shall be used. Conduit feeds to the Test Stand shall be IMC or rigid conduit. Conduit runs shall be installed perpendicular and parallel to facilities and the Test Stand to be installed. When the Test Stand is installed near existing power lines, the Test Stand shall be located for proper clearances in accordance with IEEE C2. Oil-resistant, liquid-tight, flexible metal conduit may be used to connect to Test Stand components (valves, motors, switches, sensors) but the length shall not exceed six (6) feet.

3.5.4.2 Electrical conduit. The Contractor shall not install conduit in a manner or location that interferes with equipment or interferes with personnel access to the Test Stand or existing equipment for operation or maintenance. The Contractor shall not install conduit in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install conduit in a manner or location that interferes or in any way limits the full design motion of any crane.

3.5.4.3 Test stand service voltage. The Test Stand shall be wired to draw all of its electrical power from a single circuit. If the Test Stands’ single circuit amperage does not exceed the requirement of a 20-amp circuit, the Test Stand may be designed to operate on 120-volt, 1-phase, 60-Hertz (Hz) input power. If the Test Stand’s single circuit amperage exceeds the requirement of a 20-amp circuit, the Test Stand shall be designed to operate on 480-volt, 60-Hertz (Hz) input power. The Test Stand shall be equipped with a manual, fused, or breaker type disconnect switch, readily accessible to the operator, that will deactivate the entire Test Stand and any ancillary equipment.

3.5.4.4 Electrical noise. The electrical power at ANAD may be subject to electrical noise. If the Test Stand requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the Test Stand. If the Test Stand is subject to interference from adjacent machinery, the Test Stand shall include the proper shielding to prevent malfunctions.

3.5.4.5 Electrical connections. Connections to screw-type terminals shall be mechanically secured with means to prevent loss of tightness. All other electrical connections shall be mechanically secured and soldered or brazed. Rosin base fluxes shall be used in all soldering operations. Wiring splices included soldering; crimp splices are not acceptable connections. All connections must take place within a suitable electrical enclosure.

3.5.4.6 Electrical monitoring. The Test Stand process parameters and machine functions shall be automatically, continuously monitored and maintenance warnings automatically issued before any parameter reaches unacceptable levels.

3.5.4.7 Electrical grounding. The Test Stand shall be equipped with suitable grounding devices for static discharge.

3.5.4.8 Electric motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors, unless otherwise specified, shall conform to the requirements of NEMA MG 1. Motors shall be AC, 60-Hz, or DC industrial-type motors with drip proof enclosures. All motors 10 HP or greater shall have a soft start controller. Each motor control shall conform to the requirements of NEMA ICS 1.

3.5.5 Pneumatic systems.

3.5.5.1 Pneumatic systems requirements. If the Test Stand requires a pneumatic system, the pneumatic system shall conform to the requirements of ANSI B93.114M and Section 43 15 00.00 20 E, LOW PRESSURE COMPRESSED AIR PIPING (NON-BREATHING AIR TYPE) applies to this section. The pneumatic system shall comply with ISO 4414:1998 and NFPA T2.25.1R2 200x.

3.5.5.2 Pneumatic system installation. The Contractor shall not install pneumatic systems in a manner or location that interferes with the Test Stand or existing equipment or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install pneumatic systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install pneumatic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

3.5.6 Hydraulic systems.

3.5.6.1 Hydraulic system requirements. If the Test Stand requires a hydraulic system, the hydraulic system shall conform to the requirements of NFPA / JIC T2.24.1R1. The hydraulic system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in the high-pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, a provision for draining, and a cleanout access plate if the reservoir is not removable.

3.5.6.2 Hydraulic systems fluid requirements plate. The system shall be equipped with a hydraulic fluid requirements plate mechanically attached to the Test Stand at the hydraulic reservoir fill point. The plate shall contain the Type of fluid (SAE or Military or Federal specification number) and Type of filter.

3.5.6.3 Hydraulic systems installation. The Contractor shall not install hydraulic systems in a manner or location that interferes with the Test Stand or existing equipment or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install hydraulic systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install hydraulic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

3.5.7 Plumbing, drainage and waste.

3.5.7.1 Chilled water anti-siphon provisions. If the Test Stand requires chilled water, incoming water lines shall have adequate anti-siphon provisions to prevent water supply contamination.

3.5.7.2 Water back flow check valve. If the Test Stand requires water, the contractor shall install a Fresh Water Back Flow Check Valve.

3.5.7.3 Plumbing, drainage and waste systems installation. All plumbing work shall comply with National Association of Plumbing-Heating-Cooling Contractors/American Society of Plumbing Engineers (NAPHCC/ASPE) Publication - National Standard Plumbing Code. All materials used in the installation of the equipment shall conform to industry standards and shall be compatible with and shall meet the performance requirements of the equipment being installed. Workmanship shall be in accordance with standard commercial practice. Runs shall be installed perpendicular and parallel with existing facilities and the equipment being installed. Bypasses shall not be installed at steam reducing stations. All heating coils shall be trapped independently. Unless otherwise specified, steam and condensate piping shall be insulated with 1-1/2-inch-thick calcium silicate with aluminum cover for outside lines and 1-1/2 inch thick fiberglass with all service jacket for interior lines unless subjected to water or vapor.

The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the Test Stand or existing equipment, personnel access to equipment for operation or maintenance, the direct access to work-in-process (WIP), component containers, racking, or in any way limits the full design motion of any crane.

3.5.8 Safety and health requirements. The Test Stand shall comply with Occupational Safety and Health Administration (OSHA) 29 CFR 1910. The Test Stand shall include warning lights/indicators to alert the Test Stand operator to unsafe operating conditions. The Test Stand shall include a manual emergency shutdown switch and shall have the ability to automatically shut down when under automatic control. All parts, components, mechanisms, and assemblies furnished on the Test Stand, whether or not specifically required herein, shall conform to all requirements of OSHA 29 CFR 1910. Covers, guards, or other safety devices normally furnished as standard on the manufacturer's commercial Test Stands supplied to the commercial market shall be provided for the point of operation and all other parts of the Test Stand that present safety hazards. All special guarding shall meet OSHA 29 CFR 1910. The safety devices shall not interfere with the operation of the Test Stand. Guards shall be removable to provide easy access to the guarded parts.

3.5.8.1 OSHA limitations. The Test Stand shall comply with OSHA limitations and control of noise levels, radiation, electromagnetic emission, noxious vapors, heats etc, as applicable.

3.5.8.2 Safety devices. The Test Stand shall be equipped with safety devices to adequately protect the operator from all hazards incident to its operation.

3.5.8.3 Protection against electrical shock. Protection against electric shock shall be incorporated. All front access panels and doors shall be furnished with electrical interlocks to remove power from the cabinets while panels or doors are open.

3.5.8.4 Safety related signage. Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the Test Stand, visible to maintenance personnel and permanently marked.

3.5.8.5 Noise level. Noise emitted by the Test Stand shall be no greater than 80 decibels measured at the operator’s location or three (3) feet from any point on the test stand whichever is closer. The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighting shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the Test Stand into conformance with this requirement shall not interfere with visibility needed for safe operation of the Test Stand.

3.5.9 Ergonomics. The Test Stand shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

3.5.10 Environmental compliance. The Test Stand provided under this contract shall meet all applicable Environmental Protection Agency (EPA) and Alabama Department of Environmental Management (ADEM) regulations and restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user’s health and shall be adhered to during the manufacture, service, transportation, storage and operation of the test stand.

3.5.11 Energy Efficiency. The Test Stand and its components that directly consume energy in normal operation shall be designed and constructed for energy efficiency in accordance with the developments available within the industry. Pneumatic circuits shall be designed for minimum air consumption.

3.5.12 System of units. All stimuli and measurements shall be entered and displayed in engineering units. Engineering units shall be from the U.S. Customary System of Units "English", and not Metric.

3.5.13 Nameplates. All words on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background. All plates shall be corrosion resistant. All plates shall be mechanically attached to the Test Stand – adhesive alone will not be considered sufficient to meet this requirement.

3.5.13.1 Test stand nameplate. The Test Stand shall a nameplate mechanically attached to the Test Stand – adhesive alone will not be considered sufficient to meet this requirement, and shall contain, at a minimum, the following information:

a. Nomenclature.

b. Manufacturer's name, Address and Phone Number.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Facility Circuit Breaker or Buss Duct Switch Location Reference Number

g. Short-circuit/over current rating.

h. Contract number.

i. National stock number (if applicable).

j. Date of manufacture.

3.5.13.2 Component nameplates. Laminated plastic nameplates shall be provided for equipment devices and panels furnished. Each nameplate shall identify the device as it is identified on the applicable schematic, such as pump "P-1" or valve "VLV-402". Laminated plastic shall be 1/8-inch-thick, white with black center core. Nameplates shall be a minimum of 1 by 3 inches with minimum 1/4-inch-high-engraved block lettering. Nameplates for devices smaller than 1 by 3 inches shall be attached by a stainless-steel chain or cable. All other nameplates shall be mechanically attached to the Test Stand or panel surface next to the device – adhesive alone will not be considered sufficient to meet this requirement. The nameplate shall remain in place, undisturbed, when a component is replaced.

3.5.14 Maintainability and interchangeability. The test stand shall be designed to maximize maintainability and interchangeability of component parts.

3.5.14.1 Maintainability. The Test Stand shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. Components with proprietary mechanical, electrical and communication interfaces shall not be used without government approval. When non-commercial off-the-shelf components are used the Contractor shall provide all documentation including any electronic files and a manufacturing source required for production of those components. The government shall have the right to produce these components for use by the government only. All replaceable components shall be designed and manufactured to such standards as shall permit replacement and adjustment without the need for modification of the components or the Test Stand. All replacement components shall be available domestically at the location of intended use.

3.5.14.2 Interchangeability. All components shall be manufactured to definite standards, clearances, and tolerances in order that any such parts of a particular type of model may be replaced, interchanged, and adjusted without modification of the replacement components or any other components of the test stand. All parts shall be marked per MIL-STD-130. The components manufacture and part number shall be used when the components is referenced in drawings, schematics and any other documentation.

3.5.15 Workmanship. Standards of workmanship shall ensure that the test stand shall have the stability, strength, safety, and efficient operating characteristics found in those test stands that are state of the art in the marketplace.

3.5.16 Tools. All tools, other than common hand tools, required for normal operation and maintenance of the Test Stand shall be provided.

3.5.17 Construction.

3.5.17.1 General construction. The Test Stand shall be so constructed as to be capable of performing the operations specified herein. All surfaces shall be clean and free of extraneous materials. External surfaces shall be smooth and free from sharp edges, rounded or beveled, unless sharpness is required for performance. All screws, pins, and similar parts shall be installed to prevent loss of tightness. Parts subject to adjustment or removal shall not be permanently installed or deformed. The Test Stand shall be constructed of parts, which are new, without defects, and free of repairs. The structures shall withstand all forces encountered during operation of the Test Stand to its maximum rating and capacity without permanent distortion or failure.

3.5.17.2 Materials. Materials shall conform to the applicable specifications and shall be as specified herein and on the applicable drawings. Materials which are not covered by applicable specifications or standards shall be of the best quality, and entirely suitable for the purpose intended. Materials that are nutrients for fungi shall not be used. Any material that is adversely affected by contact with Test Stand compounds shall not be used.

3.5.17.3 Corrosion resistance. The Test Stand shall be constructed of corrosion resistant material or material that is treated or coated to be corrosion resistant. Test Stand materials not specifically designated herein or in the contract shall be of a quality commensurate with commercial practice within the applicable machine industry. When dissimilar metals are used in contact with each other, suitable protection against galvanic corrosion shall be applied.

3.5.18 Lubrication. All bearings (except sealed-for-life type), mating gears, and sliding parts shall be provided with standard means for lubrication. Oil holes, grease fittings, and filler caps shall be accessible. Lubrication reservoirs, if applicable, shall have means for checking levels. Means shall be provided to ensure lubrication for all moving parts. Re-circulating lubrication systems shall include a cleanable or replaceable filter. Means for determining oil level in each reservoir shall be by an oil level sight gauge, a low oil level warning light or similar device and shall be in clear view of the operator's normal workstation. An automatic lubrication system shall be provided for all ways and axis screws. Each lubricant reservoir shall have at least a 24-hour capacity and means for determining fluid level. Any greases, oils, or fluids used to initially charge the lubricant system shall be free of contaminants known to be hazardous to human health.

3.5.18.1 Lubrication plate. A lubrication plate shall be attached to the Test Stand. The information provided on the plate shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of lubricant(s) with SAE number or lubricant identifier.

d. Viscosity

e. Federal or Military Specification Number (if applicable)

3.5.18.2 Lubrication points. Grease fittings conforming to ANSI AS35411 Fittings & Lubrication shall be provided in accessible positions not requiring removal of threaded fasteners at all necessary lubrication points. Pressure relief fittings shall be provided where use of high-pressure lubrication equipment could cause damage.

3.5.19 Drive train gears. The gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the Test Stand. Gears in the drive train shall be hardened and ground steel. Working surface hardness shall be not less than Rockwell C-48.

3.5.20 Castings and forgings. Castings shall be free of visible blowholes, porosity, hard spots, shrinkage, defects, cracks, scale, mismatching or other defects. Forgings shall be free of visible scale, inclusions, cold shuts, mismatching, or other defects. Mechanical and chemical properties of the castings and forgings shall be adequate to meet the performance requirements of this specification. No processes such as welding, peen, plugging, or filling with solder or paste shall be used for reclaiming any defective part. Such processes may be used only for enhancing surface finish and appearance.

3.5.21 Welding, brazing and soldering. Welding, brazing, and soldering shall be of a quality, which shall sustain the performance requirements of the welded, brazed, or soldered part. These operations, however, shall not be employed as repair measures for defective parts. Welding, brazing, or soldering shall be employed only where specified in the original design. Any material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations.

3.5.22 Painting. Unless otherwise specified painting and finishing of the Test Stand when allowed shall be in accordance with the best practice in the industry. Immediately prior to painting, surfaces shall be clean, dry, and free of foreign matter. The protective paint coating shall be not less than 2.0 mil in thickness. That paint adhesion shall be such that no paint shall be peeled by fiberglass tape, when two intersecting knife cuts expose the base metal for a distance of not less than two inches. The surface hardness of the paint shall be between the industrial standards of H and HB for pencil lead.

3.5.23 Recovered materials. The Contractor is encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

3.6 Acceptance.

3.6.1 Preliminary performance test. Preliminary performance testing is not required by this specification.

3.6.2 Conformance. The Test Stand shall meet the requirements of this specification and conform to the manufacturer’s own drawings, specifications, standards, and quality assurance practices. The Government reserves the right to, at any time during the contract period, require proof of such conformance or to inspect the Test Stand to determine compliance with the requirements of this specification.

3.6.3 Calibration. The Contractor shall verify Test Stand calibration for using the calibration procedure and test equipment provided with the Test Stand. The Contractor shall not proceed with calibration until the Contracting Officer's Representative (COR) confirms that installation is complete and meets all related requirements herein. The Contractor shall provide all resources, equipment, and instruments required to perform Test Stand calibration. All equipment and instrumentation used to calibrate the Test Stand shall be traceable to the National Institute of Standards Technology (NIST). Test Stand calibration shall be witnessed and verified by ANAD calibration and engineering personnel. Training for ANAD calibration personnel shall be provided during calibration (see requirements of 7.0).

3.6.3.1 Certificate of calibration. Upon completion of Test Stand calibration, the Contractor shall provide a certificate of calibration stating the date of calibration, recommended date for next scheduled calibration, and NIST traceability information for the calibration equipment/instruments used. The certification shall also include the nomenclature, part/model number, and serial number of the Test Stand and shall be signed by the Contractor.

3.6.4 Final performance test. Final performance testing will take place at Anniston Army Depot upon completion of installation and calibration. The Contractor shall demonstrate the gymnasticators ability to meet the requirements of the applicable test specification. The Contractor shall demonstrate proper operation of all gymnasticator controls, functions, and features. The Government will provide the gun mounts to be tested and any consumables required to prepare the gun mounts for test. All tests must be witnessed and by the COR. Should a malfunction or test stand failure occur during any test, the Contractor will correct the problem and repeat the entire test from the beginning. The COR will verify the accuracy of all stimuli, measurements and results meet the requirements of this specification and the applicable test specification.

3.6.5 Final acceptance. Final acceptance of the test stand will take place at Anniston Army Depot. The Government will accept the Test Stand only after the Contractor successfully completes the requirements of paragraphs 3.6 including subparagraphs and provides all training and documentation required herein. Final acceptance will be at Anniston Army Depot.