Attachment 2 -Statement of Work.pdf

Attachment 2

STATEMENT OF WORK (SOW)

AUTOMATIC WIRING ANALYZER (AWA)

70Z03820QE0000041

1.0 General

1.1 Background

The United States Coast Guard (USCG), Aviation Logistics Center (ALC) provides Programmed Depot Maintenance (PDM) and Heavy Maintenance support for various USCG Maritime Rescue Aircraft. This support includes major aircraft electrical-wire-interconnect-system (EWIS)/avionic assemblies and sub-assembly inspection, repair, upgrade/modification, and/or replacement. After repairs or modifications have been made, verification of installation conformance and proper configuration management are paramount. Testing of the entire EWIS system/assembly for proper component operation and condition before applying electrical power is vital for component and operator safety and proper systems operation.

The preferred method of testing is the use of an Automatic Wiring Analyzer (AWA). The AWA is capable of quickly, accurately and consistently testing the entire aircraft wiring systems much faster and more completely than manual testing. The AWA can test the entire aircraft wiring systems in a matter of minutes compared to hours/days for manual testing. Additionally, once programmed, the AWA performs the same tests on every subsequent test-run which is vital to maintaining proper configuration management. The AWA can collect, print and store failure data for future trend analysis. A single, scalable, distributed switching, random adapter hook up AWA with the proper adapter cable libraries is ideal for meeting the needs for each aircraft type maintained by the ALC.

1.2 Scope

The USCG requires a commercially available Drive In Theatre Maintenance Company (DIT- MCO) 2650 Modular Test Analyzer (MTA), Distributed Switching, Random Hook-Up capable, AWA with zero insertion force (DL1-156 or equivalent) front panel connectors for testing the airframe wiring harnesses for the MH-60T aircrafts.

1.3 Required Product

1.3.1 The AWA must perform, at a minimum, insulation resistance, breakdown and leakage measurements; circuit continuity, discontinuity, and resistance measurement; Alternating Current (AC) and Direct Current (DC) voltage measurements; capacitance measurements, diode forward/reverse bias tests, Zener diodes tests, Light Emitting Diode (LED) operation, potentiometer value measurements, and AC Dielectric (HIPOT) testing.

1.3.2 The AWA must incorporate Latching Matrix (LM) type switching cards capable of breaking a test circuit and injecting programmed AC or DC voltages (section 1.3.5) into the Unit-Under-Test (UUT) to energize/operate components such as relays, blowers, fans, lights, etc.

The AWA must be capable of performing tests listed in section 1.3.1 using other test points concurrently while injecting programmed voltages on the LM test points. These cards must have a front panel connection visually different from standard switch modules/card connections. Each switch module must include a minimum of ten (10) LM points in addition to the total number of switching points.

AUTOMATIC WIRING ANALYZER (AWA)

1.3.3 The AWA must be capable of running all test programs, specifically DITMCO NexGen Electrical Test Suite (NETS™), currently in use at the ALC without modification or conversion.

The system must be able to perform all custom test applications and utilities in current operation that were developed around the unique hardware and software architecture of the current AWA in use without manual intervention by the operator or the programmer. Must be able to run test program files written in NETS™ conventional addressing schemes and/or written in product (reference designator) language.

1.3.4 The AWA software must allow for ongoing modification of current DITMCO NETS™ tests and for local development of new test programs by original equipment manufacturer (OEM) trained USCG ALC Automatic Circuit Analysis Test Systems (ACATS) Programmers. The AWA’s operating systems must include a manual mode for use of an operator handheld test probe(s) to test one specific circuit. The AWA’s operating systems must include self-contained test program file editor.

1.3.5 The AWA must include both a programmable (automatically controlled via the test program) variable AC power source capable of providing 0 to 240 VAC, 60 to 400hz at 5 ampere (Amps) or greater and a programmable (automatically controlled via the test program) variable DC power source capable of providing 0 to +/-120 VDC at 5 Amps or greater.

1.3.6 The AWA must run current AWA test program files that include IEEE/GPIB/VIRTCOMP or equivalent software commands that operate programmable/remote controllable power supplies (section 1.3.5).

1.3.7 The AWA must have Ethernet interface to a USCG ALC supplied computer system (computer, monitor, keyboard, mouse, etc.) for operations. Must be capable of operating via a remote wireless electronic tablet type device.

1.3.8 The AWA system software must be capable of down-loading test files from a main-frame server, operating independently, and then up-loading test result data to the main-frame server at the conclusion of the testing. The AWA’s operating systems must be able to import test program files generated off-station, without requiring manual or automatic conversions/alterations. Must protect test program files from operator modification by having the option to use password or authority protection services. Protected test program files must run directly on the AWA.

1.3.9 The AWA must include a test results data storage program that can be sorted, used to generate failure and condition trend reports. Data stored must include circuit end points, test results value, causal noun and verb, correction noun and verb, failure zone location, repair man-hours, repair component, product identification (ID), operator ID, test start date, test end date and operator notes. Must automatically archive all selected test data onto the local or ALC ACATS network server hard drive. Must provide test data retrieval that allows archived or most recent test data to be printed or saved to a USCG/ALC approved storage medium such as the ALC ACATS server hard drive, encrypted portable hard drive or memory stick, compact disk (CD), and/or digital video disk (DVD).

AUTOMATIC WIRING ANALYZER (AWA)

1.3.10 Must provide test report options that allow the operator to print and/or store all test/failed-test data. Must provide clear and informative real-time feedback display of the test parameters, test status, test results and errors. Must provide a dwell-time-bypass mode that will complete the test as soon as a pass condition occurs and the minimum dwell time has elapsed.

Must provide built-in self-test that isolates analyzer failures to locally replaceable modules or printed circuit cards. Must be able quantize and print all detected test errors with all test information reported to the operator when directed by the operator.

1.3.11 Software must include provisions for an interactive library of connectors, wire lists, and cable inventories to provide build instructions, reference drawings, bills of materials and cable labeling.

1.3.12 The AWA must be capable of sampling the UUT’s environment temperature and humidity, automatically import readings into each test run and be usable for automatically selecting the appropriate test parameter set without operator intervention or input.

1.3.13 The AWA must be useable immediately after movement. They shall not have any requirement for calibration/resetting after being moved into the use position. Any calibration verification/calibration shall be performance/time based not movement/hook-up based.

1.3.14 The AWA may include a calibration verification program and any specialized tools or equipment necessary to complete the verification. If included, local operators must be able to perform an automatic calibration verification using vendor supplied calibration verification tools if necessary. The operators shall not be required to make any adjustments to potentiometers, measurements with external instruments, or adjustments of any method. The process must take less than five (5) minutes. The tester must not require a calibration verification schedule frequency of more than current AWA’s once every three (3) months.

1.3.15 Out-of-calibration testers must be made capable by either local adjustment by trained ALC ACATS Section personnel or by module/printed circuit board replacement. The suspect modules/printed circuit boards shall then be returned to the OEM for calibration or repair.

1.3.16 The AWA must have random hook-up capabilities for all Test Adapter Cables (TACs) to the tester modules. Accessories need to provide local capabilities for programming TAC IDs must be included. The Random Hook-up language must be compatible with current language being used on legacy testers.

1.3.17 The AWA shall include a one-time-purchase Lifetime-Site license for unlimited USCG ALC programmer and operator terminals at the USCG ALC sites. Lifetime software revisions and patches must be included with license.

2.0 Applicable Documents Required

Provide at a minimum an electronic copy of all current and new OEM Operator Manuals, Component Maintenance Manuals (CMMs), revisions, specifications, service bulletins, AUTOMATIC WIRING ANALYZER (AWA) amendments, modifications and any other documentation necessary for the ease of maintenance and operation of the AWA throughout the lifetime of the product. The vendor shall provide updates as they become available.

3.0 Requirements

3.1 AWA Requirements

3.1.1 Unless otherwise specified, the AWA must meet or exceed the performance characteristics of the current AWAs, models DITMCO 2650, 2524, 2135 and 2115 currently in use at ALC. In addition, each AWA must meet the following minimum requirements:

a. Have a minimum of 25,000 total separate test points each, each expandable to 100,000, connected simultaneously and capable of meeting or exceeding the requirements specified in Table 1.

b. Must be able to make low resistance (4-wire Kelvin) measurements of < 0.100 ohms.

c. Must be able to simultaneously run bulk scans when programmed.

d. Must be able to detect momentary (10 microseconds or longer) breakdowns or arcs in the UUT. If current exceeds a programmed limit, the dielectric test must fail even if the current returns to normal prior to the completion of the test.

e. Provide an option for providing high current/constant current testing of items such as circuit breakers and current sensing relays, etc.

3.1.2 The AWA main control unit and the programmable power supplies must be completely contained within a mobile (lockable casters, one-person movable) cabinet/cart. All distributed switching unit cabinets must be self-contained (one-person-moveable) and require no external operating voltages other than those provided by/through the main control unit and the control tether cable. Units must be moveable without requiring any calibrations or adjustments before usage and/or after movement.

3.1.3 The system must be designed in such a manner as to allow strategic placement of individual tester switch modules in locations in or around the aircraft in order to minimize TAC lengths.

3.1.4 The entire AWA system must operate with input power of a single power outlet source.

3.1.5 The AWA must operate without accuracy fluctuations within all temperature and humidity conditions found in both environmentally conditioned and unconditioned spaces, such as open aircraft hangars and air conditioned/heated avionics repair shops. Humidity levels may reach 100% with occasional surface condensation occurring.

3.1.6 The design and construction must be in accordance with best industry practices at the time of manufacture. All components must be current technology and currently available.

3.1.7 All components/modules must be self-cooling.

AUTOMATIC WIRING ANALYZER (AWA)

3.1.8 Protective devices must exist to protect the user and AWA from undesirable or abnormal conditions. The following protective devices must exist as a minimum:

a. User actuated Emergency Stop switch prominently positioned.

b. A conspicuous warning beacon light that automatically activates during high voltage testing.

3.1.9 All components must be firmly attached and secured to/within its assigned cabinet at all times.

3.1.10 Must comply with Federal Communications Commission (FCC) Electromagnetic Suppression regulations applicable at the time of manufacture.

3.1.11 Test programs must be locally developable and modifiable by USCG personnel.

3.1.12 The systems must be designed to allow for simplicity of operation by locally trained

USCG operators without requiring specialized computer skills.

3.1.13 If the system utilizes a programming and/or operating software that different from the current software, vendor must include a class at the USCG site to a minimum of five (5) USCG ALC ACATS Section Programmers/Maintainers. The class shall include Basic and Advanced Programming as well as equipment maintenance.

3.1.14 If the system utilizes a programming and/or operating software that different from the current software, vendor must include a class at the USCG site to a minimum of ten (10) USCG ALC ACATS Operators. The class shall include Basic and Advanced Operation skills.

4.0 Contract Information

4.1 Free on Board (F.O.B.) Point

The F.O.B. point for shipments under this contract is F.O.B. Destination. F.O.B. Destination - Prices in the schedule include all applicable customs, duties, taxes and shipping charges;

therefore, no additional charges for shipping will be allowed unless a bilateral modification is completed.

4.2 Packaging, Handling, Shipping and Transportation

The offeror shall ship the DIT-MCO AWA under the manufacturer’s standard commercial practice.

4.3 Marking Instructions

All shipping containers/packages shall be marked for delivery IAW with the Purchase Order.

All components, which require special care during packing, handling or shipping shall be identified and marked appropriately. The exterior of the package or shipping container shall be

AUTOMATIC WIRING ANALYZER (AWA)

legibly marked with the following information in such a manner that the marking shall not be rendered illegible when opened.

NSN

Part Number Nomenclature Serial Number Purchase Order/Line Item Number Contractor’s Name and Address

4.4 Inspection and Acceptance

Inspection and acceptance under this contract shall be performed at destination by USCG ALC ACATS personnel and consist of count, condition and compliance with the purchase order. Full and clear traceability to the original equipment manufacturer (OEM) must be provided with delivery of each item. If full and clear traceability is not provided, the USCG will not accept delivery of the item and invoice may not be approved for payment. Inspection and acceptance deficiencies may delay or cause rejection of invoice payments.

5.0 Delivery and Installation

5.1 Delivery Requirements

Items ordered under this contract will be ordered by and delivered to the USCG/ALC in Elizabeth City, NC.

USCG Aviation Logistics Center Receiving Section, Bldg. 63 1664 Weeksville Road Elizabeth City, NC 27909-5001 Purchase Order Number (to be determined at time of issuance)

The contractor must pack, ship, unpack, assemble, and inspect the AWA at their final delivery point in Elizabeth City, NC.

5.2 Setup and Startup

Following assembly, the contractor must verify proper operation of each entire AWA system, i.e.: unit must be able to perform a complete self-test and calibration verification, at a minimum.

5.3 Demonstration and Familiarization

5.3.1 Following setup, the contractor must demonstrate all performance characteristics required by this SOW. The contractor must provide a copy of any completed written demonstration printout noting successful operation of all capabilities and a printout of any test runs and calibration values.

AUTOMATIC WIRING ANALYZER (AWA)

5.3.2 Following demonstration, the contractor must perform on-site operation, maintenance and calibration familiarization for up to six (6) ALC ACATS Section Programming/Maintenance personnel.

6.0 Warranty

The contractor must provide a minimum one (1) year warranty for all parts, travel, and labor and guarantees the AWA to be 100 percent operational within 48 hours following government notification of a fault. Warranty period will begin at the time the AWA is accepted (date Government signs the vendor invoice) by the Government.

7.0 Invoicing

7.1 Invoicing Instructions

The Contractor’s invoice shall be submitted IAW FAR 52.212-4 to the designated billing office for payment as noted below. The invoice shall include the purchase order number, contract line item number (CLIN), CLIN description, quantity, unit price, and extended price. The offeror shall also submit copies to the Contract Specialist. The Contractor is HIGHLY encouraged to submit invoices electronically to ALC-Fiscal@uscg.mil.

Chief, Fiscal Branch

USCG ALC

Fiscal Branch, Bldg. 63 1664 Weeksville Road Elizabeth City, NC 27909 Purchase Order Number: (to be determined at time of issuance)

7.2 Payment Information

All payments will be made electronically IAW FAR 52.232-33. The contractor may submit invoice five (5) days after shipment of items. The invoice will not be approved until all items have been receipted.

AUTOMATIC WIRING ANALYZER (AWA)

PERFORMANCE SPECIFICATIONS

TABLE 1

STIMULUS

SOURCE RANGE ACCURACY

Low DC Voltage 0.2 to 30 V ±5% or better High DC Voltage 30 to 2000V ±5% or better

Constant DC Current 0.005 to 2.0 A ±5% or better

CONSTANT CURRENT RESISTANCE MEASUREMENTS

STIMULUS (AMPS DC) RANGE (OHMS) ACCURACY

0.1 to 2.0 (Minimum range) 0.1 to 99.9 M Minimum ±1% or better

0.1 to 0.975 (4-Wire only) 0.1 to 999 Minimum ±2% or better

1.0 to 2.0 (4-Wire only) 0.01 to 0.0999 Minimum ±1% or better

CONSTANT VOLTAGE RESISTANCE MEASUREMENTS

STIMULUS (VOLTS DC) RANGE (OHMS) ACCURACY

0.1 to 2000 up to 5 G minimum ±10%

DIELECTRIC DETECTOR

STIMULUS LIMITS (AMPS) ACCURACY

250 to 2000 DC in 2 V steps 0.5 to 2.5 Amps Minimum Range ±20% or better

VOLTAGE MEASUREMENTS

DC VOLTAGE (VOLTS) ACCURACY AC VOLTAGE (VOLTS) ACCURACY

0.01 to 0.990 ±10% ± 10 mV 1 to 9.99 ±15% or better 1 to 9.99 ±5% ± 10 mV 10.0 to 99.9 ±15% or better

10 to 99.9 ±5% ± 100 mV 100 to 500 ±10% or better 100 to 1500 ±5% ± 1V

CAPACITANCE MEASUREMENTS DWELL TIMES

RANGE ACCURACY RANGE (SECONDS) ACCURACY

10 to 999.9 pf ±10% +10 pf 0.1 to Unlimited ±2mS ± 1 conversion 1 to 9.999 nf ±5% +50 pf

10 to 999.9 nf ±2% + 100 pf 1 to 5000 µf ±5%