BPSC Statement of Work.pdf

A r g o n n e N a t i o n a l L a b o r a t o r y | 9 7 0 0 S . C a s s A v e n u e | L e m o n t , I L 6 0 4 3 9

Bipolar Power Supply Controller

APS-U Document #: WBS Number:

U2.03.03.03.05.02

Revision:

ICMS Content ID:

APS Upgrade Point of Contact (POC): Byron Jordan Responsible Institution: Andrews Technologies Inc.

Responsible Institution POC: Tim Kostelancik Period of Performance: Dec 2024

Abstract The APS-U Project is building a new storage ring that requires 200 Bipolar Power Supply Controllers (BPSC). This document outlines details and requirements related to the fabrication, testing, delivery, and acceptance of BPSC units.

Statement of Work APS Upgrade

APS-U Bipolar Power Supply Controller Statement of Work

Table of Contents

1 Introduction

1.1 Scope

1.2 Documents and Specifications

2 Deliverables

2.1 BPSC Production Schedule

2.2 Long Lead Time Parts

2.3 Reports and Documentation

2.3.1 Initial Project Meeting

2.3.2 Monthly Progress Reports

2.3.3 Individual Unit Reports

3 Quality Assurance and Inspection

3.1 Quality Assurance

3.2 Inspection and Factory Acceptance Tests

3.3 Test Results and Certificates

4 Fabrication Standards

5 Packaging and Shipping

6 APS-U Acceptance Tests

7 Attachments

Revision Table

Revision Date Reason 0 12/01/2024 Original

1 Introduction

1.1 Scope

The Advanced Photon Source Upgrade Project (APS-U) is planning a storage-ring upgrade that will reduce the electron-beam emittance by a factor of ~75. This ultra-low emittance is achieved by replacing the present storage ring lattice with a multi-bend achromat (MBA) lattice. The MBA lattice will increase the x-ray coherent fraction by two orders of magnitude and decrease the horizontal source size by a factor of ~20.

This new MBA lattice contains 200 Bipolar Power Supply Controllers (BPSC). The design of BPSC is the responsibility of APS-U. The contractor will produce six (6) more BPSC (turn key) units based on prints and technical documents provided by APS-U and deliver the qualified BPSC units according to this Statement of Work.

The contractor is responsible for fabrication, quality control, test, documentation, and delivery of BPSC with their test and measurement results.

All components are to be fabricated from released drawings and the corresponding 3D models. All notes and recommended procedures on drawings and in travelers shall be read and understood by the contractor prior to fabrication. Any proposed change must be documented and be approved by APS-U using an APS Upgrade Supplier Disposition Request before implementation.

The design, drawings, 3D model, and procedures are proprietary. The contractor shall not share APS-U , 3D model, and procedures with other buyers. The contractor shall not use APS , 3D model, and procedures in their own production.

1.2 Documents and Specifications

APS-U will provide the following documents and specifications for the manufacturing of the BPSC.

1) Mechanical drawings including front and back panel designs for the chassis

2) Gerber files of each PCB

3) Bill of Materials for each PCB

4) Firmware that will be programmed on SD cards

5) Bill of Materials for the chassis

6) BPSC Supplier Test Procedure

2 Deliverables The new storage ring required 200 BPSC installed in the storage ring with 5 extra units stored as overage. The APS-U will require six (6) additional units. Three (3) units will be installed, while the remaining three (3) will be added to the existing overage. Therefore, the contractor shall deliver six (6) more BPSC units in total.

2.1 BPSC Production Schedule

BPSC Weeks Week # Min Units Total Units Contract Award 0 0 Delivery 17 14 6 6

Table 1 BPSC Production Schedule

The delivery is due seventeen (17) after issuing of the contract award. Faster delivery may be permissible and is encouraged provided prior permission is granted and quality is not sacrificed. APS-U shall finish all BPSC testing.

2.2 Long Lead Time Parts

One component of the design, the MitySOM module (5CSX-H6-42A-RC) from Critical Link, is known to have a long lead time because large quantities are only produced when ordered. Therefore, once the contract is awarded, the contractor shall immediately place an order for the full quantity of this component. APS-U shall include a step payment to cover the cost of this individual component. Procurement of

2.3 Reports and Documentation

The following documents and reports are to be provided by the contractor at the following stages during the project.

2.3.1 Initial Project Meeting

The contractor provides schedule for project consistent with above milestones Manufacturing plan

2.3.2 Monthly Progress Reports

Monthly progress reports shall be submitted to the APS-U technical point of contact by the contractor. These reports may be a bullet list in an email that details the manufacturing progress.

2.3.3 Individual Unit Reports

Measurements and test results for the finished assembly of each BPSC unit shall be recorded on a Vendor Traveler form and shall be provided with each BPSC unit being delivered. Digital records in PDF format are acceptable and shall be provided at least two days before the unit is shipped. The design of the Vendor Traveler Form shall be reviewed and approved by APS-U before use.

3 Quality Assurance and Inspection

3.1 Quality Assurance

The contractor shall adhere to all quality control requirements as specified in this document and the accompanying Quality Assurance Procurement Requirements Form (ANL-407). Any deviations or changes to the requirements of these documents shall be reported to APS-U.

For traceability, the contractor shall have a mechanism, a serial number for example, to identify each unit. If the serial number mechanism is used, the serial number shall be included on the rear panel of the chassis.

3.2 Inspection and Factory Acceptance Tests

The contractor shall perform the tests specified in the following document and attach the test results to each unit:

BPSC_VendorTestProcedure.docx

APS-U reserves the right to inspect all materials and parts used for completion of this contract and to observe all factory tests. In addition, the APS-U reserves the right to visit physically, or virtually if necessary, the contractor during the fabrication period at mutually agreed upon dates.

3.3 Test Results and Certificates

The BPSC shall be fully tested prior to delivery to APS-U. The test results must demonstrate that each BPSC meets all specifications described in the test procedure.

All tests must be properly recorded, and the results submitted to APS-U. These reports shall contain the signature and title of the authorized personnel who perform the tests and measurements. The data submitted shall also be transmitted in electronic PDF format to the APS-U technical representative. Any non-conformances during the manufacturing process must be reported to the APS-U QA representative within 72 hours.

4 Fabrication Standards BPSC shall be constructed in a neat and workmanlike manner and shall meet or exceed Class 2 criteria in the following IPC Standards:

Acceptability of Electronic Assemblies (IPC-A-610D) Requirements & Acceptance for Cable and Wire Harness Assemblies (IPC-A-620)

Acceptability of Printed Boards (IPC-A-600F) Generic Standard on Printed Board Design (IPC-2221) Sectional Design Standard for Rigid Organic Printed Boards (IPC-2222) Guidelines for Printed Board Component Mounting (IPC-CM-770E) Component Packaging and Interconnecting with Emphasis on Surface Mounting

(IPC-SM-780)

5 Packaging and Shipping Proper packaging to ensure that deliverables are not damaged during shipment is the responsibility of the contractor. All BPSC should be properly packed before shipping.

BPSC shall be fully assembled and packed in boxes. All boxes should have a shock indicator attached. The shipping boxes shall be loaded onto a pallet so that it can be moved using standard handling devices such as a forklift or pallet jack.

Damaged shipments are likely to be rejected by the ANL Receiving Department and be returned to the contractor. Packaging should be suitable for long-term storage of the controllers in a warehouse environment.

The BPSC shall be covered and wrapped to protect it from moisture and dust within the shipping boxes.

Each shipment box shall be labeled on the outside with the information shown below:

APS-U BPSC

Quantity Recipient: Argonne National Laboratory, Advanced Photon Source Upgrade Address: 9700 S. Cass Avenue, Lemont, IL 60439 Gross weight of each shipment box Conspicuous arrows to indicate its upright position

All BPSC shall be shipped to Argonne National Laboratory or an offsite location to be specified by APS-U later.

6 APS-U Acceptance Tests APS-U will conduct incoming inspection on 100% of delivered units.

APS-U will conduct functional testing on 100% of delivered units.

APS-U will conduct performance testing on 10% of delivered units.

The qualification tests APS-U will perform are listed below:

Inspect for shipping damage Visual inspection (rust, hardware markings, paint, de-lamination, etc.)

Functional Test

a. Front Status LEDs

b. Local Reset

c. DAC Module Analog Output to Power Supply

d. ADC Module Analog Input from Power Supply

e. DIO Module Power Supply Status and Control

f. SPI Connectivity with BPECMS

g. Ethernet Connectivity

Performance Test

a. Accuracy

b. Reproducibility

c. Stability

If a unit fails the functional or performance test, APS-U shall perform diagnostics and determine the cause of the failure. If APS-U determines the failure is due to manufacturing issues, either quality of the production or quality of the components, APS- U shall notify the contractor and decide if the unit needs to be returned to the contractor for repair or replacement.

7 Attachments [1] Contractor Test Procedure [2] Traveler for APS-U BPSC [3] Assembly Instruction Package [4] APS-Upgrade Project Procurement Quality Requirements Form (APSU ANL-407) [5] APS-Upgrade Project Supplier Disposition Request form