DRAFT_Statement_of_Work_(SOW)_Interface_Test_Adapter_(ITA)_for_B-2_Test_Program_Set_(TPS).pdf

ITA STATEMENT OF WORK

FOR

B2 TPS DEVELOPMENT

76th Software Maintenance Group

Tinker AFB, OK 73145

16 October 2015

1. INTRODUCTION

1.1 Organization.

1.1.1 Identification.

AFSC/OC-ALC/76th SMXG/556th SMXS, Oklahoma City Air Logistics Center, Department of the Air Force, Tinker AFB, OK.

1.1.2 Mission.

OC-ALC is responsible for the maintenance, repair and support of the US Air Force bomber and tanker aircraft and engines. The B-2 Bomber Software Squadron (556th SMXS), hereafter referred to as the Government, is responsible for development of hardware and software components of the Test Program Sets (TPSs) for repair of electronics in depot level (D-Level) Shop Replaceable Units (SRUs) and Intermediate Level (I-Level) Line Replaceable Units (LRU). These TPSs are used with state-of-the-art automatic test systems to accurately and efficiently detect and diagnose electronic component failures.

1.2 Background and Objective.

1.2.1 Background.

The B-2 Bomber and other strategic aircraft/systems employ state-of-the-art electronics and information systems technology. The Government develops test programs and test program interfaces to test the component subsystems. The requirements of these tests and the Automatic Test Equipment (ATE) dictate the design and acquisition of high quality, reliable test adapters.

1.2.1.1 The following document is applicable to this SOW: Product Requirement Specification

1.2.2 Objective.

This effort provides the Government with the critical engineering designs and assembled ITA hardware needed to develop the Test Programs. Based on a review of Government Furnished Information (GFI), this effort will result in the development of a manufacturing design package needed to build and assemble each Interface Test Adapter (ITA) and it will also result in the fabrication and assembly of the ITAs using Government furnished and Contractor purchased materials. The Government will review this design and accept the hardware copy to be used in developing the TPS for the associated Air Force weapon system.

1.3 Teleprocessing.

The Contractor shall deliver documents and reports for Government review and approval electronically. The Contractor shall utilize AMRDEC SAFE for all electronic deliveries. The Contractor shall have the capability to participate in voice teleconferences and video-teleconferences as required.

1.4 Performance.

Certification by the Government of satisfactory performance is contingent upon the Contractor performing in accordance with the terms and conditions of this document, the approved technical and cost proposal, and all amendments. Normally the Government and the Contractor's representative(s) will meet telephonically to review performance.

2. TECHNICAL REQUIREMENTS

2.1 Task Description.

Deliverables will be requested and controlled by means of specific objectives and constraints. Deliverables to be performed will be within the scope of work as follows:

2.1.1 Scope of Work.

This task encompasses the engineering and technical services required to design and fabricate ITAs that will interface mechanical, electrical, and optical interconnections between a Unit Under Test (UUT) and ATE to allow execution of the test program. This effort will involve LRU ITAs. The Contractor shall design, fabricate and deliver all ITAs in accordance with the ITA Product Requirement Specification for B-2 TPS Development and the associated ITA Design Package.

The Contractor shall review the GFI and develop the manufacturing design package needed to build each ITA. Based on Government approval, the Contractor shall then use this design package to build and assemble the ITA using Government furnished and Contractor purchased materials for delivery to the Government. For each ITA, the Contractor shall execute the tasks defined in

2.1.2 below.

2.1.2 Statement of Work

2.1.2.1 The Government will provide Air Force drawings numbers within ten business days of contract award.

2.1.2.2 The Contractor shall develop manufacturing design drawings in sufficient detail to build and assemble ITAs and to allow re-procurement of ITAs in accordance with MIL-STD-31000A paragraph 5.3.1.3. The design will require Production Level III Technical data packages.

2.1.2.3 The Contractor shall submit a Preliminary Design Review (PDR) Package (CDRL A001). The Contractor shall identify any concerns about the Government’s design requirements in the PDR package.

The PDR submission shall also include a detailed project schedule with key milestones and resources assigned to this ITA. (CDRL A001, CDRL A002).

2.1.2.4 The Government will provide access to an actual UUT for mechanical design and form/fit. The UUT will be shipped via DD1149. The Contractor shall observe standard electro-static damage (ESD) precautions when handling the UUT.

2.1.2.5 Finalization of ITA designs shall be done at the Critical Design Review (CDR). The CDR shall be held in person or via voice or video teleconference. In either case, the Contractor shall document the results of the CDR. The Contractor shall NOT begin fabrication of the ITA until approval of the design. The Contractor shall produce CDR minutes and presentation material (CDRL A001, CDRL A003, CDRL A004).

2.1.2.6 The Contractor shall fabricate the first copy of the ITA based upon the approved CDR design. The Contractor shall, with concurrence of the Government, correct and modify the mechanical design during fabrication and assembly to correct design issues. The Contractor shall deliver the ITA, along with a copy of any redlined drawings to the Government (CDRL A001).

2.1.2.7 The Contractor shall deliver an Acceptance Test Procedure (ATP).

The Government will approve the ATP before use by the Contractor (CDRL A005).

2.1.2.8 The Contractor shall conduct an Acceptance Test IAW the approved ATP. The Government reserves the right to witness any acceptance test.

2.1.2.9 The Contractor shall deliver an Acceptance Test Report for all ITAs

(CDRL A006).

2.1.2.10 The Government will check and verify the ITA hardware against the design package, for form/fit with the UUT and ATE and the ITA Product Requirements Specification. Products shall be 100% error free and meet stated tolerances of drawing and specifications. The Government will notify the Contractor of any mechanical design or fabrication issues discovered during acceptance testing.

2.1.2.11 The Government shall have up to 180 working days from the delivery of the initial copy of the manufactured hardware to discover any electrical or mechanical design deficiencies. During that time, the Government will be integrating the ITA with rest of the TPS and ATE. This integration activity will drive changes to the electrical and mechanical design. The Government shall document design changes, and submit the changes to the Contractor for incorporation into the drawing package. The contractor shall incorporate the design changes into the TDP (CDRL A001).

All design changes specified by the Government shall be incorporated prior to delivery at no additional cost to the Government. The Government will provide approval for the updated TDP.

2.1.2.12 The Contractor shall fabricate and deliver the two remaining ITAs based on the updated and approved TDP. The Contractor shall deliver an updated copy of the TDP (CDRL A001).

2.1.2.13 The Contractor shall participate in program activities, meetings, teleconferences, and discussions. The Contractor shall assist in the preparation of briefing materials and meeting minutes as required.

2.1.2.14 The Contractor shall submit Monthly Status Reports to the Government (CDRL A007).

2.1.2.15 The Contractor shall deliver three ITAs in accordance with SOW paragraph 2.1.2.6 and 2.1.2.8 to the following address:

Tommy Vo 7532 Joint Star Drive Bldg 9001, Post S54 Tinker AFB, OK 73145-8845

(P) (405)-582-5058

TOMMY.VO@US.AF.MIL

The Contractor shall ship the ITAs with a cover letter on the prime Contractor’s letterhead, describing the contents. The Contractor shall notify the Delivery POC above and Administrative POC via e-mail when items ship.

The Contractor shall provide the tracking number for the shipment in the e-mail.

2.2 Deliverables.

All deliverables must meet commercial and professional standards and the requirements set forth in contractual documentation. The Contractor shall deliver all end items specified. The following items are deliverables that fall within the scope of this task.

2.2.1 Contract Data Requirements List.

CDRL Number DID Number DID Title

A001

DI-SESS-81000E

Product Drawings, Models and Associated Lists

A002 DI-MGMT-80507C Project Planning Chart A003 DI-ADMN-81250A Conference Minutes A004 DI-ADMN-81373 Presentation Material A005 DI-NDTI-80603A Test Procedure A006 A007

DI-NDTI-80809B

DI-MGMT-80368A

Test Inspection Report Status Report

2.2.2 Criteria for Acceptance.

Specific criteria for acceptance of deliverables will be as follows, the Contractor shall ensure the delivered ITAs meet the requirements of the applicable Government provisions as outlined in the ITA Product Requirements Specification.

A requirement analysis matrix will be used to 1) identify the source of all requirements, 2) show how those requirements are evaluated (the acceptable methods include inspection, analysis with back up data, demonstration, or test) and, 3) the test parameters used to verify the results. Government approval and acceptance will be documented on the matrix.

3.0. GOVERNMENT FURNISHED PROPERTY AND SERVICES.

3.1. Government Furnished Property (GFP).

In Accordance With (IAW) FAR 45.107(a)(1)(iii), the Government Property Clauses are not required when the cumulative acquisition cost of the GFP is less than the Simplified Acquisition Threshold (SAT) $150,000 and contracts or modifications are awarded under FAR Part 12. However, the Contractor shall comply with the contract terms and conditions which includes this SOW. The Contractor shall ensure all GFP is secured at the close of each workday. The Government retains title to all GFP, until the Government properly disposes of the GFP as authorized by law or regulation. This GFP shall not be used for the performance of any other contract. The GFP is identified in the Schedule Government Furnished (SGFP) Attachment 3, Appendix B.

3.1.1. Shipment to Contractor’s Facility.

The Government will package and ship the GFP to the Contractor's facility, Free-On-Board (FOB) Destination, (Government’s expense).

3.1.2. Return Shipment to Government.

When applicable (e.g., GFP not incorporated into deliverable on contract), the Contractor shall package and ship the GFP to the Government, FOB Destination (Contractor’s expense) to the Administrative Point of Contact (POC) cited in SOW 4.1. Within eight (8) work hours of GFP shipment, Contractor shall provide the shipment date and tracking information via e-mail to the Administrative POC.

3.1.3. Loss of Government Property.

3.1.3.1. The Contractor’s off-site liability for the Government Property shall begin when the GFP is delivered to the Contractor’s site, FOB Destination (Government’s expense). The Contractor shall remain liable for this GFP until the return shipment/delivery is received by the Government, FOB Destination (Contractor’s expense).

3.1.3.2. Since the GFP is less than the Simplified Acquisition Threshold (SAT) $150,000, the Government will use the Report of Survey (ROS) to process Loss of Government Property incidents/accidents.

3.1.4. GFP Identification Labels.

When applicable, the Contractor shall clearly label (without damaging) Government Furnished Property to distinguish it from Contractor Furnished Property, in accordance with the contract terms and conditions and this

SOW.

3.1.5. GFP Inventory, Records, Reports, Repair, and Disposal.

The responsible Government Organization, 556 SMXS/MXDPBA, for the GFP will be responsible for GFP inventory, record keeping, reporting requirements, repair, and disposal of all GFP used or in the possession of the Contractor during the performance of this contract.

3.1.6. Additional or Replacement GFP.

Additional or Replacement GFP requires Contracting Officer approval to be incorporated by bilateral contract modification.

3.2. Shared Property of the Government. Not Applicable.

3.3. Government Furnished Services (GFS).

Government Furnished Services are applicable during the performance of this contract.

The Government will furnish the following services at Tinker AFB (TAFB), OK:

3.3.1. Security Forces.

The Government will provide general on-base security forces’ service. The security forces’ telephone numbers are 911 for emergencies, 405-734-2000 for crimes in progress and 405-734-3737 for non-emergency calls. The off-base 911 center receives 911 cell phone calls. Cell phone callers need to advise the 911 off-base center they are on TAFB in order to be connected with the on-base 911 center.

3.3.2. Fire Emergency and Routine Services.

The Government will provide general on-base fire protection services. The Contractor shall comply with fire prevention rules and regulations enforced by the TAFB Fire Prevention Branch. Call 911 for emergencies. For routine fire prevention matters call 405-734-3981 or 405-734-3982 and 405-734-7964 for after hours and weekends. For routine calls to dispatch call 405-734-7964.

3.3.3. Utilities.

The Government will provide utility services. These utilities include natural gas, electricity, water, and sewer for the sole purpose of accomplishing this contract.

If the contractor requires additional utility services, it shall be the contractor’s responsibility to provide. Contractor shall use due care and diligence in efforts to conserve utilities to reduce utility costs.

3.4. Intangible Government Property.

Intangible Government Property is not covered by FAR Part 45 plus supplements, but is covered by FAR Part 27 and DFARS Part 227 plus supplements.

When applicable and in accordance with Government procedures, the Government will furnish, without cost, Intangible Government Property to the Contractor. All Intangible Government Property shall remain at all times sole property of the U.S. Government.

All Intangible Government Property used, input, processed, acquired, modified, developed, and/or generated by the Contractor in support of this contract, in any media, shall remain at all times sole property of the U.S. Government.

The Contractor may not use or disclose any Intangible Government Property for any purpose or in any manner not specifically authorized or required by the contract and this

PWS.

The Contractor shall ensure all Intangible Government Property is secured at the close of each workday. The Contractor shall use reasonable care to avoid losing and/or damaging Intangible Government Property. If the Contractor’s failure to use reasonable care causes loss and/or damage to Intangible Government Property, the Contractor shall be liable for the cost to replace the Intangible Government Property, which may be deducted from the contract price.

The Contractor shall use, input, process, maintain, and return all Intangible Government Property in the English language, readable and in a readily retrievable format, which requires no additional software or tools to read and retrieve beyond those already installed on the affected U.S. Government computers.

During contract performance, contract completion, and/or termination, the Contractor shall return all Intangible Government Property to the Government POC or Contracting Officer Representative (COR). The Contractor shall comply with the applicable contract clauses and this PWS.

3.4.1. Government Furnished Information (GFI).

The Government will provide an ITA Design Package. The ITA Design Package will typically include an ITA identification, a preliminary mechanical layout, electrical connector specifications, wiring diagrams or a wire list, an initial parts list, GFP list (SGFP, Attachment 3, Appendix B), and interface definitions. The GFI shall only be used for the performance of this contract.

3.5. Contractor Acquired Property (CAP). Not Applicable.

4. ADMINISTRATIVE CONSIDERATIONS

4.1 Points of Contact.

Timothy Robillard

556 SMXS/MXDPBA

7532 Joint Star Drive Bldg 9001, Post S54 Tinker AFB, OK 73145-8845

(P) (405)-582-5053 559SMXS.CONTMGMT@us.af.mil

Contractor shall include Contract Number or Purchase Order Number in correspondence and transportation (shipping) information.

4.2 Place of Performance.

Work is to be performed primarily at Contractor facilities. Meetings and ITA acceptance test activities may take place on-site at the Government facilities at Tinker AFB, Oklahoma.

mailto:559SMXS.CONTMGMT@us.af.mil

4.3 Hours of Work.

Contractor personnel are expected to conform to customer agency normal operating hours, but may work other operating hours with the concurrence of the Government.

Operating hours shall be from 7am to 4pm Central Standard Time.

4.4 Security

This project is UNCLASSIFIED.

1. PRODUCT REQUIREMENTS SPECIFICATION

1.1 OVERVIEW OF THE PRODUCT REQUIREMENTS SPECIFICATION FOR ITA

This document defines the Product Requirements Specification for the Interface Test Adapter (ITA) for use on the B-2 Versatile Depot Automatic Test System (VDATS). The ITA specification includes hardware design criteria, test requirements, and delivery guidelines. The ITA hardware provides an interface between the VDATS tester and the Unit Under Test (UUT). The UUT may be either a Line Replaceable Unit (LRU) or Shop Replaceable Unit (SRU). The VDATS tester is hereafter referred to as the Automated Test Equipment (ATE). The terms ITA Hardware and TPS Hardware (Test Program Set Hardware) may be used interchangeably throughout this document, but mean the same thing.

1.2 APPLICABLE DOCUMENTS

The following documents form a part of this specification to the extent specified herein.

If a document is referenced within this specification without indicating specific paragraphs as being applicable, then the document is applicable in its entirety. The applicable documents:

ASME Y14.44 Reference Designations for Electrical and

Electronics Parts and Equipment

MIL-STD-130N

Identification Marking of U.S. Military Property

MIL-DTL-14072E Finishes for Ground Based Electronic Equipment

FED-STD-595C

Colors Used in Government Procurement

Federal Code, Title 29, Section 12, Part 1910 (1985)

Occupational Safety and Health Administration (OSHA) Regulations

MIL-STD-31000

Department of Defense Standard Practice Technical Data(Packages)

200625633 DA Drawing Tree

2. REQUIREMENTS

2.1 GENERAL

This section identifies the performance requirements which must be met for an acceptable design, fabrication, and delivery of ITA hardware.

2.2 ITA HARDWARE

The following paragraphs identify specific hardware requirements for the ITA.

2.2.1 ITA HARDWARE DESIGN

The ITA hardware design shall meet all the requirements specified in this specification. In the event of a conflict between the original baseline design and this specification, the original baseline design shall take precedence.

2.2.2 DRAWINGS NUMBERS & PART NUMBERS

Each TPS hardware set and sub-assemblies shall utilize new Air Force Drawing Numbers and Part Numbers.

2.2.3 TPS HARDWARE PARTS

The TPS hardware shall provide all interfaces between the UUT and ATE required for accomplishing testing of the UUT and for self-testing the ITA.

The TPS hardware includes connectors, wiring, circuitry, cabling, card guides, holding fixture, cooling fixture, extender cards, wrap-around self-test circuit cards, and any other equipment necessary.

2.2.4 INTERFACE TEST ADAPTER

The ITA shall be the mating device between the ATE and the UUT. The ITA shall be designed using Virginia Panel Corporation’s Series 90 double tier interface to connect to the VDATS ATE. Some ITAs will require an additional connection to a VDATS Augmentation rack located next to the VDATS ATE which will utilize a Virginia Panel Corporation Series 90 single tier interface in addition to the double tier found on the VDATS ATE. A removable cover shall be provided to protect the ATE contact pins during storage and shipping. All electrical interfaces to the UUT shall pass through the ITA. ITA design shall include strain relief to prevent damage during normal operation and storage. ITA design shall include wiring maintenance loops that allow enough wire length to replace each pin a minimum of two (2) times. ITA wiring shall be neatly routed within the ITA utilizing cable ties and hold downs. The ITA shall be designed with a 20% expansion capability. Terminal blocks shall be utilized when splicing 4 or more connections together on a single wire run. Proper ITA wire gauge shall be selected to prevent damage to the ITA while under normal operation. The ITA shall have its internal wiring scheme such that the wiring shall not be damaged during normal maintenance. ITA connectors shall be clearly labeled with their associated connector identification numbers. Handles shall be installed on the ITA to allow for quick installation and removal of the ITA on the ATE. Vents shall be installed on the ITA when there is heat generating components within the ITA. Fans or forced air cooling shall be installed on the ITA when vents alone cannot compensate for the heat generating components.

2.2.5 CONNECTORS

Connectors utilized during tear down or installation of TPS hardware on the ATE shall be connected and disconnected by hand and shall not require special tools. All connectors shall be identified and clearly labeled by sequentially numbered “J” or “P” reference designators. “J” designation shall identify connector jacks. “P” shall identify connector plugs.

Connectors shall include protective covers that are attached to the ITA, holding fixture, or cable via a cord. The external connectors and connector covers shall be metallic whenever available. Connectors shall be spaced far enough apart so that they can be grasped firmly for connecting and disconnecting. The space between adjacent connectors shall be no less than 1 ½ inches with the mating connectors installed, unless approved by the Government. The mating connector-engaging mechanism shall lock or tighten in its fully closed position. Identical ITA connectors shall be keyed differently.

2.2.6 CABLES

Cables shall be protected with flexible, rugged sheathing. Cables shall include strain relief designs with back shells to protect against damage caused by normal use or storage. Cables shall be designed for rapid replacement of individual pins.

Each cable shall be clearly labeled with Type K2 non-metallic identification bands in accordance with MIL-STD-130N. All cables shall be identified by sequentially numbered “W” reference designators. Cables will not use cable ties on wire bundles within a protective covering. Cables shall have assemblies constructed such that a minimum of three inches of wire shall be exposed between the cable covering and the connector when the connector shell is removed.

2.2.7 HOLDING FIXTURES

The holding fixture shall be used to provide electrical contact between the UUT and ITA and to provide physical support required to secure the UUT during test. Holding fixtures shall be clearly labeled in accordance with MIL-STD-130N. Holding fixture connectors shall be clearly labeled with their associated connector identification numbers. If required, holding fixture air hoses shall be designed to quickly connect and disconnect to/from the holding fixture without any special tools.

2.2.9 FINISH

Finish to be powder coat P/N: RFB607R8, DuPont Axalta Coating Systems, Alesta, Supreme Black. External machined parts, are to be anodized then hardcoated, black.

2.2.10 GROUNDING

Each ITA chassis shall be electrically referenced to the ATE Single Point Ground (SPG). Ground loops shall be avoided. The design of the ground systems shall protect personnel from electrical hazards, provide the necessary shielding for signal circuits and minimize Electromagnetic Interference (EMI). Primary AC power return (Neutral) shall remain isolated from all signal and chassis grounds.

2.2.11 ELECTROMAGNETIC INTERFERENCE

The TPS hardware shall achieve an electromagnetic compatibility level such that operation does not interfere with normal operation of the UUT, other TPSs, or similar equipment in the area of intended usage.

2.2.12 SAFETY

Precautionary markings on the ITA and holding fixture shall be provided to warn personnel of hazardous conditions and to ensure personnel and equipment safety. The ITA shall utilize the ATE safety interlock to disconnect power supplies when the ITA is removed from the Interface Connector Assembly (ICA) of the ATE.

2.2.13 ELECTRICAL COMPLEXITY

All electrical incompatibilities between the UUT and the ATE shall be resolved by the use of passive circuitry within the ITA. Active circuits and circuitry requiring alignments or adjustments shall only be used as a last resort.

2.2.13.1 ELECTRICAL CONTINUITY

The resistance of each point-to-point path of the ITA shall not exceed 500 milliohms.

2.2.13.2 INSULATION RESISTANCE

The ITA circuitry shall have insulation resistance of more than 100 megohms when subjected to 500 plus or minus 50 volts direct current (Vdc) for a period of 50 to 70 seconds, measured between all mutually insulated circuit paths and between all mutually insulated circuit paths and the ITA enclosure.

2.2.13.3 SELF-TEST PROVISIONS

The ITA will include a Government designed wrap-around self-test provisions so that each electrical path through the ITA can be verified by tests. The ATE will be used to perform the ITA self-tests. The supplier shall optimize connector location and orientation to facilitate self-testing. For SRU type ITAs, a wrap-around circuit card will be fabricated to meet the self-test provisions.

2.2.14 WEIGHT

The ITA weight mounted on to the ICA shall not exceed the manufacturers’ established weight limits of the ATE Interface Connector Assembly (ICA).

Any ITA weighing more than 40 pounds shall include 2 person lift warnings.

2.2.15 ACCESSIBILITY

The ITA design shall provide easy access to repairable/replaceable components, wires, cables, and assemblies by use of hinged maintenance access door(s). Quick disconnect and captive hardware shall be used to secure these access doors. ITA access shall be such that, with the ITA connected to the driver/detector card cage, ITA SRUs are accessible for circuit probing.

2.2.16 RELIABILITY

TPS hardware elements shall be designed with a Mean Time Between Failure (MTBF) of no less than 1,000 hours.

2.2.17 MAINTAINABILITY

The following basic maintainability principles shall apply as goals during the design of the TPS hardware:

a) Design to utilize easily removable circuit cards and assemblies.

b) Design for rapid and positive identification of defective parts.

c) Design for use of standard tools.

d) Design for personnel safety.

e) Design with common standard replacement parts.

2.2.18 MEAN TIME TO REPAIR

The TPS hardware mean time to repair shall be less than one (1) hour.

2.2.19 ENVIRONMENTAL CONDITIONS

The TPS hardware shall be designed so that it shall not suffer damage, deterioration, or degradation of performance when used and stored in a shop environment.

2.2.20 DISSIMILAR METALS

Dissimilar metals that cause electrolytic corrosion when used in contact with each other shall be avoided when possible. When dissimilar metals are required to be joined, the surfaces shall be insulated with an approved sealing compound to assure protection from electrolytic corrosion.

2.2.21 CARD GUIDES

UUTs with card edge connectors shall utilize card guides affixed to the ITA to support the UUT during testing. Card guides shall be designed to allow diagnostic probing to be conducted in a safe and accessible manner.

2.2.22 CIRCUIT CARD ASSEMBLIES

The design requirements for Circuit Card Assemblies (CCAs) within the ITA are as follows:

a. Printed wiring boards shall be utilized for all CCAs.

b. CCAs shall not be hardwired to the ITA. CCAs shall use connectors for connection to the UUT to facilitate CCA replacement and repair.

c. Components shall be mounted on CCAs, unless the mounting of a component would jeopardize the engineering integrity of the design (i.e., transformers, power loads).

d. Each component mounted on the CCA(s) shall have the location of that component labeled on the CCA with a unique identifier, as shown in ASME Y14.44.

3. RESPONSIBILTY

3.1 GENERAL

This section establishes the procedures for verification of the requirements outlined in Section 2.

3.2 VERIFICATION METHODS DEFINITIONS

Reference Table 4.0:

3.2.1 INSPECTION

Verification by inspection shall consist of visual examination and related non-destructive examinations to determine compliance of the product with the requirements.

3.2.2 ANALYSIS

Verification by analysis shall consist of the review and evaluation of data, drawings, or test results to verify that a requirement has been satisfied.

3.2.3 DEMONSTRATION

Verification by demonstration shall consist of performing an in-process activity whose purpose is to exhibit the performance of the product under intended service use conditions to verify that a requirement has been satisfied. Demonstrations shall be performed utilizing production copies of hardware and software.

3.2.4 TEST

Verification by test shall consist of performing an activity that exhibits the performance of the product under controlled conditions that are real or simulated to verify that a requirement has been satisfied. This activity may require the use of special test equipment and instrumentation to obtain quantitative and qualitative data. Tests shall be performed utilizing production copies of hardware and software.

4. PREPARATION FOR DELIVERY

The preparation for delivery section describes the ITA marking, ITA packaging, and verification cross reference index table.

4.1 ITA MARKING

Marking and identification of TPS hardware shall be in accordance with MIL-STD-130N.

Electrostatic Discharge Sensitive items shall be marked in accordance with MIL-STD-130N.

A Type A identification plate shall be applied to each ITA in accordance with MIL-STD- 130N using color style II with black background and white characters, using character size 9, and free text lettering. Identification plate should be 3.5 in wide and 1.5 in long. An Unique Item Identifiers (UII) shall be applied to each ITA in accordance with Construct #2 in MIL-STD-130N. The UII label shall include a 1-D matrix for each field accompanied by the 2-D matrix and the applicable human-readable information.

At a minimum, the identification plate shall include the following Government supplied information:

a. Weapon system identification

b. Nomenclature

c. Government Entity (CAGE) Code and Part or Identifying Number (PIN)

d. Part Number

e. Serial Number

f. Manufacturer

g. Contract #

h. Weight

4.1.1 ITA Product Marking

Purchased parts which are marked by the manufacturer shall not be renumbered.

4.1.2 NON-AVAILABLE IDENTIFICATION ITA INFORMATION

If the ITA information is not available at the time of marking, a blank shall be provided for marking to be added when the information is made available.

4.2 CABLE MARKING

Marking and identification of cables shall be in accordance with MIL-STD-130N.

Electrostatic Discharge Sensitive items shall be marked in accordance with MIL-STD-130N.

Main cable(s) shall include at a minimum:

a. Assembly Number

b. Manufacturer

c. UUT CPIN and Cable Number

d. Serial Number

Each connector attached to the cable shall include at a minimum:

e. Cable Number and Connector Number

f. Mating Data (Information on what connectors the cable mates with for both UUT and self-test cards)

4.2.1 Cable Product Marking

Purchased parts which are marked by the manufacturer shall not be renumbered.

4.2.2 NON-AVAILABLE IDENTIFICATION CABLE INFORMATION

If the ITA information is not available at the time of marking, a blank shall be provided for marking to be added when the information is made available.

4.3 PACKING AND PACKAGING

Preservation methods, packing designs, and packaging shall be adequate to ensure protection against natural and induced environments. Packaging insulation shall be adequate to prevent ITA and associated ITA cabling from being damaged due to accidental drop or sudden movement during shipment.

Table 4.0 Verification Cross Reference Index

N/A = Not Applicable I = Inspection A = Analysis D = Demonstration T = Test

SECTION 2

REQUIREMENTS

PARAGRAPH

TITLE

METHODS SECTION 3

VERIFICATION

REFERENCE

PARAGRAPH

N/ A

I A D T

2. Requirements

2.1 General

2.2 ITA Hardware

2.2.1 ITA Hardware Design

2.2.1(S1) The ITA hardware design shall meet all the requirements specified in this specification.

X X X X 3.3.1, 3.3.2, 3.3.3, 3.3.4

2.2.1(S2) In the event of a conflict between the original baseline design and this specification, the original baseline design shall take precedence.

X 3.3.2

2.2.2 Drawing Numbers and Part Numbers

2.2.2(S1) Each TPS hardware set and sub-assemblies shall utilize new Air

Force Drawing Numbers and Part Numbers.

X 3.3.2

2.2.2(S2) The Air Force Drawing Numbers and Part Numbers will be provided to the Contractor at the Post Award Conference.

X N/A

2.2.3 TPS Hardware Parts

2.2.3(S1) The TPS hardware shall provide all interfaces between the UUT and ATE required for accomplishing testing of the UUT and for self-testing the ITA.

X 3.3.2

2.2.3(S2) The TPS hardware includes connectors, wiring, circuitry, cabling, holding fixture, cooling fixture, extender cards, wrap-around self test circuit cards, and any other equipment necessary.

X 3.3.1

2.2.3(S3) The TPS Hardware shall be labeled in accordance with MIL-

STD-130N.

X 3.3.2

2.2.4 Interface Test Adapter

2.2.4(S1) The ITA shall be the mating device between the ATE and the

UUT.

X 3.3.2

2.2.4(S2) The ITA shall be designed using Virginia Panel Corporation’s Series 90 double tier interface to connect to the VDATS ATE and a VPC Series 90 single tier to connect to the Augmentation rack.

X 3.3.2

2.2.4(S3) A removable cover shall be provided to protect the ATE contact pins during storage and shipping.

X X 3.3.1, 3.3.2

2.2.4(S4) All electrical interfaces to the UUT shall pass through the ITA. X 3.3.2

2.2.4(S5) ITA design shall include strain relief to prevent damage during normal operation and storage.

X X 3.3.1, 3.3.2

2.2.4(S6) ITA design shall include wiring maintenance loops that allow enough wire length to replace each pin a minimum of two (2) times.

X X 3.3.1, 3.3.2

2.2.4(S7) ITA wiring shall be neatly routed within the ITA utilizing cable ties and hold downs.

X X 3.3.1, 3.3.2

2.2.4(S8) The ITA shall be designed with a 20% expansion capability X X 3.3.1, 3.3.2

2.2.4(S9) Terminal blocks shall be utilized when splicing 4 or more connections together on a single wire run.

X X 3.3.1, 3.3.2

2.2.4(S10) Proper ITA wire gauge shall be selected to prevent damage to the

ITA while under normal operation.

X 3.3.2

2.2.4(S11) The ITA shall have its internal wiring scheme such that the wiring shall not be damaged during normal maintenance.

X 3.3.1

VERIFICATION

REFERENCE

PARAGRAPH

N/ A

I A D T

2.2.4(S12) ITA connectors shall be clearly labeled with their associated connector identification numbers.

X 3.3.2

2.2.4(S13) Handles shall be installed on the ITA to allow for quick installation and removal of the ITA on the ATE.

X X 3.3.1, 3.3.2

2.2.4(S14) Vents shall be installed on the ITA when there is heat generating components within the ITA.

X X 3.3.1, 3.3.2

2.2.4(S15) Fans or forced air cooling shall be installed on the ITA when vents alone cannot compensate for the heat generating components.

X X 3.3.1, 3.3.2

2.2.4(S16) The Contractor shall produce a thermal analysis when proposing vents, fans, or forced air cooling to the ITA.

X 3.3.2

2.2.5 Connectors

2.2.5(S1) Connectors utilized during tear down or installation of TPS hardware on the ATE shall be connected and disconnected by hand and shall not require special tools.

X 3.3.3

2.2.5(S2) All connectors shall be identified and clearly labeled by sequentially numbered “J” or “P” reference designators.

X X 3.3.1, 3.3.2

2.2.5(S3) “J” designation shall identify connector jacks. X 3.3.2

2.2.5(S4) “P” shall identify connector plugs. X 3.3.2

2.2.5(S5) Connectors shall include protective covers that are attached to the ITA, holding fixture, or cable via a cord.

X 3.3.3

2.2.5(S6) Connectors shall be spaced far enough apart so that they can be grasped firmly for connecting and disconnecting. The space between adjacent connectors shall be no less than 1 ½ inches with the mating connectors installed, unless approved by the

Government.

X X 3.3.2,3.3.3

2.2.5(S7) The mating connector-engaging mechanism shall lock or tighten in its fully closed position. Identical ITA connectors shall be keyed differently.

X 3.3.3

2.2.6 Cables

2.2.6(S1) Cables shall be protected with flexible, rugged sheathing. X X 3.3.1, 3.3.2

2.2.6(S2) Cables shall include strain relief designs with back shells to protect against damage caused by normal use or storage.

X 3.3.2

2.2.6(S3) Cables shall be designed for rapid replacement of individual pins. X X 3.3.2, 3.3.3

2.2.6(S4) Each cable shall be clearly labeled with non-metallic bands in accordance with MIL-STD-130N.

X X 3.3.1, 3.3.2

2.2.6(S5) All cables shall be identified by sequentially numbered “W” reference designators.

X 3.3.2

2.2.6(S6) Cable will not use cable ties on wire bundles within a protective covering.

X 3.3.1

2.2.6(S7) Cables shall have assemblies constructed such that a minimum of three inches of wire shall be exposed between the cable covering and the connector when the connector shell is removed.

X X 3.3.2, 3.3.3

2.2.6(S8) Cable Spare Wires: 10% of each wire type with a minimum of 1 of each type. Max of 5 for each type. No contacts on spare wires.

Spares should be folded back in the backshell with heat shrink over end. Spares should be documented in the ITA schematics and wire lists labeled as spare with any applicable designation of wire type. Parts list should reflect the quantity increase for spares as well.

X X 3.3.1, 3.3.2

2.2.7 Holding Fixture

VERIFICATION

REFERENCE

PARAGRAPH

N/ A

I A D T

2.2.7(S1) The holding fixture shall be used to provide electrical contact between the UUT and ITA and to provide physical support required to secure the UUT during test.

X X 3.3.2, 3.3.3

2.2.7(S2) Holding fixtures shall be clearly labeled in accordance with MIL-

STD-130N.

X X 3.3.1, 3.3.2

2.2.7(S3) Holding fixture connectors shall be clearly labeled with their associated connector identification numbers.

X X 3.3.1, 3.3.2

2.2.7(S4) If required, holding fixture air hoses shall be designed to quickly connect and disconnect to/from the holding fixture without any special tools.

X 3.3.3

2.2.9 Finish

2.2.9(S1) Finish to be powder coat P/N: RFB607R8. DuPont Axalta

Coating Systems, Alesta, Supreme Black. External machined parts are to be anodized then hardcoated, black.

X X 3.3.1, 3.3.2

2.2.9(S2) External machined parts are to be anodized then hardcoated, black.

X X 3.3.1, 3.3.2

2.2.10 Grounding

2.2.10(S1) Each ITA chassis shall be electrically referenced to the ATE

Single Point Ground (SPG).

X 3.3.2

2.2.10(S2) Ground loops shall be avoided. X 3.3.2

2.2.10(S3) The design of the ground systems shall protect personnel from electrical hazards, provide the necessary shielding for signal circuits and minimize Electromagnetic Interference (EMI).

X 3.3.2

2.2.10(S4) Primary AC power return (Neutral) shall remain isolated from all signal and chassis grounds.

X 3.3.2

2.2.11 Electromagnetic Interference

2.2.11(S1) The TPS hardware shall achieve an electromagnetic compatibility level such that operation does not interfere with normal operation of the UUT, other TPSs, or similar equipment in the area of intended usage.

X X 3.3.2, 3.3.4

2.2.12 Safety

2.2.12(S1) Precautionary markings on the ITA and holding fixture shall be provided to warn personnel of hazardous conditions and to ensure personnel and equipment safety.

X X 3.3.1, 3.3.2

2.2.12(S2) The ITA shall utilize the ATE safety interlock to disconnect power supplies when the ITA is removed from the Interface Connector Assembly (ICA) of the ATE.

X X 3.3.2, 3.3.3

2.2.13 Electrical Complexity

2.2.13(S1) All electrical incompatibilities between the UUT and the ATE shall be resolved by the use of passive circuitry within the ITA.

X 3.3.2

2.2.13(S2) Active circuits and circuitry requiring alignments or adjustments shall only be used as a last resort.

X 3.3.2

2.2.13.1 All electrical paths have continuity less than 500 milliohms. X X 3.3.3, 3.3.4

2.2.13.2 All electrical paths have insulation resistance greater than 100 megohms.

X X 3.3.3, 3.3.4

2.2.13.3 ITA has self-test provisions to verify all electrical paths. X X X 3.3.1, 3.3.2, 3.3.3

2.2.14 Weight

2.2.14(S1) The ITA weight mounted on to the ICA shall not exceed the manufacturers’ established weight limits of the ATE ICA.

X 3.3.2

2.2.14(S2) Any ITA weighing more than 40 pounds shall include 2 person lift warnings.

2.2.15 Accessibility

VERIFICATION

REFERENCE

PARAGRAPH

N/ A

I A D T

2.2.15(S1) The ITA shall provide access to repairable/replaceable components and assemblies by use of hinged maintenance access door.

X X 3.3.1, 3.3.3

2.2.15(S2) Quick disconnect and captive hardware shall be used to secure this access doors.

X X 3.3.1, 3.3.3

2.2.15(S3) ITA access shall be such that, with the ITA connected to the driver/detector card cage, ITA SRUs are accessible for circuit probing.

X 3.3.3

2.2.16 Reliability

2.2.16(1) TPS hardware elements shall be designed with a Mean Time Between Failure (MTBF) of no less than 1,000 hours.

X 3.3.2

2.2.16(2) MIL-HDBK-217F shall be used as guidance in calculating

MTBF.

X N/A

2.2.17 Maintainability

2.2.17(S1) The following basic maintainability principles shall apply as goals during the design of the TPS hardware:

X N/A

2.2.17(S2) a) Design to utilize easily removable circuit cards and assemblies.

X 3.3.2

2.2.17(S3) b) Design for rapid and positive identification of defective parts. X 3.3.2

2.2.17(S4) c) Design for use of standard tools. X 3.3.2

2.2.17(S5) d) Design for personnel safety. X 3.3.2

2.2.17(S6) e) Design with common standard replacement parts. X 3.3.2

2.2.18 Mean Time To Repair

2.2.18(S1) The TPS hardware mean time to repair shall be less than one (1) hour.

X 3.3.2

2.2.19 Environmental Conditions

2.2.19(S1) The TPS hardware shall be designed so that it shall not suffer damage, deterioration, or degradation of performance when used and stored in a shop environment.

X 3.3.2

2.2.20 Dissimilar Metals

2.2.20(S1) Dissimilar metals that cause electrolytic corrosion when used in contact with each other shall be avoided when possible.

X 3.3.2

2.2.20(S2) When dissimilar metals are required to be joined, the surfaces shall be insulated with an approved sealing compound to assure protection from electrolytic corrosion.

X 3.3.2

2.2.21 Card Guides

2.2.21(S1) UUTs with card edge connectors shall utilize card guides affixed to the ID to support the UUT during testing X X 3.3.2, 3.3.3

2.2.21(S2) Card guides shall be designed to allow diagnostic probing to be conducted in a safe and accessible manner.

X 3.3.3

2.2.22 Circuit Card Assemblies

2.2.22(S1) Printed wiring boards shall be utilized for all CCAs. X 3.3.1

2.2.22(S2) CCAs shall not be hardwired to the ITA. CCAs shall use connectors for connection to the UUT to facilitate CCA replacement and repair.

X X 3.3.1, 3.3.2

2.2.22(S3) Components shall be mounted on CCAs, unless the mounting of a component would jeopardize the engineering integrity of the design (i.e., transformers, power loads).

VERIFICATION

REFERENCE

PARAGRAPH

N/ A

I A D T

2.2.22(S4) Each component mounted on the CCA(s) shall have the location of that component labeled on the CCA with a unique identifier, as shown in ASME Y14.44.

X 3.3.1

Attachment 1

UNCLASSIFIED

UNCLASSIFIED

List of Acronyms

AFIL Acceptance Fault Insertion List AT Acceptance Test ATP Acceptance Test Procedure ATE Automatic Test Equipment ATS Automatic Test System BFIL Blind Fault Insertion List BIT Built-In Test CAGE Commercial and Government Entity CPIN Computer Program Identification Number DR Design Review EMI Electromagnetic Interference ESD Electrostatic Sensitive Device GFE Government Furnished Equipment IATE Intermediate Automatic Test Equipment ICA Interface Connector Assembly IFIL Integration Fault Insertion List I-Level Intermediate Level ITA Interface Test Adapter LRU Line Replaceable Unit MTBF Mean-Time-Between-Failure MTTR Mean-Time-To-Repair NSN National Stock Number OSHA Occupational Safety and Health Administration PIN Part or Identifying Number RFI Ready-For-Issue SPG Single Point Ground SRU Shop Replaceable Unit STTO Safe-To-Turn-On TAR Test Accuracy Ratio TP Test Program TPS Test Program Set TRR Test Readiness Review UUT Unit Under Test VDATS Versatile Depot Automatic Test System VCRI Verification Cross Reference Index