Attachment 01 - Statement of Work Revised 10Jun24 Final_Redacted.pdf

Table of Contents

1. OVERVIEW

1.1. Scope

2. APPLICABLE DOCUMENTS

2.1. General Information

2.2. Government Documents

2.3. Non-Government Publications, Specifications, Standards, and Handbooks

2.4. Order of Precedence

3. GENERAL REQUIREMENTS

3.1. Prototype Equipment

3.2. Measuring and Indicating Device Graduations

3.3. Safety, Environmental, Hazardous Materials

3.4. Lubrication Data

3.5. Instrument, Control Panel, and Plate Marking

3.6. General Equipment Requirements

3.7. Machine Operating Controls

3.8. Replacement Parts

3.9. Special Tooling and Equipment

3.10. Hardware/Software Agreements

3.11. General CNC Machine Requirements

3.12. Network Communication and Sensing

3.13. Network Security Requirements

3.14. CAD/CAM Software (Option)

4. STC MODEL REQUIREMENTS

4.1. Machine Configuration

4.2. Machine Axes

4.3. Machine Bed and Rotary Axis

4.4. Machine Traversing Bed

4.5. Mill Table (Standard)

4.6. Mill-Turn Table (Option)

4.7. Machine Column

4.8. Tilting Spindle Head Housing and Saddle

4.9. Spindle Head

4.10. Spindle

4.11. 6-Axis Spindle Head (Option)

4.12. Power Failure Protection

4.13. Machine Pallet

4.14. Automatic Pallet Changer

4.15. Automatic Tool Changers

4.16. Machine Coolant System

4.17. Coolant Wash Down Hose

4.18. Through Spindle Air Supply

4.19. Flex-Nozzle Air Supply

4.20. Chip Conveyor

4.21. Chip Briquette System (Option)

4.22. Miscellaneous Requirements

4.23. STC Model Size and Capacity

4.24. STC Model Alignment and Accuracy Tolerances

4.25. Machine Controller/PLC Operating Systems and Interfaces

4.26. Machine Controller Functions

4.27. GE P11TF12 Compliance

4.28. Spindle Crash Detection

4.29. Machine Post Processor (Option)

4.30. Workpiece Probing

4.31. Tool Length Offset/Breakage Detection System

4.32. Handheld Operator Pendant

4.33. Non-Warranty Replacement Spindle (STC 1250X Accessory)

5. ECOSPEED MODEL REQUIREMENTS

5.1. Machine Configuration

5.2. Machine Axes

5.3. Machine Bed

5.4. Machine Column

5.5. Machine Spindle Head

5.6. Machine C-Axis

5.7. Automatic Pallet Changer

5.8. Automatic Tool Changers

5.9. Automatic Right Angle Head Changer

5.10. Machine Coolant System

5.11. Tool Taper Air Purge

5.12. Chip Conveyor

5.13. Miscellaneous Requirements

5.14. Ecospeed Size and Capacity

5.15. Ecospeed Alignment and Accuracy Tolerances

5.16. Machine Controller/PLC Operating Systems and Interfaces

5.17. Machine Controller Functions

5.18. Machine Post Processor (Option)

5.19. Workpiece Probing

5.20. Tool Length Offset/Breakage Detection System

5.21. Handheld Operator Pendant

5.22. Non-Warranty Spindle Replacement (Ecospeed 1540 Accessory)

6. RVU MODEL REQUIREMENTS

6.1. General Description

6.2. Machine Configuration

6.3. Machine Axes

6.4. Machine Crossrail

6.5. Crossrail Saddle

6.6. Turret Assembly

6.7. Spindle

6.8. Grinding Wheel Hub

6.9. Rotary Table

6.10. Pallet Receiver

6.11. Pallet Transfer Station (Option)

6.12. Machine Pallet

6.13. Turning Capability

6.14. Automatic Tool Changers

6.15. Machine Coolant System

6.16. Wheel Dressing Capability

6.17. Chip Conveyor

6.18. Miscellaneous Requirements

6.19. RVU Model Size and Capacity

6.21. Machine Controller/PLC Operating Systems and Interfaces

6.22. Machine Controller Functions

6.23. Time Display and Part Count

6.24. Spindle Crash Detection

6.25. Power Failure Protection

6.26. Tool Management

6.27. Tool Dimension Control/Gap Elimination System

6.28. Machine Post Processor (Option)

6.29. Workpiece Probing

6.30. Tool Length Offset/Breakage Detection System

6.31. Handheld Operator Pendant

6.32. Non-Warranty Spindle Replacement (Option)

7. TVU MODEL REQUIREMENTS

7.1. General Description

7.2. Machine Configuration

7.3. Machine Axes

7.4. Machine Column

7.5. Machine Crossrail

7.6. Machine Carriage

7.7. Carriage Ram

7.8. Ram Accessories

7.9. Spindle

7.10. Rotary Table

7.11. Pallet Receiver

7.12. Pallet Transfer Station (Option)

7.13. Machine Pallet

7.14. Automatic Tool Changers

7.15. Coolant System

7.16. Chip Conveyor

7.17. Tool Air Supply

7.18. Miscellaneous Requirements

7.19. TVU Model Size and Capacity

7.20. TVU Model Alignment and Accuracy Tolerances

7.21. Machine Controller/PLC Operating Systems and Interfaces

7.22. Machine Controller Functions

7.23. Spindle Crash Detection

7.24. Machine Post Processor (Option)

7.25. Basic Workpiece Probing

7.26. Tool Length Offset/Breakage Detection System

7.26.2. Handheld Operator Pendant

7.27. Non-Warranty Spindle Replacement (Option)

8. FLEXIBLE MANUFACTURING SYSTEM REQUIREMENTS (OPTION)

8.1. FMS System Description

8.2. FMS Hardware Requirements

8.3. FMS Cell Control System Description

8.4. FMS Definitions

8.5. FMS Control Hardwar/Software Requirements

8.6. FMS Database Requirements

8.7. FMS Communications and Connectivity Requirements

8.8. FMS Functional Requirements

8.9. Pallet and Fixture Management

8.10. NC Program Management

8.11. Workload Management

8.12. Tool Data and Control Management

8.15. System Status Monitoring

8.16. Artifact and Part Probing Data Transfer

8.17. Preventative Maintenance Notifications & Reporting

9. TRANSPORTATION, RIGGING, FOUNDATIONS, AND INSTALLATION

9.1. Transportation

9.2. Rigging

9.3. Installation

9.4. Leveling

9.5. Utility Hook-Up

9.6. System Charging

9.7. Installation and Foundation Drawings

9.8. Foundation

10. TRAINING REQUIREMENTS

10.1. Training Overview

10.2. Initial Training

10.3. Follow-Up Training

10.4. Advanced Training

11. TOOLING, ACCESSORIES, & TECHNICAL DATA

11.1. Tooling

11.2. Accessories

11.3. Zero-Point Clamping System (Option)

11.4. Machine and Equipment Technical Data

12. EXTENDED MACHINE WARRANTY SERVICE (OPTION)

12.1. OEM Extended Warranty Service

12.2. Extended Warranty Requirements

12.3. Predictive Maintenance Requirements

12.4. Machine Uptime Guarantee

13. QUALITY ASSURANCE

13.1. Responsibility for Inspection

13.2. Responsibility for Compliance

13.3. Classification of Inspections

13.4. Inspection Conditions

13.5. (Origin) Inspection/Acceptance Test

13.6. (Destination) Inspection/Acceptance Test

13.7. Machine/Equipment Examination

13.8. Acceptance Tests

13.9. Initial Post Award Meeting

13.10. Plan of Action and Milestones (POA&M)

13.11. Design/Progress Review Meetings

14. OTHER REQUIREMENTS

14.1. Safety and Quality Control

14.2. Foreign Object Damage (FOD) & Dropped Object Prevention (DOP)

14.3. Housekeeping

14.4. Standard Operating Procedures

14.5. Non-Government Owned IT System or Devices

15. INSTALLATION RESPONSIBILITIES

16. APPENDICIES

Appendix A – STC /MT Tool List

Appendix B – STC1250/1800 Tool List

Appendix C – STC1000 Tool List

Appendix D – STC1250X and Ecospeed 1540 Tool List

Appendix E – RVU and TVU Model Tool List

Appendix F – STC 1000 / 1250 / 1800 / 1800MT Model Accessory List

Appendix G – STC 1250X / Ecospeed F1540 Accessory List

Appendix H – RVU and TVU Non-Warranty Spindle Option List

Appendix I – RFID Tool Data Format

Appendix J – RFID Tool Management Flow Logic

Appendix K – MTConnect Adapter Data Tag Output

Appendix L – Contract Deliverable Schedule

Appendix M – STC Models and Ecospeed Post Processor Test Piece (Tinker AFB)

17. TABLES

Table I: Simulation Software Program

Table II: Maximum Layout Dimensions by Machine Model

Table III: Mill Turning Option Requirements (Minimum Unless Indicated Otherwise)

Table IV: 6-Axis Spindle Head Requirements

Table V: STC Model Requirements

Table VI: STC Model Accuracy and Repeatability

Table VII: Ecospeed F1540 Requirements

Table VIII: Ecospeed F1540 Accuracy and Repeatability

Table IX: Grinding Wheel Hub Requirements

Table X: RVU Model Requirements

Table XI: RVU Model Accuracy and Repeatability

Table XII: TVU Model Requirements

Table XIII: TVU Model Accuracy and Repeatability

Table XIV: Minimum Quantity of Extension Modules Required by Model

Table XV: Zero-Point Clamping System Requirements

18. FIGURES

Figure 1: STC Model Machine Configuration

Figure 2: Ecospeed 1540 Model Machine Configuration

Figure 3: RVU Model Machine Configuration

Figure 4: TVU Model Machine Configuration

1. OVERVIEW

1.1. Scope. The content of this specification describes the minimum requirements for the name brand procurement of Starrag and Starrag subsidiaries 5 & 6-axis machining centers, vertical grinding machines, vertical turning lathes and Flexible Manufacturing System (FMS). Models included in this specification are STC1250, 1250MT, 1250/170, 1250MT/170, STC1250X, STC1000, 1000/MT, STC1800, 1800MT, 1800/170, 1800MT/170, Ecospeed F1540, Berthiez

RVU 1100/100, Berthiez RVU 1350/125, Berthiez RVU 2800/250, Berthiez TVU 1400/100F.

Except for Ecospeed Model F1540, all models shall be offered as a standalone standard or custom build for integration into an FMS. Equipment, materials, labor, and services shall be provided as a turn-key solution and completed in accordance with the specification(s) defined within this document as needed to deliver and install the machine(s).

2. APPLICABLE DOCUMENTS.

2.1. General Information. The Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation, and safety as applicable. The term “most recent edition” shall be understood to mean, “most recently released edition as of date of issuance of contract.” While every effort has been made to ensure the completeness of this section, users are cautioned that they must meet all specified requirements of documents cited throughout this SOW.

2.2. Government Documents. The following Government documents form a part of this document to the extent specified herein.

2.2.1. Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein.

2.2.2. U.S. Department of Labor

OSHA 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/)

(Application for copies should be addressed to the U.S. Department of Labor, 200

Constitution Ave, Washington, D.C. 20210)

2.2.3. Environmental Protection Agency

40 CFR 82 – Protection of Stratospheric Ozone

40 CFR part 761 – Polychlorinated Biphenyls (PCB) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions.

(Application for copies should be addressed to the U.S. Department of Labor, 200

Constitution Ave, Washington, D.C. 20210)

2.2.4. Federal Standards

FED-STD-H28B – Screw Thread Standards for Federal Services, 2019 or most recent edition

FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

(Application for copies should be addressed to Superintendent of Documents, Government

Printing Office, Washington, D.C. 20402-001).

2.2.5. Military Standards

MIL-STD-130N w/Change 1: Identification Markings of U.S. Military Property (2012 Ed.)

Item Unique Identification Marking (IUID) or most recent edition

(Application for copies should be addressed to Air Force Product Data Systems

Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

2.2.6. National Institute of Standards and Technology (NIST)

FIPS 140-3: Security Requirement for Cryptographic Modules

(Request for information should be addressed to Information Technology Laboratory, National Institute of Standards and Technology, Gaithersburg, MD 20899-8900. This document is available free of charge at https://doi.org/10.6028/NIST.FIPS.140-3)

2.2.7. Other Government Documents, Drawings, and Publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein.

Local Facility Documents

2.3. Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein.

2.3.1. National Fire Protection Association (NFPA)

NFPA 1 – Fire Code, 2010 edition or most recent edition

NFPA 70 – National Electrical Code, 2014 edition or most recent edition

NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition.

NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

(Application for copies should be addressed to National Fire Protection Association, Battermarch Park, Quincy, MA 02269)

2.3.2. Telecommunications Industry Association (TIA) Standard

EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data Circuit- Terminating

Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition.

(Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.3.3. National Electrical Manufacturers Association (NEMA)

NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

NEMA ICS 1 – Industrial Control and Systems General Requirements (2015 Ed.) or most recent edition

NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

(Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

2.3.4. Underwriter Laboratories, Inc.

UL 508A – Industrial Control Panels

(Application for copies should be addressed to Underwriter Laboratories, Inc. 333 Pfingsten

Road, Northbrook, IL 60062)

2.3.5. American Society for Testing and Materials.

ASTM SI 10 – American National Standard for use of the International System of Units (SI):

The Modern Metric System, 2010 or most recent edition.

(Application for copies should be addressed to ASTM Headquarters, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959)

2.3.6. American National Standards Institute

ANSI/(NFPA) T2.25.1 – Pneumatic Fluid Power – System Standard For Industrial Machinery

– Supplement to ISO 4414:1998 – Pneumatic Fluid Power – General Rules Relating To

Systems (2005) or most recent edition.

ANSI/ASME B5.1M – T-Slots, Their Bolts, Nuts, and Tongues (1985) or most recent edition.

ANSI B11.19 – Performance Requirements for Risk Reduction Measures: Safeguarding and

Other Means of Reducing Risk (2019) or most recent edition.

ANSI B11.20 – Safety Requirements for the Integration of Machinery into a System (2017) or most recent edition.

ANSI B11.22 – Safety Requirements for Turning Centers and Automatic Numerically

Controlled Turning Machines (2020 Rev.) or most recent edition

ANSI B11.23 – Safety Requirements for Machining Centers and Automatic, Numerically

Controlled Milling, Drilling, and Boring Machines (2012 Rev.) or most recent edition.

ANSI B11.25 – Safety Requirements for Large Machines (2022) or most recent edition.

ANSI/AGMA ISO 1328-1-B14 (PESO) – Cylindrical Gears - ISO System Of Flank Tolerance

Classification - Part 1: Definitions And Allowable Values Of Deviations Relevant To Flanks

Of Gear Teeth

(Application for copies should be addressed to American National Standards Institute, Attn:

Sales Department, 1430 Broadway, New York, NY 10018-3363)

2.3.7. American Welding Society INC (AWS)

AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most recent edition

(Applications for copies should be addressed to the American Welding Society Inc., 550

North LeJeune Road, Miami, FL 33126)

2.3.8. International Organization for Standardization (ISO)

ISO 2047:1997/Amd 1:2016 – Test condition for internal cylindrical grinding machines with horizontal spindle; Testing of accuracy – Amendment 1 (3rd edition, May 2016) or most recent edition.

ISO 2433:1999 – Machine tools: Test condition for external cylindrical and universal grinding machines with a movable table; Testing of accuracy (3rd edition, Dec 1999) or most recent edition.

ISO 4413 – Hydraulic fluid power-General rules and safety requirements for systems and their components (2010 Ed.) or most recent edition.

ISO 4414 – Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.) or most recent edition.

ISO 8573-1 – Compressed air: Contaminants and purity classes; Part 1 (3rd edition, Apr 2010) or most recent edition.

ISO 13041-6 – Test conditions for numerically controlled turning machines and turning centres: Accuracy of finished test piece (2nd edition, June 2009) or most recent edition.

ISO 10791-7 – Test conditions for machining centres: Accuracy of finished test pieces (3rd edition, January 2020) or most recent edition.

(Application for copies should be addressed to the International Organization for

Standardization (ISO) 1 rue de Varembé, Casepostalea56, CH211Geneva 20, Switzerland)

2.3.9. Society of Automotive Engineers (SAE)

SAE EIA-267-C – Axis and Motion Nomenclature for Numerically Controlled Machines

(2015 Ed.) or most recent edition

(Application for copies should be addressed to: Society of Automotive Engineers 400

Commonwealth Drive; Warrendale, PA 15096)

2.3.10. European Standard (EN)

EN1822:2019 - High efficiency air filters (EPA, HEPA and ULPA) (2019) or most recent edition

2.4. Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3. GENERAL REQUIREMENTS. Unless otherwise indicated, the following requirements in

Section 3 apply to all equipment and subcomponents as applicable. Use of the term “Contractor” implies the “Contractor or authorized sub-contractor.”

3.1. Prototype Equipment. The Contractor shall provide new, current, and commercially available machine/equipment models. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. Parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.2. Measuring and Indicating Device Graduations. Measuring and indicating devices on the equipment shall be graduated in both US customary units and International System of Units (SI).

3.3. Safety, Environmental, Hazardous Materials.

3.3.1. Safety and Health Requirements. Machine parts, components, mechanisms, and assemblies furnished on the machine, whether specifically required herein, shall comply with requirements of OSHA 29 CFR 1910.

3.3.2. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI

B11.19, B11.20, B11.22, B11.23, and B11.25 as applicable. The safety devices shall prevent operator contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts. Guarding shall be constructed and attached in a manner as to not create safety hazards. Incorporated safety devices shall not limit the OEM intended operation of the machine.

3.3.3. Emergency Stop Devices (e-Stop). Equipment designs shall incorporate a single emergency stop function. The emergency stop function may, as the design dictates, be accomplished by one or more emergency stop devices. Emergency stop devices shall conform to the requirements of NFPA 79. The Contractor shall ensure all emergency stop devices are placed at accessible, normal operating locations.

3.3.3.1. Safety Device Layout Analysis (FMS Only). As a deliverable, the Contractor shall provide to the Government technical POC a detailed safety device layout analysis illustrating the recommended type, location, and intended span of control for all safety-related control devices no later than one hundred thirty (130) calendar days post award. The analysis shall encompass both FMS and all integrated equipment. The Contractor shall use ANSI B11.20-2007 or newer revision for development of the analysis. The Contractor shall be responsible for providing the

Government an updated layout analysis for each subsequent new machine or piece of equipment added to an existing FMS.

3.3.4. Slip Hazards. Non-slip stepping surfaces shall be provided in locations where it is necessary for operator/maintenance personnel to step or walk on parts of a machine that presents a potential slip hazard due to wet/slick conditions from coolant, chip, swarf, or lubricants.

3.3.5. Unintended Projectile Protection. Each machine shall come equipped with means to protect personnel from the unintended ejection of workpiece, tooling, and fluids. The means of protection shall not deteriorate over time due to contamination by lubricants, metal removal fluids, solvents, etc. The protection shall be of sufficient strength that it can absorb the energy and momentum associated with the speed and mass of potential projectiles derived in the use of the equipment.

3.3.6. Work Envelope Monitoring. The Contractor shall provide a work envelope monitoring system for each machine that complies with ANSI B11.25 regarding viewing of the work envelope with fully enclosed equipment.

3.3.6.1. Workpiece Monitoring System. Each machine shall come provisioned with a workpiece video monitoring system. The system shall be of a design that is properly protected for a flood coolant machining environment. The installation location of the viewing system shall not interfere with the operation of the machine or machine accessories. Workpiece monitoring video camera(s) within the machine enclosure shall be installed at a location(s) that permit direct visual access to the components and the cutting process. The system shall permit, at a minimum, operator remote control of the camera tilt, pan, and zoom functions via motor drive. The system shall come provisioned for concurrent transmission of video feed across the Government industrial network.

3.3.6.2. Workpiece Monitoring Display. Each machine system shall come provisioned with a separate, minimum 21-inch, display located at the machine’s main control panel that permits the concurrent observation of the video output and machine control display. The display shall be mounted in a manner that allows for its future maintenance or replacement without requiring modification(s) to machine enclosure.

3.3.7. Spindle Function Limit. Machines shall come configured to reduce rapid operations to

25% of normal and spindle rotation to no greater than 50 rpm when the work envelope access door is in the open position.

3.3.8. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels

(dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator’s work position or any point three (3) feet away from the equipment. Noise generated by the work piece and ambient workplace shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.3.9. Mercury Restriction. The machines shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.3.10. Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machines/equipment.

3.3.11. Lead. Lead and materials containing lead shall not be used on or in the machines with the exception to radiation cladding and lead solder in circuits.

3.3.12. Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited. The machine shall be considered PCB free providing certification to be verified containing less than 5 parts per million (<5ppm) in accordance with 40 CFR part 761.

3.3.13. Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.3.14. Energy Conservation & Management. Where applicable, equipment designs and configurations shall consider both active and passive energy efficiency and power conservation management features e.g., regenerative braking, machine sleep mode, automated machine warm-up procedures, etc.

3.3.14.1. Pump Energy Conservation. The Contractor shall provision applicable pumps with means of electronic management that optimizes rotational speed and power usage based on actual demand. The management feature shall be integrated into the equipment’s control and sensing system.

3.3.14.2. Total Energy Consumption Monitoring. The Contractor provision all machines and

FMS with a Siemens SENTRON PAC3200 or equivalent power monitoring device. The device shall, at a minimum, be configured to measure the TOTAL system energy consumption in kilowatt-hour (kWh) for the respective piece of equipment. The total energy consumption value shall be available for data collection purposes IAW the method described in Paragraph 3.12.3.

3.3.15. Electrical Enclosures. Construction of electrical enclosure(s) shall conform to NEMA

ICS 6 standards. Electrical enclosure(s) shall be a NEMA type 12 intended for indoor, non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. Machine electrical cabinet shall meet requirements of NFPA70 and NFPA 79.

Electrical enclosure(s) shall provide means for ventilation.

3.3.15.1. Electrical Enclosure Lighting Device. A lighting device shall be incorporated inside each enclosure. Each lighting device shall provide adequate lighting for troubleshooting and maintenance purposes.

3.3.15.2. Enclosure Outlets. All internal and external enclosure electrical outlets shall conform to the requirements of NFPA 79.

3.3.15.3. Enclosure Arc Flash Protection. Each machine electrical and disconnecting device enclosure shall be marked for arc flash hazard warning in accordance with NFPA 79.

3.3.16. Machine Maintenance Mode Feature. Each machine shall come equipped with a key operated feature for placing a machine in maintenance vs normal operation mode for troubleshooting and repair purposes. The key feature shall be located in an accessible area on the outside of the machine’s electrical enclosure within view of the operator control station. The machine HMI shall report when maintenance mode is active. Placement of the key in maintenance mode shall inhibit activation of all autonomous machine and FMS functions.

3.4. Lubrication Data. The Contractor shall provide the following information and the US equivalent on all liquid or grease lubricants contained within equipment/system or in bulk (5 gallons or more) supplied under this procurement.

3.4.1. Liquid Lubricants

• Viscosity grade in ISO units

• Viscosity Index

• AGMA and/or SAE classification as applicable

• Mil Spec and/or NATO Code as applicable

• Cincinnati Milacron Specification Number as applicable

• Viscosity in Centistokes (cst) @ 40° C and 100° C

• Type Additive package. Example: ZDDP, Rust inhibitors, Foam inhibitors.

• Neutralization, the TBN (alkalinity) and/or TAN (acidity).

• Flash point

• Pour point

3.4.2. Grease Lubricants

• National Lubrication and Grease Institute (NLGI) Number

• Type and percent of thickener

• Dropping point

• Maximum Service Temperature

• Base oil viscosity range in SUS or centipoise

3.5. Instrument, Control Panel, and Plate Marking.

3.5.1. Data Plate Requirements. All words on data plates shall be in the English language.

Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.5.2. Lubrication Plate. Each machine shall come with lubrication plates. All plates shall be securely attached to each machine at locations readily visible to an observer without the need for disassembly or movement of machine components. The plate shall contain the following information:

• Points of Lubrication Application

• Servicing Interval

• Type of Lubricant

• Viscosity

• Military or Federal Specification for Each Lubricant (If available)

• Size and Type of Each Lubricant Filter

3.5.3. Machine Nameplate. Each machine shall come with a machine nameplate. The nameplate shall be securely attached to each machine at locations readily visible to an observer without the need for disassembly or movement of machine components. The nameplate data shall meet the requirements of NFPA 79 and contain, at a minimum, the following information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

• Manufacturer’s Name

• Manufacturer’s Model Designation

• Manufacturer’s Serial Number

• Rated voltage, number of phases, and frequency

• Full-load current for each supply

• Ampere rating of the largest motor or load

• Short-circuit current rating of the industrial control panel

• Maximum ampere rating of the short-circuit and ground fault protective device, where provided.

• Electrical diagram number(s) or number of the index to the electrical drawings

3.5.4. Identification Marking of Military Property. In addition to the requirements of Paragraph

3.5.3, each machine shall come with an Item Unique Identification Marking (IUID) plate. The

IUID plate shall marked in accordance with MIL-STD-130N and all applicable documents with

Machine Readable Information (MRI), and item identification marking, and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the following information.

• Nomenclature

• Cage Code

• Manufacturer

• Model Number

• Serial Number

• Date of Manufacture

• Contract Number

3.5.5. Warranty Data Plate. At machine acceptance, Contractor shall securely attach a warranty data plate to the machine enclosure. In accordance with MIL-STD-130N, the data plate shall include the statement “WARRANTED ITEM” and the warranty expiration date.

3.6. General Equipment Requirements. Unless otherwise noted, the following requirements shall apply all equipment components.

3.6.1. General Construction. All Equipment and sub-components shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.6.2. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder, or filling with paste shall be used for reclaiming any defective part.

3.6.3. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.6.4. Threads. All threaded parts used on the machines and their related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein.

3.6.5. Gears. All gears of axis drive trains shall conform to or exceed all provisions of

ANSI/AGMA ISO 1328-1-B14 (PESO). All gears shall be of proper width and size to transmit full-rated torque and power throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.6.6. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function.

The condition and finish of all surfaces shall be in accordance with the manufacturer’s commercial practice.

3.6.7. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.6.8. Painting. The machines shall be painted in accordance with the manufacturer’s commercial practice. Paint shall not contain lead.

3.6.9. Workmanship. Workmanship of the machines shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.6.10. Bearing Information. The Contractor shall provide bearing manufacturer and part number for all bearings used in all rotating equipment supplied under this contract. The information shall be included on the sectional drawings for each bearing location. The Contractor shall provide the operating speed for constant speed units and the normal operating speed range for variable speed equipment.

3.6.11. Fans and Blowers. The Contractor shall provide the following information on fans and blowers supplied with the proposed equipment:

• Fan and blower type(s)

• Number of rotating fan blades/vanes

• Number of stationary fan blades/vanes

• Rotating speed(s)

3.6.12. Fan and Blower Access. The design of each machine shall ensure access to all fans and blowers for the purpose of performing maintenance without the need for significant disassembly of the machine.

3.6.13. Belts. The Contractor shall provide the following information for belt driven fans:

• Number of belts

• Belt length(s)

• Belt Part Number

• Diameter of the drive sheave at the drive pitch line

• Diameter of the driven sheave at the drive pitch line

3.7. Machine Operating Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be installed in a location convenient for their intended use.

3.7.1. Control Panel Display Language. All control panels shall display information in the

English language.

3.8. Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include, but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. All replacement parts shall have a guaranteed availability for a minimum of ten years.

3.9. Special Tooling and Equipment. The Contractor shall provide the Government all special tooling and equipment required for proper operation of each machine listed in the award e.g., special tools needed for the regular maintenance. The Contractor shall provide the Government technical POC a list outlining all special tools and equipment required for each machine and piece equipment indicated in the award no later than fifteen (15) calendar days post award. The document shall be provided to the Government in a search capable digital (.pdf) format.

3.10. Hardware/Software Agreements. The Contractor shall ensure all hardware/software agreements entered into for the fulfillment of these requirements are transferable to the

Government.

3.10.1. Third Party Software License. The Contractor shall provide all necessary license(s) for third party applications needed to meet the requirements outline in this statement of work. The

Contractor shall transfer ownership of all licenses to the Government for sustainment over the lifecycle of the system no later than the completion of (destination) acceptance inspection. All license(s) provided to Government:

• Shall be provided in a floating license server configuration.

• Shall not be subscription based.

• Shall not require a connection to the internet for its activation, use, or updating.

3.11. General CNC Machine Requirements. Unless otherwise noted, the following requirements shall apply to all CNC machines and associated accessory components.

3.11.1. Machine Bases. The machine bases shall be a stress relieved and heavy-duty ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects.

The bases shall be of strength and size to provide support for all loads within the machines rated capacity without distortion to the bases, machine, or other machine components.

3.11.2. Machine Ways. The ways shall be of a type suitable for high grade precision numerically controlled machines covered by this document. Machine ways shall be constructed of hardened, precision ground steel. The ways shall be hand scraped to its final condition. Movement of the slides on the way surfaces shall be through adjustable, preloaded, re-circulating roller bearing cartridges or nonmetallic way liners having a low coefficient of friction with slip-stick and damping properties including hydrostatics. Protection of the machine ways shall be either telescoping or curtain type way covers equipped with way wipers.

3.11.3. Machine Axis Measuring Systems. Each machine axes shall come provisioned with linear glass scales for axis traversing distance calculations. The rotary axis shall also have a measuring system designed for the specified performance. All measurement systems shall be fully encapsulated by housings or sealed machine structure to prevent coolant, debris, and swarf from interfering with the system or causing damage.

3.11.4. Machine Enclosures. Each machine shall be housed within a self-contained enclosure.

The enclosure shall provide containment for coolant/chips and for operator safety in the event of a broken tool. The enclosure shall come equipped with interlocking sliding doors. Interlocking doors shall provide unhindered access to the work envelop for unloading/loading of tools, raw material, and parts. The enclosure shall be constructed with safety windows for operator visibility of the workpiece and machine spindle. Enclosure doors shall contain a reinforced safety glass for all workpiece viewing windows IAW Paragraph 3.3.5.

3.11.5. Mist/Emission Extractors. Each machine shall come provisioned with a mist and fume extractor system. The extractor shall remove dust, mist, and fumes generated during turning, cutting, and grinding operations. The extractor shall automatically activate and operate concurrently during machining operations without the need for operator input. Access to the system filter shall be made readily available for maintenance and replacement. Air filtration quality shall meet EU13/H13 (DIN24183/EN1822).

3.11.6. Workpiece Area Lighting. Each machine shall come provisioned with a built-in Light

Emitting Diode (LED) type work light that illuminates the area of the workpiece fixture. The

LED light shall comply with NFPA 79 requirements, have a protective shield, and supply a minimum of 400 lux or greater. Replacements LED light shall be commercially available in

North America.

3.11.7. Hydraulic System. Each machine’s hydraulic system shall conform to ISO 4413. The system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. A means shall be provided for controlling fluid temperature, so that it does not exceed 120℉ during normal operation. Each Machine shall report all hydraulic pressure and temperatures values as well as report when those values exceed OEM established thresholds to the

Government external network IAW methods outlined in Paragraph 3.12.3.

3.11.8. Pneumatic System. Pneumatic system(s) and components provided with each machine, as applicable, shall conform to both ANSI/NFPA T2.25.1-2005 and ISO 4414:1998 or more recent edition. Pneumatic system(s) shall come complete including all pumps, valves, plumbing, cylinders, and pressure controls necessary to operate the machine and its ancillary equipment.

Each machine provided shall integrate with the facility source compressed pneumatic air. The existing source pneumatic air available at the facility ranges from 80 to 120 psi. Source air integration shall maintain air quality class IAW ISO 8573-1 as applicable for machine make and model listed in the award. Upon reaching or exceeding threshold values, each machine shall alarm and report to both operator HMI and Government industrial network using methods described in Paragraph 3.12.3.

3.11.9. Operator Compressed Air. Each machine shall come equipped with a compressed air quick disconnect located with 10 feet of the operator workstation. The compressed air quick disconnect shall be provision to supply manually regulated, filtered dry compressed air at a minimum of 70 PSI. The filter-regulator shall come equipped with a gauge for displaying system pressure in PSI.

3.11.9.1. Compressed Air Discharge Pressure Limit. All manually operated compressed air devices supplied by the Contractor that are intended for the clearing of debris from surfaces shall meet OSHA 29 CFR 1910.242(b). Such devices shall be of a design or possess a mechanism that limits nozzle discharge pressure to 30 PSI or less in the event of intentional or unintentional nozzle obstruction.

3.11.9.2. Compressed Air Chip Guarding. All manually operated compressed air devices supplied by the Contractor intended for clearing of debris from surfaces shall meet OSHA 29

CFR 1910.242(b). Such devises shall employ a design that creates a protective air cone during use with the intent to reduce the risk of operators or others from being struck by traveling debris.

3.11.10. Electrical System. Each machine shall conform to NFPA 79. The existing source power available by the Government is 480 volt, 3-phase, 60 Hertz (Hz). Each machines’ electrical system shall be tolerant of fluctuation of +/- 10 percent. The electrical system shall be complete including electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with a means of locking the device in the off position only. Wiring inside electrical enclosures shall be individually labeled.

3.11.10.1. Enclosure Electrical Outlets. Each machine shall come equipped with one (1) 120V

(15A) duplex outlet located externally on the enclosure outer surface within 10 feet of the machine controls. Access to the outlet shall be unobstructed by machine components.

3.11.11. Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.11.12. Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.11.13. Electrical Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-

1. Each motor shall have an identification plate with the following information below. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer’s design and construction drawing(s).

• Manufacturer

• Model Number

• Voltage

• Amperage

• Horsepower

• Phase

• Frequency

• Frame Number

3.11.14. Lubrication. Each Machine shall come equipped with a system that provides lubrication

(oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements.

Recirculating lubrication systems shall include a filter that is cleanable or replaceable. The lubricant reservoir shall have at least a 24-hour capacity. Each machine shall come provisioned to report to the operator HMI that a low-level lubrication condition exists via electronic means.

When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible. The lubrication low-level status signal shall be available for data collection via methods outlined in Paragraph 3.12.3.

3.11.15. Initial Lubrication Fill. The Contractor shall be responsible for the initial filling of all lubricants, grease, and milling coolant required to operate a machine or piece of equipment. The

Contractor shall use the current manufacture and type milling coolant in use by the Government at the time of award. The current milling coolant in use by the Government is TRIM MicroSol

585XT semisynthetic, microemulsion coolant. The Government will notify the Contractor in writing no later than thirty (30) calendar days prior to machine delivery of a change in machining coolant manufacture and type in use.

3.11.16. Analog Hour Meter. The Contractor shall provision each machine with a non-resettable type, digital or analog hour meter to display accumulated operating time of the system. The hour meter(s) shall be mounted on the main electrical panel and be visible from the outside. The hour meter(s) shall be sealed to prevent the entrance of dust, moisture, and capable of withstands shock/vibration generated by the machine. The hour meter(s) shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one (1) hour.

3.11.17. Machine Warm-Up Program. The Contractor shall provision each machine control with a warm-up program unique to the machine make/model. The program shall include a complete set of machine cycles required to achieve OEM recommend component warm-up motion and dwell time. The design of the warm-up program shall take into consideration the potential presence of both workpiece and active in-spindle tool within the work envelope and avoid the likelihood of unintended contact.

3.11.17.1. Warm-up Program Minimum Requirement. The machine warm-up program shall include, at a minimum, spindle warm-up with incremental RPM increases and programmed dwell time at each level and warm-up of axis drives with a traverse of each axis.

3.11.17.2. Warm-up Program Initiation. Each machine control shall come provisioned with the functions for both automatic (control self-initiated) and semi-automatic (operator triggered) initiation of a warm-up program. The automatic or semi-automatic initiation of a warm-up program shall be subject to the program halt requirements outlined in paragraph 3.11.17.

3.11.17.3. Warm-up Program Enable/Disable Function. Each machine control shall come provisioned with a function that permits the discrete on-off selection for both automatic and semi-automatic initiation of a machine warm-up program. The selection of “off” shall prohibit initiation of a warm-up program for the respective mode of operation.

3.11.17.4. Warm-up Program Function Admin Control. Each machine control shall require

“maintenance” level or higher administrative control access to enable and disable both warm-up program initiation functions.

3.11.17.5. Warm-up Program Manual Initiation. Each machine control shall come provisioned with a function that permits operator semi-automatic initiation of a machine warm-up program.

3.11.17.6. Warm-up Program Autonomous Initiation. Each machine control shall come provisioned with function for the time-dependent input directing the automatic initiation of a machine warm-up program. The function shall permit the manual entering of initiation frequency based on discrete calendar day(s) of the week e.g., Mon, Tues, Wed, etc., and the time of day

(hh:mm).

3.11.17.7. Warm-up Program Halt. Each machine control shall be provision to automatically halt or prevent the initiation of a warm-up program if any of following conditions exist.

• Persistence or activation of a machine safety feature.

• Persistence or activation of a machine or machine sub-component fault code.

• Presence of the machine key in maintenance mode.

3.11.18. Shutdown Program. The Contractor shall provision each machine control with a shutdown program. The program shall be capable of a controlled, automatic shutdown of the

NC-control without fault upon completion of a NC part program. The program shall maintain warm condition for spindle, controls, and circulating coolant system.

3.11.19. Preventative Maintenance Action Notification. The Contractor shall provision each machine control with the capability to schedule, track, display, notify, report, and acknowledge completion of OEM recommended, machine specific Preventative Maintenance (PM) notifications. A PM notification, at a minimum, shall contain a short description of the service required to be performed and a discrete “target value” indicating when the action is to be completed. PM notification occurrence/re-occurrence shall be based on OEM recommended best practices e.g., calendar days, component cycles, component run-time, or combination thereof.

Each machine control shall automatically report “due” and “overdue” preventative maintenance actions to the Government industrial network using methods described in Paragraph 3.12.3.

3.11.19.1. PM Due Notification. A preventative maintenance action shall be considered to be

“due” when the current PM action of interest for which a notification was issued falls within a plus or minus ten percent (±10%) window of the target completion value. A due PM notification shall automatically report to the Government industrial network using methods described in

Paragraph 3.12.3. A PM notification that indicates a maintenance action is due shall not prevent the operation of a machine.

3.11.19.2. PM Overdue Notification. A preventative maintenance action that exceeds the target completion value by greater than ten percent (>10%) shall automatically report to the

Government industrial network, using methods described in Paragraph 3.12.3, that the subject maintenance action is now “overdue”. With the exception of “operator” PM actions, an overdue maintenance notification shall prohibit activation of the machine’s “cycle start” function until the acknowledgement of PM completion. An “overdue” maintenance action shall not prevent the application of power to the affected equipment.

3.11.19.3. PM Notification Reset.