DRAFT_MTE_450V_PS_SOW_Performance_Specification_CDRL_Package_24_Jan_2019_Eglin_(rev2).pdf

STATEMENT OF WORK (SOW)

AN/MSQ-T43(V)1&4

MODULAR THREAT EMITTER (MTE)

450 VOLT POWER SUPPLY ASSY (1A3PS1) UPGRADE

Attachment 1, Performance Specification

Attachment 2, CDRL Package

PREPARED BY COMBAT & MISSION SUPPORT BRANCH

AFLCMC/HBZCA

6057 BOX ELDER Ln, BLDG 1285 HILL AFB, UT

84056-5811

1.0 SCOPE

This Statement of Work (SOW) defines requirements for First Article Testing (FAT) and delivery of a replacement MTE 450 Volt High Voltage Power Supply (PS) Assembly (1A3PS1). The existing power supply is a linear, non-regulated supply. The replacement shall be a linear, regulated, variable supply as further specified in the Performance Specification. Following successful accomplishment of Production Representative Article (PRA) First Article objectives and following a Government optional production decision, the Government will purchase 21 additional power supplies. This program includes the associated program management, engineering and logistic support planning necessary for the First Article Testing (FAT), demonstrations, production planning, and technical data necessary to support a minimum of a 10-year period after delivery for follow-on sustainment of production units and components.

1.1 BACKGROUND

This program is initiated to complete the redesign and replacement of the existing MTE 450 Volt

Power Supply in response to Air Combat Command requirements specified in HQ ACC/A3AR

Form 1067, dated 2 August, 2011. The 450V High Voltage Power Supply sources voltage and current to the system track transmitter. It is a linear, non-regulated supply consisting of a Wye to

Delta Step-up Transformer (T1) and the Rectifier Filter Assembly (PS1) which houses the 3-phase bridge rectifier, storage capacitors, inductor, resistors and fault relay K1. The current 1A3PS1 assembly does not protect the host system track transmitter from voltage surges that may be present on the commercial AC line voltage inputs. Furthermore, the on/off nature of the supply does not allow users to adjust the high voltage output which is necessary when seasoning a new magnetron.

In order to mitigate the limitations of the existing system, migration to a regulated, adjustable supply shall be accomplished.

A 2017 project to replace the original 450 Volt Power Supply produced a Production

Representative Article (PRA) and data package that requires redesign. The PRA and data as requested by the contractor will be provided as Government Furnished Equipment/Government

Furnished Information (GFE/GFI) but the contractor shall not hold the Government liable for any mistakes or missing information.

Improvements to the PRA and technical data will include:

a. The power supply unit shall meet its operational requirements and provide an output voltage of between 200 VDC - 450 VDC. The DC output voltage must be able to switch on via a 28

Volt signal trigger after the initial turn on is activated.

b. The rise time characteristic of the 28 volt triggered DC output voltage shall meet its intended DC set-point voltage in no greater than 3 seconds once the 28-volt push button / signal trigger is activated. The rise time is defined from the measured 10% to 90% points of the power supply DC output voltage.

c. The 120 VAC input power is always present during the ON/OFF sequencing. The 120 VAC is always energized to the power supply.

d. All addendum requirements, will not shorten the life cycle usage of 10,000+ hours Mean

Time Between Failure (MTBF) of the power supply (10-year period for AN/MSQ-

T43(V)1&4).

e. Production Representative Article (PRA) testing is required during development at the vendor’s facility. The PRA test procedures will be developed and delivered NLT 20 days prior to testing (IAW CDRLs A005 and A008 that are approved) by the Government before accomplishing the PRA First Article Acceptance Test (FAT).

f. Production Representative Article (PRA) will be developed. Preliminary Design Review

(PDR) and Critical Design Review (CDR) data for the intended design-build shall be delivered to the Government Contracting Officer for Government approval reviews IAW

CDRL A004 and A007.

g. All schematics, assembly drawings, drawings, bill of material and technical orders will be updated and approved by the Government. These documents will be delivered IAW

CDRLS A009, A013, A014 and A016.

h. The 450V power supply lid/top cover will be fastened by screws that are accessible on both ends, (Not on top of lid/cover). This shall not violate any environmental design requirements.

i. Environmental / vibration testing will be required, and test reports delivered to the

Government IAW contractual requirements.

j. The period of performance will begin upon activation of contract award and will last no longer than nine consecutive months. The complete design analysis, fabrication, and testing after contract modification award shall be complied with during the period of performance.

k. The contractor shall deliver to the Government Contracting Officer all final engineering drawings NLT 15 days prior to the Physical Configuration Audit (PCA). The PCA will be performed and data delivered IAW CDRLs A004 and A007. During the PCA, all component parts shall be visible for the team to view and identify.

l. The Factory Acceptance Test (FAT) shall be performed at the contractor’s facility. The Site

Acceptance Test (SAT) shall be conducted on an operational AN/MSQ-T43(V)1&4 system.

m. The regulated 450V Power Supply must meet or exceed specifications for the operational legacy power supply currently fielded in the AN/MSQ-T43 (V) Systems.

Upon successful testing, demonstration, and acceptance of the First Article unit, the Government intends to purchase an additional 21 units. The intent is to obtain Department of Defense approval to re-procure production 1A3PS1 assemblies through exercising production options or using a

Technical Data Package (TDP) that includes the performance specifications and the technical data developed under this SOW, IAW CDRLs A005, A007, A008, A009, A013, A014, A015 and A016.

2.0 APPLICABLE DOCUMENTS

The following documents are applicable to this SOW and/or attached appendices to the extent specified herein.

2.1 Department of Defense Specifications

Performance Specification, AN/MSQ-T43(V) MTE 450 V Power Supply 1A3PS1

2.2 AN/MSQ-T43(V) Technical Orders

Technical Order Title

43D7-11-36-1 OPERATION AND MAINTENANCE INSTRUCTIONS, MAINTENANCE LEVEL

43D7-11-36-1-1 OPERATION AND MAINTENANCE INSTRUCTIONS, MAINTENANCE LEVEL

43D7-11-36-3 CIRCUIT DIAGRAMS, MAINTENANCE LEVEL

43D7-11-36-3-1 CIRCUIT DIAGRAMS, MAINTENANCE LEVEL

43D7-11-36-4 ILLUSTRATED PARTS BREAKDOWN

43D7-11-36-06 GROUND WORK UNIT CODE MANUAL, MAINTENANCE LEVEL

43D7-11-36-6WC-1 PREVENTIVE MAINTENANCE WORKCARDS

43D7-11-36-9 ALIGNMENT INSTRUCTIONS, MAINTENANCE LEVEL

43D7-11-36-13 SPECIAL MAINTENANCE INSTRUCTIONS, DEPOT MAINTENANCE LEVEL

43D7-11-36-23 SPECIAL MAINTENANCE INSTRUCTIONS, DEPOT MAINTENANCE LEVEL

2.3 Department of Defense Manuals

DoD-5220.22-M National Industrial Security Program Operating Manual (02/28/2006)

2.4 Other Government Documents

DFAR Clause 252.227-7015

DFAR Clause 252.227.7102-1 a&b

DFARS 252.211-7003 Item Identification and Valuation (17 October 2017)

MIL-STD-130 Identification Marking of U.S. Military Property

2.5 Availability of DoD Documents

Unless otherwise indicated, copies of specifications, standards and handbooks listed above are available for the Standardization Document Order Desk, 700 Robbins Ave., Bldg. 4D, Philadelphia

PA 19111-5094.

2.6 Non-Government standards and other publications

ASME Y14.24-1999 Types and Applications of Engineering Drawings. ISO 9001:2015 Quality

Management System – Requirements.

2.7 Availability of Non-Government standards and other publications.

Unless otherwise indicated, standards and handbooks listed are available from commercial and professional publishing sources.

2.8 Government Furnished Information (GFI) and Government Furnished Equipment

(GFE)

The Government shall provide the redesigned power supply unit to the contractor and an accessible reference library containing all associated technical data. The contractor shall make requests for

GFI and GFE to the SPO through the contracting officer no later than 60 days prior to the need date.

The SPO will attempt to secure the requested GFI and GFE if it can be made available and released for the contractor’s use. The Power Distribution Unit is not available as GFE (houses the 1A3T1 and 1A3PS1), however, 1A3T1 and 1A3PS1 may be available. Requests for access to MTE systems at various EW ranges may be coordinated through the System Program Office.

3.0 REQUIREMENTS

3.1 General

The work required by this contract shall be performed in accordance with the Performance

Specification, AN/MSQ-T43(V) MTE 450 Volt Power Supply (VPS) 1A3PS1, and this SOW. The contractor shall redesign, develop, fabricate, and test a First Article unit to meet the performance criteria specified by the MTE 450 VPS 1A3PS1 Performance Specification and in accordance with the detailed requirements of 3.2.1 below. The regulated 450 VPS shall perform to the specifications provided, improving the overall system performance. The contractor shall provide program management, engineering management, logistic support planning, and system documentation in accordance with the detail requirements of 3.3 below.

3.1.1 Technical Data

The contractor shall provide a complete Technical Data Package (TDP) IAW CDRLs A005, A007, A008, A009, A013, A014, A015 and A016 of the production-quality power supply suitable for manufacture or repair activities by other sources. All rights to drawings generated in connection with this effort shall be transferred to the Air Force. The contractor is expected to deliver a full non-propriety data package with full government rights in data (GRID) for organic Government operations, maintenance and sustainment to include production-level drawings, operator and maintenance technical orders and software source codes/firmware. The Government shall have unlimited rights, in all drawings, designs specifications, notes and other works developed in the performance of this contract. The contractor shall provide (but is not limited to) complete drawings, parts lists, operating instructions, maintenance and troubleshooting instructions, interface specifications, manufacturer/supplier sources, software, and other information as needed, suitable for procurement, repair, and calibration of the developmental and COTS items as applicable. If the contractor makes any corrections to the existing government documentation in order to successfully design and/or test the replacement articles, the contractor shall crosscheck such with the government and provide corrected documents (with agreed-upon changes) back to the government

(AFLCMC/HBZCA)." All TO change pages and COTS manuals shall have unlimited data rights.

Data regarding items designed or developed specifically for this project in which government funds were used shall also have unlimited government use rights.

The TDP shall include any/all Commercial or Commercial-Off-The-Shelf (COTS) Manuals and associated supplemental data, prepared as defined in this SOW and the associated Data Item

Description (DID), and CDRL Form 1423, for all COTS items that are used to produce or create the design, including the Key Performance Parameters used by the contractor to select the item. All schematics, assembly drawings, drawings, bill of material and technical orders will be updated.

CDRLs A005, A007, A008, A009, A013, A014, A015 and A016.

3.2 Detail Tasks

3.2.1 Engineering, Fabrication and Test

Program Management, engineering, testing and reviews will be accomplished using

Contractor/Government entrance/exit agreed upon criteria. The program shall be managed and conducted using ISO9001:2015 Quality Management Systems – Requirements or an equivalent quality assurance system.

3.2.1.1 Design and Engineering

The contractor shall successfully deliver a First Article MTE 450 V Power Supply, which meets or exceeds the program specifications and design criteria. The power supply shall be an improved, modified design that includes an adjustable, regulated feature. Use of Off the Shelf (OTS) equipment that can be modified to work in this application is acceptable. The engineering approach will use trade-offs between performance, reliability, maintainability, supportability, reproducibility, and life cycle cost management criteria, as required, to deliver a reliable, supportable and cost effective power supply. The First Article unit will be fit compatible within the existing MTE Power

Distribution Unit Assembly.

Since existing power supply specifications are limited, the contractor shall accomplish a site visit to characterize the electronic static and dynamic performance specifications of the power supply under load conditions. Physical interfaces will also be verified. The MTBF of this power supply shall be

10,000+ hours.

The contractor shall generate, maintain, certify and submit engineering drawings, schematics, parts lists, vendor control drawings, etc., as applicable (CDRLs A009). At a minimum, the government requires Limited Government Use data rights for vendor OTS equipment used to fulfill this contract. The government requires unlimited data rights on the modifications added to vendor OTS equipment built as a result of this acquisition. The contractor shall obtain, evaluate and submit

COTS – Commercial Off-The-Shelf (COTS), Government Off-The-Shelf (GOTS) technical hardware / software/firmware operational, Maintenance manual(s) data. This data shall support the sustainability and mission requirements of the 450 VPS (1A3PS1) as required by (CDRL A014). If the COTS / GOTS data is not available or insufficient to meet the above requirements the contractor shall provide the data IAW (CDRL A013).

The government requires full data rights for custom power supply designs built to fulfill this contract. Design authority for all items developed under this task shall be transferred to the Air

Force with delivery of the Technical Data Package (CDRL A016). The Government also requires applicable license rights to custom applications, custom firmware and/or 3rd party software used in the design of this power supply.

3.2.1.2 Systems Requirement Review (SRR)

The contractor shall develop a draft System/Subsystems Specification prior to the SRR (CDRL

A015). The SRR shall be held at the contractor’s facility no later than 45 days after receipt of award (ARO). This requirement will necessitate that the site visit described in paragraph two of

Section 3.2.1.1 also occur before the SRR. The SRR will be a flow down of requirements from the

MTE Performance Specification, SOW and pre SRR site visit. The SRR will be successfully completed when the draft System/Subsystem Specification is approved by the Government.

Changes to the draft systems specification and agreements reached during the SRR shall be documented in the formal systems specification.

3.2.1.2.1 Compatibility

The contractor shall build and deliver the MTE replacement 450 VPS, (1A3PS1) PRA, to the form, fit and modified function that is compatible with Power Distribution Unit Assemblies mechanical and electrical interfaces as defined in the MTE Performance Specification, SOW and other applicable documents. A Physical Configuration Audit (PCA) shall be conducted as part of the FAT to verify that the 450 VPS, (1A3PS1) PRA physical item conforms exactly to engineering drawings

(CDRLs A004, A005, A007 and A009). During the PCA, nearly all component parts shall be visible for the team to view and identify.

3.2.1.2.2 Design Analysis (DA)

The contractor shall conduct a design analysis of the proposed power supply and submit IAW

CDRL A017. Detailed physical and performance design characteristics shall be specifically identified and shall describe how these design characteristics are employed to meet system requirements. Thermal dissipation shall also be addressed in the power supply design.

In addition, the engineering rationale for selecting one methodology over another shall be described. Reviews shall include discussion of alternatives and the ramifications thereof, risk assessments, and trade-offs made. (CDRL A002)

The contractor shall support informal Technical Interchange Meetings (TIMS) and conference calls as mutually agreed between the contractor and the Government. Whenever possible, informal

TIMS will be held in conjunction with Program Reviews.

3.2.1.3 Preliminary Design Review (PDR)

The contractor shall conduct a formal Preliminary Design Review at the contractor’s facility no later than 75 days ARO. Informal reviews may also be held at times agreed to by the Government and the contractor. The contractor shall incorporate changes approved during the PDR and incorporate those changes into the Subsystem Specification. Written procuring activity approval of the PDR is required before the contractor is authorized to proceed with First Article unit fabrication.

3.2.1.4 Critical Design Review (CDR)

The contractor shall conduct a Critical Design Review at the contractor’s facility, not later than 110 days ARO. At CDR, the contractor shall formally report the results of prefabrication tests and describe changes made to the post PDR design that were made as a result of the these tests including trade-off impacts. The contractor shall incorporate all changes approved during CDR into the Subsystem Specification. As a result of the DA analysis conducted in paragraph 3.2.1.2.2, the

PDR in 3.2.1.3, and a closed CDR, the contractor shall formalize and freeze the baseline design of the power supply and place further changes under configuration control of the Government.

3.2.1.5 Fabrication

The contractor shall correct and document any characteristics that are found to inhibit or make fabrication unnecessarily costly but that do not negatively impact power supply performance or effectiveness. The First Article unit shall use the hardware and, if any, firmware expected to be used in the production option. Design and fabrication changes that occur throughout the program shall be incorporated into the hardware and firmware as applicable. The configuration resulting from any such changes shall be fully documented and controlled by the Government approved contractor configuration management system.

3.2.1.6 Long-Lead Materials

The list of First Article unit long lead items requested to be ordered prior to the CDR shall be submitted to and require the approval of the Range Threat SPO (Hill AFB, UT) before orders are placed. The contractor shall provide rationale and pricing information in support of the long lead request.

3.2.1.7 Test and Evaluation

The contractor shall plan for, conduct and evaluate the results of environmental and performance tests on the First Article units to demonstrate full compliance of all equipment and software with the output of SRR. Environmental/shake testing will be required, with test reports. Vendor OTS equipment previously tested to equivalent or better environmental, EMI/EMC and shake & vibration specifications need not retest for this requirement. Evidence of certification shall be required. Tests shall be conducted in accordance with the test plan developed by the contractor and approved by the Government. The contractor shall document the test plans (CDRL A008), test procedures (CDRL A005) and test/inspection reports (CDRL A006). The tests may be conducted at the contractor’s facilities or at an independent laboratory or commercial testing facility.

A Factory Acceptance Test (FAT) shall also be conducted at the contractor’s facility to verify, to the full extent possible, that the power supply meets the specifications and characteristics as defined in the SSS. This test shall be conducted and reported IAW CDRLs A005, A006, and A008.

Integration and site acceptance testing shall be conducted on an AN/MSQ-T43 MTE system, located on a Government test and training range, or as otherwise specified by the Government. The purpose of such tests is to demonstrate performance in the MTE systems intended to receive this new modified, adjustable, regulated 450 V power supply assembly (CDRLs A005, A006, and

A008). For each system, integration testing shall be conducted in at least a two-step process, a low level interoperability test that validates all interface functions, followed by an operational high level test in a Site Acceptance Test (SAT) environment. Issues identified in the SAT shall be resolved with additional lower level testing, as appropriate, and agreed upon by Government, system integrator and power supply developer. As required, a second week of integration and SAT should be planned to allow for resolution of any difficulties encountered during initial integration or SAT of the First Article unit. (CDRLs A005, A006)

Each production unit shall also be tested by the contractor to verify that it preforms to the design specifications and each power supply shall be delivered with a certificate of compliance. Tests shall be conducted and reported as defined by CDRL’s A005 & A006.

3.3 Program Planning

3.3.1 Program Management

The contractor shall establish and maintain management operations and reporting that shall include the following areas as applicable to the contract (CDRL A002):

a. Program Planning and Control,

b. Subcontractor Control,

c. Financial Management and Cost Status Reporting,

d. Data Management,

e. Management and Accountability for Government Furnished Equipment, Material or

Information,

f. Risk Management,

g. Security,

h. Configuration Management,

i. Quality Management (per ISO 9001:2015 or equivalent).

3.3.1.1 The contractor shall implement a Management Program that clearly defines how the First

Article unit and the Production Option units will be managed and controlled. The management program shall include sufficient detail to identify contractor and subcontractor responsibilities. The

Government foresees a need in the future for production. Upon Government acceptance of the First

Article unit, the Government reserves the right to negotiate quantity and type of production assets needed. The contractor shall plan for Government approved configured unit production.

3.3.1.2 The contractor shall employ program management office processes and procedures to manage all technical performance, reliability, maintainability, integrated logistics support (ILS), cost, schedule, and data delivery requirements of the contract. The contractor shall generate

Conference Minutes (CDRL A001), Contractor’s Progress, Status, and Management Report

(including applicable contract funds status, in company format) (CDRL A002), and an updated

Contract Work Breakdown Structure (CWBS) CDRL A003 per the associated Data Item

Descriptions (DIDs).

3.3.1.3 The contractor shall perform subcontractor management sufficient to ensure that subcontractors perform in accordance with the requirements of this contract Contractor’s Progress, Status, and Management Report (including applicable contract funds status, in company format)

(CDRL A002). The contractor shall flow down all applicable requirements of this program and ensure compliance by any subcontractors.

3.3.1.4 The contractor shall plan for and conduct program management reviews at the contractor’s facility or at a mutually agreed location. These reviews will provide program status, report progress on contract deliverables, schedule status, financial status and the achievement of program objectives. The program review meetings will be held in conjunction with the, PDR and CDR meetings when mutually agreeable.

3.3.1.5 The contractor shall implement security procedures for classified processing and protection of classified data as required for hardware and firmware in accordance with the DoD-5220.22M

National Industrial Security Program Operating Manual (NISPOM, August 1 2018) and the

Electronic Warfare Threat Emitter Security Classification Guide Range Threat Systems OO-ALC

(14 April 2014) and the DD-254 of this contract. This program is not anticipated to have classification requirements; however, access to classified and export-controlled data may be required as well as access to controlled locations.

3.3.2 Engineering Program

The contractor shall implement best commercial engineering practices in their engineering program to ensure that appropriate studies are performed and that engineering criteria are applied to subsystem hardware, computer, and firmware design. The contractor shall ensure that the power supply will operate properly in the stated environment and deliver the necessary power under the dynamic and static loads presented by the target system. The contractor shall provide engineering data that documents the physical design, configuration and testing of the power supply in accordance with CDRLs A006, A007, A009, A013, A014, A015, A016 and A017.

3.3.3 Logistic Support Planning

The contractor shall implement an ILS program to ensure that supportability of the power supply is considered and incorporated into the physical design and that the Technical Data Package is accurate, complete and in compliance with the associated DIDs. The ILS program shall address logistics support, operation and maintenance, maintenance planning, support equipment definition, training materials, spare parts recommendations, drawings, Packaging, Handling, Shipping and

Transportation (PHS&T) data all to be included in the Commercial Manual (CDRL A014). The contractor shall implement an IUID marking program using the guidance of DFARS 252.211-703

(CDRLs A010, A011)

In an effort to maintain high levels of Operational Availability, the Contractor shall also identify power supply subcomponents and sub-assemblies with the highest risk of failure. Furthermore, the power supply shall be supportable for at least 10 years. The contractor shall show how this will be accomplished. Any contractor provided commercial manuals shall comply with the requirements of

MIL-PRF-32216 and shall include but not be limited to, troubleshooting instructions, operating instructions and removal and replacement instructions. (CDRLs A013 and A014) Furthermore, the power supply shall be designed such that no special or unique tools are required for installation, testing, troubleshooting or removal.

3.3.4 Manufacturing Planning

The contractor shall consider during the development of this new MTE 450 V Power Supply

1A3PS1 the technician’s ability to access replaceable parts, efficiencies and processes for this task.

3.3.5 Counterfeit Parts Prevention

The contract shall plan and implement procurement practices and procedures to include procurement of all parts and materials from original qualified parts/materials equipment manufacturer (OEM) or it franchised/authorized distributor. The contractor shall submit a Counterfeit Prevention Plan (CDRL

A012).

4.0 PERFORMANCE

4.1 Period of Performance

The Period of Performance for this project is 9 months allotted for First Article development & test and an optional 6 months for build, test and delivery of 21 production units. Early delivery of the

First Article unit and production units is acceptable.

4.2 Deployment

Assets will be shipped to the following locations. The commercial manual shall be shipped with each power supply. Best commercial practices will be used to package and ship the power supplies.

Location DODAAC Quantity

Nellis AFB FB4852 4

Eielson AFB FB5004 5

Mountain Home AFB FB4897 6 (PRA First Article testing)

Dare County, NC FB4809 1

Hill AFB SW3210 5 (spares)

4.3 Schedule

Contract Data Requirements List Delivery Schedule is as outlined in the following table.

Paragraph Description CDRL DID Due Date

3.3.1.2 Conference Minutes A001 DI-ADMN-81250B/T 5 working days following the conference

3.2.1.2.2

3.3.1

Contractor's Progress and Status Report

A002 DI-MGMT-81928/T First Submittal NLT 30 calendar days after contract award. Subsequent submittals shall be submitted NLT 10 working days following the end of the preceding month

3.3.1.2 Contract Work

Breakdown Structure

(CWBS)

A003 DI-MGMT-81334D/T Contractor shall submit a proposed draft CWBS as an attachment to the Government

Post Award Meeting (PAM) presentation material. First

Government approved submittal

NLT 30 calendar days after completion of the Government conducted PAM. The monthly updated CWBS shall be provided as an attachment to each submittal of DI-MGMT-

81928/T (Contractor's Progress and Status Report).

3.2.1.2.1

Configuration Audit

Plan

A004 DI-SESS-81646B/T Draft Initial submittal shall be submitted NLT the Preliminary

Design Review (PDR). Final

NLT 20 calendar days before first (1st) planned Audit event.

Paragraph Description CDRL DID Due Date

3.2.1.2.1

3.2.1.7

Test Procedures A005 DI-NDTI-80603A Initial submittal shall be submitted NLT 20 calendar days prior to the application Development Production Representative Article (PRA) First Article Test (FAT)

3.1.1

3.2.1.7

3.3.2

Test / Inspection

Reports

A006 DI-NDTI-80809B/T NLT 15 working days after each test

3.1.1

3.2.1.2.1

3.3.2

Configuration Audit

Summary Report and

Certification

A007 DI-SESS-81022D/T NLT 15 working days following test event

3.2.1.7 Acceptance Test Plans

(FAT, SAT)

A008 DI-QCIC-80553A/T NLT 30 calendar days before

First Article test

3.1, 3.1.1

3.2.1.1

3.2.1.2.1

3.3.2

Product

Drawings/Models and

Associated Lists

A009 DI-SESS-81000E/T NLT 60 calendar days following successful First

Article test

3.3.3 IUID Marking Plan A010 DI-MGMT-81803/T NLT 90 calendar days following contract award

3.3.3 IUID Marking Activity

and Verification Report

A011 DI-MGMT-81804A/T NLT 30 calendar days following completion of IUID requirement

3.3.5 Counterfeit Prevention

Plan (CPP)

A012 DI-MISC-81832/T Draft Initial submittal shall be submitted NLT the Preliminary

Design Review (PDR). Final

NLT 20 calendar days after

Critical Design Review (CDR).

3.1.1, 3.3.2

3.3.3

Technical Manuals A013 TMCR-

TM-86-01Q450vPS

Deliver IAW

TM-86-01Q450VPS

5. QUALITY ASSURANCE

5.1. QUALITY ASSURANCE REQUIREMENTS

Unless otherwise specified in the contract, the contractor is responsible for the performance of all inspections and tests necessary to assure compliance with the requirements specified herein. The contractor shall utilize and maintain an inspection system acceptable to the Government for the goods and services purchased under this contract. The contractor shall permit the Government to review their procedures, practices, processes, and related documents to determine such acceptability.

A quality program that complies with International Organization for Standardization Document ISO

9001:2015 - “Model for Quality Assurance in Design/Development, Production, Installation and

Servicing” will fulfill the requirements for an inspection system acceptable to the Government.

At the Government’s request, the contractor shall provide for the Government’s review a copy of their quality program manual, including a matrix that traces the provisions of ISO 9001:2015, or equivalent, to the contractor’s documented procedures.

6. DELIVERY

6.1 PREPARATION FOR DELIVERY

The unit(s) shall be prepared for delivery in accordance with MIL-STD-2073-1E(3) Method 10 and

Special Packaging Instructions (SPI) reference number F000003Xe7, unless otherwise specified in the contract.

END SOW

3.1.1, 3.3.2

3.3.3

Contractor Furnished

Aeronautical

Equipment or

Contractor Furnished

Equipment Notices

(CFAE/CFE Notices

A014 DI-TMSS-80067C/T NLT 90 calendar days prior to the scheduled PRA First 1st

Article.

3.2.1.2 System/Subsystem

Specification (SSS)

A015 DI-IPSC-81431A/T NLT 15 working days following the SRR and NLT 15 calendar days following any mutually agreed upon modifications after the SRR.

Paragraph Description CDRL DID Due Date

3.1.1

3.2.1.1

Technical Data

Package

A016 DI-SESS-80776A/T NLT 60 calendar days following successful First

Article test

3.2.1.2.2 Subsystem Design

Analysis Report

A017 DI-SESS-80567B/T Initial NLT 20 calendar days prior to the PDR and Final NLT than 30 calendar days prior to the CDR.

ATTACHMENT 1

Performance Specification

FOR

AN/MSQ-T43(V)1&4)

450 Volt Power Supply (1A3PS1)

1.0 SCOPE

This document defines the requirements for a 450 (+4%) volt, 3-phase, 60 Hz, high voltage power supply. The power supply sources the voltage and current to the transmitter circuits that drive the

Pulse Forming Network (PFN), Pulse Transformer (PT), magnetron and other low current, sensing and switching circuits. The power supply is installed within a weather resistant enclosure and mounted on the radar platform. The AN/MSQ-T43(V)1&4 is a mobile, ground-based system.

1.1 BACKGROUND

The 450 volt, high voltage power supply sources voltage and current to the system track transmitter.

It is a linear, non-regulated supply consisting of a Wye to Delta step-up transformer (T1) and the rectifier filter assembly (PS1) which houses the 3-phase bridge rectifier, storage capacitors, inductor, resistors and fault relay K1. Transformer T1 receives 3-phase, 120 VAC from a commercial or generator power source and outputs 3 phase, 350 VAC to the PS1 assembly. The

PS1 assembly rectifies and filters the 350 VAC to a nominal 450 VDC (+4%). Fault relay K1 is used to disable high voltage when certain transmitter faults occur. When a candidate fault occurs, the +28 volts that is connected to the coil of relay K1 in the PS1 assembly goes to zero which opens the relay and disables the high voltage to the modulator. Control of the +28 volt supply is independent of the PS1 assembly.

Furthermore, as described in the system TO (43D7-11-36-1, paragraph 5.16.5.7), and external to the

450 V power supply, there is a, “… charging SCR assembly that controls the charging of the modulator energy storage capacitor. The storage capacitor charging procedure is initiated when charging SCR Q1 is fired by the delayed trigger input pulse. Charging SCR Q1 then connects charging choke 1A8L1 to the modulator storage capacitor. The charging reactor and the storage capacitor form a DC resonant charging network which nearly doubles the 450V power supply voltage. The storage capacitor charge level is maintained on a pulse-by-pulse basis in order to ensure a constant magnetron output from pulse to pulse. The regulation procedure is initiated when regulator SCR Q2 is fired by the energy regulator trigger pulse. Conduction current through Q2 is then routed through a second (bucking) winding on the charging choke. This current, when induced into the charging choke main winding, is equal to the charging current in amplitude, but opposite in phase, thus stopping the storage capacitor charging. Almost all of the bucking current is discharged back into the 450 volt power supply assembly 1A3PS1, thereby enhancing regulator efficiency”.

2.0 APPLICABLE DOCUMENTS

Unless otherwise specified, the following documents of the issue in effect on the date of the invitation for bids or requests for proposal form a part of this specification to the extent specified herein.

2.1 GOVERNMENT MILITARY STANDARDS

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-20703-1 Standard Practice for Military Packaging

MIL-STD-2073-1E3, Method 10

DFAR-252.211-7003 Item Unique Identification and Valuation

MIL-STD 461 Requirements for the Control of Electromagnetic Interference

Characteristics of Subsystems and Equipment

MIL-HDBK-781A Reliability Test Methods, Plans, and Environments for Engineering

Development, Qualification, and Production

2.2 OTHER PUBLICATIONS

ISO 9001:2015 Model for Quality Assurance in Design, Development, Production, Installation and Servicing

2.3 INTERFACE CONTROL DOCUMENTS (ICDs)

716436 Power Supply Assembly 450V

SD716436 450V Power Supply Schematic Diagram

BTP716436 Power Supply Assembly, 450V Bench Test Procedure

WD714577 Power Distribution Wiring Diagram

3.0 REQUIREMENTS

[R001] The contractor shall be responsible for validating the operational voltage and current requirements of the existing supply to ensure that the new supply performs as required under static and dynamic load conditions. As described in Section 3 above, relay K1 (located within 1A3PS1 assembly) inhibits the high voltage when certain system faults are encountered.

[R002] The contractor shall ensure that this functionality is included in the new power supply by either using the existing K1 relay or by implementing an equivalent method.

[R003] The new power supply shall also be required to sink the bucking current described in

Section 3 above without damage to the power supply or host system.

[R004] The power supply shall not induce disruptive power supply spikes or low/high frequency noise into the host system.

3.1 GENERAL REQUIREMENTS

This project will replace the original 450 volt linear, DC power supply with a linear, regulated, variable, 200 - 450 volt DC supply (power supply variability may go to 0 volts).

[R005] The 450 VDC Power Supply shall be fabricated using best-commercial practices and utilize

Government Off-The-Shelf (GOTS) or Commercial Off-The-Shelf (COTS) and Non-

Developmental Items (NDI) to the maximum extent possible in an effort to reduce NRE and to benefit from current, state-of-the-art technologies. Documented modification of COTS or GOTS equipment to meet the requirements of this project is acceptable. Modification data as ‘Altered Item

Data ‘shall be delivered in the CDRL A009 submittal.

3.2 PERFORMANCE REQUIREMENTS

3.2.1 ELECTRICAL CHARACTERISTICS

Electrical connection from the system to the power supply, both T1 and PS1, is accomplished with terminal boards that accept #8 lugs.

[R006] The power supply unit shall meet its operational requirements of being able to provide an output set-point voltages of between 200 VDC and 450 VDC, and for the DC output voltage to be able to be switched-on via a 28 Volt signal trigger after the power supply unit has initially been turned-on and stabilizes.

[R007] The rise time characteristic of the 28 volt triggered DC output voltage shall meets its intended set-point DC voltage of no greater than 3 seconds from the time the 28 Volt signal trigger is activated. The rise time is defined from the measured 10% to 90% points of the power supply

DC output voltage.

The 120 VAC input power is always present during the ON/OFF sequencing. The 120 VAC is always energized to the power supply.

The 450 VDC Power Supply shall, at a minimum, meet the following electrical performance requirements:

Requirement

Number

Title Specification

[R008] Input Voltage 115V ac min, 3-phase, 60 Hz 230V ac min, phase to phase, 60 Hz

[R009] Line Regulation < 0.1% of max V for line change within specified input voltage range

[R010] Typical Output Current 8.5 – 9.5 A, typical operating Approximately 30-50 A instantaneous peak current (Transmitter operating at

.0014 (.14%) Duty Cycle – max)

[R011] Output Voltage Regulated, Variable 200 – 470 VDC

[R012] Load Regulation < 0.1% of max V at full load step

[R013] Voltage Ripple < 30 mV

[R014] Stability < 1% max/8 hours at constant voltage, current and

Temperature, allowing for a 30 minute warm-up

[R015] Temperature

Coefficient

< 0.05%/C

[R016] Max Output Power The specification for the max output power of the original power supply is not recorded in any documents available to the AF. Output power to be determined by the contractor based on static and dynamic operating conditions of the system.

[R017] Protection Circuitry The Air Force is not in possession of certain minimum specifications for the original power supply such as noise, efficiency, isolation, missing phase protection, over temperature, over current, or over/under voltage protection requirements.

Protections shall be included in the power supply, typical to industry standards that will protect itself and the host system from damage or failure.

3.2.2 ENVIRONMENTAL REQUIREMENTS

Requirement

Number

Title Specification

[R018] Temperature Operating -30 to +55 Degrees C (-22 to 131 F)

Storage -51 to +68 Degrees C (-59.8 to 154.4 F)

[R019] Humidity 5 TO 95% Relative Humidity, Non-condensing, Operating, and Storage

[R020] Shock (Non-Operating) 20 G, 11 ms, in 3 Axes, Both Directions

[R021] Vibration (Non-

Operating)

See Fig. 1.

[R022] EMI/EMC The power supply shall the meet the requirements of

MIL-STD-461F, Sections 5.5, 5.7, 5.13, 5.14, 5.15,

5.17 & 5.20 For Air Force Ground Equipment

Figure 1. Vibration Level

3.2.3 MECHANICAL SIZE AND WEIGHT REQUIREMENTS

[R023] The new 450V Power Supply shall be fit compatible with the existing AN/MSQ-T43(V)

MTE Power Distribution Unit. In the event that a COTS or GOTS solution is not fit compatible but meets the other specifications, the COTS or GOTS solution can be repackaged or installed into a new housing that is fit compatible.

[R024] The new housing shall provide equivalent or better environmental protection as the original equipment.

[R025] The 450V Power Supply lid/top cover will be fastened by screws that are accessible on both ends, (Not on top of lid/cover).

Requirement

Number

Title Specification

[R026] Weight (See Fig. 2) The maximum weight of the new 450 VDC Power

Supply shall not exceed the legacy 450 VDC Power

Supply.

Weight PS1 64 lbs.

Weight T1 100 lbs. max

Total Weight < 164 lbs.

[R027] Dimension (See Fig. 2) PS1 8 x 16.75 x 9.25 inches (H x W x D)

T1 8 x 12 x 8.5 inches (H x W x D)

TOP VIEW

SIDE VIEW FIGURE 2. – Location and Dimensions

FIGURE 3. – System Location

FIGURE 4. – Redesigned Power Supply

3.3 USER INTERFACES

[R028] The 450 V power supply design shall provide local means to set and display voltage and current levels.

[R029] Display methods selected shall operate at the minimum specified temperature and be viewable in both low light and sunlight conditions.

3.4 LOGISTICS (RAM)

3.4.1 RELIABILITY

Reliability type failures are chargeable failures as referenced and defined in MIL-HDBK-781A

(paragraph 3.1.4.1 and 4.7).

[R030] The new 450 VDC Power Supply shall have a MTBF of no less than 10,000 hours.

[R031] COTS and non-developmental items shall be included in the MTBF requirements.

3.4.2 AVAILABILITY

[R032] The new 450 VDC Power Supply shall have an Operational Availability (Ao) of 95%. The total operational time for a given year is defined as 10 hours per day, 5 days per week, and 50 weeks per year for the life of the system. Expected life of the system is 20 years. (Ao =

Uptime/Total Time)

3.4.3 MAINTAINABILITY

[R033] The new 450 VDC Power Supply shall be designed to facilitate easy repair with minimum, calibration, alignment, and adjustment.

[R034] The maximum time to correct a fault (i.e., a reported error) shall be no greater than 30 minutes exclusive of travel time and access time.

[R035] When repaired by a maintenance technician of skill level 5 or equivalent, 60% of all failures shall be corrected within 30 minutes or less and 90% of failures shall be corrected within 60 minutes or less.

[R036] Troubleshooting and replacement shall be to the line replaceable unit (LRU) level.

[R037] The new 450 VDC Power Supply scheduled maintenance period shall not exceed 10 minutes, excluding travel time and access time.

[R038] Scheduled maintenance periods shall be required no more frequently than once per 6 month

(180 days).

[R039] Local and field repair of the new 450 VDC Power Supply components shall be within the capability of unit maintenance personnel.

3.5 TEST DIAGNOSTIC CAPABILITY AND USER MAINTENANCE

[R040] The new 450 VDC Power Supply shall include hardware that will facilitate fault isolation and test in support of Line Replaceable Unit (LRU) level maintenance.

[R041] As a minimum, the 450 V power supply design shall provide local means and appropriate maintenance access to isolate power supply faults and failures through use of such features as panel indicators, test points and/or access ports.

[R042] The minimum level of maintenance and repair shall be at the Line Replaceable Unit level.

As an objective, repair options will include modules or parts, as recommended by the manufacturer, which can reasonably be replaced in the field thus reducing system down time and MTTR.

3.6 MARKING AND ITEM IDENTIFICATION

[R043] Marking shall be in accordance with MIL-STD-130.

[R044] All Power Supply CI’s shall use IUID marking IAW DFAR-252.211-7003.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 VERIFICATION METHODS

4.1.1 Demonstration (D). Demonstration is a verification method whereby success is determined by observation. Also included in this category are tests that require simple quantitative measurements such as dimensions, time to perform, etc.

4.1.2 Test (T). Test is defined as verification of the specification requirements through the application of established test procedures within specified environmental conditions and subsequent compliance confirmation through analysis of the data generated. This requirement may be fulfilled by submission of data which demonstrates the required test has been successfully completed.

4.1.3 Analysis (A). Analysis is defined as verification that specification requirements have been met by technical evaluation of equations, charts, reduced data, etc.

4.1.4 Inspection (I). Inspection is defined as a visual verification that the system (including system documentation) complies with specification requirements.

4.2 VERIFICATION MATRIX

TABLE 1. Verification Matrix

Requirement Name/Section Title Requirement

Number

Verification

Method

Comments

Requirements R001 T

Requirements R002 T/A

Requirements R003 T/A

Requirements R004 T/A

General Requirements R005 D/A/I

Electrical Characteristics R006 T

Electrical Characteristics R007 T

Electrical Characteristics R008 T

Electrical Characteristics R009 T

Electrical Characteristics R010 T

Electrical Characteristics R011 T

Electrical Characteristics R012 T

Electrical Characteristics R013 T

Electrical Characteristics R014 T

Electrical Characteristics R015 T

Electrical Characteristics R016 T/A

Electrical Characteristics R017 T/A

Environmental Requirements R018 T

Environmental Requirements R019 T

Environmental Requirements R020 T

Environmental Requirements R021 T

Environmental Requirements R022 T/A

Mechanical Size and Weight Requirements R023 D

Mechanical Size and Weight Requirements R024 D

Mechanical Size and Weight Requirements R025 D

Mechanical Size and Weight Requirements R026 D

Mechanical Size and Weight Requirements R027 D

User Interface R028 D

User Interface R029 D

Reliability R030 A

Reliability R031 A

Availability R032 D

Maintainability R033 D

Maintainability R034 D

Maintainability R035 D

Maintainability R036 D

Maintainability R037 D

Maintainability R038 D

Maintainability R039 D

Maintainability R040 D

Maintainability R041 D

Maintainability R042 D

Marking and Item Identification R043 D

Marking and Item Identification R044 D

5.0 NOTES

5.1 DEFINITIONS

COTS – Commercial Off-The-Shelf

GOTS – Government Off-The-Shelf

MTBF – Mean time between failures (MTBF) is defined as cumulative operation time divided by the number of failures occurring within the time period.

MTTR – For the purpose of this specification, the Mean Time To Repair (MTTR) time includes all maintenance actions required to correct the malfunction and restore the power supply to full operation (includes preparation, test, troubleshooting, removal and replacement of components, repair, adjustment, functional check, and reconfiguration).

Cumulative time basis – The cumulative time basis is the total operating (on) hours, including standby and active (radiate) states. Any exceptions to this general rule of chargeable failures are stated under each requirement.

Failure – a condition caused by operational, maintenance, physical, or other environments, which result in the inability of the equipment to perform its required or expected functions.

Fault – a declared error by the software or hardware that may be resettable or if not resettable, it becomes a failure.

ATTACHMENT 2

AN/MSQ-T43(V)1&4

450 Volt Power Supply (1A3PS1)

CDRL PACKAGE

Note:

For General Data Management, Submissions Information And Explanations

SEE DODM 5010.12-M

MTE 450VPS1 (1A3PS1) 17 JANUARY 2019 CDRL PACKAGE

TABLE OF CONTENTS

CONTRACT: MTE 450VPS1 (1A3PS1)

CONTRACT ID:

CONTRACT NO./PR:

SYSTEM ITEM: AN/MSQ-T43(V)1&4 Modular Treat Emitter (MTE) 450VPS1 (1A3PS1)

CDRL

SEQ. NO.

DID/TITLE DID NUMBER SOW PARA

A001 Conference Minutes DI-ADMN-81250B/T 3.3.1.2

A002 Contractor's Progress and Status Report DI-MGMT-81928/T 3.2.1.2.2 / 3.3.1

A003 Contract Work Breakdown Structure (CWBS) DI-MGMT-81334D/T 3.3.1.2

A004 Configuration Audit Plan DI-SESS-81646B/T 3.2.1.2.1

A005 Test Procedures DI-NDTI-80603A/T 3.2.1.2.1 / 3.2.1.7

A006 Test/Inspection Reports DI-NDTI-80809B/T 3.1.1 / 3.2.1.7 / 3.3.2

A007 Configuration Audit Summary Report and Certification DI-SESS-81022D/T 3.1.1 / 3.2.1.2.1 /

3.3.2

A008 Acceptance Test Plan DI-QCIC-80553A/T 3.2.1.7

A009 Product Drawings/Models and Associated Lists DI-SESS-81000E/T 3.1 / 3.1.1 / 3.2.1.1 /

3.3.2

A010 Item Unique Identification (IUID) Marking Plan DI-MGMT-81803/T 3.3.3

A011 Item Unique Identification (IUID) Marking Activity, Validation and Verification Report

DI-MGMT-81804A/T 3.3.3

A012 Counterfeit Prevention Plan DI-MISC-81832/T 3.3.5

A013 Technical Manuals TMCR-TM-86-

01Q450vPS

3.1.1 / 3.3.2 / 3.3.3

A014 Contractor Furnished Aeronautical Equipment or

Contractor Furnished Equipment (CFAE/CFE) Notice

DI-TMSS-80067C/T 3.1.1 / 3.3.2 / 3.3.3

A015 System/Subsystem Specification (SSS) DI-IPSC-81431A/T 3.2.1.2

A016 Technical Data Package DI-SESS-80776A/T 3.1.1 / 3.2.1.1

A017 Subsystem Design Analysis Report DI-SESS-80567B/T 3.2.1.2.2

END OF CDRL TABLE

1. DISTRIBUTION STATEMENT

1.1. The following Distribution Statements when identified as a requirement on the CDRL shall be affixed to deliverable MTE data item document.

1.2. Technical Order Data delivered per CDRL A013. The following disclosure, distribution, warning, handling and destruction notice statements as aligned shall be used:

1.2.1. DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of

Defense of the United…