TRCECOMBB01_A_(10-7-11)_signed.pdf

TRCECOMBB01

Revision A

7 October 2011

SUPERSEDING

TRCECOMBB01

20 June 2007

TECHINICAL REQUIREMENTS (TR)

STANDARD FAMILY OF DOD

PORTABLE RECHARGEABLE BATTERIES

PREPARED BY:

ARI HEMAN

PROJECT LEADER, RECHARGEABLE BATTERIES

POWER & ENVIRONMENTAL DIRECTORATE

US ARMY CECOM-LCMC

APPROVED BY:

TUAN PHAM

CHIEF, PRD BRANCH

POWER & ENVIRONMENTAL DIRECTORATE

US ARMY CECOM-LCMC

TRCECOMBB01 Rev A Appendix A

DISTRIBUTION STATEMENT A: Approved for public release, distribution unlimited.

INDEX:

Paragraph Requirement Page

1.0 Scope

2.0 Applicable Documents

3.0 Requirements

3.1 Basic Performance Requirements

3.2 Requirements for Configuration Control

3.3 Requirements for Product data

3.4 Requirements for Quality Assurance System

3.5 Requirements for Contractor Performed

First Article Testing & follow-on production

Lot testing

3.6 Information Cards

3.7 Safety

3.8 Requirements for Packaging

3.9 Post-award Orientation Conference

3.10 In-Process Technical Reviews

3.11 Warranty

3.12 Marking and labels

3.13 Soldering and inspection in accordance with

Industry standards.

Appendix A Exceptions to Specifications

1.0 Scope. The establishes the Government‟s requirements for various DOD portable

Rechargeable Batteries identified in paragraph 3.1 in accordance with the referenced documents listed herein. These rechargeable batteries are used in various DOD equipments and had been managed by the Army in prior years.

1.1 Cross-Reference Table. The following table is provided for cross-referencing purposes (for information only): Exceptions to these specifications are at appendix A.

Rechargeable Battery: Rechargeable Battery

NSN:

Non-rechargeable

Equivalent

MIL-PRF-32052

Slash Sheet

BB-2590/U, 6140-01-490-4316 BA-5590 1

BB-390B/U 6140-01-490-4317 BA-5590 1

BB-2600A/U 6140-01-490-4311 BA-5600 2

BB-2800/U 6140-01-490-5372 BA-5800 3

BB-2847A/U 6140-01-493-8092 BA-5847 4

BB-503B/U 6140-01-419-8193 N/A 5

BB-326/U 6140-01-533-7674 N/A 6

BB-2557/U 6140-01-490-5387 BA-5557 7

BB-577/U 6140-01-071-5070 BA-5557 7

BB-2588/U 6140-01-493-7623 BA-5588 9

BB-388A/U 6140-01-490-4313 BA-5588 9

2.0 Applicable Documents. The following documents are applicable to the extent cited.

2.1 Military

and Federal Stds

Document No. Document Title Applicability

DoDD- 5230.24 (D) Distribution Statements on Technical Documents Required

FED-STD-

FED-STD-

MIL-STD-

MIL-HDBK-

810E

263A

461E

Test Procedures for Packaging Materials

Colors Used In Government Procedures

Environmental Test Methods

Standard Practice for Military Marking

Electrostatic Discharge Control Handbook for

Protection of Electrical and Electronic Parts, Assemblies and Equipment ( Excluding

Electrically Initiated Explosive Devices)

Requirements For The Control Of

Electromagnetic Interference Characteristics Of

Subsystems and Equipment

Required

2.2 Military and Federal Specs

MIL-C-

CFR-

46168

53039

53072

Title 49

Coating, Aliphatic Polyurethane, Chemical Agent

Resistant

Coating, Aliphatic Polyurethane, Single

Component, Chemical Agent Resistant

Chemical Agent Resistant Coating (CARC)

System Application Procedures and Quality

Control Inspections

Transportation

2.3

Commercial

Documents

ASTM-D-

ASTM-D-

EIA-

EIA-

ANSI/AIM-

BC1-1995

Standard Practice for Visual Evaluation of Color

Differences of Opaque Materials

Standard Practice for Commercial Packaging

Symbols and Labels for Electrostatic Sensitive

Devices

Requirements for Handling ESDS Devices

Uniform Symbology Specification Code 39

2.4

Government

Documents

MIL-PRF-

MIL-B-

SC-C-

32052(CR)

32052/1 (CR)

32052/2 (CR)

32052/3 (CR)

32052/4 (CR)

32052/5 (CR)

32052/6 (CR)

32052/7 (CR)

32052/9 (CR)

18E

179495

Performance Specification for Batteries, Rechargeable, Sealed , General Specification for, Dated 7 December 1999, and, Supplement 1 to

MIL-PRF-32052(CR), Dated 7 December 1999

And Amendment 1 Dated 6 October 2000

Performance Specification Sheet for, Battery, Rechargeable, Sealed, BB-XX90/U, BB-

X590/U, BB-390/U, Dated 7 December 1999

And Amendment 1 Dated 6 October 2000

Performance Specification Sheet for Battery, Rechargeable, Sealed, BB-XX60/U, Dated 7 December 1999 And Amendment 1

Dated 6 October 2000

Performance Specification Sheet for Battery, Rechargeable, Sealed, BB-XX80/U, Dated 7 December 1999 And Amendment 1

Dated 6 October 2000

Performance Specification Sheet for Battery, Rechargeable, Sealed, BB-XX47/U and BB-

X847/U, Dated 7 December 1999

And Amendment 1 Dated 6 October 2000

Performance Specification Sheet for Battery, Rechargeable, Sealed, Nickel Cadmium, BB-

503/TAS, Dated 7 December 1999

Performance Specification Sheet for Battery, Rechargeable, Sealed BB-XX16/U, Dated 7 December 1999 And Amendment 1

Dated 6 October 2000

Performance Specification Sheet for Battery, Rechargeable, Sealed, BB-XX57/U & BB-557, Dated 7 December 1999 And Amendment 1

Dated 6 October 2000

Performance Specification Sheet for Battery, Rechargeable, Sealed, BB-XX88/U and BB-

388/U, Dated 7 December 1999

And Amendment 1 Dated 6 October 2000

Military Specification for Batteries, Non-

Rechargeable, Dry, Dated 21 January 1983 (For

Type IV Connector Only )

Connector, Battery, Miniature Circular, Socket

Contact, Plug for Secondary Battery

SM-C- 804749 Connector, Plug, Coaxial Required

3.0 Requirements. The contractor shall produce the items in the quantity set forth in either section B of a contract or an individual Delivery Order issued by the Government in accordance with Documents listed above, this document, all “Exceptions to Specifications” documents and

Appendix A of this document. In the event of a conflict between the requirements of this document and any drawings for the item on contract, the requirements of this document shall govern.

3.1. Basic Performance Requirements. The rechargeable batteries listed below shall meet or exceed the requirements as specified in this document, MIL-PRF-32052 (CR), the amendments to the specifications, and “Exceptions to Specifications” listed in appendix A of this document.

Notes cover all batteries listed. Required charger compatibility is listed below:

Rechargeable

Battery

End item Example

PP-8498/U

compatible

PP-8481B/U

PP-8444

BB-390B/U SINCGARS & over 71 other systems Y Y Y

BB-2590/U SINCGARS & over 71 other systems Y Y N

BB-388A/U AN/PRC-126 Y Y Y

BB-2588/U AN/PRC-126 Y Y N

BB-2847A/U Thermal Weapon Sight (TWS) Y Y Y

BB-2600A/U Handheld Terminal Unit (HTU) Y Y Y

BB-2800/U PLGR (Position locater), Cam Y Y Y

BB-326/U MELIOS Y Y Y

BB-503B/U DRAGON SIGHT Y N Y

BB-2557/U IREMBASS, Raven controller Y Y N

BB-557/U IREMBASS, AF test set Y Y Y

Battery Notes:

a. Rated capacities for each battery can be found in the Exceptions to MIL-PRF-32052 the specifications listed in Appendix A. Order of precedence is exceptions to the specifications, then amendments, then the basic specification.

b. These battery nomenclature are for cylindrical cells and cannot be designed or built with any pouch or prismatic cells. PLEASE NOTE that prismatic and/or pouch configurations of the above batteries are NOT being procured within this contract/solicitation/delivery order.

c. Each battery shall include on its label the CECOM rechargeable web site URL:

http://battery.army.mil

3.2 Requirements for Configuration Control.

3.2.1 Configuration Baseline.

3.2.1.1 Configuration Baseline for All Batteries on Contract. The applicable Configuration

Baseline (CB) for the listed Configuration Item (CI)/Computer Software Configuration Item

(CSCI) is as follows:

CI/CSCI CB

All Batteries MIL-PRF-32052(CR), Performance Specification for

Batteries, Rechargeable, Sealed, General Specification For, Dated 7 December 1999, and Supplement 1 (7 Dec. 1999), and

Amendment 1, and exceptions to specifications.

BB-2590/U, BB-390B/U MIL-PRF-32052/1(CR), Performance Specification Sheet for

Battery, Rechargeable, Sealed, BB-XX90/U, BB-X590/U, BB-390/U, Dated 7 December 1999 And

Amendment 1, and exceptions to specifications.

BB-2600A/U MIL-PRF-32052/2 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, BB-XX60/U, Dated 7 December 1999 And Amendment 1 and exceptions to specifications.

BB-2800/U MIL-PRF-32052/3 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, BB-XX80/U, Dated 7 December 1999 And Amendment 1 and exceptions to specifications.

BB-2847A/U MIL-PRF-32052/4 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, BB-XX47/U and BB-

847/U, Dated 7 December 1999 and Amendment 1

BB-503B/U MIL-PRF-32052/5 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, Nickel Cadmium, BB-503/TAS, Dated 7 December 1999, and exceptions to specifications.

BB-326/U MIL-PRF-32052/6 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, BB-XX16/U, Dated 7 December 1999 And Amendment 1, and exceptions to specifications.

BB-2557/U and BB-557/U MIL-PRF-32052/7 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, BB-XX57/U, BB-2588/U and BB-388A/U MIL-PRF-32052/9 (CR), Performance Specification Sheet

For Battery, Rechargeable, Sealed, BB-XX88/U and BB-

388/U, MIL-B-18E Military Specification for Batteries, Non-Rechargeable, Dry

(For Type IV Connector) Dated 21 January 1983

Connector, Battery, Miniature Drawing # SC-C-179495

Circular, Socket Contact, Plug

For Secondary Battery

Connector, Plug, Coaxial Drawing # SM-C-804749

After FAT approval, the Configuration Baseline (CB) will be finalized. The Government will assume Configuration Control of the new baseline after FAT approval. Any deviations from the new, established CB shall be subject to the requirements specified in para. 3.2.3 of this document.

3.2.2 Configuration. Each CI/CSCI, as developed/built and delivered, shall conform to the cited

CB and (if applicable) all subsequent CB‟s that will be made contractually binding by the

Procuring Contracting Officer (PCO). Configuration changes not directly affecting the configuration baseline do not require Government approval prior to incorporation, but must be documented by the contractor.

3.2.3 Departures from CB. No changes or departures from the CB are acceptable except for changes or departures which are submitted in accordance with DI-MISC-80711 and are approved by the Government Configuration Manager (C Mgr.) or Configuration Management Officer

(CMO) and which are made applicable to the contract by the PCO. Configuration Control shall be affected by the Configuration Control Documents (CCDs) as follows:

3.2.3.1 Engineering Change Proposal (ECP) includes both the engineering change and the supporting documentation by which the change is described and suggested. An ECP describes changes to the CI/CSCI and associated Government documents and data that are affected by the proposed engineering change.

3.2.3.1.1 A Notice of Revision (NOR) shows the detailed changes that must be made to technical documentation, except specifications, (one NOR per document) following approval of an ECP. The NOR is submitted as part of the ECP. The NOR should indicate the existing revision letter of the document being revised and the new revision letter reflecting the configuration after the proposed change.

3.2.3.1.2 A Specification Change Notice (SCN) is used to delineate the exact change(s) in a specification that will be distributed to users when the ECP is approved. The SCN is submitted as part of the ECP. The SCN is not used for a military or federal document, only a Request for

Waiver can be used for those documents.

3.2.3.1.3 Value Engineering Change Proposal (VECP) is the same as an ECP except there are proposed cost savings for the program. The contractor shall follow the guidance in Section I of this contract for VECPs.

3.2.3.2 Request for Waiver (RFW) describes a departure from configuration documentation for a specific number of units or period of time. Any departure from the requirements identified in

MIL-PRF-32052(CR), the specification sheets, the amendments and the Exceptions to the

Specifications shall be submitted as a RFW. Contractor shall identify the impact of the RFW on performance, operational readiness and logistics support of the affected CIs. The Government will require compensation for any RFW.

3.2.3.3 Contractor shall provide all supporting program or cost data with the CCD. The contractor shall uniquely and sequentially identify (including the use of the contract number) each ECP, VECP, NOR, SCN or RFW. The identification (I.D.) number should use less than 16 characters. It should be clear from the I.D. # whether the CCD is an ECP, VECP, or RFW. For example, the first letter of the I.D.# could be as follows:

„E‟ for „ECP‟

„V‟ for „VECP‟

„W‟ for „RFW‟

3.2.3.4 Content of Configuration Control Documents (CCDs): As a minimum, the CCDs should include the following information:

a. Description of change.

b. Justification for change.

c. Description of how the contractor proposes to implement the change.

d. Effectivity of change: list serial numbers that will be affected.

e. Effect of change on production delivery schedule.

3.2.4 Identification of Authorized Personnel. The contractor shall identify to the PCO, Administrative

Contracting Officer (ACO), and the technical office identified on the DD Form 1423 for DI-

MISC-80711, the name(s) of the official(s) of its organization who are authorized to submit

CCDs 30 Days after Contract (DAC).

3.2.5 Engineering Change Notices (ECNs). Engineering Change Notices describe changes to the contractor‟s configuration baseline (other than those changes that affect the Government‟s

CI/CSCI as specified in para. 3.2.1 which must be implemented in accordance with the requirements of para. 3.2.3). Copies of all approved ECNs that affect any of the items on this contract must be provided to the Government Technical Activity identified in Block 6 on the

DD1423 for DI-MISC-80711.

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item)

Form Approved OMB No. 0704-0188

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

A TDP X TM OTHER

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

All Items On Contract

1. DATA ITEM NO. 2. TITLE OF DATA ITEM 3. SUBTITLE 17. PRICE GROUP

Scientific and Technical Reports Configuration Control

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE 18. ESTIMATED

TOTAL PRICE

DI-MISC-80711 TR Para’s: 3.2.1.1,

3.2.1.2 and 3.2.3

AMSEL-LCP-IEP

INSERT

7. DD 250 REQ 9.DIST STATEMENT

REQUIRED

10. FREQUENCY 12. DATE OF FIRST

SUBMISSION

14. DISTRIBUTION IN

LT

ASREQ SEE ITEM 16

b. COPIES

SECT. B

8. APP CODE

N/A

11. AS OF DATE 13. DATE OF SUBSEQUENT

SUBMISSION

a. ADDRESSEE Draft

Final

SEE ITEM 16

Reg

Repro

16. REMARKS:

Data Item Description DI-MISC-80711: Delete Block 10 instructions entirely and follow instructions in TR found at para 3.2.

The Configuration Baseline is identified in TR para.3.2.1. The contractor shall prepare and submit Configuration Control Documents in accordance with the TR section for Configuration Control (Para 3.2.3) when a change to or departure from a contractual baseline document is deemed necessary. Each draft submission may be delivered in Microsoft

WORD format on standard compact disc and/or email attachment. The final shall be delivered in Adobe pdf format on compact disc and/or email attachment and shall include the contractor’s approval signatures.

Alternative delivery media may be discussed with the Contracting Officer prior to delivery.

AMSEL-LC-CCS-E-PS

AMSEL-RD-C2-AP-B

PCO

ACO

QAR

AMSEL-LC-LEO-E-ET

AMSEL-LC-LEO-E-EP*

* 1 COPY VECP ONLY.

15. TOTAL 0 7 0

G. PREPARED BY H. DATE I. APPROVED BY J. DATE

Ari Herman 9 / 23 / 11 Tuan Pham 9 / 23 / 11

DD Form 1423-1, 1 Jun 90

3.2.6 Documentation. The contractor shall document by serial number each product configuration, applicable documentation, maintenance support requirements and spares in relation to the contractor‟s configuration baseline. The data in use shall be available for

Government review and use.

3.2.7 Use of CB Data. The contractor shall assure that all necessary contractor‟s activities have access to and use of the contractually specified configuration baseline(s), approved changes and departures, and

Effectivity data. The data in use shall be available for Government review and use.

3.3 Requirements for Product Data/ Data Rights.

The contractor grants to the Government the royalty free, worldwide, non-exclusive, irrevocable, and unlimited data rights in technical data for the Performance Specifications and

Product Drawings ( Product Data) that may be delivered to the Government.

3.4. Requirements for Quality Assurance. The contractor shall implement and maintain a

Quality Assurance Approach that meets or exceeds the requirements established below. These requirements are commonly accepted practices employed by industry in both national and international manufacturing environments.

3.4.1.1 Quality Approach. The contractor shall establish/maintain a higher level quality approach to satisfy contract or order requirements.

3.4.1.2 Initial Quality Planning. The contractor, during the earliest practical phase of the contract, shall conduct a complete review of the contract requirements to identify all the resources necessary for assuring product integrity.

3.4.1.3 Design. The contractor shall establish/maintain controls over the design process to ensure that contract requirements are satisfied.

3.4.1.4 Document Control The contractor shall establish/maintain procedures that control the adequacy, completeness, current revision, and changes of all documents (work instructions, drawings, specifications, etc.).

3.4.1.5 Records. The contractor shall maintain and utilize records required for effective operation of the quality approach. The quality approach shall ensure that these records are complete ( including subcontractor records) and reliable. The contractor shall maintain these records for at least two years after final delivery.

3.4.1.6 Control of Purchases. The contractor shall ensure that all supplies and services, purchased from suppliers conform to contract requirements. The contractor shall require that their subcontractors control the product integrity of their services and supplies.

3.4.1.7 Government Furnished Material (GFM). For all GFM received under this contract the contractor shall be responsible for conducting all necessary inspections, maintenance, and tests.

The contractor shall be responsible for reporting all inspection results, maintenance actions, losses, and damage to the Government.

3.4.1.8 Materials Control. The contractor shall maintain controls over all materials and products throughout the manufacturing process. These controls shall enable the identification of materials which have passed inspection from those which have not. The contractor shall maintain records identifying the status and final destination of all materials/products.

3.4.1.9 Nonconforming Material. The contractor shall establish and maintain a system for controlling material, which does not satisfy contract requirements, including procedures for its identification, segregation, and disposition (rework/repair, scrap, etc.).

3.4.1.10 Corrective Action. The contractor shall have a program in place to promptly detect nonconforming material and conditions adverse to product integrity. It shall then initiate the corrective actions required to satisfy contract requirements.

3.4.1.11 Manufacturing Operations/Process Controls. The contractor‟s quality approach shall be responsible for assuring/monitoring that all manufacturing operations/processes are accomplished under controlled conditions. Controlled conditions include documented work instructions (including workmanship), production equipment, special work environments, inspections/tests, work specifications, and approval/rejection criteria.

3.4.1.12 Inspection and Testing. The quality approach shall assure that all inspections and tests required to satisfy contract or order requirements are conducted.

3.4.1.13 Measuring, Testing, and Inspection Equipment. The contractor shall provide and maintain gages (including production tooling used for inspection purposes) and other measuring and testing equipment to assure that products conform to contract requirements. These devices shall be calibrated against certified measurement standards, which are traceable back to national/international standards.

3.4.1.14 Inspection and Test Status. The contractor shall maintain a system for the identification of the inspection and test status of all products throughout the manufacturing cycle.

3.4.1.15 Quality Audits. The contractor shall perform internal quality audits to verify the effectiveness of their quality approach.

3.4.1.16 Training Requirements. The contractor shall identify/provide for the training needs of their personnel performing quality functions.

3.4.1.17 Service. The contractor shall establish/ maintain procedures for performing/ verifying that contract service requirements are satisfied.

3.4.1.18 Statistical Quality Control and Analysis. The contractor shall establish/utilize statistical methods whenever appropriate to satisfy the contract or order requirements.

3.4.1.19 Continuous Process Improvement. The contractor shall monitor the effectiveness of their quality approach and continually improve quality processes.

3.4.1.20 Handling, Storage, Preservation, Packaging, and Shipping. The contractor shall establish/maintain procedures for handling, storage, preservation, packaging, and shipping to protect the quality of products and prevent damage, loss, deterioration, degradation or substitution of products.

3.4.2 Electrostatic Discharge Control Program. The following clauses describe the contractor‟s requirements for establishing an Electrostatic Discharge (ESD) Control Program.

3.4.2.1 Requirements for Electro Static Discharge Control Program All personnel involved with incoming inspection, material storage and handling, manufacturing, testing and packaging are responsible for assuring that ESD controls are adhered to. The contractor‟s Quality Assurance personnel shall audit and monitor the ESD control program within the facility. The requirements of EIA 625 apply to distributor handling of ESD devices.

3.4.2.2 Program Documentation. The contractor shall establish and document an Electrostatic

Discharge Control Program in accordance with the best industry practices and this document.

MIL-HDBK-263A shall be used as a guide in establishing this program. The contractor shall develop plans and procedures to implement the requirements of this document. All contractor generated documentation relative to ESD control shall be available for Government review upon request.

3.4.2.3 Training. The contractor shall conduct a training program for all personnel who handle

ESD sensitive materials and monitor the ESD control program.

3.4.2.4 Documentation. The contractor shall document Material and Assembly Handling

Procedures which prevent the possibility of damage to ESD sensitive components and assemblies. ESD controls shall be maintained from the receipt and testing of parts, through the manufacturing, inspection, storage and packaging of the final assembly. All ESD sensitive components and assemblies which contain ESD sensitive components, as defined in paragraph

3.4.2.5, shall be handled in accordance with these procedures. ESD handling procedures shall include, as a minimum:

3.4.2.4.1 The removal (or anti-static treatment) of non-conductive material from areas where

ESD sensitive material is handled or stored.

3.4.2.4.2 The protection of ESD sensitive material during storage and transport, using ESD shielding bags, conductive containers or conductive foam.

3.4.2.4.3 The establishment of ESD control work stations, which are isolated or separated from areas of high personnel traffic.

3.4.2.4.4 The use of static dissipative materials on the work surfaces of ESD control workstations.

3.4.2.4.5 The grounding of personnel who handle ESD sensitive material, using wrist straps or heel straps with conductive flooring.

3.4.2.5 Classification of ESDS parts, assemblies and equipment. The contractor shall identify each ESDS part, assembly and equipment applicable to the contract as class 1 or 2.

Identification and classification of class 3 items shall be required for mission critical or essential parts, assemblies and equipment when designated by the Engineering Support Activity.

3.4.2.5.1 Sensitivity classification.

Class 1: Susceptible to damage from ESD voltages greater than 0 to 1,999 volts.

Class 2: Susceptible to damage from ESD voltages greater than 2,000 to 3,999 volts.

Class 3: Susceptible to damage from ESD voltages greater than 4,000 to 15,999 volts.

3.4.2.6 Design protection. Assemblies and equipment shall be designed to provide ESD protection for the sensitivity level of the most sensitive ESDS part chosen for the design. The minimum requirements are:

Assemblies - 2000 volts

Equipment - 4000 volts

3.4.2.7 Protection of parts and assemblies. Where class 1 parts must be used, protective circuitry should be incorporated at the lowest practical level of assembly to meet the design requirements of 3.4.2.5.

3.4.2.8 Marking of hardware. Unless otherwise specified, marking shall be as follows.

3.4.2.8.1 Parts. ESDS parts shall be marked with the symbol illustrated on figure 1.

3.4.2.8.2 Assemblies. ESDS assemblies shall be marked with either the symbol on figure 1

(sensitive electronic devise symbol) or the EIA Standard RS-471 symbol as illustrated on figure

2. The symbol shall be located in a position readily visible to personnel when the assembly is incorporated in its next higher assembly. When physical size or orientation of the assembly precludes compliance with this requirement, alternative marking procedures shall be developed and implemented upon concurrence by the Engineering Support Activity.

3.4.2.8.3 Equipment. Equipment containing ESDS parts and assemblies shall be marked with either the sensitive electronic devise symbol or the EIA standard RS-471 symbol. The symbol shall be located on the exterior surface of the equipment and readily visible to personnel prior to gaining access to ESDS parts and assemblies within the equipment. The following ESD caution statement should be placed adjacent to the ESDS symbol:

“CAUTION CONTAINS PARTS AND ASSEMBLIES SUSCEPTIBLE TO DAMAGE BY

ELECTROSTATIC DISCHARGE (ESD).”

3.4.2.8.4 External equipment terminals. The sensitive electronic device symbol or EIA standard

RS-471 symbol shall be applied on the exterior of the equipment cabinet adjacent to external terminals connected internally to ESDS parts and assemblies.

3.4.2.9 Quality assurance provisions. Quality assurance requirements shall be established to verify conformance to this standard. These provisions shall include monitoring and auditing of

ESD requirements invoked on subcontractors, suppliers, and vendors.

3.4.2.9.1 Preparation of internal quality records. The contractor shall prepare and maintain internal records of each quality evaluation performed to ensure compliance with the ESD control plan. These records shall identify the date of the evaluation, evaluation participants, items or activities reviewed, objectives of the evaluation, all detected problems, and any recommendations and corrective actions resulting from evaluation.

3.4.2.9.2 Internal quality reporting. The contractor shall prepare internal reports that provide to contractor management the results and recommendations from the quality evaluations specified herein. The quality evaluation reports should identify the activities performed, all detected problems, necessary remedial action, identified trends in the problems reported, and recommended changes to improve quality.

Figure 1. Sensitive Electronic Device Symbol

Figure 2. Electrostatic Discharge Symbol

3.5. Requirements for Contractor Performed First Article Testing (Pre-Production FAT) and follow-on production lot testing/ acceptance criteria.

3.5.1 General. The contractor shall perform First Article Testing (FAT) in accordance with

FAR 52.209-3 (see Section I of this contract) and this TR. As part of FAT, the contractor shall:

a. Manufacture the pre-production units in accordance with Table 1 below. Two weeks prior to the scheduled FAT, the Government Quality Assurance Representative (QAR) shall be notified to select the test unit(s) used for FAT from the pre-production samples.

b. Develop the test procedures and plans necessary to demonstrate that these units conform to the requirements established by the applicable specification(s) and other technical data provided in this contract.(Para 3.5.4)

c. Notify the Government and test the First Article units. (Para 3.5.5)

d. Provide a First Article Test Report to the Government, which documents the FAT results. (Para 3.5.6)

e. Insure all equipment used to take performance readings for acceptance tests are kept within the performance parameters delineated by the manufacturer of that equipment. All equipment manufactured by the contractor shall be listed and the parameters established and maintained for this equipment also.

Table 1. Pre-Production Units

Item Quantity Required

BB-390B/U 50

BB-2590/U 50

BB-388A/U 20

BB-2588/U 20

BB-2847A/U 20

BB-2600A/U 20

BB-2800/U 20

BB-326/U 20

BB-503B/U 20

BB-2557/U 20

BB-557/U 20

3.5.1.1 Government Interchangeability Testing: After successful Group A acceptance tests, the contractor‟s QAR shall select eight (8) battery samples for Charger and adapter interface testing by the ARMY. These batteries will not be returned unless there is a failure thus requiring an evaluation, corrective action, and retest. The contractor shall be responsible for all shipping costs to and from the government as required. Shipments shall be within 15 days of the start of

First Article Testing to the following address (The Government shall be notified prior to shipment):

U.S. Army CECOM-LCMC

ATTN: AMSEL-LCP-IEP (Rechargeable POC)

Building 5100

5100 Magazine Rd

Aberdeen Proving Ground, MD, 21005

Government testing will verify that the batteries mate properly, capable of being charged, and are otherwise fully compatible with the PP-8498/U and PP-8481B/U chargers. Failure of this test will result in complete FAT failure and may result in a complete redesign of the battery.

The Government shall not grant First Article Approval until successful completion of these charger tests.

3.5.2 First Article and Production Lot Testing Requirements. First Article and Production Lot

Testing

Requirements shall be in accordance with MIL-PRF-32052(CR), the applicable specification sheets for all batteries, the amendments, and all exceptions to the specifications. Any failure within Group B or C tests represents failure of the entire First Article or scheduled production lot.

3.5.2.1 Scope. This section prescribes test requirements for the pre-production first article testing and follow-on production lot testing. The contractor shall submit a test and evaluation plan for the tests to be performed to verify their design and performances are in compliance with paragraph 3.1. The government will not accept any production quantities until the first article tests are successfully completed in accordance with MIL-PRF-32052 (CR), the applicable specification sheets, the applicable amendments, exceptions to specifications and the requirements specified in the applicable Technical Requirements document.

3.5.3 Production of First Article Units. All FAT samples shall be assembled at the same location at which production units will be assembled, using the same parts, materials, and manufacturing processes to be employed for subsequent production. No change to these requirements shall be made without written approval from the Procuring Contracting Officer

(PCO).

3.5.4 Test Plan. The contractor shall prepare and submit a First Article Qualification Test Plan in accordance with DI-NDTI-81307 as implemented by the DD Form 1423 for DI-NDTI-81307.

A test plan is required for each battery ordered and the requirements of MIL-PRF-32052 (CR), applicable specification sheets, the amendments, and the Exceptions to the Specifications. The plan is due 90 calendar days after contract award for Government review and comment. In addition to the information required by DI-NDTI-81307, this submission shall contain:

a. Step-by-step test procedures for each test and the data sheets (see 3.5.6.3) to be employed to document the results of testing. Acceptance and failure criteria shall be listed for each test.

b. Identification of required test facilities, and equipment.

c. A consolidated test milestones schedule.

d. A table which cross references the paragraph number of the specification requirement

(including a brief description of the requirement) and the associated paragraph number of the

First Article Qualification Test Plan.

3.5.5 Notice of FAT Performance. As required by FAR 52.209-3, written notices concerning the time and location of FAT shall be furnished to the PCO, the Administrative Contracting

Officer and the Government Technical Activity POC, AMSEL-LC-CCS-E-PS, two weeks prior to testing via electronic means (email or FAX).

3.5.5.1 Reporting of FAT Failures. Reporting of FAT failures shall be by the FAT Report. In addition, FAT failures shall be verbally reported to the Government's Quality Assurance

Representative (QAR) and CE-LCMC Technical Activity listed in Block 6 of the DD Form 1423 for DI-NDTI-80809B within twenty four hours of occurrence. The failure analyses and corrective action procedures specified in this contract apply to the testing samples and shall be completed prior to acceptance of any material.

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item)

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

D TDP TM OTHER NDTI

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

All Items on Contract

First Article Qualification Test Plan

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE 18. ESTIMATED

DI-NDTI-81307 TR Para 3.5.4. AMSEL-LCP-IEP

REQUIRED

10. FREQUENCY 12. DATE OF FIRST

SUBMISSION

DD

AS REQ 90 DAYS ARO*

SECT. B

8. APP CODE

N/A

11. AS OF DATE 13. DATE OF SUBSEQUENT

SUBMISSION

a. ADDRESSEE Draft

A

A First Article Qualification Test Plan shall be required for each

Rechargeable Battery specified in para 3.1 of this TR.

Submit draft and final separately via Letter of Transmittal. Government requires 20 calendar days for review/comments. Submit final based on

Government comments within 20 calendar days of receipt of Government comments, via DD-250.

Each draft submission may be delivered in Microsoft WORD format on standard compact disc and/or email attachment. The final shall be delivered in Adobe pdf format on compact disc and/or email attachment and shall include the contractor’s approval signatures. Alternative delivery media may be discussed with the Contracting Officer prior to delivery.

*ARO= After Receipt of Order

AMSEL-SF-SEP(KLIMIK)

QAR

15. TOTAL 6 6 0

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item)

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

E TDP TM OTHER NDTI

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

All Items on Contract

Test/Inspection Report First Article Test Report

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE 18. ESTIMATED

DI-NDTI-80809B TR Para 3.5.6. AMSEL-LCP-IEP

REQUIRED

10. FREQUENCY 12. DATE OF FIRST

SUBMISSION

DD

ASREQ 300 DAYS

ARO*

b. COPIES

SECT. B

8. APP CODE

N/A

11. AS OF DATE 13. DATE OF SUBSEQUENT

SUBMISSION

a. ADDRESSEE

A First Article Test Report shall be required for each Rechargeable

Battery in para 3.1 of this TR.

Submit report of First Article Test results separately for each item under contract via Letter of Transmittal. Government requires 20 calendar days for review/comments. DD-250 can be submitted along with report.

Submit revised report within 20 days after receipt of government comments. Government requires 15 days to provide comments/approval.

Each draft submission may be delivered in Microsoft WORD format on standard compact disc and/or email attachment. The final shall be delivered in Adobe pdf format on compact disc and/or email attachment and shall include the contractor’s approval signatures. Alternative delivery media may be discussed with the Contracting Officer prior to delivery.

* After Receipt Of Order

AMSEL-SF-SEP (KLIMIK)

15. TOTAL 0 5 0

3.5.6 FAT (Pre-Production Testing) Report. A FAT Report shall be prepared and data sheets shall be submitted to the CECOM-LCMC Technical Office at Commander, CECOM-LCMC, ATTN: AMSEL-LCP-IEP, Aberdeen Proving Ground 21005 in accordance with FAR 52.209-3 and DI-NDTI-80809B as implemented by the DD Form 1423 for DI-NDTI-80809B. The FAT

Report shall be complete, accurate, readable, and shall provide sufficient data to determine that the hardware item meets all the requirements delineated in the contract. The report will include the following and be in contractor‟s format and is due 15 calendar days after test completion:

3.5.6.1. General Data.

a. Contractor's name and address.

b. Contract number.

c. Nomenclature, type number and (if assigned) stock number of item represented by the

First Article.

d. Name and address of plant where First Article was fabricated and assembled.

e. Place and date of performance of tests.

f. Identification (including date) of applicable equipment specifications and associated amendments and exceptions.

g. Sample size or quantity submitted for test or inspection.

3.5.6.2 Cross Reference. A table which cross-references the paragraph numbers of the specification, the test procedures, and data sheet entry.

3.5.6.3 Test Procedures. A description of test procedures, including test circuits and test equipment (referenced by manufacturer‟s type, model, serial number, and date of latest calibration) used by the contractor to obtain conformance data.

3.5.6.4 Test Results. Complete test results showing actual or quantitative observations and all required calculations. „GO/NOGO‟ data is allowable (under certain circumstances) only with prior Government approval. Allowable tolerances for each parameter shall be presented. Test data should also include the date that the test was performed, name and signature of tester, name and signature of the Government verifier/witness (if applicable) and serial number of the equipment. Test results shall cite detailed qualitative and quantitative data results such as test categories, test conditions, test methods employed, and types of inspection and test equipment used during the test or inspection. All data sheets shall include test requirements, acceptance level and test results.

3.5.6.4.1 FAT Failures. FAT failures shall list all requirements not complied with during FAT.

If none, this should be explicitly stated. For each requirement not met, a corrective action to remove the noncompliance will be proposed. This corrective action must include retest or other verification that the corrective action does remedy the problem/failure. The corrective action will address changes in design or manufacturing process, which will preclude this deficiency in subsequent production units. Re-testing and/or verification of the proposed corrective action must be implemented prior to contractor entering into production.

3.5.6.5 FAT/Production Discrepancies. Any Government approved (see paragraph 3.5.3), difference between the parts, materials and processes used to manufacture FAT samples and production units shall be documented in the FAT report.

3.5.6.6 N/A

3.5.7 FAT Approval. FAT samples shall meet all contractual requirements or all variances shall be documented by Government approved waivers. First Article approval will be contingent upon the submission of a complete and acceptable FAT report to include verification of corrective action for reported FAT failures to include adequacy of identified changes to the design/manufacturing process.

3.5.8 N/A

3.5.9 Disposition of First Article Samples. Upon successful completion of FAT, the contractor shall dispose of the FAT samples and all remaining pre-production units specified in Table 1 of this document as follows:

3.5.9.1 One sample of each battery shall be retained at the contractor‟s facility for use as a reference by the QAR or other Government representative. At the completion of the contract, these samples shall be delivered to the Government as specified in para .3.5.9.2.

3.5.9.2 All other FAT and preproduction units shall be shipped to the Government for further testing purposes at the following address:

U.S. Army CECOM-LCMC

ATTN: AMSEL-LCP-IEP (Rechargeable POC)

Building 5100

5100 Magazine Rd

Aberdeen Proving Ground, MD, 21005

The FAT samples shall be shipped in the complete packaging requirements specified in the contract for these items.

3.5.10 Production Test Procedures. Production test procedures used to test production units shall be identical to those used to test First Article samples.

3.5.10.1 Once FAT is approved, proposed changes to the production test procedures will be submitted to the Government Technical Activity (see paragraph 3.5.5) for evaluation. Such submissions will provide complete justification for the change. Changes to the approved test procedures shall not be implemented without written Government approval.

3.5.10.2 Any notice of approval of test procedures or changes thereto shall not relieve the contractor from complying with all contractual requirements.

3.5.11 Use of FAT Samples as a Manufacturing Standard. The FAT samples shall NOT serve as a manufacturing standard.

3.5.12 Requirements for Contractor Performed Tests During Production.

3.5.12.1General. All production test requirements shall be in accordance with MIL-PRF-32052

(CR), the applicable specification sheets, the amendments, the Exceptions to the Specifications, and the Technical Requirements. Any failure within Group B or C tests represents failure of the entire scheduled production lot.

3.5.12.2 For all items on contract: All production units shall incorporate the same design, parts and materials, and processes used to manufacture the FAT units. Any variances from the FAT units that affect the performance, design, form, fit, and function requirements of the items must require Government approval prior to implementation into production. The proposed changes shall be submitted to the Government Technical Activity for evaluation (see 3.5.3).

3.5.12.2.1 If an alternative cell vendor or cell type is contemplated for any battery on contract, other than the one that passed the original First Article Test (FAT), an additional FAT shall be conducted and report submitted to the Government Technical Office four (4) months prior to any scheduled deliveries in accordance with (IAW) MIL-PRF-32052(CR) and it‟s exceptions. The

Government Technical Office shall be notified 2 weeks prior to any additional battery FAT. Any proposed cell and subsequent battery produced shall at least be equal to or greater than the performance of the original proposed battery. The sampling plan shall be IAW MIL-PRF-32052 paragraph 4.3.2. If alternative cells are delivered within a battery, the contractor must track all serial numbers and manufacturing date codes being delivered to the Government and provide this information to the Government, when requested.

3.5.12.3 Production Lot Failures. Production lot failures shall be reported to the Government‟s

Quality Assurance Representative (QAR) and to the CE-LCMC Technical office within twenty-four hours of occurrence. The failure analysis, corrective action and required re-inspection procedures specified in this contract apply to the testing samples and shall be completed prior to acceptance of any material. Production failures shall be reported in accordance with para. 3.5.13 of this document.

3.5.13 Failure Analysis/ Corrective Action. The Government shall be notified within 24 hours of any failures. A Failure Analysis/ Corrective Action Letter shall be submitted

NLT 72 hours from failure occurrence as implemented by the DD1423 for DI-RELI-

81315. The Government shall review and accept/reject the contractor‟s corrective action and re-inspection plan prior to continuation of any test. In addition to the information required by DI-RELI-81315, the contractor‟s report shall include the following:

a. Contractor‟s name, address, and applicable contract number.

b. Number of units in sample and number of failed units subjected to test.

c. Root cause of failure.

d. Re-inspection plan to validate the corrective action, consisting of all applicable tests and examinations. The plan shall include identification of previous functional, environmental, and reliability tests, if any, invalidated by the corrective action changes and recommendations of those tests which should be repeated to prove the corrective action.

e. Proposed disposition of items in the inspection lot at time of failure of any inspection and of items manufactured under the same conditions and which the Government considers subject to the same failure mechanism.

3.5.13.1 Final acceptance and shipment approval will be withheld until results of the re-inspections substantiate that the corrective action was effective, as authorized by the PCO.

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

F TDP TM OTHER RELI

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

All Items on Contract

1. DATA ITEM NO. 2. TITLE OF DATA ITEM 3. SUBTITLE 17. PRICE GROUP

Failure Analysis and Corrective Action

Report

Failure Analysis/ Corrective

Action

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE 18. ESTIMATED

DI-RELI-81315 TR Para 3.5.13 AMSEL-LCP-IEP

REQUIRED

10. FREQUENCY 12. DATE OF FIRST

SUBMISSION

LT

AS REQ SEE ITEM 16

SECT. B

8. APP CODE

N/A

11. AS OF DATE 13. DATE OF SUBSEQUENT

SUBMISSION

a. ADDRESSEE

Data Item Description (DID) reference to MIL specs/stds is for guidance only.

Failure reports shall be submitted within 72 hours of failure occurrence.

Technical Activity is AMSEL-LC-CCS-E-PS, 732-532-4948. FAX# 732-

532-8465.

15. TOTAL 0 4 0

3.5.14 Manufacturing of Items. All items shall meet all requirements of the contract and shall be manufactured and assembled at the contractor‟s current facility or vendor‟s facility as specified in the bid proposal.

3.6 Information Cards. All operating instructions should be on the battery in accordance with

32052(CR) and the applicable specification sheet. Additional instructions may be required (see para. 3.14).

3.7 Safety.

a. SAR Test Plan – The contractor shall prepare a SAR Test Plan in accordance with the

CDRL for DI-NDTI-80566 below for each battery. The approved test plan for lithium ion batteries shall address all safety tests specified in Table 1, as a minimum.

Table 1. Summary of Unique Safety Tests Required in Support of the SAR Group Requirement Test Description Cell Quantity Battery Quantity

UL 1642, paragraphs:

19.3

Crush Projectile

5 fresh

2 UN Document

T1: Altitude T2: Thermal Test

T3: Vibration

T4: Shock T5: Ext Short Circuit

10 fresh/10 fully discharged 4 fresh/4 fully…