AWA_SOW_6-15-15.docx

STATEMENT OF WORK (SOW)

AUTOMATIC WIRING ANALYZER (AWA)

SOLICITATION HSCG38-15-Q-010109

1.0 BACKGROUND

1.1 The United States Coast Guard (USCG), Aviation Logistics Center (ALC) provides Programmed Depot Maintenance (PDM) and Heavy Maintenance support for various USCG Maritime Patrol Aircraft. This support includes major aircraft electrical-wire-interconnect-system (EWIS)/avionic assemblies and sub-assembly inspection, repair, upgrade/modification, and/or replacement. After repairs and/or modifications are made, verification of installation conformance and proper configuration management are paramount. Testing of the entire EWIS system/assembly for proper component operation and condition before applying electrical power is vital for component and operator safety and proper systems operation.

1.2 The preferred method of testing is to use an Automatic Wiring Analyzer (AWA). The AWA is capable of quickly, accurately and consistently testing entire aircraft wiring systems much faster and more completely than human hand testing. The AWA can test entire aircraft wiring systems in a matter of minutes compared to hours and days for human testing. Additionally, once programmed, the AWA performs the same test each and every time which is vital to maintaining proper configuration management. The AWA can collect, print and store failure data for future trend analysis. A single, scalable, distributed switching, random adapter hook up AWA with the proper adapter cable libraries is ideal for meeting the needs for the multiple aircraft types maintained by the ALC.

2.0 SCOPE

2.1 The scope of this Statement of Work (SOW) is intended to establish and provide the testing requirements for the purchase of one commercially available Distributed Switching, Random Hook-Up capable, Automatic Wiring Analyzer with zero insertion force (DL-156, DIN 41618HD or equivalent) front panel connectors for testing the airframe wiring harnesses for the HC-144A/HC-27J aircrafts.

2.2 The AWA must perform, at a minimum, insulation resistance, breakdown and leakage measurements; circuit continuity, discontinuity, and resistance measurement; Alternating Current (AC) and Direct Current (DC) voltage measurements; capacitance measurements, diode forward/reverse bias tests, Zener diodes tests, LED operation, potentiometer value measurements, and AC Dielectric (HIPOT) testing.

2.3 The AWA must incorporate Multiple-Bus-Architecture (MBA) type switching cards capable of breaking a test circuit and injecting programmed AC or DC voltages (paragraphs 2.4 and 2.5) into the Unit-Under-Test (UUT) to energize and operate components such as relays, blowers, fans, lights, etc. Circuit cards must be interchangeable throughout the system as needed. These test points must power components without the need for special or highly modified adapter cables. The AWA must be capable of performing tests listed in paragraph 2.2 using other test points concurrently while injecting programmed voltages on the MBA test points. These cards must have a front panel means of visually differentiating them from standard switch modules/cards.

2.4 The AWA must include a programmable (automatically controlled via the test program) variable AC power source capable of providing 0 to 240 VAC, 60 to 400hz at 5 Amps or greater.

2.5 The AWA must include a programmable (automatically controlled via the test program) variable DC power source capable of providing at a minimum 0 to 120 VDC at 5 Amps or greater.

2.6 The AWA must run/convert current AWA test program files that include IEEE/GPIB/VIRTCOMP/Equivalent software commands that operate programmable/remote controllable power supplies.

2.7 The AWA software must allow for local development of new test programs and ongoing modification of these tests by trained USCG ALC Automatic Circuit Analysis Test Systems (ACATS) Programmers.

2.8 The AWA must be capable of running all test programs currently in use at the ALC with minimal modification or conversion. The system must be able to perform all customized test applications and utilities that were developed around the unique hardware and software architecture of the AWAs currently in use without manual intervention by the operator or the programmer.

2.9 The AWA must have Ethernet interface to a USCG ALC supplied computer system (computer, monitor, keyboard, mouse, etc) for operations.

2.10 System software must be capable of down-loading test files from a main-frame server, operating independently, and then up-loading test result data to the main-frame server at the conclusion of the testing.

2.11 The AWA must include a test results data storage program that can be sorted and used to generate failure and condition trend reports. Data stored must include circuit end points, test results value, causal noun and verb, correction noun and verb, failure zone location, repair man-hours, repair component, product ID, operator ID, test start date, test end date and operator notes.

2.12 The AWA must be capable of sampling the UUT environment’s temperature and humidity, automatically transmit/import readings into each test program and be usable for automatically selecting the appropriate test parameter set without operator intervention or input.

2.13 The AWA must include a calibration verification program and any specialized tools or equipments necessary to complete the verification.

2.14 Provide random hook-up capabilities for all Test Adapter Cables (TACs) to the tester modules. Provide local capabilities for programming TAC IDs.

2.15 Provide a one-time-purchase Lifetime-Site license for unlimited USCG ALC programmer and operator terminals at the USCG ALC sites. Lifetime software revisions and patches must be included with license as well training materials listed in paragraphs 3.13 and 3.14.

3.0 REQUIREMENTS

3.1 Unless otherwise specified, the AWA must meet at a minimum, the performance characteristics of the current AWA models DITMCO 2524, 2135 and 2115 currently in use at ALC. In addition, the AWA must meet the following minimum requirements:

a. The AWA must have at a minimum 45,000 total separate test points, expandable to 100,000 or more, connected simultaneously and capable of meeting or exceeding the requirements specified in Table 1.

b. The AWA must include at a minimum 5000 MBA points, expandable as needed, located randomly as needed, as listed in paragraph 2.3.

c. Make low resistance (4-wire Kelvin) measurements of < 0.100 ohms.

d. Simultaneously run bulk scans when programmed.

e. Be able to perform an automatic calibration verification using vendor supplied calibration verification tools. There must be no operator adjustments to potentiometers, measurements with external instruments, or adjustments of any method. The process must take less than five minutes. The tester must not require a calibration verification schedule frequency of more than once every three months.

f. Include a manual mode for use of an operator handheld test probe to test one specific point.

g. Provide self contained test program file editor.

h. Import test program files generated off-station, without requiring manual or automatic conversions/alterations.

i. Provide test report options that allow the user to print/store all test data or failed test data.

j. Automatically archive all test data on the local or network server hard drive.

k. Provide test data retrieval that allows archived or most recent test data to be printed or saved to a USCG/ALC approved storage medium such as the ALC server hard drive, encrypted portable hard drive or memory stick, CD, and/or DVD.

l. Provide built-in self test that isolates analyzer failures to locally replaceable modules or printed circuit cards.

m. Protect test program files from operator modification by allowing the option to encode. Protected test program files must run directly on the AWA.

n. Quantize and print all detected test errors with all test information reported to the operator when directed by the operator.

o. Run test program files written in conventional addressing schemes and/or written in product language.

p. Provide clear and informative real-time feedback display of the test parameters, test status, test results and errors.

q. Software must include an interactive library of connectors, wire lists, and cable inventories to provide build instructions, reference drawings, bills of materials and cable labeling.

r. The AWA must provide a dwell time bypass type mode that will complete the test as soon as a pass condition occurs and the minimum dwell time has elapsed.

s. The AWA must detect momentary (10 microseconds or longer) breakdowns or arcs in the Unit-Under-Test (UUT). If current exceeds a programmed limit, the dielectric test must fail even if the current returns to normal prior to the completion of the test.

3.2 The AWA main control unit and programmable power supply(ies) must be completely contained (with the exception of TAC and interconnect cabling) within a mobile (lockable casters, one person movable) cabinet/cart. All distributed switching unit cabinets must be self contained, (one-person-movable) and require no external operating voltages other than those provided by/through the main control unit and the control tether cable. Units must be movable without requiring any calibrations or adjustments before usage after movement. System must be designed in such a manner as to allow strategic placement of tester modules in locations in and around the aircraft in order to minimize the lengths of the TACs.

3.3 The entire AWA system must operate with input power of a single 115 VAC ± 5%, 1 Phase, 20 amp circuit breaker outlet.

3.4 The AWA must operate without accuracy fluctuations within all temperature and humidity conditions found in both environmentally conditioned and unconditioned spaces, such as open aircraft hangars and air conditioned/heated avionics repair shops. Humidity levels may reach 100% with occasional surface condensation occurring.

3.5 Design and construction must be in accordance with best industry practices. All components must be current technology and currently available.

3.6 The AWA components must be self cooling.

3.7 Protective devices must exist to protect the user and AWA from undesirable or abnormal conditions. The following protective devices must exist as a minimum:

a. User Emergency Stop switch prominently positioned.

b. A conspicuous warning beacon light that automatically activates during high voltage testing.

3.8 All components must be firmly attached and secured to the cabinet at all times.

3.9 The AWA must comply with Federal Communications Commission (FCC) Electromagnetic Suppression regulations applicable at the time of manufacture.

3.10 Programming. The system’s test programs must be locally developable and modifiable by USCG personnel.

3.11 Programmer Training. Initial basic and advanced programmer training must be provided at the USCG site to a minimum of four (4) USCG ALC ACATS Group personnel. This training must be provided before the tester is delivered.

3.12 Operation. The system must be designed for operation by locally trained USCG operators without requiring specialized computer skills.

3.13 Operator Training. Vendor must provide an initial “Train-the-Trainer” class at the USCG site to a minimum of four (4) USCG ALC ACATS Group personnel to allow for local training of AWA operators.

3.14 Training Materials. A programmer training syllabus must be provided to the USCG ALC ACATS Program Manager for future programmer qualification verification. This syllabus must include operator training lesson plans and skills verification tests both written and hands-on. The syllabus must be formatted to allow for USCG personnel to train and certify all current and future equipment operators. This syllabus must be provided in a format that allows for easy installation and implementation of vendor provided upgrades, modifications, or other lesson plan changes. Hardcopy printability is also required.

4.0 SUPPORT EQUIPMENT

The following items are separate line items for the AWA system:

4.4 Cable Storage Options: Provide a system for safe and organized storage of all TACs and umbilical cables.

4.5 Remote Operation Device: Capable of being operated by a remote wireless electronic tablet type device.

4.6 1553 Data Buss, Twisted pair identification and fault location, and cable shield testing: Provide a method of testing, measuring, quantifying, identifying and displaying 1553 data buss circuit polarity and signal loss, twisted-pair correct wire-pair identification, and cable shielding connection.

4.7 Fault Location Option: Be capable of adding a fault locator program that automatically determines and displays the approximate location of a fault along the length of the unit-under-test.

4.8 High Current/Constant Current testing: Provide an option for providing high current/constant current testing of items such as circuit breakers and current sensing relays, etc.

5.0 APPLICABLE DOCUMENTS

Provide at a minimum an electronic copy of all current and new OEM Operator Manuals, Component Maintenance Manuals (CMMs), revisions, specifications, service bulletins, amendments, modifications and any other documentation necessary for the ease of maintenance and operation of the AWA. Provide updates as they become available.

6.0 MARKING AND PACKAGING

The offeror shall comply with ASTM D3951-10 (August 01, 2011), Standard Practice for Commercial Packaging. Packaging, packing, and preservation shall be in accordance with best commercial practices to enable shipment to destination. Packaging material shall not consist of the following: popcorn, shredded paper, Styrofoam of any type, or peanut packaging. The internal packaging material shall be sufficient to prevent damage during shipment, handling, and storage. Preservation protection must be sufficient to prevent corrosion, deterioration, or decay during warehouse storage.

7.0 INSPECTION AND ACCEPTANCE

Final inspection and acceptance will be performed by ALC ACATS personnel for quantity, condition, and compliance with the contract.

8.0 DELIVERY AND INSTALLATION

The contractor must pack, ship, unpack, assemble, and inspect the AWA at its final delivery point in Elizabeth City, NC.

9.0 SETUP AND STARTUP

Following assembly, the contractor must verify proper operation of the entire AWA, i.e.: unit must be able to perform a complete self test and calibration verification, at a minimum.

10.0 DEMONSTRATION AND FAMILIARIZATION

10.1 Following setup, the contractor must demonstrate all performance characteristics required by this SOW. The contractor must provide a Government approved written demonstration checklist.

10.2 Following demonstration, the contractor must perform on-site operation, maintenance, and calibration familiarization for up to twelve (12) Government personnel.

11.0 WARRANTY

The contractor must provide a minimum one (1) year warranty for all parts, labor and vendor travel for warranty support and guarantees the AWA to be 100 percent operational within 48 hours following government notification of a fault. Warranty period will begin at the time the AWA is accepted (date Government signs the Form DD250) by the Government.

12.0 PERFORMANCE SPECIFICATIONS.

TABLE 1

STIMULUS

ACCURACY

±5% or better

±5% or better

±5% or better

CONSTANT CURRENT RESISTANCE MEASUREMENTS

CONSTANT VOLTAGE RESISTANCE MEASUREMENTS

DIELECTRIC DETECTOR

VOLTAGE MEASUREMENTS