SOW with System - POWERPC CIRCUITCARD REPAIR.doc

POWERPC CIRCUIT CARD REPAIR

AN/SPS-73 SURFACE SEARCH RADAR

SPECIFICATION FOR POWERPC CIRCUIT CARD REPAIR

Developed By: Seaton B Woody Rev-0 18 July 2012

TABLE OF CONTENTS

Revisions Record iii Consolidated List of References iv Consolidated List of Government-furnished Property v Consolidated List of Critical Inspection Items vi Principal Characteristics vii General Requirements WORK ITEM 1: PowerPC Single Board Computer , Repair

Revisions Record This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

Consolidated List of References

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

· MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

· Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

· Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications:

· IPC Standards: https://portal.ipc.org/Association/Index.htm

· ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

· NFPA: http://www.nfpa.org

· SSPC Standards and pictorial guides: http://www.sspc.org/

· ISO/IEC Standards: http://www.iso.org/iso/store.htm

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication TIO-97-01 REV C, Operation and Maintenance Manual for Surface Search Radar (SSR) Coast Guard Technical Publication TM-SSR-1 REV C, Operators Manual for AN/SPS-73 Surface Search Radar Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Coast Guard Planned Maintenance Procedure Card 45173 Coast Guard Electronic Field change Bulletin F.C. No. 7 Type 1 to the AN/SPS-73(V) Surface Search Radar Enclosure (3) Software Build 11.8 Installation Procedures

OTHER REFERENCES

ANSI/AIM BC1-1995, Uniform Symbology Specification –Code 39 ANSI/NCSL Z540.3-2006, Calibration Standards ASTM-D 3951-98, 10 Nov 1998, Standard Practice for Commercial Packaging IPC-7711B, Nov 2007, Rework, Modification and Repair of Electronic Assemblies IPC-A-610E-2010, Acceptability of Electronic Assemblies ISO/IEC 17025:2005 , General Requirements for the Competence of Testing and Calibration Laboratories MIL-STD-129P w/CHANGE 4, 19 Sep 2007, Standard Practice Military Marking for Shipment and Storage MIL-STD-2073-1E w/CHANGE 1, 7 Jan 2001, Standard Practice for Military Packaging Consolidated List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

($/Unit)

P/N: CUS/VGM1-S420EBPUVXRX

P/N: CUS/VGM1-S420EPUVXRX

P/N: CUS/VGMD-S530EBSNBNNB1

P/N: CUS/VGMD-S540QCSNBNNB1

P/N 1720549

*Government-furnished property, shall be returned to Coast Guard upon completion of the contract.

Consolidated List of Critical Inspection Items The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the contract period (see SFLC Std Spec 0000_STD, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

This section is not applicable to this package.

Principal Characteristics This section is not applicable to this package.

General Requirements

1. SCOPE

1.1 Intent. This item describes the general requirements to be followed by the Contractor while conducting repairs.

2. REFERENCES

Coast Guard Drawings None.

Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Other References None

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of the PowerPC circuit card repair.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

4. NOTES

None

WORK ITEM 1: PowerPC Single Board Computer, Repair

1. SCOPE

1.1 Intent. This Work Item describes the requirements for the Contractor to repair the PowerPC Circuit Card Assembly (CCA).

1.2 Government-furnished property.

($/UNIT)

P/N: CUS/VGM1-S420EBPUVXRX

P/N: CUS/VGM1-S420EPUVXRX

P/N: CUS/VGMD-S530EBSNBNNB1

P/N: CUS/VGMD-S540QCSNBNNB1

P/N: 1720549

*Government-furnished property, shall be returned to Coast Guard upon completion of the contract.

2. REFERENCES

Coast Guard Drawings None.

Coast Guard Publications Coast Guard Technical Publication TIO-97-01 REV C, Operation and Maintenance Manual for Surface Search Radar (SSR) Coast Guard Technical Publication TM-SSR-1 REV C, Operators Manual for AN/SPS-73 Surface Search Radar

Coast Guard Planned Maintenance Procedure Card 45173 Coast Guard Electronic Field change Bulletin F.C. No. 7 Type 1 to the AN/SPS-73(V) Surface Search Radar Enclosure (3) Software Build 11.8 Installation Procedures Other References ANSI/AIM BC1-1995, Uniform Symbology Specification –Code 39 ANSI/NCSL Z540.3-2006, Calibration Standards ASTM-D 3951-98, 10 Nov 1998, Standard Practice for Commercial Packaging IPC-A-610E-2010, Acceptability of Electronic Assemblies IPC-7711B, Nov 2007, Rework, Modification and Repair of Electronic Assemblies ISO/IEC 17025:2005, General Requirements for the Competence of Testing and Calibration Laboratories MIL-STD-129P w/CHANGE 4, 19 Sep 2007, Standard Practice Military Marking for Shipment and Storage MIL-STD-2073-1E w/CHANGE 1, 7 Jan 2001, Standard Practice for Military Packaging

3. REQUIREMENTS

3.1 General.

3.1.1 Critical inspection report.

None.

3.1.2 Technical representative.

Not applicable.

3.1.3 Protective measures.

Electrostatic Discharge Control. The contractor shall protect packaged parts and equipment by developing and employing an electrostatic discharge program IAW Electrostatic Discharge Control Programs for Protection of Electrical and Electronic Parts, Assemblies and Equipment, MIL- STD-1686. All printed circuit card assemblies shall have an initial wrap of cushioning material conforming to (MIL-P-81997, Type 1 applies). The circuit card and its initial cushioning or cushioned pouch shall then be placed into a heat-sealed bag conforming to MIL-B-117G (Type 1, Class F, Style 1 applies).

3.1.4 Interferences.

None.

3.1.5 Contractor repair process. The overhaul/repair requirements described herein are considered to be the minimum and are not intended to replace any procedures, controls, examinations, or tests employed by the Contractor to assure the quality of the product.

3.1.6 Ready for issue condition. The Contractor shall perform the level of repair required to return a defective PowerPC Circuit Card Assembly (CCA) to a Ready for Issue (RFI) or ”A” condition. The CCA is considered to be in a RFI condition when the criteria for Target or Acceptable Conditions are met for Class 3 High Performance Electronic Products in accordance with IPC-A-610E. The Contractor shall ensure each CCA returned to the Coast Guard is loaded and functions with dosFs 2.0 software (or subsequentt software version in use by the Coast Guard), Raytheon 11.8 Version AN/SPS-73 operating software (or current software version in use by the Coast Guard), and operates in a v11 system configuration. The Coast Guard may test to validate the CCA is in RFI condition IAW paragraph 4.1.3 (Coast Guard test). CAUTION This equipment contains parts and assemblies sensitive to damage by electrostatic discharge. Use precautionary procedures when touching, removing, or inserting.

3.1.7 Inspection. The Contractor shall inspect each received PowerPC CCA ensuring it was not damaged during shipment and that it is listed in this Work Item as Government furnished property. The Contractor shall complete the Property Discrepancy Report to document and report damage sustained during shipment, incorrectly received items that are not PowerPC CCAs, items that are not the correct National Stock Number or part number, and discrepancies in the quantity received compared to the delivery order. The Contractor shall at a minimum include on the Property Discrepancy Report, the delivery order number, the CCA serial number, the CCA nomenclature if not a PowerPC, and the date the Contractor received the CCA. The Contractor shall submit the Property Discrepancy Report to the Coast Guard Contracting Officer (KO) via email within ten days of receipt of the material being reported. The Property Discrepancy Report shall be clear, legible, and in English.

3.1.7.1 Initial Open and Inspect Reports. The Contractor shall submit an Open and Inspect Report (OIR) for each CCA inspected to include cost breakdown of parts, labor and overhead cost to repair CCA to the KO via email within thirty days of receipt. The OIR shall be clear, legible, and in English.

3.1.8 Materials. The Contractor shall be responsible to provide all spare parts, current technical manuals/information, discrete components, consumable materials, and other items needed to repair each CCA. The Contractor shall use only new replacement parts during repair that are equal or better quality to the CCA component being replaced; reclaimed or recycled parts are not acceptable and shall not be used. In the event required materials are not available, the Contractor shall submit a Condition Found Report (CFR) to the KO via email within twenty days explaining the issue and recommended solution.

3.1.9 Repair time. The Contractor shall have thirty days to install Government Furnished Property (GFP) and an additional thirty days to repair the first lot of CCA’s, after receipt of approval of the CFR by the KO. Working days are considered Monday through Friday excluding Holidays.

3.1.10 Beyond economical repair. Repair requirements do not include CCAs received which are severely damaged (repair cost > 50% of CCA value). In the event that a severely damaged CCA is received, the Contractor shall submit a CFR to the KO via email within thirty days of CCA receipt. The CFR shall be accurate, concise, legible, and in English. A sample CFR is provided in paragraph 4.3 (Reports). The KO will determine the disposition of all items delivered to the Contractor that are determined to be beyond economical repair. The Contractor shall not proceed with the repair of a severely damaged CCA until a firm fixed price and delivery schedule are negotiated and authorization to repair the CCA is received from the KO.

3.1.11 Use of a Subcontractor. The use of a Subcontractor for repairs is authorized; however, the Subcontractor shall be bound to all requirements of this Work Item. The Government contracted vendor shall be solely responsible to ensure all provisions and requirements of this Work Item are met.

3.1.12 Status report. The Contractor shall submit a bi-weekly Status Report of all CCAs received, pending repair, being repaired and pending shipment for return to the Coast Guard. The report shall include at a minimum the contract and delivery order number, the CCA serial number, date the Contractor received the CCA, and the expected date the CCA will be returned to the Coast Guard or the date shipped to the Coast Guard. The Status Report shall also contain the upcoming bi-weekly period’s repair inspection/test schedule, refer to paragraph 3.1.15 (Coast Guard quality assurance inspection) and any Radar system maintenance or repairs completed as outlined in paragraph 3.1.16.3. The Bi-Weekly Status Report shall be submitted via email to the KO on Thursday of each bi-weekly period or the preceding day if Thursday is a holiday. The report shall be accurate, concise, legible, and in English. A sample status report is provided in paragraph 4.3 (Reports). The Contractor may recommend alternate methods to provide repair/return status. If the recommendation is approved by the KO, the alternative method may be used.

3.1.13 Warranty. The Contractor shall provide the industry standard warranty for labor and material on all repairs following Coast Guard acceptance. The Coast Guard reserves the right to seek warranty repairs after the CCA is returned to the Coast Guard for all CCAs that fail to meet the “pass” condition outlined in paragraph 4.2(Coast Guard test).

3.1.14 Test equipment calibration. The Contractor shall maintain a test equipment calibration program in accordance with either the ISO/IEC 17025 or ANSI/NCSL Z540.3 for all applicable equipment used to assess, repair, and test the CCAs. The Contractor’s test equipment calibration records shall be maintained and available to present for verification upon the request of the KO. The test equipment calibration records shall be made available to the Coast Guard Quality Assurance (QA) Inspectors upon request.

3.1.15 Coast Guard SFLC quality assurance inspection. The Coast Guard reserves the right to witness, verify, or have performed any of the inspections/test set forth herein and provided by the Contractor as testing objectives/criteria, functional, operational, and QA tests where such inspections are deemed necessary to assure that supplies and services conform to contract requirements. The Contractor shall use their own facilities for the performance of the inspections and tests; the Contractor may use an alternate facility if approved by the KO. The Contractor shall provide advance notice of inspections or test for the upcoming bi-weekly period to the KO in the Bi-Weekly Status Report, refer to paragraph 3.1.12 (Status report).

3.1.16 Government furnished property. An operational AN/SPS-73 Radar will be furnished to assist the Contractor in diagnosing, repairing, and testing PowerPC CCA(s). The Contractor’s use of the Radar system is mandatory and will be provided during the base year of the contract.

3.1.16.1 The AN/SPS-73 Radar System includes the following modules/parts:

($/UNIT)

SAOP

Antenna/Pedestal

3.1.16.2 The Contractor shall assume full responsibility for the material condition of all GFP. The Contractor shall safeguard GFP to include protection from physical, electrical, and environmental hazards. The Contractor shall provide the physical location/address of GFP to the KO within two calendar days of receipt and whenever the equipment is relocated. Verification of GFP location may be necessary and shall be provided within two calendar days of the KO’s request. Location of the equipment shall be made via email or by other methods if approved by the KO.

3.1.16.3 The Contractor shall assume full responsibility for the operational condition of the Radar system. The Contractor shall install, operate, maintain, and repair the Radar system. The Contractor shall de-install the Radar system at the end of the contract and return it to the Coast Guard. The Contractor shall train their personnel to operate, maintain, and repair the Radar system to the extent necessary to maintain the PowerPC CCA repair schedule outlined in paragraph 3.1.9 (Repair time). Equipment installation information and system diagrams provided in TIO-97-01 are to be used for installation of the Radar system; step-by-step instructions are not provided. The Contractor shall be familiar with Radar system operating procedures in order to ensure PowerPC CCA are RFI as outline in paragraph 3.1.6 (Ready for issue condition). Equipment operating instructions and system functions are provided in publications TM-SSR-1 and TIO-97-01. Preventive Maintenance shall be performed on the Radar system as outlined in the Coast Guard Index of Maintenance Procedures (IMP) for the SSR AN/SPS-73, IMP 45173. All maintenance completed shall be reported to the KO on the Bi-Weekly Status Report paragraph 3.1.12 (Status Report). The Contractor shall perform all repairs necessary to keep the Radar system in good working order; flowcharts to diagnosis the cause of an equipment failure and corrective maintenance instructions are outlined in TIO-97-01. If the Radar system were to fail or need repair, the Contractor shall determine the cause of the failure and repairs needed to return the equipment to the same condition in which received. The Contractor shall submit a CFR to the KO via email within three working days of the failure outlining the probable failure, the extent of repairs required, and materials needed to return the Radar system to operational condition; a cost estimate with a breakdown of labor and materials shall accompany the CFR. The Contractor shall go forward with Radar system repairs only after a firm fixed price has been negotiated and authorization to proceed is received from the KO. To support the Contractor’s effort in maintaining the Radar system, the Coast Guard will supply the modules/parts listed in 3.1.16.1 above when available. Module/parts availability is defined as when the item is in Coast Guard SFLC inventory and is not required to support an operational asset; the Coast Guard Item Manager is solely responsible to make this determination. Request for GFP to repair the Radar system shall be made on the CFR as noted above. Module/parts that have failed shall be returned to the Coast Guard in the same container and with the documentation in which the RFI replacement part was received. The package the module/parts will be marked with Not Ready For Issue (NRFI). The defective module/part shall be returned within seven calendar days from receipt of the RFI replacement item. Radar system outages, repair efforts, parts used, and repair completion status shall be reported in the Weekly Status report outlined in paragraph 3.1.12 (Status report). The KO may direct return of the failed module/part prior to receipt of a replacement module/part. In the case of a software change provided to the contractor by the Coast Guard, the contractor shall install and implement the change within ten working days.

3.1.16.4 The Coast Guard shall be responsible for the transfer of the Radar system. Transfer of the Radar system includes arranging delivery to the Contractor’s facility, and providing all funding for shipping and handling. The SAOP physical characteristics are width 28 inches, depth 26 inches, Height, 50 inches, and weight 320 pounds not including the shipping container. The Pedestal physical characteristics are width 30 inches, depth 54 inches, height 57 inches, and weight 64 pounds. The Radar antenna physical characteristics are width 95 inches, depth 10 inches, height 7 inches, and weight 19 pounds. The Contractor shall be responsible for the transfer of the Radar system back to the Coast Guard. The Contractor shall deliver the Radar system to the Coast Guard within ten working days after the PowerPC repair contract expires; the Contractor shall notify the KO via email within one day after shipment. The KO may direct return of the furnished Radar system before the end of the contract. In such a case, alternatives for future repair and testing of the CCA will be jointly determined by the Contractor and KO.

3.1.16.5 The Contractor shall package and return the Radar system in the same container(s) that it was received. In the event of loss or damage to the original container, the Contractor shall provide an equal replacement container(s) in accordance with ASTM-D 3951 and shall be suitable for shipment by rail or motor freight. The Radar system shall be packaged in such a manner as to prevent damage to the equipment. The Contractor is responsible for correcting and repairing any damage due to shipment. Container(s) shall be assembled with screws to permit ease of removal of the cover(s) or lid(s) from the base and the Radar system shall be bolted to the framing system(s). Suitable cribbing shall be provided to prevent damage during shipment. Loose fill packing materials shall not be used. The Radar system shall be shrink-wrapped or otherwise covered and sealed to prevent water damage.

3.1.16.6 The container(s) shall be marked; marking shall consist of the Acquisition Control Number (ACN) or National Stock Number (NSN), Item Name, Part Number, Contract Number and Delivery Order Number, Shipping Weight, Quantity, unit of issue, and the words "U.S. Coast Guard SFLC Material, "Condition-A". The marking shall be ½ inch black lettering on a white background.

3.2 Detail Requirements. The Contractor shall visually inspect, test, repair, and clean the CCA to return the item to RFI condition.

3.2.1 Inspection. The Contractor shall visually inspect each PowerPC CCA for completeness, flaws, and defects in accordance with IPC-A-610E. The Contractor shall ensure components are attached to the circuit board in the method defined by the OEM at the time of manufacturing or in accordance with IPC-A-610E. The Contractor shall ensure all CCA hardware is complete and installed in accordance with IPC-A-610 section 4; each O-ring gasket shall be in place, in good condition, and properly installed. The Contractor shall document all defect conditions found as part of the final report, refer to paragraph 3.2.9 (Final report).

CAUTION

Use a chip extraction tool to remove the DIP EPROM from the socket to avoid damaging parts.

3.2.2 Battery replacement. The Contractor shall replace the batteries in each CCA, using the same type as removed.

3.2.3 Hardware repair. The Contractor shall repair all defects noted in paragraph 3.2.1 (Inspection) and paragraph 3.2.5 (Test/debug requirements) in accordance with IPC-A-610E and IPC-7711B to include: (1) proper mounting and connection of piece parts, (2) proper repair of circuit card anomalies, (3) proper application of coatings and treatments, and (4) proper cleaning of the CCA.

CAUTION

Do not install the VGM1/VGMD into a system whose backplane is not compatible with the correct pin-out for the specific CCA.

CAUTION

When loading Firmware/software, it is critical that the disks be loaded in the correct order to prevent damage to the PowerPC CCA.

3.2.4 Firmware load/IP address. The Contractor shall “re-flash” the CCA with the firmware designated for the specific model/serial number for the PowerPC or use a compatible substitute to test and evaluate CCA functions. The Contractor shall ensure the software provided in Government furnished property loads and the CCA completely boots. Additional information on loading firmware/software can be found in Coast Guard F.C. 7. The contactor shall test the PowerPC CCA with the Internet Protocol (IP) address set to 211.0.0.10 through 211.0.0.21. The Contractor shall list all the firmware/software loaded for each repaired CCA on the final report, refer to paragraph 3.2.9 (Final report).

3.2.5 Test/debug requirements. The Contractor shall perform the functional testing required to ascertain the operational condition and failure condition of the received PowerPC CCA. The functional test is described in 4.2 (Functional test). The Contractor shall perform the tests on CCA aspects necessary to determine the overall condition. The aspects include but are not limited to: power-up / self test, soft and hard resets, CPU and mailbox functions, equipped and attached peripheral memory, interrupts, data/address buses, registers, clock - calendar functions, front panel controls/options, Ethernet / serial interfaces, switches, LEDs, PCM slots, and other installed expansion options. The aspects listed are to be considered minimum and are not intended to replace any procedures the Contractor employs to determine the condition of the CCA. The Contractor shall document all defect conditions found as part of the final report, refer to paragraph 3.2.9 (Final report).

3.2.6 Final repair. The Contractor shall document and replace all components determined to be faulty or at the end of their expected life cycle during the firmware load and testing process defined in paragraphs 3.2.4 (Firmware load/IP address) and 3.2.5 (Test/debug requirements). Paragraph 3.2.3 (Hardware repair) shall be followed when repairing the CCA and retest/debug the CCA as noted in paragraph 3.2.5 (Test/debug requirements) to validate a RFI condition following CCA repairs.

3.2.7 Cleaning. The Contractor shall clean CCAs in accordance with IPC/EIA J-STD-001(Series) and IPC-7711B Number 2.2. A cleaning process shall be used to remove flux residue, particulate matter, chlorides, carbonates and white residues in accordance with IPC-A-610E section 10.6. All temporary markings and tags to include the CG-5236 Serviceable/Unserviceable Tag shall be removed.

3.2.8 Final inspection. The Contractor shall perform a final inspection of each CCA to include: (1) a visual inspection of workmanship, assembly and fit, materials, parts, and finish/surface appearance, and, treatment for prevention of corrosion and (2) verification of all operations specified in this Work Item and cited references are completed. All final inspection observations and measurements shall be recorded on the final report as comments and certified complete by the Contractor inspection representative’s signature.

3.2.9 Final report. The Contractor shall develop a final report for each PowerPC CCA received. In each report the Contractor shall note if a Property Discrepancy Report and/or a CFR was submitted and discrepancy(s) noted as stated in 3.1.7 (Inspection) and 3.1.10(Beyond economical repair); document the visual inspection results as defined in 3.2.1 (Inspection); list the firmware/software loaded as stated in 3.2.4 (Firmware load/IP address); list pass–fail indication found during testing/debugging as stated in 3.2.5 (Test/debug requirements); list all CCA repairs stated in 3.2.3 (Hardware repair) and 3.2.6 (Final repair); and note the results of the final inspection and sign certifying completion as stated in 3.2.8 (Final inspection). The Contractor shall document all findings on the final report clearly, legibly, and in English. The final report shall be sent to the Contracting Officer’s Repersentative via email within five days of completing repairs and shall be inserted in the shipping container with that specific CCA when returned.

3.3 Return shipping requirements.

3.3.1 Preservation. The Contractor shall preserve/protect each CCA in accordance with MIL-STD-2073-1E Table J-Ia Code GX.

3.3.2 Unit pack. The Contractor shall individually package and return all items in the same container that it was received. Old markings shall be removed from the containers prior to applying the new markings. A copy of the final reports shall be included in the container. In the event of loss or damage to the original container, the Contractor shall document the damage to the container and recommend replacement via CFR. The contractor shall provide an equal replacement container in accordance with ASTM-D 3951.

3.3.3 Marking. The Contractor shall mark each CCA package clearly, legibly, permanently, and in English.

3.3.4 Electrostatic discharge (ESD) sensitive. The Contractor shall mark all unit packs, intermediate, and exterior containers of ESD sensitive devices that are susceptible to damage from ESD in accordance with MIL-STD-129 P paragraphs 5.2.20.1 and 5.5.20.2.

3.3.5 Package labeling. The Contractor shall mark each CCA package with the following:

· National Stock Number/ Activity Control Number.

· Item Name

· Part Number

· Contract Number and Delivery Order Number

· Date of Repair

· The Words “COAST GUARD SFLC MATERIAL” CONDITION (A)- for RFI Units

· The Words “COAST GUARD SFLC MATERIAL” CONDITION (Q) – for Severely Damaged units

· Quantity & Unit of Issue (i.e. “1-EA”)

3.3.6 Bar coding. The Contractor shall bar code all CCA packaging using Code 39 requirements in accordance with ANSI/AIM BC1. The Contractor shall apply the following:

· The standard marking required in paragraph 3.3.5 (Package labeling) for all packaging configurations can be applied separately or as part of the Bar Code Label. If the latter option is used the label size shall be adjusted appropriately.

· The National Stock Number and purchase order / contract number shall be bar coded with Human Readable Interpretation (HRI) immediately below the bar coding on unit and unitized packs.

· All HRI shall be placed below its associated bar code.

The Contractor shall use labels that are intended for long term indoor applications where the labels will endure intermittent outdoor exposure. Each label the Contractor uses shall have porous surfaces and consist of paper without plastic laminate.

4. NOTES

4.1 Equipment descriptions.

4.1.1 Synergy VGM1/VGMD PowerPC assemblies. The Synergy VGM1/VGMD PowerPC assemblies are a Verabus Module Eurocard Bus (VMEbus) single board computer. The assembly is based on the G2 PowerPC 604E or G3/G4 Power 750/7400 processor running between 200MHz and 400MHz. The CCA conforms to VME 6U fit/form requirements.

4.1.2 AN/SPS-73 Surface Search Radar. The VGM1/VGMD PowerPC CCA is the microprocessor within the AN/SPS-73 Surface Search Radar (SSR). The AN/SPS-73 SSR consists of one or more SAOP. The SAOP is a Raytheon designed unit consisting of Commercial off the Shelf assemblies. The SAOP combines the Radar Processor (RP) and Operator Position (OP) functions to provide complete control of the Radar. The RP and OP CCAs are housed in a 21-slot or 5-slot VME bus chassis. The VME chassis is compliant with IEEE 1014 VME bus specification Rev C.1 and D.1. The SAOP processing systems are connected by a 100Base-T LAN through a 100Base-T hub; it interfaces with external systems via the LAN and supports Radar and Display Distribution System and other Radar inputs. The SSR supports National Marine Electronics Association 0183 inputs and Electronic Industries Association standard RS-232 and RS-422. The PowerPC CCA is the microprocessor within the SSR controlling all data transfer between the circuit cards in the VME chassis, software processing, tracking functions, and supports keyboard and trackball OP functions.

4.1.3 PowerPC version and application. There are four versions of the PowerPC CCA NSN: 5998-01-461-6349 listed in paragraph 1.2 (Government-furnished property) operating in thirteen different AN/SPS-73 SSR configurations to include: WAGB-400 (V1), WHEC-378 (V2), WIX-295 (V3), WMEC-270 (V4), WMEC-224 (V5), WMEC-210 (V6 Dual), WLIC-160 (V8), WTGB-140 (V9), WPB-110 AND WPB-87 (V11), VTS-A Vessel Traffic System (V14), VTS-B Vessel Traffic System (V15), and VTS-C Vessel Traffic System (V16). The PowerPC operation in each AN/SPS-73 Radar version is nearly identical; the specifics of each configuration are identified in the TIO-07-01.

4.2 Functional test. Functional tests are defined as those go, no-go (pass/fail) tests which sequentially exercise a function (truth) table or in which the device is operated as part of an external circuit and total circuit operation is tested.

Bi-Weekly Status Report

TEST/INSPECTION SCHEDULE & COMMENTS

USCG C3CEN ELECTRONICS REPAIR FACILITY

ERF TEST PROCEDURE MANUAL

SECTION: RADAR

TITLE: 3A2A101 Power PC CCA REFERENCES: 1. RADAR-001 3A3 Keyboard Assembly

2. RADAR-002 3A4 TRACKBALL ASSEMBLY

3. AN/SPS-73(V) System Level Operation and Maintenance Manual.

TEST DATA SHEET NO: RADAR-003

PAGE (S): PAGE 22 OF 2

DATE: 02 DEC 2011

REVISION: (C)

MB:

PU32:

RGS2:

Quality Assurance has used ONLY calibrated test equipment to certify this equipment is operating in accordance with OEM standards.

(stamp here)

Established by OEM and/or C3CEN Quality Assurance Results

Pass

Fail

Pass

Present

Engineering Change Notices and/or Electronic Field Change Bulletins, TCTO’s, (list ECN and/or FC’s here, if none write N/A)

Cleanliness CG-5236 tag with NSN: 5998-01-461-6349 Pass

Fail

Pass

Present

Notes: EG. LEDS lit, loop cycles, etc.

REPAIR

REPAIR TECHNICIAN RESULTS

FUNCTIONAL TEST

BRIDGE_NAV

BRIDGE_SHIP

Pass

Fail

Pass

Fail

END REPAIR PROCESS

QA

QUALITY ASSURANCE TECHNICIAN RESULTS

FUNCTIONAL TEST

BRIDGE_NAV

BRIDGE_SHIP

Pass Fail

Pass

Fail

Pass

Fail

Pass

Fail

Pass

Fail

No errors detected

Test Procedure Number: RADAR-003

Date: 22MAY08

Revision: (D ) 02 DEC 2011

Place Stamp of Approval Here

Section: RADAR

NSN: 5998-01-461-6349

Equipment: 3A2A101 PowerPC CCA Reference(s):

1. RADAR-001 3A3 Keyboard Assembly

2. RADAR-002 3A4 TRACKBALL ASSEMBLY

3. AN/SPS-73(V) System Level Operation and Maintenance Manual.

Equipment, or equivalent, required:

1. ESD safe wrist strap.

2. VME Card Cage

3. AN/SPS-73(V) Mock-up

4. Laptop, with LAN Connections.

5. Buffalo Graphics Simulator Visual and Physical Inspection

1. Ensure all hardware is in place and fastened securely

2. Ensure all Engineering Change Orders, TCTO’s and/or Field Change Bulletins are completed.

3. Ensure all applicable labels and CG-5236 tag is in place.

4. Ensure the equipment is clean and free of corrosion.

5. Ensure the equipment is not damaged or broken in any manner.

Screen and Repair Test Set-Up

1. Ensure VME Card Cage is unplugged from the AC outlet.

2. Energize laptop. (see boot procedures for, Appendix A: Laptop)

3. Disconnect Network Cables from the Serial port and the Ethernet port, if applicable, on the Power PC CCA.

4. Remove mockup PowerPC card by placing one thumb on each end of card. Push up on top end and down on bottom end

5. Insert Power PC CCA to be tested. Ensure card is solidly seated in VME card cage.

6. Connect the Network Cable to the serial port for the Power PC under test.

Screen and Repair Test

1. Confirm the correct IP address on the 8-bit user switches on the front of the Power PC CCA to be tested. BRIDGE_NAV or BRIDGE SHIP addresses will be used, referencing System Level Operation and Maintenance Manual, see attachment appendix B.

2. Install 11.8 software disk into PCMCIA slot

3. Ensure Hyper Terminal is set up. (see boot procedures for, Appendix A: Laptop)

4. Energize the VME Card cage by plugging power supply into outlet.

5. Monitor STS LEDS and USR LEDS.

6. Monitor hyper terminal program on laptop.

Screen and Repair Test Complete (Repair Technician) Quality Assurance Test Set-Up

1 Ensure SAOP is powered down as per the AN/SPS-73(V) System Level Operation and Maintenance Manual, pages 2-3 and 2-4.

2 Disconnect Ethernet Connection cable from mockup PowerPC card.

3 Disconnect Hyper Terminal Connection cable from mockup PowerPC card 4 Remove mockup PowerPC card by placing one thumb on each end of card. Push up on top end and down on bottom end.

5 Insert card to be tested. Ensure card is solidly seated in VME card cage.

6 Connect Ethernet Connection cable to PowerPC card to be tested.

7 Connect Hyper Terminal Connection cable to serial port to Power PC to be tested.

Quality Assurance Test

1. Confirm the correct IP address on the 8-bit user switches on the front of the Power PC CCA to be tested. BRIDGE_NAV or BRIDGE SHIP addresses will be used, referencing System Level Operation and Maintenance Manual, see attachment appendix B.

2. Install 11.8 software disk into PCMCIA slot

7. Ensure Hyper Terminal is set up. (see boot procedures for, Appendix A: Laptop)

3. Energize SAOP; confirm software version 11.8 loads.

4. Acquire target.

5. Change target label.

6. Change target name.

7. Confirm that SAOP correctly tracks targets generated by radar simulator.

8. Keyboard Function:

i. Rotate dimmer knob at upper right of keyboard fully clockwise and fully counter-clockwise, ensuring the backlighting brightens and dims.

ii. Left-click inside the ULABEL text box on bottom right side.

iii. Press each letter and punctuation key, verifying each key functions. Do not include the number key pad.

iv. Press the LEFT ARROW key twice to verify the cursor moves to the left.

v. Press DELETE key to verify the letter after the cursor is deleted.

vi. Press the RIGHT ARROW key to verify the cursor moves to the right.

vii. Press BACKSPACE to verify that the letter to the left of the cursor deletes and the cursor movers back one space.

viii. Press CAPSLOCK and verify the light above it comes on. Type a few letters to ensure they all appear in uppercase form. Turn CAPSLOCK off.

ix . Hold down one SHIFT key and press a letter to confirm that it is capitalized.

Repeat with the other SHIFT key.

x. Backspace all the letters in the text box.

xi. Press the NUMLOCK key and verify the light above it comes on.

xii. Press all numbers in the keypad and verify they function.

xiii. Press the TAB key. The ULABEL text box should no longer be highlighted. The

PRI: button should now be highlighted.

xiv. Press the UP ARROW key. A menu should appear. Press the UP and DOWN

ARROW keys and verify the highlighted item changes accordingly. Left-click on

NONE.

xv. Press the TAB key again. The PRI: button will no longer be highlighted. AFFIL:

should now be highlighted.

xvi. Left-click AFFIL:. A menu should appear. Press ESCAPE. AFFIL: should no longer be highlighted. PRI textbox should be highlighted.

xvii. Press F2 five times. The display background should brighten.

xviii. Press F1 five times. The display background should dim.

xix. Press F3 five times. Entire display should dim.

xx. Press F4 five times. Entire display should brighten.

xxi. Press F5. RADAR BRIGHTNESS slide bar should decrease by 5%.

xxii. Press F6. RADAR BRIGHTNESS slide bar should increase by 5%.

xxii. Press F7. MENU BRIGHTNESS slide bar should decrease by 5%.

xxiii. Press F8. MENU BRIGHTNESS slide bar should increase by 5 %.

xxiv. Press F9. RADAR and MENU BRIGHTNESS should both decrease to 50%.

xxv. Press F10. RADAR and MENU BRIGHTNESS should both increase to 100%.

xxvi. With target video on PPI, move cursor over a target and press CTRL-A. Verify target is acquired.

xxvii. The following keys are not utilized by the system and are therefore not tested:

INS, HOME, END, PG UP, PG DN, PRINT SCRN, SCRL LOCK, PAUSE, F11

and F12.

9. Trackball Function:

i. Roll trackball around and ensure that the cursor follows the movement of the trackball.

ii. Left-click ROT/RAD button after the 180-second magnetron warm-up is complete.

iii. Observe ROT/RAD button change to Green-On then back to Red-Off.

iv. Observe Radar State label at bottom right of display change from Red-Stby to

Green-Rot then Green-Rot/Rad.

v. ROT/RAD button changes to Green-On.

vi. Radar image appears in PPI.

vii. Right-click a spot on the PPI. Ensure that a menu appears next to the spot where the cursor is.

viii. Left-click away from the menu to get rid of the menu.

ix. Center-click a position on the Track Sensitivity sliding bar on the right side of the screen. Ensure the sliding bar moves to the position indicated by the cursor.

9. Confirm that CCA runs for 02 hours continuously with no errors.

End of Quality Assurance Test

End of Test

Use the following Appendix to ensure that the laptop used to run the Hyper Terminal program is set up correctly to record information from the Power PC CCA’s Ethernet port.

Equipment Required

1. Laptop

2. Female Ethernet to Female DB9 Adapter

3. Ethernet Cable

Test Set-Up:

1. Connect Adapter to COM PORT 1 on laptop.

2. Connect Ethernet cable between Adapter and Power PC CCA.

Test:

1. If first test of current due-in; starting from desktop:

Open HyperTerminal Test Results > Power PC > Select “Make a new folder” from File and Folder Tasks Shortcut > Rename “New Folder” to date, due-in number, and quantity of cards to be tested. Example: 15DEC2010 DI 606610 (QTY 10)

2. Open hyper terminal program:

Start Menu > All Programs > Accessories > Communications > HyperTerminal

3. Upon HyperTerminal Start up you must enter a name for the connection. Click OK.

Settings:

Connect using: COM PORT 1

Click OK.

Input the following:

Bits per second: 9600

Data bits: 8

Parity: None

Stop bits: 1

Flow Control: Hardware

Click OK.

5. File Save:

Transfer > Capture Text > Browse > Desktop Icon (from shortcut bar) > HyperTerminal Test Results > Power PC > Current Test Result Folder > Save using the following format: Serial Number, Date, Type of test (Initial, Upgrade, Final) > Click Save > Click Start.

Example: 804756 15DEC2010 INITIAL

6. Hyper Terminal will start recording when SAOP is energized.

7. Upon completion of test:

Transfer > Capture Text > Stop.

8. Next Card (If same due-in):

Repeat process starting at Step 5.

Once complete due-in has been tested, using the external hard drive, transfer all saved .txts to a CGWSIII for printing.

4.3 Reports.

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