14RGR64_0001_att_1.doc

N00164-14-R-GR64

Vacuum Reflow Furnace

Crane Division, Naval Surface Warfare Center (NSWC Crane) Code GXRS, Building 3168

300 HWY 361

Crane, IN 47522-5001

10 June 2014 Vacuum Reflow Furnace (used in soldering electronic components)

1.0 Purpose:

This document outlines the specifications for a programmable vacuum and pressure furnace for high reliability microelectronic package assembly allowing void-free solder attach with or without the use of flux (System).

2.0 General Requirements:

Paragraphs 2.1 through 2.11 define the minimum requirements for compliance to Environmental, Safety, and Health issues.

2.1 The System shall meet National Fire Protection Association (NFPA) Codes and Standards; NFPA-30 Flammable and Combustible Liquids Code, NFPA-70 National Electrical Code, and NFPA-79 Electrical Standard for Industrial Machinery and Appendices.

2.2 All Contractor supplied coolant or lubricants shall have flash points of a Class III B liquid at or about 200 degrees Fahrenheit (°F), per National Fire Protection Association NFPA-30.

2.3 All components, where applicable and available, shall be Listed, Classified, or Recognized, and shall be labeled by Nationally Recognized Testing Labs (NRTL), such as Underwriter Laboratories (UL) and/or Factory Mutual (FM), for their intended application.

2.4 The operator shall be guarded against accidental contact from all electrical and electronic components and wiring. All switches and controls accessible to the operator shall not exceed 120 volts (V) potential across the contacts of the equipment ground.

2.5 All packaged assemblies and subassemblies of the System having internal voltages exceeding 50 volts shall be affixed with a label which states, “Danger – Electrical Shock Hazard”, and/or shall be identified with a label with the internationally recognized symbol for high voltage.

2.6 The System shall be supplied with a red “mushroom-type” Emergency Power Off (EPO) button at the operator station. Activation of the EPO shall return any clamped components to the least hazardous condition and shall cause a braked shutdown of any rotational components. When activated, the EPO shall require a manual reset, and shall not cause any damage to the equipment. When appropriate, other portions of the equipment shall have an additional EPO.

2.7 The System shall comply with 29 Code of Federal Regulations (CFR) 1910 Subpart O and shall be equipped with the following new minimum guards and interlocks:

· Guards, shields, or other protective covers shall be required to cover injurious high or low temperature parts and hazardous moving parts, e.g. belts, drive shafts, drive screws, sharp edges, pinch points, or other potential hazards.

· All guards and shields shall be constructed to provide access to the guarded parts for maintenance and shall not interfere with operation of the System.

· Interlocks shall be required whenever access can be gained, without the use of a tool, to an area that would allow inadvertent contact with electrical, mechanical, or chemical hazards.

2.8 The System and associated equipment shall not emit noise levels in excess of 80 decibels (A Weighted) except as follows:

· The noise levels shall not exceed 75 dBA in the areas attended by operators.

· Noise level shall be based on an 8-hour Time Weighted Average (TWA) measured in accordance with procedures and conditions specified in Section 10 of the published “Noise Measurement Techniques” January 1976 or latest edition issued by the Association for Manufacturing Technology (AMT) (formerly the National Machine Tool Builders Association [NMTBA]). These measurements shall be performed only under the operating conditions specified in section 10.1.3.b of the publication.

2.9 The System shall contain no asbestos or asbestos containing materials and shall be free of Polychlorinated Biphenyl (PCB’s).

2.10 Contractor shall provide a certificate of compliance for any tests performed at Contractor’s facility to validate that the System meets the requirements of this specification. (CDRL A001)

2.11 Material Safety Data Sheets (MSDS) for all oils, lubricants, coolant additives and cleaner fluids shall be provided a minimum of 12 weeks prior to shipment. (CDRL A002)

3.0 Specific Requirements:

3.1 The Solder Reflow Furnace (System) shall consist of a single, self-contained machine consisting of all components necessary to provide a solder reflow process under vacuum or pressure. System software shall contain statistical process control programs and have network connectivity capability.

4.0 Minimum System Level Capabilities:

4.1 The System shall consist of one independent machine capable of producing 95% void-free solder joints in attaching surface mount packaged components and bare die components to ceramic and organic based circuit board conductors using low and high temperature solder alloys.

5.0 Graphical User Interface (GUI):

5.1 System shall have a GUI that allows the System operator to manipulate all functions of the System.

5.2 GUI functions shall be intuitive to the operator and shall not require special skill set or training (other than System training provided by System supplier).

5.3 GUI shall be used to store all System parameters.

6.0 Reflow Chamber:

6.1 Reflow Chamber shall be capable of handling the following minimum component sizes:

· 127mm (5.0 inch) wide

· 178 mm (7.0 inch) long

· 76 mm (3.0 inch) height

6.2 System shall be capable of manual loading of components into and out of the System reflow chamber.

6.3 Fixtures are to be used to hold components in place during reflow operation.

6.4 The System reflow chamber shall be capable of holding all profile temperatures to +0 degrees Celsius (oC)/-5oC (+0oF/-9oF).

6.5 Maximum temperature difference between components shall be less than 7oC (45oF) (5°C (41oF) within an individual component).

6.6 An inert gas atmosphere shall be developed in the System reflow chamber with a maximum oxygen content of 50-75 ppm.

7.0 Reflow Profile:

7.1 System shall have a programmable heating and cooling profile to allow soldering of low and high temperature solder alloys.

7.1.1 The System shall be capable of temperature Ramp-Up and Ramp-Down rates for low and high temperature solder alloys. A sample of low temperature alloy (eutectic SnPb, 63% tin, 37% lead) and high temperature solder alloy (SAC 305, 96.5% tin, 3% silver, 0.5% copper) (eutectic AuSn, 80% gold, 20% tin) reflow profiles are as follows (not limited to):

T = Temperature t = time Data in table above is representative of process parameters for reflowing certain solder alloys. This data is not considered a requirement for this specification. Contractor shall specify performance parameters of their System at time of quotation.

A graphical representation of these profiles is as follows:

7.2 Programming of System profiles and System parameters shall be accomplished through System Graphical User Interface (GUI).

7.3 The System GUI shall have the capability to manipulate the following reflow profile parameters (not limited to):

· Ramp-Up:

Average Ramp-Up Rate (TSMAX to TP) oC or oF per second

· TSMIN:

Preheat Peak Minimum Temperature oC or oF

· TSMAX:

Preheat Peak Maximum Temperature oC or oF

· tS:

Time between TSMIN and TSMAX seconds

· TL:

Solder Melting Point oC or oF

· tL:

Time Maintained above TL seconds

· tP:

Time within 5°C of Peak Temperature seconds

· Ramp-Down:

Ramp-Down Rate oC or oF per second

· t 25°C to TP:

Time from 25°C to Peak Temperature minutes

· Pressure:

Gas Pressure

Kilo Pascal (kpa) or Pounds/inch2 (psi)

· GF:

Gas Flow Rate

Cubic Feet per

Minute (CFM) or psig

· Vacuum:

Vacuum Pressure

Torricelli (torr)

· VR:

Vacuum Ramp Rate torr/second

· Cooling:

Cooling Water Flow Rate

Liters Per Minute

(LPM) and Gallons

Per Minute (GPM)

7.4 Multiple reflow parameter profiles shall be stored on System Personal Computer (PC).

7.5 Actual System reflow chamber temperature and profile temperature shall be capable of being displayed simultaneously on System monitor, saved to Compact Disc (CD) or Digital Versatile Disc (DVD), and printed to paper copy.

8.0 Data Transfer Capabilities:

8.1 If outside data transfer is required, data shall be transferred via Ethernet and standard electronic media transport mechanisms (CD/DVD reader & writer, Universal Serial Bus (USB) port for external drive connection).

9.0 Physical Dimensions:

9.1 The System working footprint, including the required additional servicing area surrounding the System, shall be the following maximum:

· 175 cm (69 inch) Width

· 200 cm (79 inch) Depth

· 205 cm (81 inch) Height

9.2 System height shall not exceed 270 cm (106 inch) with the access door open.

9.3 The System shall be capable of being moved through a doorway that is 180 cm (71 inch) wide and 210 cm (83 inch) tall in order to get the System into the room where it is to be installed.

9.4 Contractor may partially disassemble the System to accommodate installation.

9.5 System shall be a maximum of 3000 kilograms (6614 pounds).

10.0 Air Requirements:

10.1 The System shall be able to operate at a compressed air pressure of 7.73Kg/cm2 (110 psi).

10.2 The Contractor shall provide a compressed air ballast tank for System if required.

10.3 The maximum air consumption shall be 170 liters per minute (6.0 CFM).

11.0 Cooling Requirements:

11.1 Contractor shall identify specification for interfacing Vacuum Reflow Furnace with Chiller in order for NSWC Crane to connect existing Chiller.

12.0 Vacuum Requirements:

12.1 Vacuum equipment to supply necessary vacuum levels for 95% void-free solder attach shall be supplied by contractor and be an integrated part of the System.

13.0 Venting Requirements:

13.1 A 7.6 cm (3.0 inch) diameter vent is available at installation sight if venting of System is required.

13.2 Contractor shall provide venting requirements when submitting quote and to be included in Site Preparation documentation in section 17 below.

14.0 Power Requirements:

14.1 The System shall be capable of operating on 480 Volts (V) Alternating Current (AC), three phase, 60 Hertz (Hz) and 208 VAC, three phase, 60 Hz.

14.2 Contractor shall supply any equipment necessary to convert Government supply power (480 Volts (V) Alternating Current (AC), three phase, 60 Hertz (Hz) and 208 VAC, three phase, 60 Hz) to System power requirements.

14.3 Control system power shall contain an uninterruptable power supply and be configured for no loss of data upon power outage.

Operating Conditions:

14.4 The System shall be capable of operating at a room temperature range of 18 °C (64 oF) through 25 °C (77 oF).

14.5 The System shall be capable of operating at a relative humidity range of 30% through 60%.

14.6 The System shall be capable of operating in a class 100,000 clean room without detriment to the 100,000 class clean room facility and equipment.

15.0 Documentation:

15.1 The Contractor shall provide manuals (with System delivery) describing standard operation procedures, maintenance procedures, and parts (i.e. diagrams and lists) in English. (CDRL A003)

16.0 Shipping:

16.1 The Contractor is responsible for all packaging, crating, and rigging required for shipment to Government facility. Freight On Board (FOB) destination.

17.0 Site Preparation and Installation:

17.1 Site Preparation:

· The Contractor shall provide instructions for site preparation when submitting proposal. Instructions shall include, at a minimum all utility requirements needed to operate the System. Instructions may be in the form of drawings or written instructions. (CDRL A004)

· Documentation shall include all utility requirements needed to operate the System.

· The Contractor shall provide input line power conditioning equipment if required by the System to operate properly.

· Site preparation shall be the responsibility of the Government.

· Any special components necessary for proper site preparation shall be the responsibility of the contractor (i.e. air filters, air regulators).

18.0 Installation:

18.1 The Government shall schedule installation with the Contractor (should occur within thirty (30) days of delivery after Government has completed utility connections described in section 18.5 below).

18.2 Contractor shall provide written information describing proper rigging and handling of the System from the transport vehicle into the room, and inside the room to the installed position. The information shall include at a minimum: location of lift points; component weight; identification of components with high center of gravity. (CDRL A005)

18.3 The Contractor shall prepare the System for operation including any disassembly and reassembly required for placement of System at Government’s site.

18.4 Installation time shall not exceed five (5) days.

18.5 The Government shall unpack the System, set it in the proper location within NSWC Crane facility and make all utility connections prior to Contractor inspection and final installation. The System power will remain off until Contractor inspects installation.

19.0 Training:

19.1 The Contractor shall provide an instructor for a minimum of two days of training at the Government’s facility immediately following installation.

19.2 Training shall be for Government’s engineer, technician, operator, and maintenance personnel and shall be comprehensive enough to permit trainees to become proficient in the operation and maintenance of all System equipment.

20.0 Inspection and Testing:

20.1 The System shall be assembled and inspected prior to shipment. The Contractor shall be responsible for the performance of all inspection requirements as specified herein.

20.2 The Contractor shall ensure that the System is fully operational and meets all of the Government’s specifications prior to shipment.

· Deliverables will be inspected for compliance to this statement of work.

· The Government reserves the right to perform an initial inspection on the deliverables at the contractor's facility. This inspection shall be coordinated with the Contractor. A final inspection will be performed at destination.

· Rejection. If any products offered fail to meet this requirements document, the System shall be rejected. The Government reserves the right to terminate inspection upon any failure of the System during the demonstration. Contractor will be allowed 2 weeks to repair or replace any noncomplying products at Contractor’s expense before System is rejected.

20.3 Any test facilities other than the Contractor’s factory shall have prior Government approval.

21.0 Acceptance:

21.1 Final acceptance of the System shall occur after the System has been installed and operated in accordance to the specification for thirty (30) calendar days.

21.2 Prior to final acceptance Contractor shall correct any problems at Contractor’s expense.

22.0 Maintenance:

22.1 A preventative maintenance schedule for the entire System shall be supplied at time of proposal. (CDRL A006)

22.2 A recommended spare parts list including current cost information shall be provided for informational purposes only. (CDRL A007)

22.3 Any System components requiring metrology grade calibration shall be called out in quote.

23.0 Points of Contact (POC):

23.1 The Requiring Technical Activity (RTA) POC is Mr. Matt Walsh, 812-296-2031, email matthew.r.walsh@navy.mil. Mr. Robert Fizer, 812-854-3898, email robert.fizer@navy.mil is the POC for non-substantive communications of a technical nature. The Contracting Office POC for all substantive communications is Pamela Ryan, 812-854-8849, email pamela.d.ryan@navy.mil. Only the Contracting Officer has the authority to change the requirements of this SOW. All communications between prospective contractors and the Government shall flow through the contracting office until a contract is awarded.

This specification shall be the document used for purchasing the System. Should there be conflict between this document and your specification, this document shall take precedence. The goal is to eliminate any differences before a purchase order is placed.

Distribution Statement A