Sample_Task.pdf

N68936-14-R-0008 Attachment P4

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SAMPLE TASK

for

D-Band Noise Technique Control Modulator (TCM) Circuit Card Assembly

1.0 The contractor shall convert the E/F Band (2-4 GHz) Noise Card using Drawing # 1611AS14006-1 to produce a variant prototype D Band (1-2 GHz) Noise Card. The prototype unit shall meet all the performance requirements of the E/F Band Noise card while operating from 1-2 GHz.

2.0 Physical Characteristics:

2.1 The Unit shall meet all dimensions per drawing 1611AS14006-1.

2.2 The weight of the Unit shall be no greater than 3 pounds.

2.3 The Unit finish shall be in accordance with drawing 1611AS14006-1.

2.4 The Unit shall be labeled and marked in accordance with drawing 1611AS14006-1. New part number shall be assigned by the Government.

2.5 The connectors shall be in accordance with drawing 1611AS14006-1.

3.0 Design and Construction:

3.1 Workmanship shall be in compliance to IPC-A-610 Class 3.

3.2 Soldering shall be in accordance to J-STD-001 Class 3. The type of solder shall be SN63PB37 unless otherwise instructed per the drawings.

3.3 Conformal Coat material complying with IPC-CC-830 Rev B shall be used for protection of parts and printed wiring boards.

3.4 Any Bonding process using electrically conductive bonding material shall be supplemented with a mechanical connection to ensure adequate electrical continuity for the service life of the Unit.

3.5 The Unit shall be designed to function and operate as required herein, following a storage period of 5 years at temperatures varying from -54 ˚C to +71 ˚C and relative humidity ranging from 15 percent to 95 percent. The Unit shall achieve specification performance requirements within 180 seconds after application of primary power.

4.0 Quality Systems:

4.1 The contractor's quality assurance (QA) program shall meet the requirements of ANSI/ISO/ASQ Q9000 Series or an equivalent quality system model with prior Government

Page 2 28 April 2014 approval. The QA program shall address material and parts selection, process control, workmanship, inspection and configuration management.

5.0 Testing:

5.1 Separate test procedures shall be prepared by the contractor and approved by the procuring activity for the First Article and Acceptance testing. The first article environmental, first article EMI and first article reliability tests shall be included as part of the first article test procedure.

Test procedures shall be submitted for approval by the contractor to the procuring activity 20 days prior to the start of First Article or Acceptance testing. ATSO reserves the right to comment and have the contractor revise the test procedures.

5.2 Detailed test data shall be prepared by the contractor for the First Article and all subsequent production Units. This data shall identify all rejections and corrective actions taken. The contractor shall submit the test data to the procuring activity for approval 10 days before shipment of the Unit(s).

5.3 Unless otherwise specified, all tests and inspections shall be conducted under the following conditions:

Temperature +23 ± 10˚C (ambient) Atmospheric pressure Normal pressure of the test facility Humidity 10% to 90%

5.4 The Unit shall be designed to meet the environmental requirements in accordance with this sample task. The Unit shall not exhibit any temporary or permanent degradation as the result of exposure to any of the required environments.

5.5 The first article sample shall be manufactured using the same methods, materials, processes and procedures proposed for production. Any production by the contractor before acceptance of the first article sample shall be at the Contractor's risk. Subsequent to first article approval, the Contractor shall not change materials, processes, or procedures without prior approval from the procuring activity.

5.6 Unless otherwise specified in the contract or purchase order, the first article sample shall consist of one Unit. After first article testing has started, adjustments shall not be performed upon the Unit during or after first article testing has completed. The first article testing and inspections shall be conducted by the contractor with oversight by the procuring activity.

5.7 The Unit shall be tested to the following environmental tests:

5.7.1 Full-Functional

5.7.2 High Operating Temperature:

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Testing shall be in accordance with MIL-STD-810 High Temperature Method 501.5 Constant temperature exposure Unsheltered exposure Deviations from the MIL-STD:

o 24 hour pre-soak at +71˚C “Non-Operating Conditions” followed by 2 hours at +71˚C while the UUT is in “Operating Conditions” o After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions

5.7.3 Low Operating Temperature:

Testing shall be in accordance with MIL-STD-810 Low Temperature Method 502.5 Constant temperature exposure Unsheltered exposure Deviations from the MIL-STD:

o 24 hour pre-soak at –54˚C “Non-Operating Conditions” followed by 2 hours at (- 40˚C) while the UUT is in “Operating Conditions” o Two hour operating dwell shall start after the UUT reaches temperature stabilization

5.7.4 Thermal Shock:

Testing shall be per MIL-STD-810 Temperature Shock Method 503.5 Procedure I-C Multi-cycle shocks with constant extreme temperature

Use MIL-STD-810, Figure 503.5-3: Multi-Cycle Shocks as shock profile reference Deviations from the MIL-STD:

o Temperature extremes shall be –40˚C and +71 ˚C

5.7.5 Humidity:

Testing shall be per MIL-STD-810 Humidity Method 507.3 Procedure II- Aggravated Use MIL-STD-810, Figure 507.5-7: Aggravated Temperature-Humidity Cycle as a temperature profile reference with temperature changes in compliance with below Deviations from the MIL-STD:

o Post-conditioning shall be eliminated o Perform “Limited Functional Tests” checks of the fifth and tenth cycles at both temperature conditions o UUT shall be oriented in its operational upright state (Note: No additional protection shall be used. It is permitted to connect non-operating ports in a normal mating fashion.)

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Individual Aggravated Humidity Cycle

Time Temperature (˚C) Temperature (˚F) Relative Humidity (%)

00:00 28 82 85 minimum 02:00 71 160 95 08:00 71 160 95 16:00 28 82 85 minimum 24:00 28 82 85 minimum

5.7.6 Random Vibration:

Testing shall be per MIL-STD-810 Vibration Method 514.6 Procedure I - General Vibration

Deviations from the MIL-STD:

o The vibration profile shall be per below o The vibration duration shall be 1 hour minimum in each of the three orthogonal axes

(lateral, longitudinal and vertical) o No vibration isolators shall be used o UUT shall be in “Monitoring Conditions” during vibration exposure.

o A response accelerometer attached to or near the UUT is required (tri-axial accelerometer recommended for best practice) o Out of axis response warning levels are set at -3 dB input vibration profile PSD

Random Vibration Profile

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Frequency vs. PSD Frequency (Hz) PSD (g2/Hz)

10 0.06

1000 0.06

2000 0.015

GRMS = 9.46

5.7.7 Mechanical Shock:

Testing shall be per MIL-STD-810 Shock Method 516.6 Procedure I – Functional Shock Deviations from the MIL-STD:

o Three 12 g 11 ms half sine shocks in each +/- direction in all three orthogonal axes (lateral, longitudinal and vertical) for a total of 18 shocks o UUT shall be in “Monitoring Conditions” during shock exposure o No vibration isolators shall be used o After the conclusion of the test, “Limited Functional Tests” post data is required at ambient conditions

5.7.8 Temperature-Altitude:

Testing shall be per MIL-STD-810 Temperature, Humidity, Vibration and Altitude Method 520.3 Procedure III – Qualification

Deviations from the MIL-STD:

o Humidity and Vibration are excluded o Altitude and Temperature conditions per below

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Temperature-Altitude Profile

Temperature vs. Altitude

Elapsed Time (Minutes)

Temperature (˚C) Altitude (Ft)

UUT

On**/Off***

0 -40 Ambient Off 60 -40 Ambient Off 60* -40 40,000 On 90 -40 40,000 On 90* +71 Ambient Off 150 +71 Ambient Off 150* +40 40,000 On 180 +40 40,000 On

* Chamber transition times not included ** UUT On is defined as “Operating Conditions” *** UUT Off is defined as “Non-Operating Conditions”

5.7.9 Full-Functional

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6.0 Other Deliverables (Government Format):

Modified schematic drawing Modified Bill of Materials (BOM) Modified Printed Wiring Board (PWB) drawing Modified Assembly drawing Modified Gerber Files Modified source code (firmware and/or software as required)