RST-EPS-SOW-0055-_Draft2020.8.24.pdf

Effective Date: TBD

National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

RST-EPS-SOW-0055, Revision -

Roman Space Telescope (RST), Code 448

RST Solar Array Panels Statement of Work

DRAFT

Roman Space Telescope Reviewed – Not Subject to Export Control

RST Solar Array SOW RST-EPS-SOW-0055, Revision - Draft ii CHECK https://ipdtdms.gsfc.nasa.gov/frontmenu_dsp.cfm

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

RST Solar Array Statement of Work

Review/Signature/Approval Page

Prepared by:

David Kim

Approved by:

Electronic Approval available on-line at the RST CM Tool https://ipdtdms.gsfc.nasa.gov/frontmenu_dsp.cfm iii Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Preface This document is a Roman Space Telescope (RST) Configuration Management (CM)-controlled document.

Note: Prior to May 20, 2020, the project name was Wide Field Infrared Survey Telescope

(WFIRST).

For the purposes of configuration management, the prefixes “WFIRST” and “RST” are completely interchangeable. For example, RST-MGMT-PROC-0024 is the same as WFIRST-

MGMT-PROC-0024.

Changes to this document require prior approval of the applicable Configuration Control Board (CCB) Chairperson or designee. Proposed changes shall be submitted to the RST CM Office (CMO), along with supportive material justifying the proposed change.

In this document, a requirement is identified by “shall,” a good practice by “should,” permission by “may” or “can,” expectation by “will,” and descriptive material by “is.”

Questions or comments concerning this document should be addressed to:

RST Configuration Management Office Mail Stop 448 Goddard Space Flight Center Greenbelt, Maryland 20771 iv Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Change History Log

Revision Effective Date Description of Changes (Reference the CCR & CCB/ERB Approval Date)

Revision - TBD Initial Release per CCR-0277 v Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Table of TBDs/TBRs/TBSs [optional]

Item No. Location Summary Individual/ Organization

Actionee

Due Date vi Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Table of Contents

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Related Documentation

1.3.1 Applicable Documents and Drawings

2 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 Program Management

2.2 Reporting

2.2.1 Telecons

2.2.2 Status Reports

2.3 Advanced Notifications

2.4 Reviews and Meetings

2.4.1 Kick-off Meeting

2.4.2 Design Conformance Review (DCR)

2.4.3 Pre-Environmental Review (PER)

2.4.4 Pre-Ship Review (PSR)

2.4.4.1 Final Mass Properties Measurement

2.4.4.2 End Item Data Package (EIDP)

2.4.5 Technical Interchange Meetings (TIM)

2.4.6 Manufacturing Readiness Review (MRR)

2.5 Documentation

2.6 NASA/GSFC Furnished Data, Equipment, and Facilities

2.6.1 Insulated Substrates

2.6.2 Connectors

2.6.3 Witness Foils

2.6.4 Coarse Sun Sensor (CSS) Wire

3 DESIGN AND ANALYSIS

3.1 Interface Control Documentation

3.2 Drawing Package

3.3 Computer Models

3.4 Thermal Analysis Data

3.5 Worst Case Circuit Analysis Report

3.6 Parts Stress Analysis Report

3.7 Radiation Hardness Analysis Report

3.8 Reliability Analysis Report

3.9 Failure Modes and Effect Criticality Analysis Report

3.10 Electrical Output Predictions

3.11 Mass Analysis

4 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

4.2 Solar Array Panels

4.3 Connector Savers

4.4 Supporting Hardware

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4.4.1 Mating Connectors, Test Harnesses, and Connectors for Breakout Boxes

4.4.2 Connector Caps

4.4.3 Witness Foils

4.5 Sample CICs

4.6 Diode Boards

4.7 Repair Parts

5 PERFORMANCE VERIFICATION AND TEST

5.1 Qualification Coupon Test Plan

5.2 Flight Solar Array Panels Test Plan

5.3 Qualification Coupon Test Procedures

5.4 Flight Solar Array Panel Test Procedures

5.5 Solar Cell Qualification Test Reports

5.6 Solar Panel Qualification Coupons Test Reports

5.7 Flight Solar Array Panel Thermal Vacuum Test Reports

6 QUALITY ASSURANCE

6.1 General Requirements

6.1.1 Quality Assurance Plan/Manual

6.1.2 Surveillance of the Contractor

6.1.2.1 Government Source Inspection

6.1.2.2 Contractor Source Inspection

6.1.2.3 Government Mandatory Inspection Points (GMIPs)

6.1.3 Anomaly Reporting

6.1.4 Configuration Management

6.1.5 Ground Support Equipment Interfaces

6.2 System Safety Requirements

6.3 Reliability Requirements

6.3.1 Stability Trending

6.3.2 Limited-Life Items

6.3.3 Control of Sub-Contractors and Suppliers

6.4 Design Verification Requirements

6.4.1 Verification Requirements

6.4.2 Analysis, Trending, and Reporting of Test Data

6.5 Workmanship Standards and Processes

6.5.1 General

6.5.2 New or Advanced Packaging Technologies

6.5.3 Workmanship: Use of Alternate Workmanship Standards

6.5.4 Electrostatic Discharge Control Requirements

6.5.5 Training and Certification of Contractor Personnel

6.5.6 Hardware Handling, Cleaning, and Packaging

6.5.7 Splices, Circuit Board Trace Cuts, and Jumper Wires

6.5.8 Use of Water Soluble Flux

6.5.9 Lead-Free and Tin Whisker Control Measures

6.6 EEE Parts Requirements

6.6.1 General

6.6.2 Plastic Encapsulated Microcircuits (PEMs)

6.6.3 Radiation Hardness

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6.6.4 Parts Age Control

6.6.5 GIDEP Alerts and Problem Advisories

6.6.6 Reuse of Parts and Materials

6.6.7 Part Notification of Failure

6.7 Materials, Processes Requirements

6.7.1 Materials and Processes Control

6.7.2 Commercial-Off-The-Shelf (COTS), Vendor-Designed and Fabricated, and Bilateral

Agreement Furnished Hardware

6.7.3 M&P Usage Documentation

6.7.4 Materials Usage Agreements (MUAs)

6.7.5 Detailed Requirements

6.7.5.1 Flammability Control (NASA-STD-6016 Section 4.2.1.1)

6.7.5.2 Toxic Offgassing (NASA-STD-6016 Section 4.2.1.2)

6.7.5.3 Fluid Compatibility (NASA-STD-6016 Section 4.2.1.3)

6.7.5.4 Oxygen Compatibility (NASA-STD-6016 Section 4.2.1.4)

6.7.5.5 Electrical Wire Insulation Materials (NASA-STD-6016 Section 4.2.1.5)

6.7.5.6 Titanium (NASA-STD-6016 Section 4.2.2.3)

6.7.5.7 Tin (NASA-STD-6016 Section 4.2.2.11)

6.7.5.8 Polyvinylchloride (NASA-STD-6016 Section 4.2.3.2)

6.7.5.9 Composite Materials (NASA-STD-6016 Section 4.2.3.3)

6.7.5.10 Limited-Life Items (NASA-STD-6016 Section 4.2.3.5)

6.7.5.11 Thermal Vacuum Stability (NASA-STD-6016 Section 4.2.3.6)

6.7.5.12 External Environment Survivability (NASA-STD-6016 Section 4.2.3.7)

6.7.5.13 Glycols (NASA-STD-6016 Section 4.2.3.9)

6.7.5.14 Adhesive Bonding (NASA-STD-6016 Section 4.2.4.3)

6.7.5.15 Nondestructive Evaluation (NDE) Plan (NASA-STD-6016 Section 4.2.5.1)

6.7.5.16 Sandwich Assemblies (NASA-STD-6016 Section 4.2.6.2)

6.7.5.17 Fastener Installation (NASA-STD-6016 Section 4.2.6.5)

6.7.5.18 Contamination Control (NASA-STD-6016 Section 4.2.6.6)

6.7.5.19 Packaging (NASA-STD-6016 Section 4.2.6.7)

6.7.5.20 Shelf-Life Items

6.7.5.21 Printed Wiring Boards (PWBs)

6.7.5.22 Solder Flux

6.7.5.23 Fasteners with LL Longitudinal Locking Elements

6.7.5.24 Gold-Indium Intermetallic

6.7.6 Materials Procurement Requirements

6.8 Contamination Control Requirements

6.8.1 Contamination Control Plan

6.8.2 Surface Cleanliness

6.8.3 Material Outgassing

6.8.4 Thermal Vacuum Bake-outs

6.8.5 Wiping and Cleaning Materials

6.8.6 Gloves and Finger Cots

6.8.7 Room Cleanliness

6.8.8 Assembly Room Temperature

6.8.9 Assembly Room Humidity

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6.9 Metrology

6.9.1 Use of Calibrated and Non-calibrated Instruments

7 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY

APPENDIX A ABBREVIATIONS AND ACRONYMS

APPENDIX B GSFC PCB SUBMITTAL AND MATERIAL SELECTION FORMS

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List of Figures

No table of figures entries found.

xi Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

List of Tables Table 3-1. FMEA Severity Categories

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1 INTRODUCTION

1.1 Purpose

The Roman Space Telescope (RST) is a mission responding to the 2010 National Research Council New Worlds, New Horizons (NWNH) Astronomy and Astrophysics Decadal Survey top priority recommendation in the large space mission category. The science program includes two dedicated investigations to tackle outstanding questions in dark energy research and exoplanet exploration, and includes a substantial General Observer program to enable targeted investigations of astrophysical phenomena to advance other goals from the Decadal Survey. A coronagraph instrument is included in the payload for purposes of advancing the present state of the art of coronagraph technology. This document defines the work to be performed by the Contractor in the design, development, fabrication, and delivery of the RST Solar Array Panels.

1.2 Scope

This Statement of Work (SOW) defines contractor tasks, deliverables, responsibilities, and schedule, either within this document or by reference. The Contractor shall provide the facilities, personnel, services, tools, equipment, and materials necessary to design, analyze, manufacture, test, and deliver the hardware in accordance with the requirements of this SOW and documents referenced herein.

1.3 Related Documentation

In the event of a conflict between the SOW and the specification, the SOW shall take precedence.

The latest versions of all documents below shall be used unless otherwise specified in this SOW.

RST documents can be obtained from the RST CM Tool.

1.3.1 Applicable Documents and Drawings

The following documents and drawings in effect on the day this SOW was signed shall apply to the fabrication and to the electrical, mechanical, and environmental requirements of the Solar Array to the extent specified herein. In the event of a conflict between this SOW and specification and any referenced document, this SOW will govern.

Document Number Title

AIAA S-111A-2014

AIAA S-111A-2005

Qualification and Quality Requirements for Space Solar Cells

AIAA S-112A-2013 Qualification and Quality Requirements for Electrical Components on Space Solar Panels

AMS 2488 Anodic Treatment – Titanium and Titanium Alloys Solution pH 13 or Higher

ASTM E-595-07 Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

DOD-HDBK-83575 General Handbook for Space Vehicle Wiring Harness Design and Testing

EEE-INST-002 Instructions for EEE Parts Selection, Screening, Qualification, and Derating

FAA AC 20-71 Federal Aviation Administration Advisory Circular (AC) 20- 71, “Dual Locking Devices on Fasteners”

GSFC-STD-7000A General Environmental Verification Standard (GEVS) IEST-STD-CC1246E Product Cleanliness Levels and Contamination Control

Program MIL-A-8625F Anodic Coatings for Aluminum and Aluminum Alloys MIL-DTL-5541 Chemical Conversion Coatings on Aluminum and Aluminum

Alloys

MIL-DTL-27500

(NEMA WC27500)

Cable, Power, Electrical, and Cable Special Purpose, Electrical Shielded and Unshielded, General Specification

MSFC-STD-3029A Guidelines for the Selection of Metallic Materials for Stress Corrosion Cracking Resistance in Sodium Chloride Environments

NASA-HDBK-7005 Dynamic Environment Criteria NASA-STD-5001B Structural Design and Test Factors of Safety for Spaceflight

Hardware NASA-STD-5017A Design and Development Requirements for Mechanisms NASA-STD-5019A Fracture Control Requirements for Spaceflight Hardware NASA-STD-5020 Requirements for Threaded Fastening Systems in Spaceflight

Hardware NASA-STD-6016 Standard Materials and Processes Requirements for Spacecraft NASA-STD-7001 Payload Vibroacoustic Test Criteria NASA-STD-8719.24 NASA Expendable Launch Vehicle Payload Safety

Requirements NASM 33540 Safety Wiring, Safety Cabling, Cotter Pinning, General

Practices for NFPA 70 National Fire Protection Association National Electric Code RST-EPS-LIST-0114 RST Solar Array Panels Deliverable Items List and Schedule RST-EPS-SPEC-0173 RST Solar Array Panels Specification WFIRST-SYS-SPEC-0033A RST Cleanliness Specification

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

2 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 Program Management

The Contractor shall designate a single individual who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule and cost constraints.

The Contractor shall designate and identify by name a single individual who shall serve as a point of contact with the NASA/GSFC Contracting Officer’s Representative (COR) for all technical aspects of the Solar Array Panels contract.

The Contractor shall establish and apply a program control system for managing all resources, controlling schedules, managing all engineering, manufacturing and procurement activities, configuration management, Quality Assurance, documentation control, and distribution

2.2 Reporting

The Contractor shall prepare and present to the NASA/GSFC COR biweekly (every other week) status reports via telecon and a bimonthly written report (DIL #2).

2.2.1 Telecons

The Contractor shall prepare and present to the NASA/GSFC COR a status report via biweekly telecon. This shall include, but shall not be limited to a review of the previous week’s:

accomplishments and progress against the original schedule; procurements; key personnel changes; completed designs, drawings, and documents; material and process changes; test and inspection results; performance assurance issues; requirements verification changes; hardware shipments; action or open items; problems; and the next week’s planned activities.

2.2.2 Status Reports

The Contractor shall prepare and submit to the NASA/GSFC COR a written Bimonthly Status Report in a PDF file to e-mail addresses supplied at contract award. The report shall include the same information reported in the weekly telecons but for the previous month rather than the previous week. In addition the report shall include the next month’s planned activities, and updates to the schedule or a statement that the Contractor is on the last schedule submitted.

The Contractor shall provide, as part of the monthly report, a list of all open anomaly and failure reports and a separate list of the anomaly and failure reports closed during the month. For each reported anomaly, nonconformance and failure, there shall be a report that documents the investigation and engineering analysis needed to determine the cause and corrective actions to disposition the nonconformance.

2.3 Advanced Notifications

The Contractor shall notify the NASA/GSFC COR at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, TIM’s, and deliveries at either the

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contractor’s or a sub-contractor’s facility to allow timely participation by the GSFC Quality Assurance representative (DIL #4). Event specific notification requirements (such as failures, anomalies, etc.) are included in the appropriate sections.

2.4 Reviews and Meetings

2.4.1 Kick-off Meeting

The Contractor shall organize and hold a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW (DIL #5).

The Contractor shall provide to the NASA/GSFC COR a Kick-off Presentation Package and all other required deliverables (DIL #6). The Kick-off Meeting shall address program management and quality assurance activities outlined in this SOW, as well as the performance and environmental requirements outlined in the Solar Array Panels specification in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

• Program Management

• Quality Assurance

• Solar Array Panels Design Description

• Preliminary Interface Control Documents

• Flight Heritage

• Facilities

• Qualification Verification Plan and Procedure

2.4.2 Design Conformance Review (DCR)

The Contractor shall organize and present a Design Conformance Review to a NASA/GSFC Review Team at the contractor’s facility prior to the manufacturing program. (DIL #7) The Design Conformance Review shall address all program management, design, drawings, analysis, manufacturing, test, and quality assurance activities outlined in this SOW and the RST Solar Array Panels Specification in sufficient detail to ensure that the proposed design conforms to all requirements and is ready for fabrication to begin.

The Contractor shall provide to the NASA/GSFC COR a Design Conformance Review Presentation Package and all other required deliverable data prior to the review (DIL #8). At a minimum, the design package should cover the following areas:

• Program Management

• Quality Assurance

• Electrical, Mechanical, and Environmental specifications

• Parts, including stress analysis and radiation hardness assessment

• Drawing Package

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• Fabrication, Assembly, and Inspection Flow plan, a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled Solar Array Panels

• Facilities

• Qualification Coupons Test Plan

• Preliminary Flight Panels Test Plan

• Materials and Processes

• Solar Cell Qualification Report

• Contamination Control (for items sensitive to contamination or with explicit surface cleanliness or outgassing requirements)

• Mechanical/Structural analyses

• Electrical Worst-Case analyses

• Failure Modes Effects Criticality Analysis

• Flight Heritage

• Verification Matrix (per Section 7.5.1)

• Preliminary Mass Analysis

Review minutes shall be prepared and, as a minimum, shall include attendance, action items, action item accomplishment responsibility and agreements. All items shall be in sufficient detail to be self-explanatory. A Design Conformance Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items (DIL#9).

2.4.3 Pre-Environmental Review (PER)

The Contractor shall organize and conduct a Pre-Environmental Review (PER) at the contractor’s facility before the environment test program begins (DIL #10). This presentation shall demonstrate overall conformance of the requirements specified in the RST Solar Array Panels Specification and this SOW for this phase of the procurement. This presentation shall cover programmatic (e.g., schedule), technical, test and verification, and quality assurance topics, and address any changes made to the Verification Matrix since DCR (DIL #11). This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware. This review will summarize results from the qualification coupon tests.

2.4.4 Pre-Ship Review (PSR)

The Contractor shall hold a Pre-Ship Review at the contractor's facility at the completion of verification tests and prior to the shipment of each hardware item to NASA/GSFC (DIL #12).

This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to NASA/GSFC, and note any activities that are incomplete. In particular, the contractor shall present the completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable (DIL #13). Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with NASA/GSFC during the review.

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An End Item Data Package (EIDP) shall be made available for review during pre-ship reviews for each of the different hardware deliverables (DIL #14). This package shall also be delivered with each end item with the level of detail required of that item. The package should be comprised of, but not limited to, the following data:

• The deliverable Solar Array Panels, serial number, part number, and classification status (e.g., flight, non-flight, ground support).

• Appropriate approval signatures (e.g., contractor’s quality representative, product design lead, government Representative)

• Work orders for the final assembly and associated tests

• As-Built vs. As Designed Parts List, (EEE parts, includes serialization/revisions)

• As-Built Final Drawing Package (including rework instructions, if any)

• Problem/anomaly reporting (complete copies of report)

• Deviations/Waivers/shortages/open items/non-conformances and their dispositions, with supporting rationale

• Status of all action items from previous reviews

• Class I MRBs (complete copies of reports)

• List of As-Built Materials and Processes used

• Achieved surface cleanliness and outgassing rate data (when applicable)

• Log of total operating time and failure-free operation

• List and status of all identified Life-Limited Items

• Trended Critical Parameters Data (when applicable)

• Verification matrix (including environmental), test data and reports

• Photograph Documentation (Pre and Post conformal coating, Pre-Closure and Closed)

• Certificate of Conformance, with management signature

• End Item Inspection Report

• As-Built Configuration List

• Mate/Demate log

• Printed circuit board coupon results

• Storage and Transportation Plans and Requirements

2.4.4.1 Final Mass Properties Measurement

The Contractor shall update the mass estimate for each solar array panel to reflect measured values and include the update in the End Item Data Package (DIL #14).

2.4.4.2 End Item Data Package (EIDP)

The Contractor shall prepare and deliver a data delivery package to the GSFC with the flight panels (DIL #14). For each panel, this report shall contain the as built configuration list, a list of parts and materials used in the panel, a list of processes used to manufacture the panel, a test log book for each test which documents the total operating time and cycles for each test, a list of open items and the reason the items are open, results of the verifications required by this specification including dates of completion and what test equipment was used, TQCM data, a

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summary of all repairs for that flight panel, a series of digital color photographs of each side (back and front) of that flight panel, a copy of all Material Review Board (MRB) actions generated against the panel, and a copy of all problem/failure reports generated against the panel.

The Contractor shall document the issue numbers of the drawings and specifications to which particular hardware has been fabricated, inspected, and tested as the as-built configuration. The Contractor shall provide evidence of compliance with the as-built documentation as a basis for acceptance of the hardware.

2.4.5 Technical Interchange Meetings (TIM)

The Contractor shall plan for and facilitate up to three (3) informal, face-to-face technical interchange meetings to be held at the contractor facilities (DIL #15). These TIMs shall support review and coordination of technical issues including, but not limited to, parts, test plans, test procedures, software changes, design modifications, and design analyses.

2.4.6 Manufacturing Readiness Review (MRR)

The Contractor shall organize and present a Manufacturing Readiness Review to a NASA/GSFC Review Team at the Contractor’s facility or by telecon at NASA/GSFC’s discretion (DIL #66).

This review shall demonstrate the success of the qualification coupons, their tests, and the manufacturer’s readiness to begin fabrication of the flight panels. This review shall cover programmatic, technical, test and verification, and quality assurance topics, and address any changes made to the Verification Matrix since DCR. This review shall also provide an opportunity to review drawings and analyses required for approval before the start of fabrication.

The contractor shall provide a MRR Presentation Package (DIL #67). This shall address qualification coupon performance in environmental tests and manufacturing readiness in sufficient detail to ensure that the proposed build conforms to all requirements and is ready for fabrication to begin. The design package shall include the following:

a) Qualification Coupon Test Report

b) Updated Mass Analysis

c) Readiness for Flight Panel Manufacturing

d) Manufacturing Flow with Inspection Points

e) Updated Schedule

The Contractor shall supply an updated schedule that includes milestone charts depicting critical paths and indicating critical dates in the program. The Contractor shall define the start, implementation, and completion dates for the detailed activities associated with the design, analysis, manufacturing, and testing of all components, subassemblies, and panels. The Contractor shall identify the vendor lead times for procured parts and materials.

2.5 Documentation

In addition to that documentation specifically called for in the contract, upon request by the NASA/GSFC COR, the Contractor shall make available a copy of any document or data generated during this contract performance for review by GSFC at either the contractor's facility

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or via the internet. This includes, but is not limited to, technical reports and memorandums, drawings, schematics, studies, analyses, parts and materials data, test data, alerts, etc.

2.6 NASA/GSFC Furnished Data, Equipment, and Facilities

NASA/GSFC shall furnish the following list of data, equipment, and facilities to the contractor.

If there are additional items that the contractor believes are necessary in order to fulfill this contract, they shall be stated in the response to this procurement.

2.6.1 Insulated Substrates

NASA/GSFC will provide qualification coupon and flight panel insulated substrates in accordance with the Contract Schedule that the contractor shall populate in accordance with the RST Solar Array Panels Specification.

a) Unpopulated, Insulated Qualification Coupon Substrate(s), Quantity of 3

b) Unpopulated, Insulated Flight Solar Array Panel Substrate(s), Quantity of 6

2.6.2 Connectors

NASA/GSFC will provide qualification coupon and flight panel connectors in accordance with the Contract Schedule that the Contractor shall install in accordance with the RST Solar Array Panels Specification.

a) Connectors for Qualification Coupons, Quantity of 3

2.6.3 Witness Foils

NASA/GSFC will provide witness foils (6 or more as required) that the Contractor shall keep with each panel at all times to monitor the panel environment in accordance with the RST Solar Array Panels Specification.

2.6.4 Coarse Sun Sensor (CSS) Wire

NASA/GSFC will provide twisted, shielded wire (8 or more as required) for the Coarse Sun Sensors (CSSs) that the Contractor shall install on the panels in accordance with the RST Solar

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3 DESIGN AND ANALYSIS

The Contractor shall perform analyses of the technical and environmental requirements specified in the RST Solar Array Panels Specification to ensure compliance of the hardware fabrication and to assemble the documentation necessary to ensure its usability by NASA/GSFC users.

3.1 Interface Control Documentation

NASA/GSFC will provide document(s) and/or drawing(s) that define, in detail, all electrical, thermal, and mechanical interfaces.

3.2 Drawing Package

The Contractor shall supply a drawing package for the flight panels and the qualification coupons consisting of: assembly drawings, drawings of all contractor-installed hardware, and wiring diagrams. The package shall specify the location of wire feed through holes for the solar cell circuits and their diameter for the qualification coupons and flight panels. The drawing format will be agreed upon between the Contractor and NASA/GSFC. NASA/GSFC will use this information to determine the center of mass location and other mass properties.

The Contractor shall provide a drawing package that includes, but is not limited to (DIL #17):

ELECTRICAL: assembly and interface drawings (board level schematics available on request) MECHANICAL: assembly and interface drawings

3.3 Computer Models

The Contractor shall deliver the following models used in the performance of the below analyses or used for Computer-Aided Design (CAD)/Computer-Aided Manufacturing (CAM)/Computer- Aided Engineering (CAE) (DIL #18):

Drawing package required by Section 3.2 of this SOW in dxf format.

3.4 Thermal Analysis Data

The Contractor shall provide data that will enable NASA/GSFC to accurately model the thermal performance of the solar array panels (DIL #21). This data shall enable a thermal analysis that illustrates that the device and/or the electronic part junction temperatures are within the Electrical, Electronic, and Electromechanical (EEE) parts derating guidelines for operation in a vacuum environment. Analysis shall prove that component will be within junction derating temperatures when S/C thermal interface is at maximum qualification temperature and when component is operating at maximum power dissipation. By analysis or by similarity to other flight qualified parts, the Contractor shall also prove that operation at minimum survival temperature is not an issue. This data shall include Beginning of Life (BOL) and End of Life (EOL) solar cell efficiency as a function of temperature, operating voltage, and degradation, maximum blocking diode and bypass diode dissipations, and the BOL and EOL surface finish

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thermal properties (i.e., solar absorptance, IR emittance) that will be used to perform the analysis.

3.5 Worst Case Circuit Analysis Report

The Contractor shall perform worst-case analyses for critical parameters that are subject to variations that could degrade performance, and provides any data that can question the flightworthiness of the design (DIL #23). These analyses shall address the worst case conditions for the analysis performed on each component. Each analysis shall encompass the mission life and consider the critical parameters set at maximum and minimum limits and include the effect of environmental stresses on the operational parameters being evaluated.

The Worst Case Analysis Report shall include the following:

a) Address worst case conditions performed on each component.

b) Discuss how each analysis includes the mission life.

c) Discuss consideration of critical parameters at maximum and minimum limits.

d) The effect of environmental stresses on the operational parameters being evaluated.

The results of these analyses shall be summarized in a Contractor format Worst Case Circuit Analysis Report that will be provided to the NASA/GSFC COR for review.

3.6 Parts Stress Analysis Report

The Contractor shall perform parts stress analyses on Electrical, Electronic, and Electromechanical (EEE) parts and devices as employed in the circuit designs of the Flight Item to certify conformance with the derating requirements of EEE parts (DIL #24). The analyses shall be documented, and justification shall be included for all applications that do not meet the derating criteria. The Contractor shall use NASA document EEE-INST-002, Instructions for EEE Parts Selection, Screening, Qualification, and Derating to establish criteria. Contractor derating guidelines may be considered in place of EEE-INST-002 guidelines but shall be submitted for approval (DIL #25). The results of these analyses shall be summarized in a Contractor format Parts Stress Analysis Report that shall be provided to the NASA/GSFC COR for review.

3.7 Radiation Hardness Analysis Report

The Contractor shall document the radiation hardness assessment for each EEE part with respect to total ionizing dose (TID) (DIL #26). For the solar cells, the Contractor shall document the radiation degradation characteristics of the cell in terms of 1-MeV electron equivalent fluence using the relative damage coefficients for the solar cell used or Displacement Damage Dose (DDD) method. The Contractor shall include the relative damage coefficients used in the analysis in this report.

3.8 Reliability Analysis Report

The Contractor shall provide a numerical reliability assessment of the component, using reliability data from historical on-orbit performance, life-testing, or data books, such as MIL-

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HDBK-217F (DIL #27). The results of this analysis shall be summarized in a Contractor format Reliability Analysis Report that will be provided to the NASA/GSFC COR for review.

3.9 Failure Modes and Effect Criticality Analysis Report

The Contractor shall perform an FMECA (Failure Modes and Effects Criticality Analysis) to identify potential failures with severity categories 1, 1R, 1S, 2, 2R, 3, and 4 per Table (DIL #28).

The FMECA shall be updated throughout the development life cycle to address design changes that result in changes to failure modes, causes, effects, system impact, or to mitigation status and corresponding retention rationale. FMECA shall be performed at the interface and functional level of the component.

Table 3-1. FMEA Severity Categories

Category Severity Severity Description 1 Catastrophic Failure modes that could result in serious injury, loss of life (flight or ground personnel), or loss of launch vehicle.

1R Failure modes of identical or equivalent redundant hardware items that could result in Category 1 effects if all failed.

1S Failure in a safety or hazard monitoring system that could cause the system to fail to detect a hazardous condition or fail to operate during such condition and lead to Category 1 consequences.

2 Critical Failure modes that could result in loss of one or more mission objectives as defined by the NASA/GSFC COR.

2R Failure modes of identical or equivalent redundant hardware items that could result in Category 2 effects if all failed.

3 Significant Failure modes that could cause degradation to mission objectives.

4 Minor Failure modes that could result in insignificant or no loss to mission objectives

The loss of a single string component is considered as a category 2 and the loss of a redundant component is a 2R.

The results of these analyses shall be summarized in a Contractor format Failure Modes And Effects Criticality Analysis Report that shall be provided to the NASA/GSFC COR for review.

3.10 Electrical Output Predictions

The Contractor shall include a prediction of the output of the flight solar array panels under beginning of life test conditions (AM0, 28°C), at beginning of life hot (0.948 AM0, 136°C), and at end of life (0.948 AM0, 60°C) as defined in the specification (DIL #68). The Contractor shall predict the I-V curve, taken at the flight connector, under 0.948 AM0 illumination at 60ºC and

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136ºC after exposure to the space environment for an interval of 5.25 years, which is the contractually defined end of life (EOL) for the array. The prediction shall be presented with both graphical and tabular data and shall include the values of short-circuit current (Isc), open-circuit voltage (Voc), current at maximum power (Imp), voltage at maximum power (Vmp), maximum power (Pmax), and power at 34.5V. The prediction shall account for all environments defined in the specification including the effects of thermal cycling and high temperature soak.

3.11 Mass Analysis

The Contractor shall supply a mass estimate by component at the DCR and updated at the MRR for the flight panels and qualification coupons.

The Contractor shall supply a final measured mass in the EIDP for each flight solar array panel.

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4 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

The Contractor shall either procure or manufacture all components required to assemble, integrate, and test the Solar Array Panels to support the delivery dates as called for in the contract (Section B Table) and listed in the DILS document (RST-EPS-LIST-0114).

The Contractor shall assemble the quantities of Solar Array Panels hardware described below.

4.2 Solar Array Panels

The Contractor shall provide the following hardware to meet the requirements of the RST Solar

a) Qualification coupons in sufficient quantity to meet the testing requirements of AIAA-S- 112A-2013 as tailored in the RST Solar Array Panels Specification. Qualification coupons are identical to the flight panels in every respect except size and number of components (DIL #76)

b) Flight Solar Array Panels (DIL #77)

c) Shipping containers for Qualification Coupons and, if requested, Flight Solar Array

Panels (DIL #78)

The Contractor shall include in the proposal the cost to purchase all hardware including all supporting hardware.

4.3 Connector Savers

The Contractor shall supply flight quality connector savers for each flight connector on the flight panels. Prior to delivery, the Contractor shall use the savers for every connection made to flight connectors (DIL #79). Connector savers shall be vacuum compatible.

4.4 Supporting Hardware

4.4.1 Mating Connectors, Test Harnesses, and Connectors for Breakout Boxes The Contractor shall supply test harnesses with connectors on one end that mate to the flight panels’ flight and test connectors. The connectors on the other end shall mate to breakout boxes.

The harness between the mating connector and the breakout box connector shall be four meters ±0.02 meters long. The connectors and the harness shall be flight-quality.

There shall be one test harness with connectors for each test connector and flight connector on a panel (DIL #80).

4.4.2 Connector Caps

The Contractor shall supply a flight quality closeout cap for each of the test connectors (DIL #81).

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4.4.3 Witness Foils

The Contractor shall replace the witness foils described in Section 2.6.3 of this document and deliver the used ones to the NASA/GSFC COR (DIL #82).

4.5 Sample CICs

The Contractor shall deliver sample coverglass, interconnect, cell (CIC) assemblies of the type used on the qualification coupons and flight solar array panels. NASA/GSFC will measure the solar absorptance and emittance of these CICs to more accurately model the thermal performance of the solar array (DIL #83).

4.6 Diode Boards

All flight and test diode boards shall meet the requirements of the RST Solar Array Panels Specification.

Prior to population of the flight boards, the Contractor shall provide test boards for each board type used in the flight hardware.

a) The test board shall be clearly identified with the part number and revision letter, serial number, vendor identification and date code or production lot number.

b) The paperwork accompanying the test board shall include the part number and revision letter, serial number, vendor identification and date code or production lot number.

Two weeks prior to shipping the boards, the Contractor shall notify the NASA/GSFC COR that they plan to ship (DIL #84).

Flight diode boards shall not be assembled prior to notification that the representative test boards have been satisfactorily evaluated by the NASA/GSFC COR.

The Contractor shall not use printed wiring boards or printed circuit boards on flight or qualification articles.

4.7 Repair Parts

The Contractor shall supply parts sufficient to repair 100 damaged solar cells on the completed panels including the covers, cells, bypass diodes, if not integrated into the cell, interconnects, and electrostatic and magnetic cleanliness hardware. The Contractor may supply these parts as cover, interconnect, cell assemblies (CICs) if that fits its repair procedures better than individual parts. In addition, the Contractor shall supply parts sufficient to repair 30 damaged covers on the completed panels. The Contractor may supply these parts as CICs if that fits its repair procedures better than covers (DIL #85).

In addition, the Contractor shall supply the following items to facilitate any repairs needed.

a) 1,000 centimeters of each type wire it has used in fabricating the panels.

b) 10 blocking diodes of the type it has used in fabricating the panels.

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c) 1 terminal board of each type it has used in fabricating the panels.

d) Spare connectors, pins, and sockets as required by the Contract Hardware Deliverables

List.

e) With the exception of adhesives, other parts deemed necessary to repair the panels.

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5 PERFORMANCE VERIFICATION AND TEST

5.1 Qualification Coupon Test Plan

The Contractor shall deliver a Qualification Coupon(s) Test Plan for the verification tests required by the RST Solar Array Panels Specification (DIL #69). Tests must demonstrate acceptable performance over the specified range of performance requirements, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems. The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method and instrumentation, and give the sequence of the tests. The plan shall include a test matrix summarizing all tests that will be performed.

5.2 Flight Solar Array Panels Test Plan

The Contractor shall deliver a Test Plan for the verification tests required by this document and by the RST Solar Array Panels Specification (DIL #70). Tests must demonstrate acceptable performance over the specified range of performance requirements, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems.

The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method and instrumentation, and give the sequence of the tests. The plan shall include a test matrix summarizing all tests that will be performed.

The Contractor shall formally control this document and shall indicate all changes made after the initial approval by the GSFC. After test plan approval, the NASA/GSFC COR must approve all changes in writing.

5.3 Qualification Coupon Test Procedures

The Contractor shall supply Qualification Coupon Test Procedures, step-by-step instructions for performing tests outlined in the Test Plan (DIL #71). The procedures shall define the environmental conditions for the tests, required equipment and facilities, test constraints, use of diagnostic or performance test software, operating conditions, tolerance on all input stimuli, data to be recorded and pass/fail limits. Test procedures shall also include Safe-to-Mate procedures to verify that Ground Support Equipment (GSE) can safely be mated to interfaces and that interfaces are safe to accept mating with the GSE. Test procedures shall be contractor controlled documents and shall indicate changes made after the initial release.

5.4 Flight Solar Array Panel Test Procedures

The Contractor shall deliver Test Procedures (DIL #72). The verification procedures shall be step-by-step instructions for performing tests outlined in the Test Plan. The procedures shall define the environmental conditions for the tests, required equipment and facilities, test constraints, use of diagnostic or performance test software, operating conditions, tolerance on all input stimuli, data to be recorded and pass/fail limits. Test procedures shall also include Safe-to-

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Mate procedures to verify that GSE can safely be mated to interfaces and that interfaces are safe to accept mating with the GSE.

5.5 Solar Cell Qualification Test Reports

The Contractor shall supply a solar cell qualification report detailing the results of tests to qualify the RST solar cells per the RST Solar Array Panels Specification, and Qualification and Quality Requirements for Space Solar Cells, AIAA-S-111A-2014 (or AIAA-S-111-2005 with a summary of flight heritage) (DIL #73).

5.6 Solar Panel Qualification Coupons Test Reports

The Contractor shall supply a Solar Panel Qualification Report detailing the qualification coupon functional performance before, during, and after each environmental exposure required by this document and the RST Solar Array Panels Specification (DIL #74).

5.7 Flight Solar Array Panel Thermal Vacuum Test Reports

The Contractor shall supply a Flight Solar Array Panel Thermal Vacuum Test Report detailing the flight panel functional performance before, during, and after the thermal vacuum cycling required by this document and the RST Solar Array Panels Specification (DIL #75).

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6 QUALITY ASSURANCE

6.1 General Requirements

6.1.1 Quality Assurance Plan/Manual

The Contractor shall have a Quality Management System that is compliant with the requirements of SAE AS9100 Quality Systems - Aerospace - Model for Quality Assurance in Design, Development, Production, Installation and Servicing or equivalent, as documented in a Quality Assurance Plan. The Plan shall be delivered to the NASA/GSFC COR for approval, and GSFC shall be notified of any changes to the QA program (DIL #37).

6.1.2 Surveillance of the Contractor

The work activities and operations of the contractor, subcontractors, and suppliers are subject to evaluation, review, survey, audit, and inspection by NASA/GSFC representative.

The Contractor shall provide the NASA/GSFC representative with documents, records, equipment, and a suitable work area within their facilities that are required by the representative to perform their overview activities.

6.1.2.1 Government Source Inspection

The Government may elect to perform inspections at a supplier's facilities. The following statement shall be included on all procurement documents: “All work on this order is subject to inspection and test by the Government in accordance with the inspection clauses in the contract.”

The Government quality representative who has been delegated NASA quality assurance functions on this procurement shall be notified immediately upon contractor receipt of any supplier/subcontractor orders. The Government representative shall also be notified 48 hours in advance of the time that articles or materials are ready for inspection or test.

6.1.2.2 Contractor Source Inspection

The Contractor shall ensure that its procurement documents impose the applicable requirements on subcontractors and other suppliers. The Subcontractor and other suppliers shall in turn impose the requirements on their procurement sources.

The Contractor shall perform source inspection at the subcontractor's or supplier's facilities in accordance with the procurement documentation or when one or more of the following conditions exist:

• In process, end item controls, or tests that are destructive in nature prevent the contractor from verifying quality after delivery to the contractor's facility.

• It is not feasible or economical for the contractor to determine the quality of procured articles solely by inspections or tests performed at the contractor’s facility.

• Qualification tests are to be performed by the subcontractor or supplier.

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• Products are shipped directly from the source to NASA, by-passing the contractor's inspection facilities.

6.1.2.3 Government Mandatory Inspection Points (GMIPs)

The Contractor shall plan for the following GMIPS. The Contractor shall provide work instructions, procedures, drawings, etc. that are appropriate for the activities. The following are examples of activities that may be subject to GMIPS:

• Inspect 100% solder

• Inspect 100% crimps

• Inspect 100% conformal coating, staking, and potting

• Rework inspection

• Pre-closure inspection

• Pre-Ship Inspection/Data Review

6.1.3 Anomaly Reporting

The Contractor shall have a documented process for anomaly reporting and disposition. The process will establish an anomaly review board (ARB) whose membership will include a government representative as a voting member with approval authority for proposed actions on all major nonconformances (DIL #38).

The process shall require major anomalies to be submitted to the ARB and the government. The Contractor shall report major hardware anomalies beginning with the first application of power at the component level, major software anomalies beginning with flight software acceptance testing and when interfacing with flight hardware, and major mechanical system anomalies beginning with the first operation.