SOW for Design ARSR4 CPTS 8-14-26.docx

STATEMENT OF WORK

FOR

Design a Replacement ARSR4 Collector Power Supply Test Station (CPSTS) with functions similar to the current test station with CPS Interface, Test/Repair software and procedures to test the ARSR4 CPS and Preamp Power Supply (PPS) units to specification

CPSTS P/N: 18323ASSYKA422100G01, NSN NA

Revision A

REV

BY

1.0 Overview

This Statement of Work (SOW) is issued by the Federal Aviation Administration (FAA), Radar Product Division, AJW-L900, for the design, development, fabrication, testing and delivery of a replacement Air Route Surveillance Radar (ARSR4) Collector Power Supply Power Supply Test Station (CPSTS) with similar features as outlined in Exhibit 6.1 that has the ability to test and repair the ARSR4 CPS and the ARSR4 PPS in according to the specifications listed below in Exhibit 6.2. This new CPSTS will replace the legacy system due to obsolescence, and repair capability issues with the current CPSTS. The new CPSTS is required to have similar mechanical design requirements and equivalent electrical performance or better using current generation components compared to the legacy system.

Reference Documents:

Exhibit 6.1 reference document “TI 6340.52: ARSR4 SYSTEM COLLECTOR POWER SUPPLY TEST SET (CPSTS) MAINTENANCE MANUAL

Exhibit 6.2 reference document “TI 6340.59: ARSR4 SYSTEM UUTs TESTED ON COLLECTOR/PREAMP POWER SUPPLY TEST SET

TI 6340.26 ARSR4 Collector and Preamplifier Power Supply

Military Standards:

2.0 Contracting Officer’s Representative (COR)

The Contractor Officer’s Representative (COR) is formally designated with this responsibility by the Contracting Officer to provide direction and Government oversight to the Contractor on matters related to this contract.

3.0 Scope

The contractor shall furnish all labor, plant facilities, parts, supplies, materials, fixtures, equipment, tools, test equipment, technical data/expertise, and other facilities necessary to accomplish the design of a replacement CPSTS and test process and adapter in accordance with FAA’s manufacturing and test specifications, FAA Specifications (listed in Exhibit 6.1 and 6.2) and all other terms, conditions and provisions contained herein.

This SOW will cover all engineering costs, design costs, and the labor and material necessary to furnish a CPSTS unit and test process to specification for the CPS and PPS and adapter hardware. It is anticipated that a Firm Fixed Price Contract will be utilized for award for this effort.

4.0 Quality Control

The contractor shall establish and maintain a Quality Control Program in accordance with the requirements of ISO-9001:2008. A Compliant Quality Management System is required. An auditable system containing all elements of the ANSI/ASQ/ISO Q9001-2008 standard shall exist. Equipment will be inspected in accordance with conformance to Technical Specifications and Packaging Specifications as stated in the contract. The equipment will be accepted/rejected at destination by the FAA. Certificates of Conformance shall be supplied where applicable. The Contractor may find information at www.asq.com.

The Government and the contractor agree that equipment used to design the CPSTS is standard manufactured items and for that reason it may not be necessary to require Government inspection and examination of all work in progress at any time or place during normal working hours. However, in the event an abnormal failure rate (to be determined by a FAA Systems Engineer) is experienced, both parties agree that an in-plant quality control review shall be provided. Accordingly, the Government reserves the right to assign an in-plant Quality and Reliability Officer (QRO) to this contract if it is determined by the Contracting Officer to be in the best interest of the government.

5.0 Requirements

The Contractor shall design the CPSTS test unit and test process and to a normally operating, serviceable condition, including all the following:

(a) Unit shall meet performance specifications listed in exhibits 6.1 and 6.2

(b) The unit shall meet standard workmanship requirements.

(c) Record test data from the CPS and PPS units provided by the FAA when returned to the FAA. Sample datasheet will be submitted to FAA, and datasheet will be subject to approval by the FAA.

(d) The CPSTS shall be marked with the serial number (S/N) and part number (P/N) being separate identification on separate lines so there is no confusion in receiving as to what the S/N and P/N are.

The following format shall be used when marking the label:

Contract or PO # CPSTS P/N: vendor# S/N:

Rev: A

5.1 Deliverables

Contractor shall:

A. Deliver a production CPSTS unit and test process to specification and hardware in a normally operating serviceable condition. It shall be delivered to the Enroute Shop at the FAA Logistics Center.

B. One (1) copy of the datasheet shall accompany the unit.

C. The contractor shall provide a block diagram of all parts and associated part numbers along with the identification of contractor that supplies the material except for internal components that are proprietary to the supplying vendors. This includes schematics, parts list, theory of operation, and other related documents that are not proprietary.

D. Shipping shall be standard contractor shipping and billing practices using FAA standards.

E. The contractor shall deliver an engineering report for the initial development work that specifies the measurements taken for the CPSTS and parts utilized, and invoices for NRE effort. Invoices shall include any mechanical and electrical work for which NRE is paid.

F. The Contractor shall participate in the final acceptance and approval of the CPSTS unit and CPS software and hardware qualification testing at the FAA’s Enroute Shop in Oklahoma City.

G. The Contractor shall support/participate in meetings with the FAA as required.

FAALC, AJW-L900 will:

A. Provide assistance, cooperation, information, Government Furnished Equipment (GFE), data, a suitable work environment for onsite meetings or onsite work environment to OEM for successful completion of the project.

B. Furnish equipment, hardware, and Software license (if required) to support project.

C. Government Furnished Equipment (GFE) will include one (1) CPS and one (1) PPS unit for development purposes and if necessary, other hardware equipment at the FAA that will aid in development.

D. Coordinate with all FAA organizations including Second Level Engineering (AJW-142) and OEM to execute the requirements to manufacture a CPSTS and software/fixturing for testing and repair capability for the CPS/PPS LRUS.

E. Participate in the final acceptance and approval of the CPSTS and hardware.

F. Provide status updates at Program Management Reviews

5.2 Place of Performance

The Contractor shall perform the work of the contract on the Contractor’s premises.

5.3 Inspection and Acceptance

A. Final inspection, test, and acceptance will be accomplished by the FAALC, Oklahoma City, OK.

B. System will be tested by utilizing a serviceable CPS and PPS unit against the test station to ensure that the system meets all requirements contained in Exhibit 6.2.

6.0 Exhibits

6.1 Exhibit 1, TI 6340.52: ARSR4 SYSTEM COLLECTOR POWER SUPPLY TEST SET (SPSTS) MAINTENANCE MANUAL

6.2 Exhibit 2, IT 6340.59: ARSR4 SYSTEM UUTs TESTED ON COLLECTOR/PREAMP POWER SUPPLY TEST SET

TABLE OF CONTENTS

CHAPTER 1 - GENERAL INFORMATION

CHAPTER 2 – COLLECTOR POWER SUPPLY PN 3D56068G01 REPAIR

CHAPTER 3 – PREAMPLIFIER POWER SUPPLY PN 3D56068G02 REPAIR

6.3 Introduction

This statement of work (SOW) is for the technical requirements for the fabrication, testing, and delivery for a new CPSTS for the Air Route Surveillance Radar, model 4 (ARSR-4). The new CPSTS is to replace a legacy unit that is obsolete and difficult to repair. An example of the legacy CPSTS is shown in Figure 1.1.

6.4 Background

The CPS is used in nine locations in the Radar Transmitter (Unit 9). The PPS is used in two locations in unit 9. The PPS subassemblies are the same as the CPS subassemblies except for the A31 PPS Control assembly.

Subassemblies of CPS/PPS

Step- Start Control A1 A three-phase, full-wave bridge rectifier rectifies the input of 208 volts ac line-to-line (167 - 243 vac), three-phase primary power. The rectifier output is +280 volts dc (+15 percent, -25 percent) and limits surge current during start-up. When this power line is initially energized, surge-limiting resistors, in series with the positive half-wave rectifiers, limit the surge current. Following a 40-millisecond delay after input power is applied, the resistors are bypassed by gated silicon-controlled rectifiers (SCRs) to remove current limiting.

Step-up Converter Control A2 The step-up converter control A2 circuit employs a current mode controller to regulate the output voltage across the energy storage capacitor banks at +350 volts dc by controlling on-drive duration to the up-converter FETs Q4, Q5 and Q6.

CPS Control A31 CPS control A31 is a central processing board for most of the timing, control, and BITE data signals involved in CPS operation. All CPS timing or clock signals are derived from the system 5.2 MHz clock input to CPS control A31

Switch Assembly A32 Switch assembly A32 is a forward converter with output to the primary of a three secondary output transformer.

+5-volt Regulator A33 The +5-volt regulator A33 consists of regulator integrated circuit UI with associated rectifying, filtering, and adjusting components.

-15-volt Regulator A34 The -15-volt regulator A34 consists of regulator integrated circuit UI with associated rectifying, filtering, and adjusting components.

+15/+12-volt Regulator A35 The +15/+12-volt regulator A35 consists of linear regulator integrated circuits UI and U2 with associated rectifying, filtering, and adjusting components.

House Supply Control A36 The house supply consists of three small regulators which provide low voltage power to the CPS and to the bus regulator. House control A36 provides witching drive to FETs Q1 and Q2 on switcher A32.

Switcher Control A37 through A41 (one resistor is different between the 2 LRUs) The switcher control senses current signal feedback sample from the switcher module and determines whether the power supply stays on-line or off-line.

The CPS, in conjunction with other CPSs and the bus regulator, conditions collector power for the solid-state radio frequency (RF) amplifiers. The CPS converts ac to dc, provides energy storage for bridging of short-time power interruptions, and regulates voltage by controlling the restoration of charges to storage capacitor banks in the RF amplifiers. CPS operates as a feedback-controlled, on-off current source in supplying this voltage. The storage capacitor banks are in parallel with other CPSs to precisely restore and regulate the RF panel storage voltage between transmitter RF pulses. Samples of the dc storage voltages in the RF panels are averaged between the bus regulator and each CPS to obtain a single voltage sample. This sample is compared with a reference voltage in each CPS to control its operation. Primary power input is nominally 208 volts ac, three phase at 60 Hz. Collector power supply output is nominally 60 amperes (average) at a selected voltage between +28- and +40-volts dc. Timing and enabling signals coming from the bus regulator.

The PPS conditions power for the RF preamplifiers, converts ac to dc, provides energy storage in the PPS storage capacitor banks for bridging of short-time power interruptions, and supplies power to the preamplifier linear regulators. The PPS operates as a feedback-controlled, on-off current source in supplying this voltage. The storage capacitor banks precisely restore and regulate the PPS storage voltage. A sample of the dc storage voltage is compared with a reference voltage in the PPS to control its operation. Primary power input is nominally 208 volts ae, three phase at 60 Hertz. Preamplifier power supply output is nominally 50 amperes (average), at selected output voltage between +28- and +40-volts dc. Timing and enabling signals come from the bus regulator.

The current legacy CPSTS consists of a single two bay console, a computer (Intel Pentium, software), laser printer, and associated computer console. See figure 1.1. These two bay cabinets contain custom designed equipment and Commercial Off-The Shelf (COTS) test equipment, which is controlled by an Intel Pentium based computer. A general-purpose interface bus (GPIB) connects the computer to the custom designed equipment and to the COTS test equipment. It is a computer diagnostic test set designed to functionally test and diagnose the CPS and PPS used in the ARSR4. CPSTS is also used to verify failures and troubleshoot units returned to the FAA Depot for repair.

Figure 1.1 Collector Power Supply Test set

The test set unique application consists of a CPSTS instrument library, self-test and Unit Under Test (UUT) programs. The Test Set software is made up of test set control software, UUT test software and software development tools to support CPSTC test set. The CPSTS use a common test set control program written in Borland C++.

These test set use the Borland C++ programming environment for both the test executive user interface software and for the test programs. The standard application template used is the Dialog app in Borland Object Windows Library (OWL). All of the files for the Collector and Preamplifier TPSs share their CPP source files in common.

Instrument driver Library The file TDI.DLL is the run-time library containing all the instrument functions needed to interface with the GPIB instruments on the Test set. The source code is in the directory \CPSTS\sw\dat\dll_drvr.

IEEE 488 bus driver library The file GPIB.DLL is the runtime library for the National instruments IEEE-488 bus interface card in the Test set computer. It contains the functions needed by TDI.DLL to control the IEEE 488 bus protocol.

Self-Test Software The self-test program for both the CPSTS and the PSTS exercises the internal self-test of each of the IEEE-488 programmable instruments on the test set. It also wraps around and tests digital inputs and outputs.

The self-test software uses the same common user interface and instrument driver modules as the UUT test software.

UUT Test Software The CPSTS tests only the CPS and PPS UUTs.

6.5 Electrical Requirements

The following provides brief descriptions of the performance and diagnostic tests for the CPS and PPS. The UUT test for the CPS and the PPS consists of the following performance tests:

These tests perform safe-to-turn-on resistance checks of the input power lines and semiconductor devices to verify that power can be mined on to the UUT.

200 Step start control These tests verify the proper operation of the 3-phase rectifier control circuitry and the phase detector output of the step start control assembly. The phase detector will disable the power supply output if 3-phase input power is incorrect.

300 Step up converter This test checks the operation of the step-up converter which steps up the rectified 208 volts to 350 Vdc, the drive waveform output of the converter to the step-up Field Effect Transistors (FETs) are checked and the 350 Vdc level is adjusted.

400 House supply checkout This test checks the switcher drive for the four internal house supplies and sets the voltage for each supply to the proper level, 500 Fuse failure and switcher sync This test verifies the fuse failure indicator, which indicates the failure of a main switcher fuse (F4 through F 10). The synchronization of the switcher drive waveforms into each main switcher half is checked.

600 Output overvoltage This test checks the proper operation of the overvoltage detector and sets the maximum output voltage level.

700 Switcher high power This test checks the output voltage and current capability of each main switcher, one at a time, with the other switchers disabled by removal of their supply fuses. The timing of the switcher current waveform is also verified.

800 Fine charge control This test verifies the free charge control circuitry of the main control board, properly modulates the switcher output of switcher No. 3 and No. 4 to regulate the voltage output level properly.

900 Bus regulator interface tests Test 900 consists of the following tests:

· Reference voltage in test - This test verifies that the reference voltage in at J1 pin 49 of the CPS is 9.7 -/+0.2 Vdc,

· Bus voltage in test - This test verifies that the bus voltage in at J1 pin 47 of the CPS is 9.7 -/+0.2 Vdc.

· Current sample 1 pulse width - This test verifies that the current sample 1 waveform at J1 pin 7 of the CPS has a pulse width of 400 microseconds minimum as shown in figure 2-1.

Figure 2-1 Current Sample 1 Waveform

· Current sample 1 peak amplitude - This test verifies that the current sample 1 waveform at J1 pin 7 of the CPS has a peak voltage of 7.0 Vdc minimum as shown in figure 2-1.

· Current sample 2 pulse width - This test verifies that the current sample 2 waveform at J1 pin 8 of the CPS has a pulse width of 700 microseconds minimum as shown in figure 2-2, The pulse width is measured between the 50 percent amplitude point on the leading edge and the 50 percent amplitude point on the second trailing edge.

Figure 2-2 Current Sample 2 Waveform

· Current sample 2 peak amplitude - This test verifies that the current sample 2 waveform at J1 pin 8 of the CPS has a peak amplitude of 7.0 Vdc minimum as shown in figure 2-2.

· Current sample 2 step voltage peak amplitude - This test verifies that the current sample 2 waveform at J1 pin 8 of the CPS has a voltage peak of 3 Vdc minimum for step voltage at the trailing edge as shown in figure 2-2.

· Current sample 3 pulse width - This test verifies that the current sample 3 waveform at J 1 pin 9 of the CPS has a pulse width of 400 microseconds minimum as shown in figure 2-3.

Figure 2-3 Current Sample 3 Waveform

· Current sample 3 voltage peak amplitude - This test verifies that the current sample 3 waveform at J1 pin 9 of the CPS has a peak voltage of 7.0 Vdc minimum as shown in figure 2-3.

1000 Regulation performance This test uses the oscilloscope to verify that the variation in output voltage ripple between adjacent output pulses is less than 12 millivolts as shown in figure 2-4, This measurement also uses the Preamble Differential Amplifier.

Figure 2-4 CPS/PPS Output Waveform

1100 Covers on performance test This test verifies the performance of the UUT after the covers have been replaced. The house supply samples, output voltage ripple and current samples are rechecked.

6.6 Mechanical Requirements

Internal Wiring: All internal hookup wiring shall be MIL-W-16878/4 (PTFE insulated).

Internal Wire and Cable Marking: All internal wiring shall have shrink wire labels applied at both ends. At a minimum, the wire labels shall indicate the terminal to which the wire is attached. All cables shall have cable labels that at a minimum indicate the connector to which the cable is connected.

Subassembly Labeling: All subassemblies that are designed to be removed, replaced, or repaired shall be marked with a vendor supplied part number unique to that part. All connectors and terminals on the subassemblies shall be marked with a plug, jack, or terminal number that matches the connected wire or cable.

Assembly Marking: The CPSTS shall be externally marked according to the vendor part number, serial number, and contract number and date of manufacturing.

6.7 Reliability and Maintainability:

Reliability: The unit shall have a minimum meantime between failure (MTBF) rates of 10,000 hours. Reliability shall be predicted in accordance with MIL-HDBK- 217F (CHG 2), using the parts count reliability prediction method found in appendix A.

For component failure rate calculations, use the “Ground, Fixed” or Gf environment. Suitable part failure rates provided from a documented source for the specific parts used in the design may be substituted for those found in MIL-HDBK- 217F (CHG 2).

Operating Environment The unit shall meet all specifications during operation with an ambient temperature between +10 to +40 degrees C, a relative humidity from 5 to 90 percent noncondensing.

Unit Startup: The unit shall meet all electrical powerup requirements within 90 seconds of being turned on from an unpowered condition for all ambient temperatures between +10 degrees and +40 degrees C.

Repair Capabilities: The CPSTS shall be designed and constructed so that it can be disassembled, tested, and repaired down to the subassembly level. Disassembly, reassembly, and testing shall not require any specialized tools, materials, or equipment other than those found in a typical electronics repair shop.

Additional Requirements:

Test Documentation: Test plans, test data sheets, procedures, assembly drawings, part list, and schedules to meet the requirements in this document shall be submitted to the FAA for review and comment at least two weeks prior to testing. The FAA shall approve these plans prior to testing.

Development and Testing:

Development The Contractor shall deliver an engineering report for a production CPSTS unit and test process for the CPS and PPS that specify the measurements taken for the CPSTS, parts utilized, performance parameters, block diagram, and invoices for purchased parts. Invoices shall include any mechanical work for which NRE is paid.

Qualification Testing: After passing qualification testing at the Contractor, the CPSTS and other hardware and software shall be provided to the FAA for qualification testing at the FAA Enroute Shop. Qualification testing shall consist of operational testing, self-testing, testing of the CPS and PPS testing. The qualification test duration shall be at least one (1) week of continuous operation. The Contractor shall provide an engineering report detailing the results of the in-system qualification test.

Repair Instructions: The Contractor shall provide a repair instruction manual containing the disassembly, testing, repair, and reassembly instructions for the CPSTS and hardware. These instructions shall list all tools, equipment, and materials needed to disassemble the unit, test each subassembly, repair or replace each subassembly, tune each subassembly, tune the overall assembly, and test the overall assembly. A Test Data Sheet (TDS) that has space to record every Factory Acceptance Test (FAT) measurement shall be included in the repair manual. Included in the repair instruction manual shall be a list of manufacturers and part numbers for each replaceable subassembly.

Repair Instruction Approval: The Contractor shall submit the repair instruction manual to the FAA for approval. If there are any changes needed to the manual, the changes shall be submitted to the FAA for approval.

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