SOW RPB-MPPT (PS-MPPT-40M) Range Power Box (Rev. 5-20-20).pdf

Rev. 5/20/20

STATEMENT of WORK for

RANGE POWER BOX – MPPT (RPB-MPPT)

1.0 General. The U.S. Coast Guard has been converting range lights and other DC-powered aids to navigation marine light and sound signals to operate with 12 volts DC solar power. Many of these 12VDC-powered aids to navigation require solar arrays necessitating use of photovoltaic charge controllers with the capability to harvest the maximum amount of solar energy possible under varying sunlight conditions without overcharging the battery. The photovoltaic charge controller box described by this SOW is based on Morningstar Corporation’s Maximum Power Point Tracking ProStar PS-MPPT-40M solar charge controller module and has been named the Range Power Box - MPPT (RPB-MPPT) by the Coast Guard and will be referred to simply as RPB-MPPT hereafter.

2.0 Requirements. The requirements of this statement of work is for the Contractor to:

(1) procure the PS-MPPT-40M controller modules, the weatherproof enclosures, mounting panels, RTS battery temperature probes w/ cable, stuffing tubes, labels, and miscellaneous hardware, and (2) assemble these parts to form the finished RPB- MPPT box in accordance with this statement of work.

2.1 Materials. Materials used shall be suitable for use in the marine environment.

Fasteners shall be nonmetallic, nickel-plated brass, or 316 series stainless steel.

2.2 Environment. The RPB-MPPT shall be designed to operate in temperatures between

-10 degrees F to +125 degrees F, 100% humidity, and a salt-air environment. The components shall be designed to withstand the jars and vibrations associated with transport by truck, boat, and aircraft, and vibration associated with vortex shedding and ice acting upon a structure.

2.3 Enclosure. The enclosure shall be Hoffman catalog number A181610CHQRFG (18” x 16” x 10” fiberglass enclosure, Type 4X, Solid Cover/Quick Release latches).

2.4 Mounting Panel. The mounting panel shall be Hoffman catalog number A18P16AL (16.75” x 14.88” aluminum). The PS-MPPT-40M controller module shall be oriented

PS-MPPT-40M

upright, centered, and mounted to the mounting panel. The mounting panel shall then be installed upright inside the enclosure.

2.5 Temperature Compensation. Each RPB-MPPT shall have external battery temperature compensation using Morningstar’s Remote Temperature Sensor (RTS) probe. The RTS cable shall be connected to the PS-MPPT-40M controller module’s terminal strip. The RTS probe’s cable shall be 33 feet in length. An appropriately-sized Dorn or Hubbell liquid tight stuffing tube or cord connector shall be installed to the enclosure’s bottom surface (near left side) as a watertight entrance/exit point for the RTS cable.

2.6 DIP Switch Settings. The eight (8) individual DIP switches in each controller’s DIP Switch Block shall be set to the following USCG default positions before shipping:

1=OFF, 2=OFF, 3=ON, 4=OFF, 5=ON, 6=ON, 7=ON, 8=OFF (i.e., 00101110).

2.7 Firmware Upgrade. The contractor shall ensure that each deliverable RPB-MPPT has been upgraded with the latest firmware for the PS-MPPT-40M charge controller modules available from Morningstar Corp’s support webpage (support.morningstarcorp.com) before shipping. This is a critical step since once the controllers are field-installed, firmware upgrades will not be possible in most cases.

2.8 Label. A durable waterproof vinyl stick-on label with the following information shall be centered and permanently affixed to the outside of the front cover door of the enclosure:

Range Power Box – MPPT

(RPB-MPPT)

Property of USCG

Lettering shall be black in color against a white background; lettering font shall be Arial bold font face. Font size for line “Range Power Box – MPPT (RPB-MPPT)” shall be minimum 48; font size for line “Property of USCG” shall be 36.

2.9 Instructions. The original instructions booklet accompanying each PS-MPPT-40M charge controller module shall be included with each RPB-MPPT and shall detail installation, operation, maintenance, and troubleshooting. All other non-essential tags, advertisings, product announcements, and other paper materials that may have been included with the controller module shall be omitted.

2.10 Preproduction Sample. One preproduction sample RPB-MPPT with the instructions manual shall be shipped to the address listed in the contract for examination and inspection to ensure that all requirements of this statement of work are met.

2.11 Failure Responsibility. The Contractor must correct any deficiencies identified during the preproduction examination and inspection before commencement of production lot fabrication is authorized.

3.0 Preservation, Packing, Marking, and Shipping.

3.1 Preservation. Per MIL-SPEC-2073-1E, Method 10.

3.2 Packing. Shall be in accordance with MIL-STD-2073-1E Level B, to protect these assemblies and items during moderate worldwide shipment, handling, and storage conditions. The Contractor may propose alternate packaging solutions that meet these requirements and will be considered by the Government on a case by case basis.

3.2.1 Packaging. Each RPB-MPPT shall be individually packaged in a single-walled (SW) corrugated fiberboard (CF) Regular Slotted box (0201), in accordance with ASTM D5118/D5118M with dunnage to prevent movement and damage of parts.

3.2.2 Closure of regular slotted boxes (0201). Shall be in accordance with ASTM D1974/D1974M, Closure Method 2C5 (see illustration of an example below). The tape shall comply with Specification ASTM D5749, Type II, Grade B.

3.3 Marking. Each packaged item shall have a waterproof label securely attached or waterproof stencil on each box or crate in the upper left-hand corner of the two longest sides (two opposite sides if square) of each box or crate in accordance with MIL-STD-129R. The lettering/marking shall be in capital letters/numbers of equal height, clearly visible, and the largest size practical for the package size within the acceptable range as specified in MIL-STD-129R.

3.3.1 Identification text marking on unit packs and intermediate containers. Unless specifically exempted in the contract or solicitation, the following identification text information shall be marked on all unit packs and intermediate containers, in the order listed. This requirement applies to all unit packs and intermediate containers repacked for shipment by military installations. Additional identification marking may be required by the contract and shall be placed either below the identification text marking or in a conspicuous location on the identification-marked side of the container. The following information shall be on the label attached to each box or crate.

NSN/NATO/ACN stock number (tbd). The in-the-clear NSN text, if applicable, shall include spaces or dashes and any prefix or suffix specified in the contract or solicitation. The encoded NSN in the linear (Code 39) bar code shall not include spaces or dashes, unless otherwise specified in the contract or solicitation.

CAGE code. The CAGE code of the company awarded the contract for the item being shipped. The CAGE code shall be preceded by the abbreviation “CAGE”.

Part number. The part number for the RPB-MPPT shall be RPB-CHRGCTRL-

MPPT. The part number shall be preceded by the abbreviation “PN” or “P/N” on all exterior markings.

Item description or nomenclature. The exact name and description of an item as it appears in the contract, purchase order or requisition shall be shown. Item description may be marked on more than one line if required due to space limitations. Standard abbreviations, although not desired, may be used if marking length is excessive. If item description matches the PN, this line may be omitted.

Quantity and UI. A non-definitive UI shall be accompanied by a quantitative expression such as “PG (10 EA)” or “1 RO (150 FT).” For a single definitive item

“1 EA.”

Procurement instrument identifier (PIID) (e.g. 17 character contract number or purchase order number). Contracts with a delivery order number (also 17 characters) under the above contract number or purchase order number shall be listed below the above contract number.

Manufactured date. The date the item, material, or commodity was fabricated, processed, produced, or formed for use. This date shall be preceded by an abbreviation “MFD DATE” followed by the date, where “5/20” indicates a date of manufacture of May 2020.

Gross Weight. The gross weight shall be expressed in pounds rounded up to the nearest pound. The gross weight shall be preceded by the abbreviation “WT”.

Serial number(s). When an item is assigned a serial number, that number shall be applied and preceded by an abbreviation “SER NO”.

Additional marks. The words “CONDITION A” and on the next line “USCG

SILC-WOPL MATERIAL” shall be placed immediately below the identification text marking on the unit packs and intermediate containers.

See examples for required information, label example, and placement below.

3.3.2 Multipack. An exterior container, box or palletized unit load containing multiple packages of the same or different National Stock Numbers (NSNs) shall also be marked “MULTIPACK” near the above label(s). The quantity on the labels on the outside of the multi-packed box/pallet shall indicate the total quantity within the box/pallet of each NSN. The items in the MULTIPACK shall be secured by box, cardboard, shrink wrap, strapping, etc. If possible, group the items together by NSN.

3.3.3 Pallets. The Coast Guard Warehouse accepts only standard size pallets 48 x 40 inches (maximum) due to shelving restrictions.

3.4 Bar coding. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388:2007 Code 39 Symbology. See examples for label placement and Bar Codes below.

3.4.1 Bar code label. Can be applied separately or as part of the marking required in 3.3.1.

3.5 Shipping. All items shall be shipped FOB destination. Unless otherwise specified per the contract, the Contractor shall ship all items to the Coast Guard warehouse:

U.S. Coast Guard Surface Forces Logistics Center 2401 Hawkins Point RD Receiving Room - Building 88 Curtis Bay, MD 21226

A shipping address shall be attached to at least the top of one box or crate on each pallet.

Normal delivery hours at the warehouse (are Monday through Friday 0730-1300 (excluding Federal Holidays). Deliveries outside this window shall require prior written approval by the Contracting Officer.

The pre-production RPB-MPPT shall be shipped F.O.B. Destination to:

Commandant (WOPL c/o CG-43) Attn: Mr. Kam Agi U.S. Coast Guard, Stop 7714 2703 Martin Luther King Jr. Ave. S.E.

Washington, D.C. 20593-7714

3.5.1 Shipment details. The Contractor shall notify the COR and Contracting Officer within three (3) business days of:

date of shipment the contracted items/delivery order leaves the Contractor's facility name of the shipping company tracking number(s) of shipment expected arrival date and time at the Coast Guard facility

Example of unit container, intermediate container, and exterior container identification markings

Barcoding Examples: