CSEL__Technical_Requirements_Rev_6-19-17_(non-rechargeable).docx

CDRL’s 6140-01-633-9444 16 March 15

TECHNICAL REQUIREMENTS

CSEL Non-Reachargeable Battery

TABLE OF CONTENTS

APPLICABLE DOCUMENTS

Military and Federal Standards

Military and Federal Specifications

Other Documents

Commercial Documents

Combat Survivor/Evader Locator System, AN/PRQ-7, Hand-Held Radio, Non-Rechargeable Battery, Performance Specification, dated 12 March 2009 with Change notices A01, A02, A03, A04, & A05

Security Documents

CONFIGURATION BASELINE

The applicable Configuration Baselines (CB), for the listed Configuration Item (CI) and/or Computer Software Configuration Item (CSCI), are as listed in the table below.

Configuration Change Process.

The contractor shall establish a system for managing the configuration changes to the IPN baseline.

Configuration.

Each CI, as developed/built and delivered, shall conform to the cited CB.

Application Management.

Application Management.

In performing Application Management, the Government must assess the impact of design changes to the Configuration Item. The Government is the Configuration Management authority on application management for all external applications and for all Major changes that affect the Commercial Item Part Number (CIPN) specified in paragraph 3.2.1. A Major change is defined as any change that will impact any of the following conditions of the IPN:

Application Activity.

The Government is an Application Activity (AA) for changes that affect the Contractor’s CIPN. The CSEL Project Office possesses document change authority over the changes affecting the IPN. Any changes that affect the conditions identified above shall be submitted for Government approval IAW the procedures outlined below. Configuration changes not directly affecting the configuration baseline conditions identified do not require Government approval.

Departures from CB.

Changes that affect the CIPN conditions shall be submitted for Government approval in accordance with this document and the DD Form 1423 for DI-MISC-80711A.

Changes from Boeing.

Changes directed by Boeing shall not require prior government approval. The Government shall be notified of any such changes with effectivity data.

Request For Change (RFC).

The Request For Change (RFC) includes both the engineering change and the supporting documentation by which the change is described and suggested. An RFC describes changes to the CI and associated Contractor documents and data that are affected by the proposed engineering change. The RFC also describes a full impact analysis of the effect of the change on the logistics, interface, design, cost and schedule requirements of the IPN.

RFCs could be generated as any of the following categories: Change Directive; Change Request; Engineering Change Package; Engineering Change Proposal; Engineering Change Request; Engineering Change Memo; Engineering Change Notice.

RFCs shall contain the following elements as a minimum:

Contractor-approved changes that adversely impact any of the IPN conditions listed may require re-evaluation by the Government of the IPN. Re-evaluation may include operational testing re-assessment or re-assessment of the logistics impact of the proposed change. An approved change to the design of the IPN must be verified to ascertain that the IPN has achieved the functional attributes and requirements specified in the baselined Product Definition Information (IPN) and that it is adequate for its intended purposes. The Government is not obligated to accept any IPNs that no longer meet the Government’s requirements as established by the IPN at the time of contract award.

Obsolescence Reporting N/A

Part Revisions N/A

CHEMICAL AGENT RESISTANT COATING (CARC)

Paint Colors

Other

Special Instructions

X = Applicable

Antenna Elements, including protective covers, i.e. fiberglass shields.

Attachment 0001 SPRBL1-17-R-0016 Page 8 of 38 Issue: 22 June 2017

PACKAGING

Wood Packing Material Wood packing material includes pallets. See DLAD 52.247-9012 Requirements for Treatment of Wood Packaging Material (WPM).

Military Packaging DS7029 and/or DS7033 Preservation, Packing and Marking Instructions

DS7029 - DS7033 LEGEND

The below codes are for special markings:

DS7029 - DS7033

Special Markings

SPECIALIZED TESTING

DLADS 52.247-9012 Sampling shall be IAW Boeing specifications 4866112-007 and 4866112-020.

AN/PRQ-7 Battery Functional Testing

AN/PRQ-7 Battery Functional Testing as described by 4866112-717 shall be performed by Boeing. The contractor is responsible for making arrangements with, and funding Boeing to perform this test. The POC at Boeing is:

Dave Wallace Boeing Contracts 714-421-9810

Additionally, the contractor will need to obtain an AN/PRQ-7 (battery test variant with no GPS and VUM module) with the 4866112-040 Battery Test Software (called out in 4866112-040 para 4.8.19.2). This radio can be obtained from Boeing, there is no additional cost for this service.

Navy testing:

Batteries must attain approval under Lithium Battery Safety Program per Naval Sea Systems Command S9310-AQ-SAF-010.

1. The contractor shall be solely responsible for arranging with the Navy for the required testing.

2. Contractor responsibilities:

a. Quote for bid/proposal - During the solicitation phase of the acquisition, the company shall contact by email the following POC’s with a request for a quote for the Navy testing. The cost for the Navy testing shall be included in the price proposal.

Julie Simmons, julie.a.simmons18.civ@mail.mil

Mark Tisher, mark.t.tisher.civ@mail.mil

The following information shall be provided in the request (include “Request for Quote” in subject line):

(1) Solicitation number

(2) Battery nomenclature and NSN

(3) Duration of contract to be awarded; include option periods

The Navy will provide the quote and a POC, and specify the location for the testing. If the company is awarded the contract, the POC provided by the Navy will be the POC for all Navy testing actions related to this solicitation/contract.

b. Test Services Agreement (TSA) or Cooperative Research and Development Agreement (CRADA)

In order for the Navy to test batteries for a contractor, a TSA or CRADA, depending on the testing location, will be required.

(1) TSA

(1)a In order for the Navy to test batteries for a contractor, a TSA between the contractor and the Navy must first be in place in accordance with Title 10, United States Code, Section 2539b (Availability of Samples, Drawings, Information, Equipment, Materials, and Certain Services). The contractor shall contact the Navy NLT 15 DAC to initiate the process of establishing the agreement.

(1)b The TSA will apply to the contract and all battery types to be tested.

(1)c The agreement has an expiration date. The contractor shall request an agreement that will be in effect for the life of the contract.

(2) CRADA – The TSA requirements above also apply to a CRADA

c. Navy Test Plan – The contractor shall request from the Navy within 15 DAC a test plan for the Navy testing to be included in the FAT Plan. A navy test plan is required for each battery type to be tested. Navy requires 15 days to prepare the plan and send it to the contractor.

d. Safety Data Package Requirements (SDPR) – The contractor shall submit to the Navy within 15 DAC a SDPR (form included in this document) completed to the maximum extent possible for each battery type to be tested. The completed form shall be updated as additional data becomes available and an updated form will be submitted to the Navy. A fully completed form shall be submitted with the FATP.

e. Navy Testing Samples

(1) The number of samples per battery will be 15. The samples shall be shipped NLT 180 DAC to the Navy at the contractor’s expense.

(2) The fifteen (15) samples shall be as follows:

(3) The samples shall be shipped with a DD-Form-1222 and the SDPR. Each battery type is to be packaged in a separate box. Mark each box as follows:

Shipping address will be provided in the Navy test plan.

f. Test Report - The Navy will require 60 days to complete testing and prepare the report. The Navy’s report will be provided to the contractor NLT 240 DAC. A copy of the report will be included in the FAT Report.

g. Funding - The contractor shall provide to the Navy the required funding for the testing NLT 150 DAC. Testing shall not start until the required funding has been received at the Navy. Additionally, the TSA must be in place in order for the Navy to accept the funding.

h. Retesting – The quote by battery type provided by the Navy shall cover the initial testing of 15 samples. Any retesting shall require additional funding from the contractor.

i. Disposition of Samples – The Navy will dispose of the samples 30 days after the test report is issued to the contractor except for any failure batteries that the contractor has requested in writing to be returned. The contractor shall arrange for the return of any samples.

3. Navy responsibilities:

a. Provide the company with a quote, POC and location for testing.

b. Assist the contractor to establish testing agreements.

c. Provide the contractor with a Navy approved test plan for the required Navy testing. Test plan shall include approval signatures, document number, contractor name, contract number, NSN, and battery type.

d. Include shipping instructions for the samples in the test plan.

e. Perform the required testing.

f. Provide the contractor with a Navy approved test report. Report shall include approval signatures, document number, contractor name, contract number, NSN, PIN and BA number.

(Draft) 28 August 2008 Safety Data Package Requirements References:

S9310-AQ-SAF-010, 1.2.2.1 & 1.4.2

BATTERY PIN:

TYPE DESIGNATION:

MFGR PART NUMBER:

ELECTROCHEMISTRY:

(CAGEC)

ADDRESS:

(Title)

(Phone)

(e-mail)

NSN:

Contract Number:

INSTRUCTIONS:

Complete form in accordance with the schedule established by the contract or purchase order.

Complete all blanks exclusive of the revision block. All applicable data is required.

Unless specifically asked for a minimum (MIN) or maximum (MAX) value, use nominal or average values for numeric entries.

To change status of a checkbox: Right click on the empty box; select “Properties” from the pull-down menu; Select “Checked”; the status block for “Not Checked” will automatically deselect.

This template is provided in Microsoft Word format; when completed, the form shall be saved in Read Only format, PDF or Microsoft Word.

Once completed, the form shall be provided in accordance with the delivery requirements of the contract or purchase order.

REVISION BLOCK

PARAMETER

Electrode Type or Alignment (i.e., Bobbin, spirally wound, etc…):

N/A

MAX Open circuit voltage:

MIN Open circuit voltage:

MAX Closed circuit1 voltage:

MIN Closed circuit1 voltage:

Ampere-Hour1 rating:

Watt-Hour1 rating:

MAX Continuous Discharge Rate (MCDR):

MAX Weight of lithium:

Cell type(s)3 or P/N(s):

N/A

Hermetically sealed (Y/N):

N/A

Cell Shape (Cylindrical or Prismatic):

N/A

Describe any additional cell feature designed to prevent electrolyte leakage.

N/A

NOTES:

1For closed circuit voltage, capacity, and energy ratings, use a C/10 discharge load at 70ºF (21ºC). The value “C” is the rated ampere-hour capacity.

2Series/Parallel configurations shall be designated as xS/xP; i.e., a battery with 5 cells in series and no parallel cell strings will be designated 5S/1P. A battery with 4 cells in series and 3 parallel strings will be designated 4S/3P. A single-cell battery will be designated 1S/1P.

Multi-section batteries will be designated as xS/xP+xS/xP, i.e., a two-section battery with a single cell string of 5 cells in each section will be designated as 5S/1P+5S/1P.

3If more than one cell type will be used for this battery, provide rationale below and describe any additional safety features required as a result if any (add more lines if necessary):

DD Form 1423-1, DI-NDTI-81307

BATTERY DIMENSIONS (inches)

Connector:

Terminals:

Enclosure:

Material (include MSDS if applicable):

Flammability rating (cured):

Temperature range (cured):

Controls (see S9310, 1.4.1.3):

Storage Temperature Range:

Operating Temperature Range:

Barometric Pressure Range (if applicable):

Features employed to prevent water intrusion during testing:

Shelf Life:

10% MCDR:

1% MCDR:

Intermittent operation (C/30 discharge rate, 8 hours on, 16 hours off):

Operation in extreme2 cold:

Operation in extreme2 hot:

Use outside3 of pressure range (if applicable):

1Include an oblique, cabinet projection pictorial drawing as defined by ASME Y14.4, to include details showing all battery enclosure seams and effects of any draft angles used.

2Extreme conditions are those outside of the listed ranges.

Short circuit (Internal):

Short circuit (Accidental; see S9310, 1.4.2.5):

|_| Slow-Blow |_| Medium Blow |_| Fast Blow

Part Number:

Trip/Open Rating:

Where located1 in battery circuit?

N/A

P/N:

Trip/Open Rating:

Where located1 in battery circuit?

N/A

Vent Mechanisms

Charge Protection (If applicable, specify how charge protection will be accomplished):

Cell/Battery Yield Pressure (See S9310, para. 1.2.2.1.12)

What design features are employed (if any) to assure that the battery will not be adversely affected by changes in barometric pressure?

What design features are employed to prevent fragmentation of the battery enclosure during testing in accordance with 4.6.3?

Interchangeability – What design features are employed (if any) to assure that the battery will not be interchangeable with commercial batteries used in consumer products?

1Include an electrical diagram of the battery using graphic symbols as defined by IEEE Std. 315 (ANSI Y32.2).

PRODUCT SAFETY IN PRODUCT REALIZATION & MANUFACTURING:

Contaminants in basic cell components

Electrolyte mixing process

Minimum amount of carbon

Balance in active materials

Electrode alignment

Avoiding use of tapes or sealing methods on electrode core wind

Providing strong weld adhesion of positive cell tab

Cell closure processes

Weld burrs on top-shells

Assurance for heat-shrink materials

Sealing process for battery enclosures (Watertight Integrity)

NOTES

1Process controls may include requirements applied to purchase orders for purchased materials or components.

SPECIAL CONTROLS OR PRECAUTIONS. Describe any controls or precautions that may be necessary or are recommended, if any, in the listed areas.

Fire Fighting1

Transportation1

Storage1

Use1

Disposal1

Exposure to toxic substances1 in the event of leakage, venting, rupture explosions, or fires.

NOTES

1Include a Material Safety Data Sheet (MSDS) or Product Safety Data Sheet (PSDS), as applicable. If any of the information required above is provided in the MSDS or PSDS, cite the page and section or paragraph reference on the sheet rather than repeating the information here.

PREPARER’S SIGNATURE BLOCK:

ATTACHMENTS. Please list any attachments to this file - including pictorial drawings, electrical diagrams & MSDS/PSDS - and where applicable, include the file name in the description of the attachment.

CONTRACT DATA REQUIREMENT LIST (CDRL) DD 1423-1

CDRL List

Individual CDRLs

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item) Original Form Approved OMB No. 0704-0188

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP X TM OTHER

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

LT

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

SEE ITEM 16

Reg

Repro

16. REMARKS: Data Item Description DI-MISC-80711A: Delete block 10 instructions entirely and follow instructions in this contract for departures from the configuration baseline

Government requires 30 days for review.

Data shall be submitted and exchanged electronically in Microsoft Office 2000 or later suite of applications (MS Word, Excel, Power Point, PDF). Alternate formats may be allowed subject to Government review and approval.

RDER-PRP-G

ACO

PCO

QAR

15. TOTAL

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch 6/19/17

CONTRACT DATA REQUIREMENTS LIST

Form Approved

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP TM OTHER NDTI

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

DD

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

A

SEE ITEM 16

16. REMARKS:

Government requires 30 days for review/comments/approval of all submissions.

Submit final within 30 days of receipt of Government comments, via DD-250.

Item 13. Revisions – After the test plan has been initially approved, a revised test shall be submitted for review and approval (with DD250) when procedure or design changes affect the PLTP.

Each submission shall be delivered in PDF format on compact disc or email attachment and shall include the contractor’s approval signatures. The plan shall include the following:

SEE CONTINUATION PAGE

RDER-PRP-G

ACO

15. TOTAL

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch

6/19/17

DD Form 1423-1, 1 Jun 90 PAGE 1 OF 2

1. The delineation and allocation of tests to be performed for each production lot and the order of such tests (this may be prescribed in applicable technical data).

2. Step-by-step test procedures for each test and the data sheets to be employed to document the results of testing.

3. Identification of required test facilities, equipment and personnel.

4. A table which cross references the paragraph number of the specification to the associated paragraph numbers of the Production Lot Test Plan.

CONTRACT DATA REQUIREMENTS LIST

Form Approved

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP TM OTHER NDTI

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

DD

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

A

SEE ITEM 16

16. REMARKS:

Government requires 30 days for review/comments/approval of all submissions.

Submit final within 30 days of receipt of Government comments, via DD-250.

Item 13. Revisions – After the test plan has been initially approved, a revised test shall be submitted for review and approval (with DD250) when procedure or design changes affect the PLTP.

Each submission shall be delivered in PDF format on compact disc or email attachment and shall include the contractor’s approval signatures. The plan shall include the following:

SEE CONTINUATION PAGE

RDER-PRP-G

ACO

15. TOTAL

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch 6/19/17

DD Form 1423-1, 1 Jun 90 PAGE 1 OF 2

1. The delineation and allocation of tests to be performed and the order of such tests (this may be prescribed in applicable technical data).

2. Step-by-step test procedures for each test and the data sheets to be employed to document the results of testing.

3. Identification of required test facilities, equipment and personnel.

4. A table which cross references the paragraph number of the specification to the associated paragraph numbers of the Production Lot Test Plan.

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item) Form Approved

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP TM OTHER

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

DD

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

A

LEAVE BLANK

16. REMARKS:

Data Item Description DI-SAFT-80102B: Delete Block 10 instructions entirely and follow instructions below.

Submit SAR via DD-250. Government requires 30 days to review and approve/disapprove.

The plan shall be delivered as an email attachment. It will have the contractor’s approval signatures and shall be delivered in Adobe PDF format.

The SAR Plan will include the following:

SEE CONTINUATION SHEETS

RDER-PRP-G

ACO

PCO

CECOM SAFETY

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch 6/19/17

DD Form 1423-1, 1 Jun 90 PAGE 1 OF 2

Safety Assessment Report (SAR) Test Plan. The contractor shall prepare a SAR Test Plan IAW the CDRL for DI-NDTI-80566A below. The SAR Test Plan shall include the following information:

(1) Cover page that includes contract number, contractor’s name, address, cage code, place of manufacture and assembly, date of submittal, signature blocks and signatures of author and approval authority and document version.

(2) Introduction and objectives.

(3) List of tests performed in tabular format, including references, length of time to perform tests, test milestone schedules.

(4) Identification of required test facilities and locations.

(5) Identification of equipment, (including serial numbers, calibration dates).

(6) Title of the test to be conducted, (the tests listed in Table 3 must be included as a minimum).

(7) Purpose of each test.

(8) Test and validation procedures for each test.

(9) Test parameters.

(10) Test requirements and test pass/fail criteria.

(11) Data sheets.

(12) The test plan shall also reference the approved FAT procedures used to perform the tests identified IAW ParagraphParagraph4.2.2 of MIL-PRF-49080D and shall also include a brief summary of the FAT procedures mentioned above.

Form Approved

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP TM OTHER NDTI

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

DD

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

A

16. REMARKS:

Data Item Description DI-NDTI-80809B: Delete Block 10 instructions entirely and follow instructions below.

Government requires 30 days for review/comments/approval of all submissions.

Submit final within 30 days of receipt of Government comments, via DD-250.

The report shall be delivered as an email attachment. Attachments exceeding email system limits shall be delivered via AMRDEC SAFE https://safe.amrdec.army.mil/safe . It shall have the contractor’s approval signatures and shall be delivered in PDF format.

The report shall be complete, accurate, and readable and shall provide sufficient data to determine that the hardware item meets all the requirements delineated in the contract. The report shall include the following:

SEE CONTINUATION PAGE

RDER-PRP-G

ACO

15. TOTAL

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch 6/19/17

DD Form 1423-1, 1 Jun 90 PAGE 1 OF 3

1. General Data.

k. name and address of requiring Government activity

l. report date

m. Date code and serial number of both contractor and Government FAT units.

2. Summary. For each test state the number of samples tested, results, dates, failures, corrective action, location of data and any other pertinent information.

3. Cross Reference. A table which cross-references the plan procedures and the data presented in the report.

4. Test Results. Complete test results showing actual or quantitative observations and all required calculations. Allowable tolerances for each parameter shall be presented. ‘GO/NOGO’ data shall be avoided wherever possible. Test data should also include the date that the test was performed, name of tester, name and signature of the Government verifier/witness (if applicable) and serial number of the equipment.

5. Failures. The report shall list all requirements not complied with during testing. If none, this should be explicitly stated. For each requirement not met, a failure analysis report shall be prepared for each failure and included in the FAT report. As a minimum the failure analysis shall include the identification of the failed battery, description of the failure based on the specification, findings, root cause, corrective action, retest and the impact of the failure on other tests. A corrective action to remove the noncompliance will be proposed. This corrective action must include retest or other verification that the corrective action does remedy the problem/failure. The corrective action will address changes in design or manufacturing process which will preclude this deficiency in subsequent production units. Verified corrective action must be implemented prior to contractor entering into production. A copy of the failure analysis reports shall be included in the report. The impact of the failure on the entire lot will be evaluated by the Government and a partial test, including tests that passed, or a full test may have to be repeated at no additional cost to the Government and at the sole discretion of the Government based on the failure analysis report.

6. FAT/Production Discrepancies. Any Government approved difference between the parts, materials and processes used to manufacture FAT samples and production units shall be documented in the test report. If there will be no difference between FAT and production, this shall be explicitly stated in the report.

7. Plan Deviations. Although the contractor is required to submit changes to the test plan to the Government for approval prior to testing, if a deviation from the plan is discovered after testing, such deviations shall be clearly discussed in the report with their impact on the results. If no such deviations exist, then the report should state that the test plan was followed without any deviations. Any deviations from the test plan may result in a new, partial or full testing at the contractor’s expense as determined by the Government.

Form Approved

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP TM OTHER NDTI

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

DD

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

A

16. REMARKS:

Data Item Description DI-NDTI-80809B: Delete Block 10 instructions entirely and follow instructions below.

Government requires 30 days for review/comments/approval of all submissions.

Submit final within 30 days of receipt of Government comments, via DD-250.

The report shall be delivered as an email attachment. Attachements exceeding email system limits shall be delivered via AMRDEC SAFE https://safe.amrdec.army.mil/safe . It shall have the contractor’s approval signatures and shall be delivered in PDF format.

The report shall be complete, accurate, and readable and shall provide sufficient data to determine that the hardware item meets all the requirements delineated in the contract. The report shall include the following:

SEE CONTINUATION PAGE

RDER-PRP-G

ACO

15. TOTAL

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch 6/19/17

DD Form 1423-1, 1 Jun 90 PAGE 1 OF 3

1. General Data.

k. name and address of requiring Government activity

l. report date

m. Date code and serial number of both contractor and Government FAT units.

2. Summary. For each test state the number of samples tested, results, dates, failures, corrective action, location of data and any other pertinent information.

3. 3. Cross Reference. A table which cross-references the plan procedures and the data presented in the report.

4. Test Results. Complete test results showing actual or quantitative observations and all required calculations. Allowable tolerances for each parameter shall be presented. ‘GO/NOGO’ data shall be avoided wherever possible. Test data should also include the date that the test was performed, name of tester, name and signature of the Government verifier/witness (if applicable) and serial number of the equipment.

5. Failures. The report shall list all requirements not complied with during testing. If none, this should be explicitly stated. For each requirement not met, a failure analysis report shall be prepared for each failure and included in the FAT report. As a minimum the failure analysis shall include the identification of the failed battery, description of the failure based on the specification, findings, root cause, corrective action, retest and the impact of the failure on other tests. A corrective action to remove the noncompliance will be proposed. This corrective action must include retest or other verification that the corrective action does remedy the problem/failure. The corrective action will address changes in design or manufacturing process which will preclude this deficiency in subsequent production units. Verified corrective action must be implemented prior to contractor entering into production. A copy of the failure analysis reports shall be included in the report. The impact of the failure on the entire lot will be evaluated by the Government and a partial test, including tests that passed, or a full test may have to be repeated at no additional cost to the Government and at the sole discretion of the Government based on the failure analysis report.

6. FAT/Production Discrepancies. Any Government approved difference between the parts, materials and processes used to manufacture FAT samples and production units shall be documented in the test report. If there will be no difference between FAT and production, this shall be explicitly stated in the report.

7. Plan Deviations. Although the contractor is required to submit changes to the test plan to the Government for approval prior to testing, if a deviation from the plan is discovered after testing, such deviations shall be clearly discussed in the report with their impact on the results. If no such deviations exist, then the report should state that the test plan was followed without any deviations. Any deviations from the test plan may result in a new, partial or full testing at the contractor’s expense as determined by the Government.

Form Approved

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA. 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. Please DO NOT RETURN your form to either of these addresses. Send completed form to the Government Issuing Contracting Officer for Contract/PR No. listed in Block E.

TDP TM OTHER

BA-5301A/U Non-rechargeable Battery

17. PRICE GROUP

18. ESTIMATED TOTAL PRICE

INSERT

IN

DD

b. COPIES

SECT. B

SUBMISSION

a. ADDRESSEE

Draft Final

A

LEAVE BLANK

16. REMARKS:

Data Item Description DI-SAFT-80102B: Delete Block 10 instructions entirely and follow instructions below.

Submit SAR via DD-250. Government requires 30 days to review and approve/disapprove.

The report shall be delivered as an email attachment. It will have the contractor’s approval signatures and shall be delivered in Adobe PDF format.

The SAR will include the following:

SEE CONTINUATION SHEETS

RDER-PRP-G

ACO

PCO

CECOM SAFETY

Ari Herman

RDER-PRP-G

Electronics Engineer

RDER-PRP-G

Chief, Generator/ECU Special Operations Branch 6/19/17

DD Form 1423-1, 1 Jun 90 PAGE 1 OF 8

1. Safety Assessment Report (SAR). The contractor shall prepare a Safety Assessment Report (SAR) for each battery. The SAR shall document the safety risk being assumed with the batteries during use, storage, transportation, or disposal, and is required prior to first delivery of the batteries. Each SAR shall identify all safety features of the battery, results of all required testing, and specific controls or precautions to be followed in the use, storage, transportation, or disposal of the batteries; and shall provide verification of compliance to safety requirements identified in the battery specifications. Specific tests, to be identified by the Government, will be witnessed by the QAR or other designated Government representative. The contractor shall provide the QAR and the technical office specified by the PCO with two weeks advance notification of all safety-test scheduling in order to allow witnessing.

1.1 Battery and SAR Acceptance – Delivery of the batteries is contingent on an approved SAR. The SAR approval requires that there be NO medium, serious or high-level risks during normal operation between –20 and 160oF.

1.2 SAR Content. The SAR shall include the following information:

b. Introduction – stating the purpose of the SAR.

c. System Description - historical summary of cell and battery development; diagrams or pictures of the cell, battery, and all labeling; location of cell manufacture and battery assembly; a description and manufacturers part numbers of major battery and cell components including but not limited to safety devices (including separators). This section shall also include the following information, as a minimum, in tabular format: a list of the maximum and nominal battery voltages, operational and storage temperature ranges, maximum and minimum safe (e.g., no swelling, leakage, venting, or rupture) temperatures, battery capacity in amp-hours, maximum battery discharge rate, total battery weight, weight of lithium per cell and battery in grams, battery volume, type of connector, case material, cell packaging material, parameters of the safety devices, applicable references (e.g., specifications, etc.), and date codes and serial numbers of test samples.

d. Operation, storage, transportation, and disposal - description of procedures for operation; description of any special skills or safety procedures/precautions to assure safe operation, storage, disposal, and transportation; fire fighting procedures for individual batteries, one package of batteries, and bulk quantities (100 or more batteries) of batteries, including precautions, and recommendations; complete list of warnings, labeling (including CDD), cautions, and safety procedures required in technical manuals and training courses; pictures or diagrams of warning or caution labels. The SAR shall also identify maximum quantities of batteries allowed per shipping mode and by container as required by the Code of Federal Regulations (49 CFR 173.85). A description and details shall be provided on all packaging and markings to be employed on production batteries in addition to the results of any UN packaging testing.

e. Test Description and Results of Safety Testing – The SAR shall include a summary of the results of First Article and Transportation Testing.

f. System Safety Engineering - summary of safety methodology used to rank hazards; description of methods, analyses, and tests used to identify hazards; list of all pertinent references.

g. Conclusions and Recommendations – an assessment of the results of the system safety effort; a list of significant residual hazards; signed statement by the contractor safety manager and program manager stating that all hazards have been identified, eliminated and/or controlled, and that the battery is ready for test and operation. Recommendations shall be provided for the safe integration of the battery in an end item to reduce the possibility of damage to the battery or to the end item. Recommendations for implementation in an end item shall also be provided to address possible personal injury in the event of leakage, venting/rupture, or explosions of the battery if subjected to abusive conditions.