SOW_-_Sinker_EDM_Rev7.docx

U.S. ARMY ARDEC – Benét Labs Watervliet, NY Equip. Engr. Spec. #BPE-2016-2 Date: Feb 22, 2017 Rev. 7

One New Sinker Electrical Discharge Machine Table of Contents

1. Scope

1.1 Abbreviated Description 2

2. Applicable Standards and Publications 2

3. Requirements

4. Quality Assurance Provisions

5. Preservation, Packaging and Delivery Instructions 21

6. Instructions for Preparing Technical Offers 21

1.0 SCOPE.

1.1 Scope. This purchase description describes the minimum requirements for the procurement of one (1) Sinker EDM Machine equivalent to a Mitsubishi model EA12PS Sinker EDM. The machine shall include all equipment, accessories, attachments, delivery, installation services, and training described herein.

2.0 APPLICABLE DOCUMENTS.

2.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

STANDARDS-FEDERAL

FED-STD-H28A (2001): Screw Thread Standards for Federal Service U.S Department of Labor, Occupational Safety and Health Administration (OSHA)

OSHA 29 CFR .1910 (2014): General Industry, OSHA Safety and Health Standards 29CFR1910

DEPARTMENT OF DEFENSE

ITEM UNIQUE IDENTIFICATION MARKING (IUID)

MIL-STD-130N (2012 edition): Identification Marking of U.S. Military Property (Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853)

(Copies of these documents are available online at http://assist.daps.dla.mil/guicksearch/ or from the Standardization Document order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2 Non-Government Publications. The following documents from a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

National Fire Protection Agency NFPA 79: Electrical Standard for Industrial Machinery (Applications for copies should be addressed to the National Fire Protection Association, AT1N: Support Services, 11 Tracy Drive, Avon, MA 02322)

National Electrical Manufacturers Association (NEMA) NEMA M G-1: Motors and Generators (Address application for copies· to National Electrical Manufacturer's Association, 1300 N. 17th St., Suite 184 7, Rosslyn, VA 22209)

International Organization for Standardization (ISO) ISO 14137:2015 “Test conditions for wire electrical-discharge machines (wire EDM) -- Testing of the accuracy”.

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembe, Casepostale56, CH211Geneva20, Switzerland)

2.3 Clarification: If there are any ambiguities or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description prior to submitting an offer, such ambiguities or discrepancies shall be reported to the contracting officer by the contractor before the date scheduled for close of bidding/receipt of proposal. Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could been foreseen had such reasonable examinations been made, may be denied.

2.4 National Standards and Specifications: All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Benét Labs, Watervliet Arsenal, OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances, material, quality, and workmanship shall meet or exceed OEM specifications. The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent apply.

3.0 REQUIREMENTS.

3.1 Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer's currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer's published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.1.2 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in both the inch/pound and Metric systems.

3.1.3 Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

3.1.4 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

3.1.4.1 Safety Guarding. Covers, guards, or other safety devices shall be provided. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.5 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the "A" weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements. The contractor shall make the maximum use of low-noise emission products, as certified by the EPA.

3.1.6 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.6.1 Compliance with Environmental Laws and Regulations: Contractor shall comply with all applicable federal, state, and local environmental laws, statutes, regulations, executive orders, permits, Army regulations (with supplements), as well as Major Subordinate Command (MSC) and installation regulation, policy, Host Tenant Agreement, Interagency Service Support Agreement, or Status-of-Forces Agreement. Contractor shall immediately report any conflicts between applicable federal, state, local environmental laws, statutes, executive orders, and provisions of Army Regulation 200-1, and any specifications within this contract to the Contracting Officer Representative (COR).

3.1.6.2 Compliance with Green Procurement Requirements: Contractor shall follow Federal EPA Comprehensive Procurement guidelines (www.epa.gov/cpg) and Army Contracting Command Quick Guide (https://acc.aep.army.mil/accapps/ACCMAP/Documents/Quick-Guide-for-Sustainable-Procurement.docx) for acquisition of building materials and products and select materials that have a long life cycle; the least toxic materials; recyclable materials; materials that are resource-efficient; materials with the maximum recycled content; materials harvested on a sustained yield basis; and products causing the least pollution during their manufacture, use, and reuse.

3.1.6.3 Compliance with License and Certification Requirements: Contractor shall obtain all license and certification required by Federal, State, and Local environmental laws and regulations necessary to adhere to the specifications of this contract. The Contractor shall submit all plans, notifications, reports, submittal documents, and fees required by Federal, State, and Local environmental laws and regulations to the appropriate Federal, State, and Local authority and/or agency as necessary to adhere to the specification of this contract. All required licenses and certifications required by Federal, State, and Local environmental laws and/or regulations shall be considered a contract deliverable upon award.

3.1.6.4 Notification of Federal and State Regulators: Contractor shall immediately notify the Designated Government Representative (DGR) and COR of the arrival on site of any Federal, State, and/or DoD environmental regulator or enforcement agent and/or the receipt of any correspondence from a Federal or State environmental agency.

3.1.6.5 Inspections of Work Sites: Contractor shall submit to potential Federal, State, Army and installation work site environmental regulatory inspections and/or investigations into noncompliance, and fully cooperate with such inspections/investigations by providing the appropriate records and documentation. Environmental regulatory agencies are authorized by law to inspect any work site for environmental compliance with regulatory requirements. If an inspection is conducted, it will not stop or disrupt ongoing contract activities. The inspection will only require the work site environmental officer, or supervisor/manager to answer questions and/or escort the inspector to specific work site areas with the potential to affect environmental quality.

3.1.6.6 Reporting Noncompliance: Contractor shall immediately report any nonconformance and/or noncompliance with applicable Federal, State or Local environmental laws, Army and installation environmental regulations or policies to the COR and DGR.

3.1.6.7 Conformance with Environmental Management System: Contractor shall take the necessary actions to identify, monitor, and control those contract operations and activities that pose risk of contamination, or can negatively impact the natural and/or human environment.

3.1.6.8 Use of Hazardous Materials: Contractor shall assign all hazardous materials management responsibilities to the appointed ECD. Contractor shall contact the DGR or COR to obtain technical assistance from Environmental Office for assisting the ECD with achieving and maintaining compliance with hazardous material storage, issue, use, and disposal requirements. Contractor shall submit to the COR and/or DGR a hazardous material inventory. The hazardous material inventory will be submitted 30 days prior to commencement of work for contracts that exceed 180 consecutive days. The inventory list will contain the hazardous material type and maximum quantities of materials anticipated to be stored on-site. The hazardous material shall be properly identified and include any applicable identification number, such as National Stock Number or Special Item Number. The Contractor shall maintain copies of Safety Data Sheets for all hazardous materials used and stored on-site during performance of the contract. Contractor shall not supply or deliver any hazardous materials or chemicals to an installation that are listed on EPA toxic chemical list without prior written approval from DGR and/or COR.

3.1.6.9 Prevention of Spills: Contractor shall adopt the installation's Spill Prevention Control and Countermeasures Plan (SPCC) if transporting, processing, storing, or in any way managing hazardous waste, hazardous material, petroleum-oils-lubricants, or other restricted items. In case of a spill, the person in control of the spill site or their designated representative shall take appropriate action to protect workers and bystanders; contain the spill (if it can be done safely); secure the spill site; restrict ignition sources; and immediately contact the installation Fire and Emergency Services (Fire Department).

3.1.6.10 Protection of Sensitive Areas: Contractor shall comply with all installation designated sensitive and/or off-limit area restrictions. Sensitive areas are generally demarked indicating what activities (e.g., driving, digging, foot traffic) are prohibited. The Contractor shall also adhere to the following installation sensitive areas requirements:

Cultural Resources Sites: Do not excavate, remove, damage, or otherwise deface any archeological resource located on public lands.

3.1.6.11 Corrective Action for Noncompliance: Contractor shall when given a verbal and/or written notice of environmental noncompliance or nonconformance by the COR, take immediate corrective action. Failure or refusal to comply promptly may be grounds for the Contracting Officer to invoke the appropriate contractual remedies. This may cause all or part of the work to be stopped immediately until satisfactory corrective action has been taken.

3.1.7 Lubricants, Hydraulic Fluids, Oils, and Coolants. Benét Labs is a tenant on the Watervliet Arsenal facility, which has established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor shall choose the required lubricants, hydraulic fluids, oils and coolants from Attachment “A”, enclosed or where designated (*see note) approved industry/commercial equivalents. If a substitute is required, the contractor shall provide, 90 days prior to delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.8 Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. Shall a low oil condition occur, the machine shall enter an emergency stop condition upon completion of the current operation. All oil holes, grease fittings, and filler caps shall be accessible.

3.1.9 Foundation. This equipment is intended to be installed in the Benét Labs Manufacturing Prototype Center, which is located on the 2nd floor of B25 at Watervliet Arsenal. A foundation cannot be installed in this instance and all equipment shall be compatible with the 2nd floor installation requirements. These requirements include avoiding the need to core drill anchor holes.

3.1.10 Safety and Environmental. The machine shall be fully designed and equipped with features to protect the machine operator, other personnel, and prevent self-damage to the machine itself in the event of malfunction and/or ordinary negligence insofar as practical.

3.1.10.1 Industry And Regulations. The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications (Section 2.2).

3.1.10.2 Material Exclusions. The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I), lead/chromium based paints, or asbestos/mercury containing materials.

Mercury is prohibited, unless specified otherwise, and with the exception of mercury vapor lamps and fluorescent lamps. Dumping of mercury-containing materials and devices such as mercury vapor lamps, fluorescent lamps, and mercury switches, in rubbish containers is prohibited. Remove without breaking, pack to prevent breakage, and transport out of the activity in an unbroken condition for disposal as directed. Immediately report to the DGR and COR instances of breakage or mercury spillage. Clean mercury spill area to the satisfaction of the Contracting Officer.

Cleanup of a mercury spill shall not be recycled and shall be managed as a hazardous waste for disposal.

3.1.10.3 Universal Waste / e-Waste Management: Universal waste including but not limited to some mercury containing building products such florescent lamps, mercury vapor lamps, high pressure sodium lamps, CRTs, batteries, aerosol paint containers, electrical equipment containing PCBs, and consumed electronic devices, shall be managed in accordance with applicable environmental law and installation instructions

3.1.10.4 Pollution Prevention / Hazardous Waste Minimization: Minimize the use of hazardous materials and the generation of hazardous waste. Consult with the Environmental Office for suggestions and to obtain a copy of the installation's pollution prevention/hazardous waste minimization plan for supporting waste minimization goals

3.1.10.5 Safety Regulation Compliance. The contractor shall comply with standard OSHA and Watervliet Arsenal safety standards, including conforming to confined space work requirements when applicable.

3.1.10.6 Permits. The contractor shall provide a list of permits and certifications required by the agencies in Standards and Publications (Section 2.2) and those recommended by the general industry. The contractor shall also provide the information necessary to obtain required permits for the system.

3.1.11 Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

3.1.12 Worked to be Performed by Benét Labs. The contractor shall be responsible for all work associated with the installation unless otherwise stated. Upon receipt of the required installation and detailed foundation drawings (see 3.1.41.1), Benét Labs will coordinate with Watervliet Arsenal personnel to designate an installation site and outline a general machine location on the shop floor. Once the machine is installed, positioned and rough leveled by the contractor or their designated rigging crew, Benét Labs, with Watervliet Arsenal personnel, will run utilities (power and air) to first points of connection on the machine. Benét Labs must be provided with sufficient time to accomplish these connections. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon his arrival and continue under his guidance.

Note: If installation instructions, foundation requirements, and electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.41), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

3.1.13 Work to be Performed by the Contractor. The contractor shall be responsible for all costs and work associated with the installation unless otherwise stated. The contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Contractor personnel shall arrange for rigging services to off-load the machine and contractor personnel shall be on-site at Benét Labs when the machine arrives, and is off-loaded, to supervise the placement of the machine on the installation site by the rigging service. Rigging service suppliers should be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. In most cases neither Benét Labs, nor Watervliet Arsenal, forklift services and/or personnel will be available for the installation. Only propane powered forklifts are permitted and must also be equipped with a roll cage. Operators of forklifts shall have, and be able to produce, valid forklift licenses. Arsenal overhead pendant cranes (within load capacities) can be used by the contractor/rigging service for the machine installation. The contractor shall provide written certification to the WVA representative that all contractor/rigger personnel are qualified, through either formal training or experience per OSHA, to operate pendant controlled overhead cranes. Contractor personnel shall also adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields and safety shoes while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine. If necessary Benét Labs can provide the contractor with information for local rigging companies.

Once the machine is positioned and rough leveled by the contractor Benét Labs and/or Watervliet Arsenal personnel will run utilities to the machine. Benét Labs must be provided with sufficient time to accomplish these connections. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 & 4 and perform the required on-site training. The contractor and the service personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances should the contractor plan on gratuitous assistance from Benét Labs for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Benét Labs assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose equitable adjustment for the assistance. Approvals should not be taken for granted since there is no guarantee that appropriate Benét Labs personnel will be readily available. In such cases, Benét Labs will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Benét Labs personnel or equipment.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Benét Labs’ or the Watervliet Arsenal’s normal work days cannot be guaranteed. Both Benét and Watervliet Arsenal follow a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractors classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Benét Labs to ship miscellaneous material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

3.1.14 Utility Connection Labor: Benét Labs shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2 Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.2.1 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

3.2.2 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.3 Threads. All threaded parts, either US or SI, used on the machine and its related attachments and accessories shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein.

3.2.4 Gears. The gears shall be of proper width and size to transmit full-rated torque and horsepower without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.2.5 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.6 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.7 Painting. The machine shall be painted in accordance with the manufacturer's commercial practice. All paint shall be of the lead free type.

3.2.1.8 Workmanship. Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology. Shims that do not appear on the engineering drawings shall not be incorporated in the machine. Spacers that do appear on the engineering drawings are permissible.

3.3 Dimensions

3.3.1 Site Access for Delivery: The equipment shall be shipped either assembled or disassembled such as to pass through the freight elevator in Watervliet Arsenal’s Building 25, where this machine is intended to be installed. This freight elevator has a maximum volume of 139-inches wide by 112-inches high, and 178-inches in depth. Further disassembly may be required to pass through machine shop aisle ways. Benét Labs strongly recommends a site visit to determine clearances. Proposals that include machines which will not accommodate transport in this elevator will not be considered.

3.3.2 Component Weight: The maximum weight of any one piece, when installed, shall not exceed 18,000 lbs.

3.3.3 Installed Floorspace/Machine Envelope: There are strict machine envelope size and access restrictions on the second floor of Bldg. 25 at the Watervliet Arsenal, where this machine is intended to be installed. One consistent restriction in the building is the available interior height of 11’4” (limitations due to lighting, cranes, and electrical bus/wiring). The offered machine must adhere to this height restriction and the machine height shall include any over travel distances. There are also width and length restrictions that vary depending upon specific locations in the proposed building. The minimum width the machine must pass through on its way to the installation site is 8’ 4”. There are building pillars spaced 18’ apart that would potentially create a length restriction but this would depend on other factors as well. Therefore, for the machine being offered, please indicate in your proposal the total required WxLxH machine envelope including any ancillary equipment (ie., coolant/hydraulic / lubrication systems, electrical cabinets, mist collector, or chip conveyor). Please note that safety requirements dictate that a minimum 3 feet of clearance around the machine be maintained. It is strongly recommended a site visit be made to Benét Labs / Watervliet Arsenal to view the building limitations.

3.4 Components. The machine shall consist of not less than the following:

3.4.1 Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

3.4.2 Worktable. A four-sided hardened (56Rc) and fixed worktable shall support loads at the max rated capacity of the machine. The table surface shall be provided with threaded holes for securing the work piece. The table surface shall be machined flat and parallel to the X and Y axes in order to maintain the positioning accuracy specified. The worktable shall have a trough or similar means for draining the dielectric fluid into the reservoir/filter. The machine shall include a door for access to the cutting area, and be angled to allow crane accessibility for overhead loading of worktable.

3.4.3 Wire Guide Column: Please ignore, does not apply.

3.4.4 Dielectric System. The dielectric system shall supply an adequate amount of dielectric fluid to the cutting area to maintaining stable operating temperatures and conductivity levels in order to efficiently run at the highest cutting rate and surface finish. Control over the dielectric shall.be both manual and automatic. The system shall pr9videmeans for recirculating the dielectric fluid and have a self-contained filter system, which is easily cleaned and serviced. The filter system shall include a minimum of four (4) spare replacement filters. The filters shall remove all particulates down to three (3) μm (microns). Means shall be provided to contain the spillage of dielectric fluid at the cutting area. The dielectric system shall be closed loop, completely assembled unit that is easily accessible for maintenance purposes.

3.4.5 Controller Features. The machine controller shall consist of a MITSUBISHI M700 series control or equivalent. The control unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be independent and shall have independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, linear and circular interpolation, programmable interface, part program and buffer edit capability, part program storage, fixed cycles, and control diagnostics. The controller shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and end signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits. The controller shall also provide, but not be limited to the following features:

A. Collision protection B. Glass scales C. Tri-color warning light (stack light) D. 15" color touchscreen monitor E. 3-D automatic part pickup and skewing for part alignment and level compensation F. All manuals, maintenance procedures and reminders exist digitally on the controller G. Automatic finding for: comer, center of hole, center of slot and edge H. Automatic wire offset I. Automatic power restart J. Battery Backup K. Display of the wire center path along a two (2) or 3-D path L. Dry run movement M. Emergency Stop N. Inch/metric switchable data selection O. Incremental/absolute programming P. Linear and circular interpolations Q. Mirror image X and Y axes R. Part scaling S. Part rotation T. Reference point return U. Ethernet connectivity V. RS-232 serial program data input interface ports W. Decimal point programming X. Menu driven Y. Parametric programming Z. Feedrate programming - IPM/MMPM AA. Software functions shall be menu driven with interactive conversational prompting to allow for programming at the machine control unit (MCU) through the QWERTY key board.

BB. Program edit, change, add and block delete CC. Sequence number search forward and backward DD. Reference zero (all axes home position) EE. Floating zero FF. Key lock for programming edit GG. Plus and minus programming HH. Programmable macros II. · Programmable dwell JJ. Wire break alarm KK. Subroutines LL. High-Speed No-Flush machining MM. Orbit speed variation relative to remaining stock in cavity NN. High speed positioning and plotting OO. Automatic alignment and pick-up routines

3.4.7 Remote Pendant A hand held pendant control shall be provided which provides manual positioning control of all axes at selectable feed rates. The pendant control shall be connected to the machine in a method which enables the operator to control machine functions while in a close observation position. The control pendant functions shall include but not limited to the following;

A. Machine stop B. Axes Jog (X, Y, Z, U and V) C. Axes positioning; increase/decrease (X, Y, Z, U and V) D. Positioning by means of an electronic handwheel E. Emergency Stop

3.4.8 Hydraulic System. The hydraulics system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.4.9 Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping or valves, fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air within the Benét Labs Manufacturing Prototype Center is 85 psi. The machine shall also be equipped with devices (ie. air dryer) to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

OFFEROR IS TO STATE REQUIRED AIR REQUIREMENTS FOR OFFERED MACHINE (AIR PRESSURE, FLOW RATE) AND IF EXTERNAL EQUIPMENT IS REQUIRED (COMPRESSOR, AIR DRY, OR FILTERS)

3.4.10 Electrical System. The machine shall conform to NFPA 79. The electrical system shall be complete. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only.

3.4.10.1 Arc Flash. All electrical enclosures shall be marked for arc flash hazard per NFPA 79.

3.4.10.2 Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA M G-1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number. Motor horsepower shall be the manufacturer's standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.4.10.3 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capacity. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.4.10.4 Electrical. The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC to the fused or breaker type disconnect switch required in the electrical disconnect paragraph (3.1.14.3). However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

OFFEROR IS TO STATE REQUIRED POWER/ELECTRICAL REQUIREMENTS FOR OFFERED MACHINE (VOLTAGE, FULL LOAD AMPS, KVA). See Attachment C and complete as much as possible

3.4.10.5 Electrical Conversion Equipment / Transformers: If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be furnished with the machine by the contractor. All transformers must meet NEMA TP 1-2002 energy efficiency requirements. Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load. See Attachment D for additional transformer requirements.

3.4.10.6 Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.4.10.7 Work Area Lighting: The enclosure shall include a sufficient number of light fixtures conveniently mounted in the work compartment to provide illumination to the work piece and entire work area when all safety shields are closed and machine is operating. The lights shall be LED type with water proof construction to resist penetration of coolant. On/Off control should be at the operator’s station. The light shall be prewired and fused. The light(s) shall be capable of illuminating the entire machine work area, and shall be constructed to meet environmental conditions inherent to machining operations. Operation voltage shall be nominal 115 VAC.

3.4.10.8 Utility Outlet: The machine shall be provided with an operational 120volt AC singlephase, 20-ampere dualreceptacle 3wire utility outlet. This outlet shall be protected by a groundfault interrupter and shall be externally mounted and easily accessible. A “noise" suppression device shall be provided.

3.5 Machine Size, Capacity, and Capability Specifications. The size, capacity, and capabilities of the machine shall be not less than specified in Table I.

Table I. Unit Specifications

3.6 Accuracy Tolerances. The accuracy tolerances of the machine shall be as specified in Table II.

Accuracies

Table II: Accuracy Tolerances

3.7 Standard Equipment. All standard equipment required for proper operation of this machine (such as special tools) shall be furnished.

3.8 Accessories. The following accessory items shall be included with the machine:

3.8.1 High Speed Rotating Spindle: A high-speed rotating spindle shall be included for use in starting small starter holes

3.8.2 Tool Holder: A rack-type five tool (5T) Position MACRO Tool Holder shall be included.

3.8.3 Programmable Flush The machine shall include the ability to perform a programmable flush routine.

3.8.4. Alignment and centering device for wire guide system

3.8.5. Chiller for dielectric fluid

3.8.6. The machine shall include, separately, a post-processor for use in DP Technology’s ESPRIT CAM software. Installation and configuration of the mill shall include two days of on-site post- processor consultation.

3.9 Quick Start Tooling Kit The following items will be included as a quick startup kit enabling the user to begin using the machine without delay:

3.9.14 Collet chuck equivalent to 3R-659.32-P, with flushing duct, for electrodes size 2-20mm

3.9.15 High dielectric strength electric discharge machining fluid, type “8010 EDM Super Supreme”. Qty. 2 barrels, 55 gallons each.

3.10 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.10.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

· Points of lubricant application

· Servicing interval

· Type of lubricant

· Viscosity

· Military or Federal Specification for each lubricant (If available)

· Size and type of each lubricant filter

3.10.2 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

· Nomenclature

· Manufacturer's name

· Manufacturer's model designation

· Manufacturer's serial number

· Power input (volts, total amps, phase, and frequency)

· Government Contract Number ·

· Date of manufacture

· Weight

3.10.3 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text.

3.11 Technical Data. One (1) hard copy and two (2) electronic copies of technical data shall be provided with each machine. All software documentation provided from the software manufacturer shall be included. The technical data shall include software, hardware and all configurable items. A complete system backup of the machine controller and PC CAM workstation shall be provided. All copies of technical data shall be legible and written in the English language. Technical data shall contain:

1) technical information

2) machine specifications

3) instructions for operation of machine

4) instructions for maintenance of the machine

5) electrical schematic

6) recommended spare parts list

7) lockout/tagout procedures

8) Procedure to backup and restore the machine controller shall be provided.

3.11.1 Installation Drawings. The Contractor shall supply with bid proposal a dimensioned cad file compatible with Auto Cad 2015 ( dwg). The cad file shall show footprint of new equipment to include ancillary pieces, utility connection points, access doors and required maintenance clearance dimensions. Cad file shall also show side and elevation views. File will be used by the govemment to verify equipment will fit into the allotted space.

3.11.2 Instrument and Calibration Procedures. Calibration procedures and/or tooling requiring operator verification or recalibration as part of a production run or on a daily or periodic basis shall be provided to the Govemment. The contractor shall provide a list of these items at the time of proposal. All items provided shall have a certificate of calibration traceable to the National Institute of Standards and Technology (NIST).

3.11.3 Lockout/Tagout. A written procedure for locking out all energy sources shall be provided in accordance with 29 CFR 1910 .14 7. The written procedure shall be provided to the Government in electronic format (Adobe PDF or Microsoft Word).

3.12 Training. Within 10 days of satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is an American citizen of good standing and repute and proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be conducted on consecutive working days between the hours of 0645 and 1530 excluding any federal holidays and weekends. The course shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and hands-on portions. All printed training aids shall be provided for the course, be in the English language, and become the property of the Government.

3.12.1 Operation/Programming Training. The contractor shall conduct a minimum of 4 days of on-site training for up to four (4) operators. The training shall include instruction and demonstration of both machine operation and programming of the control unit, as well as use of unique features and/or accessories provided.

3.12.2 Off-Line Programming Training. The contractor shall conduct five (5) days of off-site training for up to two (2) machinists on use of the off-line programming software. Training is to be conducted within two weeks after completion of the operator/programming training.

3.12.3 Electronics Maintenance. The contractor shall provide a three (3) day electronics maintenance training course for electronics maintenance of the electrical discharge machine. Maintenance training shall be conducted either on-site at the receiving activity or at the contractor's designated facility. Training shall be provided for two (2) personnel. If maintenance training is to be conducted at the contractor's designated facility, the receiving activity shall be responsible for travel, lodging and meal expenses associated with attending the training courses. Maintenance training shall be scheduled so as not to interfere with Federal Holidays.

3.12.4 Mechanical Maintenance. The contractor shall provide one (1) day mechanical maintenance training course for mechanical maintenance of the electrical discharge machine. Maintenance training shall be conducted either on-site at the receiving activity or at the contractor's designated facility. Training shall be provided for two (2) personnel. If maintenance training is to be conducted at the contractor's designated facility, the receiving activity shall be responsible for travel," lodging and meal expenses associated with attending the training courses. Maintenance training shall be scheduled so as not to interfere with Federal Holidays.

3.13 Requirements for Demonstration of Conformance and Machine Acceptance Upon installation, the contractor shall demonstrate conformance of the machine tool to the accuracy and repeatability specifications called out in table II within section 3.6 (this section has been clarified in revision 6 of this document).

3.13.1 Report of Results: The contractor shall provide a report of conformance results testing in paragraph 3.4.1.

4.0 QUALITY ASSURANCE.

4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance. All items shall meet all requirements of sections 3 and 4.

4.2 Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions between 55° F to 100° F and 10% to 95% relative humidity.

4.3 Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the machine to ensure conformance…