DRAFT_-_WVA_SOW_36-17-3408_-Two_New_Horizontal_Machining_Centers_-_Sources_Sought.docx

Equip Engr Spec # 36-17-3408 Dated 17 November 2017 Specification for New Horizontal CNC Machining Centers

Spec. # 36-17-3408 Rev. A

Manufacturing Engineering Work Group Watervliet Arsenal Watervliet, New York 12189 11/17/2017

Department of the Army

TACOM

Table of Contents

1. Scope

2. Applicable Standards and Publications 2

3. Requirements

4. Quality Assurance Provisions

5. Preservation, Packaging and Delivery Instructions 18

6. Instructions for Preparing Technical Offers 19 1.

Scope:

1.1 Abbreviated Description. This specification defines the requirements for Two New 4- axis CNC Single Spindle Horizontal Machining Centers. The machining centers’ tables shall come with built-in, full contouring rotary tables. The machine shall be equal in capability to or better than a Haas Model EC-1600ZT as specified by this document. The contractor must be able to deliver the machine as specified within 4 months of contract award.

1.2 Preparation of Proposals. Section 6 of this specification entitled "Instructions to Offerors" includes detailed instructions meant to assist offerors in making their technical proposals. Prospective offerors are advised to read section 6 carefully and completely since failure to do so and to follow the instructions and guidance therein introduces a real risk that their proposals will be classified as unacceptable.

1.3 Procurement of More Than One Machine. In this specification, requirements and terminology may be oriented toward the purchase of a single machine tool. However, this procurement is for two machine tools, as such, it shall be assumed that each requirement applies to each machine unless otherwise stated.

2. Applicable Standards and Publications. All work performed and procedures followed in association with this project shall meet or exceed all applicable and current 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.

3. Requirements. All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

3.1 General Requirements.

3.1.1 Design and Engineering. The machine shall be designed and engineered in accordance with latest standards recognized or adopted by the Association for Manufacturing Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use.

3.1.2 Materials. Materials incorporated in the construction of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability.

3.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.3.1 Alignment Retention. Nonintegral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of accidental dislocation.

3.1.4 Slideway Design and Construction. All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Please state in your proposal details of the way system being offered.

A. Integral cast iron ways shall be hardened to RC 50 to RC 54 to a depth of .100 inch or more.

B. Hardened and ground steel ways for mating with Turcite, Rulon or other such low friction forgiving materials shall be hardened within the range of RC 55 to RC 62. Actual hardness within this range shall not very more than 5 RC points.

C. Hardened and ground steel ways for use with antifriction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more. Slideway systems other than the three (3) referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.1.4.1 Replaceable Ways. If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.1.4.2 Way Wipers. All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall also be easily removable and replaceable.

3.1.5 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.

3.1.5.1 Shimming. Shims that do not appear on the engineering drawings shall not be incorporated in the machine.

3.1.5.2 Spacing. Spacers that do appear on the engineering drawings are permissible.

3.1.6 Maintainability. All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement or adjustment as applicable. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

3.1.7 Interchangeability. All parts bearing the same part number shall be functionally interchangeable.

3.1.8 Applicable Power Source. The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. OFFEROR IS TO STATE REQUIRED POWER/ELECTRICAL REQUIREMENTS FOR OFFERED MACHINE (VOLTAGE, FULL LOAD AMPS, KVA, ETC.). See Attachment C and complete.

3.1.8.1 Electrical Safety Devices. The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plugin circuit breakers or currentlimiting fuses are not acceptable.

3.1.8.2 Conversion Equipment. 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.

3.1.8.3 Motors. All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. All motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service. Each motor shall bear an identification plate containing, as a minimum, the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency and frame or mounting. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 hp or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 Hp or greater shall be of the high efficiency type.

Note: All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

3.1.8.4 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.1.8.5 Utility Outlet. The machine shall be provided with an operational 120volt 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.

3.1.9 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment D and comply as applicable.

3.1.9.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent state, federal, local laws and regulations.

3.1.9.2 Protection of the Machine. The machine shall be fully equipped with the devices necessary to prevent selfdamage in the event of malfunction and/or ordinary operator negligence insofar as practical.

3.1.9.3 Noise Levels. The government's preference is to achieve noise levels not in excess of 80 dba and shall be accomplished at no additional expense to the Government. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities (see 3.4.1.2), and shall be measured at any or various times during this test at the discretion of the Technical POC or other appointed representatives. Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a properly calibrated sound level meter set for "A" weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the proper operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.1.9.4 Ozone Depleting Substances. Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozonedepleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. All shall be replaced by new functionally equivalent substances or systems, that are approved for use by the Environmental Protection Agency (EPA) and have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: OzoneDepletionPotential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC11, CFC12 and CFC 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

3.1.9.5 Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

3.1.9.6 LeadFree and ChromiumFree Paint Certification. All paints and primers applied to the system shall be certified as lead free and chromiumfree. Lead based paint is paint that contains more than nine thousandths of one percent (0.009%) lead by weight. This certification shall be provided prior to machine delivery.

3.1.9.7 PCBFree Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection (see section 3.4), these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and its equipment shall be certified as PCBfree prior to being shipped.

3.1.9.8 Lockout/Tagout Procedures. The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.10 Identification Plate. A corrosionresistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and total amps) Government Contract Number Date of Manufacture

3.1.11 Lubrication. The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon Inc. Gearboxes or transmission cases shall be lubricated by the wetsump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Systems of the foregoing types are considered automatic systems and they shall be equipped to be fail safe to the maximum extent possible. Any sensors or other devices used to detect the presence (or absence) of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods (e.g. Grease fittings, oil cups etc.) are permissible for lubrication points not practically served by automatic systems. For nonrecirculating automatic systems (such as slideway lubrication), the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems (such as pressure spray), easily cleanable or replaceable filtration devices shall be provided. Wetsump type systems shall be equipped with means to confirm proper oil level. Sight gages, if used, shall be of the external standing tube type rather than the flushmounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.1.11.1 Lubrication Plate. A lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

3.1.11.2 Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor is requested to 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, at time of machine delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.12 Hydraulic System. Hydraulic systems provided shall be sized and powered for the intended application and shall conform industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120° F in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure as well as underpressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, antisurge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

3.1.13 Painting. All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromiumfree and leadfree. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semigloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.1.14 Machine Hold Down and Leveling. The machine base shall be provided with sufficient and properly located holes for positive holddown when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended holddown and leveling hardware.

Note: All holddown and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

3.1.15 Gears. All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.1.16 Handwheels. Where power feed and/or rapid traverse of a machine component is provided or specified, associated handwheels or cranks, if any, shall not rotate when power feed or rapid traverse is engaged.

3.1.17 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

a. Foundation Drawings, Standard or Special (see note): Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award or at least 210 days prior to scheduled delivery of the machine. All drawings shall be dimensioned in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

Note: Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specificallyshaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc. Important: See instruction par. 6.5

b. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in AutoCAD .dwg or .dxf format shall be provided on a CD. This plan shall depict the complete machine space envelope including all ancillary equipment and the dimensioned bolt-hole pattern of the holddown bolts for the machines. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power including the full load amperage requirements, air, water, etc.) required to operate the machine. This data shall be furnished as soon as possible after contract award or at least 210 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. Also, if a foundation is required for the offered machine then this drawing shall also clearly depict the outline of the foundation and provide locating dimensions from a fixed point on the machine to at least one corner of the foundation. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

c. Catalog of Standard Tooling and Accessories shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (two hard copies)

d. NonStandard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format.

e. Installation Instructions and Drawings containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished as soon as possible after contract award or at least 210 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format.

f. Lubrication Diagram or Instruction. To be delivered at time of machine delivery. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color.

g. Operating Instructions. These instructions shall be in provided in separate manuals from other technical data provided. To be delivered upon machine delivery. Four hard copies and one electronic copy.

h. Maintenance and Troubleshooting Instructions for all machine systems. This material shall also include the machines mechanical assembly drawings. To be delivered at time of machine delivery. Two reproducible hardcopies and two electronic copies on CD in AutoCAD .dwg or .dxf format of the machines mechanical assembly drawings.

i. Electrical and hydraulic schematics to be furnished. To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

Note: If, during installation and testing, the actual electrical and/or hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "AsBuilt" schematics shall be a condition of final acceptance.

j. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be furnished not later than 30 days prior to delivery of the machine. (two hard copies)

k. Programming Manuals. Where a CNC machine is offered or specified, programming manuals shall be supplied. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented and usable on the system offered or specified. These manuals shall be delivered at machine delivery. (two electronic copies)

l. Software Documentation. The offeror shall provide documentation of all system software and/or ladder logic developed to control and interface the new control/drives with the existing machine tool. One hard copy and two electronic copies. . To be delivered to the technical POC 30 days after final acceptance of the machine. Two copies of the system memory backup (S-Ram) shall be provided on seperate compact flash drives at startup of the machine.

3.1.18 Training Required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal" and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Hydraulic maintenance (if applicable)

Spindle/Axes Drives (if applicable)

Note: For all types of training, the associated technical data (see 3.1.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A training schedule showing the hours of training for each person under their assigned category, shall be sent in with proposals for review.

3.1.19 Repair/Replacement Parts and Service. The offeror shall also agree to provide parts and/or service for the contracted equipment within 72 hrs of notification of a problem. The offeror further agrees, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and be sufficient in detail to permit successful acquisition of the parts and associated repair service. In the event of a national emergency the U.S. Government reserves the right to obtain the data and use it to support operation of the machine tool(s) purchased under this contract.

3.1.20 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 80 psi and if higher or lower pressure is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 80 psi supply pressure. The machine shall also be equipped with devices 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 80 psig.

3.1.20.1 Air Booster Unit. If the machine offered requires more than 80 psi at a particular volume then an air booster unit shall be provided with the machine. If necessary, an accumulator tank shall be provided with the booster. Please state in your proposal what the machine requirements will be and if a booster and tank will be required. Installation shall be provided by the contractor. If the use of an air booster is not possible and an air compressor is required, the contractor must state this in their proposal and provide justification detailing CFM, psi, application, and duration of air usage.

3.1.20.2 Air Dryers/Filtration. The Arsenal’s preference is for the machine to not utilize a refrigerated air dryer. Only if deemed necessary by the contractor, shall the machine be provided with an appropriately sized refrigerated air dryer system complete with input and output filter cartridges. The contractor shall state in their comply sheet the reason why a refrigerated air dryer is necessary. Industrial air dryers are to be of the latest technology that will result in the most energy efficient design such as advanced heat exchangers, use of heat sink reservoir to allow on/off cycling, reduce pressure drop by use of multi-pass flow patterns, and alternative configurations such as desiccant media. Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35° F pressure dew point, minimum, from air entering the equipment at 110° F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor. All designs are to be supplied by manufacturers participating in the CAGI Refrigerated Dryer Performance Verification Program and have been tested and rated in accordance with CAGI ADF 100. Power for the refrigerated air dryer unit shall be 110 V AC and shall be wired and powered through the machine electrics. Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS HSE and Ingersoll-Rand D31NC models.

3.1.21 Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.1.22 Control of Cutting Fluids. If the machine is equipped with a coolant system, the contractor shall insure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine or leaking to the floor when producing workpieces of a size within the machine's normal working range. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leakproof metallic or nonmetallic liner.

3.1.23 Site Conditions. The machine covered by this specification will be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65° F to 95° F and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4° F per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying whatever is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.1.24 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine wherever it is needed to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable.

3.1.25 Chip Removal. An automatic chip removal unit shall be provided to convey chips of any material from the machine to an external container without manual aid. The unit shall be reversible to facilitate clearing of blockages. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The unit shall operate successfully in a variety of machining environments including drycutting, machining with cutting oils and machining with waterextendable oils. Automatic means shall be provided to return cutting fluids to the machine's coolant tank which shall be separate from the unit. The chip removal unit shall be engineered for the machine so that when fully installed in accord with instructions all points subject to periodic maintenance and lubrication shall be externally accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself.

3.1.26 Machine Installation, Startup and Testing.

3.1.26.1 Work to be Performed by the Arsenal. This project is classified as a turn-key with the contractor being responsible all work associated with the installation unless otherwise stated. Upon receipt of the required installation and foundation drawings (see 3.1.17), Watervliet Arsenal will 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 Watervliet personnel will run utilities (power and air) to first points of connection on the machine. Watervliet 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 drawings and electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.17), 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.

3.1.26.2 Work to be Performed by the Contractor. This project is classified as a turn-key with the contractor being 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. Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall layout and core drill the holes for the machine anchor bolts. Please note that the majority of the Watervliet Arsenal’s shop floor is covered with 2” thick wood block. It shall be the contractor’s responsibility to cut out and remove wood block and to supply and install any leveling pads necessary for installation. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services 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 no Arsenal forklift services and/or Arsenal 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 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(s). Watervliet does not have the resources to provide such material. Crane capacity within each building is limited (2, 5, 10 or 15 tons) and therefore if not adequate then the contractor will need to provide alternate means necessary for the installation. Specific building crane capacities where the equipment is to be installed should be verified with the WVA technical POC.

Once the machine is positioned and rough leveled by the contractor WVA personnel will run utilities to the machine. Watervliet 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 Arsenal assistance 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 Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenalfurnished equipment.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on 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. Contractor’s classified as foreign nationals may further restrict work hours and days available.

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

3.2 MachineSpecific Requirements.

3.2.1 Machine Tool Description. The Two (2) New CNC Single Spindle Horizontal Machining Centers covered by this specification shall be equal to or better than a Haas Model EC-1600ZT and shall be provided with a built-in, full contouring rotary table. Offered machines must meet or exceed the following characteristics.

3.2.1.1 Required Characteristics.

Travels:

Table:

4th axis Rotary:

Spindle:

Axis Motors:

Feedrates:

Tool Changer:

Accuracy & Repeatability:

Alignments:

General:

3.2.2 Other Required Characteristics.

3.2.2.1 Through-Spindle Coolant. The machine shall be supplied with all devices and equipment to deliver through-spindle, high pressure coolant at 1000 psi.

3.2.2.2 Auxiliary Coolant Filter System. The machine shall be equipped for with an auxiliary coolant filter system and use a 25-micron filter.

3.2.2.3 Renishaw Work Offset and Tool Probe System. The machine shall be complete with all hardware and software for a Renishaw work offset and tool probe system. Provided for CT50 tooling and shall include tool probe, transmitter, spindle orientation, macros, and coordinate rotation and scaling. Installation and training shall be included.

3.2.2.4 CT50 Pull Studs. The machine shall be provided with forty eight (48) CT50 pull studs for through-spindle coolant.

3.2.3 Other Requirements.

1. Automatic Belt Type Chip Conveyor.

2. Flush and Washdown Coolant System.

3. Remote Jog Handle.

4. Door-activated High Intensity Lighting.

5. Drive and wiring for 5th-axis.

6. Anchor Kit.

7. Expanded Memory to 64GB.

8. Oil-Skimmer

9. Home Button for User-Defined 2nd Home Position.

10. High-Speed Machining with Look Ahead Feature.

11. Keyswitch Memory Lock for Front Pendant.

12. User Definable Macros.

13. Spindle Orientation.

14. Tool Cart – Double sided rolling tool cart for use with various tool holder trays, tool boxes, etc.

15. Front Table - 2 shelf unit attaches to existing tool rack system on front of machine

16. Early power failure detection module that senses power failure and prevents the spindle from dropping protecting the workpiece and cutting tool from damage.

17. Pendant Glove box.

18. Visual Quick Programming system for horizontals.

19. Spare M-functions (at least 8)

20. Eight (8) Tool Trays for 50 Taper Toolholders.

21. Dynamic Work Offsets and Tool Center Point Control

22. Programmable Coolant Nozzle.

23. Minimum Oil Machining System.

24. Enclosure Exhaust System.

25. Service Manuals

3.3 Operator's Console. The CNC console shall house everything necessary for communicating with the control and operating the machine. This shall include at least the visual display, keyboard and disk drive. An emergency stop button shall also be located on the console. The control system shall have a means to connect to and communicate with the WVA’s network and/or DNC system. This communication shall be via RS232 with external DB9 connection, with cover. The contractor shall supply the appropriately configured DB9 connector (null modem or straight through) to communicate with the Arsenal’s “straight-through” cable. The machine shall come equipped with an Ethernet port and MT Connect adapter to allow the WVA to network the machine.

3.4 Requirements for Demonstration of Conformance.

3.4.1 Certification, Drawings and Tests Required. After delivery and installation the contractor shall demonstrate to WVA machine inspection personnel the machine alignment characteristics. Copies of the results of ball bar, laser accuracy, and alignment characteristics shall be provided for WVA records.

3.4.1.1 Certification of Completeness. The contractor shall provide written certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements.

3.4.1.2 Test of Conformance to Specified Performance Characteristics. The machine shall be dry cycled at least 30 minutes, during which time the machine shall be tested for conformance to specified performance characteristics, including but not limited to, feeds, speeds and manual as well as automatic cycling.

3.4.1.3 Test of Conformance to Specified Alignments and Accuracies. The machine shall be tested for conformance to the accuracies and alignments specified in paragraph 3.2.1.1. The contractor shall perform a bi-directional ball bar test and bi-directional laser accuracy test per ISO 230-2 and submit results to the Arsenal for inspection.

3.4.2 Provision of Materials and Equipment for Preliminary and Final Acceptance Testing.

3.4.2.1 Tooling. All cutting tools (perishable, non-perishable, & special) and toolholders required to perform the tests specified in section 3.4 shall be furnished by the contractor and shall become the property of the Arsenal.

3.4.2.2 Cutting Fluids. Any cutting fluids necessary to perform the tests specified in paragraphs 3.4 shall be furnished by Watervliet for the final acceptance.

3.4.2.3 Hydraulic Fluids and Lubricants. All hydraulic fluids and lubricants necessary to perform any of the required tests shall be furnished by Watervliet for final acceptance.

3.4.2.4 Testing and Measuring Equipment. All testing and measuring equipment, including fixtures, needed to perform any of the required tests and measure the results shall be furnished by the contractor and shall be properly calibrated to standards traceable to the National Institute of Standards and Technology (NIST).

4. Quality Assurance Provisions.

4.1 Responsibility for Inspection. The contractor shall be responsible for performing all certifications and tests required in paragraph 3.4 and shall provide such materials, supplies and equipment as are specified in paragraph 3.4.2.

4.2 Preliminary Acceptance Inspection. N/A.

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection.

4.3.1 Examination for Completeness. The contractor shall furnish the Arsenal's representatives with a certification of completeness (see par. 3.4.1.1). The Arsenal's representatives will reserve the right to examine the machine to ascertain the presence of all specified features, equipment, markings and safety devices.

4.3.2 Examination of Performance Characteristics. During the test of conformance to specified performance characteristics (see par. 3.4.1), the Arsenal's representatives will observe the machine and its equipment for proper operation. Also during this test, the Arsenal's representatives may perform independent measurements of sound levels for conformance to par. 3.1.9.3.

4.3.3 Examination of Alignments and Accuracies. During the test of conformance to specified alignments and accuracies (see par. 3.4.1) the Arsenal's representatives will observe the performance of the test and reserve the right to review the results obtained.

4.3.4 Supplementary Tests and Examinations. The Arsenal's representatives reserve the right to ask for demonstration of any specified feature or machine alignment characteristics not demonstrated during the tests conducted in accord with paragraphs 4.3.1 through 4.3.4.

4.4 Final Acceptance Inspection. The machine will be required to pass all tests specified. In addition a safety review will take place during final acceptance at WVA to test all safety features and devices for proper working order.

4.5 Warranty. Upon final acceptance of each machine a Standard Commercial Warranty shall commence for a duration of One Year, to include as a minimum, parts and labor for the duration of the warranty, at no cost to the Government. The one year period shall commence from the date of notification by the Contracting Officer of the final acceptance of each machine. Final acceptance is defined as the act of an authorized representative of the Government, by which the Government assumes ownership of existing supplies/equipment and/or approves specific services rendered, as partial or complete performance of the contract (i.e. testing, training, and delivery of all required technical documentation).

5. Preservation, Packaging and Delivery. The contractor shall utilize standard commercial methods of preservation and packaging appropriate for machine tools and acceptable to commercial carriers. As a minimum, all areas susceptible to damage from exposure to the elements shall be preserved and/or packed to prevent damage. The machine and equipment shall be blocked, braced and skidded to prevent damage during transport and to facilitate handling, loading and unloading.