AD 3.2- S9320-AM-PRO-020_MLDG REV 2.pdf

NAVSEA S9320-AM-PRO-020/MLDG REV 2

TECHNICAL MANUAL

UNDERWATER CABLE ASSEMBLY AND

ENCAPSULATED COMPONENTS, FABRICATION,

REPAIR, AND INSTALLATION MANUAL

VOLUME II

MOLDING AND INSPECTION PROCEDURES

FOR FABRICATING CONNECTOR PLUGS

FOR SUBMARINE OUTBOARD CABLES

SUPERSEDES NAVSEA 0962-LP-022-2011, NAVSEA SO 900-00-PRO-010/MLDG

AND NAVSEA S9320-AM-PRO-010/MLDG (JANUARY 1997)

APPENDIX II-E OF THIS DOCUMENT SHOULD BE USED IN LIEU OF MIL-M-24041.

DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR

CONTRACTORS ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE

REFERRED TO: COMMANDER, NAVAL SEA SYSTEMS COMMAND (CODE 03Z),

2531 JEFFERSON DAVIS HWY, ARLINGTON, VA 22242-5160

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

AUGUST 1999

THIS PAGE INTENTIONALLY BLANK TO ALLOW THE

DISTRIBUTION STATEMENT FOR THE ISSUANCE LETTER TO

BE INSERTED.

NAVSEA S9320-AM-PRO-020/MLDG REV 2

TECHNICAL MANUAL

UNDERWATER CABLE ASSEMBLY AND

ENCAPSULATED COMPONENTS, FABRICATION,

REPAIR, AND INSTALLATION MANUAL

VOLUME II

MOLDING AND INSPECTION PROCEDURES

FOR FABRICATING CONNECTOR PLUGS

FOR SUBMARINE OUTBOARD CABLES

SUPERSEDES NAVSEA 0962-LP-022-2011, NAVSEA SO 900-00-PRO-010/MLDG

AND NAVSEA S9320-AM-PRO-010/MLDG (JANUARY 1997)

APPENDIX II-E OF THIS DOCUMENT SHOULD BE USED IN LIEU OF MIL-M-24041.

DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR

CONTRACTORS ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE

REFERRED TO: COMMANDER, NAVAL SEA SYSTEMS COMMAND (CODE 03Z),

2531 JEFFERSON DAVIS HWY, ARLINGTON, VA 22242-5160

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

iv

LIST OF EFFECTIVE PAGES

This manual is a complete revision, which supersedes NAVSEA S9320-AM-PRO-010/MLDG, with an original date of January 1997.

Dates of issue for original and changed pages are:

Original August 1999

Page *Change No. No.

Title Page 0 List of Effective Pages 0 Revision Record Table of Contents 0 Foreword 0

Section I 0

Section II 0

Section III 0

Section IV 0

Section V 0

Appendix II-A Vendor Audit Requirements/List of 0 Approved Vendors

Appendix II-B Generic Assembly Traveler 0

Appendix II-C Preformed Inserts - Production and 0 Inspection

Appendix II-D Data Sheets for In-House Inspections 0

Appendix II-E Polyurethane System Requirements/ 0 Backfill Material Requirements/

List of Approved Products

Appendix II-F Test Inspection Report 0

*Zero in this column indicates an original page v

REVISION RECORD

REVISION

NO.

DATE

TITLE AND/OR BRIEF

DESCRIPTION

SIGNATURE

vi

TABLE OF CONTENTS

Paragraph Page

Issuance Letter.................................................................... i Title Page............................................................................ iii

List of Effective Pages iv Revision Record.................................................................. v

Table of Contents................................................................ vi Foreword viii

1 SECTION I

1-1 INTRODUCTION

1-1.1 Purpose 1-1.2 Scope 1-1.3 Applicability 1-1.4 Vendor Qualification

1-2 REFERENCES

1-3 PERSONNEL QUALIFICATION AND TRAINING

2 SECTION II

2-1 SAFETY AND ENVIRONMENTAL CONTROLS

2-1.1 Ventilation 2-1.2 Personal Protective Equipment 2-1.3 General 2-1.4 Electrical 2-1.5 Waste 2-1.6 Environmental Controls

3 SECTION III

3-1 EQUIPMENT REQUIREMENTS

3-1.1 Capital Equipment Required 3-1.2 General Equipment Required vii

3-2 MATERIAL REQUIREMENTS

3-2.1 Consumable Equipment & Material Requirements

4 SECTION IV

4 GENERAL MOLDING PROCEDURES

4-1 INTRODUCTION

4-2 INSPECTION REQUIREMENTS

4-2.1 Cable Inspection 4-2.2 General Connector Inspection 4-2.3 Mold Inspection

4-3 INDIVIDUAL COMPONENT PREPARATION

4-3.1 Generic Cable Preparation 4-3.2 MIL-C-24231 Style Connectors Cable Preparation 4-3.3 Shielded Cable Preparation 4-3.4 General Connector Preparation 4-3.5 Non-Conductive Coated (Plasma Spray Coated)

Backshells

4-4 CONNECTORIZATION

4-4.1 MIL-C-24231 Connector (MIL-C-24231 Style) 4-4.2 Crimp Style Connectors (MIL-C-24217, Others)

QA-1 VISUAL INSPECTION OF SOLDER JOINTS

QA-1.1 Quality Control Inspection QA-1.2 Continuity QA-1.3 Insulation Resistance viii

4-5 ENCAPSULATING (BACKFILL) INNER DIAMETER (ID)

OF CONNECTOR

4-6 PRIMING SYSTEM APPLICATION

4-7 MOLD PREPARATION

4-8 POLYURETHANE PREPARATION

4-8.1 Type I, Two Component Systems 4-8.2 Type II, Frozen Cartridges 4-8.3 Injection Process

QA-2 QUALIFICATION TESTING

QA-2.1 Visual Inspection QA-2.2 Electrical Continuity QA-2.3 Insulation Resistance QA-2.4 Non-Destructive Bond Tests QA-2.5 Hydrostatic Pressure Test

4-9 PRESHIPMENT INSPECTION

APPENDICES

II-A Vendor Audit Requirements/List of Approved Vendors................ II-A1 II-B Generic Assembly Traveler..................................…..................... II-B1 II-C Preformed Inserts – Production and Inspection............................ II-C1 II-D Data Sheets for In-House Inspections........................................ II-D1 II-E Polyurethane System Requirements/Backfill Material Requirements/

Lists of Approved Products ............................................................. II-E1 II-F Test Inspection Report.................................................................... II-F1 ix

FOREWORD

This document provides minimum generic guidelines, current technical references, and sample generic production support forms for:

Manufacture of all outboard submarine cable assemblies:

Molding Inspection Testing

Manufacture of preformed molded inserts:

Production Inspection

Generic “Shop Travelers” Generic “Data Sheets for In-house Inspection” Generic “Test Inspection Report” form Generic “Preformed Insert Production and Inspection” form Audit requirements for vendors Approved Vendor List

This manual is a complete revision, which supersedes NAVSEA S9320-AM-PRO-010/MLDG, with an original date of January 1997.

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of this NAVSEA technical manual. All errors, omissions, discrepancies, and suggestions for improvements to this NAVSEA technical manual shall be reported to NAVSEA.

SECTION I

1-1. INTRODUCTION.

1-1.1 Purpose. The purpose of this document is to provide minimum generic guidelines, current technical references, and sample generic production support forms for:

Manufacture of all outboard submarine cable assemblies:

Molding Inspection Testing

Manufacture of preformed molded inserts:

Production Inspection

Generic “Shop Travelers” Generic “Data Sheet for In-house Inspection” form Generic “Test Inspection Report” form Generic “Preformed Insert Production and Inspection” form Audit requirements for vendors Approved Vendor List (AVL)

Each manufacturer should use these forms as a basis to develop their own forms tailored to the particular cable assemblies in production. The resultant forms should contain at a minimum the items outlined in the generic forms and add the additional requirements of the technical references specified in this manual for the cable assemblies/components being produced.

1-1.2 Scope. These procedures apply to all outboard submarine cable assemblies.

1-1.3 Applicability. These procedures shall be used on all cable assemblies utilizing polyurethane molded boots.

1-1.4 Vendor Qualification: Only these vendors which are qualified, per the audit requirements of Appendix II-A, of this document and listed on the Approved Vendors List in Appendix II-A, shall be authorized to fabricate submarine outboard cable assemblies.

1-2. REFERENCES. The following documents, of the issue in effect, form a part of this procedure to the extent specified herein. Whenever the referenced documents conflict with this cable assembly molding procedure the molding portion of this document shall govern. Copies of these documents shall be maintained in the cable fabrication facility.

MILITARY SPECIFICATIONS:

MIL-C-22520 - Crimping Tools, Terminal, Hand or Power Actuated MIL-C-24217 - Connectors, Electrical, Deep Submergence, Submarine MIL-C-24231 - Connectors, Plugs, Receptacles, Adapters, Hull

Inserts & Hull Insert Plugs, Pressure-Proof, General Specification

MIL-I-16923 - Insulating Compound, Electrical, Embedding

MILITARY STANDARDS:

MIL-STD-129 - Standard Practice for Military Marking MIL-STD-202 - Test Methods for Electronic and Electrical Component Parts MIL-STD-1504 - Abrasive Blasting MIL-STD-2073 - Standard Practice for Military Packaging

DRAWINGS:

Applicable Mold Assembly Drawings Applicable Cable Assembly Drawings

OTHER:

Naval Ships Technical Manual S9086-KC-STM-000/Ch 300 Joint Industry Standard J-STD-001 Requirements for Soldered Electrical and Electronic

Assemblies Joint Industry Standard J-STD-006 Requirements for Electronic Grade Solder Alloys and

Fluxed and Non-Fluxed Solid Solders for Electronic Soldering Applications Occupational Safety and Health (OSHA) Safety Standards, Code of Federal Regulations

10CFR20

1-3. PERSONNEL QUALIFICATION AND TRAINING. Cable assembly fabricators shall establish and maintain a thorough, detailed training program based upon the techniques and procedures outlined within this manual for personnel charged with making up cable assemblies and for personnel charged with in-process and final inspection of cable assemblies. The training program shall be documented, and certification and qualification cited at the facility. All cable assemblies must be fabricated by qualified, certified personnel and inspected by qualified, certified personnel. This training/certification program shall be reviewed and conformance to this manual demonstrated during facility audits.

SECTION II

2-1. SAFETY AND ENVIRONMENTAL CONTROLS

2-1.1 Ventilation. Good ventilation is mandatory for all chemical processes. Adherence to all ventilation requirements specified in Material Safety Data Sheets (MSDS) is mandatory. Local, state, and federal guidelines/requirements, including 10CFR20 OSHA Safety Standards, should be strictly followed.

2-1.2 Personal Protective Equipment. Personnel shall wear required protective equipment as specified in the MSDS of the material being used. At a minimum, all chemical processes require personnel to wear rubber gloves, protective eyewear, and a lab coat/apron. Splashes or spills shall be washed from the skin immediately with soap and water.

2-1.3 General. No smoking, welding, or other source of open flame or sparks shall be allowed in close proximity of the molding operation. Although the polyurethane compounds and primers are flame resistant, the solvents are highly flammable or contain chlorinated hydrocarbons that decompose in fire to give off highly toxic gases.

Use safety cans for the transfer and storage of solvents. Do not leave solvent saturated rags in open areas; place them into safety waste cans immediately after use.

2-1.4 Electrical. Check all electrical equipment in accordance with the Electrical Safety Precautions of Section II of NAVSEA Technical Manual S9086-KC-STM-000/Ch 300.

2-1.5 Waste. Adherence to all local, state, and federal regulations, concerning wastes generated due to these procedures, shall be mandatory.

2-1.6 Environmental Controls. This section defines the minimum standards for working environments applicable to the molding of Navy outboard submarine cable assemblies.

The term working environment refers to those environmental factors that may affect the quality characteristics of the work in process. Those factors include:

a. Cleanliness: Requirements have been assigned to various work areas based on engineering judgment and the potential for contamination of work in process. The cable assembly molding area shall have floors, walls, and workspaces with easily cleaned surfaces. Residue and unused materials shall not be allowed to accumulate and require prompt clean up/stowage. Clean-up of equipment and work areas shall be accomplished on a daily basis.

b. Lighting: The lighting intensity of work areas has been found to affect productivity, error rate, and operator fatigue. Supplemental lighting shall be used when necessary to improve precision and minimize operator fatigue. The cable assembly molding area shall have a minimum of 100 foot-candles illumination; supplemental illumination may be utilized to realize this requirement at specific work stations.

c. Air temperature: These limits have been defined where the worker exerts a direct influence on product quality and have been defined based upon consideration of worker comfort, static electricity, and potential for corrosion. The dry bulb temperature taken during normal working hours at or near the workstations shall be 75ºF ±5ºF.

d. Relative humidity: Designated relative humidity shall be measured at room temperature in proximity to the workstations during regular work hours.

NOTE: The relative humidity shall be less than or equal to 50%.

e. Dust control: Outside air shall be filtered to remove dust particles. Filter shall have a minimum arrestance of 65%.

f. Ventilation or exhaust: Mechanical ventilation hoods with external exhaust shall be utilized to mix chemicals or vapor degrease, or when local environmental/safety and common sense dictate.

g. Noise: Hearing protection shall be provided in areas designated by the local Safety Office as High Noise Areas. The only area in a cable assembly molding facility that may pose a serious noise hazard would be a grit-blasting system.

h. Habitat: No food, drink, personal grooming material, or smoking material is allowed in cable assembly molding areas. No eating, drinking, personal grooming, or smoking is allowed in cable assembly molding areas.

SECTION III

3-1. EQUIPMENT REQUIREMENTS

3-1.1 Capital Equipment Required. The following is a list of capital equipment required to properly mold a cable assembly:

a. Proper mold assemblies, as required, by applicable specifications of cable assembly

b. Standard vacuum equipment capable of drawing a vacuum of less than 5mm (30 in) of mercury

c. Grit blaster

d. An accurate gram balance

e. Non-destructive bond test system

f. Hydrostatic pressure tank

g. If Type II urethanes (two-part, premixed, degassed, and frozen cartridges) are used, a freezer capable of maintaining the manufacturer’s recommended storage temperature and large enough to hold an adequate supply.

h. If urethanes requiring an oven cure are utilized, an oven capable of maintaining required cure temperatures and are large enough to accommodate the molding operation will be required.

3-1.2 General Equipment Required. The following is a list of general equipment required to properly mold a cable assembly:

a. A thermometer 0-220 °F

b. Soldering iron; soldering system

c. Rubber gloves

d. Safety eyewear

e. Lab coat/apron

f. Wire strippers

g. Diagonal cutting pliers

h. Metal/plastic spatula

i. Cable cutters

j. Ohmmeter

k. Megger

l. Box/Exacto knife

m. Round edge probe

n. Laboratory ring stands or equivalent

o. Heat gun

p. Calibrated crimping tools and dies

q. Pressure tank

3-2. MATERIAL REQUIREMENTS

3-2.1 Consumable Equipment and Materials Required. The following is a list of consumable equipment and materials required to properly mold a cable assembly:

a. Connector components as per applicable specification for Cable assembly (MIL-C-24231 or MIL-C-24217)

b. Polyurethane molding compound, as per Approved Products

List (APL)

c. Connector shell primer, as per APL and polyurethane manufacturer’s

TDS

d. Cable jacket primer, as per APL and polyurethane manufacturer’s TDS

e. Cleaning solvents: Acetone, Methyl Ethyl Ketone (MEK), or Isopropyl Alcohol (or equivalent)

f. Plug connector backfill material, as per APL

g. Thomas & Betts Shield crimp rings, or equivalent, (for shielded cables) with properly sized (to receptacle) jumper wire

h. Cable: as per cable assembly specification or drawing

i. Injection tube

j. Shrink sleeving - Per drawing/specification for cable

k. Non-acid resin flux

l. Tape or protective ring

m. Tags - Per cable drawing

n. Solder J-STD-006 (60/40, or SN63)

o. A clean, dry polyethylene or metal container, having at least three times the volume of material to be degassed

p. 1/2" wide bristle (acid) brushes

q. Pressure sensitive tape

r. Lint free cloths

s. Abrasive paper, 60-80 grit or equivalent

t. Non-silicone mold release

u. List of documents used during manufacture:

1. Cable assembly dwgs

2. Manufacturer’s instructions for primer preparation and use

3. Manufacturer’s instructions for mixing, degassing and curing of backfill material

4. Manufacturer’s instructions for mixing, degassing and curing of polyurethane

PROCEDURE NUMBER

TITLE

NAVSEA S9320-AM-PRO-020/MLDG

REV

MOLDING & INSPECTION PROCEDURES FOR

FABRICATING CONNECTOR PLUGS FOR SUBMARINE

OUTBOARD CABLES

PROCESS

PROCEDURE

MATERIAL

EQUIPMENT

4-1

GENERAL MOLDING PROCEDURES

INTRODUCTION

BECOME FAMILIAR WITH ALL REFERENCED SPECIFICATIONS, STANDARDS,

MATERIAL SAFETY DATA SHEETS (MSDS), AND THE CABLE ASSEMBLY

DRAWINGS FOR THE APPLICABLE SYSTEM.

PREPARE A SHOP TRAVELER FOR THE CABLE ASSEMBLY TO BE

FABRICATED. A SAMPLE GENERIC SHOP TRAVELER IS FOUND IN

APPENDIX II-B.

SHOP TRAVELER WILL ACCOMPANY CABLE ASSEMBLY AND BE UPDATED

THROUGHOUT FABRICATION PROCESS. IF CABLE ASSEMBLY FAILS TO

MEET REQUIREMENTS AT ANY POINT IN THE FABRICATION PROCESS,

NOTE FAILURE ON SHOP TRAVELER. REJECT AND/OR REPAIR, AS

REQUIRED. SHOP TRAVELER SHALL BE ANNOTATED AS A REWORK. AN

INSPECTION REPORT DETAILING CAUSE OF FAILURE, REWORK PROCEDURE

PERFORMED AND TESTING DONE TO SATISFY THE DISCREPANCY SHALL BE

ATTACHED AS WELL. CONTINUE FABRICATION PROCESS.

IF CABLE ASSEMBLY IS REJECTED AS BEING NON-REPAIRABLE, NEW CABLE

ASSEMBLY SHALL BE STARTED WITH NEW SHOP TRAVELER MAINTAINING

TRACEABILITY.

VERIFY THAT ALL CONSUMABLE MATERIALS ARE AVAILABLE,

WITHIN SHELF LIFE, AND MEET THE REQUIREMENTS OF THE

APPLICABLE TECHNICAL DATA SHEETS (TDS).

4-1

(CONT’D)

ANY DISCREPANCIES BETWEEN THE MOLDING MANUAL AND THE

APPLICABLE DRAWING SPECIFICATIONS SHOULD BE NOTED ON THE SHOP

TRAVELER. MOLDING MANUAL SHALL TAKE PRECEDENCE DURING

FABRICATION PROCESS ONLY.

ALL TEST REQUIREMENTS SHALL FOLLOW REQUIREMENTS OF APPLICABLE

DOCUMENTS. IF NOT SPECIFIED ELSEWHERE, MINIMUM TEST

REQUIREMENTS OF THIS MANUAL SHALL BE MET.

4-2

4-2.1

INSPECTION REQUIREMENTS:

CABLE INSPECTION (RECOMMENDED)

VISUALLY INSPECT BULK CABLE ON THE REEL TO DETERMINE THAT THE

CABLE MEETS REQUIRED SPECIFICATION AND IS THE TYPE REQUIRED BY

THE APPLICABLE CABLE ASSEMBLY DRAWING.

COMPLETE AND SIGN DATA SHEET (DS1), APPENDIX II-D, FOR THIS

SECTION.

REMOVE THE REQUIRED LENGTH OF CABLE FROM THE REEL.

IT IS RECOMMENDED THAT THE CABLE ASSEMBLY FABRICATOR INSPECT

THE ENTIRE LENGTH OF THE CABLE JACKET FOR IMPERFECTIONS. IF ANY

IMPERFECTIONS ARE FOUND, CUT NEW CABLE. REPEAT INSPECTION.

STRIP EACH END OF THE CABLE DOWN TO THE BARE WIRE SUFFICIENTLY

TO EXPOSE ENOUGH WIRE TO PERFORM ELECTRICAL TESTS.

PERFORM CONTINUITY TEST ON EACH CONDUCTOR AND/OR SHIELD

(Limit ≤ 1 Ω, OR AS REQUIRED BY CABLE SPECIFICATION OR CABLE

ASSEMBLY DRAWING).

CABLE

CABLE

CUTTERS

(OR EQUIV)

WIRE

STRIPPERS

OHMMETER

PERFORM DC INSULATION RESISTANCE @ 500 VDC (LIMIT: ≥ 1GΩ, OR AS

REQUIRED BY CABLE SPECIFICATION OR CABLE ASSEMBLY DRAWING).

TAG EACH CABLE WITH IDENTIFYING SERIAL NUMBER FROM THE

ACCOMPANYING SHOP TRAVELER.

TAG

MEGOHMETER

4-2.2 GENERAL CONNECTOR INSPECTION

REMOVE THE CONNECTOR ASSEMBLY FROM THE PROTECTIVE STORAGE

BAG.

DISASSEMBLE THE CONNECTOR ASSEMBLY TO COMPONENT LEVEL.

INSPECT CONNECTOR COMPONENTS FOR DAMAGE AND CONFORMANCE TO

APPLICABLE SPECIFICATIONS OR DRAWINGS.

PRE-FORMED POLYURETHANE CONNECTOR INSERTS, UTILIZED ON

MIL-C-24231 STYLE CONNECTORS, SHALL BE EITHER PROCURED OR

FABRICATED IN ACCORDANCE WITH MIL-C-24231. POLYURETHANE

INSERTS SHALL BE INSPECTED IN ACCORDANCE WITH APPENDIX II-C.

CONNECTOR

COMPONENTS

4-2.3

MOLD INSPECTION

OBTAIN MOLD FOR APPLICABLE SPECIFICATION OR CABLE ASSEMBLY

DRAWING.

DISASSEMBLE MOLD TO COMPONENT LEVEL. INSPECT MOLD FOR DAMAGE.

CLEAN ALL MOLD COMPONENTS, AS REQUIRED, USING SOLVENT.

LINT-FREE CLOTH

MEK, ACETONE,

ISOPROPYL

ALCOHOL (OR

MOLD

CAUTION:

CLEAN TEFLON COATED MOLDS WITH ISOPROPYL ALCOHOL ONLY.

RE-ASSEMBLE MOLD TO ENSURE PROPER FIT OF ALL COMPONENTS.

SET MOLD ASIDE UNTIL READY TO USE.

EQUIV)

4-3

4-3.1

INDIVIDUAL COMPONENT PREPARATION:

GENERIC CABLE PREPARATION:

CUT LENGTHS SHALL BE OBTAINED FROM APPLICABLE CABLE ASSEMBLY

DRAWINGS. AS A MINIMUM REQUIREMENT, THE MAXIMUM AMOUNT OF

CABLE JACKET POSSIBLE SHALL BE MAINTAINED WITHIN THE MOLDED

BOOT ENVELOPE.

REMOVE OUTER JACKET AS APPLICABLE.

REMOVE THE WIRE INSULATION ON THE INDIVIDUAL CONDUCTORS, AS

INDICATED ON APPROPRIATE SPECIFICATION OR CABLE ASSEMBLY

DRAWING.

CLEAN THE CONDUCTOR WITH A STIFF BRUSH AND APPROPRIATE

SOLVENT.

MEK, ACETONE

BOX/EXACTO

KNIFE

WIRE

STRIPPERS

W/FIXED DIE

ACID BRUSH

FIGURE 1. TYPICAL CABLE PREPARATION

FIGURE 1 SHOWS THE BASIC LAYOUT FOR CUT LENGTHS AND WIRE

PREPARATION. DIMENSIONS A THROUGH E WILL BE DETERMINED FROM

APPLICABLE CABLE ASSEMBLY DRAWINGS.

4-3.2

MIL-C-24231 STYLE CONNECTORS CABLE PREPARATION:

TIN THE STRIPPED WIRES OF THE CABLE WITH SOLDER. NON-ACID RESIN

FLUX SOLDER SHALL BE UTILIZED.

REMOVE THE FLUX FROM THE TINNED AREA WITH APPROPRIATE SOLVENT.

J-STD-006 SOLDER

(60/40, or SN63)

ALCOHOL, MEK,

ACETONE (OR

SOLDER

SYSTEM

4-3.3

SHIELDED CABLE PREPARATION:

REMOVE ENOUGH OF THE OUTER JACKET TO EXPOSE THE BRAIDED SHIELD

AND MAINTAIN PROPER CUT LENGTHS. IF CABLE BEING UTILIZED

CONTAINS MORE THAN ONE SHIELD, CRIMP RINGS SHALL BE STAGGERED

IN SUCH A MANNER AS TO ENSURE A STREAMLINED CONDUCTOR BUNDLE.

UNLESS OTHERWISE SPECIFIED IN DRAWINGS, SPECIFICATIONS, ETC.,

CRIMP RINGS SHALL BE UTILIZED WITH SHIELDED CABLES. CRIMP RINGS

SHALL BE INSTALLED USING CALIBRATED TOOLING AND IN ACCORDANCE

WITH MANUFACTURER’S SPECIFICATIONS.

FIGURES 2 & 3 SHOW THE TWO BASIC METHODS FOR INSTALLING CRIMP

RINGS.

THOMAS & BETTS

CRIMP RINGS (OR

KNIFE (OR

APPROPRIATE

CALIBRATED

CRIMP TOOL

EACH CRIMP RING SHALL BE INSULATED WITH SHRINK SLEEVING.

SHRINK SLEEVING HEAT GUN

FIGURE 2: INSTALLATION OF CRIMP RINGS (FOLD BACK METHOD).

FIGURE 3: INSTALLATION OF CRIMP RINGS (STRAIGHT METHOD)

4-3.4

GENERAL METAL AND GRE CONNECTOR PREPARATION:

ALL AREAS OF THE METAL/GRE CONNECTORS, WHICH ARE TO BE IN

CONTACT WITH EITHER POLYURETHANE OR EPOXY BACKFILL, SHALL BE

CLEANED IN PREPARATION FOR GRIT BLASTING.

VAPOR DEGREASING IS ONLY ALLOWED ON PLAIN METAL SHELL

CONNECTORS.

PROTECT ALL AREAS NOT TO BE GRIT BLASTED WITH EITHER A

PROTECTIVE RING OR TAPE.

GRIT BLAST ALL AREAS TO BE BONDED USING # 36 TO # 80 ALUMINUM

OXIDE (OR EQUIV., EXCLUDING ALL OTHER METAL OXIDE GRITS). CLEAN

AND DRY PROFILE. FIGURE 4 SHOWS THE GENERAL LOCATIONS FOR GRIT

BLASTING.

ALCOHOL

TAPE, PROTECTIVE

RING

ALUMINUM OXIDE

MIL-STD-1504

TYPE I GRADE A

BRUSH

GRIT BLASTER

FIGURE 4: CONNECTOR HOUSING PREPARATION.

NOTE:

PRIMER SHALL BE APPLIED TO OUTER SURFACES OF THE GRIT

BLASTED CONNECTORS WITHIN EIGHT HOURS OF GRIT BLASTING.

IF NOT USED WITHIN THIS TIME FRAME, THE ENTIRE CONNECTOR

PREP SHALL BE REDONE. SEE SECTION 4-6.

REMOVE GRIT BLAST DUST WITH CLEAN, DRY AIR AND LINT-FREE CLOTH.

LINT-FREE CLOTH

CLEAN, DRY

ALL GRIT BLASTED CONNECTORS SHALL BE PROTECTED FROM

ENVIRONMENT UNTIL READY FOR PRIMING.

AIR SUPPLY

4-3.5

NON-CONDUCTIVE COATED (PLASMA SPRAY COATED) BACKSHELLS:

DO NOT GRIT BLAST PLASMA SPRAY SURFACES!!

CLEAN WITH ISOPROPYL ALCOHOL ONLY.

IF REQUIRED, BY THE APPLICABLE SPECIFICATIONS, GRITBLAST THE

INNER DIAMETER (ID) OF CONNECTOR USING #36 TO #80 GRIT

ALUMINUM OXIDE. MAKE CERTAIN TO PROTECT ALL OTHER SURFACES.

ALUMINUM OXIDE

GRIT

MIL-STD-1504

TYPE I GRADE A

GRIT BLASTER

4-4

4-4.1

CONNECTORIZATION:

MIL-C-24231 STYLE CONNECTORIZATION

SLIDE THE COUPLING NUT ONTO THE CABLE. SLIDE CABLE

THROUGH THE CONNECTOR BODY. FIGURE 5 SHOWS PROPER

CONNECTORIZATION.

COUPLING NUT

FIGURE 5: CONNECTORIZATION OF A MIL-C-24231 STYLE CONNECTOR

CLEAN SOLDER CUPS ON PRE-FORMED CONNECTOR INSERT WITH

SOLVENT; LET AIR DRY. TIN SOLDER CUPS AND REMOVE ANY EXCESS

SOLDER. DO NOT USE ACID RESIN FLUX.

REMOVE REMAINING FLUX WITH ISOPROPYL ALCOHOL AND ACID BRUSH.

REFER TO APPLICABLE CABLE ASSEMBLY DRAWING FOR CONNECTOR

WIRING DIAGRAM.

SOLDER WIRE (S) TO APPROPRIATE CUP (S).

SELF CHECK: CHECK TINNED SOLDER CUPS FOR PROPER

COVERAGE, AS SHOWN IN FIGURE 6.

PROPERLY ALIGN INSERT INTO CONNECTOR.

CABLE SHALL BE PERMANENTLY IDENTIFIED WITH A UNIQUE CABLE

IDENTIFICATION NUMBER (FROM THE SHOP TRAVELER) AND THE CABLE

ISOPROPYL

ALCOHOL (OR

SYSTEM DESIGNATION NUMBER, AS APPLICABLE.

FIGURE 6: SOLDERING CRITERIA

4-4.2

CRIMP STYLE CONNECTORS (MIL-C-24217, OTHERS):

OBSERVE THE FOLLOWING PROCEDURES IN CRIMPING CONDUCTORS TO

SOCKET CONTACTS.

INSPECT THE SOCKET CONTACTS FOR DAMAGE. DISCARD DAMAGED

CONTACTS.

UTILIZE THE APPROPRIATE TURRET HEAD WITH THE BASIC CRIMPING

TOOL IN ACCORDANCE WITH MIL-C-22520 AND MANUFACTURER’S

INSTRUCTIONS.

INSERT THE STRIPPED CONDUCTORS INTO THE CONTACT CRIMP BARREL.

THE CONDUCTOR SHOULD BE VISIBLE IN THE INSPECTION HOLE AT THE

BOTTOM OF THE BARREL.

WITH THE CONDUCTOR IN THE CRIMP BARREL, INSERT THE FRONT END OF

THE CONTACT THROUGH THE INDENTOR OPENING INTO THE POSITIONER.

SQUEEZE THE TOOL HANDLES TOGETHER UNTIL THE POSITIVE STOP IS

REACHED. THE TOOL WILL THEN RELEASE AND RETURN TO THE FULLY

OPEN POSITION. REMOVE THE CRIMPED CONTACT FROM THE

POSITIONER.

INSERT CRIMPED SOCKET CONTACT INTO FRONT INSULATOR.

PROPERLY ALIGN FRONT INSULATOR INTO PLUG SHELL.

SOCKET CONTACTS

FRONT INSULATOR

APPROPRIATE

CALIBRATED

TURRET HEAD

CRIMP TOOL

PIN INSERTION

TOOL

QA-1

QA-1.1

VISUAL INSPECTION OF SOLDER JOINTS:

QUALITY CONTROL INSPECTION:

THIS SECTION IS HIGHLY RECOMMENDED THOUGH NOT ABSOLUTELY

REQUIRED. THESE ELECTRICAL CHECKS CAN BE USED AT THIS POINT IN

THE PROCESS TO DETECT ERRORS, WHICH CAN EASILY BE CORRECTED.

AFTER THIS POINT IN THE PROCESS, WIRING ERRORS WILL REQUIRE A

MAJOR REWORK TO REPAIR, RESULTING IN LOST TIME, AND POSSIBLY

LOSS OF SOME MATERIALS. TAKING ACTUAL DATA, AS OPPOSED TO

PASS/FAIL INFORMATION, CAN AID IN DETERMINING PROCESS ERRORS

AND/OR ENHANCEMENTS TO THE PROCESS. THIS SECTION IS HIGHLY

RECOMMENDED FOR FIRST TIME BUILDS AND TROUBLE SHOOTING OF THE

PROCESS.

QA-1.2

CONTINUITY:

CHECK CONTINUITY BETWEEN CONNECTOR SOCKETS AS LISTED BELOW.

LIMITS: ≤ 1Ω PIN TO PIN (UNLESS OTHERWISE SPECIFIED)

SIGN AND DATE DATA SHEET (DS2), APPENDIX II-D

CHECK CONFORMANCE TO WIRING DIAGRAM.

OHMETER (OR

QA-1.3

INSULATION RESISTANCE (IR):

****CAUTION****

VOLTAGES ASSOCIATED WITH THE MEGOHMETER CAN BE

HARMFUL. OBSERVE NORMAL SAFETY PRECAUTIONS.

UPON COMPLETION OF EACH READING, AND PRIOR TO

DISCONNECTING EACH LEAD, ENSURE THAT THE MEGGER

MEASURE/CHARGE/DISCHARGE SWITCH IS SET TO

DISCHARGE.

1. SET APPLIED VOLTAGE TO 500 VOLTS (OR AS REQUIRED).

2. SET RANGE AS NECESSARY.

3. MEASURE IR BETWEEN THE FOLLOWING:

A. PIN TO EVERY OTHER PIN

B. PIN TO CONNECTOR SHELL

LIMITS: INSULATION RESISTANCE SHALL BE >1GΩ

FOR ALL READINGS (UNLESS OTHERWISE SPECIFIED).

4. RECORD READINGS ON INSULATION RESISTANCE DATA SHEET

(DS3), APPENDIX II-D. RECORD EQUIPMENT USED, SERIAL

NUMBER, MODEL NUMBER, AND CALIBRATION DATE.

5. SIGN AND DATE THE RECORD SHEET.

6. SIGN AND DATE DATA SHEET (DS3), APPENDIX II-D.

MEGOHMMETER

4-5

ENCAPSULATING (BACKFILL) INNER DIAMETER (ID) OF

CONNECTOR:

ONLY THOSE BACKFILL MATERIALS DESIGNATED IN APPROVED

PRODUCTS LIST (APL), APPENDIX II-E OF THIS DOCUMENT, OR AS

SPECIFIED IN THE APPLICABLE SPECIFICATIONS OR DRAWINGS

SHALL BE UTILIZED.

DETERMINE PROPER AMOUNT BY WEIGHT OF MATERIAL TO COMPLETELY

FILL THE BACK SHELL. MIX IN SEPARATE, CLEAN, CONTAINER IN

ACCORDANCE WITH MANUFACTURER’S TECHNICAL DATA SHEETS (TDS).

MIX WITH PLASTIC OR METAL SPATULA ONLY (WOOD SPATULA

SHALL NOT BE USED). MIX IN CLEAN METAL OR PLASTIC

CONTAINER ONLY. FOR MIL-C-24217 STYLE CONNECTORS,

PROVISIONS SHOULD BE MADE TO PREVENT BACKFILL MATERIAL

FROM ENTERING SOCKET CONTACTS. DO NOT USE SILICONE-

CONTAINING MATERIALS.

DEGAS MIXED COMPOUND UNTIL FIRST FOAM COLUMN COLLAPSES.

FOLLOW MANUFACTURER’S INSTRUCTIONS FOR PROPER VACUUM.

POUR OR INJECT INTO CONNECTOR ID SO AS NOT TO INDUCE OR TRAP

AIR. FILL TO APPROXIMATELY 1/32" FROM THE TOP OF THE CONNECTOR

SHELL.

BACKFILL

MATERIALS

GRAM BALANCE

METAL OR

POLY-

PROPELENE

CONTAINER

METAL OR

PLASTIC

SPATULA

VACUUM

DEGAS SYSTEM

CURE BACKFILL MATERIAL IN ACCORDANCE WITH MANUFACTURER’S TDS.

4-6

PRIMING SYSTEM APPLICATION:

PRIOR TO ABRADING THE CABLE JACKET, CLEAN THE CABLE JACKET WITH

APPROPRIATE SOLVENT USING LINT-FREE CLOTH.

ABRADE CABLE JACKET USING #60-80 ABRASIVE CLOTH 1/2" TO 1" PAST

THE MOLDED BOOT ENVELOPE.

CLEAN AND REMOVE RESIDUAL GRIT WITH LINT-FREE CLOTH

CLEAN AREA OF CONNECTOR SHELL WHICH IS TO BE PRIMED WITH

ISOPROPYL ALCOHOL AND A LINT-FREE CLOTH.

ONLY THOSE PRIMING SYSTEMS LISTED IN THE APL OF THIS

DOCUMENT (APPENDIX II-E) SHALL BE UTILIZED.

PRIMING SYSTEM SHALL BE APPLIED TO BONDING SURFACE OF

CONNECTORS AND CABLES IN ACCORDANCE WITH MANUFACTURER’S TDS.

PRIMED CONNECTOR SHALL BE MOLDED WITHIN A MAXIMUM OF FOUR

HOURS OR LESS, IF SPECIFIED BY TDS.

MEK, ACETONE,

ALCOHOL, (OR

EQUIV)

# 60-80 ABRASIVE

CLOTH (OR EQUIV)

PRIMING SYSTEM

LINT-FREE

CLOTH

ABRADED AREA OF POLYURETHANE JACKETED CABLES SHALL BE

CLEANED WITH AN APPROPRIATE SOLVENT. NO PRIMER IS

REQUIRED FOR POLYURETHANE JACKETED CABLES.

DO NOT TOUCH PRIMED SURFACES WITH BARE HANDS FROM THIS

POINT ON. DO NOT ALLOW PRIMED SURFACES TO COME IN

CONTACT WITH MOLD-RELEASED SURFACE OR TO OTHERWISE

BECOME CONTAMINATED. DO NOT TOUCH MOLD-RELEASED

SURFACE WITH HANDS.

4-7

MOLD PREPARATION:

NO SILICONE BASED MOLD RELEASE SHALL BE ALLOWED.

APPLY MOLD RELEASE TO ALL MOLD CAVITIES.

PERMANENTLY APPLIED TEFLON COATED MOLDS ARE PREFERRED.

IF UTILIZED, NO ADDITIONAL MOLD RELEASE IS NECESSARY.

CAREFULLY PLACE PRIMED CABLE ASSEMBLY INTO MOLD. MAKE CERTAIN

THE KEYWAY IS ALIGNED IN SUCH A MANNER AS TO PROVIDE PROPER

EXIT ANGLE FOR THE CABLE. THE EXIT ANGLE FOR THE CABLE SHALL BE

OBTAINED FROM SPECIFICATIONS OR DRAWINGS PRIOR TO MOLDING.

MOLD RELEASE

MOLD

DO NOT TOUCH PRIMED SURFACES WITH BARE HANDS WHILE

ALIGNING WITHIN THE MOLD. DO NOT ALLOW PRIMED SURFACES

TO COME IN CONTACT WITH MOLD RELEASED SURFACE OR BECOME

OTHERWISE CONTAMINATED. DO NOT TOUCH MOLD RELEASED

SURFACE WITH HANDS.

REASSEMBLE ALL MOLD COMPONENTS. PREHEAT MOLD, IF REQUIRED BY

POLYURETHANE SYSTEM TDS.

OVEN (OR

4-8

POLYURETHANE PREPARATION:

ONLY THOSE POLYURETHANES DESIGNATED BY THE APL OF

THIS DOCUMENT (APPENDIX II-E) SHALL BE UTILIZED.

ENSURE THAT ALL EQUIPMENT NECESSARY FOR PREPARING

AND INJECTING POLYURETHANE IS ON HAND PRIOR TO MIXING.

SEE SECTION III OF THIS DOCUMENT.

4-8.1

TYPE I, TWO COMPONENT SYSTEMS:

IF EITHER OF THE TWO COMPONENTS HAVE SOLIDIFIED, CONSULT

MANUFACTURER’S TDS TO RELIQUIFY.

POLYURETHANE

ENSURE HOMOGENEITY OF PARTS A & B PRIOR TO COMBINING.

MIX THOROUGHLY.

ALLOW BOTH PARTS A & B TO STABILIZE TO ROOM TEMPERATURE PRIOR

TO COMBINING.

MIX PARTS A & B BY WEIGHT ACCORDING TO MANUFACTURER’S TDS IN A

SEPARATE, CLEAN, DRY CONTAINER. CONTAINER SHALL BE AT LEAST

THREE TIMES THE VOLUME OF THE TOTAL POLYURETHANE.

PARTS A & B SHALL BE COMBINED BY MIX RATIO ACCORDING TO

MANUFACTURER’S TDS USING METAL OR PLASTIC SPATULA.

DEGAS POLYURETHANE SYSTEM AT 30" OF MERCURY FOR A MINIMUM OF

FIVE MINUTES OR UNTIL FOAMING SUBSIDES.

CAP THE END OF THE INJECTION TUBE AND FIX IN AN INCLINED

POSITION.

POUR DEGASSED POLYURETHANE SYSTEM DOWN THE INSIDE WALL

OF THE INJECTION TUBE SO AS NOT TO INDUCE OR TRAP AIR

INTO THE SYSTEM.

IF AIR HAS BEEN ENTRAPPED DURING THIS PROCESS, A SECONDARY

DEGAS MAY BE NECESSARY.

INSERT PLUNGER INTO TUBE. TIP UPRIGHT, REMOVE CAP, SCREW IN

APPROPRIATE NOZZLE, AND DEPRESS PLUNGER BY HAND UNTIL

POLYURETHANE EXTRUDES OUT OF THE NOZZLE.

INSERT TUBE INTO INJECTION GUN AND PROCEED WITH INJECTION

MIXING CONTAINER

& SPATULA (METAL

OR PLASTIC)

SPATULA

INJECTION TUBE &

CAP

NOZZLE

GRAM BALANCE

VACUUM

DEGAS SYSTEM

INJECTION

GUN

4-8.2

TYPE II, FROZEN CARTRIDGES:

MANUFACTURER’S TDS SHOULD BE STRICTLY ADHERED TO FOR STORAGE

REQUIREMENTS, THAWING, AND USE OF FROZEN CARTRIDGES.

AFTER FROZEN CARTRIDGE HAS BEEN PREPARED, INSERT PROPER

INJECTION NOZZLE INTO CARTRIDGE AND BLEED AS NECESSARY TO

ELIMINATE TRAPPED AIR AND UNMIXED POLYURETHANE. PLACE IN

APPROPRIATE SIZE INJECTION GUN AND PROCEED WITH INJECTION

FROZEN

CARTRIDGES

GUN

4-8.3

INJECTION PROCESS:

INSERT NOZZLE INTO INJECTION PORT OF MOLD. INJECT UNTIL

POLYURETHANE FLOWS OUT OF VENT HOLES AND INTO OVERFLOW

RESERVOIR ON MOLD.

SOME MOLDS MAY HAVE A SECONDARY FILL PORT. WHEN THE

POLYURETHANE BEGINS TO FLOW FROM THE HIGHER OPPOSING

SIDE INJECTION PORT; PLUG THIS PORT. CONTINUE INJECTING

UNTIL POLYURETHANE FLOWS OUT OF THE VENT HOLES AND INTO

OVERFLOW RESERVOIR.

CURE POLYURETHANE IN ACCORDANCE WITH MANUFACTURER’S TDS.

IF SPECIFIED IN MANUFACTURER’S TDS, SHORTENED DEMOLD

TIMES ARE ACCEPTABLE. MOLDED PART MUST THEN COMPLETE

PROPER CURING CYCLE.

ALLOW MOLD TO COOL TO ROOM TEMPERATURE PRIOR TO DISASSEMBLY

OF MOLD AND REMOVAL OF PART. REMOVE PART FROM MOLD. TRIM AND

REMOVE FLASHING IN ACCORDANCE WITH MIL-C-24231/MIL-C-24217.

KNIFE (OR

QA-2

QA-2.1

QUALIFICATION TEST:

VISUAL INSPECTION:

VISUALLY INSPECT THE ASSEMBLY IN ACCORDANCE WITH MIL-C-24231 AS

FOLLOWS:

1. MOLDED PLUGS AND INSERTS SHALL BE FREE OF FLASH, BLOW HOLES,

OR OTHER IMPERFECTIONS.

2. SMALL GAS BUBBLES THAT FORM ON THE OUTER CIRCUMFERENTIAL

SURFACE OF THE MOLDED BOOT SHALL NOT BE CAUSE FOR REJECTION

PROVIDED THE MOLDED PARTS ARE IN ACCORDANCE WITH THE

REQUIREMENTS SPECIFIED.

3. THE FLASH SHALL BE REMOVED AND THE WIDTH OF THE FLASH EDGES

SHALL NOT BE GREATER THAN 1/32 INCH. FLASH EDGES SHALL BE

SMOOTH.

4. SIGN AND DATE THE DATA SHEET (DS4), APPENDIX II-D.

QA-2.2

ELECTRICAL CONTINUITY:

1. ELECTRICAL CONTINUITY SHALL BE MEASURED BETWEEN PINS

AS LISTED BELOW:

OHMMETER

LIMITS: ≤ 1 Ω (UNLESS OTHERWISE SPECIFIED)

PIN TO PIN

2. CABLE ASSEMBLY SHALL NOT HAVE CONTINUITY BETWEEN

THE FOLLOWING:

A. PIN TO EVERY OTHER PIN OF THE SAME CONNECTOR

B. PIN TO SHELL

3. RESULTS SHALL BE RECORDED ON THE APPROPRIATE SHOP

TRAVELER DATA SHEET.

4. RECORD EQUIPMENT USED, MODEL NUMBER, AND CALIBRATION

DATE.

5. SIGN AND DATE DATA SHEET (DS5).

QA-2.3

INSULATION RESISTANCE:

****WARNING****

VOLTAGES ASSOCIATED WITH THE MEGOHMMETER CAN BE

HARMFUL. OBSERVE NORMAL SAFETY PRECAUTIONS.

UPON COMPLETION OF EACH READING, AND PRIOR TO

DISCONNECTING EACH LEAD, ENSURE THAT THE MEGGER

MEASURE/CHARGE/DISCHARGE SWITCH IS SET TO DISCHARGE.

MEGOHMMETER

1. SET APPLIED VOLTAGE TO 500 VOLTS (OR AS REQUIRED).

2. SET RANGE AS NECESSARY.

3. MEASURE IR BETWEEN THE FOLLOWING:

A. PIN TO EVERY OTHER PIN

B. PIN TO CONNECTOR SHELL

LIMITS: INSULATION RESISTANCE SHALL BE ≥ 1GΩ, OR AS

REQUIRED BY CABLE SPECIFICATION OR CABLE ASSEMBLY

DRAWING.

4. SIGN AND DATE THE DATA SHEET (DS6).

QA-2.4

NON DESTRUCTIVE BOND TESTING:

DO NOT APPLY EXCESSIVE FORCE WHEN PERFORMING THIS TEST.

DO NOT USE A SCREWDRIVER.

1. BETWEEN MOLDED STRAIN RELIEF AND PLUG BODY

A. USING A ROUND EDGE PROBE (RIGID/ PLASTIC OR METAL

ROUND EDGE

[NOT A SCREWDRIVER]) WITH NO SHARP EDGES OR CORNERS,

LIFT (DO NOT PRY) IN AREA INDICATED IN FIGURE 7. REPEAT

TEST IN FOUR DIFFERENT EQUALLY SPACED LOCATIONS ABOUT

THE CIRCUMFERENTIAL BOND LINE OF THE CONNECTOR.

B. IF POLYURETHANE PEELS BACK TO REVEAL BARE CONNECTOR

MATERIAL, MOLDED BOOT SHALL BE REMOLDED/REPAIRED, AS

REQUIRED FOR CONFORMANCE TO THIS DOCUMENT.

PROBE

FIGURE 7: POLYURETHANE TO METAL NON-DESTRUCTIVE BOND TEST.

(DO NOT USE COUPLING NUT FOR LEVERAGE).

2. BETWEEN MOLDED STRAIN RELIEF AND CABLE JACKET:

A. SET UP NON-DESTRUCTIVE BOND TEST SYSTEM, AS INDICATED BY

FIGURE 8.

B. INSPECT THE BOND LINE WHILE BENDING THE CABLE OVER THE

MANDREL WITH FIVE-POUND LOAD APPLIED (TO AID IN

INSPECTION OF BOND LINE) AND ROTATING, AS SHOWN

IN FIGURE 8.

LOADING SHALL BE APPLIED IN SUCH A MANNER AS TO MAINTAIN

TENSION ON CABLE ASSEMBLY. LOADING OF MORE THAN 5 LBS MAY

BE NECESSARY DEPENDING ON CABLE SIZE AND STIFFNESS.

C. IF POLYURETHANE SEPARATES FROM CABLE JACKET, MOLDED

BOOT SHALL BE REMOLDED/REPAIRED, AS REQUIRED FOR

CONFORMANCE TO THIS DOCUMENT.

3. RECORD THE RESULTS OF STEP 1 AND STEP 2 ABOVE ON

THE DATA SHEET FOR NON-DESTRUCTIVE BOND TESTING.

4. SIGN AND DATE THE DATA SHEET FOR THIS TEST (DS7).

NON-

DESTRUCTIVE

BOND TEST

FIGURE 8: NONDESTRUCTIVE BOND TEST BETWEEN STRAIN RELIEF AND CABLE JACKET.

QA-2.5

HYDROSTATIC PRESSURE TEST:

WHEN MAINTENANCE IS CONDUCTED AT NAVAL INTERMEDIATE

LEVEL MAINTENANCE FACILITIES, THE HYDROSTATIC PRESSURE

TESTING REQUIREMENT IS WAIVED.

1. ENSURE THAT ALL O-RINGS ARE PROPERLY INSTALLED AND THAT

CONNECTORS ARE MATED PROPERLY TO THE FIRST FIXTURE

PRIOR TO TESTING.

2. HYDROSTATIC PRESSURE TESTING SHALL BE PERFORMED IN

ACCORDANCE WITH THE APPLICABLE PROCUREMENT

SPECIFICATION. IF NO SPECIFICATION, THE FOLLOWING

TESTS SHALL BE PERFORMED:

A. 0 TO 100 PSIG - HOLD FOR FIVE MINUTES AT 100 PSIG

CYCLE THREE TIMES.

B. 1000 PSIG - HOLD FOR ONE HOUR FOR ONE CYCLE.

C. THE PROFILE FOR THIS TEST IS SHOWN IN FIGURE 9 BELOW.

1. INSULATION RESISTANCE READINGS SHALL BE RECORDED AT 0 PSI,

PRIOR TO PRESSURE CYCLING; AT 1000 PSI; AND AGAIN AT 0 PSI,

PRIOR TO REMOVAL FROM THE TANK.

FIGURE 9: HYDROSTATIC PRESSURE PROFILE.

ALL INSULATION RESISTANCE READINGS SHALL BE RECORDED

WHILE CABLE ASSEMBLY IS SUBMERGED IN WATER WITHIN THE

PRESSURE TANK.

4. RECORD DATA ON TRAVELER DATA SHEET FOR THE CABLE

ASSEMBLY BEING TESTED.

5. REJECT ANY CABLE ASSEMBLY WHICH DOES NOT MEET

SPECIFICATION REQUIREMENTS.

6. SIGN AND DATE DATA SHEET (DS8).

4-9

PRESHIPMENT INSPECTION

PRE-PACKAGED O-RINGS, IF REQUIRED, SHALL BE PROVIDED WITH EACH

CABLE ASSEMBLY. DUST PROOF CAPS SHALL BE INSTALLED ON ALL

CONNECTORS.

ENSURE PROPER MARKINGS ARE FOUND ON CABLE ASSEMBLY.

ENSURE TEST INSPECTION REPORT (DS9), APPENDIX II-F, IS PROPERLY

COMPLETED AND IS PACKAGED WITH CABLE ASSEMBLY.

II-A1

APPENDIX II-A

VENDOR AUDIT REQUIREMENTS/

LIST OF APPROVED VENDORS

II-A2

APPENDIX II-A

VENDOR AUDIT REQUIREMENTS/LIST OF APPROVED VENDORS

PERSONNEL QUALIFICATION AND TRAINING:

Cable assembly fabricators shall establish and maintain a thorough, detailed training program for personnel charged with in-process and final inspection of cable assemblies. Further, cable assembly fabricators shall establish and maintain a rigorous qualification and certification/re-certification program for these personnel. The certification program shall be documented, and certification and qualification cited at the facility. All cable assemblies must be fabricated by qualified, certified personnel and inspected by qualified, certified personnel. Further, this program shall ensure that personnel will become proficient in the molding of cable assemblies in accordance with NAVSEA S9320-AM-PRO-010/MLDG Volume II.

WIRING AND MOLDING PERSONNEL QUALIFICATION:

General:

The personnel who perform wiring, molding inspection, and testing operations in fabricating a pressure-proof harness are the key to a reliable harness fabrication. The technician must handle all components (cables and connectors) very carefully at all times. The technician must use extreme care to not nick conductors. The contacts must be attached to the connectors in a very exacting fashion. Care must be exercised in mixing primers and potting materials as well as molding the connector assembly. Once molded, the harness assembly must be non-destructively tested using great care not to damage the assembly in handling.

In many respects, the technician must serve as his/her own inspector. There are no economical or sure methods for checking assembled harnesses for nicks in conductors, or voids in potting compounds. X-ray techniques are available but have not exposed possible problem areas with any degree of certainty.

The best method for assuring properly fabricated, reliable harness assemblies is to make use of well trained, conscientious, capable technicians who will closely follow prescribed procedures.

Qualification:

The technician qualification should be based on the successful completion of a short course embodying all of the procedural information contained in NAVSEA S9320-AM-PRO-010/MLDG Volume II.

II-A3

Course Descriptions:

The study course for technician qualification should include the following work topics:

Subject Approximate Days

(a) Procedures familiarization 1/2

(b) Specification familiarization 1/2

(c) Safety precautions 1/2

(d) Cable inspection 1/2

(e) Connector inspection 1/2

(f) Preparation of molding compounds 1/2

(g) Preparation of cables 1/2

(h) Soldering and crimping conductors to contacts 1/2

(I) Epoxy pre-potting connector 1/2

(j) Potting plug inserts with polyurethane 1/4

(k) Preparing the plug and receptacle sleeve 1/4

(l) Assembling and molding the conductor 1

(m) Inspection and test of fabricated harnesses 1/2

From the above, it is seen that a 5 day course should be mandatory in qualifying a technician for fabricating pressure-proof connector plugs.

VENTILATION:

The cable molding facility shall meet the minimum requirements of ventilation, as set forth in the MSDSs and TDSs of the chemicals used in the cable assembly fabrication and environmental requirements of OSHA regulations, as well as Section 2-1.6 of this manual.

PERSONAL PROTECTIVE EQUIPMENT:

The cable molding facility shall meet the minimum requirements of providing personal protective equipment (and training in its use) to assigned personnel, as set forth in the MSDSs and TDSs of the chemicals used in the cable assembly fabrication and the requirements of OSHA regulations, as well as Section 2-1.6 of this manual.

ELECTRICAL EQUIPMENT:

All electrical equipment utilized for cable assembly fabrication shall be calibrated. All safety requirements of Section II of the NAVSEA Manual S9086-KS-STM-000/CH 300, Electrical Safety Precautions, shall be followed.

WASTE:

All local, state, and federal requirements concerning chemical wastes shall be strictly followed.

II-A4

SOLDERING:

All soldering shall be performed by qualified personnel trained and certified to the requirements of the JOINT INDUSTRY STANDARD J-STD-001, Requirements for Soldered Electrical and Electronic Assemblies.

ENVIRONMENTAL CONTROL:

All requirements and standards of Section 2-1.6 of this manual shall be adhered to.

REFERENCE DOCUMENTS:

All reference documents listed in section 1-2 of this manual shall be readily available to cable assembly fabricators. The most recent revisions or applicable cable assembly drawings shall be on hand.

TRACEABILITY:

All cable assembly documentation, including the cable assembly traveler and QA records, at a minimum, shall be maintained at the cable assembly fabrication site for a minimum of seven years.

POSITIVE MATERIAL CONTROLS:

A system shall be established and maintained to coordinate and monitor material activities within the fabrication facility (Material Tracking) in accordance with the following:

Stores and Material Storage Control: To avoid improper storage and poor storage control which can result in damaged, unserviceable, or otherwise nonconforming material and equipment, the activity’s stores and material storage control will be examined during validation. The Validation Plan shall require general inspections of stores and storage facilities at the activity being validated with particular emphasis placed on those areas which are involved with the particular item for which the activity is being validated. These general inspections will ensure, as a minimum, that:

a. Stored material and equipment are properly marked to accurately indicate the identity of the material/equipment.

b. Stored items are adequately protected and controlled to prevent deterioration, damage, degradation, or unauthorized used or issue.

c. Shelf lives and dates of expiration are recorded and monitored.

d. Material condition status (i.e., serviceable, unserviceable, etc.) is plainly and prominently marked and items are physically segregated according to status.

e. A stored material inventory is kept and maintained in a current status.

f. Adequate material storage procedures/documentation is available and kept current.

g. Documents that are to remain with the items being stored are kept at a central point or with the appropriate item as applicable.

h. Material and equipment, which are susceptible to environmental deterioration, are stored in facilities capable of maintaining the required environment. (This includes cleanliness, humidity, temperature, pressure, vibration, radiation, etc.).

i. Adequate periodic stores and storage inspections are accomplished.

II-A5

j. Provisions are available for the disposal of unserviceable, unrepairable equipment and materials.

II-A6

LIST OF APPROVED VENDORS

VENDOR NAME

& ADDRESS

DATE CERTIFIED NEXT

CERTIFICATION

DUE DATE

POINT OF CONTACT

& TELEPHONE

NUMBER

II-B1

APPENDIX II-B

GENERIC ASSEMBLY TRAVELER

Appendix II-B GENERIC SHOP TRAVELER FOR S9320-AM-PRO-010/MLDG

II-B2

SERIAL NO. SYSTEM DESIGNATION NO.

PROC

COMPLETED

QA INSPECT.

INITIALS

STAMP

CABLE INSPECTION (DS1)

4-2.2

GENERAL CONNECTOR INSPECTION

MOLD INSPECTION

GENERIC CABLE PREPARATION (CUT LENGTH)

4-3.2

24231 CABLE PREPARATION

SHIELDED CABLE PREPARATION

GENERAL CONNECTOR PREPARATION

NCC CONNECTOR PREPARATION

CONNECTORIZATION (MIL-C-24231 STYLE)

SELF CHECK: TINNED SOLDER CUPS

WIRE IN ACCORDANCE WITH WIRING DIAGRAM

4-4.2

CRIMP STYLE CONNECTORS (MIL-C-24217)

WIRE IN ACCORDANCE WITH WIRING DIAGRAM

QA-1 QUALITY CONTROL INSPECTION

QA-1.1

ELECTRICAL CONTINUITY (VERIFY WIRING TO

DRAWING) (DS2)

QA-1.2

INSULATION RESISTANCE (DS3)

4-5

ENCAPSULATING ID OF CONNECTOR

BACKFILL MATERIAL:

EXPIRATION DATE:

LOT #:

PRIMING SYSTEM APPLICATION

PRIMING SYSTEM (CON):

PRIMING SYSTEM (CABLE):

LOT #: ________________________________

CAUTION: DO NOT TOUCH PRIMED SURFACES

II-B3

Appendix II-B GENERIC SHOP TRAVELER FOR S9320-AM-PRO-010/MLDG

PROC

COMPLETED

QA INSPECT.

INITIALS

STAMP

MOLD PREPARATION

CAUTION: DO NOT USE SILICON MOLD RELEASE

CAUTION: DO NOT TOUCH PRIMED SURFACES

4-8

POLYURETHANE PREPARATION

TYPE I, TWO COMPONENT SYSTEMS

POLYURETHANE SYSTEM:

TYPE II, FROZEN CARTRIDGES

4-8.3

INJECTION PROCESS

QA-2

QUALITY CONTROL INSPECTION

VISUAL INSPECTION (DS4)

ELECTRICAL CONTINUITY (PER DWG, DS5)

INSULATION RESISTANCE (DS6)

NONDESTRUCTIVE BOND TEST (DS7)

HYDROSTATIC PRESSURE TESTING (DS8)

4-9

PRESHIPMENT INSPECTION (DS9)

REMARKS:

II-C1

APPENDIX II-C

PREFORMED INSERTS - PRODUCTION AND INSPECTION

II-C2

APPENDIX II-C. PREFORMED INSERT INSPECTION REQUIREMENTS

ALL VISUAL INSPECTIONS ARE TO BE PERFORMED WITH THE NAKED EYE (WITHOUT THE

USE OF EXTERNAL MAGNIFICATION)

SECTION

4-2.2

INSPECTED

BY

A

ENSURE PROPER ALIGNMENT OF SOCKET CONTACTS.

ALL SHOULD BE EQUALLY SPACED, PERPENDICULAR

TO THE FACE AND THE SOLDER CUPS SHOULD BE

ALIGNED PROPERLY (PER MIL-C-24231).

B

THERE SHALL BE NO FOREIGN MATERIAL INSIDE OF

SOCKET CONTACTS.

C

ENSURE THAT THERE ARE NO SUSPENDED DEFECTS

(FLOWLINES, FOLDS, GEL CRACKS, POROSITY, AND

AIR BUBBLES) WHICH BRIDGE THE ELECTRICAL PINS.

D

NO SUSPENDED OR SURFACE DEFECTS (FLOWLINES,

FOLDS, GEL CRACKS, POROSITY, AND AIR BUBBLES)

LOCATED ON THE OUTSIDE, CIRCUMFERENTIAL LIP

OF THE MOLDED PREPOT ARE ALLOWED. THIS AREA

FORMS A SECONDARY WATER SEAL THROUGH

COMPRESSION CONTACT BETWEEN THE HULL INSERT

AND BODY OF THE CONNECTOR.

E

NO SURFACE DEFECTS (FLOWLINES, FOLDS, GEL

CRACKS, POROSITY, AND AIR BUBBLES) LOCATED ON

THE FACE OF THE PREPOT WHICH WOULD ALLOW THE

SPREAD OF SEAWATER BETWEEN CONNECTOR PINS

REGARDLESS OF LEAKPATH ARE ALLOWED.

F

NO BUBBLES OR VOIDS IN CONTACT WITH THE

ELECTRICAL PINS AT THE FACE OF THE INSERT OR

WITHIN THE MOLDED PART. (SMALL SURFACE

BUBBLES AT THE BACK OF THE INSERT AROUND THE

SOLDER CUPS OR ALONG THE SIDE ARE ACCEPTABLE.)

II-D1

APPENDIX II-D

DATA SHEETS FOR IN-HOUSE INSPECTIONS

II-D2

APPENDIX II-D

SERIAL NO. ________

4-2.1 INSPECTION DATA - DS1

INSPECTION

PASS/FAIL

INSPECTOR

VISUAL INSPECTION

VERIFY CUT LENGTH

CONTINUITY (≤ 1Ω) (RECORD ALL

READINGS)

PIN TO PIN (CONDUCTOR TO

CONDUCTOR)

INSULATION RESISTANCE (≥ 1GΩ)

(RECORD ALL READINGS)

PIN TO EVERY OTHER PIN

SHIELD TO EVERY PIN

TESTED BY: _______ DATE:

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

II-D3

APPENDIX II-D (CONTINUED)

DATA SHEETS FOR IN-HOUSE INSPECTIONS (CONTINUED)

QA-1.1 INSPECTION DATA - DS2

CONTINUITY (≤ 1Ω)

NO CONTINUITY BETWEEN:

EVERY PIN TO SHIELD

WIRE STRIPPING INSPECTION

CHECK FOR NICKS AND GOUGES

STRIPPING MEASUREMENTS (FIGURE 1)

SOLDER (J-STD-0001)

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

II-D4

QA-1.2 INSPECTION DATA - DS3

INSULATION RESISTANCE (APPLIED VOLTAGE - 500 VDC)

TEST CONDITION

INSULATION

RESISTANCE

(LIMIT: ≥ 1GΩ)

SHIELD TO EVERY PIN

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

INSPECTION DATA - DS4

INSPECT RUBBER FOR VOIDS AND

IMPERFECTIONS

O-RING SURFACES

II-D5

II-D6

QA-2.2 INSPECTION DATA - DS5

ELECTRICAL CONTINUITY

READINGS

(LIMIT: ≤ 1 Ω)

CONTINUITY BETWEEN (CHECK TO DRAWING):

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

QA-2.3 INSPECTION DATA - DS6

INSULATION RESISTANCE (APPLIED VOLTAGE - 500 VDC)

INSULATION

RESISTANCE

(LIMIT: ≥ 1GΩ)

EVERY PIN TO SHELL (BOTH ENDS)

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

II-D7

QA-2.4 TEST INSPECTION - DS7

NON-DESTRUCTIVE BOND TESTING

BETWEEN MOLDED STRAIN RELIEF AND PLUG BODY

BETWEEN MOLDED STRAIN RELIEF AND CABLE JACKET

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

II-D8

QA-2. 5 INSPECTION DATA - DS8

HYDROSTATIC PRESSURE TEST

TEST

INSULATION RESISTANCE (W/500VDC APPLIED VOLTAGE)

0 PSIG

(PRE PRESSURE)

>1 GΩ*

1000 PSIG

> 1 GΩ*

0 PSIG

(POST PRESSURE)

> 1 GΩ*

EVERY PIN TO SHELL (BOTH

ENDS)

TEST EQUIPMENT: _________________________

CALIBRATION DATE: _________________________

* OR AS SPECIFIED BY GOVERNING DOCUMENTS

II-E1

APPENDIX II-E

POLYURETHANE SYSTEM REQUIREMENTS/

BACKFILL MATERIAL REQUIREMENTS/

LISTS OF APPROVED PRODUCTS

ONLY THOSE POLYURETHANE/PRIMING SYSTEMS AND BACKFILL MATERIALS LISTED IN THE

LISTS OF APPROVED PRODUCTS OF THIS APPENDIX HAVE BEEN TESTED AND QUALIFIED TO

THIS SPECIFICATION.

APPENDIX II-E SHOULD BE USED IN LIEU OF MIL-M-24041

ONLY THOSE MATERIALS IN THE LIST OF APPROVED PRODUCTS OF THIS APPENDIX SHALL

BE USED IN FABRICATING SUBMARINE OUTBOARD CABLE ASSEMBLIES.

II-E2

APPENDIX II-E

THE FOLLOWING IS A LISTING OF THE PROPERTIES OF POLYURETHANES:

SCOPE: This specification covers the requirements of chemically cured, polyurethane compounds for the molding, encapsulating, and potting of watertight electrical connectors, cables, and cable end seals.

QUALIFICATION: The compounds furnished under this specification shall be products, which are qualified for listing on the applicable list of approved products contained herein.

COMPOSITION: Before mixing, the compound shall be a two-component, polyurethane system consisting of a prepolymer and a curing agent. The prepolymer shall cure by the addition of the curing agent, and shall not depend on solvent or moisture evaporation for curing.

Primer: The use of a primer to improve the adhesion of the compound shall be required. The primer/polyurethane system shall be tested and proven, per the requirements of this document, and these systems shall then be added to the list of approved products. The primer shall be applied in strict conformance with the manufacturer's recommendations.

Toxicity: The…