ALFS_Improved_Cable_Perf_Spec_Rev0.75.doc

SOLICITATION NO. N00019-15-R-0001

Attachment (2)

KR NO. N00019-xx-x-xxxx

MD NO. N00019-xx-xx-xxxx

Performance Specification (PS)

For the

Airborne Low Frequency Sonar (ALFS)

Sonar Replacement Cable

On the

MH-60R Aircraft

Date 11 September 2014 Prepared by:

MH-60 Program Office

PMA-299

Naval Air Systems Command

Document #XXXXXX

1.0 SCOPE

1.1 This document establishes the requirements for the procurement and acceptance test procedures for the AN/AQS-22 Airborne Low Frequency Sonar (ALFS) Improved Cable.

2.0 APPLICABLE DOCUMENTS

2.1 Unless otherwise specified, the following documents of the issue shown below shall form a part of this specification to the extent specified. Should a later revision of any document specified become available, that revision may be used provided no requirements of the earlier revisions are degraded. In the event of a conflict between the documents referenced and the contents of this drawing, this specification shall take precedence.

2.1.1 Government Specifications/Standards:

2.1.2 MILITARY

MIL-HDBK-2036

ELECTRONIC EQUIPMENT SPECIFICATION, PREPARATION OF

MIL-DTL-83420M

WIRE ROPE, FLEXIBLE, FOR AIRCRAFT CONTROL, GENERAL SPECIFICATION FOR

MIL-PRF-85285D

COATING: POLYURETHANE, AIRCRAFT AND SUPPORT EQUIPMENT

MIL-STD-202

TEST METHODS FOR ELECTRONIC AND ELECTRICAL COMPONENT PARTS

MIL-STD-45661

CALIBRATION SYSTEMS REQUIREMENTS

2.1.3 Commercial Specifications/Standards:

EIA-364-39B

HYDROSTATIC TEST PROCEDURE FOR ELECTRICAL CONNECTORS, CONTACTS AND SOCKETS

ASTM D4565-99(2004) e1 STANDARD TEST METHODS FOR PHYSICAL AND ENVIRONMENTAL PERFORMANCE PROPERTIES OF INSULATIONS AND JACKETS FOR TELECOMMUNICATIONS WIRE AND CABLE

ASTM D4566-08

STANDARD TEST METHODS FOR ELECTRICAL PERFORMANCE PROPERTIES OF INSULATIONS AND JACKETS FOR TELECOMMUNICATIONS WIRE AND CABLE

ASTM E8/E 8M

STANDARD TEST METHODS FOR TENSION TESTING OF METALLIC MATERIALS

UL 2556

STANDARD FOR WIRE AND CABLE TEST METHODS

ISO 10012-1

QUALITY ASSURANCE REQUIREMENTS FOR MEASURING EQUIPMENT

2.1.4 Government Test Procedure

XXX-XXX

NAVAIR OPERATIONAL TEST PLAN FOR THE ALFS IMPROVED CABLE

2.2 INSPECTION RESPONSIBILITY

Unless otherwise specified in the contract or purchase order, the Government is responsible for conducting the Test Article Tests and the supplier is responsible for the performance of the Quality Conformance Tests as specified below and in Table 1. Table 1 is included as a summary of required testing on the last page of this specification after all requirements and tests have been described.

2.3 CLASSIFICATION OF INSPECTION

The inspections performed under this specification shall be of the following classifications:

a.

Test Article Tests b.

Quality Conformance Tests

2.3.1 TEST ARTICLE TESTS. Test article tests are indicated in Test-Article Column of Table 1 will be conducted by the Government using a quantity of (3) Cables per vendor.

2.3.2 QUALITY CONFORMANCE TESTS. Quality Conformance Tests are those tests indicated in Quality Conformance column in Table 1. Quality Conformance Tests shall be performed on a 100% basis.

3.0 REQUIREMENTS

3.1 GENERAL

The current ALFS cable consists of a copper coaxial center conductor with shielding, a cable strength member, and cable outer jacket of pressure extruded Hytrel® 5556 with Hytrel® 40CB concentrate for UV protection. Figure 1 depicts current configuration.

The ALFS Improved Cable shall be capable of supporting an attached load of 177 pounds above the ocean surface and 220 pounds below the ocean surface, without damage or change in performance while pulled over a sheave with a minimum diameter of 7 inches at a maximum speed of 10.5 feet per second.

Figure 1: Cable Construction

3.2 CONSTRUCTION

The ALFS Improved cable shall meet or exceed all specifications listed in this section.

3.2.1 The cable shall incorporate a copper coaxial center conductor with shielding. The cable characteristic impedance shall be 50 ± 3 ohms.

3.2.2 The cable outer jacket shall provide UV protection.

3.2.3 The cable outer surface shall be black in color and have an Infrared reflection coefficient equal to or greater than the current cable.

3.2.4 The cables outer jacket must allow for application of paint (M85285-1-H-17925) for optical sensor synchronizations purposes.

3.2.5 The cable shall be resistant to damage caused by abrasion and friction heating due to surface contact during high-speed (<= 10 fps) reeling operations. The cable jacket shall be able to withstand storage for up to 4 hours on a reel under tension without deforming the jacket into a non-round condition that no longer meets the dimension requirements of para. 3.2.13.

3.2.6 The cable shall have a dielectric withstanding voltage of at least 2500V RMS.

3.2.7 The cable capacitance shall be 125 pF per foot maximum.

3.2.8 The cable shall be capable of carrying a pulsed AC current of 4.6 A RMS at 10% duty cycle for an indefinite duration without degradation. The cable shall be capable of withstanding a continuous DC current of 1.5 A without degradation.

3.2.9 The cable shall have a minimum bend radius not to exceed 3.5 inches.

3.2.10 The cable breaking strength shall be 3000lb minimum.

3.2.11 The service life of the cable under any combination of operation and storage conditions shall be a minimum of 60 months, with a goal of 120 months.

3.2.12 The cable shall be:

a. Production cables = 2600 (+10/-0) feet long

b. Test Article cables = 2600 (+10/-0) feet long.

3.2.13 The cable diameter shall be 6.70mm +/- 0.05mm (0.2618 to 0.2657 inches).

3.2.14 The cable linear mass shall be equal to or less than 3.70 pounds per 100 feet.

3.2.15 The cable shall meet or exceed the requirements as listed in Sections 3.3, 3.4, 3.5, 3.6 and 3.7.

3.3 ENVIRONMENTAL CONDITIONS

3.3.1 OPERATING TEMPERATURE

The cable shall be capable of meeting all electrical requirements as specified in section 3.4 when operating in seawater over the temperature range of -40ºC to +65ºC limited to the temperatures at which seawater remains a liquid.

3.3.2 NON-OPERATING TEMPERATURE

When subjected to non-operational conditions, the cable shall be capable of exposure to temperatures over the range of -54 ºC to +85ºC throughout the service life of the cable and shall meet the electrical requirements as specified in section 3.4 after exposure.

3.3.3 HYDROSTATIC PRESSURE

3.3.3.1 PROCEDURE. The cable shall be hydrostatically tested 1,305 +10/-0 psi for 3 cycles as follow:

a. Increase the pressure to 1,305 psi over a period of one minute.

b. Maintain the pressure at 1,305 psi for 15 minutes.

c. Return to atmospheric pressure instantaneously.

d. Maintain atmospheric pressure for 15 minutes. Conduct electrical testing per section 3.4.1 and 3.4.3.

3.3.3.2 REQUIREMENT. The cable shall be capable of withstanding a hydrostatic pressure of up to and including 1,305 psi while meeting all electrical requirements as specified in section 3.4, without physical or electrical damage.

3.3.4 HUMIDITY

3.3.4.1 PROCEDURE. The cable shall be tested In Accordance With (IAW) Condition B of MIL-STD-202, Method 103B. The cable shall be terminated with appropriate system plug connectors. Electrical measurements described in Sections 3.4.1, 3.4.3, and 3.4.5 shall be performed at all required test points defined in MIL-STD-202, Method 103B.

3.3.4.2 REQUIREMENT. The cable shall withstand the effects of humidity up to 95% during operating and non-operating conditions and shall meet the electrical requirements of section 3.4.1, 3.4.3, and 3.4.5 while exposed to this level.

3.4 ELECTRICAL REQUIREMENTS

3.4.1 INSULATION RESISTANCE

3.4.1.1 PROCEDURE. The insulation resistance shall be tested IAW Condition B of MIL-STD-202, Method 302, measured using a calibrated Megohmmeter capable of providing 500 VDC and reading leakage current equal to or greater than 0.1 milliamps, DC.

3.4.1.2 REQUIREMENT. The insulation resistance value at 500 VDC shall be as follows:

Center to Shield: > 250 megohms

3.4.2 ATTENUATION

3.4.2.1 PROCEDURE. The cable’s attenuation shall be measured IAW the test standard ASTM D4566-08

3.4.2.2 REQUIREMENTS. The attenuation of the coaxial cable shall not exceed 107 dB per 1000 feet at 200 MHz.

3.4.3 CONTINUITY TEST

3.4.3.1 PROCEDURE. Using an ohmmeter, perform continuity tests from one end to the opposite end of the cable’s shield and inner conductor.

3.4.3.2 REQUIREMENT. Conductors shall show continuity and shall show no evidence of open circuits. Continuity shall be defined as a resistance reading when measured with a DC ohmmeter. Readings shall be as follows:

Shield to Shield: < 24.0 ohm

Inner Conductor to Inner Conductor: < 46.0 ohm

3.4.4 CAPACITANCE

3.4.4.1 PROCEDURE. The cable’s capacitance shall be measured IAW MIL-STD-202, Method 305A at a frequency of 1 kHz.

3.4.4.2 REQUIREMENT. The cable capacitance shall not exceed 125 pF per foot.

3.4.5 DIELECTRIC WITHSTAND VOLTAGE

3.4.5.1 PROCEDURE. The cable shall be Dielectric Withstand Voltage tested IAW MIL-STD-202, Method 301 with DC potential applied for 60 seconds.

3.4.5.2 REQUIREMENT. The cable shall withstand 2500 V RMS applied between the center conductor and shield.

3.4.6 CURRENT

3.4.6.1 PROCEDURE. The cable’s ability to withstand AC and DC current shall be measured IAW test standard TBD.

3.4.7 REQUIREMENT. The cable shall be capable of withstanding an AC current of 4.6 amperes RMS minimum with a 10 percent duty cycle. They shall also be capable of withstanding a continuous DC current of 1.5 amperes minimum.

3.5 MECHANICAL REQUIREMENTS

3.5.1 VISUAL AND DIMENSIONAL EXAMINATION

3.5.1.1 PROCEDURE. Each of the finished samples selected shall be visually and dimensionally examined to determine that the completed cable conforms to this specification. The cable diameter shall be measured at every 100 foot increment from one end to the other over the entire length of the cable starting approximately 3 feet from an end. At each location, the cable shall be measured in two orthogonal directions. The examination will include the materials used and the manufacturing process.

3.5.1.2 REQUIREMENT. The cable diameter shall be 6.70mm +/- 0.05mm (0.2618 to 0.2657 inches). The entire cable jacket shall be free of kinks, gouges, or other damage.

3.5.2 TENSILE STRENGTH

3.5.2.1 PROCEDURE. The cable samples shall be 18 inches in length and prepared with terminations capable of providing the full cable breaking strength. The tensile strength of the cable samples will be measured using a calibrated instrument capable of exceeding the breaking strength of the cable while controlling the tension ramp speed. An example of a test apparatus is shown in Figure 2. In the case of a failure due to an unsatisfactory end termination, the test will be disregarded and a new test conducted.

a. Apply a load of 1125 lbs to the test specimen for 10 cycles with a speed of raising and lowering of 2 in/min. At each cycle, increase load continuously from 45 lbs to the maximum value, and then decrease back to 45 lbs, with a cycle frequency of 1 to 1.25 cycles per minute.

b. Increase the load to 1,350 lbs and then repeat cycles as in step a.

c. Increase the load to 1,575 lbs and then repeat cycles as in step a.

Figure 2: Example of Tensile Strength Test Apparatus

3.5.2.2 REQUIREMENT. The cable tensile strength shall be sufficient to meet the requirements of this specification.

3.5.2.3 The cables shall meet the electrical requirements as specified in section 3.4 after tensile testing.

3.5.2.4 Pass criteria is as follows:

1. No breaking during the 10 cycles at 1,125 lbs.

2. No breaking during the 10 cycles at 1,350 lbs.

3. No breaking during the first 3 cycles at 1,575 lbs.

4. Satisfactory Insulation Resistance, Continuity, and Attenuation.

3.5.3 ELONGATION

3.5.3.1 PROCEDURE. Two samples, at least 12 feet long and prepared with terminations capable of providing the full cable breaking strength, shall be subjected to a test where the cable is load cycled between 0 and 500 lbs 10 times. The cable’s stretch shall be measured continuously from 0 to 500 lbs during cycles 1 thru 10. An example of a test apparatus is shown in Figure 3. The amount of elongation shall be determined on a tension testing machine IAW ASTM E 8/E 8M and from this data. In the case of a failure due to an unsatisfactory end termination, the test will be disregarded and a new test conducted.

3.5.3.2 REQUIREMENTS. The cable shall not exceed 1.5 % elongation. Percent elongation shall be calculated using the formula below.

Elongation of gauge length under load

% elongation = ------------------------------------------------ x 100 ≤1.5%

Original gauge length

The cables shall meet the electrical requirements as specified in sections 3.4 after elongation testing.

3.5.4 ROTATION

3.5.4.1 PROCEDURE. The same two samples used in section 3.5.3, prepared with terminations capable of providing the full cable breaking strength, shall be subjected to a test where the cable is load cycled between 0 and 500 lbs 10 additional times. Rotation shall be measured continuously from 0 to 500 lbs during the cycles. An example of a test apparatus is shown in Figure 3. In the case of a failure due to an unsatisfactory end termination, the test will be disregarded and a new test conducted.

Figure 3: Example of Rotation and Elongation Test Apparatus

3.5.4.2 REQUIREMENTS. The cable rotation shall be sufficient to meet the requirements of this specification. The cable shall not exceed .40 degree rotation per foot at 220 lbs and 1.0 degree of rotation at 500 lbs. The cables shall meet the electrical requirements as specified in sections 3.4 after torsional deflection testing.

3.0.1 CYCLE TENSION FATIGUE

3.0.1.1 PROCEDURE. Two samples, at least 18 inches long and prepared with terminations capable of providing the full cable breaking strength, shall be subjected to a test where the cable is load cycled between 0 and 300 lbs 2000 times. An example of a test apparatus is shown in Figure 3. Prior to the beginning of the test, and at the conclusion of the test should the specimen survive the desired cycle limit, measurements shall be made of conductor and insulation resistance. During the test, continuity of the test samples (as defined in 3.4.3 adjusted for the shorter length) shall be monitored continuously. At the conclusion of the test, one sample shall be dissected and visually examined for damaged components, and the other sample shall be pulled to failure to determine its residual breaking strength. In the case of a failure due to an unsatisfactory end termination, the test will be disregarded and a new test conducted.

3.0.1.2 REQUIREMENT. The cable shall be capable of withstanding 2,000 cycles from 0 to 300 pounds, the peak recovery tension during normal operation, while maintaining a residual breaking strength of 3,000 pounds minimum.

3.0.2 BENDING FATIGUE LIFE

3.0.2.1 PROCEDURE. Two samples, at least 15 ft long and prepared with terminations capable of providing the full cable breaking strength, shall be subjected to a hybrid test where two tensions are used while stroking back and forth over a residual breaking strength sheave. A tension of 300 lbs, the peak recovery tension during normal operation shall be used during one stroke, and a tension of 225 lbs, the nominal tension during a normal deployment, shall be used during the return stroke of each machine cycle. An example of a test apparatus is shown in Figure 4. During a test, continuity (as defined in 3.4.3) shall be monitored continuously. In the event of an electrical short or an open, the failed component(s) shall be identified, and the test shall be continued. At the conclusion of the test, one sample shall be dissected and visually examined for damaged components, and the other sample shall be pulled to failure to determine its residual breaking strength. In the case of a failure due to an unsatisfactory end termination, the test will be disregarded and a new test conducted.

3.0.2.2 REQUIREMENT. The cable shall be capable of withstanding 6,000 bending cycles. The cables shall meet the electrical requirements as specified in sections 3.4 after bending fatigue testing. The residual breaking strength shall be 3,000 lbs minimum.

Figure 4: Example of Bending Fatigue Life Test Apparatus

3.0.3 FUNNEL WEAR LIFE

3.0.3.1 PROCEDURE. Two samples, at least 15 ft long and prepared with terminations capable of providing the full cable breaking strength, shall be subjected to a test where the cable is cycled back and forth with a stroke of 3 ft while the cable is being bent 12.5 degrees over a section of aluminum rod that conforms to the helicopter funnel configuration. The cable shall be subjected to 2000 bending cycles while at a tension of 300 lb. An example of a test apparatus is shown in Figure 5. During the test, continuity of the test samples (as defined in 3.4.3 adjusted for the shorter length) shall be monitored continuously. At the conclusion of the test, one sample shall be dissected and visually examined for damaged components, and the other sample shall be pulled to failure to determine its residual breaking strength. In the case of a failure due to an unsatisfactory end termination, the test will be disregarded and a new test conducted.

3.0.3.2 REQUIREMENT. The cable funnel wear life strength shall be sufficient to meet the requirements of this specification. The residual breaking strength shall be 3,000 lbs minimum.

Figure 5: Example of Funnel Wear Life Test Apparatus

3.1 OPERATIONAL CONDITIONS

3.1.1 OPERATIONAL TEST

3.1.1.1 PROCEDURE. The cable shall be subjected to the operational test procedures as defined by the NAVAIR OPERATIONAL TEST PLAN FOR THE ALFS IMPROVED CABLE which will be conducted in an operationally representative environment. The NAVAIR OPERATIONAL TEST PLAN FOR THE ALFS IMPROVED CABLE will be developed as part of the test activities.

3.1.1.2 REQUIREMENT. The cable shall be capable of performing all operational tests when terminated with electrical connectors and wrapped on a system specific reel. The cable shall meet all requirements described in the NAVAIR OPERATIONAL TEST PLAN FOR THE ALFS IMPROVED CABLE.

3.2 Logistics/Maintenance Interface

3.2.1 LOGISTICS/MAINTENANCE INTERFACE

3.2.1.1 PROCEDURE. The cable will be subjected to the same storage, shipping, repair, and maintenance procedures as currently in effect and documented for the existing cable.

3.2.1.2 REQUIREMENT. Threshold: The cable shall meet all requirements described in the NAVAIR OPERATIONAL TEST PLAN FOR THE ALFS IMPROVED CABLE with minimal changes required to integrate the cable into the existing logistics and maintenance processes and procedures. Objective: The cable shall meet all requirements described in the NAVAIR OPERATIONAL TEST PLAN FOR THE ALFS IMPROVED CABLE with no changes required to the existing processes and procedures.

Note: The supplier is not responsible for delivering a cable that is compatible with existing logistics and maintenance processes and procedures, and the Government assumes responsibility for any changes to existing logistics and maintenance processes and procedures.

Table 1: Categories of Inspection

TEST OR EXAMINATION

PARA.

NO.

TEST

ARTICLE

QUALITY

CONFORMANCE

GROUP

ENVIRONMENTAL

ELECTRICAL

MECHANICAL

OPERATIONAL CONDITIONS

Logistics/Maintenance Interface

18 in