Attachment_3_CAC_Spec_Mar_15.pdf

5 February 2013 UNCLASSIFIED PMS401-CACSpec-01

UNCLASSIFIED

Common Acoustic Cabinet Performance Specification

Prepared for:

Department of the Navy

Program Executive Office, Submarines

1339 Patterson Street SE

Washington Navy Yard, DC 20376-7021

Prepared by:

Naval Undersea Warfare Center Division

1176 Howell Street

Newport, RI 02841-1708

DISTRIBUTION STATEMENT D:

Distribution authorized to DoD and DoD contractors only; Administrative or operational use.

Other requests shall be referred to PEOSUB, PMS401 Derived from: OPNAVINST S5513.5 (Encl 02.2) Date of source: 5 February 2013 i

TABLE OF CONTENTS

1.0 SCOPE

2.0 DOCUMENTATION

2.1 Government Specifications

2.2 Government Standards

2.3 Other Government Publications

2.4 Non-Government Documents

3.0 REQUIREMENTS

3.1 Description

3.1.1 Purpose

3.1.2 Subsystem Overview and Hardware Description

3.1.3 Towed Array Power Conditioning

3.2 Interfaces Requirement

3.3 Network Requirement

3.4 Environmental Requirement

3.4.1 Operational Temperature

3.4.2 Unit Cooling Requirements

3.4.3 Humidity Requirements

3.4.4 Pressure Requirements

3.4.5 Vibration Requirements

3.4.6 Enclosure Requirements

3.4.7 Shock Requirements

3.4.8 Structureborne Noise Requirement

3.4.9 Airborne Noise Requirements

3.4.10 Inclination (Ship Motion and Altitude) Requirements

3.4.11 Power Requirements

3.4.11.1 Power Factor

3.4.11.2 Surge / Inrush Current

3.4.11.3 Input Current Harmonic Distortion

3.4.11.4 Power On/Off Sequence

3.4.11.5 Load Unbalance

3.4.11.6 Power Interface Requirements

3.4.11.7 Voltage and Frequency Tolerance

3.4.11.7.1 Voltage Tolerance

3.4.11.7.2 Frequency Tolerance

3.4.11.7.3 Voltage Spike

3.4.11.7.4 Voltage Transient

3.4.11.7.5 Frequency Transient

3.4.11.7.6 Emergency Conditions

3.4.11.7.7 SABT Power Interruption

3.4.11.7.8 Voltage and Frequency Decay

3.4.11.7.9 Voltage and Frequency Positive Excursion

3.4.11.7.10 Single-Point Grounding

3.4.11.7.11 Chassis Grounding

3.4.11.7.12 Active Ground Detector

3.4.11.7.13 Electromagnetic Environmental Effects (E3)

4.0 DESIGN AND FABRICATION

ii

4.1 Workmanship

4.2 Physical Characteristics

4.2.1 Weight

4.2.2 Dimensions

4.2.3 Installation

4.2.4 Enclosure

4.2.5 Keying

4.2.6 Cables and Connectors

4.2.6.1 Connectors

4.2.6.2 Cables

4.2.6.3 Insulation Resistance (Wire)

4.2.6.4 Cable Category Designation

4.2.6.5 Color Coding

4.2.6.6 Fiber Optic Cables

4.2.7 Protective Finish

4.3 Hazardous and Restricted Materials

4.3.1 Toxic Products and Formulations

4.3.2 Ozone-Depleting Substances

4.3.3 Prohibited or Strictly Regulated Toxic Product, Effluent, or Emission List

4.3.4 Radioactive Materials

4.3.5 Glass Fibers

4.3.6 Painting

4.3.7 Capacitors

4.3.8 Vacuum Tubes

4.3.9 Fuse/Fuseholders

4.3.10 Semiconductors

4.4 Human Factors Engineering

4.4.1 Nameplates & Markings

4.4.2 Engineering Change Instruction Record Identification Plates

4.4.3 Reference Designations

4.4.4 Serial Numbers

4.4.5 Workmanship

4.5 Safety

4.5.1 Interlocks

4.5.2 Thermal Devices

4.5.3 Battleshort

4.5.4 High Voltage Protection

4.5.5 High Current Protection

4.5.6 Leakage Current Protection

4.5.7 Electrical Bonding

4.5.8 Radiation

4.5.9 Mechanical Hazards

4.5.10 Dielectric Withstanding Voltage

4.6 Safety and Health Hazards

4.6.1 Electrical Safety

4.6.2 Grounding

4.7 Transportation, Handling and Storage

4.7.1 General

4.7.2 Temperature

4.7.3 Humidity

4.7.4 Altitude

4.7.5 Logistics

iii

4.7.5.1 Reliability

4.7.5.2 Maintainability

5.0 CAC QUALIFICATION REQUIREMENTS

5.1 Qualification Methods

5.2 Qualification Tests

5.2.1 Error Limits for Hardware

5.2.2 Critical Item Tests

5.2.3 Environmental Qualifications

5.2.4 Factory Acceptance Test (FAT)

5.2.5 Operability Tests

5.2.6 Operability and Performance Verification Tests

5.3 Maintainability Demonstration

6.0 ACRONYMS & ABBREVIATIONS

LIST OF APPENDIX

Appendix A Cable Run Sheets……………………………………………………………………………………..A-1

Appendix B Example: TI12 Servers Detailed Specification……………………………………………………….B-1

LIST OF FIGURES

Figure 3-1 Structureborne Noise Requirement for Hard Mounted Electronics Equipment Figure 4-1 Hardware Cabinet Dimensions (Exterior) Figure 4-2 Hardware Cabinet Dimensions (Top & Bottom Views) Figure 4-3 I/O Connector Identification

LIST OF TABLES

Table 3-1 Platform-Dependent Interfaces Table 3-2 Airborne Noise Table 3-3 Inclination Requirement Table 4-1 Backplane Connector Detail Table 4-2 Power Cable Requirements Table 4-3 Prohibited/Strictly Regulated Toxic Products, Effluents, or Emissions

COMMON ACOUSTIC CABINET PERFORMANCE SPECIFICATION

1.0 SCOPE

This performance specification details the operational requirements and test requirements (environmental and evaluative) for the AN/BQQ-10(V) Common Acoustic Cabinet (CAC).

2.0 DOCUMENTATION

The documents listed in Section 2.0 are incorporated by reference and to the extent specified.

Where conflicts or contradictions arise among documents, this specification will govern.

2.1 Government Specifications

NAVSEA SW280-AA-IDS-060

22 November 1993

Interface Design Specification between the TB-16 Towed Array and the AN/BSY-2 Combat System

NAVSEA SW280-AA-IRS-070

Revision C, Change 4 19 February 1993

Interface Requirements Specification for the TB-29 (XN- 1)/BQ Towed Array, Rev N (with ERN 950220)

NUWCNPT TD 11,987

3 December 2010

TB-34 Performance Specification

SHIPS-A-5930(B)

28 May 1991 Revised 1 December 1992

Submarine Thinline Towed Body, TB-23/BQ Block Upgrades Product Function Specification

SHIPS-T-5974A

18 October 1991

Contract Specification – Towed Body Improved TB-16( ) /BQ Digital Product Function Specification

Ships-T-5976 1 September 1994

Prime Item Development Specification for the TB-29 Towed Body, PMO425

2.2 Government Standards

10 CFR 20

United States Nuclear Regulatory Commission - Standards for Protection Against Radiation

21 CFR 10 OSHA Hazard Communication Standard (HCS) - Radiation-

Emitting Products (Radiation Safety)

29 CFR 20, 1910.96

OSHA Hazard Communication Standard (HCS) - Toxic and Hazardous Substances

FED-STD-595 Federal Standard 595 Fan Decks, Specs, Chips & Chip Sets

MIL-C-22750G

12 September 2011

Performance Specification: Coating, Epoxy, High-Solids

MIL-DTL-15090E

12 October 2010

Detail Specification: Enamel, Equipment, Light Gray (Navy Formula No. 111)

MIL-STD-108E

through Notice 2

Definitions of and Basic Requirements for Enclosures for Electric and Electronic Equipment

MIL-STD-167-1A

2 November 2005

Mechanical Vibrations of Shipboard Equipment (Type I – Environmental and Type II – Internally Excited)

MIL-STD-461F

10 December 2007

Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-740-1

30 December 1986

Airborne Sound Measurements and Acceptance Criteria of Shipboard Equipment

MIL-STD-740-2

30 December 1986

Structureborne Vibratory Acceleration Measurements and Acceptance Criteria of Shipboard Equipment

MIL-STD-810G

31 October 2008

Department of Defense Test Method Standard: Environmental Engineering Considerations and Laboratory Tests

MIL-STD-901D

w/Interim Change 1 17 March 1989

Shock Tests, H.I. (High Impact) Shipboard Machinery, Equipment, and Systems; Requirements for

MIL-STD-1303C

Notice 1 24 April 2001

Military Standard: Painting of Naval Ordinance Equipment

MIL-STD-1310H

17 September 2009

Department of Defense Standard Practice for Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic Compatibility and Safety

MIL–STD–1399

Section 300B 24 April 2008

Interface Standard for Shipboard Systems Section 300B Electric Power, Alternating Current

MIL-STD-1472G

11 Jan 2012

Department of Defense Design Criteria Standard: Human Engineering

MIL-STD-1474D

12 February 1997

Military Standard: Design Criteria Standard, Noise Limits

MIL-STD-2042B

Notice 1 31 May 2007

Fiber Optic Cable Topology Installation Standard Methods for Naval Ships

MIL-W-21965D

27 June 1994

Water Cooling of Shipboard Electronic Equipment; General Specification for

2.3 Other Government Publications

MIL-HDBK-454B

15 April 2007

Department of Defense Handbook: General Guidelines for Electronic Equipment

NAVSEA-S9407-AB-HBK-010

Revision 2, Change 1 1 March 1999

Handbook of Shipboard Electromagnetic Shielding Practices

NAVSEA S9510-AB-ATM-010

Nuclear Powered Submarine Atmosphere Control Manual

2.4 Non-Government Documents

ACGIN 0100DocP/A

ISBM:978-1-607269-45-5

American Conference of Government and Industrial Hygienists (ACGIH) Threshold Unit Values (TLV) for Chemical Substances and Physical Agents in the Work Environment

ANSI/ASQC Q9001-2008

15 November 2008

Quality Systems Model for Quality Assurance in Design/Development Production, Installation, and Servicing

ANSI/IPC J-STD-001E

December 2010

Requirements for Soldered Electrical and Electronic Assemblies

ANSI/UL 60950

11 December 2000

Safety of information Technology Equipment Including Electrical Business Equipment

ANSI Z136.2 ANS for Safe Use of Optical Fiber Communication Systems

Edition 1997

Utilizing Laser Diode and LED Sources

ASME Y14.44-2008

21 November-2008

Reference Designations for Electrical and Electronic Parts and Equipment

EIA 310E

September 1996

Electronic Industries Alliance EIA-310-E, Cabinets, Racks, Panels, and Associated Equipment

IEEE 315-1975 IEEE Graphic Symbols for Electrical and Electronics Diagrams (Including Reference Designation Letters)

IEEE 315A-1986

Supplement to Graphic Symbols for Electrical and Electronics Diagrams

LMFS 77C960942

Rev 6, 7 August 2000

Interface Requirements Specification/Interface Design Specification for the TB-29A Towed Array (U)

NFPA 70

National Electrical Code

3.0 REQUIREMENTS

For the purposes of the Specification, any “shall” statement specified in this specification is a requirement that must be met.

3.1 Description

3.1.1 Purpose

1. The Common Acoustic Cabinet (CAC) will provide acoustic processing for towed sonar arrays, low frequency hull sonar arrays, spherical sonar arrays, high frequency sail arrays, auxiliary sensors, and AN/BQQ-10 support modes on SSN 688/688I and SSGN 726 class submarines for the Acoustic Rapid Commercial-off-the-Shelf (COTS) Insertion (ARCI) Program.

2. The CAC is a subset of AN/BQQ-10 equipment that provides capability upgrades via rapid insertion of COTS-based hardware. This hardware shall enable “refreshes” to mitigate obsolescence and/or incorporate reliability, availability, and maintainability improvements.

3.1.2 Subsystem Overview and Hardware Description

1. The CAC shall provide COTS-based processing hardware to support array receiving, signal conditioning, beamforming, signal processing, and data manipulation.

2. The CAC shall run on the Linux Operating System.

3. The Government will provide the enclosure (i.e., cabinet without internal components, connectors, and status panels) as GFM.

4. CAC components include:

a. Heat Exchanger

b. Power Distribution to cabinet components

c. Assignable Processors1 for ship sensors and support modes

d. Signal Conditioners for sensor/element data

e. Data Distribution/Network Switches2 for data transfer between assignable processors and signal conditioners/interface receivers

f. Power Supplies for the Towed Arrays

g. Slides and cables

h. CAC connector panel

i. CAC cabinet status panel

Notes: 1. Assignable Processors are considered Tech Refresh IPT defined items. A notional specification of an Assignable Processor is provided in Appendix B.

2. Data Distribution/Network Switches are considered Tech Refresh IPT defined items.

3.1.3 Towed Array Power Conditioning

1. The CAC shall power the following towed arrays in accordance with their respective specifications:

a. TB-16

b. TB-23

c. TB-29 / TB29A

d. TB-34

2. The CAC shall provide the following:

a. Reconfiguration of power to any combination of thin-line and fat-line towed arrays.

b. Equalization of towed array signal losses.

c. Decoupling of data streams for post-processing.

3.2 Interfaces Requirement

CAC shall provide interfaces per Table 3‐1.

Table 3-1 Platform-Dependent Interfaces

INTERFACE FUNCTION REFERENCES

TB-2X Towed Array Interface Receiver

Provides array power to TB- 23 or TB-29 towed arrays

Receives TB2X Array Telemetry Data from TB-23 or TB-29 towed arrays

TB-23 towed array interface defined in SHIPS-A- 5930(B) Prime Item Development Specification for the TB-

29 Towed Body defined in Ships-T-5976 1 September 1994

- Interface Requirements Specification/Interface

Design Specification for the TB-29A Towed Array defined in LMFS 77C960942, Rev 6, 7;

August 2000

- Table 4-1 Appendix (A)

TB-16/TB-34

Towed Array Interface Receiver

Provides array power to TB- 16 and TB-34 towed arrays

Receives TB-16 and TB-34 Telemetry Data from TB-16 and TB34 towed arrays

TB-16 towed array interface defined in SHIPS-T- 5974A and in NAVSEA SW280-AA-IDS-060.

Contract Specification – Towed Body Improved

TB-16( ) /BQ Digital Product Function Specification defined in SHIPS-T-5974A 18 October 1991 TB-34 towed array interface defined in

NUWCNPT TD 11,987

Table 4-1 Appendix (A)

Support Mode Data Acquisition Units

Noise Monitoring Hydrophone (NMH), Calibrated Reference Hydrophone (CRH), accelerometer data from Unit 4175 (Data Acquisition Unit) and (U4185 & U 4186) data -- Provides data and controls

Table 4-1 Appendix (A)

Power Control & Distribution

Receives 115VAC, 60Hz, 3- Phase power from ship’s supply

MIL–STD–1399, Section 300B Table 4-2

In addition, data from each respective sensor shall be synchronized to support correlation of contracts across sensors.

3.3 Network Requirement

1. CAC shall meet or exceed processing capacity and throughput per Appendices A and B.

2. The Technical Insertion IPT will coordinate the technology selection.

3.4 Environmental Requirement

3.4.1 Operational Temperature

1. Equipment shall be designed to operate from 0C to 46C ambient environments with inlet cooling water at 35C.

2. Equipment shall be operable for a minimum of 8 hours at maximum temperature of 46C ambient environments and 35C inlet cooling water.

3. Equipment shall be designed with a High Temperature Warning Test in accordance with MIL- W-21965D.

3.4.2 Unit Cooling Requirements

1. Capabilities shall be provided to remove heat generated by system electronics (via ambient air cooling or conductive water cooling).

2. Power dissipation shall accommodate a heat component load of 5661W.

3. Cooling capacity, as rated by the heat exchanger, shall be 7,000W.

4. CAC shall operate while exposed to cooling water with the following requirements:

a. Temperature of 21°C to 35°C, nominal temperature 27°C.

b. Flow rate of 1.4 gpm per kW.

c. Pressure up to 205 psig and shall maintain reliable operation after exposure to 275 psig.

3.4.3 Humidity Requirements

CAC shall remain operable in an environment of 50C with a relative humidity of 95%.

3.4.4 Pressure Requirements

The equipment shall operate reliably within the specified performance limits after exposure to atmospheric overpressure of 2 atmospheres (14.7 psi positive differential pressure on the equipment).

3.4.5 Vibration Requirements

Vibration requirements shall comply with MIL-STD-167-1A. CAC shall retain structural integrity and meet performance requirements during and after exposure to vibrations characteristic of shipboard environments. CAC cannot become a personnel hazard after exposure to said vibrations.

3.4.6 Enclosure Requirements

1. Enclosure requirements shall comply with MIL-STD-108E.

2. During and after testing, CAC shall not malfunction, exhibit degraded performance, or deviate beyond allowable tolerances as specified for the CAC or its subsystem).

3. Water shall not drip onto CAC internal electronics, power components, or pose any safety hazard at angles of 45°.

4. Drip-proof requirement shall consist of a sprinkler discharging water vertically downward at minimum rate of 1000 in3/ft2 per hour for a minimum duration of 12 minutes per tested orientation.

3.4.7 Shock Requirements

Shock requirements shall comply with MIL-STD-901D (Amended by Interim Change #1) medium weight, Grade B.

3.4.8 Structureborne Noise Requirement

1. Structureborne noise requirements shall comply with MIL-STD-740-2.

2. For forward end, hard mounted electronic equipment mounted to a stanchion supported deck and intended for installation on multiple hull classes, the structureborne noise limits as shown in Figure 3-1, shall be used.

Figure 3-1 Structureborne Noise Requirement for Hard Mounted Electronics Equipment

3.4.9 Airborne Noise Requirements

1. Airborne noise requirements shall comply with MIL-STD-740-1.

2. The airborne noise levels shall be in accordance with Table 3‐2.

Table 3-2 Airborne Noise

Ship Space

Octave Band Sound Pressure Level (dB re 20µPa) Octave Band Center Frequency (Hz)

31.5 63 125 250 500 1K 2K 4K 8K

Equipment Spaces 92 89 84 80 79 75 75 75 75

3.4.10 Inclination (Ship Motion and Altitude) Requirements

1. The equipment shall meet all performance requirements when subjected to the combined platform conditions of pitch, roll, and yaw.

2. Equipment having internal components that may be susceptible to motions such as inclination shall remain operable before, during and after the inclination testing described in Table 3-3 Inclination Requirement.

3. The unit under test shall be oriented in each of its rectilinear axis for each condition.

Table 3-3 Inclination Requirement

Angle Rate of Cycles

Per Minute Test Time

60 5-7 30 minutes minimum 1 Note:

1. Test time is defined as the amount of time required to show that the equipment operates normally under these conditions.

3.4.11 Power Requirements

Power requirements shall comply with MIL-STD-1399, Section 300B.

3.4.11.1 Power Factor

Power factor shall comply with Section 5.2.6 of MIL-STD-1399, Section 300B.

3.4.11.2 Surge / Inrush Current

Surge / inrush peak current shall comply with Section 5.2.10 of MIL-STD-1399, Section 300B.

3.4.11.3 Input Current Harmonic Distortion

Input Current Harmonic Distortion shall comply with Section 5.2.9 of MIL-STD-1399, Section 300B.

3.4.11.4 Power On/Off Sequence

1. Conditions resulting from a power on/off sequence:

a. Shall not be hazardous to personnel or ship

b. Shall not damage equipment

c. Shall not cause any abnormal operations to CAC equipment and / or interfaces.

2. Power-off control shall be provided for each drawer or subassembly.

3.4.11.5 Load Unbalance

Connected load current imbalance across the 3-phase input line sources shall be ≤3%.

3.4.11.6 Power Interface Requirements

1. Equipment power shall be at a power factor from 0.8 lagging to 0.95 leading.

2. Maximum normal operational power limits shall be 7,414W, nominal power is 7,242W.

3.4.11.7 Voltage and Frequency Tolerance

3.4.11.7.1 Voltage Tolerance

CAC shall not malfunction, degrade performance, or deviate from specified indications (beyond the tolerances indicated in the CAC or subsystem specifications) when subjected to the voltage tolerance requirements in Table I of Section 5.1 of MIL-STD-1399, Section 300B.

3.4.11.7.2 Frequency Tolerance

CAC shall not malfunction, degrade performance, or deviate from specified indications (beyond the tolerances indicated in the CAC or subsystem specifications) when subjected to the frequency tolerance requirements in Table I of Section 5.1 of MIL-STD-1399, Section 300B.

3.4.11.7.3 Voltage Spike

1. A voltage spike test shall be conducted to evaluate the capability of the CAC to withstand and operate before, during and after experiencing a voltage spike.

2. CAC shall remain operational before, during and after experiencing a voltage spike with the characteristics specified in Section 5.1.6.2.3 of MIL-STD-1399, Section 300B.

3.4.11.7.4 Voltage Transient

The CAC shall not malfunction, degrade performance, or deviate from specified indications (beyond the tolerances indicated in the CAC or subsystem specifications) when subjected to the voltage transient requirements of section 5.1.6.2 “System Voltage” of MIL-STD-1399, Section 300B.

3.4.11.7.5 Frequency Transient

The CAC shall not malfunction, degrade performance, or deviate from specified indications (beyond the tolerances indicated in the CAC or subsystem specifications) when subjected to the frequency transient requirements of section 5.1.6.1 “System Frequency” of MIL-STD-1399, Section 300B.

3.4.11.7.6 Emergency Conditions

The CAC shall be designed to withstand electric power interruptions, rapid reapplication of power, and the emergency conditions specified in section 5.2.3 “Emergency Conditions” of MIL-STD-1399, Section 300B.

3.4.11.7.7 SABT Power Interruption

The CAC shall operate through the 8 milliseconds power interruption (Static Automatic Bus Transfer - SABT requirement) without loss of data or requirement for a manual restart.

3.4.11.7.8 Voltage and Frequency Decay

Type I, II and III systems shall return to normal operation after being subjected to the voltage and frequency decay tolerances and durations as specified in the emergency conditions portion of Table I in section 5.1 “Electric Power System Characteristics” of MIL-STD-1399, Section 300B.

3.4.11.7.9 Voltage and Frequency Positive Excursion

Type I, II and III systems shall return to normal operation after being subjected to the voltage and frequency positive excursion tolerances and durations as specified in the emergency conditions portion of Table I in section 5.1 “Electric Power System Characteristics” of MIL- STD-1399, Section 300B.

3.4.11.7.10 Single-Point Grounding

1. Grounding shall comply with MIL-STD-1310H.

2. The return or neutral wire of the input power cable shall not be grounded within the cabinet.

3.4.11.7.11 Chassis Grounding

1. All external conducting parts shall be at grounding potential at all times.

2. Each chassis within the enclosure shall be electrically bonded to minimize electromagnetic interference (EMI).

3. The DC resistance measured from the electrically conductive frame of any assembly receiving primary power and the unit electrical bond point shall not exceed 0.1 ohms.

3.4.11.7.12 Active Ground Detector

The requirements shall comply with Section 6.7a of MIL-STD-1399, Section 300B.

3.4.11.7.13 Electromagnetic Environmental Effects (E3)

The requirement shall comply with MIL-STD-461F and MIL-STD-1399 (NAVY) Section 070 – Part 1.

4.0 DESIGN AND FABRICATION

4.1 Workmanship

1. The workmanship guidance is contained in MIL-HDBK-454B (Guideline 9). Finished items and parts shall not exhibit poor material and processing such as cracks, sharp edges, nicks, burrs, deformations and missing parts which may affect appearance, operations or safety.

2. Extraneous metal shall be removed from castings or forgings.

4.2 Physical Characteristics

1. The CAC shall be designed and developed for installation in a shipboard environment as specified herein.

2. Installation shall comply with installation control drawings (ICDs).

4.2.1 Weight

1. CAC weight shall be kept to a minimum commensurate with good engineering design and the detailed requirements of this specification.

2. Maximum CAC weight shall not exceed 1500 pounds. It is a goal to keep the weight under 1200 pounds.

3. Any equipment weighing more than 35 pounds shall clearly identify actual weight on the external surface of the equipment and shall be readily visible during installation and removal.

4. Design of rack-mounted and console equipment shall maintain the center of gravity as low as practical.

4.2.2 Dimensions

1. The CAC height shall not exceed 72 inches in overall height including the resilient mount acoustic isolators.

2. CAC width and depth shall not exceed 24 inches and 28 inches including the I/O connectors.

3. The design of the CAC shall require no more than 1.5 inches of sway space at the sides and back of the cabinet and no more than 1.25 inches of sway space at the top of the cabinet when installed.

4. Internal CAC hardware shall be rack-mountable in 19-inch rack mounts per EIA 310E.

5. The height of the internal stack up shall not exceed 38U (1U = 1.75 inches).

6. The CAC’s notational dimensions are shown on Figure 4-1 (exterior view) and Figure

4-2 (top and bottom view).

4.2.3 Installation

1. Equipment designed for installation on/in the submarine shall minimize the potential for damage during the loading and installation process.

2. Equipment shall be easily disassembled and reassembled for submarine installation thru a 30 inch hatch.

Figure 4-1 Hardware Cabinet Dimensions (Exterior)

Figure 4-2 Hardware Cabinet Dimensions (Top & Bottom Views)

4.2.4 Enclosure

1. The CAC enclosure shall employ RFI door gaskets and shielding of control and indicator openings as necessary to provide RFI shielding of the enclosed electronics.

2. Internal wiring shall be shielded, twisted, or of minimum length to limit the wire lengths and loop areas exposed to E- and H-fields consistent with the shielding effectiveness of the enclosure and the noise margins of the circuits.

4.2.5 Keying

Mechanical and electrical attachments and connections shall be keyed or otherwise designed to prevent incorrect attachment or installation.

4.2.6 Cables and Connectors

4.2.6.1 Connectors

1. Connectors shall not disconnect or loosen under the environmental conditions specified herein.

2. Connector plug or receptacle contacts, when disconnected, shall not shock maintenance personnel.

3. Multi-contact connectors shall be configured to prevent improper connection positioning or mating.

4. Where connector keys and keyways are used, a consistent connector main keyway alignment shall be used. Connectors shall be configured to prevent cross connection.

5. The back panel connectors shall be in the same configuration as shown on Figure 4-3.

This ensures that no modifications are required for ships’ cables or other AN/BQQ-10 cables connecting to the CAC.

Figure 4-3 I/O Connector Identification

4.2.6.2 Cables

1. The use of cabinet stuffing tube penetrations on assemblies containing electronics is prohibited unless approved in writing by NAVSEA.

2. The CAC external unit I/O cabling shall be as shown in Table 4-1.

3. Connector pin outs shall be per Appendix A.

Table 4-1 Backplane Connector Detail

CONNECTOR

CAC UNIT

RECEPTACLES

CABLE TYPE DESCRIPTION

J41 M28876/1F182 Fiber Network Interface (Gigabit Ethernet)

J45 BJ89F-7 M17/135-00001

TB-23/29/29A

Power Telemetry TB-23 Power

J46 BJ89F-7 M17/135-00001

TB-16 Power Telemetry TB-34 Power

J47 MS3412D32-17P LSTSGA-23 AC Power Input

J48 M28876/1C181 Fiber ACINT Telemetry

J50 M28876/1F181 Fiber Network Interface (Gigabit Ethernet)

J51 M28876/1F184 Fiber Support

J54 M28876/1B1S1N Fiber TB-34 Telemetry

J55 JT83723RJ45F None ATOMS Interface

J56 M28840/10AF1S1 -- Timing

4.2.6.3 Insulation Resistance (Wire)

a. Insulation resistance of the equipment shall not be less than 10 megOhms measured at 500 VDC for electrical cables.

b. Each circuit shall be measured against all other circuits connected together and to the chassis.

4.2.6.4 Cable Category Designation

Each cable shall be assigned an Electromagnetic Interference (EMI) category in accordance with

NAVSEA S9407-AB-HBK-010.

4.2.6.5 Color Coding

1. Cabling shall be color coded (except for power) using standard color-coding conventions.

2. Shipboard electrical distribution systems are delta-connected with a floating neutral, precluding the use of the safety ground as a power-carrying conductor. Color code for conductors given in Table 4-2 shall be maintained from the input power connections to all components having the same voltage and frequency as the input power.

Table 4-2 Power Cable Requirements

POWER TYPE VOLTAGE

CONNECTOR

PIN

ASSIGNMENT

CONDUCTOR

COLOR

Single Phase

440 VAC

A VAC White C VAC Black B Safety Ground Green

115 VAC

A VAC White C VAC Black B Safety Ground Green

Three-Phase 115/440

A Phase A Black B Phase B White C Phase C Red D Safety Ground Green

DC ---

A Positive Red B Negative Black C Ground Green

4.2.6.6 Fiber Optic Cables

1. The inboard fiber optic components for transmitting optical signals throughout the ship shall comply with MIL-STD-2042 (SH), Fiber Optic Systems Design.

2. Fiber optic hardware shall be fabricated /assembled in accordance with MIL-STD-2042 (SH), Fiber Optic Cable Topology Installation Standard Methods for Naval Ships.

3. Fiber optic cable link loss testing shall be performed in accordance with MIL-STD-2042 (SH), Fiber Optic Cable Topology Installation Standard Methods for Naval Ships, Section 6, Procedure II, Method 6C1 for all cable assemblies. This includes cable assemblies internal to subsystem equipment. The pass/fail criteria for each mated pair of inboard fiber connectors shall be 0.8 dB (maximum).

4. Subsystems shall use ANSI Standard Z136.2 for fiber optic safety requirements and classification of optical sources.

4.2.7 Protective Finish

The materials and coatings shall protect the CAC from degradation in all shipboard environments.

4.3 Hazardous and Restricted Materials

Equipment shall not expose personnel to toxic substances in excess of the threshold limit values contained in ACGIN 0100DocP/A (American Conference of Government and Industrial Hygienists (ACGIH) Threshold Limit Values (TLV) for Chemical Substances and Physical Agents in the Work Environment -- ISBM:978-1-607269-45-5).

4.3.1 Toxic Products and Formulations

Toxic products and formulations such as Volatile Organic Compounds shall not be used unless specifically allowed by NAVSEA S-9510-AB-ATM-010.

4.3.2 Ozone-Depleting Substances

Class I Ozone Depleting Substances shall not be used as a part of the CAC, during the manufacturing of any of its subsystems or during maintenance processes.

4.3.3 Prohibited or Strictly Regulated Toxic Product, Effluent, or Emission List

1. Use of the 75 hazardous materials listed in Table 4-3 is to be minimized or avoided to the maximum extent practicable as a New Attack Submarine whole-ship pollution prevention initiative, either on the ship’s subsystem or specified for use in maintaining the subsystem. To the extent that the listed hazardous materials are not otherwise restricted under 15 U.S.C. Section 2606, their use shall only be permitted with the prior written approval of NAVSEA.

2. Requests for NAVSEA approval shall describe specifics for each instance the material is to be used (including component, location, how used and quantity).

4.3.4 Radioactive Materials

1. Use of radioactive materials shall conform to 10 CFR 20, Nuclear Regulatory Commission regulations and shall require approval of the procuring activity.

2. Radium shall not be used to achieve self-luminosity.

4.3.5 Glass Fibers

1. Glass fiber materials shall not be used as the outer surface or covering on cables, wire or other items where they may cause skin irritation to operating personnel. This does not preclude the use of military specification wire and cable.

2. When maintenance procedures require access to glass fibers, such as insulation, a proper caution note shall be provided.

4.3.6 Painting

1. Paint shall include fungus retardants and tolerate occasional exposure to salt-fog spray.

2. All aluminum and aluminum-alloy exterior surfaces not exposed to the weather shall be prepared and painted in accordance with MIL-STD-1303C, System 37 or 75.

3. Interior surfaces shall not be painted.

4. System 75 paint shall conform to MIL-C-22750G.

5. System 37 paint shall conform to MIL-DTL-15090E.

6. Color shall be No. 26307 as specified by FED-STD-595.

Table 4-3 Prohibited/Strictly Regulated Toxic Products, Effluents, or Emissions

1,1,1-Trichloroethane 1,1,2-Tricholoro, 1,2,2-Trifluroethane 2-Methoxyethanol 2-Nitropropane 4,4 Dimethylaniline Acetone Acrtylamino Benzene Acrylonitrile Alpha Naphthylamine Aminodiphenyl Aniline Arsenic Asbestos Benzene Bensene Hexacholoride Benzidene Beryllium Beta Napthylamine Beta Propioactone Bromine Cadmium Calcium Hypocholorite Carbon Disulfide Carbon Tetrachloride Chlorine Chloroform Chromium DDT Dichlorobenzene Dimethylaminoazobenzene Ethyl Alcohol Ethylene Dicholoride Ethylene Glycol Ethylene Oxide Ethylenimine Formaldehyde Hydrazine Hydrochloric Acid Hydrogen Cyanide Isocyanates Lead Lithium Hydroxide Mercury Methanol Methoxychoir (DMDT) Methyl Bromide Methyl Ethyl Ketone Methylene Chloride Methylenebis (2-Choloroaniline) Monoethanolamine Nickel Nitrobiphenyl Nitrosamine Nitrous Dimethylamine Ortho-Choloraniline Paradichlorobenzene Phenol Polychlorinated Biphenyls Pyridine Selenium Silver Sodium Arsenite Sodium Chromate Sulfanic Acid Tetrachloroethane Tetrachloroethane Tetrachlorethylene Tetraethyl Phosphate Toluene Toluene Diisocyanate Tri-N-Butyl Tin Hydride Tricholoroethylene Trichloroisocyauric Aic Triorthocresylphosphate Vinyl Chloride Xylene Zinc Chromate

4.3.7 Capacitors

The application and restriction on usage of capacitors shall be as specified below:

1. Compression (spring plate) type variable capacitors shall not be used.

2. Paper, paper-plastic and metalized paper capacitors in molded cases shall not be used.

3. The use of Wet slug tantalum capacitors shall require NAVSEA approval.

4.3.8 Vacuum Tubes

Vacuum tubes shall not be used, except for Cathode Ray Tubes (CRTs) or other devices used for direct view display devices.

4.3.9 Fuse/Fuseholders

1. Fuseholders shall provide blown fuse indication for newly developed items.

2. All fuses and circuit breakers shall be readily accessible for replacement.

3. Fuseholders containing spare fuses for each fuse value used shall be provided as part of the equipment.

4.3.10 Semiconductors

1. Components, such as integrated circuits, transistors, diodes and other semiconductors shall be selected to withstand an operating temperature as specified in section 3.4.1.

2. Germanium semiconductors shall not be used.

4.4 Human Factors Engineering

The guideline shall comply with MIL-STD-1472G.

4.4.1 Nameplates & Markings

Part identification shall comply with ASME Y14.44, IEEE 315, IEEE 315A-1986. Part identification may differ among COTS products.

4.4.2 Engineering Change Instruction Record Identification Plates

An identification plate, visible from the front of the unit, shall be affixed to a unit to note completion of engineering changes to equipment.

4.4.3 Reference Designations

1. Part-identification-by-reference designations shall comply with ASME Y14.44. As an exception, pluggable electronic modules may use a coordinate locator system with component part location documented in the maintenance documentation.

2. All removable panels, drawers and assemblies shall have appropriate subassembly markings to permit rapid re-installation.

4.4.4 Serial Numbers

All equipment units shall be marked with unique serial numbers.

4.4.5 Workmanship

1. Workmanship shall comply with best commercial design practices and ANSI/ASQC Q9001-2008.

2. Soldering workmanship shall comply with ANSI/IPC J-STD-001E.

4.5 Safety

1. The CAC design shall ensure that two procedural errors, or the malfunction of any single hardware or software component shall not result in catastrophic hazards (causing death, system loss or severe environmental damage) or critical hazards (causing severe injury, severe occupational illness, major system or environmental damage).

2. Marginal and negligible hazards shall be controlled to the maximum extent within established operating and cost constraints.

3. CAC safety requirements shall comply with UL PAG 1950, except for leakage current which shall not exceed 30 mA and require a warning label if over 5 mA.

4. Waivers of safety requirements shall require written approval of the procuring agency.

5. Switches for disconnecting the equipment from electrical power systems shall close all power conductors.

6. The safety ground shall not be disconnected.

7. A safety ground shall be provided on all equipment in accordance with ANSI/UL 60950.

8. Disconnect switches for the CAC shall be provided by circuit breakers in a primary power control unit external to the CAC.

4.5.1 Interlocks

1. Protective shields (preferred) or interlocks shall be provided to protect personnel from accidental contact with parts in excess of 30 Vrms or 30 VDC.

2. Interlocks shall be overridden by battleshort.

3. Interlocks shall have the ability to be bypassed by the operator for purposes of maintenance.

4.5.2 Thermal Devices

1. Temperature sensors shall be provided in the CAC to sense temperature conditions above the maximum normal operating temperatures of the equipment.

2. Whenever sensors detect abnormal temperatures:

a. A unit’s thermal warning indicator shall be illuminated.

b. A power interlock shall be opened to cause power to be removed from the CAC.

3. Power shall not be able to be reapplied until the temperature condition has returned to a safe level (unless a battleshort condition is intentionally selected).

4.5.3 Battleshort

1. A battleshort capability shall be provided for the CAC in order to maintain operation through bypass of safety interlocks as assembly protective devices.

2. A readily visible indicator light shall indicate that the battleshort switch is ON.

3. Indications shall be provided to indicate safety interlock bypasses.

4. Activation of battleshort shall not prevent normal reporting of anomalous conditions to appropriate personnel.

5. Activation of battleshort shall not cause any assembly to be energized that has previously been de-energized by unit/drawer/assembly power on/off switch.

6. Battleshort guard shall be put in place to prevent an inadvertent activation.

4.5.4 High Voltage Protection

1. Protection from dangerous voltages (30 to 500Vrms or 30 to 500 VDC) shall be provided by the use of guards, grounding and warning placards.

2. Assembly operating at potentials exceeding 500 Vrms or 500 VDC shall be enclosed completely.

3. The maximum time required to discharge components/assemblies from operating voltages (of 30Vrms or less) shall be 10 seconds.

4.5.5 High Current Protection

1. Protection from shock hazards occurring from contact with current producing circuitry of 21 maAC or 80 maDC at a potential of greater than 30 VDC or 30Vrms shall be provided.

2. For high current (≥20 Amps) power sources, positive design measures shall be incorporated by the use of guards, barriers, and warning placards.

4.5.6 Leakage Current Protection

1. In order to evaluate leakage current for potential shock hazards, a leakage current test shall be conducted that requires a dedicated ground conductor or connection path to the ship’s hull. Therefore, the leakage current test is not necessarily conducted at the ship’s interface but on all equipment requiring a ground conductor or connection path to the ship’s hull. Leakage current test limits are defined for two frequency ranges.

2. Leakage current shall meet the requirements of section 5.2.4.1 “Human Body Leakage Current Limits for Personnel Safety” of MIL-STD-1399, Section 300B.

3. The leakage current of the CAC shall not exceed 30 mA and shall require a warning label if over 5 mA.

4. The equipment load line-voltage-connections shall be isolated from the equipment chassis by 10 megOhms per kilowatt.

5. Low frequency leakage current shall comply with Section 5.2.4.1.1of MIL-STD-1399, Section 300B.

6. High frequency leakage current shall comply with Section 5.2.4.1.2 of MIL-STD-1399, Section 300B.

4.5.7 Electrical Bonding

1. All external conducting parts of the CAC shall be at ground potential at all times.

2. Bonding surfaces for the CAC shall be corrosion resistant.

3. Each chassis within the CAC enclosure shall be grounded to the enclosure.

4. Doors for the CAC that contain electrical components shall be grounded to the unit.

4.5.8 Radiation

1. The CAC shall not emit x-ray radiation at a level exceeding 0.5millirems/hour when operated at its maximum ratings, as measured two inches from the front of or any other accessible point of the unit.

2. Measurement shall be made at normal line voltage +/- 1 percent.

3. Other exposure shall be based on application criteria and limits as required by Nuclear

Regulatory Commission Rules and Regulations, 1- CFR10, Occupational Safety and Health Administration (OSHA) Regulations 29 CFR 1910.96,; and FDA Regulation 21 CFR 10, Chapter I, Subchapter J, Radiological Health.

4.5.9 Mechanical Hazards

1. The design of the CAC shall be such that maximum access and safety is provided while installing, operating, and maintaining the equipment.

2. Suitable protection shall be provided to prevent contact with moving mechanical parts such as fans, when the equipment is operating.

3. Sharp projections on the cabinet, doors, and similar parts shall be avoided.

4. Doors or hinged covers shall be rounded at the corners and provided with stops to hold them open.

5. Equipment design shall include provisions to prevent accidental pulling out of drawers or rack-mounted equipment components which could cause equipment damage and injury.

6. CAC power switches shall be designed and located so that electrical contact shall not place equipment in operation.

4.5.10 Dielectric Withstanding Voltage

1. The CAC shall be designed such as to prevent electrical breakdown such as corona, flash-over (surface discharge), spark-over (air discharge), or breakdown (puncture discharge) when the electrical power circuits are subjected to the dielectric test voltages for a period of one minute at 60 Hz.

2. The CAC high voltage assemblies shall be tested for dielectric strength in accordance with ANSI/UL 60950.

4.6 Safety and Health Hazards

1. The CAC shall incorporate features that provide for the safety of operators and support personnel during operation, maintenance and storage.

2. Safety features shall prevent any component failure from creating a personnel hazard.

3. Potentially hazardous areas shall be controlled and appropriate marking or labeling shall be used.

4.6.1 Electrical Safety

The CAC design shall include the electrical safety provisions identified in NFPA 70, National Electric Code and ANSI/UL 60950 Standards for Safety of Information Systems Equipment.

4.6.2 Grounding

1. The CAC design shall ensure that all non-current-carrying metal parts are grounded by non-current-carrying conductors.

2. System design shall ensure the system operates at a safe electrical ground potential, provides internal grounding to chassis, and incorporates adequate shielding.

4.7 Transportation, Handling and Storage

1. The CAC components, when prepared for transportation by truck, rail, air, or long term storage, shall be protected against damage from normal transportation or storage environmental conditions.

2. The CAC will have designated lifting points.

4.7.1 General

1. All equipment weighing more than 150 pounds shall have inserts to accommodate lifting eyes.

2. Hardware fasteners used in the transport of equipment shall not be utilized for shipboard installation.

3. Equipment shall be designed to minimize transport/handling requirements for cabinet disassembly.

4. Cabinet design shall integrate the requirement for both land and high altitude air transport (pressure equalizing features) to ensure cabinet internals survive land and high altitude air transport.

5. Cabinet design shall incorporate temporary protective covers for shipment, handling, and installation for such items as CRTs, RF gasket materials, protruding controls, and cabinets susceptible to damage.

4.7.2 Temperature

The equipment shall not be damaged nor shall the operational performance be degraded when restored to the operating temperature range after exposure for long periods, 24 hours minimum, in a non-operating air temperature range of +10°C to +40°C.

4.7.3 Humidity

1. The humidity requirements shall be up to 100 percent relative humidity.

2. Where applicable, consideration shall be given to means for maintaining desiccants for long-term storage in humid conditions.

4.7.4 Altitude

The altitude requirements shall be from -300 to +50,000 feet.

4.7.5 Logistics

4.7.5.1 Reliability

1. The CAC Meantime Between Failure (MTBF) shall be greater than or equal to 3,000 hours when operating in a ground benign environment with a nominal inlet cooling water temperature of 35C.

2. The quantitative CAC reliability requirements shall be demonstrated analytically by the reliability prediction.

4.7.5.2 Maintainability

The CAC Mean-time-to-Repair (MTTR) shall be less than or equal to 20 minutes.

5.0 CAC QUALIFICATION REQUIREMENTS

5.1 Qualification Methods

Qualification methods to verify system requirements include: inspection, analysis, demonstration, test or some combination thereof. Qualification methods are defined:

1. Inspection –includes examination, review of documentation and comparison with a predetermined standard. This method may require moving or disassembling.

2. Analysis –includes quantitative proof that all items meet specified requirements by the technical evaluation of equations, charts, graphs, circuit diagrams and representative data.

3. Demonstration – means the operation of the item. The item may be instrumented and its performance monitored, but only in support of the demonstration. Success/failure criteria are established for each demonstration objective.

4. Test –includes operating an instrumented item and then evaluating the resultant quantitative data. Acceptability of the item is determined by pre-established quantitative criteria. Verification is made against the required characteristics stated in the applicable specification.

5.2 Qualification Tests

The minimum sets of qualification tests for the CAC are:

1. Critical Item Test (CIT) - Including Swap-Out, Re-Run, and Remove-Replace testing

2. Environmental Qualification – of environmental conditions such as ambient air temperature, equipment cooling, humidity, pressure, vibration, enclosure, shock, structureborne noise, airborne noise, inclination (ship motion & altitude), electromagnetic compatibility, and power.

3. Factory Acceptance Test (FAT) – Including Factory Acceptance Test, Burn-in Testing, Hardware operability and Performance Verification Test (PVT).

4. Maintainability Demo (M-Demo) - The M-Demo shall demonstrate correction of organizational level hardware failures through the hardware repair/replacement process.

5.2.1 Error Limits for Hardware

No hardware faults shall be present within the contractor-furnished hardware at completion of testing.

5.2.2 Critical Item Tests

1. Sensor data routing and signal distribution Critical Item Tests (CIT) shall be demonstrated to ensure that the CAC meets the performance requirements of the Sonar Subsystem.

2. Critical item tests shall include testing of the following:

a. Sensor data routing

b. Signal distribution

c. Thermal testing (cooling, airflow).

5.2.3 Environmental Qualifications

The CAC shall be capable of operating aboard various platforms with the environmental conditions specified in the following sections. Environmental requirements are defined with consideration for all platforms.

The CAC is required to remain operational under various environmental conditions at all ship orientations for any and all combinations of ship’s motion for submerged, snorkel, and surface operations at all speeds as defined in the ship operating envelope.

The goal of this specification is to mitigate as much technical risk as is practicable by maximizing testing while minimizing cost with respect to both conducting the test as well as assets consumed. Consequently it is the recommendation of this specification to perform, where possible, as many non-destructive or low-risk tests prior to the high-risk or destructive testing.

The potentially destructive or higher risk tests, in each discipline are as follows:

Electromagnetic Compatibility Testing: CS106 Power Testing: Voltage Spike Testing Mechanical Testing: Vibration and Shock

5.2.4 Factory Acceptance Test (FAT)

1. Contractor Factory Acceptance Test (FAT) and subsequent Government approval shall ensure that the contractor can furnish a product that conforms to all contract requirements for acceptance.

2. Factory Acceptance “testing” shall include the necessary inspections and tests to ensure all product characteristics conform to drawings or specifications.

3. Contractor FAT test strategy shall include the following:

a. Verify the inspection of critical or major product characteristics or processes identified in the FAT report by independently inspecting or witnessing the supplier’s inspection or testing of these characteristics. This includes characteristics or processes performed at subcontractors.

b. Perform sample verification of all other (non-critical or non-major) product characteristics or processes to the degree necessary to establish confidence of product conformance to technical specifications.

c. Ensure that the manufacturing processes, materials, and facilities used to produce the FAT product are the same as those to be used to produce production runs.

d. Report test results that clearly demonstrate the product conformance to technical specifications.

4. Factory Acceptance Tests shall be formal test(s) performed on hardware offered for delivery. These test(s) shall demonstrate critical safety requirements (e.g., leakage current and hardware performance) and functional performance tests that selectively demonstrate compliance with the requirements of this specification as well as production inspections which ensure quality in the production process.

5. Acceptance tests are generally performed as "black box" tests. Black box testing means that the tester uses specified inputs into the system and verifies that the resulting outputs are correct, without knowledge of the system's internal workings.

5.2.5 Operability Tests

Subsystem operability test shall be a 48-hour burn-in operability test designed to minimize hardware infant mortality.

5.2.6 Operability and Performance Verification Tests

1. Unit operability and Performance Verification Tests (PVTs) shall be conducted on each function required to implement the requirements of this specification on production representative hardware.

2. PVTs shall demonstrate system compliance with all functional/performance requirements of this specification.

5.3 Maintainability Demonstration

1. The Mean Time to Repair (MTTR) requirement of this specification shall be verified by test during the subsystem M-Demo.

2. The M-Demo shall be conducted in an environment that simulates actual shipboard conditions such as proximity of adjacent equipments and restrictions/limitations on equipment accessibility.

3. The M-Demo shall demonstrate correction of organizational level hardware failures through the hardware repair/replace process.

4. Corrective maintenance time does not include time to obtain replacement items or other logistics delays, but shall include time for: fault localization initiation; fault localization;

fault isolation; remove and replace; warm up; recalibration, alignment, and/or adjustment;

and repair validation. This shall include the time to restore all hardware, processes, functions, files, and data bases to a functional state as…