2_-_FORS_System_Performance_Specification_20160322.docx

Department of the Navy Program Executive Office PMA260 Naval Air Systems Command Patuxent River, Maryland 20670-1547 PERFORMaNCE SpECIFICATION

System Specification For

FIBER-OPTIC REPAIR SET

(FORS)

Prepared By:

Naval Air Warfare Center Aircraft Division SE and ALRE Department SE and ALRE Systems Engineering Division Avionics SE Projects Branch

Date: _________ Date: _________

Date: _________ Date: _________

List of Figures and Tables

PMA260C12/3583

01 September 2015

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

Revision History

Table of Contents

Scope Identification The Fiber-Optic Repair Set (FORS), NIIN 01-528-5511, is being acquired by NAVAIR PMA-260 as common support equipment.

System Overview Fiber-optic cables are installed on Navy and Marine Corps aircraft primarily to handle high-speed data. The fiber-optic links are subject to the same environmental conditions as metallic-wire cabling and require maintenance. Some aircraft employ short fiber cable runs that are easily removed and replaced by maintainers, but in other cases long cables are routed through bulkheads, behind consoles, and under flooring, which makes cable replacement impractical anywhere but the Depot. Hence, the ability to repair fibers in the aircraft at the Organizational Level (O-Level) will reduce cost and increase mission readiness. The FORS will provide this capability.

The primary functions of the FORS are: 1) preparing and conditioning the fibers and their end faces; 2) splicing the fiber ends; and 3) restoring the physical integrity of the cable. The FORS will be used to maintain Navy and Marine Corps aircraft at the Organizational Level (O-Level) of maintenance on aircraft carriers and at shore-based facilities.

Document Overview This System Performance Specification (SPS) defines the minimum performance requirements, physical requirements, and environmental and electromagnetic requirements of the FORS.

Applicable Documents, Terms, and Definitions The following documents of the exact issue shown form a part of this specification to the extent specified herein. In the event of conflict between the listed documents and the contents of this specification, the contents of this specification shall be considered the superseding requirement.

Government Documents

Program Responsibilities and Procedures

Terms and Definitions

System Requirements Definition General Description The FORS is a complete set of equipment that will provide to the U.S. Navy and Marine Corps the ability to execute low-loss, permanent splices on damaged fiber-optic cabling in aircraft avionics bays and compartments.

FORS will be composed of a rugged transit case and equipment and accessories that have been hardened to meet the electromagnetic and environmental conditions of military applications. It will be used to: 1) prepare and condition the fibers and their end faces for a splice, 2) splice the fiber ends, and 3) restore the physical integrity of the cable.

Operational Requirements Need Navy aircraft maintenance procedures call for environmentally and electromagnetically suitable equipment for repairing and splicing fiber-optic cables installed in aircraft.

Mission utilization profile The FORS will be employed at the O-Level on the hangar deck of air-capable ships and at Navy and Marine Corps ground facilities to repair fiber-optic cables on aircraft.

Characteristics Performance Characteristics Fiber types The FORS shall repair single-mode and multimode fiber types. FORS shall repair fibers where special coatings (such as polyimide) are applied around the fiber cladding. The following fiber types shall be supported:

· Single-mode: 9/125

· Multimode: 50/125

· Multimode: 62.5/125

· Multimode: 100/140

· Multimode: 200/230 Splice preparation The FORS shall contain equipment and tools for preparing the fiber for a splice as specified below.

Exposing the bare fiber The FORS shall contain equipment and tools for removing the cable jacket, cutting any strength member (e.g., Kevlar), and stripping the fiber buffer and coating from the fiber ends.

Conditioning the fiber end faces The FORS shall contain equipment and tools to condition the end faces of the fiber (e.g., cleave, shape, polish) to achieve a low-loss connection as specified herein.

Power loss (insertion loss) The FORS shall contain equipment and tools to align and conjoin the fiber ends to create a permanent connection having a power loss of less than 0.5 dB.

Restoring the physical integrity of the cable The FORS shall restore the physical integrity of the spliced cable. Section 4.2.1.4 specifies the physical properties to be restored and their associated verification tests.

Physical Characteristics Size and weight The FORS shall have a maximum weight of 37 pounds. (This value is derived from MIL-STD-1472G, Table XXXVIII “Maximum Design Weight Limits,” assuming one lifter, a “Male and Female” population, and a lift height of five feet above floor level.)

The maximum weight applies to FORS with a uniform mass distribution and a size not exceeding 18 inches high by 18 inches wide by 12 inches deep (i.e., away from the lifter). If the depth exceeds 12 inches, the maximum weight of the FORS shall be reduced in accordance with section 5.8.6.3.3 (Load size) of MIL-STD-1472G.

Display readability If FORS equipment has a display or indicator lights, they shall be readable in low light (characterized by an illumination of 0.25 lux or less) and in full daylight (characterized by an illumination of 20,000 lux or greater).

Batteries The FORS shall be energized by batteries that are removable and replaceable by the user. The FORS shall perform at least five splice operations before the batteries must be replaced or recharged. Lithium-based batteries (if employed) shall have more than one source of supply and shall comply with NAVSEA S9310-AQ-SAF-010, Revision Two.

Transit case The FORS shall have a rugged transit case that meets the physical characteristics of section 3.7 of MIL-PRF-28800F for the environmental characteristics specified in 3.2.3.4 through 3.2.3.7 herein.

To reduce the potential for FOD and to facilitate the identification of missing items, all parts and accessories contained within the case shall be held captive. The case shall contain a durable contents chart with a diagram showing the layout of the parts and accessories within.

Operating workspace The FORS shall perform splices in the confined spaces of aircraft avionics bays and compartments. Section 4.2.2.5 specifies the validation metric for working volume.

Environmental Characteristics The FORS shall be compatible with the hangar decks of aircraft carriers and U.S. Navy and Marine Corps ground facilities. The FORS shall conform to the operational environmental requirements of MIL-PRF-28800F as specified and de-rated in the following sub-sections.

High temperature The FORS shall not be damaged and shall perform without degradation when exposed to a high operating temperature of 49 degrees Celsius (120 degrees Fahrenheit) and a high storage temperature of 71 degrees Celsius (160 degrees Fahrenheit).

Low temperature The FORS shall not be damaged and shall perform without degradation when exposed to a low operating temperature of -10 degrees Celsius (14 degrees Fahrenheit) and a low storage temperature of 40 degrees Celsius (-40 degrees Fahrenheit).

Relative humidity The FORS shall not be damaged and shall perform without degradation when the relative humidity is 5 to 95 percent in the temperature range of 10 to 30 degrees Celsius (inclusive), 5 to 75 percent in the temperature range of 31 to 40 degrees Celsius (inclusive), and 5 to 45 percent for temperatures above 40 degrees Celsius.

Bounce, loose-cargo FORS equipment shall not be damaged and shall perform without degradation after the FORS is subjected to the loose-cargo bounce test of section 4.2.3.4.

Transit drop FORS equipment shall not be damaged and shall perform without degradation after the FORS transit case (with its contents) is dropped once on each face, edge, and corner from a height of 48 inches.

Splash resistance The FORS transit case shall protect its contents from splashed seawater intrusion.

Sand and dust resistance The FORS transit case shall protect its contents from the intrusion of sand and dust particles.

Explosive atmosphere The FORS shall safely perform all operations in volatile atmospheres and shall not cause ignition of an ambient-explosive-gaseous mixture with air.

System Quality Factors (Reliability) The Mean Time Betwen Failures (MTBF) of the FORS shall be at least 50 splice operations for equipment and tools other than normal wear items (e.g., shears, strippers, and cutters).

Design and Construction Hazardous Materials Hazardous materials (i.e., restricted materials and targeted chemicals) are any items or biological, chemical, or physical agents that have the potential to cause harm to humans, to animals, or to the environment, either by themselves or through interaction with other items or agents. This includes but is not limited to materials that:

· are regulated as a hazardous material per 49 CFR 173.2

· require a Material Safety Data Sheet (MSDS) per 29 CFR 1910.1200

· are regulated as an Extremely Hazardous Substance (EHS) per 40 CFR 355, Appendices A and B

· are regulated as a Toxic Chemical per 40 CFR 372.65

· meet or have the potential to meet the definition of hazardous waste as defined by 40 CFR 261 Subparts A, B, C, or D during end use, treatment, handling, packaging, storage, transportation or disposal

· are referred to in section 101(14) or Section 102 of the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) per 40 CFR 302.4, or

· are identified as a Volatile Organic Chemical (VOC) per 40 CFR Part 51.100(s).

· are regulated as an Ozone Depleting Substance (ODS) per 40 CFR 82 Subpart A, Appendices A and B

· are identified in the Clean Air Act, Chapter 85, Subchapter I – 7412 as a Hazardous Air Pollutant (HAP) Restricted materials The following restricted materials shall not be used for the FORS throughout its life cycle, including its manufacture, operation, maintenance, and disposal:

· Asbestos

· Class-I Ozone-Depleting Substances (ODS)

· Class-II ODS

· Polychlorinated Biphenyls (PCBs)

· Hexavalent chromium Targeted chemicals Targeted chemicals shall not be used in FORS parts and components unless no technically feasible alternative exists.

The following hazardous materials are identified as targeted chemicals: Arsenic & Arsenic Compounds, Benzene, Beryllium & Beryllium Compounds, Cadmium & Cadmium Compounds, Chloroform, Chromium & Non-Hexavalent Chromium Compounds, Cyclotrimethylenetrinitramine (RDX), Cyanide Compounds, Ethylene Glycol, Formaldehyde, Glycol Ethers, Hydrazine, Hydrofluoric Acid, Isocyanates, Lead & Lead Compounds, Mercury & Mercury Compounds, Methyl Ethyl Ketone (MEK), Methyl Isobutyl Ketone (MIBK), Methylene Chloride, Methylene Dianiline (MDA), Naphthalene, Nickel & Nickel Compounds, Perchlorates, Perchloroethylene, Perfluorooctanoic Acid (PFOA), Phenol, Polybrominated Diphenyl Ethers (PBDEs), Radioactive Materials, Toluene, Trichloroethylene (TCE), and Xylene & Xylene Isomers.

Exemptions The following materials are exempted:

· Hexavalent chromium in concentrations of less than 0.1 percent by weight in any homogeneous material

· Chromium and nickel as constituents of metal alloys

· Lead as a constituent of solder Electromagnetic Compatibility For radiated emissions, the FORS shall be electromagnetically compatible with the flight deck of aircraft carriers and air-capable ships. For radiated susceptibility, field strengths associated with the hangar deck shall not cause damage to the FORS or degrade its performance.

Quality Assurance Provisions Responsibility for Testing The contractor shall be responsible for all tests and demonstrations for verifying the requirements specified in section 3 herein. The contractor may utilize its own personnel and facilities or any qualified commercial facility acceptable to the government, which reserves the right to witness or participate in any testing conducted by the contractor or its agent.

Characteristics Verification Performance Characteristics Verification Fiber types The fiber types requirements in section 3.2.1.1 shall be verified via demonstration by performing 25 splices on each of the following fiber types (or their equivalents):

Splice preparation verification The requirements of sections 3.2.1.2.1 and 3.2.1.2.2 shall be verified via demonstration. The bare fiber shall be exposed and the fiber end faces shall be conditioned (cleaved, shaped, polished, etc.) using the equipment contained in the FORS. The requirements will be considered satisfied upon successful completion of the tests specified in sections 4.2.1.3 and 4.2.1.4.

Power loss (insertion loss) verification The requirements of section 3.2.1.3 shall be verified by test using the 125 splices performed in section 4.2.4. The insertion loss of multimode splices shall be measured in accordance with Method A of TIA/EIA-455-34 using the 70/70 launch condition. The insertion loss of single-mode splices shall be measured in accordance with method B of TIA/EIA-455-34.

The following verification criteria shall apply:

a) No individual splice unit shall have an insertion loss greater than 0.5 dB, and

b) , where m (measured in dB) is the mean insertion loss of the 125 splice units and s is the standard deviation.

Restoring the physical integrity of the cable Except where otherwise specified, the following mechanical and environmental (M&E) tests shall be performed on five samples from each of the five cable types listed in section 4.2.1.1. The 25 samples shall be chosen randomly from the 125 splice units tested in section 4.2.1.3.

When a particular test calls for measuring the change in optical transmittance (OT), it shall be measured in accordance with TIA/EIA-455-20-B. The change in OT of a splice during and after any particular test shall not exceed 0.3 dB. The total change in OT of a splice after all M&E tests shall be less than 0.5 dB.

Cable twist Cable splices shall be tested in accordance with TIA/EIA-455-36 for 50 cycles. The tensile load shall be ten pounds. The change in the OT shall be measured after the 10th, 25th, and 50th cycles.

Impact Cable splices shall be tested in accordance with method A of TIA/EIA-455-2. The change in OT shall be measured after the test.

Vibration One splice from each of the five fiber types listed in section 4.2.1.1 shall be tested in accordance with test conditions II and VI of TIA/EIA-455-11. Test condition VI shall be performed to condition letter C for 30 minutes. Discontinuity shall be monitored during the test in accordance with TIA/EIA-455-32.

Thermal Shock Cable splices shall be tested in accordance with TIA/EIA-455-71A, schedule C-0, for five cycles. The low and high soak temperatures shall be -55°C and 125°C, respectively. The change in OT shall be measured continuously throughout the test.

Humidity One splice from each of the five fiber types listed in section 4.2.1.1 shall be tested in accordance with Method B of TIA/EIA-455-5. The sub-cycle shall be included in the test. The change in OT shall be monitored during and after the test.

Physical Characteristics Verification Size and weight The size and weight requirements in section 3.2.2.1 shall be verified by measuring in all three dimensions and weighing using an appropriate scale.

Display readability The FORS display requirements in 3.2.2.2 shall be verified via test. A light meter shall be used to measure the ambient illumination. While powered on, the FORS display or lights shall be observed in low light (less than 0.25 lux) and full daylight (greater than 20,000 lux) to ensure its readability.

Batteries Except for battery life, the battery requirements in section 3.2.2.3 shall be verified via demonstration. Battery life shall be verified via test by performing five splices using one set of fresh or fully recharged batteries.

Detailed instructions for the approval of lithium batteries (if employed) are contained in NAVSEA S9310-AQ-SAF-010.

Transit case The physical characteristics and FOD-prevention requirements of the transit case specified in section 3.2.2.4 shall be verified via inspection.

Operating workspace The operating workspace requirement in section 3.2.2.5 shall be verified via demonstration. The contractor shall successfully perform a splice within a workspace volume of 512 cubic inches. The dimensions of the demonstration volume shall be representative of aircraft avionics bays and compartments.

Environmental Characteristics Verification High temperature tests The FORS shall be tested in accordance with Method 501.5 Procedure I (storage) and Procedure II (operating) of MIL-STD-810G for the high temperatures specified in section 3.2.3.1. The high-temperature cycles shown in Table 501.5-III shall apply.

Low temperature tests The FORS shall be tested in accordance with Method 502.5 Procedure I (storage) and Procedure II (operating) of MIL-STD-810G for the low temperatures specified in section 3.2.3.2.

Relative humidity tests The relative humidity ranges specified in section 3.2.3.3 shall be tested in accordance with Method 507.5 Procedure II of MIL-STD-810G.

Bounce, loose-cargo test The loose-cargo bounce requirement specified in section 3.2.3.4 shall be tested in accordance with Method 514.6 Procedure II of MIL-STD-810G.

Transit drop test The FORS shall be dropped once on each face, edge, and corner (a total of 26 drops) from a height of 48 inches in accordance with Method 516.6 Procedure IV of MIL-STD-810G.

Splash resistance test If a transit case with MIL-STD-810G certifications is proposed, verification shall be accomplished via inspection. Otherwise, the splash resistance requirement specified in section 3.2.3.6 shall be tested in accordance with Method 504.1 Procedure II of MIL-STD-810G, using simulated seawater or 5% NaCl. (See item #14 of Table 504.1-II.)

Sand and dust resistance tests If a transit case with MIL-STD-810G certifications is proposed, verification shall be accomplished via inspection. Otherwise, the sand- and dust-resistance requirement specified in section 3.2.3.7 shall be tested in accordance with method 510.5 of MIL-STD-810G.

Explosive atmosphere test The FORS explosive atmosphere requirement specified in section 3.2.3.8 shall be tested in accordance with Method 511.5 Procedure I of MIL-STD-810G.

System Quality Factors (Reliability) Verification The reliability of the FORS shall be verified via demonstration. To achieve a 90% confidence that the MTBF requirement of section 3.2.4 has been satisfied, 125 splice operations (25 of each fiber type listed in 4.2.1.1) shall be performed without a failure of the FORS using the same pilot-production unit.

Design and Construction Verification Hazardous Materials The proscriptions of section 3.3.1 shall be verified via analysis.

Electromagnetic Compatibility

The following radiated emissions and susceptibility tests listed in Table V of MIL-STD-461F for Surface Ships shall be conducted: RE101, RE102, RS101, and RS103. For RS103, field strengths associated with the hangar deck (10 V/m for frequencies above 30 MHz; 50 V/m for frequencies below 30 MHz) shall be applied to determine the vulnerability of the FORS to electrical fields.

Appendix A – Requirements Verification Matrix

Performance Characteristics

Physical Characteristics

Environmental Characteristics

System Quality Factors (Reliability)

Design and Construction

* These items may be verified via inspection if a transit case with MIL-STD-810G certifications is employed.

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