Attachment_0001_Performance_Specifications.pdf

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Fiber Optics Cable Assemblies (4 fiber)

1 Scope. This specification covers the requirements for one type of fiber optic cable assembly, including connectors, fiber optic cable, and cable reels.

2 Applicable Documents

2.1 Government Documents

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto.

SPECIFICATIONS

MILITARY

DOD-STD-1678 Fiber Optics Test Methods and Instrumentation.

MIL-C-55442 Cable Assemblies and Cord Assemblies, Packaging of.

MIL-C-83526 Connectors, Fiber Optic, Circular, Environmental Resistant, Hermaphroditic, General Specification For.

MIL-PRF-85045 Cable, Fiber Optics, General Specification For

MIL-PRF-85045/8A Cable, Fiber Optics, Radiation Hardened, Type 1(Buffered Fiber), Application E(Ground Tactical) Metric

MIL-STD-130 Identification Marking Of U.S. Military Property.

MIL-STD-202 Test Methods for Electronic and Electrical Component Parts.

MIL-STD-810 Environmental Test Methods and Engineering Guidelines.

MIL-STD-1344 Test Methods for Electrical Connectors.

Performance Specifications Attachment 0001 SPRBL1-17-Q-0006

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A3159879 Cable, Fiber Optic, Ruggedized, Radiation Hardened (Metric) and Non-Radiation Hardened

A3102770 Reel, Cable, Lightweight A336463 Reel, Cable, Light-Weight Tactical

Performance Specifications Attachment 0001 SPRBL1-16-Q-0028

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2.2 Non-Government publications. The following specifications, standards, and handbooks form a part of this document to the extent specified herein.

EIA-455-2 Impact Measures For Fiber Optic Devices EAI-455-6 Cable Retention Test Procedure For Fiber Optic Cables and Interconnecting Devices EIA-455-13 Visual and Mechanical Inspection of Fibers, Cables, Connectors and/or Other Fiber Optic Devices.

TIA-455-21 Mating Durability for Fiber Optic Interconnecting

Devices.

EIA-455-42 Optical Crosstalk in Fiber Optic Components.

EIA-455-51 Pulse Distortion Measurement of Multimode Glass

Optical Fiber Information Transmission Capacity.

3 Requirements

3.1 Specification Requirements. The individual item requirements shall be as specified under section 3.6. Appendix A contains cable assembly drawings for the cable assemblies in Table 1.

3.2 First article. When specified in the contract or purchase order, a sample shall be subjected to first article inspections.

3.3 Materials. The fiber optic cable assemblies shall be constructed of materials as specified herein. All materials used shall be non-toxic, non-nutrient to fungus, and manufactured to good workmanship quality.

3.3.1 Finish. Connectors and components shall be finished with environmentally friendly materials and use environmentally friendly finishing processes.

3.4 Construction and physical dimensions. The cable harness

assemblies shall be inspected to verify the materials, construction, interchangeability, marking, and workmanship are in accordance with EIA-455-13.

3.4.1 Connectors. The connectors shall meet the requirements specified herein. Outline dimensions shall be in accordance with figure 1. Connectors may be provided in a different form as shown in figure 2 providing the dimensional requirements are maintained.

3.4.2 Fiber optic cable. Unless otherwise specified, the fiber optic cable shall conform to MIL-PRF-85045/8A using 62.5/125 multimode fiber.

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3.4.3 Reel. Unless otherwise specified, when a cable reel is required it shall conform to MIL-R-3241E or A336463. Reels are identified in Table 1 and Table 2 with their respective dimensions and weights.

Table 1. Cable Assembly Physical Requirements (MIL-R-3241E)

Cable Assembly NSN 6020-01-490-

6020-01-490-

6020-01-487-

6020-01-501-

6020-01-487-

Cable Assembly Length 25 Feet 100 Meter 300 Meter 500 Meter 1000 Meter

Length 25 +0.5/-0

Feet 100 +2/-0 meters 300 +2/-0 meters 500 +2/-0 meters 1000 +4/-0 meters Weight (Ref) 22 pounds 35 pounds 50 pounds 85 pounds

Reel (Mfg p/n) N/A RFO-300 RFO-500 RFO-1000

Flange Dia. (Ref) 16.375 inches 16.375 inches 16.375 inches

Drum Dia. (Ref) 8.875 inches 6.625 inches 6.625 inches

Drum Width (Ref) 8.0 inches 9.5 inches 17.75 inches

Reel Weight (Ref) 14 pounds 14 pounds 18 pounds

Table 2 Cable Assembly Physical Requirements (A336463)

Cable Assembly NSN 6020-01-490-

6020-01-490-

6020-01-487-

6020-01-501-

6020-01-487-

Cable Assembly Length 25 Feet 100 Meter 300 Meter 500 Meter 1000 Meter

Length 25 +0.5/-0

Feet 100 +2/-0 meters 300 +2/-0 meters 500 +2/-0 meters 1000 +4/-0 meters Weight (Ref) 16 pounds 31 pounds 45 pounds 80 pounds

Reel (Mfg p/n) N/A AFO-0100 AFO-0300 AFO-0500 AFO-1000

Flange Dia. (Ref) 17 inches 17 inches 17 inches 17 inches

Drum Dia. (Ref) 10 inches 8 inches 8 inches 8 inches

Drum Width (Ref) 2.21 inches 5 inches 8 inches 16 inches

Reel Weight (Ref) 8.5 lbs 10.5 lbs 11 pounds 12.5 pounds

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DESIGNATOR A Max B Max D Max F G Max H Max J Max X

UNITS INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES

DIMENSIONS 6.350 4.800 1.555 7.000/6.750 2.377 8.250 8.498 1.379/0.190

Figure 1: Outline Dimensions

Figure 2: Alternative Form

3.5 Intermateability. Fiber optic cable assemblies defined in this specification shall be completely intermateable with each other with respect to installation (physical) and performance (function) as specified. All connectors, and protective dust caps, shall be intermateable with each other and shall meet the interface dimensions specified in figures 3 to 5.

2.300” Max 3.800” Max 5.900” Max

1.

5” M ax

8.200” MAX LENGTH DUST CAP INSTALLED

8.450” LENGTH REQUIRED FOR DUST CAP REMOVAL

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DESIGNATOR PA PB PC PD PE PF PG PH PJ PK PL PM

UNITS Inches Inches Inches Inches Inches Inches Inches Inches Degrees Inches Degree s Inches

DIMENSIONS 1.555/

1.518

1.298/ 1.292

1.094/ 1.069

0.049/ 0.036

0.410/ 0.370

0.135/ 0.093

0.025/ 0.016

0.020/ 0.010

47°/43° 0.020/ 0.010

47°/43° 0.248/ 0.243

DESIGNATOR PN PO PP PQ PR PS PV PW PX PY PZ PPP

UNITS Inches Inches Inches Inches Inches Degree s Inches Inches Inches Degrees Inches Inches

DIMENSIONS 0.960/

0.955

0.517/ 0.513

0.821/ 0.816

0.504/ 0.492

0.022/ 0.012

47°/43° 0.503/ 0.497

0.125/ 0.092

0.023/ 0.005

47°/43° 0.680/ 0.678

0.020/ 0.012

DESIGNATOR PT PU

UNITS THREAD DESIGNATION THREAD DESIGNATION

DIMENSIONS 1.0625 -2B-.1P-.2L-DOUBLE STUB THREAD 60 DEG

"V"

1 FULL THREAD PER MIL-STD-1373 EXCEPT WITH

HIGBEE CUT AT START AND FINISH OF EACH

LEAD

MINOR DIA: 1.004 / 1.014 (SPECIAL DIA NOT PER

MIL-STD- 1373)

MAJOR DIA: 1.076 / 1.086 PITCH DIA: 1.0285 / 1.0405

1.0625 -2A-.1P-.2L-DOUBLE STUB THREAD 60 DEG "V"

1 FULL THREAD PER MIL-STD-1373 EXCEPT WITH

HIGBEE CUT AT START AND FINISH OF EACH LEAD

MINOR DIA: .9705 / .9885

MAJOR DIA: 1.050 / 1.060 (SPECIAL DIA NOT PER MIL-

STD-1373)

PITCH DIA: 1.0165 / 1.0265

DRYFILM LUBE ON EXTERNAL THREAD

Figure 3: Plug Interface Dimensions

DESIGNATOR DA DB DC CL DE DF DG DH DK PL PM PN min UNITS Inches Inches Inches Inches Inches Inches Degrees Inches Inches Inches Inches Inches

DIMENSIONS 0.049/

0.036 0.234/ 0.212

0.154/ 0.148

0.675/ 0.673

0.119/ 0.117

0.162/ 0.158

62°/58° 0.165/ 0.160

0.049/ 0.045

0.569/ 0.553

0.225/ 0.219

0.219

Figure 4: Insert Interface Dimensions (View A-A)

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DESIGNATOR CA CD CG CH CK CJ CQ CL CS CT CU CW

UNITS Inches Inches Inches Inches Inches Inches Inches Inches Inches Inches Inches Inches

DIMENSIONS 0.162/

0.158

0.1205 0.260 0.002/

0.001 0.229/ 0.209

0.110/ 0.090

0.358/ 0.338

0.675/ 0.673

0.090/ 0.078

0.264/ 0.262

0.036/ 0.028

0.104/ 0.094

DESIGNATOR CX CY KA KD KH KK KG KL KJ KB KC KE

UNITS Inches Inches Inches Inches Inches Inches Inches Inches Depth Inches Inches Inches

DIMENSIONS 0.269/

0.267 0.104/ 0.094

0.139/ 0.137

0.170/ 0.158

0.085/ 0.079

0.043/ 0.023

0.015/ 0.005

0.015/ 0.010

0.134/ 0.132

0.084/ 0.082

0.162/ 0.160

0.085/ 0.079

DESIGNATOR KF CB NOTE 1: "CS" RADIUS 2 PL ON KEY 1, 1 PL ON KEY 2 & 3, AND

NOT USED ON KEY "U"

NOTE 2: CENTER OF "CT" & "CX" RADII ARE AT CENTER OF

DATUMS -A- AND -B-

NOTE 3: "KA", "KD", AND "KJ" APPLY TO KEY 1

CONFIGURATION ONLY

NOTE 4: "KG" RADIUS 4 PL ON KEY 1, 3 PL ON KEY 2 & 3,

AND 2 PL ON KEY "U"

NOTE 5: "KB", "KC", "KE", AND "KF" APPLY TO KEYS 2, KEY

3, OR KEY "U"

UNITS Inches THREAD DESIGNATION

DIMENSIONS 0.159/

0.157

0.112-40 UNC-2B

Figure 5: Insert Interface Dimensions (View B-B)

3.6 Performance. Performance relates to the ability of the cable harness to provide optical signal transmissions. Unless otherwise specified, optical measurements will be made using industry standard practices and equipment suitable for the inspection and test.

3.6.1 Visual and mechanical inspection. The cable assemblies shall be inspected to verify the materials, construction, interchangeability, marking, and workmanship are in accordance with EIA-455-13.

3.6.2 Insertion loss. When tested in accordance with EIA/TIA-455-34 and EIA/TIA-455-171, the maximum attenuation per connection shall be 0.75 dB.

The cable loss shall not exceed 1.5 dB/km per MIL-PRF-85045/8A with 62.5/125 fiber. The maximum insertion loss values are detailed for each cable assembly in Table 2 below.

Table 2. Cable Assembly Insertion Loss.

Cable Assembly NSN 6020-01-490-

6020-01-490-

6020-01-487-

6020-01-501-

6020-01-487-

Cable Assembly Length 25 Feet 100 Meter 300 Meter 500 Meter 1000 Meter

Maximum Insertion Loss (-0.75dB per connection plus additional cable attenuation)

-1.45 dB -1.65 dB -2.00 dB -2.25 dB -3.00 dB

3.6.3 Crosstalk. When tested in accordance with EIA-455-42, the cable assembly crosstalk characteristics shall be less than -60 dB.

3.6.4 Mating Durability. When tested in accordance with TIA-455-21, 2000 cycles, cable assemblies shall exhibit no deterioration detrimental to

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operation. Cleaning the termini is permitted prior to testing insertion loss. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.5 Cable seal flexing. When tested in accordance with MIL-STD-1344, Method 2017, Procedure I, “X” distance of 50 millimeters, there shall be no loss of environmental sealing and cable assemblies shall exhibit no deterioration detrimental to operation. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.6 Water Pressure. When tested for water pressure susceptibility, cable assemblies shall exhibit no deterioration detrimental to operation. Jam nut connectors shall be mounted on a 4-inch sealed tube. No ingress of water into the tube is allowed. The test shall be accomplished using three sets of samples:

in-line connectors mated with dust caps, jam nut connectors mated with dust caps, and in-line connectors mated with jam nut connectors. The assemblies shall be immersed in water to a minimum depth of 1.00 meter for a period of not less than 48 hours. The temperature shall be maintained between 10°C and 35°C during the exposure period. During and after testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

The assemblies shall be externally cleaned, unmated, disassembled, and examined visually for water penetration into the connector.

3.6.7 Low pressure (altitude). When tested in accordance with MIL- STD-810, Method 500, Procedure III, pressure altitudes of 3.05 kilometers and

12.20 kilometers, cable assemblies shall exhibit no deterioration detrimental to operation. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.8 Temperature cycling. When tested in accordance with DOD-STD- 1678, Method 4010, per Table 4 below, cable assemblies shall exhibit no deterioration detrimental to operation. After testing, cable assemblies shall conform to insertion loss characteristics identified in paragraph 3.6.2 above.

Table 3. Temperature cycling profile.

3.6.9 Dust. When tested in accordance with MIL-STD-810, Method 510, Step Temperature (°C) Duration (hours) 1 Room ambient 24 2 Ramp to –46°C ±2°C 2 3 –46°C ±2°C 8 4 Ramp to +25°C ±2°C 2 5 +25°C ±2°C 6 6 Ramp to +71°C ±2°C 1 7 +71°C ±2°C 6 8 Ramp to +25°C ±2°C 1 9 +25°C ±2°C 6

10 Repeat steps 2 through 9 four times for a total of five cycles.

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Procedure 1, cable assemblies shall exhibit no deterioration detrimental to operation. During the test, the assembly shall be oriented in the test chamber so that the blowing air stream intersects the longitudinal axis. The assembly shall be rotated 90 degrees at least two times. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.10 Storage temperature. When tested in accordance with MIL- STD-810F, Method 501, Procedure I, constant temperature exposure at 85°C and tested in accordance with MIL-STD-810F, Method 502, Procedure I, temperature at -55°C, cable assemblies shall exhibit no deterioration detrimental to operation. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.11 Humidity. When tested in accordance with DOD-STD-1678, Method 4030, 10 test cycles, exposure for humidity shall be as specified in figure 1 in specification, cable assemblies shall exhibit no deterioration detrimental to operation. During and after testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.12 Cable retention. When tested in accordance with MIL-STD- 1344, Method 2009, with an axial load of 182 kilograms applied and maintained for 5 minutes, cable assemblies shall exhibit no deterioration detrimental to operation. During and after testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.13 Vibration (loose cargo, non-operational) . When tested in accordance with MIL-STD-810F, Method 514.5, Procedure II, 30 minutes minimum test duration, cable assemblies shall exhibit no deterioration detrimental to operation. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.14 Life. When tested in accordance with MIL-STD-202, method 108, test condition B, temperature 110 °C +5/-0 °C and relative humidity 95%, cable assemblies shall exhibit no deterioration detrimental to operation. During testing, the cable assembly shall be installed in the mating receptacles. The receptacle fiber optic cables shall exit the test chamber and be sealed to the chamber wall at the exit point. After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.6.15 Salt fog. When tested in accordance with MIL-STD-810, Method 509, Procedure 1, cable assemblies shall exhibit no deterioration detrimental to operation. During the test, the samples shall not be mounted but shall be suspended from the top of the chamber using waxed twine or string.

After testing, cable assemblies shall conform to the insertion loss characteristics identified in paragraph 3.6.2 above.

3.7 Marking. Cable assembly markings shall be heat shrinkable and at a

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minimum shall consist of the manufacturer’s part number, date code (month and year), and manufacturer’s cage code. Markings shall be in accordance with MIL- STD-130. Marking locations are specified on the individual drawings in Appendix A. Unless otherwise specified, additional manufacturer markings are permitted on the connectors, cable, and reels.

3.8 Workmanship. The cable assemblies shall be dimensionally uniform and free of flaws that would degrade performance after installation or inhibit proper connection to interfacing elements. The following shall be a minimum level of visual inspection to be performed and is not intended to restrict other pertinent workmanship inspections deemed necessary.

a. Cable assemblies shall conform to the dimensional and interchangeability requirements of this specification.

b. Loose termini, poor molding, poor fabrication, loose materials, defective bonding, damaged or improperly assembled termini, and physical defects in the seals shall not be permitted.

c. Peeling or chipping of plating or finish, galling of mated parts, nicks or burrs on metal parts, and post-molding warpage shall not be permitted.

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4 QUALITY ASSURANCE PROVISIONS

4.1 Classification of inspections. The inspection requirements specified herein are classified below:

a. First article inspection (see 4.3).

b. Qualification inspection – Prospective bidders may elect to perform qualification testing prior to formal government solicitation for fiber optic cable assemblies defined by this specification. Such testing should be equivalent to any or all of the first article inspection requirements identified in Table 4 below. Test data may be presented to the government prior to any formal government solicitation. The government may accept relevant qualification test data in lieu of actual performance of first article testing.

c. Quality conformance inspection (see 4.4).

4.2 Inspection conditions. Unless otherwise specified, all inspections shall be made in accordance with the following conditions:

a. Temperature: + 15°C to + 35°C.

b. Relative humidity: 20 to 80 percent.

c. Barometric pressure: 550 to 800 millimeters of mercury.

4.3 First article inspection (or Qualification inspection).

When required in the contract or purchase order, first article inspection shall be performed. Except as otherwise specified in the contract or purchase order, the contractor may use his own or any other facilities suitable for the performance of the inspection and test requirements specified herein.

4.3.1 Sample. Unless otherwise specified in the contract or the purchase order, the first article sample shall consist of six finished fiber optic cable assemblies.

4.3.2 Inspection routine. The sample shall be subjected to the first article inspection specified in Table 4.

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Table 4. First article inspection requirements.

4.3.3 Failures. One or more failures shall be cause for refusal to grant first article approval unless appropriate corrective action is taken.

4.3.4 Disposition of sample units. Unless specified in the contract or the purchase order, the sample units which have been subjected to the first article inspection shall be delivered to the contracting activity as a part of the test report and shall not be delivered as part of a contract or purchase order.

4.4 Quality conformance inspection.

4.4.1 Inspection of product for delivery. Inspection of product for delivery shall consist of group A inspections which shall be performed on all units to be delivered.

4.4.1.1 Group A inspection. Group A inspection shall consist of the inspections specified in Table 5.

Table 5. Group A inspection.

4.4.1.1.1

Inspection Performance Paragraph Sample Quantity Group I

Visual and Mechanical 3.6.1 6 Group II

Insertion loss 3.6.2 6 Crosstalk 3.6.3 6

Group III Mating Durability 0 3 Cable seal flexing 1.1.1 3

Water pressure 3.6.6 3

Low pressure (altitude) 3.6.7 3 Temperature cycling 3.6.8 3

Dust 3.6.9 3 Storage temperature 3.6.10 3

Humidity 3.6.11 3 Cable retention 3.6.12 3

Group IV Vibration 3.6.13 3

Life 3.6.14 3 Salt fog 3.6.15 3

Inspection Performance Paragraph

Visual and mechanical inspection 3.6.1

Insertion Loss 3.6.2

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4.4.1.1.1 Rejected lots. If an inspection lot is rejected, the contractor may rework it to correct the defects, or screen out the defective units, and resubmit for re-inspection.

4.5 Methods of inspection. Unless otherwise specified, optical measurements will be made using industry standard practices and equipment suitable for the inspection.

5 PACKAGING

5.1 Packaging requirements. The requirements for packaging shall be in accordance with MIL-C-55442.

6 NOTES

6.1 SUGGESTED SOURCES OF SUPPLY

6.1.1 Connector Supplier.

Fiber Systems International 1300 North Central Expressway Suite 100 Allen, Texas 75013

(214) 547-2400 Main

(214) 547-2481 Fax www.fibersystems.com

Qualified Connector Part Number:

FS4H1000-H-1

Stran Technologies 39 Great Hill Road Naugatuck, CT 06770

(203) 729-2572 Main

(203) 729-2689 Fax www.strantech.com

Qualified Connector Part Numbers;

900-0071-xx Plug 900-0138-xx Jam nut receptacle rear 900-0140-xx Jam nut receptacle front

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Amphenol Fibre Optic Products

2 Technology Drive Peabody, MA 01960 Phone: (978) 532-8800 Fax: (978) 532-6800 Cage Code 58982 www.amphenol.com

Qualified Connector Part Number:

TFOCA-two-064RZ-035-1-PC

Series Variant PC supplied with protective cap

Style 06: Free Plug Orientation 1, 2, 3 or U(niversal) 07: Jam-nut Receptacle Cable Variant 028: single-mode Number of Termini 035: multi-mode Material RZ: Zinc-cobalt plated Aluminum

Optical Cable Corporation (formerly Applied Optical Systems) 1700 Capital Avenue, Suite 150 Plano, Texas 75074 Cage code 335J8

(972) 509-1500

(972) 509-9009 (fax) www.occfiber.com Qualified part numbers CCTA10B2xyz and CCTA10B31CA

6.1.2 Cable Supplier.

Optical Cable Corporation P.O. Box 11967 Roanoke, VA 24022-1967 1-800-622-7711 Qualified Cable Part Number:

RK981104-09

Draka Comteq USA 20 Forge Park Franklin, MA 02038 Phone (508) 541-7100

Amphenol Spectrastrip 720 Sherman Avenue Hamden, Conn. 06514 Phone# (203) 281-5872 Cage Code 55611

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6.1.3 Reel Supplier.

Shane Industries, Inc.

16-T Hatfield Lane Poughkeepsie, NY 12603 845-485-3800 845-485-3820 Fax

Reel Part Numbers*:

RFO-300

RFO-1000

Optical Cable Corporation (formerly Applied Optical Systems) 1700 Capital Avenue, Suite 150 Plano, Texas 75074 Cage code 335J8

(972) 509-1500

(972) 509-9009 (fax) www.occfiber.com Qualified part numbers

AFO-0100-*-M-2

AFO-0300-*-M-2

AFO-0500-*-M-2

AFO-0750-*-M-2

AFO-1000-*-M-2

* = color code: T=Desert Tan, G=Olive Drab, B=Black

6.2 CABLE ASSEMBLY PART NUMBERS

NSN LENGTH PART NUMBER

6020-01-487-5267 1000 METERS A3302584-1

6020-01-501-5550 500 METERS A3302584-2

6020-01-487-5266 300 METERS A3302584-3

6020-01-490-7024 100 METERS A3302584-4

6020-01-490-2300 25 FEET A3302584-5

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Appendix A Appendix A describes the cable assemblies that are defined by the part number and NSN listed above.

Cable Assembly Drawing

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