A3014056_80063_DP_0001_T.pdf

NOTE: DATA MARKED WITH AN ASTERISK (*) IS PECULIAR TO A PRIOR MANUFACTURER. IT

DOES NOT TAKE PRECEDENCE OVER ANY OTHER DATA ON THIS DRAWING, AND IS

NOT CONTRACTUALLY BINDING ON EITHER THE CONTRACTOR OR THE GOVERNMENT.

THIS DOCUMENT HAS BEEN PURCHASED BY THE GOVERNMENT AND MAY BE REPRODUCED AND USED

IN CONNECTION WITH ANY GOVERNMENT PROCUREMENT OR MAINTENANCE OPERATION

APPLICATION REVISIONS

NEXT ASSY USED ON LTR DESCRIPTION DATE APPROVED

GENL USE P REVISED PER EC 6269465 06-08-25 G. BAILEY

00-D-C251

B. Taylor

R REVISED PER ECN0020459 07-10-24 G. BAILEY

G. Bailey 07-D-L007

REVISED PER ECN0028105 G. BAILEY

T G. BAILEY 08-08-05 05-D-J101

SPECIFICATION CONTROL DRAWING

ALL SHEETS ARE THE SAME REVISION

AEROSPACE/COMMUNICATIONS

DIVISION

FSCM NO. 31550

U.S. ARMY COMMUNICATIONS -

ELECTRONICS COMMAND

FORT MONMOUTH, NEW JERSEY 07703

DAAB07-78-C-0150

DWN R. PAPPERT

85-06-25

ENGR R. ROGERS

85-06-10

CHKD

CECOM

REVIEWED SIZE FSCM NO. DWG. NO.

APPROVED A3014056

DATE SCALE NONE SHEET 1 OF 22

A 80063

CABLE SPECIFICATION, SINCGARS

INSTALLATION KITS

NOTE!

DUE TO FORMAT DIFFERENCES CAUSED BY INDIVIDUAL PC AND

NETWORK SETUPS, THE TOTAL NUMBER OF SHEETS OF YOUR

REPRESENTATION OF THIS DOCUMENT MAY NOT AGREE WITH

THE TOTAL NUMBER OF SHEETS SPECIFIED. TO ENSURE YOU

HAVE THE COMPLETE DOCUMENT, THE LAST SHEET HAS BEEN

CLEARLY IDENTIFIED AS BEING THE LAST SHEET.

SIZE FSCM NO. DWG NO.

A 80063 A3014056

SCALE: NONE LTR T SHEET 2

1 SCOPE AND SPECIAL NOTES

1.1 Scope. This specification covers the design, construction, performance requirements and quality assurance provisions for special purpose cable assemblies for use in an outdoor environment and in military vehicles. For the purpose of this document, CABLE ASSEMBLY shall refer to an assembly with processed terminations at one or both ends, insulated conductors, EMI/EMP shielding and an outer protective covering. This specification is not applicable to radio frequency coaxial assemblies except as specified herein or by individual cable drawings.

1.2 HCI Note. Cables controlled by this specification are hardness critical items (HCI).

All changes to or proposed substitutions of HCI must be evaluated for hardness impact by the Engineering Activity responsible for survivability.

2 APPLICABLE DOCUMENTS

2.1 Issues of documents. The following documents of the issue in effect on date of invitation for bids or request for proposal form a part of this specification to the extent specified herein.

In the event of conflict between the documents referenced herein and the contents of this specification, the contents of this specification shall be considered a superseding requirement.

SPECIFICATIONS

Federal

A-A-59569 (CID) Braid, Wire (Copper, Tin Coated, Silver Coated, or Nickel Coated, Tubular or Flat)

Military

MIL-C-26482 Connector, Electrical (Circular Miniature) - Inactive

MIL-C-85485 Cable, Electric, Filter Line, Radio Frequency Absorptive

MIL-D-50030 Decontaminating Agent, DS2

MIL-DTL-22520 Crimping Tools, Wire Termination, General Specification for

MIL-DTL-53039 Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

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2.1 Issues of documents. (Continued)

SPECIFICATIONS

Military

MIL-PRF-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile, and Ordnance - Inactive

MIL-PRF-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base

MIL-W-81044 Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkane-Imide Polymer, or Polyarylene Insulated, Copper or Copper Alloy

STANDARDS

Military

MIL-STD-108 Enclosures for Electric and Electronic Equipment

MIL-STD-129 Marking for Shipment and Storage

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

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

MIL-STD-220 Method of Insertion - Loss Measurements

MIL-STD-810 Environmental Test Methods

MIL-STD-1916 DOD Preferred Methods for Acceptance of Product

MIL-STD-13231 Marking of Electronic Items

HANDBOOKS

Military

MIL-HDBK-454 General Guidelines for Electronic Equipment

NON-GOVERNMENT STANDARDS

American National Standards Institute (ANSI)

ANSI B74.18 American National Standard for Grading of Certain Abrasive Grain on Coated Abrasive Material

Association Connecting Electronics Industries (IPC)

J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies.

J-STD-004 Requirements for Soldering Fluxes.

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J-STD-006 Requirements for Electronic Grade Solder Alloys and Fluxed and Non-Fluxed Solid Solders for Electronic Soldering Applications

IPC-A-610 Acceptability for Electronic Assemblies

IPC/WHMA-A-620 Requirements and Acceptance for Cable and Wire Harness Assemblies

National Electrical Manufacturers Association (NEMA)

NEMA WC27500 Standard for Aerospace and Industrial Electrical Cable

Society of Automotive Engineers (SAE)

SAE-AMS-C-26074 Coatings, Electroless Nickel Requirements for

SAE-AMS-QQ-N-290 Nickel Plating

SAE-AMS-QQ-P-416 Plating, Cadmium (Electro Deposited)

SAE-AMS2422 Gold Plating

SAE-AS5942 Marking of Electrical Insulating Materials

SAE-AS8660 Silicone Compound NATO Code Number S-736

SAE-AS22759 Wire, Electric, Fluoropolymer Insulated, Copper or Copper Alloy

DRAWINGS

A3148008 Receiver-Transmitter, Radio RT-1439/VRC – Specification

A3148009 Receiver-Transmitter, Radio RT-1523(C)/U – Specification

Receiver-Transmitter, Radio RT-1523B(C)/U – Specification

A3249641 Receiver-Transmitter, Radio RT-1523C/D(C)/U

– Specification

A3266179 Receiver-Transmitter, Radio RT-1523E(C)/U – Specification

A3307042 Receiver-Transmitter, Radio RT-1523F(C)/U – Specification

2.2 Precedence of documents. The purchase order shall have precedence over any specification. This specification shall have precedence over all subsidiary specifications.

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3 REQUIREMENTS

3.1 Materials. All materials shall be nonhygroscopic, and shall meet the environmental requirements specified herein. All materials, parts, and processes shall be as specified. Only those materials which are not nutrients for fungus, such as those given in MIL-HDBK-454, Guideline 4, shall be used in the construction of cables.

3.1.1 Wiring. Wiring internal to the cable shall be as follows: Primary wires shall meet the requirements of SAE-AS22759/16 or MIL-W-81044/12. Shielded primary wires shall meet the requirements of NEMA WC27500. Color coding of the wires within the cable assembly is desirable but not mandatory.

3.1.2 EMI/EMP shield. A minimum of two shields shall be employed to assure compliance with paragraph 3.3.1.4. Braided shields shall consist of tinned copper per A-A-59569 (preferred), phosphorus bronze, or other approved material, and shall be placed over the entire cable assembly under the outer jacket. Shield splices and shield terminations at transitions shall be made with a complete circumferential bond. Connections that do not use a mechanical bond shall consist of a complete circumferential solder joint. Soldering shall comply with

MIL-HDBK-454.

3.1.3 Outer jacket. The outer covering of the cable assembly shall be a jacket of Neoprene (anti-fungal) or other approved equivalent with a thickness of .050 inch ± .015-.010 inch. If tubing is used for the jacket, the preinstalled wall thickness shall be a nominal thickness of 4/64 inch.

3.1.4 Internal shield termination and splices. Unless otherwise specified on the applicable cable assembly drawing, all internal shields (individual conductor shields) and splices shall be terminated using solder procedures per paragraph

3.2.1. Shield terminations shall be as close to the rear of the connector as possible. If a solder sleeve is used, slight spiralling of one lead over another before installation of the solder sleeve is desired to increase the mechanical strength of the joint and to afford better distribution of the solder. Shrinkable sleeving shall be used on connections not using solder sleeves.

3.1.5 Transitions. A transition shall be defined as a rigid component, adapting one part to another, or as an intermediary component accomplishing a change in construction. Maximum dimensions listed on individual drawings are given as outside limits to the design. Compactness of design should be a design goal since space is at a premium and oversize designs seriously affect usability of the cable.

Non-metallic transitions must meet EMI/EMP requirements 3.3.1.4, and color shall be Type II green 383 to conform to MIL-DTL-53039. Transitions overmolded may be Type II black 37030 to conform to MIL-DTL-53039.

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If metal transitions functioning primarily as external components in the cable design rather than an internal component integrated into the cable assembly are used, the plating material shall be olive drab/cadmium (SAE-AMS-QQ-P-416, Type 2, Class 3) over nickel plate (SAE-AMS-C-26074, Class 3, Grade B) or (SAE-AMS-C-26074 Heat Treat Alloy Class 4, Grade B). Usage of any other coating or plating material must have prior approval.

3.1.6 Connectors. If connectors used are part nos. other than, or are modified versions of the connectors referenced on the individual cable drawings, they must at a minimum meet the existing requirements for that connector. Also, the following requirements should be met, if possible, when connector modifications or new designs are incorporated.

3.1.6.1 Materials. Materials shall be of the lightest practical weight and shall be suitable for the purpose intended.

3.1.6.2 Finish. The surface of the finish shall be dull and non-reflective. Metallic connector shells shall be finished with a protective finish which will withstand 500 hours of salt fog without exposure of base metal due to corrosion which will adversely affect performance. Metallic connector shells using a corrosive metal shall also have an underplate of nickel per SAE-AMS-C-26074, Class 3, Grade B.

3.1.6.3 Dissimilar metals. When dissimilar metals are used in intimate contact with others, suitable protection against electrolyte corrosion shall be provided as specified in guideline 16 of MIL-HDBK-454.

3.1.6.4 Contacts. Contacts shall be made of suitably conductive materials, and shall be gold plated to a minimum of 50 micro inches in accordance with SAE-AMS2422, over nickel underplate per SAE-AMS-QQ-N-290. Contacts shall be designed so that neither the pins nor the sockets can be damaged during mating of counterpart connectors.

3.1.6.5 RFI finger spring. RFI finger springs shall be made of a spring temper copper alloy suitably protected to prevent corrosion.

3.1.6.6 Insert and grommet. Insert and grommet materials shall be high grade dielectric, having a resistance of more than 5,000 megohm at room temperature, having hardness, electrical and mechanical characteristics suitable for the purpose intended.

3.1.6.7 Insert retention. Unmated connectors shall retain their inserts in their proper location in the shell and shall show no evidence of cracking, breaking, separation from the shell, or loosening of parts during or after applying 100 ±5 lbs/sq in. of pressure to the mating surface of the inserts.

3.1.6.8 Engagement of connectors. Engagement and disengagement shall be accomplished without the use of tools. A positive detent or locking mechanism shall be included in the coupling mechanism to lock connectors in the engaged position. No connectors shall disengage, while locked in place, with less than 20

in. lbs. applied.

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3.1.6.9 Engagement seal. The seal between the mating connectors shall provide a watertight seal.

3.1.6.10 Interchangeability. All connectors of a given type and part no. shall be completely interchangeable with each other, with respect to installation (physical) and performance (function).

3.1.6.11 Dielectric withstanding voltage. With 1,000 VAC RMS applied, at sea level or above, maximum leakage current shall be less than 2 milliamperes. The test voltage shall be applied between any contact and each adjacent contact (up to a maximum of six (6)) for a minimum of one minute, and between any contacts adjacent to the shell (up to a maximum of six (6)) for a minimum of one minute.

3.1.6.12 Durability. The wired and fully assembled connectors shall be coupled and uncoupled a minimum of 1500 times. The connectors shall be completely engaged and disengaged each time at the rate of less than 300 cycles per hour.

No perceptible wear shall be observed.

3.1.6.13 Contact resistance. With mating connector fully wired and engaged, contact resistance shall not exceed 10 milliohms. Current/voltage measurements may be used to calculate the resistance. Measurements should be made at the wire entry end of the terminal. Current should be 100 ±10 milliamperes for 24 to 18 AWG terminals and 500 ± 20 milliamperes for 16 to 10 AWG terminals. Test leads may be soldered or permanently affixed to the wire entry end of the terminal.

3.1.6.14 Shell conductivity. Mated plugs and receptacles shall be electrically conductive from the plug accessory thread to the receptacle mounting flange or accessory thread. The overall DC resistance shall not exceed 2.5 millohms.

3.1.6.15 Contact retention. A load of 10 lbs. for 22 AWG, 15 lb. for 20 AWG and 25 lbs. for 16-12 AWG contact shall be applied along the longitudinal axis of individual contacts in the direction tending to displace the contacts to the rear. The contacts shall show no signs of being dislodged.

3.1.6.16 Shielding. The EMI shielding effectiveness of mated connectors shall be measured using the triaxial RF leakage methods of MIL-C-26482. Frequencies and limits should be as specified to 400 MHz.

3.1.6.17 Temperature. The connectors shall operate properly at a temperature of -55°C to 125°C. Connectors should be mated and unmated four times at both temperature extremes without any detrimental effects.

3.1.6.18 Fluid resistance. The unmated connectors shall withstand testing in hydraulic fluid conforming to MIL-PRF-5606 for 20 hours and lubricating oil conforming to MIL-PRF-7808 for 20 hours. A plug and receptacle shall be immersed simultaneously in the fluids. Mating and unmating of the connectors and a visual inspection shall reveal no degradation of the connector.

3.2 Construction.

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3.2.1 Soldering. Soldering of cable assemblies shall meet the requirements of IPC-A-610 and J-STD-001, Class 3. Solder flux and cored wire shall meet the characteristics and properties of ROLO per J-STD-004. Use SN63PB37 solder per IPC J-STD-006.

3.2.2 Contact crimping. Unless otherwise specified on the applicable cable assembly drawing, tools used to crimp connector terminals shall conform to MIL-DTL-22520.

Crimp terminations shall conform to IPC/WHMA-A620.

3.2.3 Cable assembly. The completed cable assembly shall meet all environmental conditions specified herein. The construction to be used shall be shielding that provides adequate EMI/EMP protection (paragraph 3.1.2), and an outer jacket per paragraph 3.1.3. Conduit systems shall use a nominal 80% fill factor where possible.

3.2.4 Wire stripping. There shall be no nicks or cuts in the wire strands on stripped ends of wires or shield braid due to dull or incorrect size of stripping tool dies. Thermal stripping is acceptable provided the material used for insulation meets all requirements of this specification.

3.2.5 Cable dimensions and tolerances. The dimensions of each cable shall be as specified on individual assembly drawings. Length shall be as specified in the purchase order. Allowable tolerance on length is: Cable lengths under 2 feet shall be plus/minus one quarter (1/4) inch, excluding coaxial RF cables. Cable lengths 2 feet and longer shall be plus one quarter (1/4) inch, minus zero (0) inch per foot.

All coaxial RF cable lengths shall be plus one quarter (1/4) inch, minus zero (0) inch per foot. To assure consistency of the outside diameter of the entire length of the cable, the tolerance of the OD shall be ±.03 inch.

Transition to Transition Rotational Orientation Tolerance is: Cable lengths from 0 Ft. to 2 Ft. shall be ±15°; cable lengths from 2 Ft. to 5 Ft. shall be ±20°; cable lengths from 5 Ft. to 10 Ft. shall be ±30°; cable lengths from 10 Ft. and up shall be ±45°. Connectors to transition rotational orientation tolerance is ±10°. Ninety degree coaxial connectors on RF cables should be close to alignment at the time of assembly.

3.2.6 Terminal to wire interface. Length of wire strip shall accommodate full engagement of wire (wire visible in inspection hole, where applicable) into terminal in the case of crimp terminals and solder cups (pots), and a minimum of 180° turn on solder lugs. Insulation strip gap of completed assembly shall be no more than one OD of wire insulation. All solder cup terminals shall be completely insulated with shrinkable tubing from the back of the connector insert to cover the wire insulation.

3.2.7 Gasket and seals. All gaskets and seals may be coated with silicone grease per SAE-AS8660 to assure proper assembly and function. Care should be given in not allowing grease to be deposited in areas other than the area of the seal or gasket. Do not use on silicone gaskets and/or seals.

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3.2.8 Cable terminations handling. All fittings, especially metallic, must be tightened using appropriate tools and protective coverings installed over connections and fittings to prevent damage to the finish during assembly and shipping.

3.3 Functional requirements.

3.3.1 Performance.

3.3.1.1 DC resistance. The direct current resistance of each wire conductor contained in the cable assembly being tested shall be measured using the circuit diagram of the applicable cable drawing to locate termination points. Resistance of overall shields shall be measured from connector shell mating surface to connector shell mating surface or connector shell mating surface to shield end fitting (on ends not using connectors).

The direct current resistance of each insulated wire conductor shall not exceed the sum of calculated conductor resistance (in the case of paralleled conductors, divide by the number of conductors in the parallel circuit) per applicable mil standard plus ten percent (10%). The resistance of internal shields where external connections were made should be no more than that of the largest gauge conductor, and shall be in their final configuration when measured from termination to termination. The resistance of any cable assembly or harness branch between any two connector shells or connector shell to shield end transition (on ends not using connectors) shall not be more than .020 Ohms initially, .100 Ohm after testing, plus .001 Ohms per foot of cable. Test per 4.7.3.

3.3.1.2 Continuity. Each circuit shall be continuous within the cable when tested as specified in paragraph 4.7.4. Testing should be accomplished by use of automatic equipment.

3.3.1.3 Insulation resistance. The insulation resistance between all isolated conductive parts (including connector shells, shields, and wires) of the assembly shall be 500 megohms minimum (100 megohms minimum immediately after moisture test) with 500 ±50 VDC applied. Maximum test time shall not be more than 1 minute. Test as specified in 4.7.5. Testing should be accomplished by use of automatic equipment.

3.3.1.4 Shielding effectiveness. The surface transfer impedance shall fall in the acceptable area of the graph shown in figure 1 when tested per 4.7.6.

3.3.2 Environmental requirements.

3.3.2.1 Temperature.

3.3.2.1.1 Low temperature. The cable shall not exhibit evidence of cracks, tears, splits, or other physical damage and shall meet the requirements of 3.3.1.1 and 3.3.1.3 after exposure to a temperature of -55°C ± 2°C and after testing per paragraph 4.7.7.1.

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3.3.2.1.2 Low temperature flexibility. The cable shall meet the requirements of 3.3.1.1 and

3.3.1.3 and shall exhibit no evidence of cracks, tears, splits, or any other evidence of deterioration that could adversely affect normal cable operation after being tested per 4.7.7.2. Normal wear caused by test fixture is permissible.

3.3.2.1.3 High temperature. The cable shall meet the requirements of 3.3.1.1 and 3.3.1.3 and shall exhibit no evidence of insulation or jacket deformation or deterioration after exposure to a temperature of +110°C ± 2°C for 20 hours when tested per 4.7.7.3.

3.3.2.1.4 Thermal shock. The cable shall meet the requirements of 3.3.1.1 and 3.3.1.3 and shall exhibit no evidence of cracks, tears, or splits when tested per 4.7.7.4 using the following temperature extremes:

Low -55°C ± 2°C High +110°C ± 2°C

3.3.2.2 Moisture resistance. The cable shall meet the requirements of 3.3.1.1 and 3.3.1.3 (insulation resistance to be 100 megohms minimum) when tested per 4.7.8.

3.3.2.3 Salt Fog. The cable shall meet the requirements of 3.3.1.1, and 3.3.1.3 after testing per 4.7.9. Major pitting, blisters, or flaking that exposes base metal shall be cause for failure. Discoloration or minor pitting shall not be cause for failure.

3.3.2.4 Water sealing effectiveness.

3.3.2.4.1 Immersion. The cable shall meet the requirements of 3.3.1.1 and 3.3.1.3 and shall not leak or show signs of damage after testing per 4.7.10.1. Final teardown,

3.3.2.14 shall determine internal cable condition if undetected leakage occurred.

3.3.2.4.2 Water spray. The cable shall meet the requirements of 3.3.1.3 and shall not leak or show signs of damage after testing per 4.7.10.2. Final teardown, 3.3.2.14 shall determine internal cable condition if undetected leakage occurred.

3.3.2.5 Vibration. The cable shall meet the requirements of 3.3.1.1, and 3.3.1.3 after testing per 4.7.11. During the test, there shall be no interruptions in continuity longer in duration than 10 microseconds.

3.3.2.6 Pull test. The cable shall meet the requirements of 3.3.1.1 after being subjected to paragraph 4.7.12. Elongation of five (5) percent is allowable. Percent of Elongation shall be calculated using the initial recorded length at a load of 10 lbs or less, and final length recorded at maximum load. There shall be no evidence of stress on the terminals or to the wires or termination as a result of the pull test.

Inspection may be done at teardown.

3.3.2.7 Thermal pulse. The cable shall exhibit no evidence of cracks, tears or splits, or any other signs of deterioration (internal or external) after testing as outlined in

4.7.13. Cosmetic damage such as charring and discoloration shall be permissible.

There shall be no shield visible and no cracking or flaking of the outer cover shall occur when the tested area is flexed.

3.3.2.8 Chemical biological resistance. The cable shall exhibit no evidence of cracks, tears, splits, or any other evidence of deterioration after being subjected to testing per paragraph 4.7.14.

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3.3.2.9 Altitude. The cable (test only cables with active electronic parts, including diodes) shall withstand all altitudes up to 40,000 feet, non-operating, and up to 15,000 feet operating. Tests to assure compliance with paragraph 3.3.1.3 shall be performed according to 4.7.15.

3.3.2.10 TEMPEST. Test cable shall meet requirements as specified in A3148008, A3148009, A3249641, A3266179, and A3307042 (all Classified) when tested per 4.7.16.

3.3.2.11 Insertion - Loss measurement. When tested per 4.7.17, these losses shall be at a minimum of 30 dB.

3.3.2.12 Grind test (molded material). Molded material shall exhibit uniform consistence when tested per paragraph 4.7.18.

3.3.2.13 Ozone resistance. Cable assemblies shall be tested for ozone resistance as specified in 4.7.19. At the completion of the exposure period, there shall be no evidence of cracking in the bend relief or cable jacket when examined under 7X magnification.

3.3.2.14 Final teardown and inspection. There shall be no evidence of deterioration of the cable assembly that could adversely affect normal operation when inspected as outlined in 4.7.20. Flexing the cable assembly 90° from side to side shall not reveal any openings in the total shield more than .06 inch square. Broken strands of braid shall not be cause for failure. Small droplets of water due to penetration shall be cause for cable failure. Minor condensation is allowable.

3.4 Cable identification. Unless otherwise specified on the applicable cable assembly drawings, cables shall be marked in accordance with MIL-STD-130, MIL-STD-13231, and SAE-AS5942 on a cable marker, with characters having a minimum height of 3/32 (1/8 desired) inch after assembly. The marker shall be yellow with black letters and numbers. Cables having a diameter greater than

0.625 +.125 / -.000 inch shall have markings that are located 180 degrees opposed. Marking information to be included shall be as specified on the applicable cable assembly drawing and as stated herein. Identification shall include only information as listed.

a. 80063 Assy - AXXXXXXX-X (Assy Dwg. No. and Dash No.)

b. Cable part number (CX-XXXXX) and length (Per Assy Dwg.)

c. Month and year of manufacture

d. Manufacturer’s code (CAGE)

Cable assemblies 6 feet and under shall have one band located near the center;

assemblies over 6 feet shall have two marker bands, one near each end. In addition, cable termination identification, if specified on the applicable cable assembly drawings shall be placed near the termination and separate from the cable identification on the outer surface of the jacket or on a jacket sleeve with characters having a minimum height of 3/32 (1/8 desired) inch after assembly. On cables having a diameter greater than 0.625 +.125 / -.000 inch, termination identification shall be located 180 degrees opposed. Clear shrinkable tubing shall be used to cover and protect all cable markings.

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3.5 Workmanship. Workmanship shall be in accordance with MIL-HDBK-454, guideline 9, and shall be examined for conformance to paragraph 4.7.2.

4 QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for inspection. Unless specified otherwise, the supplier shall be responsible for performance of all quality assurance tests, as specified herein.

The supplier may use any inspection facility acceptable to the buyer. Inspection records of the examinations and tests shall be kept complete, and maintained through the manufacturing cycle. The buyer reserves the right to perform any of the tests specified herein, and if nonconformance is evidenced, the buyer reserves the right to reject the project lot without liability.

4.2 Classification of tests. The inspection and tests are classified as follows: (See applicable cable drawing for listed tests required for coaxial cables)

a. First Article - 3 samples (4 samples if Step 4 option is exercised) of each nomenclature of cable by CX-XXXXX No. (Select desired lengths unless specified otherwise by procuring agency) to be used as follows - tables I and

III.

Step 1. 2 samples subject to tests in table I.

Step 2. 2 samples used in step 1 subject to tests in table III.

Tests in table III are to be performed in sequence listed.

Step 3. Retain 1 sample as spare.

Step 4. Optional cable to be submitted prior to F.A.T. for inspection and teardown by procuring agency.

b. Acceptance Test - table I - 100%

c. Performance Verification Tests - table II - 2.5% AQL special inspection level

S-4 at the normal sampling plan, no switching, per MIL-STD-1916, except as noted.

d. Requalification Tests - table III - After maximum lapsed production time of one year from date of the last cable of a cable type (CX-XXXXX) acceptance by the procuring agency, 3 cables of each nomenclature of cable by CX-XXXXX No.

(select desired lengths unless specified otherwise by procuring agency).

e. Design Performance Qualification Tests - table IV - Disposition of these tests are to be determined by the procuring agency.

4.3 Acceptance tests. The acceptance tests shall be performed on 100% of the product by the cable manufacturer on a lot basis as noted. The acceptance tests shall verify production conformance to the requirements of this specification. The acceptance tests shall be as specified in table I.

4.4 Performance verification tests. The performance verification tests shall be those tests performed on representative samples to verify construction and performance to selected environments. The tests are to be performed by the supplier or other designated testing source as specified by the buyer and shall be the tests specified in table II.

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4.4.1 Design performance qualification tests. These tests are special tests that require special and unique test facilities and information to perform test. Testing source and specific direction will be furnished to supplier as needed at time of purchase.

Tests are listed in table IV.

4.5 Requalification tests. Those that shall be performed after one year from date of the last cable of a cable type (CX-XXXXX) acceptance by the procuring agency.

Three cables of each type per table III shall be tested.

4.5.1 Design changes. Any changes to material or process of an approved design will result in requalification of that cable type. Requalification requirements will be determined by the procuring activity.

4.6 DELETED

4.7 Test methods.

4.7.1 Examination of product. The cable shall be examined to verify that the materials, construction, physical dimensions, and marking are in accordance with the applicable requirements of this specification and as specified in 3.2 and on the individual drawings. Mutilation of base metal or keys on connectors is basis for rejection of cables. Surface marks or mars that result from normal wear or shop environment shall not be cause for rejection.

4.7.2 Examination of workmanship. The cable shall be visually and mechanically examined for workmanship as specified herein. Particular attention shall be given to the examination of the following areas:

a. Physical damage to cable.

b. Use of specified materials.

c. General appearance in areas of assembly.

4.7.3 DC resistance. The direct current resistance of each wire conductor contained in the cable assembly being tested shall be measured using the applicable wiring list.

The resistance shall not exceed the value specified in 3.3.1.1. The resistance of internal component shields such as coaxial cable or twisted pair shields shall be measured between their termination points and shall not exceed the value specified in 3.3.1.1. Resistance of overall shields shall be measured from connector shell to connector shell or shield end transition and shall not exceed the value specified in 3.3.1.1.

4.7.4 Continuity. Each circuit shall be tested for continuity using a potential of no more than 10 volts. Continuity shall be tested for each conductor including shields as conductors. The cable shall meet the requirements of paragraph 3.3.1.2.

4.7.5 Insulation resistance. Insulation resistance shall be measured in accordance with Method 302 of MIL-STD-202, Test Condition B to verify conformance to 3.3.1.3.

The test potential shall be applied between each isolated conductor or shield and the connector shells, and between the connector pins of each isolated conductor or shield.

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4.7.6 Shielding effectiveness. The shielding effectiveness of the overall shield and overall shield termination shall be as specified in 3.3.1.4 when measured using surface transfer impedance measuring techniques in accordance with MIL-C-85485.

4.7.7 Temperature.

4.7.7.1 Low temperature. Subject the test cable to low temperature specified in 3.3.2.1.1.

for a minimum of two (2) hours. At the conclusion of this time and while maintaining this temperature, bend the cable (180° minimum) around a six (6) inch diameter mandrel. Mechanically restrain the cable in this bend position around the mandrel for a minimum of four (4) hours. At the conclusion of this period, and still maintaining the storage temperature, straighten cable out and mechanically restrain the cable in a straight or near straight position for a minimum of four (4) hours while still maintaining the storage temperature. At the end of the last four

(4) hour period, allow the temperature to gradually return to room temperature.

Allow the cable to soak at room temperature for a minimum of 12 hours while still in the straight or near straight position. Inspect cable for conformance with

3.3.2.1.1. To facilitate inspection, check for degradation of cable by bending cable cover the mandrel in the approximate location as before. Flexing of cable in several different rotational orientations is necessary for proper inspection.

4.7.7.2 Low temperature flexibility. The cable assembly shall be aged in a circulating air oven for a minimum of 48 hours at 110°C ± 2°C. The cable assembly shall then be conditioned for a minimum of 24 hours at the temperature of -40°C ± 2°C.

This temperature shall be continuously recorded during conditioning and testing.

A molded section or transition (only one end of cable need be tested) shall be held in a mechanical device so that the portion of the cable entering the molded section or transition flexes when the cable is flexed. The cable shall be flexed mechanically from a point a minimum of 5 inches or the cable OD x 10 from the cable entry end of the molded section or transition that is clamped in the fixture.

The part of any mechanical device which will be in contact with the test specimen shall be cold conditioned. At the end of the conditioning period, and while at the conditioning temperature, the cable shall be flexed at a fixed rate between 10cpm minimum and 30cpm maximum for 500 cycles through a 180 degree arc (90 ± 5° both directions from center). See figure 2 for dimensional requirements of a suggested test fixture.

At the conclusion of the test, the specimen shall be examined visually at room temperature under 3X magnification. There shall be no visible cracks, separation of the bond or other damage in the molded section, or visible deterioration of the cable in the flexed area. The test sample shall conform to 4.7.3 and 4.7.5 after completion of this test.

4.7.7.3 High temperature. Subject the cable to the high temperature test specified in MIL- STD-810, Method 501, Procedure 1 to verify conformance to 3.3.2.1.3. Maintain the storage temperature in accordance with 3.3.2.1.3. At the conclusion of this time, stabilize the temperature at 23°C ± 10°C and perform the test of 4.7.3 and 4.7.5.

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4.7.7.4 Thermal shock. Subject the cable to the thermal shock test specified in MIL-STD-810, Method 503, Procedure 1. After completion of this testing, stabilize the cable at room temperature (23°C ± 10°C) and conduct tests of 4.7.3 and 4.7.5.

4.7.8 Moisture resistance. Subject the cable to the moisture resistance test specified in MIL-STD-202, Method 106, except subcycle noted in 3.4 shall be omitted. After this test is completed, perform the tests of 4.7.3 and 4.7.5.

4.7.9 Salt fog. After installation of sealed mating connectors, subject the cable to the salt spray test specified in MIL-STD-810, Method 509 for 96 hours. At the completion of this test, rinse with clear water, air dry and perform the tests of 4.7.3 and 4.7.5.

4.7.10 Water sealing effectiveness.

4.7.10.1 Immersion. Subject cable to the test specified in Method 512.2 of MIL-STD-810.

The cables shall be immersed for a period of 30 minutes with sealed mating connectors installed. Transfer time from oven to water tank is not to exceed 5 minutes. The test cable shall meet the requirements of 4.7.3 and 4.7.5 after the test.

4.7.10.2 Water spray. This test shall consist of a coarse water spray (large drops) directed at the cable assembly from various directions and angles. For the purpose of this test, “test area” shall refer to the terminated ends and any joints or changes of construction along the length of the completed cable assembly.

Preparation of the test sample will consist of installing mating connectors, or suitable substitutes, and locating the “test area” on the test surface. All “test areas” of a cable assembly shall be tested. Spacing between the “test areas” shall be a minimum of two inches. The “test area” may be held stationary, if needed, by any means that does not interfere with testing. The temperature of the water spray shall be equal to, or less than, the temperature of the test specimen.

The test equipment will consist of a test surface, a movable nozzle coupled to a water supply, and a pressure gauge. The water shall not be specially treated water such as demineralized (softened), ionized or iron filtered, but shall be tap water. The nozzle shall be .3 inch to .4 inch in diameter. The nozzle pressure is to be adjusted within the range of 6 to 8 PSI (measured a maximum of 3 ft. from the nozzle) and should deliver water at an expected rate of 7-10 GPM. The water form shall be coarse spray (coarse drops). The main portion of the spray pattern shall be no more than approximately three inches in diameter at six feet. A recirculatory system may be used for conservation of water.

The test shall consist of directing the water spray at the “test area” from all horizontal directions to the test surface from a distance of 6 to 8 feet (nozzle to test area). Total test time shall be one minute per “test area”. Following the test, the cable assembly shall then meet the requirements of 3.3.2.4.2.

MIL-STD-108 is used as a test basis and definition of terms.

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4.7.11 Vibration. Subject a cable to the vibration test specified in MIL-STD-180, METHOD 514, Category 8. Test level shall be per figure 514.3-35, Duration per table 514.3-VII, as shown in MIL-STD-810. The cable assembly shall be electrically active during testing using 50-100 Vdc and a monitoring system for each series. The cable may be coiled (if necessary) and laid flat on the vibration table (test in one axis) with the end points attached to the table. Following the test, the cable assembly shall then meet the requirements of 4.7.3 and 4.7.5.

4.7.12 Cable pull test. The connector transition of the cable assembly on each end of the cable shall be clamped in a suitable holding fixture so that pull forces will be transmitted along the longitudinal axis of the cable, using care to avoid an excessive clamping force. The initial cable length should be measured with a maximum of 10 lb load to insure that the cable is straight. After the initial cable length is recorded, apply an increasing load to the cable at a rate of no more than 10-30 in/min or 40 lbs/sec to a maximum load of 125 lbs [5-10 in/min or 20 lbs/sec for coaxial RF cables to a load of 40 lbs]. The final cable length should be recorded at the maximum load. The 125 lb load should be applied for a maximum of 5 seconds. Percent elongation shall be calculated using the initial and final cable lengths recorded.

Following the pull test, the cable shall be inspected for external damage. Test samples must meet the requirements of 4.7.3 and 4.7.5 following the pull test for FAT. For Performance Verification, the requirements for post pull test are 4.7.4 and 4.7.5.

4.7.13 Thermal pulse. The test sample shall comply with 3.3.2.7 after being subject to a thermal pulse of 30 + 1, -0 Cal/Sq Cm. Test per A3148008, A3148009, A3249641, A3266179, and A3307042 (all Classified).

4.7.14 Chemical biological resistance. The test cable shall comply with paragraph 3.3.2.8 after being immersed in chemical or biological agent decontaminant DS-2. The cable shall be immersed in DS-2 per MIL-D-50030 for a minimum of 24 hrs.

4.7.15 Altitude. The cable shall be tested per Method 500.2, Procedure I of MIL-STD-810, test altitude shall be 40,000 feet. The rate of change of altitude shall not exceed 2,500 feet per minute.

4.7.16 TEMPEST. Test cables shall meet the requirements of 3.3.2.10 when tested per A3148008, A3148009, A3249641, A3266179, and A3307042 (all Classified).

4.7.17 Insertion - Loss measurement. With a 1 kHz signal injected at the cable connector plug end, the measurement shall comply with 3.3.2.11. Test per MIL-STD-220.

4.7.18 Grind test (molded material). Molded components shall be ground down to one-half of original thickness. Ground surfaces shall be examined for air bubbles and other irregularities which are caused by poor molding procedure of materials.

Grinding shall be done using coating abrasive in accordance with ANSI B74-18, Type II, Class 1, grit size 150 to 220; an equivalent abrasive is acceptable.

Sample should conform to requirements of 3.3.2.12.

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4.7.19 Ozone. The test sample(s) shall be air-oven aged in an unstressed condition for 70 ± 1/2 hours at 70°C and then kept at room temperature at least four days prior to ozone exposure. After oven exposure, the sample shall be wrapped around a 2 inch diameter mandrel and placed in the ozone chamber while on the mandrel.

The cable assembly shall then be exposed for a period of 168 ± 1/2 hours. The ozone concentration used shall be 50 ±3 parts of ozone per 100,000,000 parts air.

The temperature should be maintained at 50°C during this period. The sample shall then be examined for compliance with 3.3.2.13.

4.7.20 Final teardown and inspection. The cable assembly shall be disassembled (remove connectors, remove conductors where practical, slice and remove parts of molds, slice and remove outer jacket near ends of cable assemblies, remove portions of braid, etc.) in such a manner that parts of all portions of the cable assembly may be inspected. Sample should meet requirements of 3.3.2.14.

5 PREPARATION FOR DELIVERY

5.1 Packaging. Each cable shall be clean and dry and packaged in a manner that will afford adequate protection against corrosion, deterioration and physical damage during shipment from the supply source to the first receiving activity.

5.2 Packing. Units packaged as specified in 5.1 shall be packed in shipping containers which will afford adequate protection against damage during direct shipment from the supply source to the first receiving activity. These packs will conform to the applicable carrier rules and regulations.

5.3 Marking. In addition to any special marking required by the purchase order, each unit package and shipping container will be marked in accordance with MIL-STD-129.

6 NOTES

6.1 Intended Use. The cables are intended for use with a communications network.

6.2 Ordering Data. Procurement documents should specify the following:

a. Title, number and data of this specification

b. Applicable cable assembly drawings

c. Special tests and examination (instructions on table II and table IV)

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TABLE I. Acceptance tests (100%).

Requirement Item Definition Test Method

3.2 Examination of Product 4.7.1

3.5 Examination of Workmanship 4.7.2

3.3.1.2 Continuity 4.7.4

3.3.1.3 Insulation Resistance 4.7.5

TABLE II. Performance verification tests.

Requirement Item Definition Test Method

1/ 3.3.2.6 Cable Pull Test 4.7.12

2/ 3.3.2.4.1 3/ Immersion 4.7.10.1

2/ 3.3.2.4.2 3/ Water Spray 4.7.10.2

1/ 2.5% AQL special inspection level S-4 at the normal sampling plan, no switching, per MIL-STD-1916 unless specified otherwise by procuring agency.

2/ 2.5% AQL special inspection level S-4 at the normal sampling plan, no switching, per MIL-STD-1916.

3/ Immersion and water spray tests are interchangeable and either test may be used.

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TABLE III. Requalification and first article tests. *

Requirement Item Definition Test Method

Group I

2 cables of each type

3.3.1.1 Dc Resistance 4.7.3

3.3.2.1.1 Low Temperature 4.7.7.1

3.3.2.1.2 Low Temperature Flex 4.7.7.2

3.3.2.1.3 High Temperature 1/ 4.7.7.3

Group II

1 cable of Group I each type

3.3.2.6 Cable Pull Test 4.7.12

3.3.2.1.4 Thermal Shock 4.7.7.4

3.3.2.4.1 Immersion (F.A.T.) 4.7.10.1

3.3.2.4.2 Water Spray 4.7.10.2

3.3.2.3 Salt Fog (F.A.T. Only) 4.7.9

3.3.2.14 Final Teardown and Inspection 4.7.20

Group III

1 cable of

Group I, each type

3.3.2.2 Moisture resistance 4.7.8

3.3.2.5 Vibration 4.7.11

3.3.2.13 Ozone 4.7.19

3.3.2.12 Grind Test (Molded Material) 4.7.18

3.3.2.14 Final Teardown and Inspection 4.7.20

Group IV

Four foot section of simulated cable assembly with production shielding processed per

MIL-C-

85485A, Paragraph 4.7.24.2

3.3.1.4 Shielding (F.A.T. Only)

Effectiveness

4.7.6

1/ Immersion and water spray tests are interchangeable and either test may be used.

* Requalification tests of each cable type by CX-XXXXX No. is required after a maximum lapse production time of 1 year from date of last cable procured.

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TABLE IV. Design performance qualification tests.

(Dispositions of these tests are to be determined by the Procuring Agency)

REQUIREMENT ITEM DEFINITION TEST METHOD

3.3.2.7 Thermal Pulse (F.A.T. Only) 4.7.13

3.3.2.8 Chemical Biological

Resistance (F.A.T. Only)

4.7.14

3.3.2.9 Altitude (F.A.T. Only) 4.7.15

3.3.2.10 TEMPEST 4.7.16

3.3.2.11 Insertion - Loss Measurement 4.7.17

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