Attachment_0003_-_A3336463_Reel_Specs.pdf

A3336463

23 Mar 2012

PERFORMANCE SPECIFICATION

ITEM SPECIFICATION

FOR THE

REEL, CABLE, LIGHT-WEIGHT TACTICAL

This specification id approved for use by the Communications-Electronics Command, Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense.

AMSC: N/A FSC 8130

Distribution Statement A Approved for public release;

Distribution is unlimited

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to Commander, U.S. Army

Communications-Electronics Command, ATTN: RDER-PRC-CM, Fort Monmouth, NJ 07703 by using the ASSIST Online database at http://assist.daps.dla.mil

SPRBL1-12-Q-0056 ATTACHMENT 0003

http://assist.daps.dla.mil/

1. Scope

1.1 Scope. This specification covers light-weight tactical cable reels for fiber optic cable.

1.2 Light-weight Cable Reel Description. The five types of light-weight reels covered in this specification are used for storing and transporting military tactical fiber optic cable. The reels may be procured as commercial-off-the-shelf (COTS) equipment that meets the requirements contained in this specification.

1.3 Part or Identifying Number (PIN). PIN’s to be used for light-weight cable reels acquired to this specification are created as follows:

RLW- 123

2. Applicable Documents.

2.1 Government Documents

Document Number Title

A3159863 PERFORMANCE SPECIFICATION, CABLE ASSEMBLIES,

NONPRESSURE PROOF, FIBER OPTIC, METRIC, GENERAL

SPECIFICATION FOR

A3159864 CABLE ASSEMBLIES, NONPRESSURE PROOF, FIBER OPTIC,

METRIC

Length: 100 – 100 meters

300 – 300 meters

500 – 500 meters

750 – 750 meters

1000 – 1000 meters

RLW Prefix

A3302584 FIBER OPTIC CABLE ASSEMBLIES (4 FIBER)

A3159879 CABLE, FIBEROPTIC, RUGGEDIZED, RADIATION HARDENED

(METRIC) AND NON-RADIATION HARDENED

A3102607 Cable Assembly, Fiber Optic, CX-13295/G (300 Meters)

A3102608 Cable Assembly, Fiber Optic, CX-13295/G (1000 Meters)

MIL-PRF-85045 PERFORMANCE SPECIFICATION CABLES, FIBER OPTICS,

(METRIC), GENERAL SPECIFICATION FOR

MIL-PRF-85045/8 PERFORMANCE SPECIFICATION SHEET CABLE, FIBER OPTIC,

RADIATION HARDENED, CABLE CONFIGURATION TYPE 1

(BUFFERED FIBER), APPLICATION E (GROUND TACTICAL),

CABLE CLASS MM, (METRIC)

MIL-STD-810 Environmental Engineering Considerations and Laboratory

Tests

MIL-STD-790 ESTABLISHED RELIABILITY AND HIGH RELIABILITY QUALIFIED

PRODUCTS LIST (QPL) SYSTEMS FOR ELECTRICAL,

ELECTRONIC, AND FIBER OPTIC PARTS SPECIFICATIONS

DOD-STD-1678 FIBER OPTICS TEST METHODS AND INSTRUMENTATION

FED-STD-595 Federal Standard – Colors Used In Government Procurement

2.2 Industry Documents

ASQ Z1.4 Sampling Procedures and Tables for Inspection By Attributes

(available from www.asq.org or American Society for

Quality, 611 East Wisconsin Avenue, Milwaukee, WI 53202)

EIA-455-13 Visual and Mechanical Inspection of Fibers, Cables, http://www.asq.org/

Connectors and/or Other Fiber Optic Devices

EIA/TIA-455-12 Fluid Immersion Test for Fiber Optic Components.

3. Requirements.

3.1 Performance. Performance relates to the ability of the cable reel to store, deploy and retrieve fiber optic cable assemblies in a variety of environmental and mechanical conditions without damaging or affecting performance of the fiber optic cable assembly. Unless otherwise specified, optical measurements will be made using industry standard practices and equipment suitable for inspection and test.

3.2 Suitability of Design for Fiber Optic Cable. The design of the reel shall ensure that the fiber optic cable is not bent or stressed against the reel drum surface during take-up of the cable onto the reel. The surface area of the drum shall be uniform and continuous with no slots or holes.

3.3 Visual and Mechanical Inspection. The reels shall be inspected to verify the materials, construction, interchangeability, marking and workmanship are in accordance with EIA-455-13 and requirements of this specification.

3.4 Materials. The reel flanges shall be made from light weight, durable and non-porous material meeting the requirements of this specification and fiber optic cable assembly requirements specified in CECOM drawings A3159863, A3159864, A3302584 and applicable contract or purchase order requirements or modifications. The flanges and handle shall be fabricated from non-conductive material (excluding attaching hardware and drum).

3.4.1 Finish. The reels can be made with applicable coloring agents. Colors shall include, but not be limited to, Black, (Desert) Tan 33446 and Olive Drab 34088 as identified in table 3 of FED-STD-

595. The finish of the material shall be lusterless, non-reflective, fade resistant and free from defects. When inspected, the reels shall generally match the specified colors. Slight deviations in color consistency are acceptable.

3.5 Field Transportable. The reel flange shall be designed to enable ease of transport by grasping of the flange frame with a single bare or gloved hand. The frame will be free of sharp edges and strong enough to support the reel when fully loaded with cable without distorting or damaging the reel. The reels shall provide acceptable access to grip the flange with bare or gloved hand, allowing the fingers to fully wrap around the outer frame of the flange to lift and carry the reel.

3.6 Connector Storage. The reel shall be capable of securely storing fiber optic connectors within the drum of the reel without need for tools for removal or storage of the connectors. Foam or protective cushioning material can be used to prevent connector damage during transport.

Connectors shall fit inside the drum and be secured and protected from damage during transport. Removal of the connectors for test or cable deployment shall not require any tools.

Connectors with 1.57 inch Max OD shall fit the RLW100 and 300. Connectors with 2.1 inch Max

OD shall fit the RLW500 & RLW1000.

3.7 Operation. The reel design shall support deployment or retrieval of fiber optic cable in either manual or automated modes. A folding handle will be available for manual cable retrieval.

When used to retrieve a deployed cable (minimum of 300 full 360º turns), the handle will not crack or fail in any way. The reel shall be modular allowing operation on a simple axle or cable reel accessories (stands, backpacks, etc.).

3.8 Stacking. The reels shall be capable of being vertically stacked securely to a height of at least 5 feet without deforming, distorting or damaging any of the reels forming the stack (flange to flange without packaging) securely. The stacked reels will nest within each other, forming a secure column. None of the reels in the stack shall show any sign of deformation or damage after being stacked.

3.9 Fit On Axle. The reel shall be designed to accommodate a 1.032 inch square or round drive axle.

The fit on the axle shall be such that the axle can be completely inserted and withdrawn without binding. This test will be performed before and after storage and temperature cycling tests.

3.10 Alignment. No point on the circumference of the inside edge of either flange shall be more than one-fourth of an inch from the perpendicular to the axle. Measurements shall be taken using an empty reel (no cable) and recorded at four points 90 degrees apart on each flange.

3.11 Vibration. The reels shall be subjected to the test of 3.11.1 through 3.11.4. During vibration the test unit shall be clamped in its normal operating position on a vibration table that can be controlled to within 10% of the specified frequencies and amplitudes. Following the test, the reel shall show no evidence of permanent degradation including no loosening of parts.

3.11.1 Direction of Vibration. The reels shall be vibrated successively, over the specified ranges of applied frequencies, in three mutually perpendicular directions parallel to the edges of the reels.

3.11.2 Rate of Change of Vibration Frequency. The frequency of applied vibration shall be varied uniformly at a rate of one Hz per minute.

3.11.3 Amplitude and Frequency of Applied Vibration. The amplitude (one half of the total excursion) of the vibration table and the frequency range shall be in accordance with the following:

Frequency of Vibration (Hz) Amplitude of Vibration (in)

10 to 33 Horizontal Vertical

0.020 0.030

3.11.4 Duration of Test. The reels shall be vibrated for at least six hours, two hours in each of the three directions specified in 3.11.1.

3.12 Drop. The drop test shall be performed on a reel loaded with cable. The test sample shall be conditioned in a temperature chamber at -30º C for 24 hours prior to the test. The drop test shall be performed within ten minutes of when the reel is removed from the chamber. If the specified drops cannot be performed within 10 minutes after removal, immediately return the reel to the -30ºC temperature chamber for 1 hour before proceeding to the next 10 minute test period during which the reel may be dropped.

3.12.1 The reel shall be lifted off the floor by use of a hoist equipped with a quick release device.

When the bottom of the reel is 3½ feet above a two inch fir platform backed by a concrete floor, it shall be released so as to drop squarely on the periphery of both flanges.

3.12.2 The reel shall then be lifted as above, held until motionless, and dropped squarely on one flange, then on the other.

3.12.3 The reel shall be lifted at a single point at the edge of one flange, held until motionless, and then dropped so that the reel will land on the opposite flange at an angle to the periphery of one flange. Repeat the procedure on the other flange.

3.12.4 Upon completion of the drops, the reel shall be inspected. The reel show no evidence of permanent degradation of performance, deformation of the flange(s) or loosening of parts when tested as specified in section 3.12. Alignment measurements shall be taken before and after each drop to the point of impact. Maximum deformation is the difference between these measurements. Minor cracks in the flange which do not affect functionality of the reel are permissible.

3.13 Temperature-Humidity Cycling. The reel without cable shall be tested in accordance with MIL-

STD-1678-3, measurement 4030. The number of test cycles shall be five. Exposure cycle for humidity shall be as specified on figure 1, without steps 7.a or 7.b. Upon completion of the test, there shall be minimal corrosion on the metal drum or attaching hardware or any other deterioration.

Figure 1

3.14 Storage Testing. The reel (with cable) shall be subjected to 48 hours at -57⁰C and 48 hours at

+85⁰C. Upon completion of each test, the reel shall be inspected. No deformation of the reel flanges is permissible. Minor cracks in the flange which do not affect functionality of the reel are permissible.

3.15 Identification marking. All reels shall bear permanent identification markings in accordance with the applicable commercial drawing. Marking shall as a minimum include manufacturer name, and contact information. This information shall be confirmed through inspection.

3.16 Workmanship. The reel shall be manufactured and assembled in accordance with best commercial practices for military and heavy industrial applications. The reel shall be free from defects and sharp edges.

3.17 Dimensions and Weights. The reels shall conform to the following dimensions and weights.

Cable capacity is based upon standard military ground tactical cable in accordance with CECOM drawing A3159879 or MIL-PRF-85045/8.

RLW-100 RLW-300 RLW-500 RLW-1000

Cable Capacity 100 Meters 300 Meters 500 Meters 1000 Meters

Reel Weight MAX 8.5 Pounds 10.5 Pounds 11.0 Pounds 12.5 Pounds

Flange Diameter 17 Inches 17 Inches 17 Inches 17 Inches

Drum Diameter 10 Inches 8 Inches 8 Inches 8 Inches

Drum Width 2.21 Inches 5 Inches 8 Inches 16 Inches

Total Width 4.98 Inches 7.76 Inches 10.76 Inches 18.76 Inches

Table 1. Cable Reel Dimensions and Weights

4 QUALITY ASSURANCE PROVISIONS.

4.1 Manufacturing and Quality Controls. Suppliers wishing to supply reels to this specification must be certified to MIL-STD-790. All reels qualified to this specification are to be configuration controlled. Any changes to the design, materials or processes used to manufacture the reels must be approved by US Army CECOM in advance of implementation. U.S. Army CECOM may require requalification of the reel(s) if the change could potentially affect form, fit or function of the reels. The government reserves the right inspect the facilities of suppliers with or without prior notification for compliance with these requirements. The supplier agrees to provide full access to all equipment, procedures, manufacturing records and personnel involved with the manufacture of the reels without delay upon request of the Government.

4.2 First Article (Qualification) Inspection. When required by contract or purchase order, first article inspection shall be performed. Except as otherwise specified in the contract or purchase order, the supplier may use his own or any other facilities suitable for the performance of the inspection and test requirements specified herein. Suppliers who have previously qualified reels to this specification are exempt from first article inspection providing that no changes to design, materials or manufacturing processes have been implemented since the initial qualification.

4.2.1 Sample. Unless otherwise specified in the contract or purchase order, the first article sample shall consist of six finished reel assemblies. The samples shall be configured with 1,000 meters of military ground tactical cable per A3159879 or MIL-PRF-85045/8 for tests where cable is specified. Qualification of a smaller capacity reel shall not qualify larger capacity reels.

4.2.2 Inspection Routine. The sample shall be subjected to the first article inspection specified in table 2.

Inspection Performance Paragraph Sample Quantity

Suitability Of Design For Fiber

Optic Cable

3.1 1

Visual and Mechanical

Inspection

3.3 6

Materials 3.4 6

Finish 3.4.1 6

Field Transportable 3.5 1

Connector Storage 3.6 1

Operation 3.7 6

Stacking 3.8 6

Fit On Axle 3.9 6

Alignment 3.10 6

Vibration 3.11 1

Drop 3.12 1

Temperature-Humidity Cycling 3.13 1

Storage Testing 3.14 2

Identification marking 3.15 6

Inspection Performance Paragraph Sample Quantity

Workmanship 3.16 6

Dimensions and Weights 3.17 6

Table 2 First Article Inspection Requirements

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

4.2.4 Test Report. A test report with complete results for all required tests shall be submitted to

CECOM for review and approval. Please address to:

US Army Headquarters, CECOM Product Realization Directorate

RDER-PRC-CM

6010 Frankford St. K2-229-01

APG, Md 21005

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

5 NOTES

5.1 Suggested Sources Of Supply

Optical Cable Corporation

1700 Capital Avenue, Suite 150

Plano, TX 75074

Tel: 972-509-1500

Fax: 972-509-1500 email: orders@appliedopticalsystems.com www.occfiber.com

Qualified part numbers – see attached drawings