Attachment_0001_TECHNICAL_DATA_PACKAGE.pdf

MIL-DTL-3241F

6 January 2010

SUPERSEDING

MIL-R-3241E

9 July 1985

DETAIL SPECIFICATION

REELS, CABLE (REELS DR-5( ), DR-7( ),

DR-B( ), RC-453( )/G, RL-159( )/U)

INACTIVE FOR NEW DESIGN AFTER 25 FEBRUARY 1998

This specification is approved for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 SCOPE. This specification covers five types of steel reels for use in storing and transporting field wire and cable, designated as reels DR-5( ), DR-7( ), DR-8( ), RC-453( )/G and RL-159( )/U (see 6.4).

2. APPLI CABLE DOCUMENTS

2. 1 General. The documents listed in this section are specified in section 3, 4, or 5 of this standard.

This section does not include documents cited in other section of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in section3, 4, or 5 of this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-C-10578 - Corrosion Removing and Metal Conditioning Compound (Phosphoric Acid Base) MIL-W-12332 - Welding, Resistance, Spot, Seam, and Projection, for Fabricating Assemblies of Low-

Carbon Steel MIL-DTL-14072 - Finishes for Ground Based Electronic Equipment MIL-DTL-53039 - Coatings, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

Comments, suggestions, or questions on this document should be addressed to Defense Supply Center Philadelphia (DSCP), ATTN: DSCP-NASA, 700 Robbins Avenue, Philadelphia, PA 19111-5096 or e-mail to dscpg&inspecomments@dla.mil . Since contact information can change, you may want to verify the currency of this address information using ASSIST Online database at http://assist.daps.dla.mil .

INCH POUND

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SPRBL1-19-Q-0070

Attachment 0001 1

MIL DTL 3241F

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-22 - Welded Joint Design MIL-STD-1907 - Inspection, Liquid Penetrant and Magnetic Particle, Soundness Requirements for

Materials, Parts and Weldments MIL-STD-13231 – Markings of Electronic Items

(Copies of these documents are available online at http://assist.daps.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

US ARMY COMMUNICATIONS & ELECTRONICS MATERIAL READINESS COMMAND DRAWINDS

SC-F-639 - Reel DR-5( ), Assembly SC-F-5697 - Reel DR-7( ), Assembly SC-DL-90889 - Reel DR-8( ), Drawing and Data List SC-DL-621036 - Reel RL-159( )/U, Drawing and Data list

DL-A-3003198 - Reel RC-453( )/G, Drawing and Data list

(Copies of these documents are available from US Army Communications & Electronics Material Readiness Command, 12 WD Bldg 601 Mcafee Ctr, Fort Monmouth, NJ 07703.)

2.3 Non-Government publications. The following documents form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN SOCIETY FOR QUALITY (ASQ)

ASQ Z1.4 - Sampling Procedures and Tables for Inspection by Attributes

(Copies of this document are available from www.asq.org or the American Society for Quality, 611 East Wisconsin Avenue, Milwaukee, WI 53202.)

ASTM INTERNATIONAL

ASTM E8/E8M - Standard Test Methods for Tension Testing of Metallic Materials ASTM E10 - Standard Test Method for Brinell Hardness of Metallic Materials ASTM E18 - Standard Test Methods for Rockwell Hardness of Metallic Materials ASTM E1444 - Standard Practice for Magnetic Particle Testing

(Copies of these documents are available from www.astm.org or ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 CONSTRUCTION. Each reel shall be fabricated in accordance with the applicable drawing listed below and with performance characteristics contained herein:

Reel DR-5 ( ) -SC-F-639 Reel DR-7 ( ) -SC-F-5697 Reel DR-8( ) -SC-DL-90889 Reel DR-159( )/U -SC-DL-621036 Reel RC-453( )/G -DL-A-3003198

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Attachment 0001 2

3.2 Steel reel heads. The heads of the reels, except DR-8( ), shall be made of steel which, after heat treatment, shall have the properties specified below (see 4.10):

Tensile strength -135,000 p.s.i. minimum (see 4.10.1).

Yield strength (0.1%) -120,000 p.s.i. minimum (see 4.10.1).

Elongation at rupture -7 percent minimum (see 4.10.1).

Hardness -Rockwell C31 to C41 (Brinnell 294 to 381) (see

4.10.2).

3.3 Welding. Whenever practicable, welded joints shall conform to MIL-STD-22 and shall be such that grinding on the finished weld will be unnecessary. Spot, seam and projection welds shall conform to MIL- W-12332. Butt welds shall conform to the requirements specified in the cable reel drawings in paragraph

3.1. When spot or other intermittent welds are used to hold a part, the number of welds shall be at least two.

3.3.1 Cleaning prior to welding. Surfaces to be welded shall be cleaned In accordance with good commercial practice and shall be free from rust, scale, paint, grease, and other foreign material.

3.3.2 Process. Preheating shall be employed where distortion is likely to result from welding. Welds shall have a thorough penetration and good fusion and shall be free from scabs, blisters, abnormal pock marks, crack, voids, slag inclusions, and other harmful defects. Where undesirable internal stresses are likely to result from welding, welded items shall be stress-relieved.

3.3.3 Cleaning after welding. Welded assembles shall be cleaned to remove rust, scale, oxidation products, and excess flux by sandblasting, wire brushing, or other suitable means. Prior to painting steel parts that have been arc or acetylene welded, parts shall be subjected to vat passivation or a phosphoric acid etch in accordance with MIL-C-10578. Acid used for cleaning shall be completely neutralized and removed. Sandblast cleaned items shall be finished or a protective coating shall be applied within four hours of its cleaning.

3.3.4 Weld inspection. Inspection of weld joints shall be made in accordance with, and meet the requirements of MIL-STD-1907 (see 4.9).

3.4 Fit on axle. When tested as specified in 4.5, the fit on the axle shall be such that the axle can be completely inserted and withdrawn without binding.

3.5 Alignment. On completed reels no point on the circumference of the head shall be more than one-fourth of an inch from the perpendicular to the axle, when tested as specified in 4.6.1. Measurements shall be taken and recorded at four points 90 degrees apart on each head.

3.5.1 Plate alignment on reel RC-453( )/G. On completed reel RC-453( )/G, no point on the circumference of the plates shall be more than one-fourth of an inch from the perpendicular to the drum when tested as specified in 4.6.2. At no time shall the space within the connector compartment be less than 3 inches.

3.6 Vibration. The reels shall show no evidence of permanent degradation including no loosening of parts when tested as specified in 4.7.

3.7 Drop. The reels shall show no evidence of permanent degradation other than deformation, no evidence of loosening of parts and shall exhibit a maximum deformation of no more than one inch when tested as specified in 4.8. Alignment measurements shall be taken before and after each drop to the point of impact. Maximum deformation is the difference between these measurements.

3.8 Moisture resistance. Upon completion of test specified in 4.11, there shall be no evidence of corrosion or any other form of deterioration.

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Attachment 0001 3

3.9 Dielectric strength for reel DR-8( ). Reel DR-8( ) shall withstand the dielectric strength test specified In 4.12, without breakdown.

3.10 Identification marking. All reels shall bear identification markings in accordance with the applicable detailed drawing and MIL-STD-13231 (see 3.1).

3.11 Finish and identification. After assembly, the reels shall be finished in accordance with MIL-DTL- 14072, Finish number P210AG. The primer and final paint film shall be applied to all exterior surfaces and to all interior surfaces that can be accessed through the axle and hand holes. Finish on reels shall be smooth and free from defects, and shall be applied after completion of tests specified in 4.7, 4.8, 4.9, and 4.10 have been met. The reel shall be marked with the acronym “CARC” in accordance with a) or b) below:

a) Embossed lettering with a height of .060 +.010 inch in an adjacent panel to the panel containing the nomenclature such as “DR-5 ( ), DR-7 ( ), DR-8 ( ), RC-453 ( )/G or RL-159 ( )/U”.

The dimensions (in inches) for the embossed lettering are shown in Figure 1 except for the DR-8 reel.

The dimensions (in inches) for the embossed lettering for the DR-8 reel are shown in Figure 2.

FIGURE 1. EMBOSSED LETTERING

EXCEPT FOR DR-8 REEL

FIGURE 2. EMBOSSED LETTERING

FOR DR-8 REEL

The marking shall be in accordance with MIL-STD-13231.

b. Stenciled lettering using black CARC paint per MIL-DTL-53039 in an adjacent panel to the panel containing the nomenclature such as “DR-5 ( ), DR-7 ( ), DR-8 ( ), RL-159 ( )/U or RC-453 ( )/G”.

The marking shall be in accordance with MIL-STD-13231 and given the following lettering sizes:

Type of reel Lettering Sizes (inches high)

DR-5 ( ) 1

DR-7 ( ) 1

DR-8 ( ) ½

RL-159 ( )/U 1

RC-453 ( )/G 1

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Attachment 0001 4

3.12 Workmanship. The reels shall be manufactured and assembled in accordance with the applicable portions of the following paragraphs herein (see 4.4):

3.1 ---------------- Construction.

3.3 ---------------- Welding.

3.3.1 ---------------- Cleaning prior to welding.

3.3.2 ---------------- Process for welding.

3.3.3 ---------------- Cleaning after welding.

3.10 ---------------- Identification marking.

3.11 ---------------- Finish and identification.

3.13 First article. When specified, samples shall be subjected to first article inspection (see 4.2).

4. VERIFICATION

4.1 Classification of inspections. The inspections requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3).

4.2 First article inspection. This inspection shall consist of the inspection specified in Table I and shall include, as referenced on inspection data sheets, inspection specified in subsidiary documents and the supplementary tests. Order and quantity of equipments to be subjected to first article testing shall be as specified in Table I.

4.2.1 Standard of workmanship. Standard of workmanship, 3.12, shall be established during the visual inspection of 4.4.

TABLE I. FIRST ARTICLE TEST SCHEDULE.

TITLE REQUIREMENT

PARA

TEST

PARA

SEQUENCE

UNIT UNIT UNIT UNIT

SAMPLE 1 2 3 4

Workmanship 3.12 4.4 2 2 2 2

Fit on axle 3.4 4.5 5 6

Alignment 3.5 4.6 3 3

Dielectric strength (If applicable)

3.9 4.12 4 4

Drop test 3.7 4.8 4 3

Vibration 3.6 4.7 3 4

Moisture resistance 3.8 4.11 5

Steel reel heads 3.2 4.10

Welds inspection 3.3.4 4.9 1 1 1 1

NOTE: This test should be conducted on two reel heads randomly selected from different batches of heat treated heads prior to assembly.

(See note below)

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Attachment 0001 5

4.3 Conformance inspection. The contractor shall perform the inspection specified in 4.3.1 through

4.3.3.4. This does no relieve the contractor of his responsibility for performing any additional inspection which is necessary to control the quality of the product and to assure compliance with all specification requirements. The government reserves the right to review and evaluate the contractor's inspection procedures and examine the contractor's inspection records. The contractor's inspection records for all inspections performed shall accurately reflect the observed attributes (actual measurements shall be recorded if otherwise required by the contract or this specification) for each characteristic identified within the required inspection/test parameters as correlated with the particular product offered to the government (see 6.5).

4.3.1 Group A inspection.

4.3.1.1 Inspection lot. An inspection lot shall consist of all reels of the same type, produced under essentially the same conditions and offered for inspection at one time.

4.3.1.2 Group A tests. Group A tests shall consist of the tests specified in Table II, and shall be made on the same set of sample units in the order shown.

4.3.1.2.1 Sampling plan. Statistical sampling and inspection shall be in accordance with ASQ Z1.4 for general inspection level II. The acceptable quality level (AQL) shall be as specified in Table II. Unless otherwise specified, the Acceptable Quality Limits (AQLs) listed in this section shall be used to establish the sample sizes, however, the acceptance number shall be zero. Major and minor defects shall be defined in ASQ Z1.4.

TABLE II. Group A inspection.

Inspection Requirement paragraph

Test Method paragraph

AQL (percent defective) Major Minor

Workmanship 3.12 4.4 1% 4%

Fit on axle 3.4 4.5 see note

Alignment 3.5 4.6 see note

Dielectric strength 3.9 4.12 see note

NOTE: All defects considered major, AQL is 1%.

4.3.2 Group C inspection. This inspection shall consist of the tests specified in Table III, groups C-1 and C-2, and shall be performed on samples that have been subjected to and met group A inspection.

Sample units shall be selected at random without regard to their quality except that the samples selected at the start of the contract shall be selected from the first units produced.

4.3.2.1 Group C-1 inspection. The test specified in Table III, group C-1, shall be performed on one unit at the beginning of production and every month, or every 1,000 units, whichever comes first.

4.3.2.2 Group C-2 inspection. Weld inspection shall be performed at the beginning of production and every month or every 2,500 units, whichever comes first. The other tests specified in Table III, group C-2, shall be performed every 5000 units or every three months except that hardness shall be measured in accordance with ASQ Z1.4, Level 2, AQL 1% on each heat treated batch of heads with each batch identified through final assembly and shipment.

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Attachment 0001 6

TABLE III. Group C inspection.

Inspection Requirement paragraph Test method paragraph

Group C-1

Drop test 3.7 4.8

Group C-2

Vibration 3.6 4.7

Moisture resistance 3.8 4.11

Steel reel heads 3.2 4.10

Weld inspection 3.3.4 4.9

4.3.2.3 Noncompliance. The contractor shall immediately report, in writing, each group C failure occurrence, including details of the failure and characteristics affected. The contractor shall immediately investigate the cause of failure and further report the results of investigation and details of the proposed corrective action on (i) the process and materials, as applicable, and (ii) all units of product which were manufactured under the same conditions and which the government considered subject to the same failure. Reports shall be forwarded to the responsible technical activity designated in the contract through the quality assurance representative. After corrective action has been taken, additional sample units shall be subjected to group C inspection (all inspections, or the inspection which the sample failed, at the option of the government and group A inspection may be reinstituted; however, final acceptance and shipment will be withheld until the group C reinspection results have shown that the corrective action was effective (see 6.3).

4.3.2.4 Reinspection of conforming group C sample units. Unless otherwise specified, sample units which have been subjected to and passed group C inspection may be accepted on contract, provided that they are resubjected to and pass group A inspection after repair of all visible damage.

4.4 Workmanship. The reels shall be given a thorough visual and mechanical inspection to ascertain that the material, construction, and welding are in accordance with applicable requirements (see 3.12).

4.5 Test for fit on axle. Reels DR-5( ), DR-7( ), RC-453( )/G and RL-159( )/U shall be tested with an axle 1-1/32 inch +0 -1/64 by 1-1/32 inch +0 -1/64 to insure compliance with 3.4. Reel DR-8( ) shall be tested with an axle 11/32 inch +0 -1/64 by the 11/32 inch +0 -1/64 to insure compliance w1th 3.4.

4.6 Alignment tests.

4.6.1 Reel head. The requirements of 3.5 shall be met for reels DR-5( ), DR-7( ), RC-453( )/G and RL- 159( )/U when axle, 1-1/32 inch +0 -1/64 by 1-1/32 inch +0 -1/64 is inserted through the center of reels.

The same shall apply for reel DR-8( ) except that the axle size shall be 11/32 inch +0 -1/64 by 11/32 inch +0 -1/64.

4.6.2 Plate alignment on reel RC-453( )/G. The requirements of 3.5.1 shall be met using the drum as a reference.

4.7 Vibration test. The reels shall be subjected to the test of 4.7.1 through 4.7.4. During vibration the unlit shall be clamped in its normal operating position on a vibration table that can be controlled to within 10 percent of specified frequencies and amplitudes.

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Attachment 0001 7

4.7.1 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.

4.7.2 Rate of change of vibration frequency. The frequency of the applied vibration shall be varied uniformly at a rate of approximately one Hz per minute.

4.7.3 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

0.020 Vertical 0.030

4 7.4 Duration of test. The reels shall be vibrated for at least six hours, two hours in each of the three directions specified in 4.7.1.

4.7.5 At the conclusion of the tests, the reels shall be examined for compliance with 3.6.

4.8 Drop test. The drop test shall be performed on the reels specified in 4.8.1 prior to finishing. The reel loaded with wire or cable shall be conditioned in a temperature chamber at -40 degree F for 24 hours prior to the drop test. The drop test shall be conducted immediately as soon as the reel is removed from the temperature chamber. If all the specified drops cannot be completed within 10 minutes after removal, immediately return the reel to the -40 degree F temperature chamber for 1 hour before proceeding to the next 10 minute test period during which the reel may be dropped. After each 10 minute test period, immediately return the reel to the cold temperature chamber before proceeding to the next 10 minute test period until all the specified drops have been completed.

4.8.1 Each type of reel shall be loaded with a weight of wire or cable comparable to its normal use with total weight as follows:

DR-5( ) 125 pounds DR-7( ) 133 pounds DR-8( ) 15 pounds RC-453( )/G 150 pounds RL-159( )/U 50 pounds

4.8.2 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 3-1/2 feet above the 2 inch fir platform backed by a concrete floor, It shall be released so as to drop squarely on the perifery of both heads.

4.8.3 The reel shall then be lifted as above, held until motionless, and dropped squarely on one side.

Then repeat on other side.

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

4.8.5 At the conclusion of the tests, the reel shall be examined for compliance with 3.7.

4.9 Welding inspection. Welding shall be testing for nonvisual defects by magnetic particle method specified in ASTM E1444 for compliance with 3.3.4.

4.10 Steel reel heads.

4.10.1 The yield strength, tensile strength, and elongation at rupture of the steel reel heads shall be tested in accordance with ASTM E8/E8M for compliance with 3.2.

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Attachment 0001 8

4.10.2 The hardness of the reel heads shall be tested in accordance with ASTM E10 or ASTM E18 for compliance with 3.2. The test shall be made before paint is applied.

4.11 Moisture resistance test. The reel shall be subjected to fifteen continuous 48 hour moisture resistance cycles. A single cycle shall consist of Steps 1 through 8. The relative humidity shall be maintained between 90 and 98 percent at all times throughout each cycle and during the first conditioning period. The actual temperature of the conditioning periods and during each cycle at steps 2, 4, 6 and 8 shall be within 3 degrees F of the temperature specified.

Condition the reel at 86 degrees F for 24 hours before test.

Step 1. Raise the internal chamber temperature from 86 to 149 degrees F at a rate of not less than 15 degrees F per hour.

Step 2. Maintain the temperature at 149 degrees F for 8 hours.

Step 3. Lower the temperature from 149 to 86 degrees F at a rate of not less than 15 degrees F per hour.

Step 4. Maintain the temperature at 86 degrees F for 20 hours.

Step 5. Lower the temperature from 86 to 68 degrees F within 2 hours.

Step 6. Maintain the temperature at 68 degrees F for 4 hours.

Step 7. Raise the temperature from 68 to 86 degrees F within 2 hours.

Step 8. Maintain the temperature at 86 degrees F for 4 hours.

After completion of the fifteen cycles, condition the reel at 73 degrees F and between 40 and 60 percent relative humidity for 24 hours. Then inspect the reel for any evidence of corrosion or other deterioration.

The reel shall meet the requirements of 3.8.

4.12 Dielectric strength test for Reel DR-3( ). Reel DR-8( ) shall be tested as follows for compliance with 3.9:

a. Apply a potential of 500 volts rms, 60 hz, for 1 minute between each binding post of connector M-221 and the unfinished inside of the reel hub.

b. Apply a potential of 500 volts rms, 60 hz, for 1 minute between the two binding posts of connector M-221

5. PACKAGING.

5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When packaging of materiel is to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activities within the Military Service or Defense Agency, or within the military service’s system commands.

Packaging data retrieval is available from then managing Military Department’s or Defense Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

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Attachment 0001 9

6. NOTES

6.1 Intended use. The reels covered by this specification are intended for use In storing and transporting the following length and types of wire and cable:

Designation Capacity

Reel RL-159( )/U 2 kilometers of wire WD-1A/TT Reel DR-5( ) 1 mile of wire WF-16( )/U Reel DR-7( ) 1000 feet of cable having an outside diameter of 0.700 inch Reel DR-8 1/2 k1lometer of wire WD-1A/TT Reel RC-453( )/G 1/4 mile of Cable Assembly CX~1606( )/G or

CX-11230( )/G or 1 kilometer of Cable Assembly, Fiber optic, CX-XXXXX

6.2 Ordering data. Procurement documents should specify the following:

a. Title, number and date of the specification.

b. Type required (see 1.1).

c. Place of final inspection.

d. Packaging requirements (see 5.1).

6.3 Group C inspection. Approval to ship may be withheld, at the discretion of the government, pending the decision from the contracting officer on the adequacy of corrective action (see 4.3.3.3).

6.4 Nomenclature. The parenthesis in the nomenclature will be deleted or replaced by a letter identifying the particular design, for example, reel RC-453W/G. As soon as possible after the award of the contract, the contractor should apply to the government office specified in the contract for such information (see 1.1).

6.5 Verification inspection. Verifications by the government will be limited to the amount deemed necessary to determined compliance with the contract and will be limited in severity to the definitive quality assurance provision established in this specification and the contract. The amount of verification inspection by the government will be adjusted to make maximum utilization of the contractor's quality control system and the quality history of the product (see 4.3).

6.7 Subject term (key word) listing.

Transporting Spool Wire

6.8 Changes from previous issue. Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extent of the changes.

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Attachment 0001 10

Custodians: Preparing activity:

Army - CR DLA – IS Navy - YD Air Force - 11 (Project 8130-2009-002)

Review activities Army - MI Navy - MC Air Force - 99

NOTE: The activities listed above were interested in this document as of the date of this document.

Since organizations and responsibilities can change, you should verify the currency of the information above using the ASSIST online database at http://assist.daps.dla.mil.

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Attachment 0001 11

INCH-POUND

MIL-DTL-49104C

9 November 2011

SUPERSEDING

MIL-DTL-49104B

16 July 2007

DETAIL SPECIFICATION

CABLE, TELEPHONE WD-1A/TT (FIELD WIRE, PARALLEL PAIR)

Inactive for new design after 16 June 1997.

This specification is approved for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This specification covers stranded conductor, polyethylene insulated, parallel lay field telephone cable. Each conductor consists of seven strands: four of copper and three of steel.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 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 cited in the solicitation or contract.

FEDERAL SPECIFICATION

L-P-390 - Plastic, Molding and Extrusion Material, Polyethylene and Copolymers (Low, Medium and High Density)

Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990, Columbus, OH 43218-3990, or email to WireCable@dla.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.daps.dla.mil.

Attachment 0001 12

FEDERAL STANDARD

FED-STD-228 - Cable and Wire, Insulated; Methods of Testing

COMMERCIAL ITEM DESCRIPTION

A-A-59551 - Wire, Electrical, Copper (Uninsulated)

DEPARTMENT OF DEFENSE SPECIFICATION

MIL-DTL-3241 - Reels, Cable (Reels DR-5( ), DR-7( ), DR-8( ), RC-453( )/G, RL-159( )/U)

(Copies of these documents are available online at https://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111- 5094.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents are the issues of the documents cited in the solicitation or contract (see 6.2).

ASTM INTERNATIONAL

ASTM A641/A641M - Standard Specification for Steel Wire, Zinc-coated (Galvanized) Carbon

(Copies of these documents are available online at http://www.astm.org or from the ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.)

NCSL International

NCSL-Z540.1 - Laboratories, Calibration and Measuring and Test Equipment

(Copies of these documents are available online at http://www.ncsli.org or from NCSL International, 2995 Wilderness Place, Suite 107 Boulder, Colorado 80301-5404.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.3.

3.2 Materials.

3.2.1 Copper strands. Copper strands shall be tinned, soft or annealed copper wire in accordance with A-A-59551. Each strand shall be .011 inch 0.05 in (.28 ± 1.27 mm) diameter.

Attachment 0001 13

3.2.2 Steel strands. Steel strands shall be round steel wire .011 in 0.05 in (.28 mm ±1.27 mm) diameter. The wire shall be coated with a smooth, continuous, uniform and adherent zinc coating of commercially pure zinc (galvanized) in accordance with ASTM A641/A641M. The weight of zinc shall not be less than 25 grams of zinc per kilogram of coated strand.

3.2.3 Insulation compound. The insulation compound shall be black high-density polyethylene or copolymer, type III, class H, grade 1, in accordance with L-P-390, except that the carbon black content shall be no greater than 2.5%.

3.2.4 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life-cycle costs.

3.3 Construction.

3.3.1 Conductors. Each conductor shall be composed of four coated copper strands and three coated steel strands.

3.3.1.1 Stranding. The maximum length of lay of the strand conductor shall be one inch and the direction of lay shall be left hand. The outside strands shall lie evenly and smoothly around the central strand without crowding. An antioxidant, such as Liquid Antox manufactured by E.I. duPont deNemours and Co., Inc.; Bayol 35, manufactured by Humble Oil and Refining Co.; MX-910 lube-oil manufactured by Mohawk Refining Co.; or an equally satisfactory light oil, may be used as a lubricant in the stranding operation, in which case there shall be no excess oil on the finished stranded conductor.

3.3.2 Finished cable characteristics. The finished cable shall consist of a pair of conductors in parallel, commonly insulated in an approximate figure-8 cross section (see figure 1). The finished cable shall be twisted right-hand-lay (such as in a bunch strander) to make one twist per 12 inches (304.80 mm) when averaged over a 100-foot length. Separation of the conductors of the pair shall be by snipping the insulation at the end of the pair midway between the conductors and then tearing them apart. The tensile force necessary to separate the two conductors shall be not less than 1 pound or more than 3 pounds.

After the conductors are separated, the insulation shall not pull away from either conductor. No insulation repairs or wire splices shall be permitted in finished cable. The dimensions of the cable shall be as follows (see figure 1):

A Major axis .135 .005 inch (3.43 ±.13 mm) B Minor axis .070 .003 inch (1.78 ± .08 mm) C Conductor separation .033 .003 inch (0.84±.08 mm) (between inside surface of the conductors) D Conductor diameter .033 .003 inch (.84 ±. 08 mm)

Attachment 0001 14

FIGURE 1. Dimension characteristics.

3.3.2.1 Insulation. The pair of conductors shall be insulated with a tight well-centered compound as specified in 3.2.3 with a minimum wall thickness of .014 inch (.36 mm). The insulation on the separated conductors shall strip cleanly and readily with the use of pliers.

3.4 Physical characteristics.

3.4.1 Cable.

3.4.1.1 Tubing. The finished cable shall be capable of being looped back and wound tightly on itself for five loose turns without showing any visible strains or cracking of the insulation.

3.4.1.2 Deformation. The decrease in diameter of an insulated conductor shall not exceed 15 percent after being exposed to a temperature of 95 1 C for 1 hour +5, -0 minutes.

3.4.1.3 Cold bend and aging. The finished cable shall be capable of withstanding cold bending and aged cold bending at -40 C.

3.4.1.4 Insulation cutting load. The insulation of the finished cable shall withstand a cutting load of not less than 55 pounds.

3.4.1.5 Insulation breaking load. The insulation of the finished cable shall withstand a breaking tension load of not less than 170 pounds.

3.5 Performance.

3.5.1 DC resistance. The direct current (dc) resistance of the cable, at or corrected to 20 C, shall not exceed 46 ohms per 1,000 loop-feet.

3.5.2 Dielectric strength. The cable shall withstand a potential of 1,000 Vrms.

3.5.3 Insulation resistance. Insulation resistance of cable, at or corrected to 15.6 C, shall not be less than 10,000 meg per 1,000 feet.

D C

A

B

Attachment 0001 15

3.5.4 Attenuation. The attenuation of each pair of conductors shall not exceed the range of values shown on figure 2 under both wet and dry conditions. The dry readings shall be not more than 30% below the wet readings.

3.5.5 Crosstalk. The crosstalk to an adjacent similar cable shall be at least 55 dB down.

3.6 Flatness. The cable shall lie flat and straight when uncoiled from a reel or a spool or dispenser onto a level surface.

3.7 Workmanship. The conductors, insulation and cable shall be uniform in quality and free from defects that affect performance, serviceability, or appearance, such as lumps, kinks, splits, abrasions, scrapes, corroded surfaces, skin impurities, and faulty extruded surfaces.

1.44

2.8

0.3 0.5 1.0 2.0 4.0

A tt en ua tio n in d

B /m ile

Frequency in kHz

FIGURE 2. Attenuation.

Attachment 0001 16

4. VERIFICATION

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

a. First article inspection (see 4.3).

b. Conformance inspection (see 4.4).

4.2 Test equipment and inspection facilities. Test and measuring equipment and inspection facilities of sufficient accuracy, quality, and quantity to permit performance of the required inspection shall be established and maintained by the contractor. The establishment and maintenance of a calibration system to control the accuracy of the measuring and test equipment (i.e., non-Government standard [NGS] or federal or military standard) shall be done in accordance with NCSL-Z540.1, or equivalent requirement.

4.3 First article inspection. When required (see 6.2), first article inspection shall be performed on a representative sample of cable fabricated under the manufacturer’s normal production methods. The sample shall consist of two 1-mile lengths of finished cable with each mile wound on reel DR-5( ) conforming to MIL-DTL-3241. The first article inspection shall consist of the group A and group B inspections and tests specified in table I and table II, respectively.

TABLE I. Group A inspection.

Inspection Requirement Verification Visual and dimensional 3.3 4.5.1 DC resistance 3.5.1 4.5.10 Dielectric strength 3.5.2 4.5.8 Insulation resistance 3.5.3 4.5.9 Workmanship 3.7 4.5.1

TABLE II. Group B inspection.

Inspection Requirement Verification Coating 3.2.2 4.5.2 Conductor separation 3.3.2 4.5.14 Tubing 3.4.1.1 4.5.3 Deformation 3.4.1.2 4.5.4 Cold bend and aging 3.4.1.3 4.5.5, 4.5.5.1 Insulation cutting load 3.4.1.4 4.5.6 Insulation breaking load 3.4.1.5 4.5.7 Attenuation 3.5.4 4.5.11 Crosstalk 3.5.5 4.5.12 Flatness 3.6 4.5.13

4.4 Conformance inspection. Conformance inspection shall consist of the inspections listed for component inspection and group A and B inspections as specified in table I and table II. Conformance inspection shall be performed on every lot of cable procured under this specification.

4.4.1 Inspection lot. Unless otherwise specified (see 6.2), an inspection lot shall consist of all cable of the same Part or Identifying Number (PIN), produced under essentially the same conditions on the same machine, that is presented for inspection and shipment at one time.

Attachment 0001 17

4.4.2 Unit of product. The unit of product for determining lot size for sampling shall be the quantity of cable offered for inspection on one coil, one reel, or one spool, as applicable.

4.4.3 Component inspection. The components of the cable listed in table III shall be inspected using the applicable documents (see 4.5.1) for each lot.

4.4.4 Group A inspection. Group A inspection shall consist of the inspections specified in table I and shall be performed on each lot of cable acquired under the specification. Group A inspections may be performed at an appropriate stage of the manufacturing operation rather than on the finished cable.

4.4.5 Group B inspection. Group B inspection shall consist of the inspections specified in table II.

Group B inspection shall be performed on sample units that have been subjected to and have passed the group A inspection. Group B inspection shall be performed in any order on randomly selected samples from an inspection lot.

4.4.5.1 Sampling. A random sample shall first be selected from each lot. The sample size shall be based on the inspection lot size from which the sample was selected for group A inspection. Sampling for inspection shall be specified in table IV.

4.4.5.2 Specimen lengths. The specimen shall be of the length specified in the applicable test method.

TABLE III. Visual and dimensional examination.

Examination Requirements Verification Construction:

Conductors 3.3.1 4.5.1 Stranding 3.3.1.1 FED-STD-228, method 1531 Insulation thickness 3.3.2.1 FED-STD-228, method 1018 1/ 2/

Finished cable characteristics 3.3.2 4.5.1

1/ An average diameter shall be the average of the readings obtained by making two measurements at right angles to each other at three different points along the length of a 12 inch (304.80 mm) specimen.

2/ The average wall thickness shall be considered equal to one-half the difference between the average diameter of the insulated conductor and the non-insulated conductor for the same specimen.

Attachment 0001 18

TABLE IV. Inspection sample.

Inspection lot size 1/

Sample size

1 1 2 to 8 2 9 to 90 3

91 to 150 12 151 to 280 19 281 to 500 21

501 to 1,200 27 1,201 to 3,200 36 3,201 to 10,000 38 10,001 to 35,000 46

1/ Lot size is based on number of reels, spools, or coils.

4.4.6 Rejected lot. Failure to pass any of the tests and inspections shall constitute failure of the lot and the lot shall be rejected. If an inspection lot is rejected, the lot may be reworked to correct the defects or screen out the defective units, and the lot submitted for re-inspection. Such lots shall be separated from new lots and shall be identified as re-inspected lots.

4.4.7 Noncompliance. If a sample fails to pass group B inspection (see 4.4.5), the contractor shall notify the cognizant inspection activity of such failure and take corrective action on the materials, processes, or both, as warranted, on all units of the product. Acceptance and shipment of the product shall be discontinued until corrective action has been taken. After the corrective action has been taken, group B inspection shall be repeated on replacement articles. (This includes all tests and examinations, or only the test that the original sample failed, at the option of the cognizant inspection activity.) Group A inspection may be re-instituted; however, final acceptance and shipment shall be withheld until group B inspection has shown that the corrective action was successful. In the event of failure after re-inspection, information concerning the failure shall be provided to the cognizant inspection activity.

4.5 Methods of inspection.

4.5.1 Visual and dimensional examination. The cable shall be examined to verify that the workmanship and the characteristics listed in table III are in accordance with the applicable requirements.

The examinations and measurements specified in table III shall be made on specimens not less than 2 feet in length and cut no closer than 5 feet from the end of the sample unit. The examinations and measurements shall be performed as specified in table III.

4.5.2 Coating. The weight, uniformity, and adherence of zinc coating on steel strands shall be measured as specified in the tests for weight of tin or zinc coating, uniformity of zinc coating (Preece method; see 6.3), and adherence of zinc coating for classes 1, 2, and 3 wire of ASTM A641/A641M, with the following modifications of the Preece method:

a. All specimens shall withstand at least one immersion.

b. Uniformity shall be measured on three specimens from each sample unit of strand and the time of immersion shall be 15 +1, -0, seconds. The coating shall be uniform if all three specimens withstand the same number of immersions 1 before the end point of the measured time is reached.

4.5.3 Tubing. A specimen of finished cable shall be looped back and wound tightly on itself for five close turns. The ends shall be securely taped and the specimen shall be placed in an air oven

Attachment 0001 19 maintained at a temperature of 95 1 C for one hour +5, -0, minutes. The specimen shall then be removed from the oven and the insulation examined for strains or cracks under a magnification of at least three diameters (focal distance of 8 centimeters).

4.5.4 Deformation. A gage used for this measurement shall consist of a dial micrometer graduated to read in increments of .001 inch (.03 mm) and equipped with a flat anvil not less than .375 inch (9.53 mm) in diameter and a flat pressure foot .375 inch in diameter attached to a plunger. The anvil and pressure foot shall be parallel to within .0001 inch (.00 mm). The plunger shall support a weight of 250 grams. The gage shall be placed in an oven maintained at a temperature of 95 1 C for a period of 1 hour +5, -0, minutes. A specimen of finished cable at room temperature shall then be placed on the platform, centrally located under the foot, and its diameter shall be read exactly 5 seconds after being so placed. The gage and specimen shall then remain in the oven for a period of 1 hour +5, -0, minutes at the above temperature and the diameter of the specimen again read without disturbing the specimen or gage.

4.5.5 Cold bend. A specimen of finished cable and a mandrel of .080 .003 inch (2.03±.08 mm) diameter shall be placed in a cold chamber maintained at a temperature of -40 1 C for a period of 24 +1, -0, hours. At the end of this time, while still in the cold chamber, the specimen shall be wound around the mandrel for five close turns at the rate of approximately one turn per second. The specimen shall then be examined under a magnifying glass of at least three diameters magnification (focal distance of 8 cm) for visible evidence of cracking of the insulation. During the above processing, no object having a temperature higher than -40 1 C shall come within 12 inches (304.80 mm) of the part of the specimen being examined.

4.5.5.1 Aging. A specimen of finished cable shall be dried in an air oven for a period of at least 24 hours at 80 1 C and then transferred directly (within 5 minutes) from the air oven to an oxygen bomb containing an atmosphere of oxygen at 300 10 psi at a temperature of 70 1 C and held there for a period of 96 +2, -0 hours. Alternately, the specimen may be transferred directly to a desiccator containing a drying agent to preclude re-absorption of water and then to the oxygen bomb when the bomb is available. After 96 +2, -0 hours in the oxygen bomb, the specimen shall be transferred directly to a desiccator containing a drying agent and held there for at least 24 hours and until such time as the specimen is transferred directly to a cold chamber. The conditioned specimen shall then be tested as specified in 4.5.5.

4.5.6 Insulation cutting load. A specimen of finished cable shall be cut in half and the insulation stripped from one end of each piece. One piece shall be formed into a loop, the ends of which shall be tightly clamped in one of the grips of a tensile tester. The second piece shall be passed through the loop and its ends shall be tightly clamped in the other grip of the tensile tester. The two bare ends shall be connected in series with an electrical alarm circuit and a load shall be applied to the looped conductors by separation of the grips, at a rate of 2 inches (50.80 mm) per minute, until the grips cut through the insulation, thus making electrical contact as indicated by the electrical alarm. One of the metal grips of the tensile machine may have to be electrically insulated from the rest of the machine to avoid false indications.

4.5.7 Insulation breaking load. The breaking tension (see 3.4.1.5) load or tensile strength of the finished cable insulation shall be measured using the apparatus and method described in method 3211 of

FED-STD-228.

Attachment 0001 20

4.5.8 Dielectric strength. The dielectric strength of the finished cable shall be measured as specified in method 6111 of FED-STD-228, except that:

a. The immersion period shall be 4 hours.

b. One terminal shall be both conductors connected together and the other shall be the water.

4.5.9 Insulation resistance. The insulation resistance of the finished cable shall be measured after the dielectric strength test (see 4.5.8) is accomplished. This test shall be performed as specified in method 6031 of FED-STD-228, except that:

a. The immersion period shall be 4 hours.

b. The test voltage shall be not less than 100 volts dc.

c. The polarity of the conductors shall be maintained negative with respect to the water.

d. One terminal shall be both conductors connected together and the other shall be the water.

e. For the purpose of computation, twice the field wire footage shall be taken as the length of conductor under test.

f. If the measurement is made at a temperature other than 15.6 C, the measured value of insulation resistance shall be corrected to15.6 C. However, if the insulation resistance is equal to or greater than that required by 3.5.3, then the measurement is made at a temperature greater than 15.6 C, and no correction factor need be employed.

g. The insulation resistance test may be terminated in less than one minute if the galvanometer has ceased fluctuating and the reading indicates that a steady insulation resistance value has been obtained.

However, readings obtained on 5% of the lengths after 1 minute electrification shall be recorded.

4.5.10 DC resistance. The dc resistance of the finished cable shall be measured after the dielectric strength test (see 4.5.8) is accomplished. The test shall be performed as specified in method 6021 of FED-STD-228, except that the immersion period shall be 4 hours.

Attachment 0001 21

4.5.11 Attenuation. The attenuation of the pair of conductors shall be measured on a 50-foot length of cable and computed to db per mile. The wet readings shall be taken on cable that has been in water at least 96 hours. Measurements shall be taken at frequencies of 300 hertz, 1 kilohertz, and 4 kilohertz. If any individual reading does not meet the requirement of 3.5.4, several samples shall be measured and an average taken. The attenuation shall be calculated from direct measurements of the parameters R, L, C, and G and using the standard formula for the attenuation of a two-wire transmission line as follows:

S = 8.69 1/2 ( (R2+W2L2) (G2+W2C2) +RG-W2LC) dB/mile

Where attenuation is in decibels per mile, and 8.69 is a factor to convert nepers to decibels.

R = Resistance in ohms per mile L = Inductance in henries per mile C = Capacitance in farads per mile G = Conductance in mhos per mile W = 2 f, where f = frequency in hertz

4.5.12 Crosstalk. The crosstalk of the finished cable shall be measured on two lengths of cable, each being one mile long, and taped together at approximate one-foot intervals.