REG KSC-E-165 REV E CHG 1-2013 ELECTRICAL GROUND SUPPORT EQUIPMENT FABRICATION SPECIFICATION FOR.pdf

1、KSC-E-165E FEBRUARY 2, 2009 Change 1, June 4, 2013 Supersedes KSC-E-165D February 22, 1995 National Aeronautics and Space Administration John F. Kennedy Space Center KSC FORM 16-12 (REV. 6/95) PREVIOUS EDITIONS ARE OBSOLETE (CG 11/95) METRIC/INCH-POUND ELECTRICAL GROUND SUPPORT EQUIPMENT FABRICATION

2、, SPECIFICATION FOR EAR 99 - NO LICENSE REQUIRED The information contained in the document is technical in content, but not technical data as defined by the International Traffic in Arms Regulations (ITAR) or the Export Administration Regulations (EAR), and therefore is EAR 99 NLR, no export license

3、 required. General Prohibition Six (Embargo) applies to all items subject to the EAR, (i.e., items on the CCL and within EAR 99 NLR). You may not make an export or re-export contrary to the provisions of part 746 (Embargos and Other Special Controls) of the EAR and 22 CFR part 126.1 of the ITAR. EDD

4、R # 1312932 NASA KSC Export Control Office (321-867-9209) ENGINEERING AND TECHNOLOGY DIRECTORATEProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-16

5、5E FEBRUARY 2, 2009 Change 1, June 4, 2013 Supersedes KSC-E-165D February 22, 1995 JOHN F. KENNEDY SPACE CENTER, NASA METRIC/INCH-POUND Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Provided by IHSNot for ResaleNo reproduction or networking permitt

6、ed without license from IHS-,-,-Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 KSC-E-165E_Change1_06

7、042013.docx iii CONTENTS 1. SCOPE .1 2. APPLICABLE DOCUMENTS .1 2.1 Governmental .1 2.1.1 Specifications .1 2.1.2 Standards 3 2.1.3 Drawings 6 2.1.4 Publications 7 2.2 Non-Governmental 7 2.3 Order of Precedence .11 3. REQUIREMENTS .12 3.1 Metal and Sheet Metal Assemblies, Subassemblies, and Details

8、12 3.1.1 Surface Preparation 13 3.1.1.1 Abrasive Blasting .13 3.1.1.2 Degreasing .14 3.1.2 Protective Coatings, Thinners, and Cleaners .14 3.1.2.1 Generic Protective Coatings 15 3.1.2.2 Application of Coatings .15 3.1.2.3 Colors .16 3.1.2.4 Storage, Mixing, and Application Methods .16 3.1.2.5 Coatin

9、g Finish 17 3.1.2.6 Touchup of Welds and Damaged Coatings .17 3.1.3 Sealants and Caulking 17 3.1.4 Chip-Free Clean-Room Paint .18 3.1.5 Zones of Exposure .18 3.1.6 Aluminum Racks, Enclosures, Panels, Junction Boxes, and Miscellaneous Details 18 3.1.6.1 Materials 18 3.1.6.2 Cleaning, Treating, and Co

10、ating 18 3.1.6.2.1 Surface Preparation 18 3.1.6.3 Chromate Coatings.19 3.1.6.4 Protective Coatings 19 3.1.6.5 Finish Colors 19 3.1.7 Steel Racks, Enclosures, Junction Boxes, Assemblies, and Miscellaneous Details 20 3.1.7.1 Materials 20 3.1.7.2 Cleaning, Treating, and Coating 20 3.1.7.3 Finish Colors

11、 20 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 October 29, 20 iv 3.1.8 Fabricated Chassis .20 3.1.8.1 Materials 20 3.1.8.2 Cleaning and Treating 20 3.2 Welding and Brazing .20 3.2.1 Welding 20 3

12、.2.2 Brazing .21 3.3 Fasteners 21 3.3.1 Threaded Fasteners 21 3.3.1.1 Torque Limits for Threaded Fasteners .21 3.3.1.2 Installation of Nuts on Bolts or Screws .21 3.3.1.3 Torque Values for Standard and High-Strength Steel Fasteners .27 3.3.1.3.1 Plated27 3.3.1.3.2 Lubricated 27 3.3.1.4 Torque Values

13、 for 300 Series CRES Fasteners .27 3.3.1.4.1 Passivated .27 3.3.1.4.2 Plated27 3.3.1.4.3 Lubricated 27 3.3.1.5 Torque Values for 430 MPa (62 ksi) Tensile Strength Aluminum Alloy Fasteners (2024-T4, 7075-T6) .27 3.3.1.5.1 Anodized 27 3.3.1.5.2 Lubricated 27 3.3.1.6 Lubricants 28 3.3.1.7 Self-Locking

14、Fasteners 28 3.3.1.8 Cotter Pin, Lockwire, and Safety Cable Securing .29 3.3.1.8.1 Safety Cable .29 3.3.1.9 Nonmetallic Fasteners 29 3.3.2 Adhesives .29 3.3.3 Rivets .29 3.3.3.1 Chips, Burrs, and Foreign Material29 3.3.3.2 Rivet Substitutions .32 3.4 Identification and Marking (of GSE) .32 3.5 Elect

15、rical Wiring, Internal .32 3.5.1 Plenum-rated and Non-plenum-rated .32 3.5.2 Class I, Division 2 32 3.5.3 Wire33 3.5.4 Routing .34 3.5.5 Grouping 34 3.5.6 Breakouts .34 3.5.7 Wire Stripping 34 3.5.8 Terminals .36 3.5.8.1 Modular Terminal Junction Systems .36 3.5.8.2 Screw Terminals 36 3.5.8.3 Compre

16、ssion Terminals .36 3.5.8.4 Solder Terminals 37 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 v 3.5.8.4.1 Terminal Swaging 37 3.5.8.4.2 Rework .41 3.5.8.5 Solderless Wrap Terminals 42 3.5.9 Lacing

17、and Tying .42 3.5.9.1 Lacing 42 3.5.9.2 Cable Ties and Clamps 43 3.5.10 Termination Order .44 3.5.11 Molding and Potting Electrical Connectors .44 3.5.12 Splicing 44 3.5.13 Terminating and Grounding Shields 44 3.5.13.1 Insulated Shields Over Individual Conductors or Groups of Conductors .48 3.5.13.2

18、 Uninsulated Shields Over Individual Conductors or Groups of Conductors .49 3.5.13.3 Overall Shields Surrounding the Entire Cable Core 50 3.5.13.3.1 Tinel-Lock Rings .51 3.5.13.3.2 EMI/RFI Foil Tape and Wire Mesh .52 3.5.13.3.3 Interior Cable Runs 53 3.5.13.3.4 Exterior Cable Runs .53 3.5.13.4 Shiel

19、d Terminals 54 3.6 Terminations 54 3.6.1 Compression Type .54 3.6.1.1 Captive Nut or Screw Head .54 3.6.1.2 Clamp or Screw End 58 3.6.2 Crimp Type 58 3.6.3 Friction Type 58 3.6.4 Solder Type 58 3.6.4.1 Hand and Machine Soldering.58 3.6.4.2 Soldering Multiple Conductors in a Single Solder Cup.59 3.6.

20、5 Bonding and Grounding Type .59 3.6.6 DIN Rail-Mounted Terminal Blocks .59 3.7 Printed Wiring Boards .59 3.7.1 Material 59 3.7.2 Construction .59 3.7.2.1 Circuit Pads 59 3.7.2.2 Heat Sinks 60 3.7.2.2.1 Electrical Insulation .60 3.7.2.2.2 Thermal Resistance 60 3.7.2.3 Eyelets and Tubelets 60 3.7.2.4

21、 Workmanship .60 3.7.3 Cleaning .61 3.7.4 Rejection Criteria .61 3.7.5 Inspection .62 3.7.6 Conformal Coating.62 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 October 29, 20 vi 3.7.7 Repair .62 3.7

22、.7.1 Printed Wiring Boards Using Surface-Mount Technology (SMT)62 3.8 Sealing and Insulating 62 3.8.1 Insulation62 3.8.1.1 Heat-Reactive Tubing 63 3.8.1.1.1 Application .63 3.8.1.1.2 Visual Inspection .64 3.8.1.2 Insulation Tubing .64 3.8.2 Sealing Compound, Electrical .64 3.9 Hazardproofing 65 3.9.

23、1 Intrinsically Safe Equipment65 3.9.2 Ignitionproofing .65 3.9.2.1 Small Junction Boxes .65 3.9.2.2 Electrical Components .65 3.9.2.3 Electrical Connectors and Mated Cables .66 3.9.3 Purging and Pressurization 66 3.9.3.1 Equipment 66 3.9.3.2 Purge Pressure 67 3.9.3.3 Flow Rate .67 3.9.3.4 Purge Med

24、ia .67 3.10 Corrosion Control 67 3.10.1 Corrosion-Resistant Materials .68 3.10.2 Dissimilar Metals .69 3.10.3 Moisture Exclusion 69 3.10.4 Protective Coatings 69 3.10.5 Lubricants 70 3.11 General-Purpose Cables .70 3.11.1 Standard Bulk Cable 70 3.11.2 Unique Bulk Cable .70 3.11.2.1 Preferred Types 7

25、0 3.11.2.2 Fabrication Procedure 70 3.11.3 Connectors .72 3.11.3.1 D-Subminiature (DB) Connectors .73 3.11.4 Jacket Removal 74 3.11.5 Conductor and Shield Termination 74 3.11.6 Potting and Molding 75 3.11.7 Cable Jacket Repair75 3.11.7.1 Sleeves .75 3.11.7.2 Approved Products.75 3.11.8 Splicing 76 3

26、.11.8.1 Procedure .76 3.11.8.2 Approved Products.77 3.11.9 Thermal Protection.78 3.11.9.1 Application .78 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 vii 3.11.9.2 Approved Products.78 3.11.10 Cab

27、le Checkout 79 3.11.10.1 Cable Continuity Test 79 3.11.10.2 Cable Insulation-Resistance Tests .79 3.11.10.3 Radio Frequency Cable Tests 80 3.11.10.3.1 Continuity Tests .80 3.11.10.3.2 Insulation-Resistance Test .80 3.11.10.3.3 Time Domain Reflectometer (TDR) Test 81 3.11.11 AC Power Cables .85 3.12

28、Mineral-Insulated (MI) Cable 85 3.13 Transducers 85 3.14 Electromagnetic Interference Tests 85 3.15 Fabrication Process Waste Disposal 86 3.16 Fiber-Optic Cables .86 3.16.1 Optical-Fiber End Preparation .87 3.16.2 Cleaning .87 3.16.3 Splicing 88 3.16.3.1 Presplicing Examination 88 3.16.3.2 Splicing

29、Method .88 3.16.3.2.1 Fusion Splicing 89 3.16.3.2.2 Mechanical Splicing.89 3.16.3.2.3 Chemical Splicing 89 3.16.3.3 Splice Requirements 89 3.16.3.3.1 Location .89 3.16.3.3.2 Protection .89 3.16.3.3.3 Strength Member .89 3.16.4 Fiber-Optic Cable Assemblies .89 3.16.4.1 Cable Assembly .89 3.16.4.1.1 P

30、reassembly Verification .90 3.16.4.1.2 Preassembly Examination 90 3.16.4.2 Completed Cable Assemblies 90 3.16.5 Fiber-Optic Assemblies .91 3.16.5.1 Fiber-Optic Connector Termination 91 3.16.5.1.1 Preassembly Verification .91 3.16.5.1.2 Preassembly Examination 91 3.16.5.2 PostFiber-Optic-Connector-Te

31、rmination Inspection .91 3.16.5.3 Fiber-Optic Routing .92 3.16.6 Testing92 3.16.6.1 Fiber-Optic Splices 92 3.16.6.2 Fiber-Optic Cable Assemblies .92 3.16.6.3 Fiber-Optic Assemblies .93 3.16.6.4 Optical Time-Domain Reflectometer (OTDR) Test 93 3.16.6.5 OTDR Basic Theory of Operation .93 3.16.6.5.1 At

32、tenuation .96 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 October 29, 20 viii 3.16.6.5.2 Point Defects 98 3.16.7 Fiber-Optic Cable Assembly Installation.100 3.16.7.1 Tensile Load and Vertical Ris

33、e 100 3.16.7.2 Installation Bend Radius 101 3.16.7.3 Installed Bend Radius 101 3.16.7.4 Cable Tying 101 3.16.7.5 Dust Caps .101 3.16.7.6 Premating Inspection .101 3.16.7.7 Connector Torque 101 3.16.7.8 Sharp Edges .101 3.17 Ethernet 102 3.17.1 Ethernet Naming Conventions .102 4. QUALITY ASSURANCE PR

34、OVISIONS 102 4.1 Responsibility for Inspection and Test 102 4.2 Certification of Personnel 102 4.3 Certification of Tooling and Test Equipment 103 4.3.1 Soldering Tools 103 4.3.2 Crimping Tools 103 4.3.3 Crimping Tools, Special 104 4.3.4 Torque Wrenches .104 4.3.5 Wire Stripping Tools104 4.3.6 Solde

35、rless Wrap Tools .104 4.3.7 Test Equipment 104 4.4 Equipment Checkout 105 4.4.1 Sequence of Tests 105 4.4.2 Continuity Tests .106 4.4.3 Isolation Checks .106 4.4.4 Functional Checks 107 4.5 Completion of Tests .107 4.6 Manufacturing Instructions/Documentation 107 4.7 Commercial Off-the-Shelf (COTS)

36、Concept .107 4.7.1 Modified Off-the-Shelf (MOTS) Items .108 5. PREPARATION FOR DELIVERY 108 6. NOTES .109 6.1 Intended Use 109 6.2 Definitions109 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 ix FI

37、GURES Figure 1. Safety Cable, Tension Tool, Ferrule, and Calibration Unit .30 Figure 2. Typical Safety Cable Installations .31 Figure 3. Harness or Wire Bundle .35 Figure 4. Rolled Swage Terminals 38 Figure 5. Elliptical Funnel Swage Terminals 39 Figure 6. Funnel Swage Terminals40 Figure 7. Cable Te

38、rmination Hardware .45 Figure 8. Typical Termination Configuration for Overall Shielded Cable With Insulated Conductor Shields 46 Figure 9. Graphic Representation of Individual Shields From Source, Through Intermediate Break Points, to End Instrument .47 Figure 10. Typical Termination Configuration

39、for Overall Shielded Cable With Uninsulated Conductor Shields48 Figure 11. 360-Degree Overall Shield Termination Using a Mold Adapter .50 Figure 12. Tinel-Lock Rings and an Example of One Type of Adapter .51 Figure 13. Tinel-Lock Ring Resistance Heating Tools .52 Figure 14. Typical Installation of T

40、inel-Lock Ring 52 Figure 15. Bridge Bus Terminals 55 Figure 16. Captive and Noncaptive Nut and Screw Head Terminations 56 Figure 17. Clamp and Screw End Terminations .57 Figure 18. Application of Heat-Reactive Tubing 64 Figure 19. Unique Bulk Cable Fabrication .71 Figure 20. DB9 and DB25 Connectors

41、.73 Figure 21. DB15 Connectors .73 Figure 22. MD50 and MD68 Connectors 74 Figure 23. TDR Traces for Coaxial Cable 82 Figure 24. TDR Fault Traces for Twin-Axial Cable (Sheet 1 of 2) 83 Figure 25. Typical OTDR Block Diagram 95 Figure 26. OTDR Trace of an Installed Cable Plant .96 Figure 27. OTDR Measu

42、rement Points for Measuring Fiber Attenuation, Using Dead-Zone Fiber 97 Figure 28. OTDR Trace Showing a Nonreflective Fault With Apparent Gain and a Reflective Fault With No Apparent Loss or Gain .98 Figure 29. Extrapolation for a Point Defect Showing an Apparent Signal Gain 99 Figure 30. Exaggerate

43、d Loss Obtained at Point Defects Exhibiting Gain in One Direction by Conducting the OTDR Measurement in the Opposite Direction 100 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 Change 1, June 4, 2013 October 29, 20 x TAB

44、LES Table 1. Torque Values for Steel, Cadmium-Plated, Unlubricated Threaded Fasteners 23 Table 2. Torque Values for Steel, Lubricated (Plated, Unplated) Threaded Fasteners 24 Table 3. Torque Values for Corrosion-Resistant Steel (CRES) and Aluminum Alloy Threaded Fasteners 25 Table 4. Required Lockin

45、g Torque at Room Ambient Temperature .26 Table 5. Minimum Bolt or Screw Thread Protrusion 26 Table 6. Insulation Clearances for Wire 36 Table 7. Spacing of Lacing From Terminations 42 Table 8. Spacing of Lacing in the Harness 42 Table 9. Potential Tendency for Galvanic Corrosion 68 Provided by IHSNo

46、t for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-E-165E February 2, 2009 xi ABBREVIATIONS, ACRONYMS, AND SYMBOLS C degree Celsius F degree Fahrenheit m micrometer (1106 m) AC alternating current AHJ authority having jurisdiction AIA Aerospace Industries Associatio

47、n ANSI American National Standards Institute ASCII American Standard Code for Information Interchange ASME American Society of Mechanical Engineers ASTM ASTM International AWG American Wire Gage BHP Bulkhead Plate CH6H2 methyl hydrazine COTS commercial off-the-shelf CRES corrosion-resistant steel CS

48、A Canadian Standards Association CSMA/CD Carrier Sense Multiple Access Collision Detection DAS Data Acquisition System dB decibel DB D-subminiature DC direct current ECA Electronic Components Association EIA Electronic Industries Alliance EMI electromagnetic interference FAC Florida Administrative Code FDEP Florida Department of Environmental Protection FED Federal FOTP fiber-optic test procedures ft3/min cubic foot per minute Provided by IHSNot for ResaleNo reproduction or networ