REG KSC-GP-864 VOL IIA REV B W CHG 1-2013 ELECTRICAL GROUND SUPPORT EQUIPMENT CABLE HANDBOOK.pdf

1、KSC-GP-864 VOL IIA, REV B OCTOBER 16, 2009 Change 1, June 4, 2013 Supersedes KSC-GP-864, Vol IIA, Rev A August 9, 1999 National Aeronautics and Space Administration John F. Kennedy Space Center KSC FORM 16-12 (REV. 6/95) PREVIOUS EDITIONS ARE OBSOLETE (CG 11/95) ELECTRICAL GROUND SUPPORT EQUIPMENT C

2、ABLE HANDBOOK EAR 99 NLR 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 req

3、uired, suitable for public release. 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

4、126.1 of the ITAR. NASA KSC Export Control Office (321-867-6367 or 321-867-6066). EDDR#09399. ENGINEERING AND TECHNOLOGY DIRECTORATE Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Provided by IHSNot for ResaleNo reproduction or networking permitted

5、without license from IHS-,-,-KSC-GP-864 VOL IIA, REV B OCTOBER 16, 2009 Change 1, June 4, 2013 Supersedes KSC-GP-864, Vol IIA, Rev A August 9, 1999 JOHN F. KENNEDY SPACE CENTER, NASA Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Provided by IHSNot

6、for ResaleNo reproduction or networking permitted 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-GP-864, Vol IIA, Rev

7、B October 16, 2009 Change 1, June 4, 2013 KSC-GP-864_Vol_IIA_Rev_B_Change1_06042013.docx iii CONTENTS 1. SCOPE .1 2. APPLICABLE DOCUMENTS .1 2.1 Governmental .1 2.2 Non-Governmental 4 3. BULK CABLE.5 3.1 General Requirements 5 3.1.1 Characteristics 5 3.1.1.1 Performance Characteristics 5 3.1.1.2 Phy

8、sical Characteristics .5 3.1.1.3 Maintainability .6 3.1.1.4 Environmental Conditions .6 3.1.1.4.1 Indoor Controlled Environment .6 3.1.1.4.2 Outdoor Environment 8 3.1.1.4.3 Outdoor Launch Environment .8 3.1.1.4.4 Hazardous Locations 8 3.1.1.5 Transportability 8 3.1.2 Design and Construction 9 3.1.2.

9、1 Materials, Processes, and Parts 9 3.1.2.1.1 Cable Jacket .9 3.1.2.1.2 Insulation9 3.1.2.2 Electromagnetic-Environment Effects and Compatibility .9 3.1.2.3 Name Plates and Product Marking 9 3.1.2.3.1 Cable Identification 10 3.1.2.3.2 Cable Type Designation Method .10 3.1.2.4 Cabling and Wiring Guid

10、elines .11 3.1.2.5 Workmanship .12 3.1.2.6 Interchangeability 12 3.1.2.7 Safety .12 3.1.3 Fabrication .12 3.1.4 Testing After Assembly .12 3.2 Single and Multiple Straight Conductors .13 3.2.1 Performance Characteristics 13 3.2.2 Physical Characteristics .13 3.2.3 Overall Shielding .13 3.3 Twisted-P

11、air Cable.14 3.3.1 Characteristics 14 3.3.1.1 Performance Characteristics 14 3.3.1.2 Physical Characteristics .14 3.3.1.3 Shielding 14 3.3.1.3.1 Overall Shielding .15 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October

12、16, 2009 Change 1, June 4, 2013 iv 3.3.1.3.2 Conductor Arrangement.15 3.3.1.3.3 Internal Shields 15 3.3.2 Design and Construction: Color Codes16 3.4 Category Cable.18 3.4.1 Characteristics 18 3.4.1.1 Performance Characteristics 18 3.4.1.2 Physical Characteristics .18 3.4.1.3 Shielding 18 3.4.2 Desig

13、n and Construction 18 3.4.2.1 Color Codes .18 3.4.2.2 100-Ohm Balanced Twisted-Pair Telecommunications Outlet/Connector .19 3.4.2.3 Materials, Processes, and Parts 20 3.4.2.4 Workmanship .20 3.5 Coaxial Cable .20 3.5.1 Characteristics 20 3.5.1.1 Cable Types .21 3.5.1.1.1 Flexible, Coaxial, Single-Co

14、nductor Cables 21 3.5.1.1.2 Semirigid, Coaxial, Single-Conductor Cables .21 3.5.1.1.3 Two-Conductor Cables 21 3.5.1.1.4 Triaxial Cables .21 3.5.1.2 M17 Part Identification Number (PIN) 22 3.5.1.3 MIL-DTL-17 Coaxial Cables 22 3.6 Fiber-Optical Cables 22 3.6.1 Definitions22 3.6.2 Physical Characterist

15、ics .22 3.6.3 Design and Construction 23 3.6.3.1 General .23 3.6.3.1.1 Underground Fiber-Optical Cable .23 3.6.3.1.2 Intrabuilding Fiber-Optical Cable 23 3.6.3.1.3 Single-Mode Fiber-Optical Cable 23 3.6.3.1.4 Multimode Fiber-Optical Cable .23 3.6.3.2 Cable Assembly .23 3.6.3.3 Testing After Assembly

16、 .25 3.6.3.4 Design Considerations .25 3.6.3.5 Materials, Processes, and Parts 26 4. CONNECTORS .27 4.1 Guidelines 27 4.2 Copper Connectors.29 4.2.1 MIL-DTL-38999 Connectors .29 4.2.1.1 Characteristics 29 4.2.1.2 Series 29 4.2.1.3 Part Identification Number (PIN) 30 4.2.1.4 Specification Sheet Numbe

17、r 30 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 v 4.2.1.5 Classes31 4.2.1.6 Shell Size Number .32 4.2.1.7 Insert Arrangements .33 4.2.1.8 Contact Styles 34 4.2.1.8.1 Connectors S

18、upplied With Standard Contact Arrangements .34 4.2.1.8.2 Connectors Supplied Without Contacts .34 4.2.1.9 Polarization 34 4.2.1.10 Intended Use 36 4.2.2 AS50151 Connectors .37 4.2.2.1 PIN Construction .37 4.2.2.2 Basic Part Number .37 4.2.2.3 Classes38 4.2.2.4 Wire Range Accommodations .38 4.2.2.5 M

19、aterial Designator .39 4.2.2.6 Shell Sizes 39 4.2.2.7 Insert Arrangement 39 4.2.2.8 Contact Designator.40 4.2.2.8.1 Connectors With Contacts .40 4.2.2.8.2 Connectors Without Contacts 40 4.2.2.8.3 Insert Position 40 4.2.2.9 Intended Use 41 4.2.3 MIL-DTL-22992 Connectors .43 4.2.3.1 Characteristics 43

20、 4.2.3.2 PIN Construction .43 4.2.3.3 Classification43 4.2.3.4 Intended Use 45 4.2.4 MIL-DTL-26482 Connectors .46 4.2.4.1 Characteristics 46 4.2.4.1.1 Class .46 4.2.4.1.2 Shell Size .46 4.2.4.1.3 Termination Type and Shell Material (Hermetic Receptacles Only) 46 4.2.4.1.4 Insert Arrangement 47 4.2.4

21、.1.5 Contact Style 47 4.2.4.1.6 Insert Position 48 4.2.4.2 Notes 48 4.2.4.2.1 Intended Use (Series I).48 4.2.4.2.2 Intended Use (Series II) .49 4.3 Fiber-Optical Connectors Commonly Used at KSC 50 5. HEAT-SHRINKABLE TUBING 51 6. PREPARATION FOR DELIVERY 51 6.1 Preservation and Packaging .51 6.1.1 Re

22、els and Spools 51 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 vi 6.1.2 Cable Lengths 51 6.2 Packing .51 6.3 Marking for Shipment 51 APPENDIX A. OHMS LAW AND CONVERSION TABLE 53 AP

23、PENDIX B. ENVIRONMENTAL CONDITIONS .55 APPENDIX C. INSULATION AND JACKETING CHARACTERISTICS .59 APPENDIX D. CABLE SUBASSEMBLY DRAWINGS 65 APPENDIX E. MIL-DTL-17 TABLE 73 APPENDIX F. DEFINITIONS .89 APPENDIX G. FIBER ENDFACE INSPECTION CRITERIA AFTER POLISHING .93 FIGURES Figure 1. Building With a Pl

24、enum Airspace .7 Figure 2. Building Without a Plenum Airspace 7 Figure 3. Shielded Barbell .14 Figure 4. Twisted Conductor .15 Figure 5. Recommended Shield Terminations 16 Figure 6. Recommended Eight-Position Jack Pin/Pair Assignments (T568A) .19 Figure 7. Optional Eight-Position Jack Pin/Pair Assig

25、nment (T568B).20 Figure 8. Parts of a Typical Fiber-Optical Cable 22 Figure 9. 38999 Polarization Angles .35 Figure 10. AS50151 Alternate Insert Positions .41 Figure 11. Ohms Law.53 Figure 12. Cable Subassembly Drawing Title Page .66 Figure 13. Cable Subassembly Drawing Materials List Page/Schematic

26、 Page .68 Figure 14. Cable Subassembly Drawing Continuous/Last Page 71 Figure 15. Typical Endface of an Optical Fiber 94 Figure 16. Particle Contamination of the Endface of an Optical Fiber .95 Figure 17. Film Contamination of the Endface of an Optical Fiber95 Figure 18. Examples of Scratches on the

27、 Endface of an Optical Fiber .96 Figure 19. Cracks on the Endface of an Optical Fiber 96 Figure 20. Example of a Chip on the Endface of an Optical Fiber .97 Figure 21. Example of a Spall on the Endface of an Optical Fiber .97 Provided by IHSNot for ResaleNo reproduction or networking permitted witho

28、ut license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 vii TABLES Table 1. Cable Types Permitted in Plenum and Nonplenum Areas .8 Table 2. Telephone Wire Color Code 17 Table 3. ICEA Paired-Wire Color Code 17 Table 4. Performance Characteristics for Category Cables

29、 .18 Table 5. Color Codes for Four-Pair Horizontal Cables .19 Table 6. Typical Connectors Used at KSC 27 Table 7. Common MIL-DTL-38999, Series III, Connectors Used in GSE at KSC 30 Table 8. Series III Shell Materials and Finishes 31 Table 9. Shell Size Code for Series III Part Numbering 32 Table 10.

30、 Commonly Used Insert Arrangements .33 Table 11. Main Key and Keyway Polarization 35 Table 12. AS50151 Connectors Commonly Used at KSC 37 Table 13. Physical Characteristics of AS50151 Connector Classes 38 Table 14. Wire Range Accommodations .38 Table 15. MIL-DTL-26482 Connector Class and Series .46

31、Table 16. Fiber Connectors Commonly Used at KSC .50 Table 17. Conversion Table .53 Table 18. Maximum and Minimum Design Surface Air Temperatures 55 Table 19. Surface Thermal Radiation 56 Table 20. Vapor Concentration 56 Table 21. Relative Corrosivity of Atmosphere 56 Table 22. Mean Sea Salt Particle

32、 Concentrations in Maritime Air Masses .56 Table 23. Typical Properties of Insulation Materials .62 Table 24. Typical Properties of Jacket Materials .64 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 viii

33、This page intentionally left blank. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 ix ABBREVIATIONS, ACRONYMS, AND SYMBOLS degree C degree Celsius F degree Fahrenheit m micrometer A

34、ampere AC alternating current AHJ Authority Having Jurisdiction Al aluminum Al2O3 aluminum oxide AMS Aerospace Material Specification APC angled physical contact AWG American Wire Gauge CAD computer-aided design/drafting Cat category CATV, CATVP, CATVR community antenna television and radio distribu

35、tion cables CL2, CL2P, CL2R class 2 cables CL3, CL3P, CL3R class 3 cables cm centimeter CM, CMP, CMR, CMG communications cables COTS commercial off-the-shelf CPE chlorinated polyethylene CSPE chlorosulfonated polyethylene Cu copper DWV dielectric withstand voltage e.g. for example ECTFE ethylene chl

36、orotrifluoroethlyene EDC Engineering Documentation Center EIA Electronic Industries Alliance EMI electromagnetic interference EPR ethylene propylene rubber etc. and so forth ETFE ethylene tetrafluoroethylene FEP fluorinated ethylene-propylene fl fluid FPL, FPLP, FPLR power limited fire alarm cables

37、ft foot g gravity, gram g-cal gram-calorie grms root mean square acceleration gal gallon Gb gigabit GS ground system Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 x GSE ground suppo

38、rt equipment GSECI GSE Cable Infrastructure (Group) HCl hydrogen chloride HDBK handbook hr hour Hz hertz ICEA Insulated Cable Engineers Association IDENT identification in, “ inch ITC instrumentation tray cable ITU-T International Telecommunication Union-T KDDMS KSC Design Data Management System kg

39、kilogram km kilometer KSC John F. Kennedy Space Center L liter lb pound LC launch complex m meter Max maximum MC metal-clad mg milligram MHz megahertz mi mile MI mineral insulated MIL military Min minimum min minute mm millimeter MMH monomethylhydrazine MP, MPP, MPR multipurpose cables MS military s

40、tandard MTTR mean time to repair MV medium voltage NASA National Aeronautics and Space Administration NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association NO, No. number NPLF nonpower limited fire alarm NPLFP nonpower limited fire

41、alarm plenum cable NPLFR nonpower limited fire alarm riser cable OD outside diameter OFC, OFCP, OFCR conductive optical fiber cables Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 xi

42、 OFN, OFNP, OFNR nonconductive optical fiber cables OS overall braided shield OSDB overall double-braided (shield) OTDR Optical Time Domain Reflectometry oz ounce PC physical contact pF picofarad PFA perfluoroalkoxy PIN part identification number PLTC power-limited tray cable PSI pound per square in

43、ch PT two conductors twisted PTS two conductors twisted and shielded PTSI two conductors twisted, shielded, and insulated PVC polyvinyl chloride QPL Qualified Products List QT four conductors twisted QTS four conductors twisted and shielded QTSI four conductors twisted, shielded, and insulated REV r

44、evision RF radio frequency RFI radio frequency interference SAE Society of Automotive Engineers SBR styrene butadiene rubber ScTP screened twisted pair SH shield SLS Space Launch System SO service with oil-resistant jacket SPC silver-plated copper SPEC specification SRM solid rocket motor SS single

45、conductor shielded STD standard STP shielded twisted pair TC tray cable; tinned copper TCSH tinned-copper shield TFE extended polytetrafluoroethylene TIA Telecommunications Industry Association TPE thermoplastic elastomer TPR thermoplastic rubber TT three conductors twisted TTS three conductors twis

46、ted and shielded TTSI Three conductors twisted, shielded, and insulated UL Underwriters Laboratories Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 xii UPC ultra physical contact Vp

47、velocity of propagation WAD work authorization document XLP, XLPE cross-linked polyethylene Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-KSC-GP-864, Vol IIA, Rev B October 16, 2009 Change 1, June 4, 2013 1 ELECTRICAL GROUND SUPPORT EQUIPMENT CABLE

48、 HANDBOOK 1. SCOPE Various NASA programs at KSC make maximum use of existing ground systems (GS). Conse-quently, the designer must determine whether existing cables can be used as is or be modified, or if new cables are required. This handbook contains a list of specifications, standards, and reference documents that shall be used in the design, fabrication, and assembly of GS cables at the Kennedy Space Center (K