STATEMENT OF WORK RF CABLE ASSEMBLIES - CTR

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1 Lic. Pública Internacional 38/13 Exp. 424/13 BID STATEMENT OF WORK STATEMENT OF WORK RF CABLE ASSEMBLIES - CTR This document is stored electronically. Printed version might not be the latest. SAOCOM PROJECT COMISION NACIONAL DE ACTIVIDADES ESPACIALES BUENOS AIRES ARGENTINA

2 SAOCOM PROJECT Lic. Pública Internacional 38/13 Exp. 424/13 BID Number Title Summary STATEMENT OF WORK RF CABLE ASSEMBLIES - CTR This document defines the design configuration, materials used in manufacture, manufacturing processes and controls, and all inspections and tests carried out during and after manufacture of a RF-CTR space qualified coaxial cable assembly. Secondary Reference CirculationLevel 1 This document is digitally signed WorkflowSummary State Assignee Action Completed Date Changes Record Issue Date Author PARA Description A 09/08/2013 P.Ordoñez / M. Rodolico InitialRelease Comisión Nacional de Actividades Espaciales (CONAE) from Argentina ownsthecopyright of this document which is supplied in confidence and which shall not be used for any purpose other than that for which it is supplied and shall be only reproduced, copied or communicated, in whole or in part, for internal use of CONAE, directly or by third parties holding confidentiality agreements with CONAE. Any person other than the authorised holder obtaining possession of this document by finding or otherwise, should send it, together with his name and address, in a sealed envelope to: Comisión Nacional de Actividades Espaciales (CONAE) SAOCOM Project Av. Paseo Colón 751 (C1063ACH) Capital Federal ARGENTINA Letter postage need not be prepaid. Other postage will be refunded. Page 2 of 15

3 INDEX INDEX OBJECTIVE SCOPE OF THE SUPPLY REFERENCE AND APPLICABLE DOCUMENTS REFERENCE DOCUMENTS APPLICABLE DOCUMENTS DEFINITIONS AND ABBREVIATIONS ABBREVIATIONS AND ACRONYMS GENERAL REQUIREMENTS SUPPLY MODALITY SCHEDULE AND DELIVERY TIME COMPLIANCE CONTRACTOR TEAM AND ORGANIZATION REPORTING PACKAGING AND SHIPPING CONDITIONS DOCUMENTATION AT QUOTATION STAGE PARTICULAR REQUIREMENTS TASKS DESCRIPTION AND TECHNICAL SPECIFICATIONS GENERAL DESCRIPTION LOT CONTROL TEST CONDITIONS DATA RECORDING AND END ITEM DATA PACKAGE (EIDP) SAMPLING NOMENCLATURE EQUIPMENT MATES/DEMATES CONNECTOR MIL-PRF TESTING CABLE TESTING MECHANICALS CABLE MATERIALS AND FINISHES CABLE OUTER DIAMETER NOMINAL CABLE MASS CABLE MINIMUM BEND RADIUS ARMOR CONNECTORS CONNECTORS INTERFACE DIMENSION CONNECTOR MATERIALS AND FINISHES WEIGHT FLEX LIFE CABLE ASSEMBLY MECHANICAL LENGTH CABLE ASSEMBLY LABELING ELECTRICALS OPERATING FREQUENCY RANGE INSERTION LOSS VSWR (RETURN LOSS) IMPEDANCE ABSOLUTE PHASE MATCHING RF SHIELDING ENVIRONMENT END ITEM DATA PACKAGE EIDP PRODUCTION PROCESSES AND PROCEDURES THERMAL PRECONDITIONING / STABILIZATION OF EACH CUT CABLE LENGTH DE-GOLD...14 Comisión Nacional de Actividades Espaciales (CONAE) Page 3 of 15

4 X-RAY VERIFICATION SOLDER AND CONNECTOR ASSEMBLY POST-ASSEMBLY THERMAL CONDITIONING (IT INCLUDING CONNECTOR INTERFACE DIMENSIONS, IL, VSWR, AND EL) % MECHANICAL, VISUAL AND ELECTRICAL INSPECTION, CLEANLINESS (100% CLEANING OF EACH CABLE ASSEMBLY AND CONNECTOR INTERFACE) PACKING LABELING...15 Comisión Nacional de Actividades Espaciales (CONAE) Page 4 of 15

5 1. OBJECTIVE This document defines the design configuration, materials used in manufacture, manufacturing processes and controls, and all inspections and tests carried out during and after manufacture of a RF-CTR space qualified coaxial cable assembly. 2. SCOPE OF THE SUPPLY This document applied to the development and manufacturing of the RF cable assembly of the CTR. Any deviation of them by the contractor shall be approved by CONAE. 3. REFERENCE AND APPLICABLE DOCUMENTS 3.1 REFERENCE DOCUMENTS ANSI/NCSL Z540.3 REQUIREMENTS FOR THE CALIBRATION OF MEASURING AND TEST EQUIPMENT MIL-PRF-39012D PERFORMANCE SPECIFICATION: CONNECTORS, COAXIAL, RADIO FREQUENCY, GENERAL SPECIFICATION FOR MIL-DTL-17H, CABLES, RADIO FREQUENCY, FLEXIBLE AND SEMIRIGID, GENERATION SPECIFICATION FOR ASTM-B-501 STANDARD SPECIFICATION FOR SILVER-COATED, COPPER-CLAD STEEL WIRE FOR ELECTRONIC APPLICATION ASTM-B-298 STANDARD SPECIFICATION FOR SILVER COATED, SOFT OR ANNEALED, COPPER WIRE MIL-STD-348A, RADIO FREQUENCY CONNECTOR INTERFACESASTM-D-3159 STANDARD SPECIFICATION FOR MODIFIED ETFE-FLUOROPOLYMER MOLDING AND EXTRUSION MATERIALS ASTM-D-5205 STANDARD CLASSIFICATION SYSTEM FOR POLYETHERIMIDE (PEI) MATERIALS ASTM-D-6358 STANDARD CLASSIFICATION SYSTEM FOR POLY (PHENYLENE SULFIDE) INJECTION MOLDING AND EXTRUSIONMATERIALS USING ISO METHODS ASTM-B-196 STANDARD SPECIFICATION FOR COPPER-BERYLLIUM ALLOY ROD AND BAR ASTM-B-197 STANDARD SPECIFICATION FOR COPPER-BERYLLIUM ALLOY WIRE MIL-DTL GOLD PLATING, ELECTRODEPOSITED ASTM-B-488 STANDARD SPECIFICATION FOR ELECTRODEPOSITED COATINGS OF GOLD FOR ENGINEERING USES ASTM-A-582 STANDARD SPECIFICATION FOR FREE MACHINING STAINLESS AND HEAT-RESISTING STEEL BARS. ASTM-A-967 STANDARD SPECIFICATION FOR CHEMICAL PASSIVATION TREATMENTS FOR STAINLESS STEEL PARTS ASTM-B-16 STANDARD SPECIFICATION FOR FREE-CUTTING BRASS ROD, BAR AND SHAPES FOR USE IN SCREW MACHINES MIL-STD-202 ELECTRONIC AND ELECTRICAL COMPONENT PARTS J-STD-001ES SPACE APPLICATIONS ELECTRONIC HARDWARE ADDENDUM TO IPC J- STD-001E REQUIREMENTS FORSOLDERED ELECTRICAL AND ELECTRONIC ASSEMBLIES Comisión Nacional de Actividades Espaciales (CONAE) Page 5 of 15

6 ASTM-E-595 ANSI/NCSL Z APPLICABLE DOCUMENTS TOTAL MASS LOSS AND COLLECTED VOLATILE CONDENSABLE MATERIALS FROM OUTGASSING IN A VACUUMENVIRONMENT CALIBRATION LABORATORIES AND MEASURING AND TEST EQUIPMENT GENERAL REQUIREMENTS SAO-PAS-PR SAO-PAS-PR SAO-SYS-PL SAO-SYS-PR SAO-PAS-RS SUBCONTRACTORS NON CONFORMANCES MANAGEMENT SYSTEM ACCEPTANCE AND DELIVERY OF PRODUCTS CONFIGURATION AND DOCUMENTATION MANAGEMENT CHANGES, DEVIATIONS AND WAIVERS PROCESSES SAFETY AND PA REQUIREMENT DOCUMENT (SPARD) Comisión Nacional de Actividades Espaciales (CONAE) Page 6 of 15

7 4. DEFINITIONSAND ABBREVIATIONS 4.1. ABBREVIATIONS AND ACRONYMS AI ANSI ATM ASTM CRES CTR EL FIR IL PRF QA QTR SOW VSWR ASSEMBLY INSTRUCTIONS AMERICAN NATIONAL STANDARD INSTITUTE ATMOSPHERIC TRANSPORT MODEL AMERICAN SOCIETY FOR TESTING AND MATERIALS CORROSION RESISTANT STEEL CONJUNTO DE TRANSMISIÓN/RECEPCIÓN (TRANSMISSION/RECEPTION SET) ELECTRICAL LENGTH FINAL INSPECTION REPORT INSERTION LOSS PERFORMANCE QUALITY ASSURANCE QUALIFICATION TEST REPORT STATEMENT OF WORK VOLTAGE STANDING WAVE RATIO 5. GENERAL REQUIREMENTS Design or/and selection of deliverables of this SOW shall respect the requirements specified in the following paragraphs. Deviation of these requirements shall be clarified in quotation stage SUPPLY MODALITY Special training, software, tools, or gauges necessary for the normal employ or operation of deliverables not considered in this document, shall be informed and offered as annex in the quotation.commissioning activities, if necessary, shall be considered in quotation and planning SCHEDULE AND DELIVERY TIME COMPLIANCE All necessary tasks to perform the deliverables requested in this document shall be planned in concordance with the milestones planning described in the Particular Requirements in this document. The Contractor/Supplier shall include in the proposal a preliminary planning (Gantt chart) detailing control points and deliverables to be provided as evidence of project advancement. The lead time (in continuous days) shall be detailed in the Gantt chart.long lead items shall be detected and reported in a particular list at quotation stage. Final milestones schedule shall be agreed with SAOCOM project team at purchase order placement. Detailed Gantt chart shall be delivered as part of first data package. Consumable products with expiration date shall be supplied having into account that a 75% of the life cycle shall be available at receipt date of materials at CONAE installations CONTRACTOR TEAM AND ORGANIZATION The Contractor shall provide the organization chart of the project team affected to this work, indicating expertise and hourly dedication (part time / full time), as well contact information. Comisión Nacional de Actividades Espaciales (CONAE) Page 7 of 15

8 Training certificates can be requested in the particular requirements or by SAOCOM Mission/Product Assurance in any stage of project development, if necessary REPORTING Problems, failures or non-conformances detected during production of deliverablesto supply, shall be reported as soon as possible to SAOCOM Project Team, as detailed in SUBCONTRACTORS NON CONFORMANCES MANAGEMENT SYSTEM (See paragraph 3). Engineering changes proposals, request for deviations, and request for waivers shall be reported to SAOCOM Project Team as detailed in CHANGES, DEVIATIONS AND WAIVERS PROCESSES (see paragraph 3). Schedule compliance reports shall be supplied regularly and as requested in the specific milestones of the procurement planning and also to special requirement of SAOCOM Project Team PACKAGING AND SHIPPING CONDITIONS Special conditions for handling and storage shall be informed at quotation stage if possible. Deliverables products of this SOW shall be delivered only with the SAOCOM Project Team acceptance as defined in the procedure ACCEPTANCE AND DELIVERY OF PRODUCTS(See paragraph 3Applicable Documents). Supplier shall assure theappropriate labeling on the packaging of products to assure the correct handling and storage: Note: Items with (*), only if applicable. - Manufacturer / Supplier name - Material / Product identification - Batch identification - Manufacture date - Expiration date * - Handling conditions: Fragile condition / Manipulate with care * Electrostatic Sensitive / Handling Precaution * Weight - Storage conditions: This side up Stacking limits Storage temperature * Keep Dry* Keep Frozen / Do not freeze * - Hazard labels * Sensitive products shall be correctly protected with appropriated packaging solutions, as example: - Humidity insulation - Vibration insulation - Dust insulation - Electrostatic insulation - Thermal insulation Sensitive products packaging shall include history indicators,as example: - Humidity cards - Impact indicators Comisión Nacional de Actividades Espaciales (CONAE) Page 8 of 15

9 - Temperature cards - Inclination records cards Products supplied for Flight Model shall include a label: Do not open until ready for use. Products received with apparent damages and that has not been correctly protected and labeled according to the requested in this document, will not be accepted by SAOCOM project team DOCUMENTATION AT QUOTATION STAGE Following documents shall enclose the economical proposal at quotation stage: 1. Technical proposal. 2. Economical proposal detailed in the Quotation Breakdown form, attached to this SOW. 3. Datasheet of offered COTS products not included in the SAOCOM PPL (paragraph 5) and justification of selection. 4. Preliminary Gantt chart (paragraph 5.2) 5. Long Lead Items list (paragraph 5.2) 6. Organization Chart and contact information (paragraph 5.3) 7. Special packaging and handling conditions (paragraph 5.5) 8. ISO 9001 certification or Contractor / Supplier Quality System evidence. 9. Knowhow / Experience evidence in similar projects. 6. PARTICULAR REQUIREMENTS 6.1. TASKS DESCRIPTION AND TECHNICAL SPECIFICATIONS GENERAL DESCRIPTION The supplier shall be responsible for the design, manufacture, test, and delivery of flight quality cable assemblies procured to this specification Lot Control Records that are traceable for the specific raw materials relating to the finished cable assembly shall be retained for a minimum of seven years Test Conditions All electrical and mechanical measurements will be accomplished at the following atmospheric Conditions: Temperature -23ºC ± 3ºC, Humidity -65% Max, Pressure to 1.03 ATM (97 to 105 kilopascals) Data Recording and End Item Data Package (EIDP) Unless otherwise specified, all data shall be recorded on the applicable Final Inspection Report (FIR).Soft copy plots of Insertion Loss (IL), VSWR, S parameters and Electrical Length (EL) swept measurements will be included with the FIR on CD. Comisión Nacional de Actividades Espaciales (CONAE) Page 9 of 15

10 Sampling All tests and inspections will be performed on 100% of the Flight Assemblies Nomenclature Throughout this document, connector ends are referred to as C1 or C2 whereas C1 is the connector on the left and C2 is the connector on the right when the cable assembly is held so the labeled heat shrink end markers can be read from left to right Equipment All equipment used in the performance of the testing specified herein shall have a valid calibration status in accordance with ANSI/NCSL Z Mates/Demates Throughout manufacture and test, the number of connector mates and demates shall be tracked and recorded on the Mate/Demate log. The log will be incorporated within the FIR. The number of Mates/Demates shall not exceed Connector MIL-PRF Testing Connectors shall receive the MIL-PRF Group A and B lot acceptance testing per Test Report QTR A prior to cable assembly build Cable Testing Cable shall receive applicable MIL-DTL-17 Group A, B, and C lot acceptance testing per applicable cable Final Inspection Report prior to cable assembly build MECHANICALS Cable Materials and Finishes Cable materials and finishes shall be in accordance with the following table. Cable Component Center Conductor Electrical Shields (Helical wrapped inner shield) Mechanical Shield (Braided Outer Shield) Dielectric Core Specification Solid silver plated copper clad steel per ASTM B-501. Silver plating thickness shall be 100 micro-inches minimum. Silver plated copper foil per ASTM B-298. Silver plating thickness shall be 100 micro-inches minimum. Silver plated poly-para-phenyleneterephthalamide, Aracon, tightly braided over the inner shield with a minimum of 90 % coverage. Ultra low density PTFE in accordance with the applicable paragraph of MIL-DTL-17. Jacket Modified ETFE-Fluoropolymer in accordance with ASTM D Cable Outer Diameter Cable outer diameter shall be ± inch Nominal Cable Mass Nominal cable mass shall be 3,6(g/ft) Comisión Nacional de Actividades Espaciales (CONAE) Page 10 of 15

11 Cable Minimum Bend Radius Cable minimum bend radius shall be 0,25 inch Armor No armor is required Connectors C1 Connector shall be SMP, Female, Full Detent, Straight. Mass (g) = 0,3g IL Constant (C) =0,060 C2 shall be SMA Male, Box (Mitre Right Angle), Vented Mass (g) = 9,9g IL Constant (C) =0, Connectors Interface Dimension C1 Connector Interface dimensions shall be according to MIL-STD-348, Figure 326 C2 Connector Interface dimensions shall be according to MIL-STD-348, Figure Connector Materials and Finishes Connector materials and finishes shall be in accordance with the following table. ConnectorComponent DielectricInserts Snap Rings Gasket Specification Polyethermide thermoplastic, unreinforced, PEI0113 Per ASTM-D-5205.PTFE fluorocarbon per ASTM-D-1710 Polyphenylene Sulfide (PPS) per ASTM-D-6358 Beryllium Copper (BeCu), per ASTM-B-196 or 197, Temper TD04 (H), UNS No.C17300 or C17200 Fluorocarbon Elastomer (VITON) per ASTM-R Comisión Nacional de Actividades Espaciales (CONAE) Page 11 of 15

12 Contacts Connector Body Contact Ring Front Body Inner Sleeve Coupling Nut Contact Ring Thread Locker BeCu, per ASTM-B-196, Temper TD04 (H), UNS No. C17300, gold plate per MILDTL or ASTM-B-488Type II, Class 1, microinches thick, over NickelPlate per QQ-N-290, Class 1, microinches thick CRES Steel, Corrosion Resistant, per ASTM-A-582, Class 303. Passivate per ASTMA-967 Condition A, Non-Magnetic. CRES Steel, Corrosion Resistant, per ASTM-A-582, Class 303. Passivate per ASTMA-967 Condition A, Non-Magnetic. CRES Steel, Corrosion Resistant, per ASTM-A-582, Class 303. Passivate per ASTMA-967 Brass per ASTM-B16, UNS NO. C36000, Temper HO, gold plate per MIL-DTL-45204or ASTM-B-488 Type II, Class 1, microinches thick, over Nickel Plate per QQN-290, Class 1, microinches thick. Material: Epoxy, Polymer; Manufacturer and Part Number: Master Bond, 10HTTemperature Range: -195ºC to 204ºC Cure Time: 1 hour at 121ºC Weight The nominal cable assembly weight shall be the sum of the cable, connector, and markers specified in this document and it shall be recorded on the FIR. If a maximum weight specification is required, an additional 5 grams shall be added to address manufacturing variability Flex Life The cable shall withstand 500 flexes of 90 around a mandrel diameter 20x the cable diameter with minimal performance degradation Cable Assembly Mechanical Length The length shall be 28.0 inches, +1.5/ -0.0 inches Cable Assembly Labeling Each cable assembly shall have heat shrink sleeves overlapping the connector and cable for reinforcement and for text labeling. Text as follows: Assembly Part number Assembly serial number An alternative labeling method using wrap-around labels can also be used when specified as long as the materials are space-qualified ELECTRICALS Operating Frequency Range Operating frequency range shall be 1235 MHz MHz Comisión Nacional de Actividades Espaciales (CONAE) Page 12 of 15

13 Insertion Loss The cable assembly insertion loss is the sum of the contribution from the cable and two connectors. The insertion loss graphical display shall be smooth and continuous with a maximum ripple of ± 0.1 db. The maximum cable assembly insertion loss is calculated using the following formula Where: LMAX = Maximum cable assembly length in feet C1 and C2 = Connector constant F = Frequency in GHz VSWR (Return Loss) The VSWR Maximum of the cable assembly for the operative range frequency shall be1.20: Impedance Impedance shall be 50 ohms nominal Absolute Phase Matching Absolute phase matching shall be +/-0.5 degrees in the operating range frecuency MHz Absolute phase match /-0.5 degrees at 1275 MHz Verified in parameters S21 and S12 Information: Shall be when an assembly or sets of two or more assemblies are matched to an absolute electrical length plus a tolerance RF Shielding RF shielding shall be -80dB minimum in the operating range frequency Environment The cable assembly shall be designed and built to survive the normal environment of spaceflight, including high vibration launch and up to 100Mrads radiation Cable assemblies shall be Thermal Vacuum compatible space application o RML < 1,0 % (recovered mass loss) o CVCM < 0,10 %. (collected volatile condensable material) End Item Data Package EIDP To include completed FIR, electronic data output for each serialized cable assembly (*), x- rays, Certificate of Compliance, and waivers if applicable. (*) S parameters Comisión Nacional de Actividades Espaciales (CONAE) Page 13 of 15

14 The supplier shall provide the data in a tabular electronic copy (s2p.) and graphic printed output: o S11, S12, S21, S22 parameters characterization in the frequency range MHz with steps of 5 MHz (17 frequencies) for each cable assembly at ambient temperature PRODUCTION PROCESSES AND PROCEDURES Cables assemblies shall be manufactured under de following requirements: Thermal preconditioning / stabilization of each cut cable length. Preconditioning shall be a thermal shock per MIL-STD-202, Method 107, Condition B or failing a Thermal cycle. Each cut cable length and connector PTFE insulator shall be preconditioned De-gold De-Gold all "solder-on connector components with gold plated surfaces per J-STD-001ES. Reference the connector s Assembly Instruction or Assembly Drawing for De-Golding area. Gold removal shall consist of one tinning operation and occur on the connector assembly router X-Ray Verification The X-ray verification shall be performed during process solder and the final solder. In process solder/ assembly x-ray verification. Final solder / assembly x-ray verification Solder and Connector Assembly Soldering operations and inspections shall be performed according to J-STD-001ES Post-assembly thermal conditioning (It including Connector Interface Dimensions, IL, VSWR, and EL) Post-assembly thermal conditioning shall be Thermal Shock assemblies per MIL-STD-202, Method 107, Condition B % mechanical, visual and electrical inspection, The supplier shall be performed mechanical, visual and electrical inspections in accordance to applicable standard for Space applications Connector Interface Dimensions Insertion Loss (IL), VSWR, Electrical Length (EL) Connector Clocking Angle Comisión Nacional de Actividades Espaciales (CONAE) Page 14 of 15

15 Workmanship o Cable o Connectors o Finished Assembly o Heat Shrink Formed Elbows Length Weight Markers and Labeling Cleanliness (100% cleaning of each cable assembly and connector interface) Cable assemblies shall be cleaned with an alcohol cloth, the connector interfaces blown off with nitrogen and wiped clean with an alcohol swab Packing The connectors for each Flight Assembly shall be capped with a Non-PVC, Anti-Static dust cap. The capped assembly shall be packaged in a heat sealed bag which is first evacuated and then filled with Nitrogen. Cable assemblies shall be individually bagged in a clean room safe ESD Labeling Each bag shall be labeled as follows: DO NOT BREAK SEAL TO BE OPENED IN CLEAN ROOM ENVIRONMENT ONLY. DO NOT HANDLE. HANDLE WITH NON-POWDERED LATEX EXAM GLOVES ONLY Supplier Drawing/Revision.: Purchase Order No.: Serial No.: Description: Customer Part No.: Item No.: External Box supplied shall include a label: Abrir solamente en presencia de personal de CONAE / Do not open without the presence of CONAE personel. Comisión Nacional de Actividades Espaciales (CONAE) Page 15 of 15

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