Annex 3. GSTP activity. Draft Generic Specification for Single Mode Simplex Optical Fibre Cable Assemblies. To Statement of work TEC-QTC/2009SoW04/SH

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1 Reference TEC-QTC/2009SoW04/SH Issue 1, Revision 2, 14 August 2009 GSTP activity Annex 3 To Statement of work TEC-QTC/2009SoW04/SH Draft Generic Specification for Single Mode Simplex Optical Fibre Cable Assemblies Evaluation of optic cables assembly 1

2 SINGLE MODE SIMPLEX OPTICAL FIBRE CABLE ASSEMBLIES ESA/SCC Generic Specification No. Draft 5

3 1 INTRODUCTION SCOPE APPLICABILITY APPLICABLE DOCUMENTS ESA/SCC SPECIFICATIONS OTHER (REFERENCE) DOCUMENTS ORDER OF PRECEDENCE TERMS, DEFINITIONS, ABBREVIATIONS, SYMBOLS AND UNITS REQUIREMENTS GENERAL Specifications Conditions and Methods of Test Manufacturer s Responsibility for Performance of Tests and Inspections Inspection Rights QUALIFICATION APPROVAL REQUIREMENTS ON A MANUFACTURER DELIVERABLE COMPONENTS Lot Failure Testing and Lot Acceptance Levels MARKING MATERIALS AND FINISHES PRODUCTION CONTROL GENERAL SPECIAL IN-PROCESS CONTROLS Documentation FINAL PRODUCTION TESTS GENERAL TEST METHODS AND CONDITIONS FAILURE CRITERIA Parameter Limit Failure Other Failures FAILED COMPONENTS LOT FAILURE DOCUMENTATION BURN-IN AND ELECTRICAL MEASUREMENTS (CHART III) QUALIFICATION APPROVAL AND LOT ACCEPTANCE TESTS...12

4 8.1 QUALIFICATION TESTING General Distribution within the Qualification Test Lot Capability Approval LOT ACCEPTANCE TESTING General Distribution within the Sample Lot for Lot Acceptance Testing Lot Acceptance Level 3 Testing (LA3) Lot Acceptance Level 2 Testing (LA2) Lot Acceptance Level 1 Testing (LA1) FAILURE CRITERIA Environmental and Mechanical Test Failures Optical Failures Other Failures FAILED CABLE ASSEMBLIES LOT FAILURE DOCUMENTATION Qualification Approval Capability Approval TEST METHODS AND PROCEDURES EXTERNAL VISUAL INSPECTION WEIGHT DIMENSION CHECK OPTICAL MEASUREMENTS Optical Measurements at Room Temperature Optical Measurements at High and Low Temperature Optical Measurements During Environmental, Mechanical and Endurance Testing Optical Test Methods TEMPERATURE LIFE TEMPERATURE CYCLING RADIATION RAPID DEPRESSURISATION VIBRATION Sinusoidal Vibration Testing Random Vibration Testing Shock PERMANENCE OF MARKING TENSILE PERFORMANCE ABRASION RESISTANCE CUT THROUGH RESISTANCE CRUSH IMPACT RESISTANCE BENDING TESTS Cable Bend Repeated Bending Bend Under Tension Cold Bend Test... 29

5 Torsion Flexing Kink Connector Characteristics Mating durability Intermateability Engagement and Separation Force Strength of Cable Retention in Connector Tension Torsion Axial Compression Climatic sequence Initial Measurements Damp Heat, Accelerated, First cycle Cold Test Damp Heat Accelerated, Remaining cycles Final Measurements DATA DOCUMENTATION GENERAL Qualification Approval Capability Approval Fibre Optic Cable Assembly Deliveries Data Retention/Data Access COVER SHEET(S) LIST OF EQUIPMENT USED LIST OF TEST REFERENCES SPECIAL IN-PROCESS CONTROL DATA FINAL PRODUCTION TEST DATA (CHART II) BURN-IN AND ELECTRICAL MEASUREMENT DATA (CHART III) QUALIFICATION TEST DATA (CHART IV) Capability Approval Test Data LOT ACCEPTANCE TEST DATA (CHART V) FAILED CABLE ASSEMBLIES LIST AND FAILURE ANALYSIS REPORT CERTIFICATE OF CONFORMITY DELIVERY PACKAGING AND DiSPATCH...35 CHARTS I II III IV V Testing Levels Final Production Tests Burn-In and Electrical Measurements Qualification Tests Lot Acceptance Tests

6 1 INTRODUCTION 1.1 SCOPE This specification defines the general require ments for the qualification approval, capability approval, procurement, including lot acceptance, and delivery of single mode optical fibre simplex cables with connectors for space application. This specification contains the appropriate inspection and test schedules and also specifies the data documentation requirements. 1.2 APPLICABILITY This specification is primarily applicable to the granting of qualification approval, or capability approval to a cable assembly in accordance with ESA/SCC Basic Specification No and the procurement of such cable assemblies from qualified Manufacturers. 2 APPLICABLE DOCUMENTS The following documents form part of, and shall be read in conjunction with, this specification. The relevant issues shall be those in effect at the date of placing the purchase order. 2.1 ESA/SCC SPECIFICATIONS No , No , No , No , No , No , No No , No , Requirements for the Qualification of Standard Electronic Components for Space Application External Visual Inspection Preservation, Packaging and Dispatch of SCC Electronic Components Terms, Definitions, Abbreviations, Symbols and Units General Requirements for the Marking of SCC Components ESA/SCC Non-conformance Control System Requirements for the Capability Approval of Electronic Cable assembly Technologies for Space Applications Minimum Quality System Requirements Resistance to Solvents of Marking, Materials and Finishes With the exception of ESA/SCC Basic Specifications No , 21700, 22800, and 24600, where Manufacturers specifications are equivalent to, or more stringent than, the ESA/SCC Basic Specifications listed above, they may be used in place of the latter, subject to the approval of the appropriate Qualifying Space Agency. Such replacements shall be clearly identified in the applicable Process Identification Document (P.I.D.) and listed in an Appendix to the appropriate Detail Specification. Unless otherwise stated herein, reference within the text of this specification to the Detail Specification shall mean the relevant ESA/SCC Detail Specification. 2.2 OTHER (REFERENCE) DOCUMENTS ESA ECSS-Q-70-02, Thermal Vacuum Outgassing Test for the Screening of Space Materials

7 ESA ECSS-Q-70-21, ESA ECSS-Q-70-29, ESA ECSS-Q-70A ESA PSS Flammability Testing for the Screening of Space Materials The Determination of Offgassing Products from Materials and Assembled Articles to be used in a Manned Space Vehicle Crew Compartment Materials, Mechanical Parts and Processes Data for selection of space materials IEC IEC IEC IEC Optical Fibres Optical Fibre Cables Optical Fibre Connectors Environmental Testing IEC Environmental Testing 2.3 ORDER OF PRECEDENCE For the purpose of interpretation and in the case of conflict with regard to documentation, the following order of precedence shall apply: (a) (b) (c) (d) ESA/SCC Detail Specification. ESA/SCC Generic Specification. ESA/SCC Basic Specification. Other documents if referenced herein. 3 TERMS, DEFINITIONS, ABBREVIATIONS, SYMBOLS AND UNITS The terms, definitions, abbreviations, symbols and units specified in ESA/SCC Basic Specification No and No. (optical fibre terms,defs,etc) shall apply. 4 REQUIREMENTS 4.1 GENERAL The test requirements for qualification approval of optical fibres shall comprise final production tests (see Chart II) and qualification testing (see Chart IV). The test requirements for procurement of cable assemblies shall comprise final production tests (see Chart II) together with, when applicable, a level of lot acceptance testing (see Chart V) to be specified by the Orderer. If a Manufacturer elects to eliminate a final production test by substituting an in-process control or statistical process control procedure, the Manufacturer is still responsible for delivering cable assemblies that meet all of the performance, quality and reliability requirements defined in this specification and the Detail Specification Specifications

8 For qualification approval, procurement (including lot acceptance testing) and delivery of cable assemblies in conformity with this specification, the specifications listed in Section 2 of this document shall apply in total unless otherwise specified herein or in the Detail Specification Conditions and Methods of Test The conditions and methods of test shall be in accordance with this specification, the ESA/SCC Basic Specifications referenced herein and the Detail Specification Manufacturer s Responsibility for Performance of Tests and Inspections The Manufacturer shall be responsible for the performance of tests and inspections required by the applicable specifications. These tests and inspections shall be performed at the plant of the Manufacturer of the cable assemblies unless it is agreed by the Qualifying Space Agency prior to commencing qualification testing, or procurement, to use an approved external facility Inspection Rights The Qualifying Space Agency (for qualification approval or for a procurement) reserves the right to monitor any of the tests and inspections scheduled in the applicable specifications. 4.2 QUALIFICATION APPROVAL REQUIREMENTS ON A MANUFACTURER To obtain and maintain the qualification approval of an optical fibre cable assembly, a Manufacturer shall satisfy the requirements of ESA/SCC Basic Specification No DELIVERABLE COMPONENTS Optical fibre cable assembly delivered to this specification shall be processed and inspected in accordance with the relevant Process Identification Document (P.I.D.). Each delivered optical fibre cable assembly shall be traceable to its production lot. Optical fibre cable assemblies delivered to this specification shall have completed satisfactorily all tests to the testing level and lot acceptance level specified in the purchase order (see Para ). ESA/SCC qualified optical fibre cable assembly delivered to this specification shall be produced from lots that are capable of passing all tests, and sequences of tests, that are defined in Charts IV and V. The Manufacturer shall not knowingly supply cable assemblies that cannot meet this requirement. In the event that, subsequent to delivery and prior to operational use, a cable assembly is found to be in a condition such that it could not have passed these tests at the time of manufacture, this shall be grounds for rejection of the delivered lot Lot Failure Lot failure may occur during final production tests (Chart II), qualification testing (Chart IV) or lot acceptance testing (Chart V). Should such failure occur, the non-conformance procedure shall be initiated in accordance with ESA/SCC Basic Specification No Should such failure occur during procurement, the Manufacturer shall notify the Orderer within 2 working days, giving details of the number and mode of failure and the suspected cause. In the case where qualification approval has been granted to the component, he shall, at the same time by the same means, inform the Qualifying Space Agency in order that the latter may consider its implications.

9 No further testing shall be performed on the failed cable assemblies except on instructions from the Orderer. The Orderer shall inform the Manufacturer and the Qualifying Space Agency within 2 working days from the receipt of the telex, by the same means, what action shall be taken. In the case where lot failure occurs during qualification testing, the Manufacturer shall immediately notify the appropriate Qualifying Space Agency who will define a course of action to be followed. No further testing shall be performed on the failed components Testing and Lot Acceptance Levels This specification defines one level of testing severity that is designated by the letter B (see Chart I) and 3 levels of lot acceptance testing (see Chart V). The Lot Acceptance levels are designated 1, 2 and 3 and are comprised of tests as follows: - Level 3 (LA3) Quality Assurance Subgroup. Level 2 (LA2) - Environmental and Endurance Subgroups. Level 1 (LA1) - Mechanical Subgroup. The required lot acceptance level shall be specified in a purchase order. 4.4 MARKING All cable assemblies procured and delivered to this specification from a source qualified according to ESA/SCC Basic Specification No shall be marked in accordance with ESA/SCC Basic Specification No Thus, they shall bear the ESA symbol to signify their conformance to the ESA/SCC qualification approval requirements and full compliance with the requirements of this specification and the Detail Specification. Cable assemblies procured from sources, which are not ESA/SCC qualified, provided that they fully comply with the procurement requirements of this specification and the Detail Specification, may bear the SCC marking with the exception of the ESA symbol. 4.5 MATERIALS AND FINISHES All non-metallic materials and finishes that are not within a hermetically sealed enclosure, of the cable assemblies specified, herein shall meet the outgassing requirements as outlined in ESA ECSS-Q In addition, all cables specified herein shall meet the flammability requirements outlined in ESA document ECSS-Q and the outgassing requirements outlined in ECSS-Q Specific requirements for materials and finishes are specified in the Detail Specification. 5 PRODUCTION CONTROL 5.1 GENERAL The minimum requirements for production control, which are equally applicable to procurement, are defined in ESA/SCC Basic Specification No , Paras. 5.1 and SPECIAL IN-PROCESS CONTROLS No special in-process controls are applicable.

10 5.3 DOCUMENTATION Documentation of special in-process controls shall be in accordance with the requirements of Para of this specification.

11 CHART I TESTING LEVELS See ESA/SCC Basic Spec. No NO Is cable assembly ESA/SCCG Qualified? YES Is qualification Valid? NO YES See ESA/SCC Basic Spec. No Production Control Final Production Tests Lot Acceptance Level 1, 2 or 3 (1) Deliverable Components Release Delivery 1.1 NOTES 1. When applicable

12 6 FINAL PRODUCTION TESTS 6.1 GENERAL Unless otherwise specified in the Detail Specification, all cable assemblies used for qualification testing and all cable assemblies for delivery, including those submitted to lot acceptance tests, shall be subjected to tests and inspections in accordance with Chart II. Unless otherwise specified in the Detail Specification, the tests shall be performed in the order shown. Any cable assemblies that do not meet these requirements shall be removed from the lot and at no future time be re-submitted to the requirements of this specification. 6.2 TEST MET HODS AND CONDITIONS The applicable test methods and conditions are specified in the paragraphs referenced in Chart II of this specification. 6.3 FAILURE CRITERIA Parameter Limit Failure A cable assembly shall be counted as a limit failure if one or more parameters exceed the limits shown in Table 2 of the Detail Specification Other Failures A cable assembly shall be counted as a failure in any of the following cases: Mechanical failure. Handling failure. Lost component. 6.4 FAILED COMPONENTS A cable assembly shall be considered as a failed cable assembly if it exhibits one or more of the failure modes described in Para. 6.3 of this specification. 6.5 LOT FAILURE In the case of lot failure, the Manufacturer shall act in accordance with the requirements of Para of this specification. For the purposes of this specification, one failure in any of the tests or inspections in Chart V shall constitute a lot failure: 6.6 DOCUMENTATION Documentation of final production test data shall be in accordance with Para of this specification. 7 BURN-IN AND ELECTRICAL MEASUREMENTS (CHART III) Not applicable.

13 8 QUALIFICATION APPROVAL AND LOT ACCEPTANCE TESTS 8.1 QUALIFICATION TESTING General Qualification testing shall be in accordance with the requirements of Chart IV of this specification. The tests of Chart IV shall be performed on the cable assemblies specified in the paragraphs of section 9, which have successfully passed the tests in Chart II. These cable assemblies constitute the qualification test lot. The qualification test lot is divided into subgroups of tests and all cable assemblies assigned to a subgroup shall be subjected to all of the tests in that subgroup, in the sequence shown. The applicable test requirements are detailed in the paragraphs referenced in Chart IV. The conditions governing qualification testing are given in ESA/SCC Basic Specification No.20100, Para. 5.3, and for the extension or renewal of qualification approval in Paras. 6.3 and Distribution within the Qualification Test Lot Not applicable. 8.2 CAPABILITY APPROVAL Capability Approval of a technology domain, and the approval of cable assemblies within an approved domain, shall be in accordance with ESA/SCC Basic Specification No LOT ACCEPTANCE TESTING General The sample sizes of the 3 lot acceptance levels are specified in Chart V. All cable assemblies assigned to a subgroup shall be subjected to all of the tests of that subgroup in the sequence shown. The tests to Chart V shall be performed on the specified sample that shall have been chosen, whenever possible, at random from the proposed delivery lot. The applicable test requirements are detailed in the paragraphs referenced in Chart V. As a minimum for procurement of non-qualified components, lot acceptance level 3 tests shall apply. For procurement of qualified components, lot acceptance testing shall be performed if specified in a purchase order. Procurement lots ordered with a lot acceptance test level shall be delivered only after successful completion of lot acceptance testing Distribution within the Sample Lot for Lot Acceptance Testing Where a Detail Specification covers a range, or series, of cable assemblies that are considered similar, then it may be necessary that the sample for lot acceptance testing be comprised of cable assembly types so selected that they adequately represent all of the various mechanical, structural, electrical and electro-optical peculiarities of that range or series. The distribution of the cable assembly types will normally vary from procurement to procurement and shall be specified by the Orderer:

14 In case of manufacture of variants of the same cable size, the lot acceptance tests shall be performed on the most complex variants, thus all variants will be qualified. In case of manufacture of variants of different cable sizes, the lot acceptance tests shall be performed on each size. A qualified lot may be divided for delivery purposes Lot Acceptance Level 3 Testing (LA3) Lot acceptance level 3 tests are designated as the quality assurance subgroup and comprise attenuation measurements and a visual inspection to prove the quality of the component. For LA3 testing, the following shall apply: (a) LA3 testing shall be performed by the Manufacturer s quality assurance personnel using dedicated quality assurance equipment whenever possible. LA3 testing shall not be a repetition of routine measurements made by production personnel during final production tests. (b) When tests to Tables 2 and 3 of the Detail Specification have been performed on a sample basis, then the cable assemblies for LA3 testing shall be selected from this sample. (c) The attenuation measurements are considered to be non-destructive and therefore cable assemblies so tested may form part of the delivery lot. (d) The visual inspection test is considered to be non-destructive and therefore cable assemblies so tested may form part of the delivery lot. (e) When required in the purchase order, the Manufacturer shall notify the Orderer at least 2 working weeks before the commencement of LA3 testing. The Orderer shall indicate immediately whether or not he intends to witness the tests Lot Acceptance Level 2 Testing (LA2) Lot acceptance level 2 testing shall comprise the tests on an environmental and endurance subgroup. The tests in this subgroup are considered destructive and therefore cable assemblies of testing level B so tested shall not form part of the delivery lot Lot Acceptance Level 1 Testing (LA1) Lot acceptance level 1 testing shall comprise the tests for LA2 (environmental and endurance subgroup) plus tests on a mechanical subgroup. For the environmental and endurance subgroup, the requirements and conditions for LA2 (see Para ) shall apply. For the endurance and mechanical subgroups, the tests in this subgroup are considered to be destructive and therefore cable assemblies so tested shall not form part of the delivery lot. 8.4 FAILURE CRITERIA The following criteria shall apply to qualification testing and to lot acceptance testing Environmental and Mechanical Test Failures The following shall be counted as cable assembly failures: - Cable assemblies which fail during tests for which the pass/fail criteria are inherent in the test method, e.g. resistance to solvents, etc.

15 8.4.2 Optical Failures The following shall be counted as cable assembly failures: - Cable assemblies which, when subjected to measurement of optical characteristics, in accordance with Table 2 of the Detail Specification, fail one or more of the applicable limits Other Failures The following additional failures may also occur during qualification testing or lot acceptance testing: - Cable assemblies failing to comply with the requirements of ESA/SCC Basic Specification No Lost cable assemblies. 8.5 FAILED CABLE ASSEMBLIES A cable assembly shall be considered as failed if it exhibits one or more of the failure modes detailed in Para. 8.4 of this specification. The allowable number of failed cable assemblies per subgroup, the aggregate failure constraints and the permitted distribution of such failures are shown at the foot of Charts IV and V of this specification. When requested by the Qualifying Space Agency or the Orderer, failure analysis of failed cable assemblies shall be performed by the Manufacturer and the results provided. Failed cable assemblies shall be marked as such and be stored at the Manufacturer s plant for 24 months. 8.6 LOT FAILURE A lot shall be considered as failed if the allowable number of failures according to Chart IV or V of this specification, as relevant, has been exceeded. In the case of lot failure, the Manufacturer shall act in accordance with Para of this specification. 8.7 DOCUMENTATION Qualification Approval For qualification testing, the qualification test data shall be documented in accordance with the requirements of Para of this specification. In the case of lot acceptance testing, the data shall be documented in accordance with the requirements of Para of this specification Capability Approval Data documentation for capability approval test programmes and lot acceptance testing of cable assemblies qualified within an approved capability domain shall be in accordance with the requirements of Paragraphs 10.9 and of this specification.

16 CHART II FINAL PRODUCTION TESTS Production and Controls in accordance with Section 5 of this specification Para. 9.1 External Visual Inspection Para. 4.4 Marking + Serialisation Para. 9.2 Weight Para. 9.3 Dimension Check Para.9.6 Thermal Cycling Para Optical Measurements at Room Temperature Para Optical Measurements at High and Low Temperature Para. 9.1 External Visual Inspection To Chart IV or V

17 CHART III BURN-IN AND ELECTRICAL MEASUREMENTS Not applicable.

18 CHART IV QUALIFICATION TESTS Cable assemblies Environmental Subgroups Mechanical Subgroups Endurance Subgroup 2 Cable assemblies 5 Cable assemblies 5 Cable assemblies 1 Cable assembly 5 Cable assemblies 5 Cable assemblies Radiation Para. 9.7 Temperature Cycling Para. 9.6 Tensile Strength Para Abrasion Resistance Para Cut Through Resistance Para Connector Mating Durability Para Optical Measurements at Room Temperature Para Vibration and Shock Para. 9.9 Torsion Para Crush Para Impact Resistance Para Permanence of Marking Para Rapid Depressurisation Para. 9.8 Kink Para Flexing Para Cable Retention under Tension Para Temperature Life Para. 9.5 Optical Measurements at Room Temperature Para Cable Retention under Torsion Para Cable Retention under Axial Compression Para Optical Measurements at Room Temperature Para Climatic Sequence Para Intermateability Para Total allowable number of failures: 0

19 CHART V LOT ACCEPTANCE TESTS LEVEL 1 Three cable assemblies Mechanical Subgroup Cable Retention under Tension Para Tensile Strength Para Crush Para Impact Resistance Para LEVEL 2 - Two cable assemblies Cold Bend Para Environmental/ Endurance Subgroup Temperature Life Para. 9.5 Temperature Cycling Para. 9.6 Bend Under Tension Para LEVEL 3 One cable assembly Quality Assurance Subgroup Visual Inspection Para. 9.1 Optical Measurements at Room Temperature Para Flexing Para Return Loss Para Intermateability Para No failures allowed LEVEL 1 Lot Acceptance Mating Durability Para No failures allowed LEVEL 2 Lot Acceptance No failures allowed LEVEL 3 Lot Acceptance

20 9 TEST METHODS AND PROCEDURES If a Manufacturer elects to eliminate or modify a test method or procedure, the Manufacturer is still responsible for delivering cable assemblies that meet all of the performance, quality and reliability requirements defined in this specification and the Detail Specification. Documentation supporting the change shall be approved by the Qualifying Space Agency and retained by the Manufacturer. It shall be copied, when requested, to the Qualifying Space Agency. The change shall be specified in the Detail Specification and in the P.I.D. 9.1 EXTERNAL VISUAL INSPECTION Visual inspection shall be performed at high power illumination under three-power magnification, and confirmed under ten-power whenever results at the lower magnification are uncertain or there is evidence of deficiencies that require greater resolution. The cables shall show no evidence of defects or damage such as cracks, breaks, dents, kinks, non-uniformity, abrasions, de-laminations, contamination, imbedded foreign material, nor improper or illegible cable marking. 9.2 WEIGHT The length and weight of a specimen of optical fibre cable, of at least 3 metres long, shall be accurately measured and the resultant measurements converted into grams per metre. The result shall be in accordance with the value specified in the Detail Specification. 9.3 DIMENSION CHECK The dimensions and detail construction of the optical fibre cable assembly components shall be checked against the values specified in the Detail Specification. Optical fibre cable samples with a length of 10cm shall be taken for inspection from the beginning and the end of each cable (before connectorisation where appropriate). Fibre geometry shall be measured as described in IEC , including: - cladding diameter - cladding non-circularity - core-cladding concentricity error 9.4 OPTICAL MEASUREMENTS Optical Measurements at Room Temperature Optical measurements at room temperature shall be made in accordance with table 2 of the Detail Specification. All values obtained shall be recorded against serial numbers Optical Measurements at High and Low Temperature Optical measurements at high and low temperature shall be made in accordance with table 3 of the Detail Specification. All values obtained shall be recorded against serial numbers Optical Measurements During Environmental, Mechanical and Endurance Testing Optical measurements shall be made in accordance with Table 6 of the Detail Specification. All values obtained shall be recorded against serial numbers. Where the maximum cable length required within the

21 capability domain and the maximum permissible cable attenuation values per metre in the Detail Specification are such that total permitted change in cable attenuation is less than 0.02dB then only values greater than 0.02dB shall constitute a failure. Where connectors are included in the qualification process and OTRD methods are not available then changes in insertion loss of the optical fibre cable assembly exceeding the induced connector losses summed with the product of cable length and the maximum permissible cable attenuation values per metre in the Detail Specification shall constitute a failure Optical Test Methods The following optical test methods shall be followed where specified by tables 2 and 6 of the Detail Specification Optical Attenuation Optical attenuation shall be measured by insertion loss or backscattering techniques as described in IEC These methods may be used to characterise attenuation as a function of wavelength of a given cable or to make single wavelength measurements as appropriate. Measurement wavelength(s) shall be as specified in the Detail Specification. - method used - optical source type, wavelength and spectral width - insertion loss or attenuation coefficient measured over the wavelength range or specific wavelength as required by the Detail Specification - launching technique including mode stripping considerations (acrylate coating strips cladding modes of some fibre types) - description of all key equipment - dates of latest calibration of measurement equipment Monitoring of Changes in Optical Transmittance The optical transmittance of an optical fibre cable is measured to detect changes occurring during environmental, mechanical and endurance testing. Transmittance monitoring shall be measured by transmitted power monitoring or backscattering techniques as described in IEC Measurement conditions shall be as described in the relevant environmental, mechanical or endurance test. The cable shall be prepared in accordance with the relevant test procedure being carried out. Measurement wavelength(s) shall be as specified in the Detail Specification. - optical source type, wavelength and spectral width - insertion loss or attenuation coefficient measured over the wavelength range or specific wavelength as required by the Detail Specification - launching technique including mode stripping considerations - description of all key equipment - dates of latest calibration of measurement equipment Return loss Measurement of return loss follows similar procedures to optical attenuation measurement (para ). The insertion loss method is modified by the addition of a branching device between the light source and

22 cable assembly under tes t. The reflection loss is calculated from the ratio of optical power measured after the cable assembly under test and at the branching device port corresponding to backscattered light. Care should be taken to terminate each connection when not in use for the detector and to eliminate reflection losses from components other than the cable assembly under test. The OTDR method can be applied by comparing the reflection of the cable assembly under test with a known standard reflector, for example a cleaved fibre end immersed in a fluid of known refractive index. Measurement wavelength(s) shall be as specified in the Detail Specification. - optical source type, wavelength and spectral width - return loss measured over the wavelength range or specific wavelength as required by the Detail Specification - launching technique including mode stripping considerations -description of all key equipment -dates of latest calibration of measurement equipment Cable Cut-off Wavelength This is the shortest wavelength, λ cc, at which only the fundamental mode propagates in a single mode optical fibre cable. Measurement of the cable cut off wavelength shall follow the procedure described in IEC optical source type, wavelength and spectral width - measurement results - reference technique used - description of all key equipment - date of calibration of equipment Chromatic Dispersion The chromatic dispersion shall be measured by one of the techniques described in IEC If the capability domain or qualification process applies to cables exceeding 1 km length then any of the techniques described may be used. For shorter lengths only the interferometry technique is applicable. - method used - optical source type and wavelengths used - measurement results - equations used in calculation of results - description of computational techniques - description of all key equipment - date of calibration of equipment Mode Field Diameter The mode field diameter shall be measured in accordance with IEC , by direct far field scan, variable aperture in the far field, or near field scan. The source wavelength shall be the operating wavelength of the optical fibre cable, as specified in the Detail Specification.

23 - method used - optical source type, wavelength and spectral width - mode field diameter - description of computational techniques - description of all key equipment - date of calibration of equipment 9.5 TEMPERATURE LIFE This test shall be performed on a cable sample of the maximum length required by the capability domain or cable assembly qualification. Optical transmittance at the intended operating wavelength shall be measured throughout the test in accordance with para Before and after temperature life testing, the connector engagement and separation force shall be measured as described in paragraph The cable or cable assembly shall be placed in a gravity convected air oven, connected through suitable ports in the oven wall to the measuring equipment outside. The oven shall be maintained at the maximum operating temperature specified in table 1B of the Detail Specification. The cable assembly shall remain in the oven for 2000hrs for qualification testing and 1000hrs for lot acceptance testing. After the test, a visual inspection shall be carried out to look for any damage or other anomalies in the cable structure or connectors. - optical transmittance throughout the test - results of the external visual inspection - changes in connector engagement/separation force 9.6 TEMPERATURE CYCLING This test shall be performed on a cable sample of the maximum length required by the capability domain or cable assembly qualification. Testing category Number of cycles qualification 20 lot acceptance 10 production 5 Changes in optical transmittance shall be measured throughout the test, and a final measurement made on test completion, in accordance with Paras and of this specification. The cable sample shall be placed within the thermal chamber and connected to the optical measuring equipment outside the chamber. The sample is subjected to repetitive temperature cycles. Continuous measurements of cable power transmission shall be made throughout the test. The temperature cycle profile and the time held at each temperature are as detailed in Figure 9.6-1, with T A = minimum operating temperature, T B = maximum operating temperature (as given in table 1B of the Detailed Specification), t 1 = 5mins and the rate of temperature change = 1 C min -1. On completion of the test, the temperature is returned to 22 ± 3 C and the cable sample removed from the chamber. A visual inspection is carried out to look for any damage or other anomalies in the cable structure. - optical transmittance throughout the test - results of the external visual inspection

24 TB Chamber Temp t 1 t 1 Time, t TA 1 cycle Figure RADIATION A radiation test plan and procedure shall be generated in accordance with ESA/SCC Basic Specification No for Gamma radiation testing. Electrical measurements referred to in ESA/SCC Basic Specification No shall be replaced by optical transmission measurements as described in paragraphs and The following additional modifications shall be made for radiation testing of optical fibre cable assemblies: This test shall be performed on a cable assembly of the maximum length required by the capability domain or cable assembly qualification. Additional fibre cables of length as required by the layout of the irradiating facility will be needed to connect the cable under test to remote optical test equipment. The reel used to mount the optical fibre cable under test shall not act as either a radiation shield or sink. The orientation and geometry of the reel shall be chosen so as to meet the dose uniformity requirements of ESA/SCC Basic Specification No The fibre cable should not be wrapped onto the reel so that any bends of less than the minimum recommended radius of curvature of the fibre cable occur. Measurements of the optical fibre cable transmission shall be made, as described in paragraphs and , before testing, continuously throughout the test period, and for a further period of 12 hours after the sample irradiation has ceased, or until the radiation induced loss changes by less than 1% per hour. The ambient temperature shall be maintained at 22 ± 3 C throughout. A radiation test report shall be generated according to ESA/SCC Basic Specification No RAPID DEPRESSURISATION This test shall be performed on a cable assembly of the maximum length required by the capability domain or cable assembly qualification, with 2 short lengths of non-cabled fibre with connectors for feed through to the measuring apparatus at the vacuum chamber ports. The optical attenuation of the cable assembly shall be measured before the test, changes in optical transmittance monitored throughout the test (including during sample transfer), and a final measurement of optical attenuation made on test completion, in accordance with Paras and On completion of initial optical attenuation measurements, the cable assembly shall be placed within the vacuum chamber, with the fibre ends attached to the optical measuring equipment, outside the chamber, via the vacuum feed-through ports.

25 The chamber pressure is then reduced, from atmospheric pressure, until a stable pressure of not more than 1333 Pa is achieved. Pressure shall be reduced in a time of no more than 5 seconds. On completion of the test, the pressure is returned to atmospheric pressure and the cable assembly removed from the chamber. A visual inspection is carried out to look for any damage or other anomalies in the cable structure. - optical transmittance throughout the test - results of the external visual inspection 9.9 VIBRATION Sinusoidal Vibration Testing This test shall be performed on a cable assembly of the maximum length required by the capability domain or cable assembly qualification. Two additional cables with connectors are required for connection to the optical test equipment. The cable shall be place on a reel with wraps sufficiently tight to prevent movement during the test. A sinusoidal vibration generator is required with suitable specimen mounting fixtures for the cable reel and connectors. The cable assembly shall be subjected to vibration along each of three orthogonal axes. amplitudes shall be as follows: The vibration Frequency Amplitude Hz mm pk-pk ms -1 peak velocity g peak acceleration The sweep rate shall be 2 octaves per minute and 1 sweep is required per axis. The optical attenuation of the cable assembly shall be measured before the test, changes in optical transmittance monitored throughout the test and a final measurement of optical attenuation made on test completion, in accordance with Paragraphs and On completion of the test sequence the cable assembly shall undergo an external visual examination to look for any damage caused as a result of the vibration test. - details of cable/connector support mechanism - initial and final optical attenuation - changes in optical transmittance during the test - result of external visual inspection - description of all key equipment - dates of latest calibration of measurement equipment Random Vibration Testing This test shall be carried out as per Sinusoidal Vibration Test (para ), with the following modifications:

26 A random vibration generator is used to vibrate the test sample(s) according to the Power Spectral Density requirements given in the table below and Figure Frequency Hz PSD g 2 Hz db/oct db/oct average acceleration g (rms) 35.4 Random vibration of the test sample(s) is then carried out along each of three orthogonal directions for a period of 2.5 minutes each. Power Spectral Density PSD / g 2 Hz Frequency / Hz Figure details of cable/connector support mechanism - initial and final optical attenuation - changes in optical transmittance during the test - result of external visual inspection - description of all key equipment - dates of latest calibration of measurement equipment Shock This test is carried out as per Sinusoidal Vibration Test (9.9.1), with the following modifications: The shock generator shall be capable of generating a sawtooth pulse approximating the nominal acceleration versus time curve given by the dotted curve in Figure below. Peak acceleration of the nominal pulse, A, shall be 100 g. Duration of the nominal pulse, D, shall be 6 msec. The test sample is subjected to three test measurements along each of three orthogonal directions.

27 1.15A A 0.85A A A 0.2A - 0.2A 0.4D D D Minimum time during which the pulse should be monitored Figure details of cable/connector support mechanism - initial and final optical attenuation - changes in optical transmittance during the test - result of external visual inspection - description of all key equipment - dates of latest calibration of measurement equipment 9.10 PERMANENCE OF MARKING This test shall be carried out in accordance with ESA/SCC Basic Specification No TENSILE PERFORMANCE This test shall be carried out in accordance with IEC , clause 5. This test is intended to measure (a) Induced strain as a function of tensile load on the cable (b) the induced attenuation as a function of tensile load for the cable at the operational wavelength. The cable is loaded into the strain measuring apparatus and set up as per the above reference document, with suitable apparatus to measure the optical transmittance changes throughout the test as per Para The load on the cable shall be increased in steps until the maximum load specified in the Detail Specification has been reached, or the cable has broken. Items (a) and (b), listed above, shall be recorded for each specimen tested. On completion of the test the cable assembly shall undergo an external visual examination to look for any damage caused by the test. - details of cable clamping and loading mechanism - variation of optical attenuation with load

28 - fibre elongation with load - result of external visual inspection - description of all key equipment - dates of latest calibration of measurement equipment 9.12 ABRASION RESISTANCE This test shall be carried out in accordance with IEC , clause 6.1. The test equipment shall be in accordance with the above specification and arranged so that the surface of the cable is worn in parallel with the cable axis, over a length of 10mm ± 1mm and at the frequency defined in the above specification. Test conditions shall be as described in the Detail Specification. On completion of the test the cable assembly shall undergo an external visual examination to look for any damage caused by the test CUT THROUGH RESISTANCE This test shall be carried out in accordance with IEC , clause 15 This test shall be performed in order to check the behaviour of the finished cable if it were to come into contact with metal cutting edges. The test shall be carried out as specified in the above referenced document. The sample shall be placed on the mounting of the equipment so that the cutting needle is perpendicular to the cable axis. The test shall be carried out at ambient conditions and using a needle with diameter as specified in the Detail Specification. The test shall be performed three times. The optical fibre cable shall be moved forward 75mm between tests and turned through an angle of 120, always in the same direction. The load measured during these nine tests shall be 30N for a duration of 5 minutes. The optical attenuation shall be checked before and after the test as detailed in paragraph On completion of the test, the cable shall be visually inspected at 5 x magnification to check for signs of damage CRUSH - result of external visual inspection -optical attenuation before and after each test This test shall be carried out in accordance with IEC , clause 7. The crushing load and duration shall be as specified in the Detail Specification. The cable shall be visually inspected for signs of damage before each new load increment. Measurements of changes in optical transmittance shall be made in accordance with para throughout the test. - result of external visual inspection - changes in optical attenuation during the test

29 9.15 IMPACT RESISTANCE This test shall be carried out in accordance with IEC , clause 8. The impact energy, dimensions of the striking surface and other impact conditions shall be as specified within the Detail Specification. The cable shall be visually inspected for signs of damage after the test. Changes in of optical transmittance shall be monitored during the test in accordance with para result of external visual inspection - optical transmittance changes during the test 9.16 BENDING TESTS Cable Bend This test shall be carried out in accordance with IEC , clause 14, procedure turns of cable shall be wound onto a mandrel of diameter specified in the Detail Specification Changes in optical transmittance shall be monitored during the test in accordance with para result of external visual inspection - optical transmittance changes during the test Repeated Bending This test shall be carried out in accordance with IEC , clause 10. The cable shall be loaded and bent through 200 cycles. The weight of the cable load shall be as specified in the Detail Specification. Optical transmittance shall be measured as a function of the number of bends in accordance with para The bending radius shall be as specified in the Detail Specification. The cable shall undergo a visual inspection after the test. - result of external visual inspection - optical transmittance changes during the test Bend Under Tension This test shall be carried out in accordance with IEC , clause 20, procedure 1. A section of cable assembly exceeding 5m in length shall be bent around a mandrel of radius specified in the Detail Specification and moved at 1ms -1. The cable tension shall be as specified in the Detail Specification. The test shall be repeated for 10 cycles. Afterwards, the cable shall be visually inspected for signs of damage or weakness in the cable sheath. Optical transmittance changes shall be measured during the test in accordance with para

30 - result of external visual inspection - optical transmittance before during and after the test Cold Bend Test To be carried out as for the cable bend under tension test in para , with the following differences: After mounting the cable under test, the assembly shall be placed within a cold chamber and maintained at the minimum storage temperature specified in the Detail Specification for 4 hours. Wrapping shall then commence, as per para , within the chamber. The cable sample shall be removed from the cold chamber and allowed to warm up to room temperature, when the cable shall be wiped with a clean, dry cloth and inspected as in the above mentioned test. Optical attenuation shall be measured before and after the test. - result of external visual inspection - optical attenuation before and after the test Torsion This test shall be carried out in accordance with IEC , clause 11. The apparatus shall be set up as defined in the above reference. The test length shall be 0.5m. Optical transmittance shall be monitored throughout the test. The cable shall undergo a visual inspection on completion of the test. - result of external visual inspection - optical transmittance changes during the test Flexing This test shall be carried out in accordance with IEC , clause 12. The apparatus shall be set up as defined in the above reference, using pulley dimensions and tensioning weights as specified in the Detail Specification. The flexing cycle defined shall be repeated 100 times. Optical transmittance shall be monitored as a function of the number of flex cycles carried out. The cable shall undergo a visual inspection on completion of the test. - result of external visual inspection - optical transmittance changes during the test

31 Kink This test shall be carried out in accordance with IEC , clause 13. A sample length is taken and held in both hands with a loop made in the cable of several times the minimum allowed bend radius. The sample is then pulled steadily at each end, in the same plane, so that the loop diameter reduces to the minimum value as specified in the Detail Specification. No kink, as defined in the above reference, shall occur during this process CONNECTOR CHARACTERISTICS Mating durability One end of a cable assembly shall be mated and unmated with a matching connector on a cable connected to the optical test equipment. This process shall be repeated for 100 cycles. Changes in optical transmittance shall be monitored as described in para Engagement and separation force shall be measured before and after the test as per para and checked to be within the limits stated in the Detail Specification. An external visual inspection shall be carried out on completion of the test. - result of external visual inspection - optical transmittance changes during the test Intermateability This test requires sample cables terminated with connectors from at least 5 different production batches. A test cable assembly from the batch subject to qualification testing shall be mated with each of the sample cables. The optical attenuation shall be measured in accordance with para and return loss in accordance with paragraph Engagement and separation force shall be measured for each combination as per para and checked to be within the limits stated in the Detail Specification. An external visual inspection shall be carried out on the test connector after completion of the test. - result of external visual inspection - optical attenuation of each connector combination - engagement and separation force of each connector combination Engagement and Separation Force The connector set under test is fixed so that controlled coupling force or torque can be applied. The force or torque is measured throughout the coupling and uncoupling cycle. The holding fixtures shall be capable of holding the mating components in such a way that they do not influence the measured torque or force. Proper alignment of the mating components shall be maintained throughout the coupling cycle. - engagement and separation force of each connector combination The limits should be defined in the applicable detailed specification.