CABLE ASSEMBLY,SPEC

| |080101|A|

DOCUMENT REF DATA=MIL-STD-792

|F |060519|A|

DOCUMENT REF DATA=ISO_9001

| |081115|A|

DOCUMENT REF DATA=ISO10012

| |030415|A|

DOCUMENT REF DATA=ISO/IEC 17025

| |050515|A|

DOCUMENT REF DATA=MIL-DTL-24231

|E |130426|A|

DOCUMENT REF DATA=MIL-I-45208

|A |810724|A| 1| · DOCUMENT REF DATA=MIL-STD-45662

|A |880801|A|

DOCUMENT REF DATA=ANSI/NCSL Z540.3

| |130326|A|

DOCUMENT REF DATA=0900-LP-001-7000

| |810101|C| |01| DOCUMENT REF DATA=S9074-AQ-GIB-010/248

|1 |191112|A|

DOCUMENT REF DATA=SS800-AG-MAN-010/P-9290

|A |200324|A| |42| DOCUMENT REF DATA=S9074-AR-GIB-010A/278 (CHG A)

| |130214|A|

DOCUMENT REF DATA=S9320-AM-PRO-020/MLDG

|2 |990801|A|

1. REQUIREMENTS 3.1 ;This Cable Assembly must be manufactured in accordance with Dry Deck Shelter (DDS) procurement specification S-5343934-2, specification sheet S-5343934-2/6, part number 1208101-0109, except as amplified or modified herein.; 3.2 ;MIL-DTL-24231 and the required slash sheets must be used in lieu of MIL-C-24231.; 3.3 Contract Support Library - Additional requirements for this item are identified as Contract Support Library Reference Number ;CSD031; in ECDS at https://register.nslc.navy.mil/ 3.4 The cable assembly must be wired and molded in accordance with volume II of NAVSEA S9320-AM-PRO-020/MLDG by an approved vendor listed in CSD023 of the ECDS (Electronic Contractor Data Submission) system at: https://register.nslc.navy.mil/ 3.4.1 The approved vendor utilized for this contract, if other than the prime manufacturer, must be identified on the Special Emphasis C of C. 3.5 First Article Approval (Contractor Testing) - First Article Test (FAT) and approval is required.

3.6 Each cable assembly must be subjected to the Quality Conformance tests of specification S-5343934-2 Tables 2 and 3; except that Table 3 of S-5343934-2 must be modified by CSD031 of the Contract Support Library. 1. Examination of Product IAW paragraph 3.4 and tested to paragraph 4.6

1. Dielectric Withstanding Voltage IAW paragraph 3.6.1 and tested to paragraph 4.7.1 3.

Continuity IAW paragraph 3.6.2 and tested to paragraph 4.7.2 4. Insulation Resistance IAW paragraph 3.6.3 and tested to paragraph 4.7.3

1. Hydrostatic Pressure IAW paragraph 3.6.4 and tested to paragraph 4.7.4 6.

Post-Test Examination of Product IAW paragraph 4.6.1 3.6.1 Each conformance test must be listed separately on the Navy Special Emphasis Program (NSEP) Certificate of Compliance (C of C) as being performed and found acceptable. 3.7 The pressure tolerance must be as specified in the assembly drawing, detail drawing, design specification or elsewhere in this contract. Where pressure tolerances are not provided by drawings, specifications or specified elsewhere in this contract, the following must be used: For pressure tests below 100 PSIG, the pressure tolerance must be +1 PSIG / -0 PSIG.

For pressure tests at or above 100 PSIG up to and including 2500 PSIG, the pressure tolerance must be +2% / -0 PSIG rounded off to the nearest multiple of the smallest graduation on an analog test pressure gauge, not to exceed 50 PSIG. For pressure tests above 2500 PSIG, the pressure tolerance must be +2% / -0 PSIG, rounded off to the nearest multiple of the smallest graduation on an analog test pressure gauge, not to exceed 200 PSIG. The pressure test time tolerance must be as specified in the assembly drawing, detail drawing, design specification or elsewhere in this contract.

Where pressure test time tolerances are not provided by drawings, specifications or specified elsewhere in this contract, the following must be used: For a test duration up to and including 1 hour, the tolerance must be +5 minutes / - 0 minutes. For a test duration of more than 1 hour up to and including 24 hours, the tolerance must be +30 minutes / - 0 minutes. For a test duration of more than 24 hours, the tolerance must be +60 minutes / - 0 minutes.

3.8 Off-Gassing Analysis is required in accordance with NAVSEA SS800-AG-MAN-010/P-9290A, Appendix F, paragraphs F4.2, F4.3, and F4.4. Off-Gassing Analysis is not required for every lot of stock material (plate, bar, castings, etc.) formed by the same vendor, if NAVSEA SS800-AG-MAN-010/P-9290A, Section F4.4 is satisfied. 3.8.1 Off-Gassing Analysis must be conducted by one of the following labs: 1 ALS Simi Valley Mr.

Michael Conejo 2655 Park Center Dr. Suite A Simi Valley, CA 93065 Phone (805) 577-2083 2 Electric Boat Corp. DSS-ACL Craig Adamson 75 Eastern Point Road Groton, CT 06340-4989 Phone (860) 433-5866 3 Naval Surface Warfare Center - Crane (NSWC-Crane) Mike Jones 300 Highway 361 Bldg 3395 Crane, In 47522-5001 Phone (812) 854-6313 Note: This lab contains the only chamber authorized for ordnance sampling.

4 Naval Experimental Diving Unit (NEDU) Chuck Mayberry 321 Bullfinch Road Panama City, Fl 32407 Phone (850) 230-3163 3.8.2 Each item being supplied for the off-gas test must be odor tested prior to shipment to the off-gas test lab. Perform the odor test per the requirements specified in paragraph F.4.4.1.b of NAVSEA SS800-AG-MAN-010/P-9290A.

Note: The vendor must contact lab to determine test chamber size and depth limitations.

Note: Each shipment of material to be off-gas tested must be accompanied by paperwork identifying the following: - The NSN - The Procuring Activity - The Contract Number - The Serial Numbers of units in shipment 3.8.3 The listed labs have been assessed and accepted; however, due to the requirements of biennial reassessments there could be occasions when a given lab may have restrictions levied on them. It is incumbent upon the customer to contact the lab or NAVSEA 07Q4 to ascertain the current lab status. NAVSEA point of contact is Mr.

Greg Sorrells (SEA 07Q43) at (202)781-0910. 3.9 Welding or Brazing - When welding, brazing, and allied processes are required, as invoked by Section C paragraph 3 requirements, they must be in accordance with S9074-AR-GIB-010A/278, 0900-LP-001-7000 for brazing of piping and pressure vessel applications, or S9074-AQ-GIB-010/248 for brazing of other applications. For all production and repair welding and brazing personnel and procedures must be qualified under S9074-AQ-GIB-010/248 or 0900-LP-001-7000, as applicable.

Procedures and Qualification Data must be submitted for review and approval prior to performing any welding or brazing. 3.10 Mercury Free - Mercury and mercury containing compounds must not be intentionally added or come in direct contact with hardware or supplies furnished under this contract. Mercury contamination of the material will be cause for rejection.

3.11 Configuration Control - The Contractor must maintain the total equipment baseline configuration. For items of proprietary design, Contractor drawings showing the latest assembly configuration must be provided to the Government in electronic (C4) format. Definitions are provided elsewhere in the Contract/Purchase Order.

3.11.1 Waivers/Deviations - All waivers and deviations, regardless of significance or classification require review and approval by the Contracting Officer. Waivers and Deviations must be designated as Critical, Major, or Minor. The Contractor must provide a copy of this request to the QAR.

Requests must include the information listed below. a. A complete description of the contract requirement affected and the nature of the waiver/deviation (non-conformance), including a classification of Critical, Major, or Minor. b. Number of units (and serial/lot numbers) to be delivered in this configuration. c.

Any impacts to logistics support elements (such as software, manuals, spares, tools, and similar) being utilized by Government personnel or impacts to the operational use of the product. d. Information about remedial action being taken to prevent reoccurrence of the non-conformance. 3.11.2 All requests for Waivers/Deviations on NAVSUP-WSS Contracts must be submitted to the NAVSUP WSS Contracting Specialist via eMail.

3.11.3 ECPs - The Government will maintain configuration control and change authority for all modifications or changes affecting form, fit, function, or interface parameters of the Equipment and its sub-assemblies. The Contractor must submit an Engineering Change Proposal (ECP) for any Class I or II changes that impact the Equipment covered by this contract. ECPs must be prepared in Contractor format, and must include the following information: a.

The change priority, change classification (Class I or Class II), and change justification. b. A complete description of the change to be made and the need for that change. c. A complete listing of other Configuration Items impacted by the proposed change and a description of the impact on those CIs. d.

Proposed changes to documents controlled by the Government. e. Proposed serial/lot number effectivities of units to be produced in, or retrofitted to, the proposed configuration. f. Recommendations about the way a retrofit should be accomplished. g.

Impacts to any logistics support elements (such as software, manuals, spares, tools, and similar) being utilized by Government personnel in support of the product. h. Impacts to the operational use of the product. i. Complete estimated life-cycle cost impact of the proposed change. j.

Milestones relating to the processing and implementation of the engineering change. 3.11.4 A copy of the final waiver/deviation (both approved and disapproved) must be forwarded with the applicable asset(s). 3.12 Certificate of Compliance - (SPECIAL EMPHASIS MATERIAL) The Contractor must prepare and submit a certificate of compliance certifying that the items/components furnished under this contract comply with the requirements of the procurement document, including any/all invoked specifications and drawings. ^ QUALITY ASSURANCE REQUIREMENTS ^ 3.13 Quality System Requirements - The Contractor furnishing items under this contract/purchase order must provide and maintain a quality system in accordance with ISO-9001 as amplified or modified herein, with the calibration system requirements of ISO-10012 or ANSI-Z540.3 with ISO-17025.

A Quality System in accordance with MIL-I-45208, with the calibration system requirements of MIL-STD-45662, is acceptable as an alternate. 3.13.1 The Contractor's quality system and products supplied under the system are subject to evaluation, verification inspection, and acceptance/nonacceptance by the Government representative to determine the system's effectiveness in meeting the quality requirements established in the Contract/Purchase Order. 3.13.2 The Contractor's quality system must be documented and must be available for review by the Contracting Officer or his representative prior to initiation of production and throughout the life of the contract.

The Prime Contractor must, upon notification, make his facilities available for audit by the contracting Officer or his authorized representative. 3.13.3 See CDRL DI-QCIC-81110 (Inspection System Procedures) - All suppliers of Deep Submergence Systems Program (DSSP) material are required to submit a copy of their current documented quality system procedures to the Procurement Contracting Officer (PCO) prior to award of any contract/purchase order. Suppliers that have a copy of their current quality system procedures on file at NAVICP-Mech may request the PCO waive this requirement.

3.13.4 This contract provides for the performance of Government Quality Assurance at source. The place or places of performance may not be changed without the authorization of the Procurement Contracting Officer. Upon receipt of this order, promptly notify the Government representative who normally services your plant so that appropriate planning for Government inspection can be accomplished.

If you do not have an assigned Government representative, notify the nearest Defense Contract Management Agency (DCMA) Office. In the event that a local Government representative or DCMA Office cannot be located, our purchasing agent should be notified immediately. 3.13.5 Any changes made by the Contractor to a qualified quality system will require concurrence by the Government Quality Assurance Representative prior to adoption.

3.14 Contractor Inspection Requirements - The Contractor must maintain adequate records of all inspections and tests. The records must indicate the nature and number of observations made, the number and type of deficiencies found, the quantities approved and rejected and the nature of corrective action taken as appropriate. 3.14.1 The supplier's gages, measuring and test equipment must be made available for use by the Government representative when required to determine conformance with Contract requirements.

When conditions warrant, the supplier's personnel must be made available for operations of such devices and for verification of their accuracy and condition. 3.14.2 All documents and reference data applicable to this contract must be available for review by the Government representative. Copies of documents required for Government inspection purposes must be furnished in accordance with the instructions provided by the Government representative.

3.15 Subcontractor Inspection Requirements - The Government has the right to inspect at source, any supplies or services that were not manufactured/performed within the contractor's facility. Such inspection can only be requested by or under authorization of the Government representative. Any purchasing documents to a subcontractor must cite the applicable portions of the contractually invoked quality system (e.g. calibration requirements), plus any product requirements that apply to the supplies being purchased.

When the Government elects to perform source inspection at the subcontractor's facility, applicable purchase documents must be annotated with the following statement: "A Government inspection is required prior to shipment from your plant. Upon receipt of this order, promptly notify the Government representative who normally services your plant so that appropriate planning for Government inspection can be accomplished. If you do not have an assigned Government representative, notify the nearest Defense Contract Management Agency (DCMA) Office.

In the event that a local Government representative DCMA Office cannot be located, our purchasing agent should be notified immediately." 3.16 Government Furnished Material and/or Equipment (GFM/GFE) - When material or equipment is furnished by the Government, the Contractor must develop documented control procedures that require at least the following: 3.16.1 Visual examination upon receipt to detect damage during transit. 3.16.2 Inspection for completeness and proper type. 3.16.3 Verification of material quality received.

3.16.4 Periodic inspection and precautions to assure adequate storage conditions and to guard against damage from handling and deterioration during storage. 3.16.5 Functional testing, either prior to or after installation, or both, as required by the Contract to determine satisfactory operation. 3.16.6 Identification and protection from improper use or disposition.

3.16.7 Reporting to the Government, any GFM or GFE property found damaged, malfunctioning, or otherwise unsuitable for use. In the event of damage or malfunction during or after installation, the supplier must determine and record probable cause and necessity for withholding the material from use. 3.16.8 For GFE material, and as required by the terms of the bailment agreement, the supplier must establish procedures for adequate storage, maintenance, and inspection of bailed Government material.

Records of all inspection and maintenance performed on bailed property must be maintained. 3.16.9 Material returned to the contractor must be handled as GFM. 3.17 Traceability and Certification Requirements - To assure that correct materials are installed in DSSP systems, it is imperative that traceability be maintained from the material to all required Objective Quality Evidence (OQE).

3.17.1 The following provides the minimum requirements for maintaining material traceability and supplements the requirements specified elsewhere in the contract/purchase order. 3.18 Material Traceability - Traceability markings must be permanently applied to the material in accordance with MIL-STD-792 or to a tag affixed to the material, and annotated on the required OQE. The traceability marking may be any vendor traceability number/code which provides complete traceability to the required OQE.

Traceability Marking/Identification may include such items as Nomenclature, Part Number, Technical Description, National Stock Number (NSN), etc. Traceability must be maintained through all process operations including any subcontracted operations, to the finished component. 3.18.1 When traceability markings on the material would be removed by a manufacturing or fabrication process, the marking must be recorded prior to removal and be immediately restored upon completion of the process.

If this cannot be done or is impractical, an appropriate material control procedure (such as a bag and tag, tagging, and/or tote box control) must be employed. The material control procedure must provide a method of positive control to preclude commingling of material or loss of traceability. The traceability marking must be reapplied upon completion of the final manufacturing process.

3.18.2 The material control process must include requirements for the maintenance of traceability for items sent out for subcontracted operations. If such operations would remove traceability markings on the material, purchase or work orders must specify a method and marking location for remarking. The contractor must also ensure that subcontractor production controls are adequate to preclude commingling of materials during processing.

3.19 Final Inspection - The following inspections must be performed prior to Government inspection and acceptance. 3.19.1 Material Sampling - Material must be inspected for form, fit, and function. Lot acceptance must be based on zero defects and lot rejection based on one defect.

The sample size must be in accordance with the sampling plan(s) in the applicable military specification or standard, federal specification or standard, or drawing to which the material was manufactured. In the absence of such sampling plans, sampling inspection must be per ANSI/ASQ-Z1.4, general inspection level II (for sample size selection code), table IIA (for sample size). SMALL LOT SIZES - For lot sizes of fifty or less, the minimum sample size must be eight units.

For lot sizes of eight or less, the sample size must be one hundred percent of the lot. 3.19.2 The Manufacturer may elect to use Statistical Process Control (SPC) to assure product quality in lieu of the above attribute sampling plan, provided that the SPC methodology/system used provides acceptable products to the Government. However, the Government Inspection Activity may perform their acceptance inspection of the material using the attribute sampling plan outlined above.

3.19.3 All OQE required by the Contract and all data concerning material traceability (OQE to traceability marking) must be 100% inspected. The certification test reports must also be 100% inspected for completeness and legibility. 3.20 Test Certification - When test certifications are required elsewhere in the contract, certification documents must be positive and unqualified.

Disclaimers such as "to the best of our knowledge" or "we believe the information contained herein is true" are not acceptable. 3.20.1 If material is received without the required test certification papers or with incorrect/missing data on the certification papers, the material will be rejected. 3.21 See CDRL DI-NDTI-80809 (First Article Testing) - First Article Test/Inspection (Contractor) - The Contractor must conduct ;destructive; First Article Test/Inspection on ;one cable assembly, consisting of one-three contact plug assembly with 90 degree backshell, one-seven contact straight plug assembly, and one conduit 30 inches long; unit(s) in accordance with requirements ;of S-5343934-2 paragraph 4.4; .

3.22 See DI-MISC-80678 (SOC OFF-GASSING ANALYSIS) - Non-Metallic Material off-gassing test reports must, as a minimum, record the following data per NAVSEA SS800-AG-MAN-10/P9290, Appendix F: a. Testing facility name, address, and phone number. b. Date material tested. c.

A positive statement that material composition was reviewed by NAVSEA to identify any additional target or non-target compounds prior to testing (See note below). d. Lot or batch number of material. e. Material chemical name or product name, model number, and serial number forend items/complete assemblies. f.

Manufacturer of material. g. Sample weight. h. Sample surface area. i.

Curing procedure - a description of pretest curing (include cure time and conditions) or burn-in operation (when applicable). j. Pressure and volume of test chamber. k. Temperature of test chamber.

Indicate whether or not the electrical equipment/assembly was energized based on burn-in bench testing results. l. Total time specimen was in chamber before chemical analysis. m. Signature and date of test director. n.

Test results:

1. List of constituents analyzed or identified.
2. Method of analysis used to analyze constituent (see Table F-5).
3. Allowable limit of each constituent (see Section F.6).
4. Reporting limit for each constituent (see paragraph F.5.4.c).
5. Absolute measured level of each constituent.
6. Normalized measured level of each constituent (ppm/L or ppm/g/L - see paragraph F.4.2.c)
7. Evidence of odor before and after the test (see paragraph F.4.4.1.b).
8. Curing/burn-in testing results, including cure time and cure conditions (e.g., temperature, pressure, cleaning, etc.).

If burn-in bench testing of powered equipment was done prior to off-gas testing, annotate that along with test conditions.

Note: The product name, including model and serial number, for end items may be used for complete equipment assemblies (also known as Commercial Off the Shelf (COTS) material) when the material chemical name is unknown. The testing activity must attempt to identify the non-metallic material of complete equipment assemblies and provide them when available. This option is not allowed for non-metallic material that is fabricated from raw non-metallic material that is fabricated from raw non-metallic material.

The activity requesting laboratory off-gas testing must provide the Safety Data Sheet (SDS) to the appropriate Program Manager to ascertain whether additional target compounds or non-target compounds need to be looked for during the off-gas testing (See Section F.5.3.d). The non-metallic material off-gas test reports must be evaluated in accordance with Section F.6. All off-gas test reports will be retained and maintained in a manner suitable for audit.

Non-metallic off-gas test reports that are used to qualify a specific material or are being used in lieu of the testing specified in Section F.5.5 must be submitted to the Program Manager for approval and will be maintained to support DSS certification. 3.23 See CDRLs DI-MISC-80875 (welding procedures) and DI-MISC-80876 (weld procedure qualification data) - When production or repair welding is required, the applicable welding procedure(s) and qualification data must be submitted for review and approval.

Note: These requirements do not apply to tack/spot welds. 3.23.1 Approval of the Contractor's qualification data must be obtained prior to performing any welding (production or repair). 3.23.2 If the Contractors qualification data has previously been approved by the Navy for other contracts, a copy of the original approval letter may be submitted along with the procedures and qual...