SIST EN 16602-70-18:2015
(Main)Space product assurance - Preparation, assembly and mounting of RF coaxial cables
Space product assurance - Preparation, assembly and mounting of RF coaxial cables
This Standard defines the technical requirements and quality assurance provisions for the assembly and mounting of highreliability, radiofrequency (RF) coaxialcable interconnections for use as transmission lines in spacecraft and associated equipment.
In general, these assemblies are designed for lowloss, stable operation from the relatively low frequencies through the higher frequencies
in the microwave regions.
These transmissionline cables should not be confused with lowfrequency cables with conductive sheaths (usually copper braid), which are used in applications where shielding of the centre conductors from the surrounding electrical ambient is required. The interconnection of
those shielded cables, not covered by the present standard, is covered in ECSS-Q-ST-70-08.
This standard may be tailored for the specific characteristics and constrains of a space project in conformance with ECSS-S-ST-00.
Raumfahrtproduktsicherung - Vorbereitung, Zusammenbau und Befestigung von RF-Koaxial-Kabeln
Assurance produit des projets spatiaux - Préparation, assemblage et montage des câbles radiofréquence coaxiaux
La présente norme définit les exigences techniques et les dispositions d’assurance qualité relatives à l'assemblage et au montage d'interconnexions en câble coaxial radiofréquences (RF) destinées à servir de lignes de transmission à bord d'engins spatiaux et d'équipements associés.
En général, ces ensembles sont conçus pour un fonctionnement stable, à faibles pertes, allant de fréquences relativement basses jusqu'à des fréquences plus élevées dans la gamme des micro-ondes.
Il convient de ne pas confondre ces câbles de ligne de transmission avec les câbles basse fréquence à gaines conductrices (en général une tresse de cuivre), utilisés dans les applications où il est exigé de disposé d'un blindage des conducteurs centraux pour les isoler de l'environnement électrique ambiant. L'interconnexion de ces câbles blindés, non couverte par la présente norme, est traitée dans l'ECSS-Q-ST-70-08.
La présente norme peut être adaptée aux caractéristiques et contraintes spécifiques à un projet spatial, selon la norme ECSS-S-ST-00.
Zagotavljanje varnih proizvodov v vesoljski tehniki - Pripravljanje, sestavljanje in pritrjevanje RF-koaksialnih kablov
Ta standard določa tehnične zahteve in določbe za zagotavljanje kakovosti za sestavljanje in pritrjevanje visoko zanesljivih medsebojnih povezav z RF-koaksialnimi kabli za uporabo kot prenosni vodi v vesoljskih plovilih ter povezani opremi. Na splošno so ti sestavi namenjeni za stabilno delovanje z majhnimi izgubami od razmeroma nizkih frekvenc prek višjih frekvenc v mikrovalovnih regijah. Ti kabli za prenosne vode naj se ne bi zamenjali z nizkofrekvenčnimi kabli s prevodnimi plašči (običajno bakreni oplet), ki se uporabljajo, kadar je potrebno ščitenje središčnih vodnikov pred bližnjo električno okolico. Medsebojno povezovanje teh zaščitenih kablov, ki ni obravnavano v tem standardu, je obravnavajo v standardu ECSS-Q-ST-70-08. Ta standard se lahko prilagodi posameznim lastnostim in omejitvam vesoljskega projekta v skladu s standardom ECSS-S-ST-00.
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 16602-70-18:2015
01-januar-2015
Zagotavljanje varnih proizvodov v vesoljski tehniki - Pripravljanje, sestavljanje in
pritrjevanje RF-koaksialnih kablov
Space product assurance - Preparation, assembly and mounting of RF coaxial cables
Raumfahrtproduktsicherung - Vorbereitung, Zusammenbau und Befestigung von RF-
Koaxial-Kabeln
Assurance produit des projets spatiaux - Préparation, assemblage et montage des
câbles radiofréquence coaxiaux
Ta slovenski standard je istoveten z: EN 16602-70-18:2014
ICS:
49.060 /HWDOVNDLQYHVROMVND Aerospace electric
HOHNWULþQDRSUHPDLQVLVWHPL equipment and systems
SIST EN 16602-70-18:2015 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
---------------------- Page: 1 ----------------------
SIST EN 16602-70-18:2015
---------------------- Page: 2 ----------------------
SIST EN 16602-70-18:2015
EUROPEAN STANDARD
EN 16602-70-18
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2014
ICS 49.090; 49.140
English version
Space product assurance - Preparation, assembly and mounting
of RF coaxial cables
Assurance produit des projets spatiaux - Préparation, Raumfahrtproduktsicherung - Vorbereitung, Zusammenbau
assemblage et montage des câbles radiofréquence und Befestigung von RF-Koaxial-Kabeln
coaxiaux
This European Standard was approved by CEN on 11 April 2014.
CEN and CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving
this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning
such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN and CENELEC
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN and CENELEC member into its own language and notified to the CEN-CENELEC Management Centre
has the same status as the official versions.
CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
CEN-CENELEC Management Centre:
Avenue Marnix 17, B-1000 Brussels
© 2014 CEN/CENELEC All rights of exploitation in any form and by any means reserved Ref. No. EN 16602-70-18:2014 E
worldwide for CEN national Members and for CENELEC
Members.
---------------------- Page: 3 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
Table of contents
Foreword . 5
Introduction . 6
1 Scope . 7
2 Normative references . 8
3 Terms, definitions and abbreviated terms . 9
3.1 Terms from other standards . 9
3.2 Terms specific to the present standard . 9
3.3 Abbreviated terms. 9
4 Principles and prerequisites of reliable soldered or crimped cable
connections . 10
4.1 Principles of reliable soldered or crimped semi-rigid cable connections . 10
4.2 Prerequisites for assembly and mounting of semi-rigid coaxial cables . 10
4.3 Alternative coaxial cable technologies . 11
5 Requirements . 12
5.1 Preparatory conditions . 12
5.1.1 Facility cleanliness . 12
5.1.2 Environmental conditions . 12
5.1.3 Lighting requirements . 13
5.1.4 Equipment and tools . 13
5.2 Material selection . 15
5.2.1 Solder . 15
5.2.2 Flux . 16
5.2.3 Solvents . 16
5.2.4 Cable selection . 17
5.2.5 Connector selection . 17
5.3 Preparation of semi-rigid cable . 18
5.3.1 General . 18
5.3.2 Inspection of cable . 18
5.3.3 Cutting cable to initial oversize length . 18
2
---------------------- Page: 4 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
5.3.4 Cable forming and minimum bend radius . 18
5.3.5 Preconditioning heat treatment. 19
5.3.6 Trimming cable to final length . 20
5.3.7 Stripping the cable ends . 21
5.3.8 Inspection of stripped cable ends . 21
5.4 Preparation for soldering assembly of semi-rigid cables . 22
5.4.1 General . 22
5.4.2 Degolding and pretinning . 22
5.4.3 Solder preforms . 23
5.5 Assembly of connectors to RF coaxial cables . 24
5.5.1 Solder assembly of semi-rigid cables . 24
5.5.2 Crimp assembly of semi-rigid cables and other assembly techniques . 28
5.5.3 Completed assemblies . 28
5.6 Mounting of cables. 29
5.6.1 Semi-rigid cables with straight solder-type connectors . 29
5.6.2 Semi-rigid cables with right-angle connectors . 30
5.6.3 Other cable mounting technologies . 30
5.7 Process verification . 31
5.7.1 General . 31
5.7.2 Temperature cycling . 31
5.7.3 Vibration . 31
5.8 Quality assurance . 31
5.8.1 Data . 31
5.8.2 Nonconformance . 32
5.8.3 Calibration . 32
5.8.4 Traceability . 32
5.8.5 Workmanship standards. 32
5.8.6 Inspection . 32
5.8.7 Operator and inspector training and certification . 33
Annex A (normative) Logbook – DRD . 34
A.1 DRD identification . 34
A.1.1 Requirement identification and source document . 34
A.1.2 Purpose and objective . 34
A.2 Expected response . 34
A.2.1 Scope and content . 34
A.2.2 Special remarks . 34
Annex B (normative) Workmanship standards . 35
3
---------------------- Page: 5 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
B.1 Overview . 35
B.2 Illustrations . 35
Annex C (informative) Graphical information . 37
C.1 Overview . 37
C.2 Typical cable cut-off fixture . 37
C.3 Typical cable-forming tool . 38
C.4 Approved and non-approved straight solder-type cable-end connectors . 39
C.5 Method of producing solder performs. 40
C.6 Centre contact assembly . 40
Bibliography . 41
Figures
Figure B-1 : Photograph showing non-captive nut and preferred solder fillet . 35
Figure B-2 : Microsection through preferred solder fillet, revealing full penetration of
solder path . 35
Figure B-3 : Unacceptable solder fillet dimensions . 36
Figure C-1 : Typical cable cut-off fixture . 37
Figure C-2 : Typical cable-forming tool . 38
Figure C-3 : Approved and non-approved straight solder-type cable-end connectors . 39
Figure C-4 : Method of producing solder preforms . 40
Figure C-5 : Centre contact assembly . 40
Tables
Table 5-1: Design rules for minimum bend radius . 19
Table 5-2: Preconditioning heat treatment process . 20
4
---------------------- Page: 6 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
Foreword
This document (EN 16602-70-18:2014) has been prepared by Technical
Committee CEN/CLC/TC 5 “Space”, the secretariat of which is held by DIN.
This standard (EN 16602-70-18:2014) originates from ECSS-Q-ST-70-18C.
This European Standard shall be given the status of a national standard, either
by publication of an identical text or by endorsement, at the latest by April 2015,
and conflicting national standards shall be withdrawn at the latest by April
2015.
Attention is drawn to the possibility that some of the elements of this document
may be the subject of patent rights. CEN [and/or CENELEC] shall not be held
responsible for identifying any or all such patent rights.
This document has been prepared under a mandate given to CEN by the
European Commission and the European Free Trade Association.
This document has been developed to cover specifically space systems and has
therefore precedence over any EN covering the same scope but with a wider
domain of applicability (e.g. : aerospace).
According to the CEN-CENELEC Internal Regulations, the national standards
organizations of the following countries are bound to implement this European
Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic,
Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United
Kingdom.
5
---------------------- Page: 7 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
Introduction
The main part of this Standard is based on industrial experience and
recommendations from European soldering technology experts. Modifications
are incorporated into the text to provide for the specific requirement of
low-outgassing electrical systems which are required by scientific and
application satellites. Other additions were made in the light of recent
technological advances and results of metallurgical test programmes. The use of
processes other than solder assembly is recognized, but only certain general
requirements are given in this Standard.
These requirements apply to assemblies designed to operate within the
temperature limits from -45 °C to +85 °C. More extreme temperatures or other
unusual environmental applications require special design measures or
processing steps to provide environmental survival capability.
6
---------------------- Page: 8 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
1
Scope
This Standard defines the technical requirements and quality assurance
provisions for the assembly and mounting of high-reliability, radio-frequency
(RF) coaxial-cable interconnections for use as transmission lines in spacecraft
and associated equipment.
In general, these assemblies are designed for low-loss, stable operation from the
relatively low frequencies through the higher frequencies in the microwave
regions.
These transmission-line cables should not be confused with low-frequency
cables with conductive sheaths (usually copper braid), which are used in
applications where shielding of the centre conductors from the surrounding
electrical ambient is required. The interconnection of those shielded cables, not
covered by the present standard, is covered in ECSS-Q-ST-70-08.
This standard may be tailored for the specific characteristics and constrains of a
space project in conformance with ECSS-S-ST-00.
7
---------------------- Page: 9 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
2
Normative references
The following normative documents contain provisions which, through
reference in this text, constitute provisions of this ECSS Standard. For dated
references, subsequent amendments to, or revision of any of these publications
do not apply, However, parties to agreements based on this ECSS Standard are
encouraged to investigate the possibility of applying the more recent editions of
the normative documents indicated below. For undated references, the latest
edition of the publication referred to applies.
EN reference Reference in text Title
EN 16601-00-01 ECSS-S-ST-00-01 ECSS system — Glossary of terms
EN 16602-10-09 ECSS-Q-ST-10-09 Space product assurance — Nonconformance control
system
EN 16602-20 ECSS-Q-ST-20 Space product assurance — Quality assurance
EN 16602-60 ECSS-Q-ST-60 Space product assurance — Electrical, electronic and
electromechanical (EEE) components
EN 16602-70-02 ECSS-Q-ST-70-02 Space product assurance — Thermal vacuum
outgassing test for the screening of space materials
EN 16602-70-08 ECSS-Q-ST-70-08 Space product assurance — Manual soldering of
high-reliability electrical connections
EN 16602-70-26 ECSS-Q-ST-70-26 Space product assurance — Crimping of
high-reliability electrical connections
EN 16602-70-28 ECSS-Q-ST-70-28 Space product assurance — Repair and modification
of printed circuit board assemblies
MIL-C-17G(3) SUP1 General specification for cables, radio frequency,
flexible and semi-rigid. (8 Jan 1996)
8
---------------------- Page: 10 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
3
Terms, definitions and abbreviated terms
3.1 Terms from other standards
For the purpose of this Standard, the terms and definitions from ECSS-S-ST-00-01
apply, in particular for the following terms:
requirement
3.2 Terms specific to the present standard
3.2.1 minimum bend radius
inside radius of the bend measured on the outer surface of the cable
3.3 Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01
and the following apply:
Abbreviation Meaning
fluorinated ethylene propylene
FEP
polytetrafluoroethylene
PTFE
sub miniature version A
SMA
voltage standing wave ratio
VSWR
9
---------------------- Page: 11 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
4
Principles and prerequisites of reliable
soldered or crimped cable connections
4.1 Principles of reliable soldered or crimped semi-rigid
cable connections
Reliable soldered or crimped connections result from proper design, control of
tools, materials and work environments and careful workmanship.
The basic design concepts, adherence to which ensures reliable connections and
prevents joint failure, are:
a. Avoidance of dimensional mismatch between the coaxial-cable assembly
and the units being connected; i.e. not forcing the semi-rigid cable
assembly into position and thereby cracking or pre-stressing one of the
joints.
b. Use of cable-end connectors with retractable (non-captive) coupling nuts;
after completion of mounting, the coaxial-cable assembly is not in a state
of tension resulting from axial movement when the connectors are
threaded together.
c. Minimizing the internal stresses on the soldered or crimped connections
resulting from exposure to thermal cycling.
NOTE The thermal coefficient of expansion of the
dielectric is about ten (10) times that of copper and
in service this can introduce a tensile stress on the
joint.
d. The various assembly and mounting processes are covered by
quality-control inspection steps.
4.2 Prerequisites for assembly and mounting of
semi-rigid coaxial cables
Each supplier maintains documented soldering or crimping programmes which
meet the requirements of this Standard for the types of connections employed
and the articles involved. The programmes include procedures for training,
certification, maintenance of certified status, recertification and revocation of
certified status for soldering, crimping and inspection personnel. The supplier
also prepares and has readily available workmanship standards consisting of
10
---------------------- Page: 12 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
satisfactory work samples or visual aids which clearly illustrate the quality
characteristics for all connections involved, including the applicable
illustrations in Annex B of this Standard.
Records are kept to provide identification between the finished product and the
operator. Records are also maintained of the training, testing and certification
status of assembly operators. Records are retained for at least one year, or
longer if this is a specific requirement of the customer’s project.
Equipment and tools are verified and calibrated periodically for proper
operation, and records of tool calibration and verification are maintained (see
clause 5.8).
For soldering or crimping requirements not covered in this Standard, the
supplier submits a process procedure including all pertinent quality
requirements to the customer’s relevant project office for approval in
accordance with ECSS-Q-ST-70.
4.3 Alternative coaxial cable technologies
Alternative coaxial cable technologies are accepted for application in individual
customer programmes following the completion of qualification and batch
acceptance test programmes in accordance with clause 5.7. The precise
test-programme and results are subject to review and acceptance by the
relevant customer programme. For materials used in the alternative technology
see ECSS-Q-ST-70-71.
Some mounting requirements for alternative technologies are given in clause
5.6.3 of this Standard.
11
---------------------- Page: 13 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
5
Requirements
5.1 Preparatory conditions
5.1.1 Facility cleanliness
a. Unless classified as a cleanroom, the supplier shall maintain the areas in
which soldering is carried out in a neat orderly fashion with no loose
material that can cause contamination of the soldered connection.
NOTE Examples for loose material are dirt, dust, solder
particles, oils and clipped wires.
b. The supplier shall keep furniture to a minimum in the work areas and be
arranged to allow easy and thorough cleaning of the floor.
c. A washroom and eating, drinking and smoking facilities shall be located
close to, but outside, the soldering areas.
d. The supplier shall cover working surfaces with an easily cleaned hard
top or have a replaceable surface of clean, non-corrosive silicone-free
paper.
e. The supplier shall only use clean tools in the soldering operation.
f. The supplier shall remove excess lubricants from the tools before
soldering starts.
g. Before assembly, wire, terminal and connector contacts shall be visually
examined for cleanliness, absence of oil films and freedom from tarnish
or corrosion.
5.1.2 Environmental conditions
a. The supplier shall have an assembly area which has a controlled
environment that limits entry of contamination.
b. The supplier shall maintain the following environmental conditions in
the area:
1. Room temperature: (22 ± 3) °C
2. Relative humidity at room temperature (55 ± 10) %.
c. The work stations shall not be exposed to draughts.
12
---------------------- Page: 14 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
d. The supplier shall use a filter system to supply fresh air to the room, so
that there is a positive pressure difference with respect to adjacent rooms.
5.1.3 Lighting requirements
a. The supplier shall ensure a lighting intensity of a minimum of 1 080 lux
on the work surface.
b. The supplier shall ensure that at least 90 % of the work area is
shadowless and without severe reflections.
5.1.4 Equipment and tools
5.1.4.1 Brushes
a. The supplier shall use brushes for cleaning, provided that they do not
scratch the metal surface to be cleaned or damage adjacent materials
beyond their visual inspection requirements.
NOTE Medium-stiff natural- or synthetic-bristle brushes
can be used.
b. The supplier shall clean these brushes before use in a solvent prescribed
in clause 5.2.3.
c. The supplier shall not use wire brushes.
5.1.4.2 Files
a. The supplier shall use smooth, single cut and mill type files for dressing
copper soldering-iron tips and removing burrs from the conductor.
b. The supplier shall not use files on surface-treated tips or pretinned items.
NOTE Nickel plated is an example for surface-treatment.
c. The supplier shall keep the files in a good condition and shall be cleaned
before use.
d. The supplier shall not keep the files in a cleanroom environment.
5.1.4.3 Cutting tools
a. The supplier shall use at least the following cutting tools for the
preparation of the semi-rigid cable:
1. jeweller’s saws having fine teeth;
NOTE A 0,28 mm - 0,33 mm blade is preferred.
2. single edged razor blades;
3. wire cutters.
b. The supplier shall use the jeweller’s saw together with a cable clamping
device.
13
---------------------- Page: 15 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
NOTE An example of such a cable clamping device is
shown in Figure C-1.
c. The supplier shall cut the dielectric and inner conductor with a tool that
produces a clean, smooth-cut surface along the entire cutting edge.
d. The supplier shall not perform any twisting action during this cutting
operation.
5.1.4.4 Cable-forming tools
a. The supplier shall use bending jigs to form the cable to predetermined
shapes as identified by the engineering drawing.
NOTE An example of such a bending jig is shown in
Figure C-2.
b. The supplier shall use roller sizes consistent with each cable diameter.
c. The supplier shall use this equipment in such a way that it does not
introduce dents, nicks, wrinkles or cracks in the cable outer conductor.
5.1.4.5 Cable stripping and dressing tools
a. The supplier shall use cable stripping and dressing tools in such a way
that they do not twist, ring, nick, or score the underlying material
surface.
NOTE Many pieces of commercially available equipment
exist to strip the outer conductor or the dielectric
material. These can be automatic, power-driven
devices with precision factory-set non-adjustable
cutting and stripping dies, or precision hand-type
strippers with accurately machined cutting heads.
b. The supplier shall perform either periodic calibration or sample
evaluation during a production run.
5.1.4.6 Heat-treatment chamber
a. The supplier shall use thermal cycling cabinets, ovens, refrigeration units
or cold chambers capable of maintaining temperatures between -50 °C
and +90 °C
NOTE Under certain circumstances (see Table 5-2 step
3.3) greater temperature extremes can be required.
b. The supplier shall calibrate the working zone to within ±5 °C.
5.1.4.7 Soldering equipment
a. The supplier shall accomplish one of the following soldering methods
that conforms to the requirements on “Equipment and tools” of ECSS-Q-
ST-70-08:
1. by hand or
2. by using a resistance heating unit or
14
---------------------- Page: 16 ----------------------
SIST EN 16602-70-18:2015
EN 16602-70-18:2014 (E)
3. other contact heat source
b. When non-contact heat sources are utilized, the supplier shall set up,
operate and demonstrate to the satisfaction of the customer that the
particular method and schedule produces joints of an acceptable
standard.
NOTE This includes verification testing as detailed in
clause 5.7.
5.1.4.8 Crimping equipment
a. The supplier shall use the settings recommended by the tool
manufacturer as a guide.
NOTE This is necessary since manual crimping tools are
available; they are custom designed and applicable
only for particular connector shells.
b. The supplier shall set up the tool for the cable and connector types by a
detailed calibration programme based on the requirements of ECSS-Q-
ST-70-26.
c. The supplier shall perform verification testing as detailed in clause 5.7.
5.1.4.9 Assembly equipment, tools and processes for other
technologies
a. The supplier shall only use the equipment, tools, and processes for the
assembly of the cables and connectors that are designed to avoid damage
or degradation of the cables and connectors.
NOTE The equipment, tools, and processes can be subject
to a manufacturing audit by the customer before
application in their programme.
5.1.4.10 Defective or uncalibrated equipment or tools
a. The supplier shall promptly remove and replace defective or
uncalibrated equipment or tools from the work areas.
5.2 Material selection
5.2.1 Solder
a. The supplier shall use solder ribbon, wire and preforms, provided that
the alloy and flux conform to the requirements on “material selection” of
ECSS-Q-ST-70-08.
NOTE 1 The following solder alloys
...
SLOVENSKI STANDARD
kSIST FprEN 16602-70-18:2014
01-februar-2014
Zagotavljanje varnih proizvodov v vesoljski tehniki - Pripravljanje, sestavljanje in
pritrjevanje RF koaksialnih kablov
Space product assurance - Preparation, assembly and mounting of RF coaxial cables
Raumfahrtproduktsicherung - Vorbereitung, Zusammenbau und Befestigung von RF-
Koaxial-Kabeln
Assurance produit des projets spatiaux - Préparation, assemblage et montage des
câbles radiofréquence coaxiaux
Ta slovenski standard je istoveten z: FprEN 16602-70-18
ICS:
49.090 2SUHPDLQLQVWUXPHQWLY On-board equipment and
]UDþQLKLQYHVROMVNLKSORYLOLK instruments
49.140 Vesoljski sistemi in operacije Space systems and
operations
kSIST FprEN 16602-70-18:2014 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
---------------------- Page: 1 ----------------------
kSIST FprEN 16602-70-18:2014
---------------------- Page: 2 ----------------------
kSIST FprEN 16602-70-18:2014
EUROPEAN STANDARD
FINAL DRAFT
FprEN 16602-70-18
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2013
ICS 49.090; 49.140
English version
Space product assurance - Preparation, assembly and mounting
of RF coaxial cables
Assurance produit des projets spatiaux - Préparation, Raumfahrtproduktsicherung - Vorbereitung, Zusammenbau
assemblage et montage des câbles radiofréquence und Befestigung von RF-Koaxial-Kabeln
coaxiaux
This draft European Standard is submitted to CEN members for unique acceptance procedure. It has been drawn up by the Technical
Committee CEN/CLC/TC 5.
If this draft becomes a European Standard, CEN and CENELEC members are bound to comply with the CEN/CENELEC Internal
Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN and CENELEC in three official versions (English, French, German). A version in any
other language made by translation under the responsibility of a CEN and CENELEC member into its own language and notified to the
CEN-CENELEC Management Centre has the same status as the official versions.
CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
CEN-CENELEC Management Centre:
Avenue Marnix 17, B-1000 Brussels
© 2013 CEN/CENELEC All rights of exploitation in any form and by any means reserved Ref. No. FprEN 16602-70-18:2013 E
worldwide for CEN national Members and for CENELEC
Members.
---------------------- Page: 3 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
Table of contents
Foreword . 5
Introduction . 6
1 Scope . 7
2 Normative references . 8
3 Terms, definitions and abbreviated terms . 9
3.1 Terms from other standards . 9
3.2 Terms specific to the present standard . 9
3.3 Abbreviated terms. 9
4 Principles and prerequisites of reliable soldered or crimped cable
connections . 10
4.1 Principles of reliable soldered or crimped semi-rigid cable connections . 10
4.2 Prerequisites for assembly and mounting of semi-rigid coaxial cables . 10
4.3 Alternative coaxial cable technologies . 11
5 Requirements . 12
5.1 Preparatory conditions . 12
5.1.1 Facility cleanliness . 12
5.1.2 Environmental conditions . 12
5.1.3 Lighting requirements . 13
5.1.4 Equipment and tools . 13
5.2 Material selection . 15
5.2.1 Solder . 15
5.2.2 Flux . 16
5.2.3 Solvents . 16
5.2.4 Cable selection . 17
5.2.5 Connector selection . 17
5.3 Preparation of semi-rigid cable . 18
5.3.1 General . 18
5.3.2 Inspection of cable . 18
5.3.3 Cutting cable to initial oversize length . 18
2
---------------------- Page: 4 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
5.3.4 Cable forming and minimum bend radius . 18
5.3.5 Preconditioning heat treatment. 19
5.3.6 Trimming cable to final length . 20
5.3.7 Stripping the cable ends . 21
5.3.8 Inspection of stripped cable ends . 21
5.4 Preparation for soldering assembly of semi-rigid cables . 22
5.4.1 General . 22
5.4.2 Degolding and pretinning . 22
5.4.3 Solder preforms . 23
5.5 Assembly of connectors to RF coaxial cables . 24
5.5.1 Solder assembly of semi-rigid cables . 24
5.5.2 Crimp assembly of semi-rigid cables and other assembly techniques . 28
5.5.3 Completed assemblies . 28
5.6 Mounting of cables. 29
5.6.1 Semi-rigid cables with straight solder-type connectors . 29
5.6.2 Semi-rigid cables with right-angle connectors . 30
5.6.3 Other cable mounting technologies . 30
5.7 Process verification . 31
5.7.1 General . 31
5.7.2 Temperature cycling . 31
5.7.3 Vibration . 31
5.8 Quality assurance . 31
5.8.1 Data . 31
5.8.2 Nonconformance . 32
5.8.3 Calibration . 32
5.8.4 Traceability . 32
5.8.5 Workmanship standards. 32
5.8.6 Inspection . 32
5.8.7 Operator and inspector training and certification . 33
Annex A (normative) Logbook – DRD . 34
A.1 DRD identification . 34
A.1.1 Requirement identification and source document . 34
A.1.2 Purpose and objective . 34
A.2 Expected response . 34
A.2.1 Scope and content . 34
A.2.2 Special remarks . 34
Annex B (normative) Workmanship standards . 35
3
---------------------- Page: 5 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
B.1 Overview . 35
B.2 Illustrations . 35
Annex C (informative) Graphical information . 37
C.1 Overview . 37
C.2 Typical cable cut-off fixture . 37
C.3 Typical cable-forming tool . 38
C.4 Approved and non-approved straight solder-type cable-end connectors . 39
C.5 Method of producing solder performs. 40
C.6 Centre contact assembly . 40
Bibliography . 41
Figures
Figure B-1 : Photograph showing non-captive nut and preferred solder fillet . 35
Figure B-2 : Microsection through preferred solder fillet, revealing full penetration of
solder path . 35
Figure B-3 : Unacceptable solder fillet dimensions . 36
Figure C-1 : Typical cable cut-off fixture . 37
Figure C-2 : Typical cable-forming tool . 38
Figure C-3 : Approved and non-approved straight solder-type cable-end connectors . 39
Figure C-4 : Method of producing solder preforms . 40
Figure C-5 : Centre contact assembly . 40
Tables
Table 5-1: Design rules for minimum bend radius . 19
Table 5-2: Preconditioning heat treatment process . 20
4
---------------------- Page: 6 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
Foreword
This document (FprEN 16602-70-18:2013) has been prepared by Technical
Committee CEN/CLC/TC 5 “Space”, the secretariat of which is held by DIN
(Germany).
This document (FprEN 16602-70-18:2013) originates from ECSS-Q-ST-70-18C.
This document is currently submitted to the Unique Acceptance Procedure.
This document has been developed to cover specifically space systems and will
the-refore have precedence over any EN covering the same scope but with a
wider do-main of applicability (e.g. : aerospace).
5
---------------------- Page: 7 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
Introduction
The main part of this Standard is based on industrial experience and
recommendations from European soldering technology experts. Modifications
are incorporated into the text to provide for the specific requirement of
low-outgassing electrical systems which are required by scientific and
application satellites. Other additions were made in the light of recent
technological advances and results of metallurgical test programmes. The use of
processes other than solder assembly is recognized, but only certain general
requirements are given in this Standard.
These requirements apply to assemblies designed to operate within the
temperature limits from -45 °C to +85 °C. More extreme temperatures or other
unusual environmental applications require special design measures or
processing steps to provide environmental survival capability.
6
---------------------- Page: 8 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
1
Scope
This Standard defines the technical requirements and quality assurance
provisions for the assembly and mounting of high-reliability, radio-frequency
(RF) coaxial-cable interconnections for use as transmission lines in spacecraft
and associated equipment.
In general, these assemblies are designed for low-loss, stable operation from the
relatively low frequencies through the higher frequencies in the microwave
regions.
These transmission-line cables should not be confused with low-frequency
cables with conductive sheaths (usually copper braid), which are used in
applications where shielding of the centre conductors from the surrounding
electrical ambient is required. The interconnection of those shielded cables, not
covered by the present standard, is covered in ECSS-Q-ST-70-08.
This standard may be tailored for the specific characteristics and constrains of a
space project in conformance with ECSS-S-ST-00.
7
---------------------- Page: 9 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
2
Normative references
The following normative documents contain provisions which, through
reference in this text, constitute provisions of this ECSS Standard. For dated
references, subsequent amendments to, or revision of any of these publications
do not apply, However, parties to agreements based on this ECSS Standard are
encouraged to investigate the possibility of applying the more recent editions of
the normative documents indicated below. For undated references, the latest
edition of the publication referred to applies.
EN reference Reference in text Title
EN 16601-00-01 ECSS-S-ST-00-01 ECSS system — Glossary of terms
EN 16602-10-09 ECSS-Q-ST-10-09 Space product assurance — Nonconformance control
system
EN 16602-20 ECSS-Q-ST-20 Space product assurance — Quality assurance
EN 16602-60 ECSS-Q-ST-60 Space product assurance — Electrical, electronic and
electromechanical (EEE) components
EN 16602-70-02 ECSS-Q-ST-70-02 Space product assurance — Thermal vacuum
outgassing test for the screening of space materials
EN 16602-70-08 ECSS-Q-ST-70-08 Space product assurance — Manual soldering of
high-reliability electrical connections
EN 16602-70-26 ECSS-Q-ST-70-26 Space product assurance — Crimping of
high-reliability electrical connections
EN 16602-70-28 ECSS-Q-ST-70-28 Space product assurance — Repair and modification
of printed circuit board assemblies
MIL-C-17G(3) SUP1 General specification for cables, radio frequency,
flexible and semi-rigid. (8 Jan 1996)
8
---------------------- Page: 10 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
3
Terms, definitions and abbreviated terms
3.1 Terms from other standards
For the purpose of this Standard, the terms and definitions from ECSS-S-ST-00-01
apply, in particular for the following terms:
requirement
3.2 Terms specific to the present standard
3.2.1 minimum bend radius
inside radius of the bend measured on the outer surface of the cable
3.3 Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01
and the following apply:
Abbreviation Meaning
fluorinated ethylene propylene
FEP
polytetrafluoroethylene
PTFE
sub miniature version A
SMA
voltage standing wave ratio
VSWR
9
---------------------- Page: 11 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
4
Principles and prerequisites of reliable
soldered or crimped cable connections
4.1 Principles of reliable soldered or crimped semi-rigid
cable connections
Reliable soldered or crimped connections result from proper design, control of
tools, materials and work environments and careful workmanship.
The basic design concepts, adherence to which ensures reliable connections and
prevents joint failure, are:
a. Avoidance of dimensional mismatch between the coaxial-cable assembly
and the units being connected; i.e. not forcing the semi-rigid cable
assembly into position and thereby cracking or pre-stressing one of the
joints.
b. Use of cable-end connectors with retractable (non-captive) coupling nuts;
after completion of mounting, the coaxial-cable assembly is not in a state
of tension resulting from axial movement when the connectors are
threaded together.
c. Minimizing the internal stresses on the soldered or crimped connections
resulting from exposure to thermal cycling.
NOTE The thermal coefficient of expansion of the
dielectric is about ten (10) times that of copper and
in service this can introduce a tensile stress on the
joint.
d. The various assembly and mounting processes are covered by
quality-control inspection steps.
4.2 Prerequisites for assembly and mounting of
semi-rigid coaxial cables
Each supplier maintains documented soldering or crimping programmes which
meet the requirements of this Standard for the types of connections employed
and the articles involved. The programmes include procedures for training,
certification, maintenance of certified status, recertification and revocation of
certified status for soldering, crimping and inspection personnel. The supplier
also prepares and has readily available workmanship standards consisting of
10
---------------------- Page: 12 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
satisfactory work samples or visual aids which clearly illustrate the quality
characteristics for all connections involved, including the applicable
illustrations in Annex B of this Standard.
Records are kept to provide identification between the finished product and the
operator. Records are also maintained of the training, testing and certification
status of assembly operators. Records are retained for at least one year, or
longer if this is a specific requirement of the customer’s project.
Equipment and tools are verified and calibrated periodically for proper
operation, and records of tool calibration and verification are maintained (see
clause 5.8).
For soldering or crimping requirements not covered in this Standard, the
supplier submits a process procedure including all pertinent quality
requirements to the customer’s relevant project office for approval in
accordance with ECSS-Q-ST-70.
4.3 Alternative coaxial cable technologies
Alternative coaxial cable technologies are accepted for application in individual
customer programmes following the completion of qualification and batch
acceptance test programmes in accordance with clause 5.7. The precise
test-programme and results are subject to review and acceptance by the
relevant customer programme. For materials used in the alternative technology
see ECSS-Q-ST-70-71.
Some mounting requirements for alternative technologies are given in clause
5.6.3 of this Standard.
11
---------------------- Page: 13 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
5
Requirements
5.1 Preparatory conditions
5.1.1 Facility cleanliness
a. Unless classified as a cleanroom, the supplier shall maintain the areas in
which soldering is carried out in a neat orderly fashion with no loose
material that can cause contamination of the soldered connection.
NOTE Examples for loose material are dirt, dust, solder
particles, oils and clipped wires.
b. The supplier shall keep furniture to a minimum in the work areas and be
arranged to allow easy and thorough cleaning of the floor.
c. A washroom and eating, drinking and smoking facilities shall be located
close to, but outside, the soldering areas.
d. The supplier shall cover working surfaces with an easily cleaned hard
top or have a replaceable surface of clean, non-corrosive silicone-free
paper.
e. The supplier shall only use clean tools in the soldering operation.
f. The supplier shall remove excess lubricants from the tools before
soldering starts.
g. Before assembly, wire, terminal and connector contacts shall be visually
examined for cleanliness, absence of oil films and freedom from tarnish
or corrosion.
5.1.2 Environmental conditions
a. The supplier shall have an assembly area which has a controlled
environment that limits entry of contamination.
b. The supplier shall maintain the following environmental conditions in
the area:
1. Room temperature: (22 ± 3) °C
2. Relative humidity at room temperature (55 ± 10) %.
c. The work stations shall not be exposed to draughts.
12
---------------------- Page: 14 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
d. The supplier shall use a filter system to supply fresh air to the room, so
that there is a positive pressure difference with respect to adjacent rooms.
5.1.3 Lighting requirements
a. The supplier shall ensure a lighting intensity of a minimum of 1 080 lux
on the work surface.
b. The supplier shall ensure that at least 90 % of the work area is
shadowless and without severe reflections.
5.1.4 Equipment and tools
5.1.4.1 Brushes
a. The supplier shall use brushes for cleaning, provided that they do not
scratch the metal surface to be cleaned or damage adjacent materials
beyond their visual inspection requirements.
NOTE Medium-stiff natural- or synthetic-bristle brushes
can be used.
b. The supplier shall clean these brushes before use in a solvent prescribed
in clause 5.2.3.
c. The supplier shall not use wire brushes.
5.1.4.2 Files
a. The supplier shall use smooth, single cut and mill type files for dressing
copper soldering-iron tips and removing burrs from the conductor.
b. The supplier shall not use files on surface-treated tips or pretinned items.
NOTE Nickel plated is an example for surface-treatment.
c. The supplier shall keep the files in a good condition and shall be cleaned
before use.
d. The supplier shall not keep the files in a cleanroom environment.
5.1.4.3 Cutting tools
a. The supplier shall use at least the following cutting tools for the
preparation of the semi-rigid cable:
1. jeweller’s saws having fine teeth;
NOTE A 0,28 mm - 0,33 mm blade is preferred.
2. single edged razor blades;
3. wire cutters.
b. The supplier shall use the jeweller’s saw together with a cable clamping
device.
13
---------------------- Page: 15 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
NOTE An example of such a cable clamping device is
shown in Figure C-1.
c. The supplier shall cut the dielectric and inner conductor with a tool that
produces a clean, smooth-cut surface along the entire cutting edge.
d. The supplier shall not perform any twisting action during this cutting
operation.
5.1.4.4 Cable-forming tools
a. The supplier shall use bending jigs to form the cable to predetermined
shapes as identified by the engineering drawing.
NOTE An example of such a bending jig is shown in
Figure C-2.
b. The supplier shall use roller sizes consistent with each cable diameter.
c. The supplier shall use this equipment in such a way that it does not
introduce dents, nicks, wrinkles or cracks in the cable outer conductor.
5.1.4.5 Cable stripping and dressing tools
a. The supplier shall use cable stripping and dressing tools in such a way
that they do not twist, ring, nick, or score the underlying material
surface.
NOTE Many pieces of commercially available equipment
exist to strip the outer conductor or the dielectric
material. These can be automatic, power-driven
devices with precision factory-set non-adjustable
cutting and stripping dies, or precision hand-type
strippers with accurately machined cutting heads.
b. The supplier shall perform either periodic calibration or sample
evaluation during a production run.
5.1.4.6 Heat-treatment chamber
a. The supplier shall use thermal cycling cabinets, ovens, refrigeration units
or cold chambers capable of maintaining temperatures between -50 °C
and +90 °C
NOTE Under certain circumstances (see Table 5-2 step
3.3) greater temperature extremes can be required.
b. The supplier shall calibrate the working zone to within ±5 °C.
5.1.4.7 Soldering equipment
a. The supplier shall accomplish one of the following soldering methods
that conforms to the requirements on “Equipment and tools” of ECSS-Q-
ST-70-08:
1. by hand or
2. by using a resistance heating unit or
14
---------------------- Page: 16 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
3. other contact heat source
b. When non-contact heat sources are utilized, the supplier shall set up,
operate and demonstrate to the satisfaction of the customer that the
particular method and schedule produces joints of an acceptable
standard.
NOTE This includes verification testing as detailed in
clause 5.7.
5.1.4.8 Crimping equipment
a. The supplier shall use the settings recommended by the tool
manufacturer as a guide.
NOTE This is necessary since manual crimping tools are
available; they are custom designed and applicable
only for particular connector shells.
b. The supplier shall set up the tool for the cable and connector types by a
detailed calibration programme based on the requirements of ECSS-Q-
ST-70-26.
c. The supplier shall perform verification testing as detailed in clause 5.7.
5.1.4.9 Assembly equipment, tools and processes for other
technologies
a. The supplier shall only use the equipment, tools, and processes for the
assembly of the cables and connectors that are designed to avoid damage
or degradation of the cables and connectors.
NOTE The equipment, tools, and processes can be subject
to a manufacturing audit by the customer before
application in their programme.
5.1.4.10 Defective or uncalibrated equipment or tools
a. The supplier shall promptly remove and replace defective or
uncalibrated equipment or tools from the work areas.
5.2 Material selection
5.2.1 Solder
a. The supplier shall use solder ribbon, wire and preforms, provided that
the alloy and flux conform to the requirements on “material selection” of
ECSS-Q-ST-70-08.
NOTE 1 The following solder alloys are approved:
• 60 Sn (remainder lead): For degolding
operations, coating and pretinning.
15
---------------------- Page: 17 ----------------------
kSIST FprEN 16602-70-18:2014
FprEN 16602-70-18:2013 (E)
• 96 Sn (remainder silver): For making
coaxial-cable outer-conductor-to connector
solder joint.
• 96 Sn or 63 Sn (remainder lead): For
contact-pin soldering and cover soldering of
right angle connectors.
NOTE 2 Refer also to the table of “Chemical
composi
...
Questions, Comments and Discussion
Ask us and Technical Secretary will try to provide an answer. You can facilitate discussion about the standard in here.