November 2014 

NASA/TP—2014–218436 

Electrical Ground Support Equipment 

Fabrication, 

Specification for

Erik C. Denson 

Kennedy Space Center, Florida 

https://ntrs.nasa.gov/search.jsp?R=20150001360 2017-08-31T15:14:37+00:00Z
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November 2014 

NASA/TP—2014–218436 

Electrical Ground Support Equipment 

Fabrication, 

Specification for

Erik C. Denson 

Kennedy Space Center, Florida 

National Aeronautics and 

Space Administration 

Kennedy Space Center 
NASA/TP—2014–218436

ii

Available from:

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7115 Standard Drive

Hanover, MD 21076-1320

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5301 Shawnee Road

Alexandria, VA 22312

Available in electronic form at http://www.sti.nasa.gov.
KSC-E-165E 

FEBRUARY 2, 2009 

Change 3, November 6, 2014 

Supersedes 

KSC-E-165D 

February 22, 1995 

National Aeronautics and 

Space Administration

John F. Kennedy Space Center 

KSC FORM 16-12 (REV. 6/95) PREVIOUS EDITIONS ARE OBSOLETE (CG 11/95) 

METRIC/INCH-POUND 

APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

ELECTRICAL 

GROUND SUPPORT EQUIPMENT FABRICATION, 

SPECIFICATION FOR 

ENGINEERING AND TECHNOLOGY DIRECTORATE


KSC-E-165E 

February 2, 2009 

Change 3, November 6, 2014 

October 29, 20 

ii APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

RECORD OF REVISIONS/CHANGES 

REV 

LTR 

CHG 

NO. DESCRIPTION DATE 

C General revision. April 1, 1982 

D General revision. February 22, 1995 

E General revision. February 2, 2009 

E-1 Updated applicable documents. Added an acceptable 

lubricant and an approved thermal-barrier tape. Clarified 

requirements for (1) suitable wire/cable for cabinets, 

enclosures, and terminal distributors, (2) shielding for 

interior-type connectors, (3) cables terminated on a terminal 

strip, (4) one-piece ferrules for shield terminations, (5) solder 

terminations, (6) inspection of standard bulk cables, and 

(7) inspection of cable assemblies before potting or molding 

June 4, 2013 

E-2 Updated applicable documents. Updated standards for crimptype terminations and for tools for crimping terminal, 

conductor splices, and shield ferrules. Added acceptable 

values for torquing rear coupling nuts of connectors or cables 

for ignitionproofing. 

March 26, 2014 

E-3 1. Updated applicable document in §2. 

2. Required that welding comply with KSC-DE-512-SM in 

§3.1.2. 

3. Clarified materials for aluminum racks, enclosures, 

panels, junction boxes, and miscellaneous details in 

§3.1.6.1. 

4. Changed “detailed drawings” to “engineering drawings,” 

and added guidance for marker tape in §3.4. 

5. Clarified requirements for wirewrap wire and premises 

wiring cables in §3.5.3. 

6. Added requirements for the application of cold-shrink 

tubing in §3.8.1.3. 

7. Clarified requirements for thermal protection of cable 

assemblies and requirements for thermal blankets, 

sleeves, and hose assemblies in §3.11.9. 

8. Added Fyrejacket sleeving and Fyretape as approved 

products for thermal protection in §3.11.9.2.d. 

9. Added NFPA 70, Article 332, as a compliance 

requirement for mineral-insulated cable in §3.12. 

November 6, 2014 
KSC-E-165E 

February 2, 2009 

Change 3, November 6, 2014 

 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED iii 

CONTENTS 

1. SCOPE ...............................................................................................................1

2. APPLICABLE DOCUMENTS .........................................................................1

2.1 Governmental .....................................................................................................1

2.1.1 Specifications .....................................................................................................1

2.1.2 Standards ............................................................................................................3

2.1.3 Drawings ............................................................................................................5

2.1.4 Publications ........................................................................................................6

2.2 Non-Governmental ............................................................................................7

2.3 Order of Precedence .........................................................................................12

3. REQUIREMENTS ...........................................................................................12

3.1 Metal and Sheet Metal Assemblies, Subassemblies, and Details ....................12

3.1.1 Surface Preparation ..........................................................................................13

3.1.1.1 Abrasive Blasting .............................................................................................13

3.1.1.2 Degreasing .......................................................................................................14

3.1.2 Protective Coatings, Thinners, and Cleaners ...................................................14

3.1.2.1 Generic Protective Coatings ............................................................................15

3.1.2.2 Application of Coatings ...................................................................................15

3.1.2.3 Colors ...............................................................................................................16

3.1.2.4 Storage, Mixing, and Application Methods .....................................................16

3.1.2.5 Coating Finish ..................................................................................................17

3.1.2.6 Touchup of Welds and Damaged Coatings .....................................................17

3.1.3 Sealants and Caulking ......................................................................................17

3.1.4 Chip-Free Clean-Room Paint ...........................................................................18

3.1.5 Zones of Exposure ...........................................................................................18

3.1.6 Aluminum Racks, Enclosures, Panels, Junction Boxes, and 

Miscellaneous Details ......................................................................................18

3.1.6.1 Materials ..........................................................................................................18

3.1.6.2 Cleaning, Treating, and Coating ......................................................................18

3.1.6.2.1 Surface Preparation ..........................................................................................18

3.1.6.3 Chromate Coatings...........................................................................................19

3.1.6.4 Protective Coatings ..........................................................................................19

3.1.6.5 Finish Colors ....................................................................................................19

3.1.7 Steel Racks, Enclosures, Junction Boxes, Assemblies, and 

Miscellaneous Details ......................................................................................20

3.1.7.1 Materials ..........................................................................................................20

3.1.7.2 Cleaning, Treating, and Coating ......................................................................20

3.1.7.3 Finish Colors ....................................................................................................20

3.1.8 Fabricated Chassis ...........................................................................................20

3.1.8.1 Materials ..........................................................................................................20
KSC-E-165E 

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October 29, 20 

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3.1.8.2 Cleaning and Treating ......................................................................................20

3.2 Welding and Brazing .......................................................................................20

3.2.1 Welding ............................................................................................................20

3.2.2 Brazing .............................................................................................................21

3.3 Fasteners ..........................................................................................................21

3.3.1 Threaded Fasteners ..........................................................................................21

3.3.1.1 Torque Limits for Threaded Fasteners .............................................................21

3.3.1.2 Installation of Nuts on Bolts or Screws ...........................................................21

3.3.1.3 Torque Values for Standard and High-Strength Steel Fasteners .....................27

3.3.1.3.1 Plated................................................................................................................27

3.3.1.3.2 Lubricated ........................................................................................................27

3.3.1.4 Torque Values for 300 Series CRES Fasteners ...............................................27

3.3.1.4.1 Passivated .........................................................................................................27

3.3.1.4.2 Plated................................................................................................................27

3.3.1.4.3 Lubricated ........................................................................................................27

3.3.1.5 Torque Values for 430 MPa (62 ksi) Tensile Strength Aluminum Alloy 

Fasteners (2024-T4, 7075-T6) .........................................................................27

3.3.1.5.1 Anodized ..........................................................................................................27

3.3.1.5.2 Lubricated ........................................................................................................27

3.3.1.6 Lubricants ........................................................................................................28

3.3.1.7 Self-Locking Fasteners ....................................................................................28

3.3.1.8 Cotter Pin, Lockwire, and Safety Cable Securing ...........................................29

3.3.1.8.1 Safety Cable .....................................................................................................29

3.3.1.9 Nonmetallic Fasteners ......................................................................................29

3.3.2 Adhesives .........................................................................................................29

3.3.3 Rivets ...............................................................................................................29

3.3.3.1 Chips, Burrs, and Foreign Material..................................................................29

3.3.3.2 Rivet Substitutions ...........................................................................................32

3.4 Identification and Marking (of GSE) ...............................................................32

3.5 Electrical Wiring, Internal ...............................................................................32

3.5.1 Plenum-Rated and Non-Plenum-Rated ............................................................32

3.5.2 Class I, Division 2 ............................................................................................33

3.5.3 Wire..................................................................................................................33

3.5.4 Routing .............................................................................................................34

3.5.5 Grouping ..........................................................................................................34

3.5.6 Breakouts .........................................................................................................34

3.5.7 Wire Stripping ..................................................................................................34

3.5.8 Terminals .........................................................................................................36

3.5.8.1 Modular Terminal Junction Systems ...............................................................36

3.5.8.2 Screw Terminals ..............................................................................................36

3.5.8.3 Compression Terminals ...................................................................................36

3.5.8.4 Solder Terminals ..............................................................................................37

3.5.8.4.1 Terminal Swaging ............................................................................................37

3.5.8.4.2 Rework .............................................................................................................41
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3.5.8.5 Solderless Wrap Terminals ..............................................................................42

3.5.9 Lacing and Tying .............................................................................................42

3.5.9.1 Lacing ..............................................................................................................42

3.5.9.2 Cable Ties and Clamps ....................................................................................43

3.5.10 Termination Order ...........................................................................................44

3.5.11 Molding and Potting Electrical Connectors .....................................................44

3.5.12 Splicing ............................................................................................................44

3.5.13 Terminating and Grounding Shields ................................................................44

3.5.13.1 Insulated Shields Over Individual Conductors or Groups of 

Conductors .......................................................................................................48

3.5.13.2 Uninsulated Shields Over Individual Conductors or Groups of 

Conductors .......................................................................................................49

3.5.13.3 Overall Shields Surrounding the Entire Cable Core ........................................50

3.5.13.3.1 Tinel-Lock Rings .............................................................................................51

3.5.13.3.2 EMI/RFI Foil Tape and Wire Mesh .................................................................52

3.5.13.3.3 Interior Cable Runs ..........................................................................................53

3.5.13.3.4 Exterior Cable Runs .........................................................................................53

3.5.13.4 Shield Terminals ..............................................................................................54

3.6 Terminations ....................................................................................................54

3.6.1 Compression Type ...........................................................................................54

3.6.1.1 Captive Nut or Screw Head .............................................................................54

3.6.1.2 Clamp or Screw End ........................................................................................58

3.6.2 Crimp Type ......................................................................................................58

3.6.3 Friction Type ....................................................................................................58

3.6.4 Solder Type ......................................................................................................58

3.6.4.1 Hand and Machine Soldering...........................................................................59

3.6.4.2 Soldering Multiple Conductors in a Single Solder Cup...................................59

3.6.5 Bonding and Grounding Type .........................................................................59

3.6.6 DIN Rail-Mounted Terminal Blocks ...............................................................59

3.7 Printed Wiring Boards .....................................................................................59

3.7.1 Material ............................................................................................................59

3.7.2 Construction .....................................................................................................59

3.7.2.1 Circuit Pads ......................................................................................................59

3.7.2.2 Heat Sinks ........................................................................................................60

3.7.2.2.1 Electrical Insulation .........................................................................................60

3.7.2.2.2 Thermal Resistance ..........................................................................................60

3.7.2.3 Eyelets and Tubelets ........................................................................................60

3.7.2.4 Workmanship ...................................................................................................60

3.7.3 Cleaning ...........................................................................................................61

3.7.4 Rejection Criteria .............................................................................................61

3.7.5 Inspection .........................................................................................................62

3.7.6 Conformal Coating...........................................................................................62

3.7.7 Repair ...............................................................................................................62

3.7.7.1 Printed Wiring Boards Using Surface-Mount Technology (SMT)..................62
KSC-E-165E 

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3.8 Sealing and Insulating ......................................................................................62

3.8.1 Insulation..........................................................................................................62

3.8.1.1 Heat-Reactive Tubing ......................................................................................63

3.8.1.1.1 Application .......................................................................................................63

3.8.1.1.2 Visual Inspection .............................................................................................64

3.8.1.2 Insulation Tubing .............................................................................................64

3.8.1.3 Cold-Shrink Tubing .........................................................................................64

3.8.2 Sealing Compound, Electrical .........................................................................65

3.9 Hazardproofing ................................................................................................65

3.9.1 Intrinsically Safe Equipment............................................................................65

3.9.2 Ignitionproofing ...............................................................................................65

3.9.2.1 Small Junction Boxes .......................................................................................66

3.9.2.2 Electrical Components .....................................................................................66

3.9.2.3 Electrical Connectors and Mated Cables .........................................................66

3.9.3 Purging and Pressurization ..............................................................................66

3.9.3.1 Equipment ........................................................................................................66

3.9.3.2 Purge Pressure ..................................................................................................67

3.9.3.3 Flow Rate .........................................................................................................67

3.9.3.4 Purge Media .....................................................................................................67

3.10 Corrosion Control ............................................................................................67

3.10.1 Corrosion-Resistant Materials .........................................................................68

3.10.2 Dissimilar Metals .............................................................................................68

3.10.3 Moisture Exclusion ..........................................................................................69

3.10.4 Protective Coatings ..........................................................................................70

3.10.5 Lubricants ........................................................................................................70

3.11 General-Purpose Cables ...................................................................................70

3.11.1 Standard Bulk Cable ........................................................................................70

3.11.2 Unique Bulk Cable ...........................................................................................70

3.11.2.1 Preferred Types ................................................................................................70

3.11.2.2 Fabrication Procedure ......................................................................................71

3.11.3 Connectors .......................................................................................................73

3.11.3.1 D-Subminiature (DB) Connectors ...................................................................73

3.11.4 Jacket Removal ................................................................................................74

3.11.5 Conductor and Shield Termination ..................................................................74

3.11.6 Potting and Molding ........................................................................................75

3.11.7 Cable Jacket Repair..........................................................................................75

3.11.7.1 Sleeves .............................................................................................................75

3.11.7.2 Approved Products...........................................................................................75

3.11.8 Splicing ............................................................................................................76

3.11.8.1 Procedure .........................................................................................................76

3.11.8.2 Approved Products...........................................................................................77

3.11.9 Thermal Protection...........................................................................................78

3.11.9.1 Application .......................................................................................................78

3.11.9.2 Approved Products...........................................................................................78
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3.11.10 Cable Checkout ................................................................................................79

3.11.10.1 Cable Continuity Test ......................................................................................79

3.11.10.2 Cable Insulation-Resistance Tests ...................................................................79

3.11.10.3 Radio Frequency Cable Tests ..........................................................................80

3.11.10.3.1 Continuity Tests ...............................................................................................80

3.11.10.3.2 Insulation-Resistance Test ...............................................................................80

3.11.10.3.3 Time Domain Reflectometer (TDR) Test ........................................................81

3.11.11 AC Power Cables .............................................................................................85

3.12 Mineral-Insulated (MI) Cable ..........................................................................85

3.13 Transducers ......................................................................................................85

3.14 Electromagnetic Interference Tests ..................................................................86

3.15 Fabrication Process Waste Disposal ................................................................86

3.16 Fiber-Optic Cables ...........................................................................................86

3.16.1 Optical-Fiber End Preparation .........................................................................87

3.16.2 Cleaning ...........................................................................................................87

3.16.3 Splicing ............................................................................................................88

3.16.3.1 Presplicing Examination ..................................................................................88

3.16.3.2 Splicing Method ...............................................................................................88

3.16.3.2.1 Fusion Splicing ................................................................................................89

3.16.3.2.2 Mechanical Splicing.........................................................................................89

3.16.3.2.3 Chemical Splicing ............................................................................................89

3.16.3.3 Splice Requirements ........................................................................................89

3.16.3.3.1 Location ...........................................................................................................89

3.16.3.3.2 Protection .........................................................................................................89

3.16.3.3.3 Strength Member .............................................................................................89

3.16.4 Fiber-Optic Cable Assemblies .........................................................................89

3.16.4.1 Cable Assembly ...............................................................................................89

3.16.4.1.1 Preassembly Verification .................................................................................90

3.16.4.1.2 Preassembly Examination ................................................................................90

3.16.4.2 Completed Cable Assemblies ..........................................................................90

3.16.5 Fiber-Optic Assemblies ...................................................................................91

3.16.5.1 Fiber-Optic Connector Termination ................................................................91

3.16.5.1.1 Preassembly Verification .................................................................................91

3.16.5.1.2 Preassembly Examination ................................................................................91

3.16.5.2 Post–Fiber-Optic-Connector-Termination Inspection .....................................91

3.16.5.3 Fiber-Optic Routing .........................................................................................92

3.16.6 Testing..............................................................................................................92

3.16.6.1 Fiber-Optic Splices ..........................................................................................92

3.16.6.2 Fiber-Optic Cable Assemblies .........................................................................92

3.16.6.3 Fiber-Optic Assemblies ...................................................................................93

3.16.6.4 Optical Time-Domain Reflectometer (OTDR) Test ........................................93

3.16.6.5 OTDR Basic Theory of Operation ...................................................................93

3.16.6.5.1 Attenuation .......................................................................................................96

3.16.6.5.2 Point Defects ....................................................................................................98
KSC-E-165E 

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3.16.7 Fiber-Optic Cable Assembly Installation.......................................................100

3.16.7.1 Tensile Load and Vertical Rise ......................................................................100

3.16.7.2 Installation Bend Radius ................................................................................101

3.16.7.3 Installed Bend Radius ....................................................................................101

3.16.7.4 Cable Tying ....................................................................................................101

3.16.7.5 Dust Caps .......................................................................................................101

3.16.7.6 Premating Inspection .....................................................................................101

3.16.7.7 Connector Torque ..........................................................................................101

3.16.7.8 Sharp Edges ...................................................................................................101

3.17 Ethernet ..........................................................................................................102

3.17.1 Ethernet Naming Conventions .......................................................................102

4. QUALITY ASSURANCE PROVISIONS ....................................................102

4.1 Responsibility for Inspection and Test ..........................................................102

4.2 Certification of Personnel ..............................................................................102

4.3 Certification of Tooling and Test Equipment ................................................103

4.3.1 Soldering Tools ..............................................................................................103

4.3.2 Crimping Tools ..............................................................................................103

4.3.3 Crimping Tools, Special ................................................................................104

4.3.4 Torque Wrenches ...........................................................................................104

4.3.5 Wire Stripping Tools......................................................................................104

4.3.6 Solderless Wrap Tools ...................................................................................104

4.3.7 Test Equipment ..............................................................................................104

4.4 Equipment Checkout ......................................................................................105

4.4.1 Sequence of Tests ..........................................................................................105

4.4.2 Continuity Tests .............................................................................................106

4.4.3 Isolation Checks .............................................................................................106

4.4.4 Functional Checks ..........................................................................................107

4.5 Completion of Tests .......................................................................................107

4.6 Manufacturing Instructions/Documentation ..................................................107

4.7 Commercial Off-the-Shelf (COTS) Concept .................................................107

4.7.1 Modified Off-the-Shelf (MOTS) Items .........................................................108

5. PREPARATION FOR DELIVERY ..............................................................108

6. NOTES ...........................................................................................................109

6.1 Intended Use ..................................................................................................109

6.2 Definitions......................................................................................................109
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FIGURES 

Figure 1. Safety Cable, Tension Tool, Ferrule, and Calibration Unit .............................30 

Figure 2. Typical Safety Cable Installations ...................................................................31 

Figure 3. Harness or Wire Bundle ...................................................................................35 

Figure 4. Rolled Swage Terminals ..................................................................................38 

Figure 5. Elliptical Funnel Swage Terminals ..................................................................39 

Figure 6. Funnel Swage Terminals..................................................................................40 

Figure 7. Cable Termination Hardware ...........................................................................45 

Figure 8. Typical Termination Configuration for Overall Shielded Cable With 

Insulated Conductor Shields ............................................................................46 

Figure 9. Graphic Representation of Individual Shields From Source, Through 

Intermediate Break Points, to End Instrument .................................................47 

Figure 10. Typical Termination Configuration for Overall Shielded Cable With 

Uninsulated Conductor Shields........................................................................48 

Figure 11. 360-Degree Overall Shield Termination Using a Mold Adapter .....................50 

Figure 12. Tinel-Lock Rings and an Example of One Type of Adapter ...........................51 

Figure 13. Tinel-Lock Ring Resistance Heating Tools .....................................................52 

Figure 14. Typical Installation of Tinel-Lock Ring ..........................................................52 

Figure 15. Bridge Bus Terminals ......................................................................................55 

Figure 16. Captive and Noncaptive Nut and Screw Head Terminations ..........................56 

Figure 17. Clamp and Screw End Terminations ...............................................................57 

Figure 18. Application of Heat-Reactive Tubing ..............................................................64 

Figure 19. Unique Bulk Cable Fabrication .......................................................................71 

Figure 20. DB9 and DB25 Connectors .............................................................................73 

Figure 21. DB15 Connectors .............................................................................................73 

Figure 22. MD50 and MD68 Connectors ..........................................................................74 

Figure 23. TDR Traces for Coaxial Cable ........................................................................82 

Figure 24. TDR Fault Traces for Twin-Axial Cable (Sheet 1 of 2) ..................................83 

Figure 25. Typical OTDR Block Diagram ........................................................................95 

Figure 26. OTDR Trace of an Installed Cable Plant .........................................................96 

Figure 27. OTDR Measurement Points for Measuring Fiber Attenuation, Using 

Dead-Zone Fiber ..............................................................................................97 

Figure 28. OTDR Trace Showing a Nonreflective Fault With Apparent Gain and 

a Reflective Fault With No Apparent Loss or Gain .........................................98 

Figure 29. Extrapolation for a Point Defect Showing an Apparent Signal Gain ..............99 

Figure 30. Exaggerated Loss Obtained at Point Defects Exhibiting Gain in One 

Direction by Conducting the OTDR Measurement in the Opposite 

Direction ........................................................................................................100 
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TABLES 

Table 1. Torque Values for Steel, Cadmium-Plated, Unlubricated Threaded 

Fasteners ..........................................................................................................23 

Table 2. Torque Values for Steel, Lubricated (Plated, Unplated) Threaded 

Fasteners ..........................................................................................................24 

Table 3. Torque Values for Corrosion-Resistant Steel (CRES) and Aluminum 

Alloy Threaded Fasteners ................................................................................25 

Table 4. Required Locking Torque at Room Ambient Temperature .............................26 

Table 5. Minimum Bolt or Screw Thread Protrusion ....................................................26 

Table 6. Insulation Clearances for Wire ........................................................................36 

Table 7. Spacing of Lacing From Terminations ............................................................42 

Table 8. Spacing of Lacing in the Harness ....................................................................42 

Table 9. Potential Tendency for Galvanic Corrosion ....................................................68 
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ABBREVIATIONS, ACRONYMS, AND SYMBOLS 

°C degree Celsius 

°F degree Fahrenheit 

μm micrometer (1×10−6

 m) 

AC alternating current 

AHJ authority having jurisdiction 

AIA Aerospace Industries Association 

ANSI American National Standards Institute 

ASCII American Standard Code for Information Interchange 

ASME American Society of Mechanical Engineers 

ASTM ASTM International 

AWG American Wire Gage 

BHP Bulkhead Plate 

CH6H2 methyl hydrazine 

COTS commercial off-the-shelf 

CRES corrosion-resistant steel 

CSA Canadian Standards Association 

CSMA/CD Carrier Sense Multiple Access Collision Detection 

DAS Data Acquisition System 

dB decibel 

DB D-subminiature 

DC direct current 

ECA Electronic Components Association 

EIA Electronic Industries Alliance 

EMI electromagnetic interference 

FAC Florida Administrative Code 

FDEP Florida Department of Environmental Protection 

FED Federal 

FOTP fiber-optic test procedures 

ft3

/min cubic foot per minute 
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GP general publication 

GPa gigapascal (1×109

 Pa) 

GPS Global Positioning System 

GSE ground support equipment 

HD high density 

HGDS Hazardous Gas Detection System 

IEC International Electrotechnical Commission 

IEEE Institute of Electrical and Electronics Engineers, Inc. 

in inch 

in-lb inch-pound 

IR infrared 

ISO International Organization for Standardization 

JSC Lyndon B. Johnson Space Center 

km kilometer (1×103

 m) 

km/h kilometer per hour 

KNPR Kennedy NASA Procedural Requirements 

KSC John F. Kennedy Space Center 

ksi kip (1,000 pounds) per square inch 

L liter 

L/s liter per second 

LO2 liquid oxygen 

m meter 

m/s meter per second 

Mbps megabit (1,000 bits) per second 

MD micro DB 

MEK methyl ethyl ketone 

MHz megahertz (1×106

 Hz) 

MI mineral-insulated 

MIL military 

mm millimeter (1×10−3

 m) 

MMH monomethylhydrazine
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MPa megapascal (1×106

 Pa) 

mph mile per hour 

MS military standard 

MSFC George C. Marshall Space Flight Center 

MΩ megohm (1×106 Ω)

Nm newton meter 

N2O2 nitrogen dioxide 

N2O4 nitrogen tetroxide 

NAS National Aerospace Standards 

NASA National Aeronautics and Space Administration 

NATO North Atlantic Treaty Organization 

NEC National Electrical Code 

NEMA National Electrical Manufacturers Association 

NFPA National Fire Protection Association 

NIOSH National Institute of Occupational Safety and Health 

nm nanometer (1×10−9

 m) 

no. number 

NPR NASA Procedural Requirements 

OSHA Occupational Safety and Health Administration 

OTDR optical time domain reflectometry/reflectometer 

Pa pascal 

PC personal computer 

PCB printed circuit board 

PDS Premise Distribution System 

PNCR Product Nonconformance Report 

PTFE polytetrafluoroethylene 

PVC polyvinyl chloride 

ref reference 

RF radio frequency 

RFI radio frequency interference 

RH relative humidity 
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RIO remote input/output 

RS Recommended Standard 

RTV room-temperature vulcanizing 

s second 

SAE Society of Automotive Engineers 

SCSI Small Computer System Interface 

SOW statement of work 

SPEC specification 

SSPF Space Station Processing Facility 

STD standard 

TCLP Toxicity Characteristic Leaching Procedure 

TD Terminal Distributor 

TDR time domain reflectometer 

TIA Telecommunications Industry Association 

TJS terminal junction system 

TM technical manual 

typ typical 

UL Underwriters Laboratories, Inc. 

UTS ultimate tensile strength 

UV ultraviolet 

V volt 

VDC volt direct current 

WAD Work Authorization Document 

Ω ohm 
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ELECTRICAL GROUND SUPPORT EQUIPMENT FABRICATION, 

SPECIFICATION FOR 

1. SCOPE 

This document specifies parts, materials, and processes used in the fabrication, maintenance, 

repair, and procurement of electrical and electronic control and monitoring equipment associated 

with ground support equipment (GSE) at the John F. Kennedy Space Center (KSC). 

2. APPLICABLE DOCUMENTS 

The following documents form a part of this document to the extent specified herein. When this 

document is used for procurement, including solicitations, or is added to an existing contract, the 

specific revision levels, amendments, and approval dates of said documents shall be specified in 

an attachment to the solicitation/statement of work/contract. 

2.1 Governmental 

2.1.1 Specifications 

John F. Kennedy Space Center (KSC), NASA 

120E3100001 Specification for Heavy Duty GSE Cable, General 

120E3100003 GSE Cable Fabrication Specification 

75M11300 Marker Tape 

KSC-E-166 Installation and Assembly, Electrical Ground 

Support Equipment (GSE), Specification for 

KSC-SPEC-E-0002 Modular Electrical Enclosures, Racks, Consoles, 

and Accessories, Specification for 

KSC-SPEC-E-0017 Electrical Power Cables, Installation of 

Specification for 

KSC-SPEC-E-0024 Cable, Electrical, Shielded, Jacketed, for Harness 

Assemblies, General Specification for 

KSC-SPEC-E-0031 Cables, Electrical, Specification for 

KSC-SPEC-Z-0005 Brazing, Steel, Copper, Aluminum, Nickel, and 

Magnesium Alloys, Specification for 
KSC-E-165E 

February 2, 2009 

Change 3, November 6, 2014 

October 29, 20 

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Lyndon B. Johnson Space Center (JSC), NASA 

SE-S-0073 Space Shuttle Specification, Fluid Procurement and 

Use Control 

Federal 

A-A-59125 Terminal Boards, Molded, Barrier Screw and Stud 

Types and Associated Accessories 

A-A-59126 Terminals, Feedthru (Insulated) and Terminals, 

Stud (Insulated and Noninsulated) 

A-A-59298 Tape, Pressure-Sensitive Adhesive 

A-A-59551 Wire, Electrical, Copper (Uninsulated) 

A-A-59569 Braid, Wire (Copper, Tin-Coated, Silver-Coated, or 

Nickel-Coated, Tubular or Flat) 

Military 

MIL-A-22262 Abrasive Blasting Media: Ship Hull Blast Cleaning 

MIL-DTL-17 Cables, Radio Frequency, Flexible and Semirigid, 

General Specification for 

MIL-DTL-5541 Chemical Conversion Coatings on Aluminum and 

Aluminum Alloys 

MIL-DTL-16878 Wire, Electrical, Insulated, General Specification 

for 

MIL-DTL-22992 Connectors, Plugs and Receptacles, Electrical, 

Waterproof, Quick Disconnect, Heavy Duty Type, 

General Specification for 

MIL-DTL-24308 Connectors, Electric, Rectangular, 

Nonenvironmental, Miniature, Polarized Shell, 

Rack and Panel, General Specification for 

MIL-DTL-26482 Connectors, Electrical (Circular, Miniature, Quick 

Disconnect, Environment Resisting), Receptacles 

and Plugs, General Specification for 
KSC-E-165E 

February 2, 2009 

Change 3, November 6, 2014 

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MIL-DTL-38999 Connectors, Electrical Circular, Miniature, High 

Density, Quick Disconnect (Bayonet, Threaded and 

Breech Coupling), Environment Resistant, 

Removable Crimp and Hermitic Solder Contacts, 

General Specification for 

MIL-DTL-55302 Connectors, Printed Circuit Subassembly and 

Accessories 

MIL-DTL-83513 Connectors, Electrical, Rectangular, 

Microminiature, Polarized Shell, General 

Specification for 

MIL-P-85891 Plastic Media for Removal of Organic Coatings 

MIL-PRF-46010 Lubricant, Solid Film, Heat Cured, Corrosion 

Inhibiting 

MIL-T-713 Twine, Fibrous: Impregnated, Lacing and Tying 

QPL-46058-87 Notice 1 Insulating Compound, Electrical (for Coating 

Printed Circuit Assemblies) 

2.1.2 Standards 

National Aeronautics and Space Administration (NASA) 

NASA-STD-5005 Standard for the Design and Fabrication of Ground 

Support Equipment 

NASA-STD-5008 Protective Coating of Carbon Steel, Stainless Steel, 

and Aluminum on Launch Structures, Facilities, and 

Ground Support Equipment 

NASA-STD-6001 Flammability, Offgassing, and Compatibility 

Requirements and Test Procedures 

NASA-STD-8739.1 Workmanship Standard for Polymeric Application 

on Electronic Assemblies 

NASA-STD-8739.4 Crimping, Interconnecting Cables, Harnesses, and 

Wiring 

NASA-STD-8739.5 Fiber Optic Terminations, Cable Assemblies, and 

Installation 
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John F. Kennedy Space Center (KSC), NASA 

KSC-DE-512-SM Facility Systems, Ground Support Systems, and 

Ground Support Equipment General Design 

Requirements 

KSC-STD-132 Potting and Molding Electrical Cable Assembly 

Terminations, Standard for 

KSC-STD-E-0002 Hazardproofing of Electrically Energized 

Equipment, Standard for 

KSC-STD-E-0010 Soldering of Electrical Connections (Hand or 

Machine), Standard for 

KSC-STD-E-0012 Facility Grounding and Lightning Protection, 

Standard for 

KSC-STD-E-0015 Marking of Ground Support Equipment, Standard 

for 

KSC-STD-E-0021 KSC Telecommunication Premises Distribution 

Systems, Design of, Standard for 

KSC-STD-E-0022 Bonding, Grounding, Shielding, Electromagnetic 

Interference, Lightning, and Transient Protection, 

Design Requirements for Ground Systems 

George C. Marshall Space Flight Center (MSFC), NASA 

MSFC-STD-156 Riveting, Fabrications and Inspection, Standard for 

MSFC-STD-486 Threaded Fasteners, Torque Limits for, Standard 

Federal 

CFR Title 29, Part 1910 Occupational Safety and Health Standards 

CFR Title 40, Parts 260–282 Protection of Environment 

CFR Title 49 Transportation 

FED-STD-595 Colors Used in Government Procurement 
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February 2, 2009 

Change 3, November 6, 2014 

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State 

FAC FDEP Division 62 Florida Administrative Code (FAC), Florida 

Department of Environmental Protection (FDEP), 

Division 62 

Military 

MIL-STD-129 Military Marking for Shipment and Storage 

MIL-STD-202 Test Method Standard: Electronic and Electrical 

Component Parts 

MIL-STD-461 Requirements for the Control of Electromagnetic 

Interference Characteristics of Subsystems and 

Equipment 

MIL-STD-464 Electromagnetic Environmental Effects, 

Requirements for Systems 

MIL-STD-889 Dissimilar Metals 

MIL-STD-2073-1 Standard Practice for Military Packaging 

MS27466 Connectors, Receptacle, Electrical, Wall Mounting 

Flange, Crimp Type, Bayonet Coupling, Series I 

2.1.3 Drawings 

John F. Kennedy Space Center (KSC), NASA 

75M02047 Plate, Calibrated Bleed 

75M05218 Complex 39 Cast Chassis 

75M13302 Connector Inspection Specifications 

75M13676 Shield Rings 

79K04613 Electrical Cable Shield Termination 

79K06110 MI Cable Termination 

79K07416 Cable and Harness Assembly, Fabrication Details 

79K07491 Installation, Purge Hardware 
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79K13308 Printed Wiring Board Assembly, Electronic Control 

Module 

79K14177 Instructions for Potting and Molding Connector 

Assemblies 

79K19600 Electrical Cable Fabrication Requirements 

79K22638 Solderless Electrical Connections (Supersedes 

75M05668) 

82K03874 Miscellaneous Cable Fabrication Details, 

Specification for 

82K03878 Intrabuilding Control, Signal, and Communication 

Cable Specification for SSPF and Related Buildings 

for Kennedy Space Center 

82K04459 Electrical Connectors Termination Details 

2.1.4 Publications 

National Aeronautics and Space Administration (NASA) 

NPR 8715.3C NASA General Safety Program Requirements 

John F. Kennedy Space Center (KSC), NASA 

GP-777 Handbook for Exterior Electrical Enclosures 

KNPR 8500.1 KSC Environmental Requirements 

KNPR 8715.3-1 KSC Safety Procedural Requirements, Volume 1, 

Safety Procedural Requirements for Civil 

Servants/NASA Contractors 

KNPR 8730.1 KSC Metrology and Calibration Procedural 

Requirements 

KSC-GP-864, Volume IIA Electrical Ground Support Equipment Cable 

Handbook 

KSC-NE-9187 Sensors, Transducers and Signal Conditioning 

Systems Selection Process 
KSC-E-165E 

February 2, 2009 

Change 3, November 6, 2014 

 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 7 

KSC-TM-584 Corrosion Control and Treatment Manual 

(Copies of specifications, standards, drawings, and publications required by suppliers in 

connection with specified procurement functions should be obtained from the procuring activity 

or as directed by the contracting officer.) 

2.2 Non-Governmental 

Aerospace Industries Association (AIA)/National Aerospace Standards (NAS) 

AIA/NAS NASM25027 Nut, Self-Locking, 250 Deg. F, 450 Deg. F, and 

800 Deg. F 

AIA/NAS NASM33540 Safety Wiring, Safety Cabling, Cotter Pinning, 

General Practices for 

AIA/NAS NASM35333 Washer, Lock, Flat-Internal Tooth 

American Society of Mechanical Engineers (ASME) 

ASME B107.14 Hand Torque Tools (Mechanical) 

ASTM International 

ASTM B209 Standard Specification for Aluminum and 

Aluminum-Alloy Sheet and Plate 

ASTM B221 Standard Specification for Aluminum and 

Aluminum-Alloy Extruded Bars, Rods, Wire, 

Profiles, and Tubes 

ASTM C 920 Standard Specification for Elastomeric Joint 

Sealants 

ASTM D 3951-98 Standard Practice for Commercial Packaging 

ASTM D 4752-03 Standard Test Method for Measuring MEK 

Resistance of Ethyl Silicate (Inorganic) Zinc-Rich 

Primers by Solvent Rub 

Electronic Components Association (ECA)/Electronic Industries Alliance (EIA) 

EIA/ECA 310 Cabinets, Racks, Panels, and Associated Equipment 

EIA-364 Electrical Connector/Socket Test Procedures 

Including Environmental Classifications 
KSC-E-165E 

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October 29, 20 

8 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

International Electrotechnical Commission (IEC) 

IEC 60715 Dimensions of low-voltage switchgear and 

controlgear – Standardized mounting on rails for 

mechanical support of electrical devices in 

switchgear and controlgear installations 

IEC 60947-7-1 Low-voltage switchgear and control gear – Part 7-1: 

Ancillary equipment – Terminal blocks for copper 

conductors 

International Organization for Standardization (ISO) 

ISO 10012 Measurement management systems – Requirements 

for measurement processes and measuring 

equipment 

IPC – Association Connecting Electronics Industries 

IPC 2221 Generic Standard on Printed Board Design 

IPC 2222 Sectional Design Standard for Rigid Organic 

Printed Boards 

IPC 6011 Generic Performance Specification for Printed 

Boards 

IPC 6012 Qualification and Performance Specification for 

Rigid Printed Boards 

IPC 7711/7721 Rework, Modification, and Repair of Electronic 

Assemblies 

IPC-HDBK-001 Handbook and Guide to Supplement J-STD-001 

(Requirements for Soldered Electrical and 

Electronic Assemblies) 

IPC J-STD-001 Requirements for Soldering Electrical and 

Electronic Assemblies 

IPC J-STD-001ES Space Applications Electronic Hardware Addendum 

to IPC J-STD-001E 

IPC/WHMA-A-620 Requirements and Acceptance for Cable and Wire 

Harness Assemblies 
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February 2, 2009 

Change 3, November 6, 2014 

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National Aerospace Standards (NAS) 

NAS 1744 Splice, Conductor, Solder Style, Hot Air or 

Infrared, Shrinkable, Insulated, Immersion Resistant 

National Conference of Standards Laboratories (NCSL) 

NCSL Z540.3 Requirements for the Calibration of Measuring and 

Test Equipment 

National Electrical Manufacturers Association (NEMA) 

NEMA VE 2 Cable Tray Installation Guidelines 

NEMA WC 63.1 Performance Standard for Twisted Pair Premise 

Voice and Data Communications Cables 

NEMA WC 66 Standard for Category 6 and 6A, 100 Ohm, 

Individually Unshielded Twisted Pairs, Indoor 

Cables (With or Without an Overall Shield) for Use 

in LAN Communication Wiring Systems 

National Fire Protection Association (NFPA) 

NFPA 496 Standard for Purged and Pressurized Enclosures for 

Electrical Equipment 

NFPA 497 Recommended Practice for the Classification of 

Flammable Liquids, Gases, or Vapors and of 

Hazardous (Classified) Locations for Electrical 

Installations in Chemical Process Areas 

NFPA 70 National Electrical Code 

Society for Protective Coatings 

SSPC-AB 1 Mineral and Slag Abrasives 

SSPC-SP 1 Solvent Cleaning 

SSPC-SP 3 Power Tool Cleaning 

SSPC-SP 5/NACE No. 1 White Metal Blast Cleaning 
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Society of Automotive Engineers (SAE) 

SAE AIR6151 Torque, Threaded Application, Electrical 

Connector, Accessory and Terminal Board 

Installation 

SAE AMS 2518 Thread Compound, Anti-Seize, GraphitePetrolatum 

SAE AMS 2695C Connections, Electrical, Solderless, Wire-Wrapped 

SAE AMS-DTL-23053 Insulation Sleeving, Electrical, Heat Shrinkable, 

General Specification for 

SAE AMS-DTL-23053/1 Insulation Sleeving, Electrical, Heat Shrinkable, 

Crosslinked Chlorinated Polyolefin, Flexible 

SAE AMS-DTL-23053/5 Insulation Sleeving, Electrical, Heat Shrinkable, 

Polyolefin, Flexible, Crosslinked 

SAE AMS-DTL-23053/15 Insulation Sleeving, Electrical, Heat Shrinkable, 

Polyolefin, Heavy-Wall, Coated, Flexible, Outer 

Wall Crosslinked 

SAE AMS-I-7444 Insulation Sleeving, Electrical, Flexible 

SAE AMS-I-23053/2 Insulation Sleeving, Electrical, Heat Shrinkable, 

Polyvinyl Chloride Flexible, Crosslinked and 

Non-Crosslinked 

SAE AS 1072 Sleeve, Hose Assembly, Fire Protection 

SAE AS 7928 Terminals, Lug: Splices, Conductors: Crimp Style, 

Copper, General Specification for 

SAE AS 8660 Silicone Compound NATO Code Number S-736 

SAE AS 18121 Ferrules, Outer, Insulated, Shield Terminating, 

Type II, Two-Piece, Class I, for Shielded Cable 

SAE AS 21608 Ferrule, Shield Terminating, Crimp Style 

SAE AS 21980 Ferrules, Outer, Uninsulated, Shield Terminating, 

Type I, Two-Piece, Class I, for Shielded Cable 
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February 2, 2009 

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SAE AS 21981 Ferrule, Inner, Uninsulated, Shield Terminating, 

Type I, Two-Piece, Class I, for Shielded Cable 

SAE AS 22520 Crimping Tools, Wire Termination, General 

Specification for 

SAE AS 25036 Terminal, Lug, Crimp Style, Copper, Insulated, 

Ring Tongue, Bell-Mouthed, Type II, Class 1 (for 

105 °C Total Conductor Temperature) 

SAE AS 27212 Terminal Board Assembly, Molded-In-Stud, 

Electric 

SAE AS 50151 Connectors, Electrical, Circular Threaded, AN 

Type, General Specification for 

SAE AS 50861 Wire, Electric, Polyvinyl Chloride Insulated, 

Copper or Copper Alloy 

SAE AS 81714 Terminal Junction Systems (TJS), Environment 

Resistant, General Specification for 

SAE AS 81822 Wire, Electrical, Solderless Wrap, Insulated and 

Uninsulated, General Specification For (Stabilized 

Type) 

SAE AS 81824/1 Splice, Electric, Permanent, Crimp Style Copper, 

Insulated Environment Resistant, Class 1 

SAE AS 83519 Shield Termination, Solder Style, Insulated, HeatShrinkable, Environment Resistant, General 

Specification for 

Telecommunications Industry Association (TIA) 

TIA/EIA-455-78 FOTP-78 IEC 60793-1-40 Optical Fibres – 

Part 1–40: Measurement Methods and Test 

Procedures – Attenuation 

TIA-440-B Fiber Optic Terminology 
KSC-E-165E 

February 2, 2009 

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12 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

TIA-455-133-A FOTP-133 IEC-60793-1-22 Optical Fibres – 

Part 1–22: Measurement Methods and Test 

Procedures – Length Measurement 

Underwriters Laboratories Inc. (UL)/Canadian Standards Association (CSA) 

UL 444/CSA C22.2 Standard for Safety: Communications Cables 

2.3 Order of Precedence 

In the event of conflict between the documents referenced herein and the contents of this 

document, the contents of this document shall supersede except where otherwise noted. The 

applicable NASA contract or purchase/procurement order shall take precedence over the 

contents of this document in the event of conflicting requirements. Nothing in this document 

supersedes applicable laws and regulations unless a specific exemption has been obtained. 

3. REQUIREMENTS 

The requirements of this specification apply to the fabrication, maintenance, repair, and 

procurement of all electrical and electronic control and monitoring equipment associated with 

GSE at KSC. The contractor shall be responsible for adhering to the provisions of this 

specification. The contractor is also responsible for adhering to all local, state, and Federal safety 

regulations during performance of work specified in this document, including but not limited to, 

KNPR 8715.3-1, NPR 8715.3C, and CFR Title 29, Part 1910 (OSHA). The contracting officer 

shall be responsible for interpreting the provisions and verifying compliance with this 

specification. No substitutions of items shall be allowed unless approved by the contracting 

officer or the designated representative. If this specification is used for contracts for maintenance 

and repair, the responsibility for interpreting the provisions of and verifying compliance with this 

specification shall belong to the Government technical contact (NASA systems engineer, 

sustaining engineer, etc.). 

3.1 Metal and Sheet Metal Assemblies, Subassemblies, and Details 

Where required, all metal and sheet metal assemblies, subassemblies, and details shall be 

fabricated as specified by the applicable drawings and specifications in accordance with this 

specification, using methods that will ensure an end product of high-quality standards and 

appearance. Protective coatings for carbon steel, stainless steel, and aluminum shall be applied in 

accordance with the following paragraphs and NASA-STD-5008. Equipment racks shall be in 

accordance with KSC-SPEC-E-0002 and shall be designed to maintain the panel and chassis 

slide mounting dimensions specified in KSC-SPEC-E-0002 so standard panels and hardware 

may be used. The dimensions of standard 483-millimeter (mm) (19-inch [in]) panels shall be in 

accordance with EIA/ECA-310. Commercial off-the-shelf (COTS) racks and enclosures will 

comply with KSC-SPEC-E-0002.
KSC-E-165E 

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3.1.1 Surface Preparation 

All surfaces to be coated shall be clean, dry, and free from oil, grease, dirt, dust, corrosion, 

peeling paint, caulking, weld spatter, and any other surface contaminants. All surfaces that will 

become inaccessible after fabrication, erection, or installation shall be prepared and coated while 

accessible. Surface preparation and coating operations shall be sequenced so that freshly applied 

coatings will not be contaminated by dust or foreign matter. All equipment and adjacent surfaces 

that are not to be coated shall be protected from contamination during surface preparation. 

Surfaces shall be masked before painting to leave unpainted conductive contact areas where 

designated. Working mechanisms shall be protected against an intrusion of abrasive material. All 

surfaces shall be degreased, as required, before more surface preparation work is done or 

protective coatings are applied, or both. Additional metal-specific surface preparation shall be 

performed in accordance with NASA-STD-5008. 

NOTES 

1. Only aggregates that are free of crystalline silica 

shall be selected for use at NASA. Exemptions to 

this policy shall be coordinated with the local 

Occupational Health Office. 

2. Blasting aggregate for abrasion-sensitive hardware 

(such as bellows, gimbal joints, and other thinwalled components) shall be materials that produce 

no additional surface profile. Blasting operations 

shall not produce holes, cause distortion, remove 

metal, or cause thinning of the substrate. 

3.1.1.1 Abrasive Blasting 

The abrasive blasting system shall comply with Occupational Safety and Health Administration 

(OSHA), American National Standards Institute (ANSI), and National Institute of Occupational 

Safety and Health (NIOSH) configurations. The blasting system shall be designed to produce the 

specified cleanliness level and profile when coupled with the available compressed air supply. 

Blasting aggregates shall be clean and dry, and made of approved materials in accordance with 

MIL-A-22262 or SSPC-AB 1, Type I or II, Class A, or steel grit. Only materials approved in the 

QPL attached to MIL-A-22262 shall be used. The abrasive grade selected must produce the 

required surface profile and possess physical properties that are compatible with the 

requirements of this standard. The steel grit shall be a neutral (6.0 to 8.0 pH), rust-free, oil-free, 

dry, commercial-grade blasting grit with a hardness of 40 to 50 Rockwell C. The size shall be 

selected to produce the required anchor profile. For removing paint or cleaning aluminum, 

stainless steel, and fiberglass, in accordance with MIL-P-85891, plastic media may be used as an 

alternate. 
KSC-E-165E 

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14 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

Abrasive residues shall be removed from the surface, leaving it clean and dry before the coatings 

are applied. The particulate emissions generated during abrasive blasting operations shall be 

contained. The containment system shall comply with all applicable Federal, state, and local 

regulations as well as all NASA policies. Exemptions to this requirement shall be coordinated 

with the local environmental management office. 

Care shall be taken in identifying and selecting the aggregate to use in preparing abrasivesensitive hardware such as bellows, gimbal joints, and other thin-walled components. 

3.1.1.2 Degreasing 

Degreasing shall be done by cleaning with solvents, washing with detergent, or steam-cleaning 

in accordance with SSPC-SP 1. This procedure shall be followed when cleaning steel, galvanized 

steel, or stainless steel. NASA policy prohibits the use of chlorofluorocarbon solvents. Solvents 

shall be selected in accordance with all applicable Federal, state, and NASA environmental 

policies. Hardware shall be washed with water when high levels of chloride or other undesirable 

contaminants are found on the surfaces. This shall be accomplished using standard industrial 

pressure cleaners with a pressure-versus-volume-output balance that will provide thorough 

cleaning. High-pressure water cleaning shall not be used as a cleaning method if the existing 

paint film on a surface exceeds any of the characteristics for toxicity listed in the Toxicity 

Characteristic Leaching Procedure (TCLP). No chemical shall be added to the water used for the 

paint blasting/removal operation, and no discharge shall be directed to surface waters. A 

40-micrometer (μm) filter mesh shall be used to screen wastewater discharge on operations 

performed over pervious surfaces. Points of discharge shall be identified before water blasting 

operations are performed over impervious surfaces. All discharges shall then be channeled to 

pervious areas by using sandbags and a 40 μm filter mesh. Any residues generated in water 

blasting operations shall be disposed of in accordance with local environmental regulations. All 

records of water blasting operations shall be submitted to the local environmental management 

office. The cleaned surface shall be free of loose coating material, chlorides, dirt, dust, mildew, 

grinding/welding/cutting debris, and visible contaminants. The surface shall be clean and dry 

before abrasive blasting is done and coatings are applied. 

3.1.2 Protective Coatings, Thinners, and Cleaners 

Minimum requirements for each generic type of protective coating specified in 3.1.2.1 are listed 

in NASA-STD-5008. Thinners and cleaners for each coating shall be procured from the 

manufacturer of the coating, except for potable water epoxy as specified in NASA-STD-5008. 

To ensure intercoat compatibility, coating systems consisting of more than one coat shall be 

products of the same manufacturer, except for inorganic and polysiloxane topcoats. Additional 

metal-specific protection requirements shall be met in accordance with NASA-STD-5008. 

Continuity of use of the coating manufacturer’s system shall be maintained for the duration of an 

individual project. 
KSC-E-165E 

February 2, 2009 

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All coatings must possess physical properties and handling characteristics that are compatible 

with the application requirements of this standard, and all coatings must be self-curing. 

3.1.2.1 Generic Protective Coatings 

a. Inorganic zinc coatings 

b. Primer and/or intermediate coatings 

(1) Inhibitive polymide epoxy coatings 

(2) Noninhibitive polymide epoxy coatings 

(3) Water-reducible intermediate coatings 

c. Finish coatings 

(1) Aliphatic polyurethane coatings 

(2) Water-reducible topcoats 

(3) Inorganic topcoats 

(4) Polysiloxane topcoats 

d. Epoxy mastic coatings 

e. Coal tar epoxy coatings 

f. Potable water epoxy coatings 

g. Nonskid coatings 

3.1.2.2 Application of Coatings 

All prepared surfaces shall be coated within 6 hours after the surface preparation has been 

completed and before corrosion or recontamination occurs. Surfaces prepared under temperature 

and humidity control may be coated after 6 hours but only after a reinspection of the surface 

preparation confirms that the surface is at the specified cleanliness level. 
KSC-E-165E 

February 2, 2009 

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16 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

No coating shall be applied when contamination from rainfall is imminent or when the 

temperature or humidity is outside limits recommended by the coating manufacturer. To prevent 

condensation while the coating is being applied, the surface temperature must be at least 

3 degrees Celsius (°C) (5 degrees Fahrenheit [°F]) above the dewpoint. Wind speed shall not 

exceed 25 kilometers per hour (km/h) (15 miles per hour [mph]) in the immediate coating area 

when using spray application methods. 

NOTES 

1. Relative humidity (RH) limitations using certain 

coatings shall be followed: 

2. <40% RH solvent-based inorganic zinc coatings, 

PSX 700, and inorganic topcoats shall not be 

applied. 

3. <40% or >80% RH water-based inorganic zinc 

coatings shall not be applied. 

Any surface that shows corrosion or contamination, regardless of the length of time after 

preparation, shall be prepared again. The application and handling characteristics of coatings will 

vary. To obtain optimum performance, adequate written instructions from the manufacturer are 

essential and must be closely followed in conjunction with the requirements defined in this 

specification. The manufacturer’s recommendations for thinning, mixing, handling, and applying 

the product shall be strictly followed. Coatings shall be thoroughly worked into all joints, 

crevices, and open spaces. Newly coated surfaces shall be protected from damage. Any item of 

equipment or adjacent surface that is not to be coated shall be protected from overspray and 

splattered coatings. The particulate emissions from spray painting operations shall be contained 

while the work is being done. The containment system shall be designed to comply with Federal, 

state, and local regulations as well as NASA policies. Exemptions to this requirement shall be 

coordinated with the local environmental management organization. 

3.1.2.3 Colors 

Rack and enclosure colors shall be in accordance with NASA-STD-5008 and FED-STD-595. In 

some operational areas, textured finishes and colors other than those specified herein have 

become standard. Racks and enclosures in these areas should receive a matching color and 

texture. 

3.1.2.4 Storage, Mixing, and Application Methods 

Storage, mixing, and application methods of coating materials shall be in accordance with 

NASA-STD-5008. 
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3.1.2.5 Coating Finish 

Each coat of material applied shall be free of runs, sags, blisters, bubbles, and mudcracking; 

variations in color, gloss, and texture; holidays (missed areas); excessive film buildup; foreign 

contaminants; dry overspray; etc. Special care shall be taken to ensure complete coverage and 

proper thickness on welds, corners, crevices, sharp edges, bolts, nuts, and rivets. Each coat of 

applied material shall be rendered clean, dry, and free from surface contaminants before the next 

layer of coating is applied. 

3.1.2.6 Touchup of Welds and Damaged Coatings 

Touchup of welds and damaged coatings shall be in accordance with NASA-STD-5008. 

The coating manufacturer’s recommended drying and curing times for handling, recoating, and 

topcoating shall be followed. Coating manufacturer’s recommendations shall be followed to test 

the coating for proper curing. Proper curing of solvent-based inorganic zinc-rich coatings must 

be verified by ASTM D 4752-03 prior to further coating. Water-based inorganic zinc-rich 

coatings must be verified for curing, in accordance with the same procedure, but water must be 

substituted as the solvent. 

NOTE 

The cure rate of solvent-based inorganic zinc 

coatings can be accelerated by rinsing or spraying 

them with fresh water after an initial overnight 

drying. The number and frequency of rinse cycles 

can vary with environmental conditions. Check with 

the material’s manufacturer for recommended 

procedures. 

3.1.3 Sealants and Caulking 

Sealants shall be self-curing, single-component, polysulfide rubber or polyurethane material 

only, conforming to ASTM C 920, Type S, Grade NS, Class 25, use NT, A, and O. If not 

topcoated, the caulking shall match the color of the joint surface being caulked. If caulking is to 

be used in a clean-room environment, an approved material with low off-gassing properties shall 

be selected. 

The perimeter of all faying surfaces, joints open less than 13 mm (0.5 in), and skip-welded joints 

shall be completely sealed. For inorganic zinc primers on carbon steel, apply the sealant to the 

joint with a caulking gun after applying the primer. For topcoated zinc primers, apply the 

caulking after applying an intermediate epoxy coat; and for coatings on stainless steel, 

galvanized steel, and aluminum, apply the caulking before applying the topcoat. The bead shall 

have a smooth and uniform finish and shall be cured (tacky to the touch) before the topcoat is 

applied.
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3.1.4 Chip-Free Clean-Room Paint 

Paint systems for metal substrates in clean rooms shall pass tests for adhesion, off-gassing, 

flammability, and hypergolic compatibility at the NASA Spaceport Technology Development 

Office, Kennedy Space Center, Florida. Approved systems are listed in NASA-STD-5008. 

3.1.5 Zones of Exposure 

Coating system requirements for surfaces located in specific environments are defined in 

NASA-STD-5008. 

3.1.6 Aluminum Racks, Enclosures, Panels, Junction Boxes, and Miscellaneous Details 

3.1.6.1 Materials 

Aluminum racks, enclosures, junction boxes, and miscellaneous details shall be fabricated from 

5000-series or 6000-series aluminum alloys in accordance with KSC-SPEC-E-0002, 

ASTM B209, or ASTM B221; and material specified on the applicable drawings and 

specifications. Aluminum panels fabricated from 3.2 mm (0.125 in)-thick 6061-T6 aluminum are 

preferred, and aluminum 6063- and 5052-type alloys are acceptable. 

3.1.6.2 Cleaning, Treating, and Coating 

Aluminum castings shall be cleaned in accordance with NASA-STD-5008. Aluminum racks, 

enclosures, panels, junction boxes, and miscellaneous details shall be cleaned, treated, and 

coated in accordance with the following paragraphs. 

3.1.6.2.1 Surface Preparation 

All surfaces to be coated shall be clean, dry, and free from oil, grease, dirt, dust, corrosion, 

peeling paint, caulking, weld spatter, and any other surface contaminants that might prevent 

subsequent finishes from adhering properly. Aluminum shall be prepared by degreasing and 

abrasive blasting or mechanical cleaning. Abrasive blasting shall be used whenever possible 

using nonmetallic abrasives specified in 3.1.1.1. Mechanical cleaning shall be used only when 

abrasive blasting is impractical, would damage the structure or component, or is prohibited. 

Aluminum shall be mechanically cleaned in accordance with SSPC-SP 3, using abrasive 

discs/sheets or other approved methods. Anodized or chemical conversion coated aluminum 

surfaces shall not be mechanically cleaned. 

All corrosion and foreign matter shall be completely removed from the surface and the entire 

surface slightly roughened. 
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Abrasive blasting of bellows, gimbal joints, and other thin-walled, abrasion-sensitive 

components shall be done with walnut shells, plastic media, or an approved equivalent in 

accordance with 3.1.1.1. 

Surfaces that will be underground, submerged, or continuously wetted shall be prepared in 

accordance with SSPC-SP 5, with a profile of 75 μm to 100 μm (3 mil to 4 mil) in accordance 

with NASA-STD-5008. 

CAUTION 

Some aluminum configurations are susceptible to 

distortion and/or destruction when they are cleaned 

by abrasive blasting. Special care shall be taken to 

prevent metal damage by choosing the proper 

abrasive aggregate, reducing the blast nozzle 

pressure, and increasing the distance from the 

nozzle to the surface as necessary. In some cases, 

such as in the surface preparation of light-gage 

sheets, these precautions may not be sufficient to 

prevent distortion and an alternate procedure, such 

as abrading or mechanical cleaning, must be used to 

remove corrosion or roughen the surface. 

3.1.6.3 Chromate Coatings 

Where maximum conductivity is desired (such as in panels), chromate coatings shall be in 

accordance with MIL-DTL-5541, class 3 (clear chromate is preferred). All other aluminum 

fabrications, especially those made of softer forming alloys, should be class 1A, yellow 

chromate. Thorough chemical or mechanical cleaning shall be done before chromate coatings are 

applied. 

3.1.6.4 Protective Coatings 

Protective coatings shall be applied to aluminum surfaces as required for each zone of exposure 

as described in NASA-STD-5008. Surfaces that will be underground, submerged, or 

continuously wetted shall be coated with coal tar epoxy conforming to NASA-STD-5008. 

3.1.6.5 Finish Colors 

The topcoat colors for electrical panels shall be in accordance with FED-STD-595 color 

number 26440, light gray. The interior surfaces of junction boxes shall be finished with 

FED-STD-595 color number 27875, white. Unless otherwise specified, all other parts and 

assemblies shall be finish-painted with FED-STD-595 color number 26251, dark gray. 
KSC-E-165E 

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3.1.7 Steel Racks, Enclosures, Junction Boxes, Assemblies, and Miscellaneous Details 

3.1.7.1 Materials 

Steel racks, enclosures, junction boxes, and miscellaneous details shall be fabricated from the 

material specified on the applicable drawings and specifications, and in accordance with 

KSC-SPEC-E-0002. 

3.1.7.2 Cleaning, Treating, and Coating 

All carbon steel and stainless-steel surfaces shall be treated in accordance with 

NASA-STD-5008. Topcoat systems shall be applied according to the zone of exposure as 

defined in NASA-STD-5008. 

3.1.7.3 Finish Colors 

Unless otherwise specified, topcoat colors shall be in accordance with FED-STD-595 color 

number 26251, dark gray, except for the interior back panel surfaces, which shall be 

FED-STD-595 color number 27875, white. 

3.1.8 Fabricated Chassis 

3.1.8.1 Materials 

Chassis shall be fabricated in accordance with 75M05218. Cast chassis shall be used in all 

propellant applications. Aluminum alloy 5052-H32, or its equivalent, is preferred for items with 

formal bends. 

3.1.8.2 Cleaning and Treating 

Aluminum chassis shall be cleaned and given a chromate coating in accordance with 3.1.6.3. No 

chassis shall be given a topcoat over the chromate unless specified on the applicable engineering 

drawing. 

3.2 Welding and Brazing 

3.2.1 Welding 

The welding of all assemblies, subassemblies, and detail parts shall be in accordance with the 

drawing requirements and KSC-DE-512-SM. 
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3.2.2 Brazing 

The brazing of all assemblies, subassemblies, and detail parts shall be in accordance with 

drawing requirements and KSC-SPEC-Z-0005. Brazing shall be performed only by operators 

who have met the requirements of KSC-SPEC-Z-0005. 

NOTE 

The only electrical connections that can be brazed 

are ground connections. 

3.3 Fasteners 

Metallic fasteners shall be chosen to minimize dissimilar metal corrosion. When it is not possible 

to avoid joining dissimilar metals, the metal of the fastener shall be from a higher potential group 

than the structure. Then if corrosion does occur, the replaceable hardware items will be affected 

instead of the basic structure. Refer to GP-777 for the criteria governing the choice of fasteners. 

3.3.1 Threaded Fasteners 

3.3.1.1 Torque Limits for Threaded Fasteners 

Unless otherwise specified, torque values for fastener systems used in shear applications shall 

not exceed 60 percent of the values shown in Table 1, Table 2, and Table 3. A tolerance of 

+0 percent and –15 percent shall apply to the specified fastener types. 

In circumstances where the nut strength varies from the bolt strength, the torque requirement of 

the lower strength component shall apply. Torque values for bolts with countersunk heads and 

threaded fasteners nos. 2 through 10 are specified in MSFC-STD-486. All compression-type 

electrical connections, such as terminal strips, shall be properly tightened and checked for any 

indications of looseness. 

3.3.1.2 Installation of Nuts on Bolts or Screws 

Nuts on bolts or screws shall be installed as follows: 

a. Only sockets and wrenches that have no sharp edges or burrs that could damage 

the fastener plating or coating shall be used. 

b. Whenever clearance is a problem, torquing shall be from the bolt head side to the 

high side of the torque range as specified in Table 1, Table 2, and Table 3. 

c. The nut shall not engage any incomplete threads adjacent to the bolt or screw 

shank.
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d. Any identification mark on the washer used under the nut shall be placed opposite 

the face of the nut. 

e. When a self-locking nut is installed or removed, the locking or breakaway torque 

shall comply with the applicable torque value shown in Table 4. 

f. Bolts or screws shall be installed to extend through nuts to comply with the thread 

minimum protrusion requirement in Table 5. 
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23 

Table 1. Torque Values for Steel, Cadmium-Plated, Unlubricated Threaded Fasteners 

Fastener Size 

(mm [in]) 

Grade Ultimate Tensile Strength 

SAE2 SAE5 SAE8 862 MPa (125 ksi) 1.10 GPa (160 ksi) 1.24 GPa (180 ksi) 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

5.000 10-32 1.4 12 2.7 24 3.8 34 3.1 27 4.2 37 5.9 52 6.350 0.2500 6.2 55 9.0 80 11.5 102 10.2 90 13.0 115 16.4 145 7.938 0.3125 11.9 105 17.0 150 25.4 225 17.5 155 26.9 238 36.2 320 9.525 0.3750 20.3 180 29.9 265 42.4 375 31.1 275 45.8 405 59.9 530 

11.113 0.4375 31.1 275 54.2 480 68.9 610 56.5 500 84.8 750 97.2 860 12.700 0.5000 47.5 420 68.9 610 102.3 905 78.0 690 107.4 950 142.4 1260 14.288 0.5625 70.1 620 101.7 900 151.9 1344 113.0 1000 158.7 1404 217.0 1920 15.875 0.6250 99.4 880 138.3 1224 207.5 1836 146.4 1296 237.3 2100 284.8 2520 19.050 0.7500 155.9 1380 264.4 2340 339.0 3000 282.0 2496 508.5 4500 474.6 4200 22.225 0.8750 210.2 1860 318.7 2820 542.4 4800 433.9 3840 711.9 6300 759.4 6720 25.400 1.0000 318.7 2820 589.9 5220 817.7 7236 623.8 5520 1017.0 9000 1166.2 10320 28.575 1.1250 508.5 4500 854.3 7560 1301.8 11520 901.7 7980 1573.0 13920 1844.2 16320 31.750 1.2500 711.9 6300 1179.7 10440 1789.9 15840 1247.5 11040 2373.0 21000 2562.8 22680 

Notes: 1. These torque values apply to coarse and fine threads. 2. A tolerance of +0% and 

–15% is applicable. 

3. Add locking torque of self-locking devices to torque values specified on the drawing. 4. Torque values are for tension applications. Torque values for shear applications shall not exceed 60% of the values shown unless otherwise 

specified. 

KSC-E-165E 

February 2, 2009 

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KSC-E-165E 

October 29, 2008 24 

Table 2. Torque Values for Steel, Lubricated (Plated, Unplated) Threaded Fasteners 

Fastener Size 

(mm [in]) 

Grade Ultimate Tensile Strength 

SAE2 SAE5 SAE8 862 MPa (125 ksi) 1.10 GPa (160 ksi) 1.24 GPa (180 ksi) 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

5.000 10-32 1.0 9 2.0 18 3.4 30 3.1 27 3.7 33 4.4 39 6.350 0.2500 4.7 42 8.1 72 10.2 90 8.8 78 11.2 99 11.6 103 7.938 0.3125 8.8 78 14.9 132 22.4 198 16.3 144 23.7 210 27.1 240 9.525 0.3750 15.3 135 25.8 228 37.3 330 27.1 240 40.7 360 44.7 396 

11.113 0.4375 23.7 210 40.7 360 61.0 540 44.1 390 65.1 576 73.2 648 12.700 0.5000 35.6 315 61.0 540 89.3 790 65.1 576 93.8 830 106.2 940 14.288 0.5625 53.1 470 89.3 790 122.0 1080 97.2 860 135.6 1200 162.7 1440 15.875 0.6250 74.6 660 122.0 1080 183.1 1620 135.6 1200 195.3 1728 217.0 1920 19.050 0.7500 122.0 1080 183.1 1620 298.3 2640 217.0 1920 325.4 2880 359.3 3180 22.225 0.8750 162.7 1440 311.9 2760 474.6 4200 345.8 3060 508.5 4500 569.5 5040 25.400 1.0000 244.1 2160 474.6 4200 718.7 6360 522.1 4620 781.1 6912 881.4 7800 28.575 1.1250 372.9 3300 637.3 5640 1152.6 10200 813.6 7200 1220.4 10800 1383.1 12240 31.750 1.2500 535.6 4740 895.0 7920 1593.3 14100 1139.0 10080 1708.6 15120 1925.5 17040 

Notes: 1. These torque values apply to coarse and fine threads. 2. A tolerance of +0% and 

–15% is applicable. 

3. Add locking torque of self-locking devices to torque values specified on the drawing. 4. Torque values are for tension applications. Torque values for shear applications shall not exceed 60% of the values shown unless otherwise 

specified. 

KSC-E-165E 

February 2, 2009

24 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 
KSC-E-165E 

October 29, 2008 

25 

Table 3. Torque Values for Corrosion-Resistant Steel (CRES) and Aluminum Alloy Threaded Fasteners 

Fastener Size 

CRES 300 Series 

[552 MPa (80 ksi) Minimum UTS] 

Aluminum Alloy 

[427 GPa (62 ksi) Minimum UTS] 

Passivated Silver Plated Lubricated Anodized Lubricated 

(mm [in]) 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

Nm in-lb 

5.000 10-32 3.4 30 2.7 24 2.0 18 1.6 14 1.0 9 6.350 0.2500 7.9 70 6.3 56 4.7 42 5.1 45 2.8 25 7.938 0.3125 14.7 130 11.8 104 8.8 78 9.0 80 5.1 45 9.525 0.3750 25.4 225 20.3 180 15.3 135 16.4 145 9.6 85 

11.113 0.4375 42.4 375 33.9 300 25.4 225 26.0 230 15.3 135 12.700 0.5000 56.5 500 45.2 400 33.9 300 36.2 320 21.5 190 14.288 0.5625 79.1 700 63.3 560 47.5 420 52.0 460 28.3 250 15.875 0.6250 113.0 1000 90.4 800 67.8 600 74.0 655 48.6 430 19.050 0.7500 162.7 1440 130.0 1150 97.2 860 106.2 940 65.5 580 22.225 0.8750 257.6 2280 203.4 1800 154.6 1368 162.7 1440 97.2 860 25.400 1.0000 352.6 3120 284.8 2520 210.2 1860 217.0 1920 130.0 1150 28.575 1.1250 528.8 4680 420.4 3720 318.7 2820 325.4 2880 189.8 1680 31.750 1.2500 650.9 5760 522.1 4620 393.2 3480 406.8 3600 244.1 2160 

Notes: 1. These torque values apply to coarse and fine threads. 2. A tolerance of +0% and 

–15% is applicable. 

3. Add locking torque of self-locking devices to torque values specified on the drawing. 4. Torque values are for tension applications. Torque values for shear applications shall not exceed 60% of the values shown unless 

otherwise specified. 

KSC-E-165E 

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KSC-E-165E 

February 2, 2009 

26 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

Table 4. Required Locking Torque at Room Ambient Temperature 

Fastener 

Size 

Pitch

(mm) 

Threads 

per Inch 

Maximum 

Locking Torque, 

Installation or Removal 

Minimum 

Breakaway Torque, 

Removal 

mm in Nm in-lb Nm in-lb

4.76 0.1875 0.8 32 2 18 0.2 2.0 

6.350 0.2500 1.0 28 3.5 30 0.4 3.5 

7.938 0.3125 1.5 24 7 60 0.7 6.5 

9.525 0.3750 1.5 24 9 80 1.1 9.5 

11.113 0.4375 1.75 20 11 100 1.6 14.0 

12.700 0.5000 1.75 20 17 150 2.0 18.0 

14.288 0.5625 2.0 18 23 200 2.7 24.0 

15.875 0.6250 2.0 18 34 300 3.6 32.0 

19.050 0.7500 2.5 16 45 400 5.7 50.0 

22.225 0.8750 3.0 14 68 600 7.9 70.0 

25.400 1.0000 4.0 12 90 800 10.2 90.0 

28.575 1.1250 4.0 12 102 900 13.2 117.0 

31.750 1.2500 4.0 12 113 1000 16.2 143.0 

34.925 1.3750 4.0 12 124 1100 18.6 165.0 

38.100 1.5000 4.0 12 141 1250 22.0 195.0 

Table 5. Minimum Bolt or Screw Thread Protrusion 

Pitch 

(mm) 

Threads 

per Inch 

Protrusion 

mm in 

0.8 32 1.57 0.062 

1.0 28 1.80 0.071 

1.5 24 2.11 0.083 

1.75 20 2.54 0.100 

2.0 18 2.82 0.111 

2.5 16 3.18 0.125 

3.0 14 3.63 0.143 

4.0 12 4.24 0.167 
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3.3.1.3 Torque Values for Standard and High-Strength Steel Fasteners 

3.3.1.3.1 Plated 

Torque values for tightening clean, cadmium-plated, unlubricated steel fasteners shall be in 

accordance with Table 1. 

3.3.1.3.2 Lubricated 

Torque values for tightening steel fasteners lubricated with an approved lubricant (see 3.3.1.6) 

shall be in accordance with Table 2. 

3.3.1.4 Torque Values for 300 Series CRES Fasteners 

3.3.1.4.1 Passivated 

Torque values for tightening clean, passivated CRES fasteners shall be in accordance with 

Table 3. 

3.3.1.4.2 Plated 

Torque values for tightening clean, silver-plated CRES fasteners shall be in accordance with 

Table 3. 

3.3.1.4.3 Lubricated 

Torque values for tightening CRES fasteners lubricated with an approved lubricant (see 3.3.1.6) 

shall be in accordance with Table 3. 

3.3.1.5 Torque Values for 430 MPa (62 ksi) Tensile Strength Aluminum Alloy 

Fasteners (2024-T4, 7075-T6) 

3.3.1.5.1 Anodized 

Torque values for tightening clean, anodized aluminum fasteners shall be in accordance with 

Table 3. 

3.3.1.5.2 Lubricated 

Torque values for tightening aluminum fasteners lubricated with an approved lubricant (see 

3.3.1.6) shall be in accordance with Table 3.
KSC-E-165E 

February 2, 2009 

Change 1, June 4, 2013 

28 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

3.3.1.6 Lubricants 

Unless otherwise specified, lubricants equal to or interchangeable with those listed below may be 

used when necessary to prevent galling or other damage to fastener threads or bearing surfaces. 

Any lubricant used in liquid oxygen (LO2) systems or gaseous systems that are used in 

pressurizing or purging LO2 systems shall meet the compatibility requirements of 

NASA-STD-6001. 

a. Everlube 811 (Everlube Corporation) 

b. Drilube 701 (Drilube Company, 711 West Broadway St., Glendale, CA 91204 

[CAGE 06186]) 

c. Molykote Z (Alpha Molykote Corporation) 

d. EC1730 (Acheson Colloid Company, 1600 Washington Ave., P.O. Box 11747, 

Pt. Huron, MI 48061 [CAGE 70079]) 

e. KEL-F-90 (Minnesota Mining and Manufacturing Company) 

f. Lubricants that are applied to fasteners qualified under NASM 25027 

g. SAE AMS 2518, thread compound, antiseize, graphite-petrolatum 

h. MIL-PRF-46010, lubricant, solid film, heat-cured, corrosion-inhibiting 

i. HD Calcium Grease No. 2 (Continental Oil Company) 

j. CERAN HVA 2 (Total Lubricants USA, Inc.) Extreme Pressure, Water Resistant, 

High Temperature, Calcium Sulfonate Complex Grease 

NOTE 

When specified on drawings for space vehicles and 

equipment, grease shall be applied to the structure 

and shank, threads, and washers of the fastener 

system. After torquing, excess grease shall be 

removed with a lint-free cloth or paper towel. 

3.3.1.7 Self-Locking Fasteners 

The measured locking torque of self-locking fasteners shall be added to the specified torque to 

obtain the final applied torque.
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3.3.1.8 Cotter Pin, Lockwire, and Safety Cable Securing 

When securing fasteners with cotter pins, safety cable, or lockwire, tightening may continue 

beyond the specified torque to permit slot and hole alignment provided the final torque does not 

exceed the specified torque by more than 10 percent. AIA/NAS NASM 33540 lists the 

specifications and requirements for installation of cotter pins, lockwire, or safety cable. 

3.3.1.8.1 Safety Cable 

A safety cable system consists of one tool for tensioning, crimping, and cutting. After a cable is 

threaded through the fasteners and a loose ferrule inserted, the calibrated crimping tool tensions 

the assembly, crimps the loose ferrule, and cuts the excess cable flush to the ferrule. Figure 1 is a 

diagram of a tension tool, ferrule, and calibration unit. Figure 2 illustrates typical safety cable 

installations. 

3.3.1.9 Nonmetallic Fasteners 

Nonmetallic fasteners are useful in applications requiring good thermal and electrical insulation 

and good corrosion resistance. They shall not be used in applications requiring high-tensile or 

shear strength or those operating in high temperatures. 

3.3.2 Adhesives 

Adhesives shall not be used to mount items normally subject to replacement or to secure parts 

requiring removal when equipment is serviced. 

3.3.3 Rivets 

Although rivets were previously used at KSC, they are no longer approved for use in mounting 

items normally subject to replacement or to secure parts that must be removed when equipment 

is serviced. If rivets are used in new design, they shall be installed in accordance with 

MSFC-STD-156 unless otherwise specified on the applicable drawings. 

3.3.3.1 Chips, Burrs, and Foreign Material 

Before parts are riveted together, all chips, burrs, and foreign material shall be removed from the 

mating surfaces. Burrs may be removed from rivet holes by chamfering to a depth not to exceed 

10 percent of the stock thickness or 0.81 mm (0.032 in), whichever is less. 
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Figure 1. Safety Cable, Tension Tool, Ferrule, and Calibration Unit 
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Figure 2. Typical Safety Cable Installations
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32 APPROVED FOR PUBLIC RELEASE – DISTRIBUTION IS UNLIMITED 

3.3.3.2 Rivet Substitutions 

Rivet substitutions shall not be made without the prior approval of the contracting officer except 

when a buildup of tolerances makes it necessary to use longer or shorter rivets than specified. In 

this case, the assembler may make a substitution without requesting approval. 

3.4 Identification and Marking (of GSE) 

Markings shall be specified on the engineering drawings and in accordance with 

KSC-STD-E-0015. This includes, but is not limited to, silk screening, engraving, rubber 

stamping, stenciling, die stamping, photoetching, hot stamping, thermal transfer, computer 

printing, identification plates, welding, and cast or forged markings. All identification markings 

shall be above the component, if possible, unless otherwise specified on the drawing. The 

finished product shall display a professional appearance; and the marking shall not have ragged 

edges, unbalanced characters, or excess paint (the latter is applicable to silk screening only). 

Markings for shipment shall be in accordance with MIL-STD-129. Marker tape shall be in 

accordance with 75M11300. 

3.5 Electrical Wiring, Internal 

All wiring shall be installed in accordance with applicable engineering drawings, NFPA 70, the 

National Electrical Code (NEC), and the following paragraphs. 

3.5.1 Plenum-Rated and Non-Plenum-Rated 

Local, state, and Federal regulations regarding the required use of plenum-rated and non-plenumrated cable and wiring shall be followed. According to the NEC, a plenum is “a compartment or 

chamber to which one or more air ducts are connected and that forms part of the air distribution 

system.” To qualify as a plenum, the space above an acoustic tile ceiling or below a raised floor 

would have to extend above or below other rooms in the same building, respectively, or be open 

to ducts connecting it to other parts of the building. The concern is that during a fire, burning 

material in a plenum air space can create smoke and fumes that can travel through air ducts to the 

entire building. For this reason, there are codes to restrict the types of materials (such as wiring 

and cable) that can be placed in the plenum. 

According to the NEC, plenum-rated wire and cable must be used in plenum air spaces. Plenumrated wire and cable have a fire-retardant insulation, which inhibits the propagation of fires and 

toxic fumes. The local fire marshal is the definitive source for determining the use of plenumrated or non-plenum-rated cable and wiring. Contact the local fire marshal if questions arise 

regarding the use of plenum-rated wiring and or cables in a specific environment. 
KSC-E-165E 

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3.5.2 Class I, Division 2 

Because of the nature of business at KSC, some areas are considered (classified as) hazardous 

locations. NFPA 70, Section 500, defines Class I, Division 2, as a location: 

a.in which volatile flammable gases, flammable liquid-produced vapors, or 

combustible liquid-produced vapors are handled, processed, or used, but in which 

the liquids, vapors, or gases will normally be confined within closed containers or 

closed systems from which they can escape only in case of accidental rupture or 

breakdown of such containers or systems or in case of abnormal operation of 

equipment, or 

b. in which ignitable concentrations of flammable gases, flammable liquid-produced 

vapors, or combustible liquid-produced vapors are normally prevented by positive 

mechanical ventilation and which might become hazardous through failure or 

abnormal operation of the ventilating equipment, or 

c. that is adjacent to a Class I, Division 1, location, and to which ignitable 

concentrations of flammable gases, flammable liquid-produced vapors, or 

combustible liquid-produced vapors above their flash points might occasionally 

be communicated unless such communication is prevented by adequate positivepressure ventilation from a source of clean air and effective safeguards against 

ventilation failure are provided. 

NFPA 70, Section 500, states “This classification usually includes locations where volatile 

flammable liquids or flammable gases or vapors are used but that, in the judgment of the 

authority having jurisdiction, would become hazardous only in case of an accident or of some 

unusual operating condition.” If cable or wiring is being fabricated for use in a Class I, 

Division 2, location, the cable/wire must be rated/certified for such use. See vendor 

specifications for information on Class I, Division 2, certification. 

3.5.3 Wire 

Wire that is 1.27 mm (AWG 16) or less in diameter shall be in accordance with 

MIL-DTL-16878/1 (tin-coated/polyvinyl-chloride [PVC]-insulated) for normal usage and 

MIL-DTL-16878/25 (nickel-coated copper/polytetrafluoroethylene [PTFE]-insulated) for hightemperature applications. Wire that is 1.63 mm (AWG 14) or more in diameter shall conform to 

SAE AS 50861. All conductors shall be stranded unless otherwise specified by the applicable 

engineering drawing. Shielded wire/cable used at KSC for interconnection of cabinets, 

enclosures, and terminal distributors in outside areas and areas defined as Class I, Division 2, 

shall be in accordance with 120E3100001 (for heavy-duty GSE cables), and KSC-GP-864. 

KSC-SPEC-E-0024 (for PVC-jacketed medium-duty wires/cables) and KSC-SPEC-E-0031 (for 

neoprene-jacketed heavy-duty wire/cables) may be used for legacy systems. KSC-SPEC-E-0024 

and KSC-SPEC-E-0031 are not recommended for new designs. Wirewrap wire shall conform to 

SAE AS 81822 and the applicable engineering drawing. Uninsulated (tinned copper) bus wire 

shall conform to A-A-59551, type S (soft). NEMA WC 63.1 defines the minimum electrical 

performance and allowable conductor sizes, stranding, and shielding for premise wiring cables 
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for voice and data applications including unshielded and shielded 100-ohm (Ω) twisted pairs, 

Category 5e, and 150 Ω shielded twisted pair cables. The material and mechanical characteristics 

for these cables are covered under UL 444/CSA C 22.2, No. 214. NEMA WC 66 defines the 

minimum electrical performance and allowable conductor sizes, stranding, and shielding for 

premise wiring cables for voice and data applications for Category 6, Category 6A, and 

unshielded twisted pair cables. The material, mechanical, and physical characteristics for these 

cables are also covered under UL-444/CSA 22.2, No. 214. 

3.5.4 Routing 

Routing and connection of wires shall be either in accordance with the applicable wiring 

tabulation drawings, schematics, and fabrication drawings or, if no drawings apply, in a logical 

fashion that gives consideration to avoiding interferences and for installing any associated wiring 

required. Wires and cables shall be placed and protected so that they are not in contact with 

rough surfaces or sharp edges and so that they have enough clearance from heat-emitting parts to 

avoid damage or deterioration. Signal and power cable bundles shall be routed separately 

whenever possible. Fiber-optic cables should not be routed beneath large bundles of cables or 

with excessive bends in the fiber-optic cable to preclude deformation or damage to the cable 

jacket, cladding, or glass core. 

3.5.5 Grouping 

Unless otherwise specified, wires shall be placed so that they lie parallel in groups where 

possible, and crossovers shall be held to a minimum. Harnesses in panels, boxes, and similar 

locations shall be divided neatly into groups. The harnesses shall be divided into groups 

according to their functions (signal, power, etc.). Signal wires and power wires shall be grouped 

separately whenever possible (see Figure 3). 

3.5.6 Breakouts 

Wires and cables shall be properly supported and secured to prevent undue stress on conductors 

and terminals. Unless otherwise specified, each wire shall be tied to the bundle at the point of 

breakout. When breaking out from a group of wires to a terminal strip, the bundle shall have 

adequate clearance from the terminal lug so that a service loop may be formed. The service loop 

shall be long enough to allow the wire to be cut, stripped, and terminated two additional times 

(see Figure 3). Unless otherwise specified, breakouts of wires shall be perpendicular to the 

bundle. Plastic cableway, metallic conduit, and metallic trays are acceptable for use in wiring 

breakouts. If a wiring duct is used, the service loop shall be left in the wiring duct at each point 

of the breakout. 

3.5.7 Wire Stripping 

Insulation stripping tools and procedures shall be in accordance with IPC/WHMA-A-620 and 

Table 6. 
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Figure 3. Harness or Wire Bundle
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Table 6. Insulation Clearances for Wire 

Wire Diameter 

(mm [AWG Size]) 

Clearance 

Minimum 

(mm [in]) 

Maximum 

(mm [in]) 

Smaller than 0.8 (#20) Visible clearance 1.5 (0.060) 

0.8 (#20) through 2.6 (#10) 0.8 (0.03) Two times diameter of 

insulation 

3.3 (#8) through 6.6 (#2) 0.8 (0.03) 9.5 (0.38) 

7.3 (#1) and larger 0.8 (0.03) 12.7 (0.50) 

Coaxial and special wires According to engineering drawing 

3.5.8 Terminals 

Terminations shall be in accordance with 3.6 of this specification. Terminals shall be in 

accordance with the following paragraphs unless otherwise specified on the detail drawings. 

3.5.8.1 Modular Terminal Junction Systems 

Modular terminal junction systems shall be in accordance with SAE AS 81714. 

3.5.8.2 Screw Terminals 

Molded barrier terminal boards shall be in accordance with A-A-59125 or SAE AS 27212. Other 

types shall be in accordance with 3.6.1.1 of this specification. In accordance with SAE AS 7928, 

terminal lugs shall be used to terminate the wire wherever the screw terminal is not captive or 

where stranded wire is used. After wiring, the screw terminals shall be torqued to the values 

given by the applicable specification or 3.3.1 (or tightened snugly if the torque value is not 

specified). 

3.5.8.3 Compression Terminals 

Compression terminals shall be in accordance with 3.6.1. 
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3.5.8.4 Solder Terminals 

Solder terminals shall be in accordance with A-A-59126. 

3.5.8.4.1 Terminal Swaging 

Swaging has been used historically at KSC to provide termination to terminal boards and printed 

wiring and/or printed circuit boards (PCBs). If swage repair of legacy terminal boards, wiring 

boards, and/or PCBs is required, the swage repair shall be accomplished in accordance with the 

following paragraphs. Terminals may be slightly deformed when they are installed. Swaged 

terminals shall not be loose after soldering. 

a. Tool selection: A rolled swage tool shall be used when the swage is terminated 

directly to the terminal board or the noncircuit side of a printed wiring board or 

PCB. A full funnel swage tool shall be used when the swage is formed in contact 

with a printed conductor pattern. An elliptical funnel swage tool shall be used 

when the swage is formed in contact with a printed conductor pattern having a 

plated through-hole. 

b. Press adjustment: A separate press adjustment shall be made for each type of 

terminal to be swaged on the production board. 

c. Rolled swage: Press adjustment for a rolled swage shall be made as follows: 

(1) Install the tools into the press and vertically align the punch and anvil. 

(2) Maintaining the base of the terminal in contact with the board surface, 

adjust the press until the rolled swage produced on the terminal is 

complete and uniform (see Figure 4, view A). 

(3) Install as many terminals as necessary in the preproduction sample until 

the press adjustment is visually acceptable. 

(4) Using a production-type device suitable for soldering the terminals being 

tested, heat each terminal on the preproduction sample to 260 qC ± 28 °C 

(500 qF ± 50 qF) for a minimum of 15 seconds. 

(5) Apply a minimum torque of 0.14 newton meter (Nm) (20 inch-ounces) to 

each terminal to ensure tightness. 

(6) Visually inspect the rolled swage preproduction sample to the acceptance 

criteria specified in 3.5.8.4.1.f. 
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Figure 4. Rolled Swage Terminals 

d. Funnel swage: Press adjustment for a full or an elliptical funnel swage (see 

Figure 5) shall be accomplished as follows: 

(1) Install swaging tools capable of producing a funnel swage having an 

included angle of 36 degrees to 60 degrees into the press and vertically 

align the punch and anvil. 

(2) Maintaining the base of the terminal in contact with the board surface, 

adjust the press until the swage tool enters the terminal shank far enough 

so the angle of the funnel swage produced on the terminal begins at the 

circuitry (see Figure 6, view A). 
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(3) Visually inspect the funnel swage preproduction sample to the acceptance 

criteria specified in 3.5.8.4.1.f. 

NOTE 

All gold-plated PCB surfaces shall be properly 

prepared for soldering prior to swaging. 

Figure 5. Elliptical Funnel Swage Terminals 
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Figure 6. Funnel Swage Terminals 

e. Inspection: A first article inspection shall be performed on a production board 

before proceeding with a production run and each time thereafter when a change 

in press adjustment is made. Each completed production board shall be inspected 

for conformance to the design drawing and the acceptance criteria specified in 

3.5.8.4.1.f, using 7-power to 10-power magnification. None of the rejection 

characteristics specified in 3.5.8.4.1.g shall be visible. 
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f. Acceptance criteria: Swaged terminals shall be accepted if they meet the 

following criteria: 

(1) Terminals are oriented in accordance with the design drawings. 

(2) The terminal base is in 360-degree contact with the board surface or 

conductor pattern, as applicable. 

(3) The rolled swage is complete and uniform. 

(4) The funnel swage, beginning at the conductor pattern, has an included 

angle of 36 degrees to 60 degrees and extends 0 38 mm (0.015 in) 

minimum beyond the conductor surface. 

g. Rejection criteria: Swaged terminals and terminal boards shall be rejected for 

any of the following criteria: 

(1) Terminals are visibly bent. 

(2) Terminals have cracks, nicks, or peeled or damaged plating with the base 

metal exposed. 

(3) Terminals or board material is damaged by misaligned, improperly fitted, 

or worn swaging tools, etc. 

(4) Terminals are not approved by the procuring activity. 

(5) The board material has continuous discoloration between adjacent 

terminals, between adjacent electrical conductor paths, or between 

terminals and adjacent electrical conductor paths. 

(6) The board material is measled at the base of the terminal. 

(7) The conductor pattern is delaminated at the base of the terminal. 

(8) Radial movement of rolled swage terminals is visible after applying a 

minimum torque of 0.14 Nm (20 inch-ounces). 

(9) Terminals have cuts, scratches, or other damage that could entrap moisture 

or contamination. 

3.5.8.4.2 Rework 

A rejected terminal board shall be reworked to correct any fault other than those listed in 

3.5.8.4.1.g (5), (6), and (7). After rework, the rejected board shall be reinspected. 
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3.5.8.5 Solderless Wrap Terminals 

Solderless wrap terminals shall conform to SAE AMS 2695C. 

3.5.9 Lacing and Tying 

Lacing and tying of cable harnesses and bundles has typically been done with twine. According 

to MILT-713, “The twine is intended for lacing and tying telephone switchboard cable forms, 

hookup wires, cable ends, aircraft cable bundles, electrical and electronic equipment, and 

electrical wire-harness.”

Lacing and tying of GSE electrical harnesses and bundles shall be in accordance with 

NASA-STD-8739.4 and the following paragraphs. 

3.5.9.1 Lacing 

Lacing twine shall be in accordance with MIL-T-713, type P, class 2, using black or a 

contrasting color. Lacing operations shall be in accordance with Table 7 and Table 8. 

Table 7. Spacing of Lacing From Terminations 

Harness-Bundle Diameter 

Distance Between Terminals or 

Connectors and Lacing 

mm in mm in

Less than 13 Less than 0.5 50 2 

13 to 25 0.5 to 1 75 3 

25 or larger 1 or larger 100 4 

Table 8. Spacing of Lacing in the Harness 

Harness-Bundle Diameter Stitching Interval 

mm in mm in

Less than 13 Less than 0.5 19 0.75 

13 0.5 38 1.5 

25 1 50 2 

Larger than 25 Larger than 1 75 3 
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Lacing bars shall be used as necessary to support wiring groups and harnesses. If a harness 

assembly or wire bundle contains branches or conductor breakouts, the following procedures 

shall apply: 

a. The main trunk of the wire bundle or harness shall be laced between connectors or 

components (see Figure 3, shown previously). 

b. A terminating serve shall be constructed on the main truck of the harness or wire 

bundle at the beginning of a wye branch. 

c. The branch shall be continuously laced, beginning with a serve at the junction of 

the wye. 

d. Terminating serves shall be placed on both sides of a tee junction. 

e. Unless otherwise specified, a lacing stitch shall not be placed between each wire 

breakout. A double lock-stitch locked with a square knot shall be used when wires 

in a bundle are routed to a mounted component or component receptacle. 

f. A branch that runs between two main trucks shall be served at both the junctions. 

g. Spacing shall be in accordance with Table 7 and Table 8. 

WARNING 

Cut ends of cable ties shall not protrude to the 

extent that the sharp edges may injure a person. 

3.5.9.2 Cable Ties and Clamps 

Plastic cable ties and approved cable clamps may be used on harness or wire bundles at the 

discretion of the design activity. The ties shall be mounted snugly on the assembled conductor 

and shall be capable of being locked to prevent loosening or opening. When installing wires, 

cables, or harness bundles in vertical or horizontal cable tray systems, NEMA VE 2 (NEMA 

Standards Publication VE 2-2006) advises, “Cables may be fastened to the cable tray by means 

of cable clamps or cable ties. Generally, cables are fastened every 450 mm (18 in) on vertical 

runs. Although not required by the NEC, single conductor cables can be fastened on horizontal 

runs to maintain spacing, prevent movement due to fault-current magnetic forces, and ensure that 

the cable is confined within the cable fill area. When using cable clamps, the clamps should be 

sized correctly and only tightened enough to secure the cable without indenting the jacket. The 

same precaution should be observed with cable ties, and they should be applied with a pressure 

limiting device. Extremely long vertical drops introduce a new set of problems requiring special 

considerations. The weight per meter (foot) of the cable multiplied by the number of meters 

(feet) in the vertical drop will, in many cases, exceed the load carrying capacity of the cable tray 

component, such as the one or two rungs supporting this weight, and could exceed the allowable 

cable tension. The cable weight should be supported in such a manner as to prevent damage to 

the cable tray or cable during this type of installation. As the cable is installed, intermediate 
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supports should be installed on the vertical drop to break the cable load into segments supported 

at multiple places.” Plastic cable ties and approved cable clamps shall be installed on harness or 

wire bundles in accordance with NASA-STD-8739.4. 

3.5.10 Termination Order 

Unless otherwise specified, the wiring of connector contacts to terminal board terminals shall 

proceed pin-to-terminal in corresponding numerical or alphabetical order (e.g., pin A or 1 on the 

connector goes to terminal number 1, pin B or 2 goes to terminal number 2). The wiring between 

terminal boards shall maintain the numbering sequence on each end of the connecting cable 

(i.e., a conductor wired to terminal number 1 on one end of the cable shall be wired to terminal 

number 1 on the board at the other end). 

3.5.11 Molding and Potting Electrical Connectors 

Molding and potting of electrical connectors is done to prevent damage, degradation, and 

deterioration of electrical connectors that are exposed to the environment and to ensure electrical 

integrity, improve robustness, and increase the connectors’ useful life. Epoxy resin potting 

compositions and elastomeric compounds shall be used for molding and potting in accordance 

with section 3.11.6 of this specification. The connectors used shall be in accordance with 3.11.3. 

Molding and potting is required for all outdoor applications where a connector’s integrity could 

be compromised (1) by the environment or the effects of vibration, (2) to inhibit gas migration, 

or (3) to provide addition strain relief and support. This includes molding and potting of exterior 

connectors on enclosures, junction boxes, and remote inputs/outputs (RIOs), and potting only for 

the interior connectors. 

3.5.12 Splicing 

The splicing of conductors and/or shields shall not be permitted unless specified by the 

applicable drawing or approved by the contracting officer. When approval is given, one of the 

following splices should be used (1) soldered sleeve splices in accordance with NAS 1744 are 

acceptable for use, (2) insulated crimp splices in accordance with SAE AS 7928A are preferred, 

or (3) for applications where environmental sealing and small size and light weight are 

important, splices in accordance with SAE AS 81824. See 82K03874 for splicing instructions. 

3.5.13 Terminating and Grounding Shields 

Metallic shields shall be employed in cables to reduce the electromagnetic coupling between 

electrical circuits and their environment. Terminating and grounding shields shall be installed in 

accordance with NASA-STD-8739.4. A variety of shielding configurations are used in 

instrumentation systems at KSC, but all will be included in one of the following categories. 

These procedures apply to cables used for transmitting direct current (DC) and alternating 

current (AC) power and low-frequency analog and digital signals with harmonics of significant 

power not exceeding approximately 1 megahertz (MHz). 

At higher frequencies, radiation and other high-frequency phenomena may require a departure 

from the termination methods in this specification. Coaxial and balanced-pair cables used for 
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radio frequency (RF) and video transmission and outside-plant telephone cables are specifically 

excluded (see Figure 7 through Figure 10 for typical terminations). Specific termination 

configurations for overall shielded cables may be found in the cable subassembly drawing 

specified in the statement of work (SOW). See 79K04613 or 82K03874 for shield termination 

instructions and/or details. 

Figure 7. Cable Termination Hardware
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Figure 8. Typical Termination Configuration for Overall 

Shielded Cable With Insulated Conductor Shields 

 
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Figure 9. Graphic Representation of Individual Shields From Source, 

Through Intermediate Break Points, to End Instrument 
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Figure 10. Typical Termination Configuration for Overall Shielded 

Cable With Uninsulated Conductor Shields 

3.5.13.1 Insulated Shields Over Individual Conductors or Groups of Conductors 

Insulated shields over individual conductors or groups of conductors shall be terminated in a 

manner that provides electrical isolation between individual shields and between shields and 

ground and electrical continuity of the shields from end terminal point to end terminal point 

except at an instrument, sensor, transducer, or other end item, as described below: 

a. When the cable terminates on a terminal strip, the shields shall be terminated with 

shield terminals and each shield connected to the strip terminal point adjacent to 

the last conductor of the conductor grouping common to the shield. 

b. When the cable terminates in a connector and sufficient space exists within the 

connector, the shields shall be terminated with insulated shield terminals. Each 

shield shall be connected to the connector pin or socket adjacent to the last 

conductor or conductor grouping common to the shield (see Figure 8). The 

exception would be if the connector interfaces with an end item. In this case, the 

insulated shields over individual conductors or groups of conductors shall be 

floated within the end item connector to isolate them from the end item connector, 

from each other, from the conductors, and from the overall shield. 
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c. Insulated shields over individual conductors or groups of conductors shall be 

carried from racks and enclosures through intermediate breakpoints and be floated 

at instrument, sensor, transducer, or other end item, as specified in engineering 

drawings and documentation. See Figure 9 for details. 

In accordance with NASA-STD-8739.4, individually isolated conductor shields may be grouped 

together and terminated at a common pin in a connector or to a common ground if specified in an 

engineering drawing. No more than four shields and one drain wire may be terminated at/in the 

common point. 

3.5.13.2 Uninsulated Shields Over Individual Conductors or Groups of Conductors 

Uninsulated shields over individual conductors or groups of conductors shall be terminated in a 

manner that provides electrical isolation of the shields from ground and electrical continuity of 

the shields from end terminal point to end terminal point, except at an instrument, sensor, 

transducer, or other end item as described below: 

a. When the cable terminates on a terminal strip, the shields shall be terminated with 

shield terminals jumpered together and connected to the strip terminal point 

adjacent to the last cable conductor. The terminal strip ends of harness shields 

shall be terminated with shield terminals to prevent fraying but do not require 

jumpers between shields and are not connected to the terminal strip (see 

Figure 10). 

b. When the cable terminates in a connector, the shields shall be collected under a 

common shield terminal and connected to the connector pin or socket adjacent to 

the last cable conductor, maintaining electrical isolation between the conductor 

shields and the overall shield and connector shell. The exception would be if the 

connector interfaces with an end item. In this case, the uninsulated shields over 

individual conductors or groups of conductors shall be floated within the end item 

connector to isolate them from the end item connector, from the conductors, and 

from the overall shield. The method of terminating harness shields in connectors 

shall be the same as specified for cables, except that a wire shall be extended from 

the common shield terminal back to the terminal strip and from there shall be 

connected to the strip terminal point to which the cable conductor shields are 

connected (see Figure 10). 
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3.5.13.3 Overall Shields Surrounding the Entire Cable Core 

Overall shields shall be terminated to each connector backshell 360 degrees at both ends of a 

cable, grounded at each terminal distributor, and at any other practicable points. The intent of the 

360-degree overall shield is to create a “Faraday cage” around the conductive core to protect it 

from external electromagnetic radiation and keep its own associated signals and electromagnetic 

energy inside the cable. At cable junction points where grounding is not feasible, electrical 

continuity of the overall shields shall be maintained through the junction. See Figure 11 for a 

diagram of 360-degree shielding using mold adapters when potting and molding in accordance 

with 3.5.11 of this specification. Molding adapters shall be used for 360-degree overall shield 

terminations when specified in engineering drawings and documentation. COTS electromagnetic 

interference (EMI) backshells that employ compression-type fittings shall be used for 360-degree 

overall shield termination when specified in engineering drawings and documentation. 

Figure 11. 360-Degree Overall Shield Termination Using a Mold Adapter 
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3.5.13.3.1 Tinel-Lock Rings 

Tinel-Lock rings (shown in Figure 12) shall be used for 360-degree overall shield terminations 

when specified in engineering drawings and documentation. Tinel-Lock rings are made from a 

special shape memory metal that shrinks uniformly when heated. Tinel-Lock rings are used to 

terminate copper cable braid directly onto the rear of a connector backshell adapter. The adapter 

entry size and ring designator must be selected to suit the cable diameter and braid type. The 

resulting 360-degree terminations withstand severe shock, vibration, temperature cycling, and 

corrosion. 

 

Figure 12. Tinel-Lock Rings and an Example of One Type of Adapter 

Tinel rings are installed manually using either a bench or portable, handheld resistance heating 

tools designed specifically to install Raychem Tinel-Lock ring screened terminations (see 

Figure 13 and Figure 14). The rings are marked with thermochromic paint, which changes color 

when the correct temperature for installation is reached. The operator positions the Tinel-Lock 

on the terminations, with at least one of the patches of thermochromic paint visible. The TinelLock ring is then clamped in the jaws to start the installation. Installation is complete when the 

thermochromic paint turns black. 

This normally takes 3 seconds to 12 seconds, depending on ring size, braid type, etc. 
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 Raychem Tinel-Lock Bench-Style Raychem Tinel-Lock Handheld-Style 

Resistance Heating Tool Resistance Heating Tool 

Figure 13. Tinel-Lock Ring Resistance Heating Tools 

Figure 14. Typical Installation of Tinel-Lock Ring 

3.5.13.3.2 EMI/RFI Foil Tape and Wire Mesh 

Highly conductive foil tapes and conductive meshes are available in copper, aluminum, or tinned 

copper and provide an alternative, economical shielding solution for EMI and radio frequency 

interference (RFI) by providing a low impedance connection between a braided cable shield and 

the metal connector backshell in molded cables. An effective EMI shielded assembly is achieved 

without soldering the mesh or tape to the shield braid or backshell by wrapping the tape or mesh 

around the overall cable shield and connector backshell using an overlap wrapping method. 

Conductive foil tape or conductive mesh shall be used for 360-degree termination of overall 

shields to connector backshells when specified in engineering drawings and documentation. 
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3.5.13.3.3 Interior Cable Runs 

When the cable terminates on a terminal strip, the overall shield shall be terminated with a shield 

terminal and connected to the last terminal point on the terminal strip. A jumper shall be 

provided between this terminal point and the ground (see Figure 7). 

3.5.13.3.4 Exterior Cable Runs 

The overall shield shall be immediately terminated to ground at the terminal distributor when the 

cable run exposes the shield to lightning-induced voltages and currents. On new designs, this 

shall be accomplished by terminating the shield to a MIL-DTL-22992, SAE AS 50151, or 

MIL-DTL-38999 connector with a conductive shell and 360-degree shield termination feature. 

Because many existing cables were not fabricated in this manner, the cable/distributor interface 

must be grounded as described below (see Figure 8 through Figure 10): 

a. When the cable terminates in an exterior-type, heavy-duty (MIL-DTL-22992) 

connector, enough contacts shall be provided for the overall shield to be 

terminated on a connector contact. The overall shield shall be terminated with a 

shield terminal and connected to the last pin or socket in the connector. In the 

mating terminal distributor harness connector, the wire shall be connected to the 

last pin or socket and terminated under one of the screws on the connector 

mounting flange using an internal tooth lock washer in accordance with AIA/NAS 

NASM35333 under a lug in accordance with SAE AS 25036. 

b. When the cable terminates in an interior-type (e.g., MIL-DTL-26482, 

SAE AS 50151, or MIL-DTL-38999) connector, the overall shield shall be 

connected to the cable connector shell as shown in Figure 10 

(e.g., MIL-DTL-26482-type connectors have conductive shells). When this 

method of shield termination is employed, the mating harness connector and 

connector mounting plate must be solidly grounded to the terminal distributor. 

c. When the cable terminates on a terminal strip, the overall cable shield shall be 

terminated directly to the outer TD enclosure through the use of a conductive 

cable gland or shield ground bus in the TD enclosure cabinet (see Figure 8 

through Figure 10). 
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3.5.13.4 Shield Terminals 

Shield terminals shall be in accordance with one of the following or its equivalent: 

a. Inner or outer shield rings according to 75M13676 (includes larger sizes 

necessary to terminate cable overall shields). 

b. Two-piece shield termination ferrules qualified under SAE AS 21608-A1, 

including inner ferrules according to SAE AS 21981 and outer ferrules according 

to SAE AS 18121 and SAE AS 21980, and terminated in accordance with 

79K04613, as applicable. 

c. One-piece ferrules (i.e., SAE AS 85049/26 Shield Rings). 

d. Solder sleeve shield terminators in accordance with SAE AS 83519A or 

NASA-approved. 

Tools for crimping shield terminals shall be in accordance with 4.3.2 of this specification. 

3.6 Terminations 

Wire-type terminations shall be in accordance with the following paragraphs. Wire stripping 

tools and procedures and insulation clearance shall be in accordance with 3.5.7. There shall be no 

more than three wires per terminal and two wires per lug on a part (see Figure 15). 

3.6.1 Compression Type 

Compression-type terminals shall be suitable lugs, pressure connectors, or clamps (see Figure 16 

and Figure 17) and shall be in accordance with the following paragraphs (see also 3.5.8.3). 

Sealing compound, where specified, shall be used after tightening to prevent all types of 

compression connections from becoming loose as a result of vibration. 

3.6.1.1 Captive Nut or Screw Head 

Only solid wires may be terminated under screw heads unless the screw head or washer mates 

into a cupped or formed surface that prevents frayed strands from protruding from the terminal 

areas. The wire shall be wrapped in a clockwise direction beneath the screw head or between 

washers under the screw head, with the wire forming an eye on the end. 
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Figure 15. Bridge Bus Terminals 

 
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Figure 16. Captive and Noncaptive Nut and Screw Head Terminations 
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Figure 17. Clamp and Screw End Terminations 
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A distance equal to one diameter of the conductor shall remain between the end of the wire and 

the formed loop (see Figure 16). Only one wire may be compressed between any two surfaces of 

the terminal assembly. Terminal lugs conforming to SAE AS 7928 shall be used in all cases 

where the nut or screw head is not captive. 

3.6.1.2 Clamp or Screw End 

Clamp or screw end terminals (see Figure 17) shall be the proper size for the wire. Wire strands 

shall not be cut off to make it possible to put them into undersized terminals. Terminals shall not 

be overtightened, which could strip the threads or sever the wire strands. 

3.6.2 Crimp Type 

Crimp-type terminations shall be in accordance with NASA-STD-8739.4 and 

IPC/WHMA-A-620. Shield or coaxial ferrules of the completed termination shall not scratch, 

mar, compress, or otherwise distort the inner conductor insulation. 82K04459 lists tool, 

positioner, locator, or turret information for SAE AS 50151, MS27466, and/or MIL-DTL-38999 

connectors; SAE AS 22520 provides similar information. (79K22638 provides additional 

guidance and information.) 

3.6.3 Friction Type 

Wirewrap tools and procedures shall be in accordance with SAE AMS 2695C. 

3.6.4 Solder Type 

All solder terminations, as well as component mounting on printed wiring boards, shall be in 

accordance with the following standards and shall meet the quality assurance requirements 

established by the standards where applicable. 

a. Electrical connections not exposed to vibration or thermal cycling shall be 

soldered in accordance with IPC J-STD-001. 

b. Electrical connections exposed to vibration or thermal cycling shall be soldered in 

accordance with IPC J-STD-001ES. 

c. Electrical connections shall be soldered in accordance with IPC J-STD-001ES 

when the GSE interfaces directly with a flight item. 

d. Electrical connections shall be soldered in accordance with KSC-STD-E-0010 

when IPC J-STD-001/ES is not applicable. 

NOTE 

Connections that depend on solder shall not be used 

to terminate ground conductors (see 3.6).
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3.6.4.1 Hand and Machine Soldering 

Soldering tools and procedures shall be in accordance with IPC J-STD-001/ES, where 

applicable, and KSC-STD-E-0010. 

3.6.4.2 Soldering Multiple Conductors in a Single Solder Cup 

If the conductors are small enough to fit side by side in the solder cup, they shall be stripped and 

soldered in accordance with the applicable standard. If the conductors do not fit side by side, the 

solder cup shall not be reamed nor shall conductor strands be removed to decrease the size of the 

conductor. When the conductors to be soldered do not vary in size by more than four American 

Wire Gage (AWG) wire sizes, each conductor shall be stripped and the strands combed out. The 

strands of all conductors shall be twisted together into a single wire and tinned. The resulting 

conductor shall not be larger than the recommended AWG wire rating of the solder cup. 

3.6.5 Bonding and Grounding Type 

All bonding and grounding terminations shall be in accordance with KSC-STD-E-0022 and 

KSC-E-166 for ground systems, KSC-STD-E-0012E for facility systems, and MIL-STD-464. 

3.6.6 DIN Rail-Mounted Terminal Blocks 

IEC 60715 specifies the requirements and standards for DIN rail mounts. IEC 60947-7-1 

specifies the requirements and performance standards for terminal blocks mounted on DIN rails. 

All DIN rail-mounted assemblies shall comply with IEC 60715 and IEC 60947-7-1. In addition, 

all DIN rail-mounted terminal blocks shall be compatible with test point adapters or pluggable 

extension blocks to allow access to test points without disconnecting field wiring. 

3.7 Printed Wiring Boards 

Fabrication and documentation of printed wiring boards shall be in accordance with IPC 6011, 

IPC 6012, IPC 2222, IPC 2221, IPC-HDBK-001, and the following paragraphs. 

3.7.1 Material 

Unless otherwise specified by the applicable engineering drawing, the board material shall be a 

1.57 mm (0.062 in)-thick copper-clad laminate. 

3.7.2 Construction 

3.7.2.1 Circuit Pads 

A pad of adequate size shall be provided at each point on a conductor that makes a connection 

with a component part. The pad size shall be such that, within the extremes of tolerance allowed 

on hole locations, no abutting portion of the attaching part will protrude beyond the border of the 

pad area. Terminal pads shall meet the same requirements as conductors for spacing. The 

component part termination hole should be located on the terminal pad so there is a minimum of 
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0.38 mm (0.015 in) of copper on all sides of the hole to permit a full 360-degree solder joint. For 

miniaturization, 0.25 mm (0.010 in) copper on all sides of the hole will be accepted, provided the 

component lead diameter is no greater than 0.51 mm (0.020 in). Component lead holes shall not 

be drilled more than 0.38 mm (0.015 in) than the lead diameter. 

3.7.2.2 Heat Sinks 

The following paragraphs apply for both circuit board and chassis-mounted heat sinks for 

transistors and semiconductor rectifiers. 

3.7.2.2.1 Electrical Insulation 

When a heat sink is to be used with a semiconductor, the case and leads of the semiconductor 

shall be electrically insulated from the heat sink to preclude short-circuiting the power supply or 

damaging the semiconductor. Although individual heat sinks and duo sinks (for maintaining 

equal case temperatures on transistor pairs) are commercially available with a hard anodized 

finish for good electrical insulation, this oxide coating can be scratched when the semiconductor 

is installed into the heat sink. For this reason, high-purity beryllium oxide, mica, or Mylar 

sleeves and washers shall be used as necessary to insulate the semiconductor leads and case from 

the heat sink. These materials possess a high thermal conductivity and do not impair the 

effectiveness of the heat sink. 

3.7.2.2.2 Thermal Resistance 

Because the contacts between mated surfaces (even when machined smooth) are actually 

irregular and point to point with tiny air pockets acting as thermal insulators, a thin film of 

thermally conductive mounting compound shall be applied as necessary to both surfaces before 

mating to minimize thermal resistance between mating surfaces. Silicone grease (in accordance 

with SAE AS 8660) is recommended except in vacuum applications where the outgassing from 

silicone grease might be detrimental. 

NOTE 

A silicone compound cannot be used in lieu of a 

conventional solid electrical insulator. It should 

only be used as filler between the microstructure of 

mating surfaces. 

3.7.2.3 Eyelets and Tubelets 

Eyelets and tubelets shall not be used to make electrical connections on printed wiring boards. 

3.7.2.4 Workmanship 

Soldering and mounting of component parts shall be in accordance with 3.6.4. The completed 

board shall have a uniform appearance, a smooth and even texture, and shall be free of any 

contamination, oxide, blisters, and pits. Components shall not be placed across conductor lines 
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without adequately protecting the contact area with insulation (see 3.8). Component parts 

fabricated with welded leads, such as tantalytic capacitors, require the leads to be straight for a 

minimum of 0.80 mm (1/32 in) beyond the weld to prevent bending stress from being placed on 

the welded joint. 

3.7.3 Cleaning 

After the solder has solidified and cooled, flux and residue shall be carefully removed from each 

solder connection using a solvent as specified in IPC J-STD-001/ES, where applicable, or 

KSC-STD-E-0010. The solvents are rated according to their potential effect on the materials 

commonly used in parts, should the solvents penetrate the seals. The user is responsible for 

determining whether a particular solvent is suitable and for making sure that it will not affect the 

sleeving or marking on the part. 

NOTE 

Do not clean printed circuit boards carrying 

aluminum electrolytic capacitors with Freon, 

trichloroethylene, carbon tetrachloride, or other 

chlorine or fluorine solvents. Aluminum electrolytic 

capacitors are subject to attack by these and other 

halogenated hydrocarbon solvents. Should these 

solvents seep into the capacitor through its seal, 

they will initiate corrosion that will cause the 

capacitor to fail after a few months. A supplemental 

epoxy barrier over the end disks or headers will 

keep these solvents from seeping into the capacitor. 

Acetone, alcohols, and mineral spirits are 

acceptable cleaners. 

3.7.4 Rejection Criteria 

A printed wiring board shall not exhibit the following characteristics: 

a. Separation of the conductor pattern from the base laminate of the board 

b. Separation of plating through holes or from the conductor pattern 

c. Metal, solder, or clinched leads that reduce the minimum spacing between 

conductors 

d. Pits or scratches sufficient to reduce the cross-sectional area of a conductor by 

more than 20 percent 

e. Cold or fractured solder joints or areas where the solder does not adhere to metal 

f. Damage to the board or parts caused by burns or heat 
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g. Damage that makes it difficult to read color codes or labeling of parts on the 

board 

h. Undercutting of the conductor pattern that reduces the line width for the particular 

conductor by 10 percent or more 

3.7.5 Inspection 

Printed circuit boards shall be inspected for compliance with the standards listed in 3.6.4, where 

applicable, and within this section. 

3.7.6 Conformal Coating 

Unless otherwise specified on the engineering drawing, printed circuit boards shall be given a 

conformal coating after assembly and test. A single component polyurethane varnish in 

accordance with QPL-46058-87, Notice 1, type UR, is preferred. The conformal coating shall be 

applied in accordance with NASA-STD-8739.1. The following coating materials, or their 

equivalents, shall be used: 

a. Type 1A33 (available in aerosol) or 

b. Type 1A20 (Humiseal Division, Columbia Chase Corporation, 26-60 BrooklynQueens Expressway, P.O. Box 445, Woodside, NY 11377 [CAGE 99109]) 

3.7.7 Repair 

Printed circuit boards shall be repaired in accordance with KSC-STD-E-0010 and as directed by 

the contract technical representative when repair has been authorized by the contracting officer. 

IPC 7711/7721 may be used as a guide. 

3.7.7.1 Printed Wiring Boards Using Surface-Mount Technology (SMT) 

The standard that prescribes NASA’s requirements and procedures for hand and machine 

soldering of surface mount electrical connections is IPC J-STD-001/ES. When invoked 

contractually, it establishes workmanship standards for reliable SMT for flight hardware, 

mission-critical ground support equipment, and elements thereof. Refer to IPC J-STD-001/ES for 

standards and requirements for soldering SMT on printed circuit boards (including requirements 

for equipment, material, parts placement, soldering, cleaning, acceptance/rejection criteria, and 

rework). 

3.8 Sealing and Insulating 

3.8.1 Insulation 

Equipment shall have adequate dielectric insulation between surfaces of current-carrying parts 

and those people can touch. Insulated sleeves shall be applied over pins and terminals of relays, 

connectors, and similar items that are not protected by insulated grommets or by potting. All 
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routed conductors in harness or box assemblies shall be protected at abrasion points. The 

insulation of wires and cables shall be suitably protected in locations where they are exposed and 

susceptible to damage. 

3.8.1.1 Heat-Reactive Tubing 

Heat-reactive tubing shall not be used on components where the application of heat will damage 

the component. 

Heat-reactive tubing for these applications shall be transparent, flexible sleeving in accordance 

with SAE AMS-DTL-23053. Heat-reactive tubing used for cable jackets shall be in accordance 

with 3.11.7.1. 

The following types are preferred: 

a. SAE AMS-I-23053/2, class 2 (polyvinyl chloride, flexible, high temperature, and 

not crosslinked) 

b. SAE AMS-DTL-23053/5, class 2 (polyolefin, thin wall, and crosslinked) 

3.8.1.1.1 Application 

The procedure for applying heat-reactive tubing shall be as follows: 

a. Select tubing where the expanded size is larger than the object to be covered and 

the recovered size is smaller (see Figure 18, view B). 

b. Place the tubing over the object to be covered. 

c. Briefly expose the tubing to heat by using a portable hot-air gun or other approved 

method. The degree of heat and the exposure time will depend on the size and 

type of tubing. 

CAUTION 

Extreme care shall be exercised to ensure that the 

degree of heat used is not detrimental to the object 

being covered. 

d. The tubing quickly shrinks to a predetermined inside diameter and provides a 

griptight mechanical bond (see Figure 18, view C). The longitudinal shrinkage 

normally will be less than 10 percent.
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Figure 18. Application of Heat-Reactive Tubing 

3.8.1.1.2 Visual Inspection 

All objects covered with the tubing shall be visually inspected for shrinkage and bonding of the 

tubing. 

3.8.1.2 Insulation Tubing 

In accordance with SAE AMS-I-7444, insulation tubing shall be flexible polyvinyl chloride 

sleeving for applications where heat-reactive tubing is inappropriate. The tubing shall extend a 

distance equal to or greater than the tubing diameter above the stripped portion of the attached 

conductor. Lacing twine, in accordance with 3.5.9.1, shall be tied over the sleeving as necessary 

to prevent sliding. 

3.8.1.3 Cold-Shrink Tubing 

When specified in engineering drawings and instructions, connections exposed to unconditioned 

outside natural environments can be protected by using cold-shrink tubing (3M part numbers 

46XX, 56XX, or 76XX, as appropriate) and following the manufacturer’s instructions. Cold 

shrink shall be applied only after final verification and connection.
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3.8.2 Sealing Compound, Electrical 

A sealing compound in accordance with SAE AS 8660 shall be used where affected parts are not 

sealed hermetically, are not protected by potting or molding compounds, or have possible 

corrosion or heat loss problems. The sealing compound is used for the following reasons: 

a. As a corrosion inhibitor on mating surfaces or connections where corrosion can 

result from galvanic action of dissimilar metals or exposure to corrosive liquids 

and/or vapors (e.g., battery terminals, bonding terminals, friction, and 

compression terminals) 

b. As a heat transfer abettor on mating surfaces or joints where heat-transfer loss can 

result from corrosion, voids, or noncontacting areas (e.g., semiconductors or 

resistors that use insulating or noninsulating hardware on heat sinks) 

The compound shall be liberally applied to parts before mating or joining to fill the voids 

between the parts and seal the openings to the exterior of the joining area. This will prevent 

invasion of corrosives. The electrical contact resistance of a completed bond shall be no greater 

than an identical joint made without the compound. On insulating surfaces, the electrical 

insulating resistance shall be no less than the minimum allowable resistance for an identical joint 

without the compound. 

3.9 Hazardproofing 

For the purposes of this specification, hazardproofing means preventing ignition of hazardous 

fluids (liquids and gases) by electrically energized equipment. Hazardproofing at KSC shall be in 

accordance with KSC-STD-E-0002 and applicable sections of KSC-DE-512-SM. 

Design for all new electrical equipment to be used in hazardous (classified) locations shall 

comply with the intent of the applicable guidelines of NFPA 70 (latest released edition), 

NFPA 430 (latest released edition), and NFPA 497 (current version at start of project unless 

otherwise stated in project documentation). 

The lead design engineer shall coordinate the design and implementation of hazardproofing for 

electrically energized equipment with the NASA Fire and Rescue Office, the authority having 

jurisdiction (AHJ) over activities at KSC. 

3.9.1 Intrinsically Safe Equipment 

NEC-type (Underwriters Laboratories approved) equipment designed for use in hazardous 

atmospheres (without purge) shall be used when commercially available and shall be in 

accordance with NFPA 70 (Section 500.4) as required by the procuring activity. 

3.9.2 Ignitionproofing 

An enclosure that excludes ignitable atmospheres shall be considered to be ignitionproof. 
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3.9.2.1 Small Junction Boxes 

Small junction boxes shall be made ignitionproof by encapsulation with a nonacetic acid, twopart room-temperature vulcanizing (RTV) compound. 

3.9.2.2 Electrical Components 

Limit switches, position indicators, valves, etc., shall be made ignitionproof if all voids within 

the enclosures are encapsulated with suitable compounds. 

3.9.2.3 Electrical Connectors and Mated Cables 

Connectors in accordance with SAE AS 50151, MIL-DTL-22992, and MIL-DTL-38999 and 

cables built in accordance with 3.11 shall be ignitionproofed as follows: 

a. Lubricate the rear threads with Molykote X-15, KEL-F-90, or an equivalent. 

b. Torque the rear coupling nut to the values given in table I of 79K19600 or in 

table 4 of SAE AIR6151 with the O-rings in place. 

c. Before mating, coat the front threads with one of the lubricants listed above. 

Bayonet-coupled connectors, in accordance with MIL-DTL-26482H, are not recommended for 

hazardous locations. But if an interfacing component connector dictates that a bayonet-coupled 

connector be used, it shall be ignitionproofed by coating the entire mated plug and receptacle 

with a nonacetic acid RTV compound. 

3.9.3 Purging and Pressurization 

A hazardproofing purge is used to exclude combustible atmospheres from electrical enclosures 

that do not meet NFPA 70 requirements for use in such atmospheres. Once the enclosure has 

been purged, only positive pressure shall be required to be maintained within the enclosure. 

Purging for environmental protection alone shall not be employed if adequate protection can be 

achieved by a simpler means (see 3.10.3). 

All purging and pressurization shall be accomplished in accordance with KSC-STD-E-0002D 

and the following paragraphs. 

3.9.3.1 Equipment 

The equipment chosen shall meet the following criteria: 

a. New equipment enclosures shall be in accordance with NFPA 496 and shall 

withstand a gage pressure of 500 pascals (Pa) (2 inches of water) without leakage 

and without damage to the enclosure. 

b. Doors and/or removable access panels shall be of a design suitable for frequent 

opening and closing and shall be leaktight when closed. 
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c. A humidity indicator that changes color to indicate changes in humidity shall be 

installed to indicate when the relative humidity in the enclosure exceeds 

30 percent (when required by the procuring activity). 

d. A pressure monitoring assembly shall be installed in accordance with NFPA 496 

when required by the procuring activity’s technical representative. 

e. The purge inlet assembly shall be in accordance with 79K07491-3. The purge 

outlet assembly shall be in accordance with 79K07491-4 (where clearance is not 

restricted) and with 75M02047 (where clearance is restricted). 

3.9.3.2 Purge Pressure 

Enclosures shall be maintained so that they are sufficiently leaktight to prevent the purge 

pressure from dropping below a positive pressure of 25 Pa (0.1 in of water) during a flowing 

purge. 

3.9.3.3 Flow Rate 

Purging equipment shall be designed to maintain a flow rate of 0.2 liters per second (L/s) to 

0.5 L/s (0.5 cubic foot per minute [ft3

/min] to 1.0 ft3/min) of purge medium through the 

enclosure (to the atmosphere) under standard conditions. 

3.9.3.4 Purge Media 

The purge medium shall be one of the following: 

a. Compressed dry air 

b. Gaseous nitrogen in accordance with SE-S-0073 

If compressed air is used, the dewpoint shall not exceed –12.2 qC (10 qF), the oil content shall 

not exceed 3 parts per million by mass, and the particulate filtration shall be 20 μm absolute. 

3.10 Corrosion Control 

Electrochemical corrosion is the primary type of corrosion at KSC. Four conditions must exist 

before electrochemical corrosion can proceed: (1) there must be something that corrodes (the 

metal anode), (2) there must be a cathode, (3) there must be a continuous conductive liquid path 

(electrolyte, usually condensate and salt or other contaminants), and (4) there must be a 

conductor to carry the flow of electrons from the anode to the cathode. This conductor is usually 

in the form of an item that makes metal-to-metal contact such as a bolted or riveted joint. 

Eliminating any one of the four conditions will stop corrosion (e.g., an unbroken coating on the 

surface of the metal will prevent the electrolyte from making contact with the cathode and anode 

and the current cannot flow; therefore, no corrosion will occur as long as the coating is 

unbroken). 
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In Table 9, metals are grouped by their potential tendency for galvanic corrosion. Refer to 

KSC-TM-584 for a detailed discussion on the types and causes of corrosion and how corrosion 

can be prevented and removed. 

3.10.1 Corrosion-Resistant Materials 

Corrosion-resistant materials shall be used, including plastics where possible. Galvanized 

supports shall be specified for outside installations and for inside installations where corrosive 

agents are present. Fiberglass junction boxes and enclosures shall be used where feasible 

(see 3.1). 

3.10.2 Dissimilar Metals 

Use of dissimilar metal couples shall be avoided. MIL-STD-889B, Notice 1, shall be used in 

determining the tendency for galvanic action between a combination of metals or alloys. When 

dissimilar metals are in direct contact, the more anodic material corrodes at an accelerated rate. 

Metals placed in contact during fabrication and assembly of GSE shall come from the same or an 

adjacent grouping. When it is not possible to separate items in different groups, the more easily 

replaceable items (handles, fasteners, etc.) shall be selected from the more active group. The 

following guidelines shall be used to minimize corrosion caused by the use of dissimilar metals: 

a. The anode shall be as large as feasible in relation to the cathode. When the anode 

is large with respect to the cathode, two advantages are realized. First, because the 

anode is being dissolved by the electrolyte, uniform corrosion takes place over a 

relatively large area at a relatively slower rate, thus increasing the service life of 

the anode. Second, the small cathode areas tend to become polarized by hydrogen 

gas or polarized by alkali or insoluble salts, thereby slowing or stopping the 

reaction. 

b. When dissimilar metals must come into contact, they shall be separated by using 

nonconductive barrier materials (such as nylon washers or barrier tape in 

accordance with A-A-59298A) or with a protective coating or plating (see 3.10.4). 

c. Both the anode and the cathode shall be coated with the same material. 

d. When possible, fasteners dipped in zinc chromate primer shall be installed. 

e. The use of lock or toothed washers over plated or anodized surfaces shall be 

avoided (they break the protective coating) unless they are used to ensure a good 

electrical bond connection. 

f. Only dry-film lubricants that are graphite-free shall be used (MIL-PRF-46010F 

restricts the use of graphic as a material in the coating). 
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Table 9. Potential Tendency for Galvanic Corrosion 

3.10.3 Moisture Exclusion 

Moisture shall be excluded from equipment enclosures by providing seals (see 3.8.2) or coatings 

(see 3.10.4), dehumidification (desiccants), vapor phase inhibitors, purges (see 3.9.3), or air 

conditioning or maintaining the temperature above the dewpoint (strip heaters). Equipment shall 

not be purged for environmental protection alone if there is another way to provide adequate 

protection. 
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3.10.4 Protective Coatings 

Surfaces shall be protected with metallic, inorganic, or organic coatings as required (see 3.1, 

3.7.6, and 3.8). 

3.10.5 Lubricants 

Exposed bearing surfaces shall be protected with corrosion-inhibiting lubricants (see 3.3.1.6). 

3.11 General-Purpose Cables 

Cable and harness fabrication and assembly shall be in accordance with 79K07416, 

120E3100003, KSC-GP-864, and applicable design drawings. 79K19600 may be used for legacy 

systems but is not recommended for new designs. 

3.11.1 Standard Bulk Cable 

Cable shall be in accordance with 120E3100001, KSC-GP-864, MIL-DTL-17H, 82K03878, or 

the applicable design drawings. KSC-SPEC-E-0031 may be used for legacy systems but is not 

recommended for new designs. 

Bulk cables shall be inspected before fabrication (despooling), potting and molding (cable ends), 

and installation. All inspections shall be performed on the entire periphery of cable, under 

adequate light and, when necessary, with the use of a mirror. A 10× magnifier shall be used if a 

discrepancy is suspected. Scrapes, scuffs, inclusions, discontinuities, and minor abrasions that do 

not expose shield strands are acceptable and shall not be cause for rejection. Pinholes, voids, 

gouges, or any other discrepancy that exposes the cable overall shield braid are not acceptable 

and shall be cause for engineering evaluation or initiation of a Product Nonconformance Report 

(PNCR). 

3.11.2 Unique Bulk Cable 

3.11.2.1 Preferred Types 

The heat-shrinkable tubing used for cable jackets shall be black, flexible sleeving in accordance 

with SAE AMS-DTL-23053. The following types are preferred. 

a. SAE AMS-DTL-23053/1, class 1 or 2 (polychloroprene and flexible) 

b. SAE AMS-DTL-23053/5, class 1 or 3 (polyolefin, thin wall, flexible, and 

crosslinked) 

c. SAE AMS-DTL-23053/15 (polyolefin, thick wall, coated, and crosslinked) 
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3.11.2.2 Fabrication Procedure 

Small lengths of unique conductor-grouping bulk cable shall be fabricated according to the 

following procedure: 

a. Select a shield whose diameter is larger than the outside diameter of the wire 

bundle. The length of the shield should be specified about 10 percent longer than 

the cable length to allow for possible shortening of the shield that can result from 

braid expansion if the outside diameter has been slightly miscalculated. 

b. Use a cable jacket with a recovered diameter slightly smaller than the calculated 

overall diameter of the conductor bundle with the overall shield applied. The 

length specified should be 10 percent greater than the cable length to allow for 

shrinkage that can result from heating. 

c. Cut the conductor sets 1.15 times the required cable length to compensate for a 

shortening of the length that can result from twisting and end damage. 

d. For short cables (4,500 mm [15 ft] or less), hand-twisting of the multiple 

conductor bundle shall be accomplished without tangling. The lay shall be 

unidirectional right-hand with a length of 8 to 16 times the outside diameter of the 

multiple. The individual conductors or the conductor sets shall be relieved as the 

multiple is twisted so the sets will not be twisted. For cables over 4,500 mm, a 

simple fixture can be made that prevents tangling and gives a uniform twist (as 

shown in Figure 19). 

e. Cut the overall braided shield to the dash-number length plus about 10 percent. 

Lay the braided shield out straight on the floor or long workbench and run a fish 

tape through the length of the shield. Secure the end of the fish tape to one end of 

the conductor multiple and pull the multiple through the shield. Personnel should 

be stationed along the shield to stroke the shield as the multiple goes through. 

When finished, the shield should be stroked from the center outward in both 

directions to form the shield tightly around the multiple. 

f. Cut the polychloroprene or other approved jacket material to the dash-number 

length plus about 10 percent. Lay the jacket out straight on the floor or long 

workbench and run the fish tape through the length of the tubing. Secure the end 

of the fish tape to one end of the multiple and overall shield. (If the fish tape is 

still secured to the multiple, the tape can be wrapped around the shield at the 

secured end to prevent it from slipping back.) Then pull the cable through the 

sleeve with personnel stationed along the jacket to ensure the shield does not bind 

or catch in the jacket. 
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Figure 19. Unique Bulk Cable Fabrication 

g. The heat-shrinking process may be done in a number of ways (heat gun with 

wraparound shield, cylindrical open-ended over, etc.); but, whichever method is 

used, the heat should be applied evenly around the circumference of the cable and 

should progress slowly from one end to the other or from the center to each end in 

turn, making sure the tubing is completely shrunken as the process moves along 

the cable. A slight back-and-forth motion with a heat gun is sometimes desirable 

to start the process downstream to prevent wrinkles and distortion due to abrupt 

shrinking at one point. 

h. Cut off one end of the cable as close as possible to any damaged conductors or 

shield or tubing ends. Measure the cable and add 150 mm to 300 mm (6 in to 

12 in) to the dash-number length. Cut the cable at this point; the cable is now 

ready for termination. 
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3.11.3 Connectors 

SAE AS 50151, MIL-C-22992, MIL-DTL-38999, and MIL-DTL-26482 connectors shall be 

100-percent inspected in accordance with 75M13302 before they are mated or used in GSE flight 

interface equipment, cables, or harnesses. Installed connectors shall be inspected for damage, 

clocking, contact alignment, and spacing in accordance with 75M13302 before and after potting 

and molding operations and just prior to final acceptance. Connector substitutions shall be in 

accordance with 120E3100003 or KSC-GP-864. 79K19600 may be used for legacy systems but 

is not recommended for new designs. All other connectors shall be visually inspected for 

damage, proper clocking, and contact alignment and spacing. 

3.11.3.1 D-Subminiature (DB) Connectors 

MIL-DTL-24308F (nonenvironmental), MIL-DTL-83513F (polarized shell), and 

MIL-DTL-55302F (printed circuit subassembly) DB connectors shall be 100-percent inspected 

and tested in accordance with MIL-STD-202G and EIA-364 before they are mated or used in 

Space Shuttle or Constellation GSE flight interface equipment, cables, or harnesses. Installed 

connectors shall be visually inspected again for damage, clocking, contact alignment, and 

spacing prior to connector mates. 

DB connectors are used in many computer, audio/video, and data applications. The official name 

is D-subminiature, but many people call them “D-sub” or just “DB.” The connectors get their 

name from their trapezoidal shape that resembles the letter “D.” Most DB connectors have two 

rows of pins. Common types of D-sub connectors are DB9 and DB25 (Figure 20), used on 

personal computers (PCs) for serial and parallel ports. DB connectors use thumbscrews to secure 

the connectors. 

Figure 20. DB9 and DB25 Connectors 
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High-density (HD) DB-style connectors (Figure 21) look just like regular DB connectors; 

however, HD DB connectors have pins that are slightly smaller and placed closer together. HD 

connectors often have three rows of pins instead of two. The most common HD connector is the 

HD15, which is found on PC video cards and monitors. HD connectors use thumbscrews to 

secure the connectors. 

Figure 21. DB15 Connectors 

Another type of DB or D-sub connector is the MD, or micro DB connector (Figure 22). Micro 

DB connectors are slimmer than standard D-subs, with pins even smaller than the ones used on 

HD connectors. The MD is also commonly called a “half-pitch” DB connector. MD connectors 

are often used in Small Computer System Interface (SCSI) applications, and the most popular 

types are the MD50 and MD68 connections. MD connectors can use latch clips or thumbscrews 

as anchoring mechanisms. 

Figure 22. MD50 and MD68 Connectors 

D-sub connectors are usually described by the total number of pins that they can hold. In some 

cases, a DB25 connector may only have four or five pins loaded into it; however, it is still called 

a “DB25” connector and not a “DB4” or “DB5.” Another example is the HD15 connector used 

by monitors—most monitor cables are only loaded with 14 pins, but the connector is still called 

an HD15 connector. 

3.11.4 Jacket Removal 

The removal of outer jackets of insulation, when required, shall be accomplished by a method 

that will prevent damage to metallic shields or individual conductor insulation. Insulation shall 

have a neat, unfrayed appearance. 

3.11.5 Conductor and Shield Termination 

Conductor terminations shall be as specified in 3.6. Conductors within each individual shielded 

group shall be terminated in accordance with wiring diagrams on a row-by-row basis. Shield 

terminations for cables and cable harnesses shall be in accordance with 79K04613, 79K07416, 

82K03874, paragraph 3.5.13 of this specification, and applicable engineering drawings and 

documentation. The shield termination hardware shall be in accordance with 3.5.13.4.
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3.11.6 Potting and Molding 

Prior to potting or molding, the cable assembly shall be checked for workmanship and for 

electrical continuity and leakage between circuits as specified in 3.11.10. Unless otherwise 

specified, potting, molding, and inspection of electrical connectors and cables shall be in 

accordance with KSC-STD-132. Cable jackets shall be inspected in areas to be potted or molded 

in accordance with criteria listed in 3.11.1. Potting and molding operations shall be performed in 

accordance with applicable portions of 79K14177 and as specified in engineering drawings and 

documentation. Before potting, backshells shall be torqued to values specified in 120E3100003 

(79K19600 may be used for legacy systems but is not recommended for new designs). 

3.11.7 Cable Jacket Repair 

Damage to the cable sheath shall be repaired without affecting the serviceability of the cable 

when the overall shield braid and the conductors underneath have not been harmed. When the 

integrity of the overall shield or conductor core is lost, the cable shall be replaced or spliced 

(see 3.11.8). 

3.11.7.1 Sleeves 

The cable repair material shall consist of a heat-shrinkable sleeve coated on the inside with an 

adhesive that will melt and flow as the sleeve shrinks and will provide an environmentally sealed 

and electrically insulated connection. SAE AMS-DLT-23053 establishes the requirements for 

electrical insulating sleeving that will shrink to a predetermined size when heat is applied. A 

wraparound sleeve shall be used to repair the cable in place or when a tubular sleeve cannot be 

fitted. 

The damaged area shall be cleaned and abraded to remove dirt and improve adhesion; then the 

repair sleeve shall be installed according to the manufacturer’s instructions. 

3.11.7.2 Approved Products 

The following products, or their equivalents, are approved for use: 

a. Heavy-wall cable sleeve: Tyco Electronics (formerly known as Raychem) 

type WCS, type WCSM, or SST-FR (Tyco Electronics, 8000 Purfoy Rd., FuquayVarina, NC 27526 [CAGE 06090]) 

b. Light-wall cable sleeve: Tyco Electronics (formerly known as Raychem) 

type TCS, TCS2, or STW (Tyco Electronics, 8000 Purfoy Rd., Fuquay-Varina, 

NC 27526 [CAGE 06090]) 

c. Wraparound cable sleeve: Tyco Electronics (formerly known as Raychem) 

type MRS (Tyco Electronics, 8000 Purfoy Rd., Fuquay-Varina, NC 27526 

[CAGE 06090]) 
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3.11.8 Splicing 

Cables shall only be spliced with the approval of the contracting officer. 

3.11.8.1 Procedure 

Cable splicing shall be accomplished as follows: 

a. Strip the cable insulation to the required length, being careful to maintain the 

integrity of the overall shield. For multiconductor cables, plan the entire 

procedure so the splice sleeves will be staggered to reduce the diameter of the 

completed splice as much as possible. 

b. Slip the cable repair sleeve, in accordance with 3.11.7, over one cable end. The 

cable sleeve shall be sized to slip over the completed splice bundle and overlap 

the cable ends by a minimum of 150 mm (6 in). 

c. Place the shield braid and shield braid terminators over the cable ends if required 

by step g. 

d. Select the properly sized splice sleeve (see 3.5.12) for the conductor to be spliced. 

Splices made in accordance with NAS 1744 and SAE AS 81824 are preferred 

when environmental sealing and size considerations are important. Crimped 

splices are preferred over soldered splices when there is enough space to use 

crimping tools. 

e. Strip the conductor insulation for one-half the length of the splicing sleeve in 

accordance with 3.5.7. 

f. Install the splicing sleeve on the conductor using the approved tooling (see 4.3.2). 

Repeat the above steps for all conductors when required. Stagger the splices on a 

multiconductor cable to reduce the diameter of the bundle. 

g. Terminate the shield braid according to one of the following methods: 

(1) For a cable with an (unspliced) wire bundle diameter less than 30 mm 

(1.2 in), use a shield braid terminator (SAE AS 83519A-A1 or NASAapproved). Before beginning the splicing operation, slide a properly sized 

shield terminator over each of the cable ends to be spliced. Then slide a 

section of tubular shield braid in accordance with A-A-59569B over one 

cable end, which is sized to fit over the completed splice bundle, and 

overlap the shield braid on the cable ends. After the conductor splices 

have been completed and inspected, slide the shield over the splices and 

terminate it to the original shielding according to the manufacturer’s 

instructions. This is the preferred method for use in confined areas where 

it is difficult to operate the tooling.
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(2) For a cable with an (unspliced) wire bundle diameter of 38 mm (1.5 in) or 

less, connect the shield braids using shield rings in accordance with 

75M13676 or wing shield terminators (SAE AS 83519A-A1 or NASAapproved). Prior to splicing, slide the shield rings and braid over the cable 

ends. When the splicing operation is complete, slide the new section of the 

shield braid over the splice and crimp it to the old braid using the shield 

rings. 

(3) For larger diameter cables where shield rings and/or shield terminators are 

not available, bridge the gap with open-weave shielding braid tape, Scotch 

no. 23, or equal. Install one half-lapped layer of the tape across the splice 

bundle, making sure it laps at least 25 mm (1 in) over the cable shield at 

each end. Tack-solder each end to hold them in place. Wick as much 

solder at the juncture as possible, being careful not to melt the conductor 

insulation underneath. Shield rings and/or shield terminators shall be used 

when available. 

h. Test the cable and verify compliance with 3.11.10. 

i. Clean and abrade the outer cable jackets to remove foreign substances and ensure 

a proper bond. Position the cable sleeve across the splice bundle and shrink the 

sleeve to fit. A bead of sealant will be visible around the edge of the sleeve after 

shrinking when a proper seal has been made. 

3.11.8.2 Approved Products 

The following products, or an equivalent, are approved for use: 

a. Shield terminators in accordance with SAE AS 83519A-A1 and/or NASAapproved methods 

b. Tyco Electronics (formerly known as Raychem) shield braid terminators, 

series D-123 (Tyco Electronics, 8000 Purfoy Rd., Fuquay-Varina, NC 27526 

[CAGE 06090]) 

c. Scotch no. 24 electrical shielding tape (Electrical Specialties Division/3M, 

225-4N 3M Center, St. Paul, MN 55144 [CAGE 20999]) 
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3.11.9 Thermal Protection 

Thermal protection of cable assemblies shall be in accordance with applicable installation or 

engineering drawings. Thermal blankets, sleeves, and hose assemblies shall be in accordance 

with SAE AS1072. The following methods shall be used to apply heat-reflective tape. When the 

application of the tape requires the removal of cable identification labels, the labels shall be 

reinstalled in a highly visible and permanent manner using 6.5 mm (0.25 in) characters. 

3.11.9.1 Application 

Thermal protection application shall be accomplished as follows: 

a. Method 1: Apply a half-lapped layer of 50 mm (2 in)-wide heat-reflective, 

metallized glass-cloth tape. 

b. Method 2: Apply a base layer of half-lapped, 50 mm (2 in)-wide thermal-barrier 

tape. Cover with one layer of heat-reflective tape according to method 1. 

c. Method 3: Apply a base of two half-lapped layers of 50 mm (2 in)-wide thermalbarrier tape. Cover with one layer of heat-reflective tape according to method 1. 

d. Method 4: Apply a base of two half-lapped layers of 50 mm (2 in)-wide thermalbarrier tape. Cover with two layers of half-lapped 50 mm-wide heat-reflective, 

metallized glass-cloth tape according to method 1. 

NOTE 

When more than one layer of tape is used, each 

successive layer shall be wrapped in the direction 

opposite of the preceding layer. 

3.11.9.2 Approved Products 

The following products, or their equivalents, are approved for use: 

a. High-temperature, metallized glass-cloth tape: Scotch type 363 (Industrial Tape 

and Specialties Division/3M, 3M Center, St. Paul, MN 55144 [CAGE 52132]). 

b. Thermal-barrier tape: Scotch type AZ 1367 (Industrial Tape and Specialties 

Division/3M, 3M Center, St. Paul, MN 55144 [CAGE 52132]); or 91111 ThermoTrex High Temperature Silica Tape (TPC Wire & Cable Corp., 9600 Valley View 

Road, Macedonia, OH 44056 [CAGE 1GLC4]). 

c. Panduit stainless-steel tie MLTxH-LP (x = bundle diameter in inches) requires 

GS4MT installation tool and PME acid etching pen or IMP 250 indenter marker 

(Panduit Corporation, 17301 Ridgeland Street, Tinley Park, IL 60477 

[CAGE 06383]). 
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d. Fyrejacket sleeving and Fyretape (Federal-Mogul Systems Protection Group, 

Bentley Harris Protection Products, 241 Welsh Pool Road, Exton, PA 19341 

[CAGE 81851]). 

3.11.10 Cable Checkout 

Insulation resistance and continuity tests shall be performed by the fabricating agency on all 

cable assemblies. Cable assemblies, as defined herein, consist of cables with prefabricated 

terminations on one or both ends and less than 60 m (200 ft) in length. For assemblies longer 

than 60 m, refer to the cable assembly drawing or make a request to the contracting officer for 

minimum limits of cable insulation resistance. Prior to tests, all wiring shall be inspected to 

verify proper workmanship and positioning for adequate clearances and stress relief. The 

fabricating agency shall forward the recorder strips obtained in accordance with 3.11.10.3 and 

shall certify that every cable assembly meets or exceeds all requirements specified in 3.11.10.1 

through 3.11.10.3.3.2. 

3.11.10.1 Cable Continuity Test 

For multiconductor cable assemblies, all multiconductor assemblies shall be tested as follows: 

a. A multimeter or measuring device approved by the contracting officer or 

designated NASA technical representative shall be used. The meter shall be set at 

the lowest ohm scale applicable to the readings. 

b. Each conductor shall be tested. 

c. Each conductor of an assembly shall be tested for minimum resistance based on 

the length and type of cable. 

3.11.10.2 Cable Insulation-Resistance Tests 

For multiconductor cable, the insulation resistance shall be measured between isolated circuits 

and ground on all circuits not involving electrical components. 

a. Measuring Instrument: The resistance measurements shall be taken with an 

approved insulation-resistance instrument that has a test potential of 500 volts 

direct current (VDC). The instrument shall have a full-scale reading of 

2,000 megohms (MΩ) or greater, with a minimum accuracy of 5 percent at 

100 MΩ. The potential shall be applied long enough for the meter to become 

reasonably stable and an accurate measurement to be taken. 

b. Minimum Resistance: Minimum resistance of new cables shall be as follows: 

(1) Each shield to ground: 100 MΩ

(2) Each shield to shell of connector or receptacle (when shield is not 

terminated to the backshell): 100 MΩ
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(3) Each conductor or all conductors to any single corresponding shield: 

100 MΩ

(4) Each conductor or all conductors to any single conductor: 200 MΩ

(5) Each conductor or all conductors to ground: 100 MΩ

(6) Each insulated shield to shield: 100 MΩ

(7) Overall shields to ground shell of conductor (when shield is not terminated 

to the backshell), other shields if applicable, or conductors: 100 MΩ

Insulation resistance may become lower with service life. Acceptance of lower values for older 

cables shall be made on an individual basis (10 MΩ is a realistic lower limit for cables under 

60 m [200 ft]). 

3.11.10.3 Radio Frequency Cable Tests 

The following standard tests shall be performed for radio frequency and video cables. Alternate 

procedures may be used with the approval of the contracting officer or as specified in design 

drawings or specifications. 

3.11.10.3.1 Continuity Tests 

The continuity tests for coaxial, twin-axial, triaxial, and balanced-pair (T43) cables shall be 

performed as specified in 3.11.10.1. 

3.11.10.3.2 Insulation-Resistance Test 

3.11.10.3.2.1 Coaxial Cable 

The insulation-resistance test shall be performed by applying the ohmmeter leads of a high-input 

impedance volt-ohmmeter (set on R × highest range) to the inner and outer conductor of the 

connector ferrule. 

If the meter indicates off-scale high or infinite resistance, the testing shall proceed as follows 

(shield-to-shield and shields-to-connector-body also apply to the test): 

a. Connect the voltmeter and 125 VDC source in series. 

b. Set the meter on the 5 V range and check to see that the meter has 11 MΩ input 

resistance on this scale. 

With connectors installed, the coaxial cable shall have a resistance exceeding 500 MΩ indicated 

on the meter as 2.7 V or less. The insulation resistance from shield to shield and from shields to 

connector body may be as low as 100 MΩ (12.4 V on the 50 V scale). 
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The insulation-resistance test shall be performed in accordance with MIL-DTL-17, 

paragraph 4.8.5 and as specified by the cable and/or test equipment manufacturer.

3.11.10.3.2.2 Twin-Axial Cable and Balanced Pairs (T43, Cat5e, or Cat6) 

The insulation-resistance tests for twin-axial cable and balanced pairs (T43, Cat5e, or Cat6) shall 

be as described in 3.11.10.2. 

3.11.10.3.3 Time Domain Reflectometer (TDR) Test 

The purpose of the TDR test is to obtain the return loss-versus-distance profile of the cable 

system. A radio frequency pulse is transmitted down the cable and the energy reflected back 

from any discontinuities or impedance variation is detected and displayed. The distance to the 

discontinuity determines the time it takes for the reflected energy to return to the (reference) 

detector and the magnitude of the reflected signal is a function of the return loss (reflection 

coefficient) at the point of the discontinuity (reflection point). From this, the magnitudes and 

locations of discontinuities (faults such as breaks, misalignments, corrosion, etc.) can be 

determined and the necessary corrective actions taken. A rise on the display indicates an increase 

in impedance (a broken wire or frayed shield); a dip on the display indicates a drop in impedance 

(a short) (refer to Figure 23 and Figure 24 for examples; the actual presentation may vary 

depending on the instrument used). 

Cables shall be tested using a TDR that delivers a sine-shaped, controlled-bandwidth signal and 

has outputs for an X-Y recorder. A pulse width of 10 nanoseconds or less shall be used to test 

cables less than 90 m (300 ft) in length. Shorting plugs should be used wherever possible during 

the test. 

3.11.10.3.3.1 Coaxial Cable 

The following steps shall be performed: 

a. Connect the coaxial cable to the TDR with the opposite end open circuited and 

adjust the scope display to obtain both entrance and exit discontinuity spikes (see 

Figure 23, view D). 

b. Short the opposite end of the cable and verify that a negative spike occurs equal to 

and located at the exact former rise point of the positive spike. 

c. Open the opposite end and take a graphic readout on the recorder. Record the 

length/division setting on the printout. 
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Figure 23. TDR Traces for Coaxial Cable 
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Figure 24. TDR Fault Traces for Twin-Axial Cable (Sheet 1 of 2) 
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Figure 24. TDR Fault Traces for Twin-Axial Cable (Sheet 2 of 2)
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3.11.10.3.3.2 Twin-Axial Cable or Balanced Pairs (Cat5e, Cat6, or T43) 

The following steps shall be performed: 

a. With conductors connected to the TDR and the opposite end open, adjust the 

scope time scale to obtain both discontinuity spikes (see Figure 24, view B). 

b. Short the conductors at the opposite end and verify that a negative spike occurs 

equal to and located at the exact former rise point of the position spike. 

c. Remove the short and take a graphic readout of the open end and record the 

length/division setting. 

d. Connect the TDR to one conductor (tip) and shield and display the discontinuity 

spikes with the opposite end open. 

e. Place the short on the opposite end and verify the location and presence of the 

negative spike. 

f. Repeat steps c and e. 

g. Repeat steps d, e, and f for the other conductor (ring). 

3.11.10.3.3.3 Triaxial Cable TDR Test 

Numerous commercial bench and handheld TDR testers are available for troubleshooting and 

fault detection in triaxial cables. For test setups and instructions, refer to the manufacturers’ 

user’s guides for specific testers. 

3.11.11 AC Power Cables 

Other specially insulated or armored cables dedicated for use with alternating-current power 

shall conform to KSC-SPEC-E-0017. 

3.12 Mineral-Insulated (MI) Cable 

MI cable shall be installed in accordance with NFPA 70, Article 332; and KSC-SPEC-E-0017. 

Termination procedures shall be in accordance with 79K06110. 

3.13 Transducers 

Sensors, transducers, and signal conditioners for use in GSE systems shall be selected as 

specified in KSC-NE-9187. 
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3.14 Electromagnetic Interference Tests 

Specific ground support electronic equipment may require testing for electromagnetic 

interference. This equipment shall be in accordance with KSC-STD-E-0022 and MIL-STD-461. 

The contract technical representative shall identify this equipment and specify how the 

equipment must be tested for conducted and radiated emissions. 

3.15 Fabrication Process Waste Disposal 

Controls of waste materials generated during the fabrication process shall conform to CFR 

Title 40, Parts 260–282; Florida Administrative Code (FAC) Florida Department of 

Environmental Protection (FDEP), Division 62; KNPR 8500.1; and the following rules: 

a. No person shall collect, transport, store, recycle, use, or dispose of waste 

materials generated during the fabrication process in any manner that endangers 

the public health or welfare or the environment. 

b. These waste materials shall not be discharged into soils, sewers, drainage systems, 

septic tanks, surface waters or ground waters, water courses, or marine waters. 

c. Care shall be taken not to mix the wastes generated during fabrication. 

d. Containers/tanks used for waste disposal shall be labeled with the type of waste 

they contain. 

e. Wastes generated during the fabrication process shall be kept to a minimum 

through careful planning of the amounts of material needed. 

f. It is the user’s obligation to properly store all hazardous materials and inform the 

local emergency planning organization of the quantity on hand and its location. 

g. Each user shall maintain records on the weight of hazardous material used and 

what happened to the material, i.e., whether it was consumed in the product, 

released into the environment (spilled or released through air emissions, land 

discharge, water discharge, or underground injection), used to generate energy 

onsite, used to generate energy offsite, recycled offsite, recycled onsite, treated 

offsite, or treated onsite. 

3.16 Fiber-Optic Cables 

The following paragraphs provide requirements for termination and cabling of both single-mode 

and multi-mode fiber in accordance with NASA-STD-8739.5. Facilities, equipment, and 

materials used in the fabrication, assembly, and installation of fiber-optics shall comply with this 

specification and the requirements of NASA-STD-8739.5. Terms related to fiber-optic cables are 

defined in 6.2 and additional information may be found in TIA-440-B. 
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3.16.1 Optical-Fiber End Preparation 

The supplier’s engineering documentation shall define the parts, tooling, equipment, and 

procedures used in preparing the fiber-optic cable for termination. All parts, materials, and 

tooling and equipment shall be verified for compliance to the engineering documentation before 

fabrication activities begin. 

a. Cables shall be prepared for termination in a fashion that will allow for the fiber 

to be exposed without sustaining damage or contamination. 

b. All outer protective materials shall be removed, in the proper dimensions, in 

accordance with the supplier’s engineering documentation. 

c. The use of chemical strippers (e.g., acetone) for removal of certain buffer 

materials is acceptable. Chemically stripped fiber ends shall be thoroughly 

cleaned to remove any residual chemical stripping compounds and buffer 

materials immediately after stripping. This process shall be documented by the 

supplier. All necessary safety precautions shall be observed. 

d. All parts that come into contact with the adhesives, including all dispenser parts 

and mixing pans, as well as the fiber and connector to be bonded, must be 

thoroughly cleaned with appropriate solvents before bonding. 

e. The optical fiber shall be further prepared if warranted by the specific application, 

fiber construction, or process requirement. The supplier’s engineering 

documentation shall specify any additional requirements. 

f. Procedures for collecting, controlling, and disposing of fiber-optic waste shall be 

documented. Fiber-optic waste is a safety concern and shall be handled as such 

during disposal. Incineration is the recommended method of safe disposal. 

g. Inspection techniques that produce core illumination shall be used. 

h. The connector endface may be finished either by polishing or cleaving provided 

that the process is compatible with the quality requirements established by the 

supplier’s engineering documentation for the finished product. 

3.16.2 Cleaning 

Specific procedures shall be developed, documented, and maintained for cleaning, drying, and 

examining parts. Prior to use, the appropriate engineering activity shall verify the compatibility 

of the solvents used for cleaning the assembly and all materials, including epoxies. If not 

terminated immediately, prepared cable components shall be protected from contamination. 

Fiber-optic terminations to be cleaned shall be handled in a manner that will not degrade or 

damage the termination. Cleaning processes shall not degrade the optical characteristics of the 
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termination. Cleaning shall ensure removal of dirt, oil, grease, and particulate matter. 

Terminations shall be cleaned within a time frame that allows all contaminants to be removed. 

Cleaning solvents shall be of the type specified in the engineering documentation. Manual 

cleaning of fiber terminations shall be performed using a solvent and a wipe or swab. The wipe 

or swab shall be nonabrasive, lint-free, and manufactured either by soxhlet extraction to remove 

oils, resins, or other contaminants, or by another means that would produce only a small amount 

of nonvolatile residue. 

3.16.3 Splicing 

Fiber-optic cables shall be prepared for splicing in accordance with 3.16.1. Cleaved fiber ends 

must be clean, fragment-free, and crack-free with minimum chips or other defects as shown in 

NASA-STD-8739.5, Appendix A. Fiber cable shall have an endface angle as required by the 

engineering documentation. Equipment used shall meet the criteria in NASA-STD-8739.5. 

Splices should be of the construction, weight, and physical dimensions specified by engineering 

documentation. The design should (1) meet the requirements for optical, mechanical, and 

environmental performance as specified by engineering documents and NASA-STD-8739.5; 

(2) provide tensile strength continuity between spliced cables without the cable tensile load being 

applied to the splice junction; and (3) provide cable stress relief and environmental sealing 

between the cables and splice to prevent external contaminants from entering. The stress relief 

should provide protection from both cable tensile forces and cable axial compressive forces. The 

use of splice trays is recommended for multiple splices. 

All splice parts of the same type should be physically and functionally interchangeable without 

the need to modify them or the splicing equipment. When dissimilar metals are used in contact 

with each other, protection against electrolysis and corrosion should be provided. Metal spraying 

or metal plating of dissimilar base metals to provide similar or suitable abutting surfaces is 

permitted. Seals should provide isolation from humidity and/or contamination for splice interior 

parts. 

3.16.3.1 Presplicing Examination 

Prior to splicing, the fiber shall be examined to ensure there is no contamination, blockage of the 

internal fiber channel, unacceptable conditions as shown in NASA-STD-8739.5, Appendix A, as 

applicable, or other areas of nonconformance to the specific requirements of the engineering 

documentation. 

3.16.3.2 Splicing Method 

Splices shall be made using the appropriate method as described in the following paragraphs, or 

as specified in the engineering documentation. 
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3.16.3.2.1 Fusion Splicing 

Fusion splicing shall be performed in accordance with engineering documentation. Completed 

fusion splices shall be able to withstand a minimum 4.45 N (1 lb) pull test, or as specified in the 

engineering documentation. 

3.16.3.2.2 Mechanical Splicing 

Mechanical splicing shall not be used for cables intended for use in spaceflight operations. 

Mechanical splicing of fiber optics shall be performed in accordance with engineering 

documentation. 

3.16.3.2.3 Chemical Splicing 

Chemical splicing shall only be used for temporary joining of fiber optics (i.e., testing). 

3.16.3.3 Splice Requirements 

Completed splices shall meet the following minimum requirements: 

3.16.3.3.1 Location 

Splices shall not be located in areas where the cable is flexed except when a splice is recoated 

and rejacketed in accordance with the manufacturer’s original specifications.

3.16.3.3.2 Protection 

Splices shall be protected. If a splice enclosure cannot be used for a specific application, 

engineering documentation shall provide for other means of protection. 

3.16.3.3.3 Strength Member 

Strength members shall be secured to splice enclosures, or other means of protection, to prevent 

mechanical stress on the optical fiber. 

3.16.4 Fiber-Optic Cable Assemblies 

A fiber-optic cable assembly consists of a prepared fiber-optic cable, connector, and associated 

hardware. Materials used shall be in accordance with NASA-STD-8739.5. 

3.16.4.1 Cable Assembly 

Fiber-optic cables shall be prepared for the connector assembly in accordance with the 

procedures outlined in 3.16.1. Cables shall be identified in such a way to distinguish these cables 

from wire or coaxial cables. Cable connectors shall be permanently marked with mating 

connector designation within 15 cm (6 in) of the connector body, or as stated in the engineering 

documentation. 
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3.16.4.1.1 Preassembly Verification 

Prior to assembly, prepared fiber-optic cables shall be subject to documented in-process peer 

verification for (1) correct dimensions for the cable stripping; (2) damage to a strength member; 

(3) cracks, nicks, cuts, or other damage to cable components in the termination area, including 

optical fiber; (4) wicking or damage to the chemical strip; and (5) cleanliness as defined in 

3.16.2. Any other verifications defined in the engineering documentation shall also be 

performed. 

3.16.4.1.2 Preassembly Examination 

Prior to assembly, prepared fiber-optic connector parts shall be examined for (1) blockage in the 

internal fiber channel (the prepared fiber shall not be used to check for blockage); (2) cleanliness 

as defined in 3.16.2; and (3) cracks or deformities on the connector ferrule. 

3.16.4.2 Completed Cable Assemblies 

The connector should be of the construction, weight, and physical dimensions specified by 

engineering requirements. The design should (1) meet the requirements for optical, mechanical, 

and environmental performance as specified by engineering requirements; (2) provide stress 

relief for the cable and environmental sealing between the cables and connector to prevent 

external contaminants from entering. The stress relief and connector/cable attachment method 

should provide protection from both cable tensile forces and cable axial compressive forces. 

All connector parts of the same type should be physically and functionally interchangeable 

without the need to modify such items or the termination equipment. A complete mated 

connector design should be comprised only of parts from the same manufacturer to prevent 

problems with the connectors mating. When dissimilar metals are used in contact with each 

other, protection against electrolysis and corrosion should be provided. Metal spraying or metal 

plating of dissimilar base metals to provide similar or suitable abutting surfaces is permitted. 

Seals should be used to isolate connector interior parts from humidity and/or contamination. 

Engineering documentation shall address the maximum allowable connector coupling loss, 

connector mate durability, staking and torque values, and the minimum cable bend radii. 

For inspection purposes, clear heat-shrinkable sleeving is recommended. Completed cable 

assemblies shall be inspected to verify the following conditions: 

a. The strength member, when visible, is uniformly distributed and securely attached 

to the connector. 

b. The heat shrinkable sleeving and/or crimp sleeve is positioned properly. 

c. The connector endface geometry is compliant with engineering documentation. 

d. The connector endface meets requirements in accordance with 

NASA-STD-8739.5, Appendix A1, or the engineering documentation. 
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e. The length of the connector ferrule is compliant with engineering documentation. 

f. The strain relief device is properly positioned and attached in accordance with the 

engineering documentation. 

g. Cleanliness meets the requirements defined in 3.16.2. 

h. Cable axial alignment with the connector is within 5 cm (2 in) of the termination 

or in accordance with the engineering documentation. 

i. The assembly is free of nicks/cuts exposing underlying elements. 

j. The assembly is free of kinks or twists. 

k. The proper cable designation marking are shown. 

3.16.5 Fiber-Optic Assemblies 

Fiber-optic assemblies include such devices as electro-optical components, couplers, dividers, 

wavelength multiplexers, and splice enclosures. The optical fibers found in these devices consist 

of the fiber (core and cladding) and the coating surrounding the fiber. Optical fibers differ from 

fiber-optic cables which may have a buffer, loose tube, strength members, and outer jacket as 

additional protective sheathing. 

3.16.5.1 Fiber-Optic Connector Termination 

The optical fiber shall be prepared in accordance with 3.16.1. 

3.16.5.1.1 Preassembly Verification 

Prior to assembly, prepared optical fibers shall be subject to a documented, in-process, peer 

verification for (1) correct stripping dimensions; (2) cracks, nicks, cuts, or other damage to the 

coating and fiber; (3) chemical strip wicking or damage; and (4) cleanliness as defined in 3.16.2. 

Any other verifications (e.g., to verify heat-shrinkable sleeving dimensions or crimp sleeve 

requirements) required by engineering documentation shall be performed. 

3.16.5.1.2 Preassembly Examination 

Prior to assembly, fiber-optic connector parts shall be examined for (1) blockage in the internal 

fiber channel (the prepared fiber shall not be used to check for blockage); (2) cleanliness as 

defined in 3.16.2; and (3) cracks or deformities on the connector ferrule. 

3.16.5.2 Post–Fiber-Optic-Connector-Termination Inspection 

Terminated fiber-optics shall be inspected to verify that (1) the heat-shrinkable sleeving and/or 

crimp sleeve is positioned properly; (2) the connector endface geometry is compliant with 

engineering documentation; (3) the connector endface requirements are in accordance with 
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NASA-STD-8739.5, Appendix A, or engineering documentation; and (4) the strain relief is 

properly positioned in accordance with the engineering documentation. 

When inspecting optical fiber, inspection techniques that produce core illumination shall be used. 

3.16.5.3 Fiber-Optic Routing 

The optical fiber shall not be routed over sharp edges or corners unless appropriate protection is 

provided. The minimum bend radius of the routed optical fiber shall be in accordance with 

engineering documentation. The optical fiber shall be tied down (e.g., lacing cord) in accordance 

with the engineering documentation to prevent subsequent damage due to processing, handling, 

and operational environments. The ties shall not pinch, deform, or otherwise stress the optical 

fiber. The ties shall be loose enough to allow the fibers to move slightly due to thermal 

expansion and contraction. Overly tight ties can cause microbending of the fiber and affect 

performance or reliability. Conduits should be used to route optical fibers through areas where 

access is limited or restricted. Staking or conformal coating shall not be applied to optical fiber 

unless specifically required in the engineering documentation. 

3.16.6 Testing 

3.16.6.1 Fiber-Optic Splices 

Splices shall be verified. Optical time domain reflectometry (OTDR), as well as other 

appropriate test procedures from NASA-STD-8739.5, Appendix B, should be used after the 

completion of the splicing operation to ensure that loss characteristics are consistent with the loss 

allowances established by design and operation engineering documentation. Records of testing 

shall be maintained with the assembly/subassembly documentation. NASA-STD-8739.5, 

Appendix B, provides a list of available test and verification documents. 

3.16.6.2 Fiber-Optic Cable Assemblies 

All completed cable assemblies shall be tested to ensure that measured optical performance 

(e.g., insertion loss or return loss) meets or exceeds the performance requirements in the 

engineering documentation. Records of testing shall be maintained with the assembly or 

subassembly documentation. NASA-STD-8739.5, Appendix B, provides a list of available test 

and verification documents. 

Upon completion of initial testing (in accordance with the paragraph above), the cable 

assemblies shall be subjected to workmanship temperature cycling or preconditioning as 

identified in the engineering documentation. Cable assemblies shall be retested and, in addition, 

examined for the following: 

a. Cracks in the fiber endface using normal inspection techniques. The fiber-optic 

cable assembly shall be inspected without touching the fiber as part of the 

examination. 

b. Pistoning of the fiber in the connector. 
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c. Cracks in the epoxy bond line at the endface. 

d. Shrinkage of the outer jacket. Other cable components shall also be evaluated for 

shrinkage. An unacceptable amount of shrinkage shall be defined by an excessive 

optical loss value as specified in the engineering documentation. 

3.16.6.3 Fiber-Optic Assemblies 

All finished fiber-optic assemblies shall be tested to ensure that measured optical performance 

meets the performance requirements in the engineering documentation. Records of testing shall 

be maintained with the assembly or subassembly documentation. NASA-STD-8739.5, 

Appendix B, provides a list of available test and verification documents. 

Upon completion of initial testing (in accordance with the paragraph above), the fiber-optic 

assemblies shall be subjected to workmanship temperature cycling or preconditioning as 

identified in the engineering documentation. Fiber-optic assemblies shall be retested and, in 

addition, examined for the following: 

a. Cracks in the fiber endface. The examination shall be done using direct and back 

lighting. The optical fiber shall be back-lit using an incoherent, low-intensity light 

source from the opposite end of the fiber, without touching the fiber as part of the 

examination. When the opposite end of the fiber is not accessible, inspection 

techniques that produce core illumination shall be used. 

b. Pistoning of the fiber in the connector or termination. 

c. Cracks in the epoxy bond line at the endface. 

d. Shrinkage of the buffer or outer jacket. 

3.16.6.4 Optical Time-Domain Reflectometer (OTDR) Test 

In accordance with NASA-STD-8739.5, the optical performance (e.g., insertion loss or return 

loss) of completed fiber-optic cable assemblies, fiber-optic splices, and fiber-optic assemblies 

shall be measured to ensure that it meets or exceeds the performance requirements in the 

engineering documentation. An OTDR test using fiber-optic test procedures (FOTP) outlined in 

Appendix B of NASA-STD-8739.5 (i.e., TIA-455-78-B) shall be used for the verification. 

3.16.6.5 OTDR Basic Theory of Operation 

An OTDR sends short pulses of light into a fiber. Light scattering occurs in the fiber due to 

discontinuities such as connectors, splices, bends, and faults. An OTDR uses the effects of 

Rayleigh scattering and Fresnel reflection to measure the fiber’s condition, but the power level of 

the Fresnel reflection is tens of thousands of times higher than that of the backscatter. Rayleigh 

scattering occurs when a pulse travels down the fiber and small variations in the material, such as 

discontinuities in the index of refraction, cause light to be scattered in all directions. However, 

the phenomenon in which small amounts of light are reflected directly back toward the 
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transmitter is called backscattering. Fresnel reflections occur when the light traveling down the 

fiber encounters abrupt changes in material density that may occur when there is an air gap at 

connections or breaks. A very large amount of light is reflected, as compared with the Rayleigh 

scattering. The strength of the reflection depends on the degree of change in the index of 

refraction. 

An OTDR detects and analyzes the backscattered signals. The signal strength is measured for 

specific intervals of time and is used to characterize events. The OTDR calculates distances to 

events as follows: 

Distance = 

2

t

n

c

u

Where: 

c = speed of light in a vacuum (2.998 × 108

 m/s) 

t = time delay from the launch of the pulse to the reception of the pulse 

n = index of refraction of the fiber under test (as specified by the manufacturer) 

OTDRs are microprocessor-based diagnostic tools that can be PC-based, bench-type, or handheld models. Depending on the model, the basic setup and flow of data will be as shown in 

Figure 25. 

Refer to the manufacturer’s instructions or user’s guide for proper setup and operation of 

individual OTDRs. 

Users rely on optical time-domain reflectometry to characterize optical fiber and optical 

connection properties in the field. An OTDR transmits an optical pulse through an installed 

optical fiber. The OTDR measures the fraction of light that is reflected due to Rayleigh scattering 

and Fresnel reflection. By comparing the amount of light scattered back at different times, the 

OTDR can determine fiber and connection losses. 

When several fibers are connected to form an installed cable plant, the OTDR can characterize 

optical-fiber and optical-connection properties along the entire length of the cable plant. A fiberoptic cable plant consists of optical fiber cables, connectors, splices, mounting panels, jumper 

cables, and other passive components. A cable plant does not include active components such as 

optical transmitters or receivers. 
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Figure 25. Typical OTDR Block Diagram 

The OTDR displays the backscattered and reflected optical signal as a function of length. The 

OTDR plots half the power in decibels (dB) versus half the distance. Plotting half the power in 

decibels and half the distance corrects for round-trip effects. By analyzing the OTDR plot, or 

trace, users can measure fiber attenuation and transmission loss between any two points along 

the cable plant. Users can also measure insertion loss and reflectance of any optical connection. 

In addition, users can locate fiber breaks or faults with the OTDR trace. 

Figure 26 shows an example OTDR trace of an installed cable plant. OTDR traces can have 

several common characteristics. An OTDR trace begins with an initial input pulse. This pulse is 

a result of Fresnel reflection occurring at the connection to the OTDR. Following this pulse, the 

OTDR trace is a gradual down-sloping curve interrupted by abrupt shifts. Periods of gradual 

decline in the OTDR trace result from Rayleigh scattering as light travels along each fiber 

section of the cable plant. Periods of gradual decline are interrupted by abrupt shifts called point 

defects. A point defect is a temporary or permanent local deviation of the OTDR signal in the 

upward or downward direction. Point defects are caused by connectors, splices, or breaks along 

the fiber length. Point defects, or faults, can be reflective or nonreflective. An output pulse at the 

end of the OTDR trace indicates the end of the fiber cable plant. This output pulse results from 

Fresnel reflection occurring at the endface of the output fiber. 
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Figure 26. OTDR Trace of an Installed Cable Plant 

3.16.6.5.1 Attenuation 

The test method for measuring the attenuation of an installed optical fiber using an OTDR is 

specified in TIA/EIA-455-78-B. The accuracy of this test method depends on the user entering 

the appropriate source wavelength, pulse duration, and fiber length (test range) into the OTDR. 

In addition, the effective group index of the test fiber is required before the attenuation 

coefficient and accurate distances can be recorded. The group index (N) is provided by fiber 

manufacturers or is found using TIA-455-133-A. If the test parameters are entered correctly, 

OTDR fiber attenuation values will closely coincide with those measured by the cutback 

technique. Test personnel can connect the test fiber directly to the OTDR or to a dead-zone fiber. 

This dead-zone fiber is placed between the test fiber and OTDR to reduce the effect of the initial 

reflection at the OTDR on the fiber measurement. The dead-zone fiber is inserted because 

minimizing the reflection at a fiber joint is easier than reducing the reflection at the OTDR 

connection. 

Figure 27 illustrates the OTDR points for measuring the attenuation of the test fiber using a 

dead-zone fiber. Fiber attenuation between two points along the test fiber is measured on gradual 

down-sloping sections on the OTDR trace. No point defects should be present along the portion 

of fiber being tested. 
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Figure 27. OTDR Measurement Points for Measuring Fiber Attenuation, 

Using Dead-Zone Fiber 

OTDRs are equipped with either manual or automatic cursors to locate points of interest along 

the trace. In Figure 27, a cursor is positioned at a distance zo on the rising edge of the reflection 

at the end of the dead-zone fiber. Cursors are also positioned at distances z1 and z2. The cursor 

positioned at z1 is just beyond the recovery from the reflection at the end of the dead-zone fiber. 

Since no point defects are present in Figure 27, the cursor positioned at z2 locates the end of the 

test fiber. Cursor z2 is positioned just before the output pulse resulting from Fresnel reflection 

occurring at the end of the test fiber. 

The attenuation of the test fiber between points z1 and z2 is (P1 – P2) dB. The attenuation 

coefficient (α) is 

 

 

1 2

2 1

P P

a= dB/km

z z





The total attenuation of the fiber including the dead zone after the joint between the dead-zone 

fiber and test fiber is 

   

 

1 0

1 2

2 1

z z

Attenuation = P P dB

z z

  

If fiber attenuation is measured without a dead-zone fiber, z0 is equal to zero (z0 = 0). At any 

point along the length of fiber, attenuation values can change depending on the amount of optical 

power backscattered due to Rayleigh scattering. The amount of backscattered optical power at 

each point depends on the forward optical power and its backscatter capture coefficient. The 

backscatter capture coefficient varies with length depending on fiber properties. Fiber properties 

that may affect the backscatter coefficient include the refractive index profile, numerical aperture 
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(multimode), and mode-field diameter (single mode) at the particular measurement point. The 

source wavelength and pulse width may also affect the amount of backscattered power. 

By performing the OTDR attenuation measurement in each direction along the test fiber, test 

personnel can eliminate the effects of backscatter variations. Attenuation measurements made in 

the opposite direction at the same wavelength (within 5 nm) are averaged to reduce the effect of 

backscatter variations. This process is called bidirectional averaging. Bidirectional averaging is 

possible only if test personnel have access to both fiber ends. OTDR attenuation values obtained 

using bidirectional averaging should compare with those measured using the cutback technique 

in the laboratory. 

3.16.6.5.2 Point Defects 

Point defects are temporary or local deviations of the OTDR signal in the upward or downward 

direction. A point defect, or fault, can be reflective or nonreflective. A point defect normally 

exhibits a loss of optical power. However, a point defect may exhibit an apparent power gain. In 

some cases, a point defect can even exhibit no loss or gain. Figure 26 (shown previously) 

illustrates a reflective fault and a nonreflective fault, both exhibiting loss. Figure 28 shows a 

nonreflective fault with apparent gain and a reflective fault with no apparent loss or gain. 

Figure 28. OTDR Trace Showing a Nonreflective Fault With Apparent Gain and a 

Reflective Fault With No Apparent Loss or Gain 

Point defects are located and measured using TIA/EIA-455-78. Test personnel must enter the 

appropriate input parameters including the source wavelength, the pulse duration, and the fiber 

or cable group index into the OTDR. The nature of fiber point defects depends on the value of 

each parameter entered by the user. The pulse duration usually limits the length of the point 

defect while other input parameters, such as the wavelength, can vary its shape. If the length of 

the fiber point defect changes with the pulse duration, then the OTDR signal deviation is in fact a 
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point defect. If the length remains the same, then the OTDR signal deviation is a region of high 

fiber attenuation. Regions of high fiber attenuation are referred to as attenuation nonuniformities. 

Fiber point defects occur from factory fiber splices or bends introduced during cable construction 

or installation. For shipboard applications, manufacturers are not allowed to splice fibers during 

cable construction. Fiber joints are natural sources of OTDR point defects. However, fiber 

breaks, cracks, or microbends introduced during cable installation are additional sources of point 

defects. 

Point defects that occur at fiber joints are relatively easy to identify because the location of a 

fiber joint is generally known. A reflective or nonreflective fault occurs at a distance equal to the 

location of the fiber joint. In most circumstances, an optical connector produces a reflective fault, 

while an optical splice produces a nonreflective fault. 

Reflective and nonreflective faults occurring at distances other than fiber joint locations identify 

fiber breaks, cracks, or microbends. A fiber break produces a reflective fault because fiber breaks 

result in complete fiber separation. Fiber cracks and microbends generally produce nonreflective 

faults. 

A point defect may exhibit apparent gain because the backscatter coefficient of the fiber present 

before the point defect is higher than that of the fiber present after. Test personnel measure the 

signal loss or gain by positioning a pair of cursors, one on each side of the point defect. 

Figure 29 illustrates the positioning of the cursors for a point defect showing an apparent signal 

gain. The trace after the point defect is extrapolated as shown in Figure 29. The vertical distance 

between the two lines in Figure 29 is the apparent gain of the point defect. 

Figure 29. Extrapolation for a Point Defect Showing an Apparent Signal Gain 
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Point defects exhibiting gain in one direction will exhibit an exaggerated loss in the opposite 

direction. Figure 30 shows the apparent loss shown by the OTDR for the same point defect 

shown in Figure 29 when measured in the opposite direction. Bidirectional measurements are 

conducted to cancel the effects of backscatter coefficient variations. Bidirectional averaging 

combines the two values to identify the true signal loss. Bidirectional averaging is possible only 

if test personnel have access to both ends of the test sample. 

Figure 30. Exaggerated Loss Obtained at Point Defects Exhibiting Gain in 

One Direction by Conducting the OTDR Measurement in the Opposite Direction 

OTDRs can also measure the return loss of a point defect. However, not all OTDRs are 

configured to make the measurement. To measure the return loss of a point defect, the cursors 

are placed in the same places as for measuring the loss of the point defect. The return loss of the 

point defect is displayed when the return loss option is selected on the OTDR. The steps for 

selecting the return loss option depend upon the OTDR being used. 

3.16.7 Fiber-Optic Cable Assembly Installation 

Fiber-optic cable assemblies should not be combined in the same wiring bundle as wire or 

coaxial cable assemblies. Care must be taken to prevent damage to fiber-optic cable assemblies 

during the installation process. Fiber-optic cables shall only be installed by trained and certified 

fiber-optic personnel. Training and certification shall be in accordance with NASA-STD-8739.5. 

3.16.7.1 Tensile Load and Vertical Rise 

The maximum installation tensile load, the maximum use tensile load, and the maximum vertical 

rise for cable assemblies installed in raceways, trays, ducts, or conduits and multifiber cables 

shall be specified on the engineering documentation. 
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3.16.7.2 Installation Bend Radius 

The minimum bend radius experienced during installation (short-term) shall not be less than 

10 times the cable diameter unless specified on the engineering documentation. 

3.16.7.3 Installed Bend Radius 

The minimum installed (long-term) bend radius shall not be less than 15 times the cable diameter 

unless specified on the engineering documentation. 

3.16.7.4 Cable Tying 

For installation, fiber-optic cable assemblies shall be tied in accordance with the engineering 

documentation. The minimum long-term bend radius shall not be violated at connector 

backshells. Tie-downs shall be tight enough to capture the fiber-optic cable but shall not deform 

the cable outer jacket. The ties shall not pinch, deform, kink, or otherwise stress the cable 

assembly. 

3.16.7.5 Dust Caps 

Dust caps shall be installed on all connectors when not in use. 

3.16.7.6 Premating Inspection 

Fiber-optic cable connector or termination endfaces shall be examined before they are mated 

and, if necessary, cleaned in accordance with 3.16.3. 

3.16.7.7 Connector Torque 

Fiber-optic connectors shall be torqued in accordance with engineering documentation. 

3.16.7.8 Sharp Edges 

Fiber-optic cable assemblies shall not be routed over sharp edges or corners unless appropriate 

protection is provided. 
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3.17 Ethernet 

Ethernet is currently used in the Premise Distribution System (PDS) at KSC. There are plans to 

integrate as many systems as possible onto a redundant Ethernet transport using both copper and 

fiber cabling. KSC-STD-E-0021 lists the requirements for the PDS. Design and installation of 

Ethernet cabling, assemblies, and equipment should comply with KSC-STD-E-0021. 

3.17.1 Ethernet Naming Conventions 

The IEEE naming convention for Ethernet cables is as follows: 

a. The first number (10, 100, 1000) indicates the transmission speed in megabits per 

second (Mbps). 

b. The second term indicates transmission type: BASE = baseband; BROAD = 

broadband. 

c. The last number indicates segment length. A 5 means a 500 m segment length 

from the original Thicknet. 

d. In newer IEEE standards, letters replace numbers. For example, in 10BASE-T, 

the T means unshielded twisted-pair cables; in 100BASE-T4, the T4 indicates 

four such pairs. 

4. QUALITY ASSURANCE PROVISIONS 

4.1 Responsibility for Inspection and Test 

The supplier is responsible for the performance of all inspection and test requirements specified 

herein. Except as otherwise specified, suppliers may use their own facilities or any other 

commercial inspection and test facilities and services acceptable to the Government. Inspection 

and test records shall be kept complete and, upon request, shall be made available to the 

contracting officer. The Government reserves the right to perform any of the inspections and 

tests set forth in the specification where such inspections are deemed necessary to ensure 

supplies and services conform to the prescribed requirements. 

4.2 Certification of Personnel 

All contractors and subcontractors are required to provide personnel who have the experience, 

knowledge, and demonstrable ability required to perform the various tasks that constitute an 

assigned job. Certification shall be required for individuals performing skilled tasks including, 

but not limited to, welding, riveting, soldering, potting and molding, and quality control. Before 

work begins, a representative of the contracting officer shall verify the qualifications of the 

contractor or subcontractor personnel by one or more of the following means: 

a. Reviewing personal resumes that shall include information on the companies the 

employee worked for, a brief description of the work performed for each 
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company, and a description of any NASA specifications or procedures used in the 

work. 

b. Verifying that employees with no previous background in the type of work 

required have successfully completed a training program/school of instruction for 

that type of work. The program shall be operated by the contractor and shall 

include familiarization with NASA specifications and procedures. 

c. Verifying that employees who have previous experience have successfully 

completed a testing program. 

d. Witnessing or approving the preparation of work samples. 

4.3 Certification of Tooling and Test Equipment 

The contractor shall establish and maintain a system for the calibration of all measuring and test 

equipment used to fulfill the contractual requirements. The calibration system shall comply with 

ISO 10012:2003(E), NCSL Z540.3, or KNPR 8730.1. All tooling, measuring, and test equipment 

shall be verified for accuracy at the intervals set forth in this specification or more often as 

required by the contracting officer. If documentation cannot be located to prove that the tooling, 

measuring, and/or test equipment that was used on a particular item was properly calibrated at 

the time it was used, then the item shall be reworked or retested. 

4.3.1 Soldering Tools 

Soldering tools shall be in accordance with IPC J-STD-001/ES or KSC-STD-E-0010, when 

applicable. 

4.3.2 Crimping Tools 

Crimping tools used in installation procedures shall be checked prior to the beginning of the 

initial production and at periodic intervals not to exceed 40 hours of production service or 

30 days of time, whichever occurs first. The tools shall be inspected for wear and clearances 

between dies and limits. The clearances and dimensions shall conform to the respective standards 

of applicable specifications (such as SAE AS 22520). Tools for crimping terminals and 

conductor splices (in accordance with SAE AS 7928A and SAE AS 81824), as well as shield 

ferrules (in accordance with SAE AS 21608 and 75M13676), shall be in accordance with 

NASA-STD-8739.4 and IPC/WHMA-A-602 as follows. (79K22638 provides additional 

guidance and information.) 

a. Type I (for uninsulated terminals and splices): 

(1) Class 1: use only military-standard-approved tools 

(2) Class 2: use tools recommended by the manufacturer or approved by the 

contracting officer 
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b. Type II (for insulated terminals and splices): 

(1) Class 1: use only military-standard-approved tools 

(2) Class 2: use tools recommended by the manufacturer or approved by the 

contracting officer 

4.3.3 Crimping Tools, Special 

Special tools for crimping, insertion, removal, or other uses pertaining to Class 2 terminals (other 

than those conforming to SAE AS7928A, SAE AS 81824, or SAE AS 21608) shall be as 

specified herein or as approved by the contracting officer. 

4.3.4 Torque Wrenches 

Unless otherwise specified, torque shall be applied to fasteners using torque wrenches that are in 

accordance with ASME B107.14-2004. The torque wrench shall be chosen so the torque values 

for a particular fastener will be between 20 percent and 80 percent of the full-scale torque. 

Unless otherwise specified, the calibration of a torque wrench shall be checked before it is used 

for the first time and thereafter at intervals not to exceed 30 calendar days. A dated certification 

of these calibrations shall be attached to the wrench. Torque presetting wrenches shall be 

adjusted/calibrated, checked, and sealed with a suitable tamperproof material. The torque to 

which the wrench is set shall be clearly marked on the wrench. When practical, the torque 

wrench calibration may be checked before daily use and at the end of the day. Documenting this 

verification with a note in the Work Authorization Document (WAD) will reduce the need for 

extensive document searches to verify the certification in the event a torque wrench fails. 

If a wrench is dropped, struck, or otherwise damaged or is possibly out of calibration, the wrench 

shall be checked before it is used again. If it is found to be out of calibration, the wrench shall 

not be used until it has been recalibrated. 

4.3.5 Wire Stripping Tools 

Wire stripping tools shall be in accordance with IPC/WHMA-A-620 or KSC-STD-E-0010A. 

Their calibration shall be checked before they are used for the first time and at periodic intervals 

not to exceed 40 hours of production service or 30 calendar days. 

4.3.6 Solderless Wrap Tools 

Solderless wrap tools and inspection intervals shall be in accordance with SAE AMS 2695C. 

4.3.7 Test Equipment 

Electronic equipment (such as voltmeters and oscilloscopes) used to verify the performance of 

items during assembly and test shall be calibrated before they are used for the first time and at 

intervals not to exceed 12 months. Personnel should verify electronic test equipment has a valid 

calibration sticker prior to each use.
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4.4 Equipment Checkout 

Before equipment is used to perform any tests, it shall be inspected for workmanship using 

criteria from previous sections of this specification. Unless otherwise required by applicable 

checkout procedure documents, equipment shall be checked for the following: 

a. Electrical continuity 

b. Electrical isolation 

c. Function (applied) to equipment containing electrical- or mechanical-action 

components 

CAUTION 

The person conducting the test should verify if any 

lockout/tagout procedures have been or need to be 

implemented as required by NPR 8715.3C and/or 

OSHA Standard 29 CFR 1910.147. Do not fasten or 

touch a probe or clip to any pin of any connector 

(including cable connectors) of the equipment being 

checked. A breakout box or adapter test fixture (or 

mating contact) shall be mated to the connector to 

make all electrical measurements. 

NOTE 

Prior to any test, all test fixtures and mating 

connectors shall be inspected and approved by the 

contracting officer. All pilot lamps or other 

sensitive items shall be removed for continuity and 

isolation tests, with all power OFF and disconnected 

from other equipment/systems. 

4.4.1 Sequence of Tests 

The following sequence of equipment checkout tests shall be followed: 

a. Perform a continuity check on all normally closed connecting points. 

b. Perform isolation checks on all normally open points. 

c. Operate equipment or components and perform a continuity check on all normally 

open circuits, circuits having definite resistances, or circuits having a resistance 

change by operation. 

d. Operate equipment or components and perform isolation checks on all normally 

closed circuits supposedly opened by operation. 
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4.4.2 Continuity Tests 

During continuity tests, circuit breakers to which a power source is connected shall be in the 

OFF (open) position unless otherwise directed by a checkout procedure. Continuity tests of all 

wiring connections and verification of all termination points shall be made as follows: 

a. The contractor shall test each cable, wire bundle, or electrical assembly for 

electrical continuity according to the wire running list or schematic. 

b. The equipment approved by the contracting officer shall be used for continuity 

verification. This includes COTS testers as well as commercial or custom-made 

automatic testers. 

c. Continuity checks shall be made between all points shown as closed circuits on 

the electrical advanced schematic. The measuring device shall be capable of 

detecting a difference of 10 percent of the resistance value to be tested or equal to 

the tolerance required if less than 10 percent. 

(1) The measuring device shall be set at the lowest ohm scale applicable to the 

readings (that is, R × 1 for a 0 Ω reading and others accordingly so that a 

10-percent deviation is detectable). The verification of test equipment 

shall be performed just before the first reading. The verification shall be 

repeated whenever test equipment readings vary due to a reason such as 

the device having weak batteries. The meter shall be “zeroed” each time 

its range is changed during a test. 

(2) Each conductor of an assembly shall be tested for minimum resistance 

based on the length and type of cable. 

(3) Exposed metal shall be checked for continuity to the alternating current 

ground power line. 

4.4.3 Isolation Checks 

Isolation checks shall be made between all circuits that are shown on the advanced electrical 

schematics as normally open or that can be opened by manually, electrically, or mechanically 

operated components. All normally open circuits shall be checked to all other normally open 

points and to the chassis. Equipment or parts shall be operated as required to open all normally 

closed circuits to check the points for isolation. Isolation checks shall be made on equipment 

having electrical components and shall be as follows: 

a. The contractor shall test each cable, wire bundle, or electrical assembly for 

isolation using a standard ohmmeter set on a range of 1 MΩ or higher. Unless 

otherwise specified, isolation shall be more than 10 MΩ, or infinity.
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b. Insulation tests shall be performed on each cable, wire bundle, or exposed metal 

areas (ground potential) of panels, chassis, etc. See 3.11.10 for cable checkout. 

Chassis or other exposed metal normally at ground potential shall be tested to the 

power input line, aboveground transformer windings, and all other aboveground 

wiring with a minimum 10 MΩ reading, unless otherwise specified. This will 

ensure minimal ground fault currents due to failed or insufficient insulation. 

c. An insulation-resistance tester having a test potential of 500 VDC shall be used 

on all equipment having parts capable of withstanding 500 V between any 

possible erroneous connections. 

d. Equipment having sensitive devices (e.g., circuit cards) not capable of 

withstanding 500 V shall be removed or tested using 28 VDC in series with a 

voltmeter whose 50 V scale has a resistance of 1 MΩ. A circuit under test having 

a leak of 27 MΩ or less will cause the meter to register 1 V or more, indicating an 

unacceptably low value for isolation resistance. When checking aboveground 

wiring to the chassis, the wiring should be jumpered together as a common 

electrical point versus the chassis metal. 

4.4.4 Functional Checks 

When required by contract, functional checks shall be made on all checkout panels, distributors, 

and components that can be operated manually, electrically, or mechanically. If a malfunction is 

discovered, the checkout shall be stopped until the malfunction is corrected. 

4.5 Completion of Tests 

At the completion of tests and all work relating thereto, all parts of fabrication and equipment 

shall be thoroughly cleaned. All painted surfaces marred during installation shall be painted to 

match the original finish. 

4.6 Manufacturing Instructions/Documentation 

Normally, it is unnecessary to provide additional instructions to qualified or certified technicians. 

However, it is advisable to use reference material and other workmanship-related information for 

selecting connector/contact tools, performing connector assembly procedures, and selecting 

retention tools. Where requested by contract, a test procedure shall be submitted prior to testing, 

and data sheets shall be retained or submitted after testing is successfully completed. 

4.7 Commercial Off-the-Shelf (COTS) Concept 

NASA-STD-5005 establishes the general characteristics and requirements for performance, 

design, test, safety, reliability, maintainability, and quality assurance for facilities, systems, and 

equipment intended for use at KSC, NASA, or other KSC-responsible locations. It specifies the 

minimum requirements to provide simple, robust, safe, reliable, maintainable, environmentally 

compatible, and cost-effective facilities and GSE to support space vehicle launch operations. 

Design requirements specific to KSC are listed in KSC-DE-512-SM. 
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COTS equipment, parts, items, or components shall be used to the maximum extent possible 

when (1) they satisfy the hardware function, (2) they will not degrade the safety or reliability of 

the flight or ground system, and (3) they provide a cost savings that will exceed possible cost 

increases due to unique maintenance or logistics requirements, modifications, or an increase in 

the complexity of the interfacing equipment. In all cases, exact materials of construction and 

applicable specifications shall be determined to evaluate how well the material meets its 

requirements. Any additional qualifying tests and inspections shall be indicated in the 

engineering documentation. Control documents may be created for proposed parts that lack such 

documentation. 

4.7.1 Modified Off-the-Shelf (MOTS) Items 

A MOTS item is a COTS item that must be altered to be integrated into or meet the needs of a 

system or application. The modification may be cosmetic (i.e., changing the protective finish or 

external color), electromechanical (i.e., altering the physical configuration of equipment by 

adding to, deleting from, or modifying originally issued parts), or software-based (i.e., modifying 

the original operational code or language). MOTS items must receive revised part numbers from 

the original COTS item and are typically unique to the system requesting the modification. 

Fabrication of MOTS items may void the original COTS item warranty and reduce or eliminate 

the vendor’s liability. After modification, MOTS items must undergo additional testing to verify 

their functionality, reliability, and safety. Additional testing must validate and document that all 

NASA, KSC, and system requirements have been met. 

5. PREPARATION FOR DELIVERY 

ASTM D 3951-98 and customer/engineering requirements establish minimum requirements for 

packaging of supplies and equipment, exclusive of ammunition, explosives, or hazardous 

materials, as covered in CFR Title 49, Transportation.

MIL-STD-2073-1 outlines standard processes for the development and documentation of 

military packaging, as distinct from commercial packaging. This standard covers methods of 

preservation to protect materiel against environmentally induced corrosion and deterioration, 

physical and mechanical damage, and other forms of degradation during storage, multiple 

handling, and shipment of materiel in situations when commercial packaging cannot meet known 

distribution and environmental requirements. A decision chart is included in MIL-STD-2073-1 

for determining the applicability of commercial or military packaging practices. 

Marking for shipment and storage shall be in accordance with MIL-STD-129. 

For hazardous materials, packing and marking must comply with the hazardous materials 

regulations in CFR Title 49, Transportation. 

Personnel responsible for storing, preserving, identifying, and shipping electrical GSE must 

comply with Federal and local regulations governing the shipping and handling of hazardous 

materials where applicable. Standard commercial packaging and specialized military packaging 

as outlined in ASTM D 3951-98 and MIL-STD-2073-1, respectively, should be used in storing, 

preserving, identifying, and shipping electrical GSE. 
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6. NOTES 

6.1 Intended Use 

This document is intended to define detailed parts, materials, and process requirements and to 

ensure that essential requirements are included in the fabrication of electrical and electronic 

control and monitoring equipment associated with GSE used to support the transporting, 

receiving, handling, assembly, test, checkout, service, and launch of space vehicles and payloads 

at KSC. 

6.2 Definitions 

For the purpose of this document, the following definitions shall apply: 

100BASE-T: standard “Fast Ethernet” based on twisted pair copper wire transmitting 100 Mbps. 

100BaseT4/T2 (Cat3 cabling). T4 indicates four twisted pairs; T2 indicates two twisted pairs. 

10BASE-T: standard “plain vanilla” Ethernet based on unshielded twisted pair wire. 

bridging router: router that automatically forwards a message it does not understand. 

cleave: the process of separating an optical fiber by a controlled fracture of the glass for the 

purpose of obtaining a fiber end that is flat, smooth, and perpendicular to the fiber axis. 

CSMA/CD: Carrier Sense Multiple Access Collision Detection that is an arbitration mechanism 

for competing Ethernet messages. 

ground support equipment: equipment necessary to support the transporting, receiving, 

handling, assembly, test, checkout, servicing, and launch of space vehicles and payloads. 

multimode optical fiber: an optical fiber that will allow more than one bound mode to 

propagate. 

protocol: agreed-upon format for transmitting or storing data. 

single-mode optical fiber: an optical fiber in which only the lowest order bound mode (which 

may consist of a pair of orthogonally polarized fields) can propagate at the wavelength of 

interest. 

socket: (1) a hollow piece or part into which something fits, the socket for a pin to mate in a 

receptacle connector, the socket used on a torque wrench to fit a specific sized nut or bolt, etc. 

(2) (Ethernet usage) roughly analogous to a port and is a communication endpoint for a TCP or 

UDP connection. Sockets can also be used for interprocess communication on a single computer, 

and multiple sockets can be made to communicate with one another. Sockets are bidirectional, 

which means that both sides of the connection can send and receive information. 

twisted pair: standard wire format for Ethernet cables.
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NOTICE. The Government drawings, specifications, and/or data are prepared for the official use 

by, or on behalf of, the United States Government. The Government neither warrants these 

Government drawings, specifications, or other data, nor assumes any responsibility or obligation, 

for their use for purposes other than the Government project for which they were prepared and/or 

provided by the Government, or any activity directly related thereto. The fact that the 

Government may have formulated, furnished, or in any way supplied the said drawings, 

specifications, or other data is not to be regarded, by implication or otherwise, as licensing in any 

manner the holder or any other person or corporation nor conveying the right or permission to 

manufacture, use, or sell any patented invention that may relate thereto. 

Custodian: Preparing Activity: 

NASA – John F. Kennedy Space Center 

Kennedy Space Center, Florida 32899

John F. Kennedy Space Center 

Engineering and Technology Directorate 

Electrical Division
STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSAL

INSTRUCTIONS 

1. The preparing activity must complete blocks 1, 2, 3, and 8. In block 1, both the document number and revision letter 

should be given. 

2. The submitter of this form must complete blocks 4, 5, 6, and 7. 

3. The preparing activity must provide a reply within 30 days from receipt of the form. 

NOTE: This form may not be used to request copies of documents, nor to request waivers or clarification of 

requirements on current contracts. Comments submitted on this form do not constitute or imply authorization to 

waive any portion of the referenced document or to amend contractual requirements.

I RECOMMEND A CHANGE: 1. DOCUMENT NUMBER 

KSC-E-165E, Change 3 

2. DOCUMENT DATE 

November 6, 2014 

3. DOCUMENT TITLE 

Electrical Ground Support Equipment Fabrication, Specification for 

4. NATURE OF CHANGE (Identify paragraph number and include proposed rewrite, if possible. Attach extra sheets as needed.) 

 

5. REASON FOR RECOMMENDATION 

 

6. SUBMITTER

a. NAME (Last, First, Middle Initial) 

 

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c. ADDRESS (Include Zip Code) 

 

d. TELEPHONE (Include Area Code)

 

7. DATE SUBMITTED 

 

8. PREPARING ACTIVITY

a. NAME (Last, First, Middle Initial)

Denson, Erik C. 

b. ORGANIZATION

Engineering and Technology Directorate, 

Electrical Division 

c. ADDRESS (Include zip code) 

Kennedy Space Center, FL 32899 

KSC FORM 21-610NS (2/94) (C/G 2/94)
REPORT DOCUMENTATION PAGE Form Approved 

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burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington 

Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. 

Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of 

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PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. 

1. REPORT DATE (DD-MM-YYYY)

06-11-2014 

2. REPORT TYPE 

Technical Publication 

3. DATES COVERED (From — To) 

4. TITLE AND SUBTITLE 

Electrical Ground Support Equipment Fabrication, 

Specification for 

5a. CONTRACT NUMBER 

 5b. GRANT NUMBER 

 5c. PROGRAM ELEMENT NUMBER 

 

6. AUTHOR(S)

(1) Denson, Erik C. 

5d. PROJECT NUMBER 

 5e. TASK NUMBER 

 5f. WORK UNIT NUMBER 

 

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

(1) National Aeronautics and Space Administration 

 Kennedy Space Center, FL 32899 

8. PERFORMING ORGANIZATION 

REPORT NUMBER 

NASA/TP–2014–218436 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

 

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12. DISTRIBUTION/AVAILABILITY STATEMENT 

Unclassified – Unlimited Distribution: Standard 

Subject Category: 

Availability: NASA CASI (301) 621-0390

13. SUPPLEMENTARY NOTES

14. ABSTRACT

This document specifies parts, materials, and processes used in the fabrication, maintenance, repair, and 

procurement of electrical and electronic control and monitoring equipment associated with ground 

support equipment (GSE) at the John F. Kennedy Space Center (KSC).

15. SUBJECT TERMS

ground support equipment, GSE, electrical and electronic control and monitoring, fabrication, 

maintenance, procurement

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 

ABSTRACT 

UU 

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OF 

PAGES

135 

19a. NAME OF RESPONSIBLE PERSON

Erik C. Denson 

a. REPORT 

U 

b. ABSTRACT 

U 

c. THIS PAGE 

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19b. TELEPHONE NUMBER (Include area code) 

(321) 867-6537 

Standard Form 298 (Rev. 8-98) 

Prescribed by ANSI Std. Z39