D-500-0255-531-1 (256687-000) - Tyco Electronics

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 1 of 15

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MIL-STD-1553B Multiplex DataBus Box Couplers and

Terminators Connectorized with D-6025 Connector Interface

1.0 Introduction

1.1 Scope

This specification covers the Raychem D-500-0255 series of MIL-STD-1553B

multiplex data bus box couplers and D-621-XXXX series of MIL-STD- 1553B

terminators.

1.2 Description

Items covered by this specification are non-repairable components installed as parts

of a data bus system. They provide intrinsic EMI shielding.

1.3 Classification

These items are classified (solely dependent upon the connector interface type and

environmental resistance) as follows:

a. Connector Type: Threaded connector type

Bayonet connector type

b. Environmental Resistance of Connector:

General purpose (terminators only)

Environment resistant

Environment resistant, 1000 hour salt spray

1.4 Intended Use

Data bus box couplers covered by this specification provide fault isolation by series

resistance and transformer coupling between the bus cables and stub cables in

accordance with MIL-STD-1553B. Data bus terminators covered by this specification

provide matched impedance bus termination or stub termination with a resistive load

simulating a remote terminal (RT). These products may be used in applications within

the operating temperature range of -55°C to +125°C.

2.0 Applicable Documents

2.1 Issues of Documents

The following documents, of the issue in effect on date of order or request for

proposal, form a part of this specification to the extent specified herein. However, this

specification takes precedence over the referenced documents.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

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2.2 Department of Defense

Specifications

Military

MIL-T-21038 Transformers, Pulse, Low Power

MIL-R-39007 Resistors, Fixed, Wire-Wound (Power Type), Established

Reliability General Specification for

MIL-R-55182 Resistors, Fixed, Film, Established Reliability

MIL-C-85485 Cable, Electric, Filter Line, Radio Frequency Absorptive

Federal

QQ-S-571 Solder: Tin Alloy; Tin-Lead Alloy; and Lead Alloy

Specifications

Military

MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes

MIL-STD-129 Marking for Shipment and Storage

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-202 Test Methods for Electronic and Electrical Component Parts

MIL-STD-454 Standard General Requirements for Electronic Equipment

MIL-STD-810 Environmental Test Methods and Engineering Guidelines

MIL-STD-1344 Test Methods for Electrical Connectors

MIL-STD-1553B Aircraft Internal Time Division Command/Response Multiplex

Data Bus

MIL-STD-45662 Calibration Systems Requirements

(Copies of Department of Defense documents may be obtained from the Naval

Publications and Forms Center, 5801 Tabor Avenue, Philadelphia, PA 19120-5099.)

4.5 Raychem Corporation

D-6025 D-621 Series Connectors for Coaxial, Triaxial and Twinaxial

cables

(Copies of Raychem documents may be obtained from Raychem Corporation, 300

Constitution Drive, Menlo Park, CA 94025.)

3.0 Requirements

3.1 Specification Control Drawings

The requirements for individual items under this specification shall be as specified

herein and in the applicable specification control drawing. In the event of conflict

between the requirements of this specification and those of the specification control

drawing (SCD), the latter shall govern.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 3 of 15

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3.2 Classification of Requirements

The requirements for these products are classified herein as follows:

Requirement Paragraph

Qualification 3.3

Materials 3.4

Design and Construction 3.5

Performance 3.6

Identification 3.7

Workmanship 3.8

3.3 Qualification

Items furnished under this specification or listed on Qualified Products List D-6021-

QPL shall be products which are qualified to this specification.

3.4 Materials Requirements

All materials used in the manufacture of these products shall be of the quality and

form best suited for the purpose intended. All materials used shall conform to the

requirements specified herein.

3.4.1 Dissimilar Metals

When dissimilar metals are used in intimate contact with each other, protection

against electrolytic corrosion shall be provided as specified in MIL-STD-454,

Requirement 16.

3.4.2 Component Materials

Materials for specific components of these items shall be as follows:

a. Isolation transformer--Per MIL-STD-1553B and MIL-T-21038

b. Resistors--Per MIL-STD-1553B, and MIL-R-55182 or MIL-R-39007

c. Box coupler housing--Aluminum alloy

d. Terminator housing--Stainless steel

e. Solder--QQ-S-571

f. Connectors--Per Raychem Specification D-6025 and the applicable

specification control drawing.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 4 of 15

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3.5 Design and Construction Requirements

These items are designed to be nonrepairable components which are connectorized

for inclusion in data bus harnesses. They shall consist of encapsulated electrical

components within an EMI shielded housing. Box couplers consist of encapsulated

transformer/resistor modules, and terminators consist of encapsulated resistors.

3.5.1 Weight, Configuration and Dimensions

Weight, configuration and dimensions of couplers and terminators shall be as shown

in the applicable specification control drawings.

3.5.2 Interchangeability

All items having the same part number shall be completely interchangeable with each

other in regard to installation and performance.

3.6 Performance Requirements

When tested in accordance with the procedures defined in 4.5, couplers and

terminators shall conform to the requirements specified herein and in the applicable

specification control drawing. Tests marked with an asterisk (*) are not applicable to

general, purpose terminators (see 1.3).

3.6.1 Functional Tests

3.6.1.1 Transformer/Resistor Module Requirements. Transformer/resistor modules and their

component elements shall meet the requirements of MIL-STD- 1553B.

3.6.1.2 Box Coupler Input Impedance. When box couplers are tested as specified in 4.5.3.1,

the input impedance shall be 3000 -* (number of stubs) ohms, minimum over the

temperature range specified.

4.5.19.1 Box Coupler Waveform Integrity Test

When single stub box couplers are tested as specified in 4.5.3.2, the droop of the

waveform on the bus leads shall not exceed 20 percent. Overshoot and ringing shall

be less than ± 1.0 volt peak.

4.5.19.2 Box Coupler Maximum Voltage Test

When a box coupler is tested as specified in 4.5.3.3, the voltage on the coupler's bus

cables shall be between 8 and 10 V p-p.

4.5.19.3 Box Coupler Minimum Voltage Test

When a box coupler is tested as specified in 4.5.3.4, the voltage on the coupler's bus

cables shall be between 5 and 7 V p-p.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 5 of 15

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4.5.19.4 Terminator Resistance Test

When a terminator is tested as specified in 4.5.3.5, the measured DC resistance of the

resistor shall meet the requirements of the applicable specification control drawing.

4.5.19.5 Transmission Test

When box couplers and terminators are tested as specified in 4.5.3.6, there shall be no

word errors detected during functional operation.

4.5.20 Insulation Resistance

When specimens are tested as specified in 4.5.4, the insulation resistance between

each conductor and the enclosure shall be 100 megohms minimum.

4.5.21 Dielectric Strength

When specimens are tested as specified in 4.5.5, there shall be no arcing or

breakdown between each conductor and the enclosure. The leakage current shall be 2

milliamperes maximum.

4.5.22 Temperature Shock

When tested as specified in 4.5.6, specimens shall function normally during the test,

and there shall be no evidence of damage detrimental to performance.

3.6.5 Temperature Altitude

When tested as specified in 4.5.7, specimens shall function normally during the test,

and there shall be no evidence of damage detrimental to performance.

3.6.6 Altitude Immersion*

When tested as specified in 4.5.8, specimens shall meet the insulation resistance

requirement of 3.6.2, and there shall be no evidence of damage detrimental to

performance.

3.6.7 Moisture Resistance*

When tested as specified in 4.5.9, specimens shall meet the insulation resistance

requirement of 3.6.2, and there shall be no evidence of damage detrimental to

performance.

3.6.8 Rain*

When tested as specified in 4.5.10, specimens shall function normally during the test,

and there shall be no evidence of damage detrimental to performance.

3.6.9 Salt Spray*

When tested as specified in 4.5.11, specimens shall function normally during the test,

and there shall be no evidence of damage detrimental to performance.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 6 of 15

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3.6.10 Sinusoidal Vibration. When tested as specified in 4.5.12, specimens shall function

normally during the test, and there shall be no evidence of damage detrimental to

performance.

3.6.11 Random Vibration. When tested as specified in 4.5.13, specimens shall function

normally during the test, and there shall be no evidence of damage detrimental to

performance.

3.6.12 Mechanical Shock. When tested as specified in 4.5.14, specimens shall function

normally during the test, and there shall be no evidence of damage detrimental to

performance.

3.6.13 Dust (Fine Sand)*. When tested as specified in 4.5.15, specimens shall function

normally during the test, and there shall be no evidence of damage detrimental to

performance.

3.6.14 Humidity*. When tested as specified in 4.5.16, specimens shall function

normally during the test, and there shall be no evidence of damage detrimental

to performance.

3.6.15 Fluids Resistance*. When tested as specified in 4.5.17, specimens shall meet the

insulation resistance requirement of 3.6.2, and there shall be no evidence of

damage detrimental to performance.

3.6.16 EMI Shielding Effectiveness. When specimens are tested as specified in 4.5.18, the

surface transfer impedance shall not exceed 14 milliohms per meter over the

frequency range 1 MHz to 30 MHz.

3.6.17 Post Test Examination. When visually examined as specified in 4.5.19, specimens

shall not show any evidence of damage detrimental to performance.

3.7 Product Identification

The minimal information on the label shall be the part number, the description,

"Raychem", and the FSCM code. All marking shall be in accordance with MIL-STD-

130 and shall remain legible after completion of the tests specified herein.

3.8 Workmanship

Box couplers and terminators shall be processed in such a manner as to be consistent

in quality; they shall be free from defects that would adversely affect life,

performance or appearance.

4.0 Quality Assurance Provisions

4.1 Responsibility for Inspection. The supplier is responsible for the performance of all

inspection tests specified herein. The supplier may utilize his own or any other

suitable testing facility. Inspection records of the tests shall be kept complete and

available to the buyer as specified in the contract or order.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 7 of 15

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4.1.1 Test Equipment and Inspection Facilities. Test and measuring equipment and

inspection facilities of sufficient accuracy, quality, and quantity to permit

performance of the required inspection shall be established and maintained by the

supplier. A calibration system to control the accuracy of the measuring and test

equipment shall be maintained in accordance with MIL-STD- 45662.

4.2 Classification of Inspections. The examination and testing of items covered by this

specification shall be classified as follows:

a. Qualification inspection (See para. 4.3)

b. Acceptance inspection (See para. 4.4)

4.3 Qualification Inspection. Qualification inspection shall consist of all of the tests in

Table I performed in the order of listing.

4.3.1 Qualification Test Samples. Test samples submitted for qualification shall be

produced using equipment and procedures normally used in production. Test samples

shall be interconnected with MIL-STD-1553B data bus cable into data bus networks

in order that correct function of the components can be verified during environmental

exposure. Mating connectors shall be torqued to the specified value and of the same

environment resistance and finish as those on the components under test.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 8 of 15

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Table I. Qualification Inspection

Test Group 1

Test Sequence Requirement

Paragraph

Procedure

Paragraph

Visual examination 3.1, 3.4, 3.5,

3.7, 3.8

4.5.2

Functional tests 3.6.1 4.5.3

Insulation resistance 3.6.2 4.5.4

Dielectric strength 3.6.3 4.5.5

EMI shielding effectiveness 3.6.16 4.5.18

Temperature sock 3.6.4 4.5.6

Temperature altitude 3.6.5 4.5.7

Sinusoidal vibration 3.6.10 4.5.12

Random vibration 3.6.11 4.5.13

Mechanical shock 3.6.12 4.5.14

Dust (fine sand)* 3.6.13 4.5.15

Humidity* 3.6.14 4.5.16

Insulation resistance 3.6.2 4.5.4

Dielectric strength 3.6.3 4.5.5

Functional tests 3.6.1 4.5.3

Post test examination 3.6.17 4.5.19

* Environment resistant types only.

Test Group 2

Test Sequence Requirement

Paragraph

Procedure

Paragraph

Visual examination 3.1, 3.4, 3.5,

3.7, 3.8

4.5.2

Functional tests 3.6.1 4.5.3

Insulation resistance 3.6.2 4.5.4

Dielectric resistance 3.6.3 4.5.5

EMI shielding effectiveness 3.6.16 4.5.18

Rain* 3.6.8 4.5.10

Salt spray* 3.6.9 4.5.11

Altitude immersion* 3.6.6 4.5.8

Insulation resistance 3.6.2 4.5.4

Dielectric strength 3.6.3 4.5.5

Functional tests 3.6.1 4.5.3

Post test examination 3.6.17 4.5.19

* Environment resistant types only

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

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Test Group 3

Test Sequence Requirement

Paragraph

Procedure

Paragraph

Visual examination 3.1, 3.4, 3.5,

3.7, 3.8

4.5.2

Fluids resistance* 3.6.15 4.5.17

Insulation resistance 3.6.2 4.5.4

Dielectric strength 3.6.3 4.5.5

Post test examination 3.6.17 4.5.19

* Environment resistance types only.

4.4 Acceptance Inspection. Lot acceptance inspection shall consist of the tests listed in

Table II. Acceptance inspection shall be performed on every lot of items

manufactured under this specification. In process examination may be used for

acceptance inspection.

Table II Acceptance Inspection

Test Requirement

Paragraph

Procedure

Paragraph

Inspection

Level*

AQL*

Visual examination 3.1, 3.4, 3.5,

3.7, 3.8

4.5.2 II 1%

Waveform integrity 3.6.1.3 4.5.3.2 100% --

Coupler maximum voltage 3.6.1.4 4.5.3.3 100% --

Coupler minimum voltage 3.6.1.5 4.5.3.4 100% --

Termination resistance 3.6.1.6 4.5.3.5 100% --

Insulation Resistance 3.6.2 4.5.4 100% --

* Inspection Level and AQL per MIL-STD-105.

4.4.1 Rejected Lots. If an inspection lot is rejected, the lot shall be replaced, or the

defective units shall be reworked to correct the defect or screened out. If the lot is

reworked or the defective units are screened out, the lot shall be resubmitted for

inspection. Resubmitted lots shall be inspected using tightened inspection in

accordance with MIL-STD-105. Before resubmitting, full particulars concerning the

rejection and the action taken to correct the defect shall be recorded.

4.4.2 Examination of Preparation for Delivery. Preparation for delivery of material

ready for shipment shall be examined to determine compliance with the

requirements of Section 5.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

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4.5 Test Procedures

4.5.1 Test Conditions. Unless otherwise specified, all tests shall be performed at ambient

temperature, pressure, and relative humidity as specified in the general requirements

of MIL-STD-202. Tolerances for test conditions shall meet the general requirements

of MIL-STD-202 and MIL-STD-810.

4.5.2 Visual Examination. Specimens shall be visually examined to ensure conformance

with 3.1, 3.4, and 3.5 of this specification.

4.5.3 Functional Tests

4.5.3.1 Box Coupler Input Impedance (see 3.6.1.2). Input impedance shall be measured as

described in MIL-STD-1553B at room temperature and at the temperature rating

extremes.

4.5.3.2 Box Coupler Waveform Integrity Test (see 3.6.1.3) Box couplers shall be tested

using the test configuration shown in Figure 1. The maximum terminal output voltage

of 27 V p-p shall be applied at point A using the wave- form specified in MIL-STD-

1553B, paragraph 4.5.1.5.1.1.2 (250 kHz frequency). Droop, overshoot and ringing

shall be measured on the bus leads at point B.

Figure 1 Box Coupler Waveform Integrity Test

4.5.3.3 Box Coupler Maximum Voltage Test (see 3.6.1.4). Box couplers shall be tested using

the test configurations shown in Figures 2 and 3, respectively. The maximum

terminal output voltage of 27 V p-p shall be applied at V1 using the 250 kHz

waveform described in 4.5.3.2. The output voltage shall be measured at V2. This test

shall then be repeated using a 1 MHz waveform similar to that described in 4.5.3.2.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 11 of 15

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Figure 2. Module Voltage Tests

Figure 3. Box Coupler Voltage Tests

4.5.3.4 Box Coupler Minimum Voltage Test (see 3.6.1.5). Box couplers shall be tested using

the test configurations shown in Figures 2 and 3, respectively. The minimum terminal

output voltage of 18 V p-p shall be applied at V1 using the 250 kHz waveform

described in 4.5.3.2. The output voltage shall be measured at V2. This test shall then

be repeated using a 1 MHz waveform described in 4.5.3.2.

4.5.3.5 Terminator Resistance Test (see 3.6.1.6). The DC resistance of the terminator

shall be measured in accordance with MIL-STD-202, Method 303.

4.5.3.6 Transmission Test (see 3.6.1.7). MIL-STD-1553B words shall be transmitted over a

network composed of box couplers and terminators interconnected with suitable data

bus cable. The transmitter output shall be 18 V p-p with a 300-nanosecond rise time.

A special terminal equipped with counters shall be used to count the number of

correct words and error words received during the test.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 12 of 15

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4.5.4 Insulation Resistance (see 3.6.2). Specimens shall be tested in accordance with

MIL-STD-202, Method 302, Test Condition B (500 Vdc). Insulation resistance shall

be measured between each conductor and shield of attached cables.

4.5.5 Dielectric Strength (see 3.6.3). Specimens shall be tested in accordance with

MIL-STD-202, Method 301, using 500 Vac, 60 Hz. The test voltage shall be

applied for I minute between each conductor and shield of attached cables.

Leakage current shall be recorded.

4.5.6 Temperature Shock (see 3.6.4). Specimens shall be tested in accordance with MIL-

STD-202, Method 107, Test Condition B, except that the low temperature shall be

-55*C, the dwell time shall be 4 hours and the number of cycles 3. During this test,

the specimens shall be subjected to the transmission test of 4.5.3.6.

4.5.7 Temperature-Altitude (see 3.6.5). Specimens shall be exposed to the temperature-

altitude conditions shown in Table III. During this test, except for Step 1, the

specimens shall be subjected to the transmission test of 4.5.3.6.

Table III. Temperature Altitude Conditioning

Step Temperature

(°C)

Altitude

(ft)

Duration

(hrs)

1 -65 Site 2.0

2 -54 Site *

3 -54 70,000 *

4 -10 Site *

5 95 Site 16.0

6 71 Site 4.0

7 95 Site 0.5

8 36 50, 000 4.0

9 60 50, 000 0.5

10 10 70,000 4.0

11 35 70,000 0.5

* Duration sufficient to allow temperature stabilization.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 13 of 15

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4.5.8 Altitude Immersion (see 3.6.6). The specimens shall be tested in accordance with

MIL-STD-1344, Method 1004.1, omitting Paragraph 4.3. At least one foot of cable

attached to the mating connectors shall not be immersed in the water bath.

4.5.9 Moisture Resistance (see 3.6.7). The specimens shall be tested in accordance with

MIL-STD-202, Method 106, omitting Step 7b and Paragraph 3.6. At the end of

the test, while the specimens are still in high humidity, they shall be subjected to

the transmission test of 4.5.3.6.

4.5.10 Rain (see 3.6.8). Specimens shall be tested in accordance with MIL-STD-810,

Method 506, Procedure I. The test conditions shall be as shown in Table IV. The test

shall be conducted with rain impinging at 45 degrees upon the front, back and end

faces of the box couplers. During this test, the specimens shall be subjected to the

transmission test of 4.5.3.6.

Table IV. Rain Test Conditions

Step Step

Duration

(min)

Wind

Velocity

(mph)

Rainfall

Rate

(inch/hr)

1 5 0 2

2 5 40 2

3 5 40 2

4 5 40 2

5 10 0 2

4.5.11 Salt Spray (see 3.6.9). Specimens shall be tested in accordance with MIL-STD-26-2,

Method 101, except, the exposure time shall be 48 hours for environment resistant

components and 1000 hours for components with 1000 hour salt spray finish. During

the last day of the test the specimens shall be subjected to the transmission test of

4.5.3.6.

4.5.12 Sinusoidal Vibration (see 3.6.10). Specimens shall be tested in accordance with MIL-

STD-202, Method 201, except the frequency range shall be 5 to 50 Hz. During this

test, the specimens shall be subjected to the transmission test of 4.5.3.6.

4.5.13 Random Vibration (see 3.6.11). Specimens shall be tested in accordance with MIL-

STD-202, Method 214, Test Condition II, Test Letter G, for 8 hours in each of three

mutually perpendicular directions. During this test, the specimens shall be subjected

to the transmission test of 4.5.3.6.

4.5.14 Mechanical Shock (see 3.6.12). Specimens shall be tested in accordance with MIL-

STD-202, Method 213, Test Condition A. During this test the specimens shall be

subjected to the transmission test of 4.5.3.6.

Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

DCR #: T-13866

No: D-6021

Rev: A

Date: February 12, 1990

Page: 14 of 15

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4.5.15 Dust (Fine Sand) (see 3.6.13). Specimens shall be tested in accordance with MIL-

STD-202, Method 110. During this test the specimens shall be subjected to the

transmission test of 4.5.3.6.

4.5.16 Humidity (see 3.6.14). Specimens shall be tested in accordance with MIL-STD-1344,

Method 1002, Type III. The specimens shall be subjected to the transmission test of

4.5.3.6 during the last 3 cycles of the test.

4.5.17 Fluids Resistance (see 3.6.15). The specimen shall be subjected to the test fluids in

accordance with MIL-STD-1344, Method 1016, except that Steps 4.1 and 4.4 shall

be omitted.

4.5.18 EMI Shielding Effectiveness (see 3.6.16). Specimens shall be tested in accordance

with MIL-C-85485, Paragraph 4.7.24. The box couplers shall be located at

approximately the center of the test specimen, and signals shall be measured on the

bus conductors. Stub connectors shall have shielded caps. The cable type shall be

Raychem 10613 or equivalent.

4.5.19 Post Test Examination (see 3.6.17). The tested samples shall be visually examined

without magnification for any evidence of damage which could impair proper

functioning.

5.0 Preparation For Delivery

5.1 Packaging and Packing. Unless otherwise specified in the procurement document,

packaging and packing shall be in accordance with commercial practice.

5.2 Marking. Unless otherwise specified, packages shall be marked in accordance with

MIL-STD-129.