TE D-6021 Multiplex databus box couplers and terminators connectorized with d-6025 connector interface Datasheet

MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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.
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Page 1 of 14
MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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
Bus
Aircraft Internal Time Division Command/Response Multiplex Data
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.)
2.3
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.)
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Page 2 of 14
MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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.
3.2
Classification of Requirements
The requirements for these products are classified herein as follows:
Requirement
Qualification
Materials
Design and
Construction
Performance
Identification
Workmanship
3.3
Paragraph
3.3
3.4
3.5
3.6
3.7
3.8
Qualification
Items furnished under this specification or listed on Qualified Products List D-6021-QPL
shall be products that 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
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Page 3 of 14
MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
f.
3.5
Connectors--Per Raychem Specification D-6025 and the applicable
specification control drawing.
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.
3.6.1.3 Box Coupler Waveform Integrity Test
When single stub box couplers are tested as specified in 4.5.3.2, the drop
of the waveform on the bus leads shall not exceed 20 percent. Overshoot
and ringing shall be less than ± 1.0 volt peak.
3.6.1.4 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.
3.6.1.5 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.
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Page 4 of 14
MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
3.6.1.6 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.
3.6.1.7 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.
3.6.2
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.
3.6.3
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.
3.6.4
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.
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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.
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.
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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.
4.1.1
4.2
4.3
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.
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)
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.
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
Table I. Qualification Inspection
Test Group 1
Test Sequence
Visual examination
Functional tests
Insulation resistance
Dielectric strength
EMI shielding effectiveness
Temperature sock
Temperature altitude
Sinusoidal vibration
Random vibration
Mechanical shock
Dust (fine sand)*
Humidity*
Insulation resistance
Dielectric strength
Functional tests
Post test examination
Requiremen
t Paragraph
3.1, 3.4,
3.5, 3.7, 3.8
3.6.1
3.6.2
3.6.3
3.6.16
3.6.4
3.6.5
3.6.10
3.6.11
3.6.12
3.6.13
3.6.14
3.6.2
3.6.3
3.6.1
3.6.17
Procedure
Paragraph
4.5.2
4.5.3
4.5.4
4.5.5
4.5.18
4.5.6
4.5.7
4.5.12
4.5.13
4.5.14
4.5.15
4.5.16
4.5.4
4.5.5
4.5.3
4.5.19
Test Group 2
Test Sequence
Visual examination
Functional tests
Insulation resistance
Dielectric resistance
EMI shielding effectiveness
Rain*
Salt spray*
Altitude immersion*
Insulation resistance
Dielectric strength
Functional tests
Post test examination
* Environment resistant types only
Requiremen
t Paragraph
3.1, 3.4,
3.5, 3.7, 3.8
3.6.1
3.6.2
3.6.3
3.6.16
3.6.8
3.6.9
3.6.6
3.6.2
3.6.3
3.6.1
3.6.17
Procedure
Paragraph
4.5.2
4.5.3
4.5.4
4.5.5
4.5.18
4.5.10
4.5.11
4.5.8
4.5.4
4.5.5
4.5.3
4.5.19
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
Test Group 3
Test Sequence
Visual examination
Fluids resistance*
Insulation resistance
Dielectric strength
Post test examination
* Environment resistance types only.
4.4
Requirement
Paragraph
3.1, 3.4, 3.5,
3.7, 3.8
3.6.15
3.6.2
3.6.3
3.6.17
Procedure
Paragraph
4.5.2
4.5.17
4.5.4
4.5.5
4.5.19
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
Procedure
Paragraph
Paragraph
Visual examination
3.1, 3.4, 3.5,
4.5.2
3.7, 3.8
Waveform integrity
3.6.1.3
4.5.3.2
Coupler maximum voltage
3.6.1.4
4.5.3.3
Coupler minimum voltage
3.6.1.5
4.5.3.4
Termination resistance
3.6.1.6
4.5.3.5
3.6.2
4.5.4
Inspection
Level*
II
AQL*
100%
100%
100%
100%
100%
------
1%
Insulation Resistance
* 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.
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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.
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
with counters shall be used to count the number of correct words and error
words received during the test.
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 temperaturealtitude 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)
1
-65
2
-54
3
-54
4
-10
5
95
6
71
7
95
8
9
10
11
36
60
10
35
Altitude
(ft)
Site
Site
70,000
Site
Site
Site
Site
Duration
(hrs)
2.0
*
*
*
16.0
4.0
0.5
50, 000
50, 000
70,000
70,000
4.0
0.5
4.0
0.5
* Duration sufficient to allow temperature stabilization
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
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.
Step
1
2
3
4
5
Table IV. Rain Test Conditions
Step
Wind
Duration
Velocity
(min)
(mph)
5
0
5
40
5
40
5
40
10
0
Rainfall
Rate
(inch/hr)
2
2
2
2
2
4.5.11 Salt Spray (see 3.6.9). Specimens shall be tested in accordance with MIL-STD-262, 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 MILSTD-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 MILSTD-202, Method 213, Test Condition A. During this test the specimens shall be
subjected to the transmission test of 4.5.3.6.
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MIL-STD-1553B Multiplex DataBus Box Couplers and
Terminators Connectorized with D-6025 Connector
Interface
D-6021
Revision A1
25-Mar-15
4.5.15 Dust (Fine Sand) (see 3.6.13). Specimens shall be tested in accordance with MILSTD-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-STD1344, 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 MILSTD-129.
© 2015 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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