Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 1 of 13
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MIL-STD-1553B Multiplex Data Bus Spliced-In Couplers and Terminators
1.0 Introduction
1.1 Scope
This specification covers Tyco Electronics MIL-STD-1553B multiplex data bus
spliced-in couplers and terminators with shielded twisted pair, data bus cables.
1.2 Description
Items covered by this specification are EMI-shielded, environmentally-sealed, non-
repairable assemblies, which are installed as integral parts of a data bus harness.
1.3 Classification
These items are classified as follows:
• Couplers, including types with integral terminators
• Terminators
1.4 Intended use
Data bus couplers covered by this specification provide fault isolation by transformer
coupling with isolation resistors between data bus cables and stub cables connected to
remote terminals. Data bus terminators covered by this specification provide matched
impedance termination at each end of a data bus cable. These products may be used
in applications where the maximum hot spot temperature while operating does not
exceed the rated operating temperature of the coupler or terminator.
1.5 US Air Force Drawings
These couplers and terminators are designed to meet or exceed the requirements for
MIL-STD-1553B couplers and terminators referenced in US Air Force Drawing
8340707.
1.6 European Specifications
Some couplers covered by this specification are designed to comply with the
requirements of EN 3567.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 2 of 13
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2.0 Applicable Documents
2.1 Issues of Documents
The following documents form a part of this specification to the extent specified
herein. This specification takes precedence over the referenced documents.
2.2 Referenced Documents
2.2.1 Military Specifications
MIL-H-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile and Ordnance
MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4, JP-5 and JP-5/JP-8 ST
MIL-PRF-7808 Lubricating Oil: Aircraft Turbine Engine, Synthetic Base, NATO
Code Number 0-148
MIL-C-85485 Cable, Electric, Filter Line, Radio Frequency Absorptive
2.2.2 Military Standards
MIL-STD-129 Marking for Shipment and Storage
MIL-STD-202 Test Methods for Electronic and Electrical Component Parts
MIL-HDBK-454 Standard General Guidelines for Electronic Equipment
MIL-STD-810 Test Methods and Engineering Guidelines
MIL-STD-1344 Test Methods for Electrical Connectors
MIL-STD-1553 Aircraft Internal Time Division Command/Response Multiplex
Data Bus
2.2.3 US Air Force Drawings
8340707 MIL-STD-1553B Data Bus System Components
2.2.4 American Society for Testing and Materials (ASTM) Documents
D-1655 Aviation Turbine Fuels (Type Jet A-1)
2.2.5 American National Standards Institute
ANSI/ASQC Z1.4 Sampling Procedures and Tables for Inspection by Attributes
2.2.6 AECMA Documents
EN 3567 Aerospace series Couplers for use in multiplex data bus systems in
accordance with STANAG 3838
2.2.7 ISO Documents
ISO 10012-1 Quality Assurance Requirements for Measuring Equipment, Part 1.
2.2.8 Tyco / Electronics (Raychem Wire & Harnessing) Specifications
D-6029 Final Electrical Tests for MIL-STD-1553B Multiplex Data Bus
Couplers, Terminators, and Harnesses
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 3 of 13
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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, the latter shall govern.
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
Product Identification 3.7
Workmanship 3.8
3.3 Qualification
Items furnished under this specification shall be products that are qualified to this
specification by testing, by engineering analysis, by similarity to already-qualified
items, or by a combination of these methods.
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.
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-HDBK-454,
Guideline 16.
3.4.2 Fungus Resistance
Finishes and materials shall be fungus-inert in accordance with MIL-HDBK-454,
Guideline 4 (Fungus growth rating of 0 or 1), and encompassing the fungus species
listed in MIL-STD-810, Method 508.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 4 of 13
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3.4.3 Component Materials
Materials for specific components of these items shall be as shown in the applicable
specification control drawings.
3.5 Design and Construction Requirements
Couplers and terminators are designed and constructed to withstand handling during
installation and maintenance. They shall consist of electrical components, within an
EMI-shielded housing, environmentally-sealed or with an environmentally sealed
cover, and attached data bus cables.
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
Couplers and terminators shall conform to the requirements specified herein and in
the applicable specification control drawing. Unless otherwise specified, room
temperature shall be 25±5°C. The nominal characteristic impedance of the databus
cable is 77-Ohm.
3.6.1 Electrical Tests
3.6.1.1 Internal Components
When tested in accordance with 4.5.3.1 components used in the construction of
DataBus couplers and terminators shall meet the following requirements as specified
by MIL-STD-1553:
Transformers: Turns Ratio
Input Impedance
Waveform Integrity
Common Mode Rejection
Isolation Resistors: Resistance
Termination Resistors: Resistance
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 5 of 13
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3.6.1.2 Finished Couplers and Terminators
When tested in accordance with 4.5.3.2 finished couplers and terminators shall meet
the requirements of Specification D-6029.
3.6.1.3 Functional Test
Functional testing shall consist of transmitting MIL-STD-1553B words between one
stub and another of a single coupler or a group of couplers in accordance with 4.5.3.3.
No detected errors shall be allowed. This functional test may be used instead of
discontinuity monitoring during environmental testing.
3.6.1.4 Voltage Withstand
3.6.1.4.1 Signal Circuits to Shield
When specimens are tested as specified in 4.5.3.4.1, there shall be no arcing or
breakdown between each conductor and shield of attached cables or between bus and
stub signal conductors.
3.6.1.4.2 Shield to Water Bath
When specimens are tested as specified in 4.5.3.4.2, there shall be no arcing or
breakdown between the cable shield and the water bath in which the specimen is
immersed. This test is not applicable to couplers with a mounting eyelet that is
electrically connected to the EMI case.
3.6.1.5 Insulation Resistance
3.6.1.5.1 Signal Circuits to Shield
When specimens are tested as specified in 4.5.3.5.1, the insulation resistance between
each conductor and shield of attached cables shall be 100 megohms minimum.
3.6.1.5.2 Shield to Water Bath
When specimens are tested as specified in 4.5.3.5.2, the insulation resistance between
the cable shield and the water bath in which the specimen is immersed shall be 1000
megohms minimum. This test is not applicable to couplers with a mounting eyelet
that is electrically connected to the EMI case.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 6 of 13
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3.6.1.6 EMI Shielding Effectiveness (Surface Transfer Impedance)
When specimens are tested as specified in 4.5.3.6, the surface transfer impedance
shall not exceed the limits shown in Table 1.
Table 1: Surface Transfer Impedance
Attached Cable
Shield Style
USAF Drawing
8340707 Class
Maximum Zt @ 1 MHz
(milliohms / meter)
Single Braid A or B Not required
Optimized Single Braid C 50
Optimized Double Braid D 10
EMP Hardened E 1.0
3.6.2 Environmental Tests
Couplers and terminators shall be able to meet the functional test requirements of
3.6.1.3 and the voltage withstand requirements of 3.6.1.4 after any of the
environmental tests referenced below.
3.6.2.1 Thermal Cycling (-65oC to max rated temperature)
When specimens are tested as specified in 4.5.4.1, there shall be no visual evidence of
functional damage. Specimens shall exhibit no discontinuities during the test and
shall pass the functional test requirement of 3.6.1.3 at both high and low
temperatures.
3.6.2.2 Altitude Immersion (75,000 ft)
When specimens are tested as specified in 4.5.4.2, there shall be no visual evidence of
functional damage, and specimens shall meet the insulation resistance requirements
of 3.6.1.5 following the altitude immersion conditioning.
3.6.2.3 Moisture Resistance (10 day cyclic humidity)
When specimens are tested as specified in 4.5.4.3, there shall be no visual evidence of
functional damage, and specimens shall meet the insulation resistance requirements
of 3.6.1.5 following the moisture conditioning.
3.6.2.4 Salt Spray (1000 hrs)
When specimens are tested as specified in 4.5.4.4, there shall be no visual evidence of
functional damage.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 7 of 13
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3.6.2.5 Sinusoidal Vibration (0.06-in double amplitude)
When specimens are tested as specified in 4.5.4.5, there shall be no visual evidence of
functional damage and no electrical discontinuities greater than 1 microsecond during
the vibration conditioning.
3.6.2.6 Random Vibration (34g rms)
When specimens are tested as specified in 4.5.4.6, there shall be no visual evidence of
functional damage and no electrical discontinuities greater than 1 microsecond during
the vibration conditioning.
3.6.2.7 Mechanical Shock (100g, 6 msec)
When specimens are tested as specified in 4.5.4.7, there shall be no visual evidence of
functional damage and no electrical discontinuities greater than 1 microsecond during
the shock test.
3.6.2.8 Fluids Resistance (39oC and 135oC)
When specimens are tested as specified in 4.5.4.8, there shall be no visual evidence of
functional damage.
3.6.3 Post Test Examination
When specimens are visually examined as specified in 4.5.5 after the performance of
any of the Environmental Tests of 3.6.2, any evidence of damage that could impair
proper functioning shall constitute failure.
3.7 Product Identification
Couplers and terminators shall be labeled on an external surface with the appropriate
part number, lot number or serial number, and the brand name or manufacturers
name. All marking shall remain legible after completion of the tests specified herein.
Couplers that are subsequently fabricated into harnesses are not required to be
individually marked.
3.8 Workmanship
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 or
performance.
4.0 Quality Assurance Provisions
4.1 Responsibility for Inspection
Tyco Electronics is responsible for the performance of all inspection tests specified
herein. Tyco Electronics may utilize its own or any other suitable testing facility.
Inspection records of the tests shall be kept complete and available.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 8 of 13
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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. A calibration system to control the accuracy of the
measuring and test equipment shall be maintained in accordance with ISO 10012-1.
4.2 Classification of Inspections
The examination and testing of items covered by this specification shall be classified
as follows:
a. Qualification inspection (See paragraph 4.3).
b. Acceptance inspection (See paragraph 4.4).
4.3 Qualification Inspection
Qualification inspection shall consist of all of the tests in Table II. Environmental
tests may be performed on individual couplers or a part of a test sequence.
Table II. Qualification Inspection
Test Sequence Requirement
Paragraph
Procedure
Paragraph
Examinations
Specification Control Drawings 3.1 4.5.2
Material 3.4 4.5.2
Design & Construction 3.5 4.5.2
Post Test Examination 3.6.3 4.5.5
Product Identification 3.7 4.5.2, 4.5.5
Workmanship 3.8 4.5.2
Electrical Tests
Internal Components 3.6.1.1 4.5.3.1
Finished Couplers and Terminators 3.6.1.2 4.5.3.2
Functional Tests 3.6.1.3 4.5.3.3
Insulation Resistance 3.6.1.4 4.5.3.4
Dielectric Strength 3.6.1.5 4.5.3.5
EMI Shielding Effectiveness 3.6.1.6 4.5.3.6
Environmental Tests
Temperature Shock 3.6.2.1 4.5.4.1
Altitude Immersion 3.6.2.2 4.5.4.2
Humidity 3.6.2.3 4.5.4.3
Salt Spray 3.6.2.4 4.5.4.4
Sinusoidal Vibration 3.6.2.5 4.5.4.5
Random Vibration 3.6.2.6 4.5.4.6
Mechanical Shock 3.6.2.7 4.5.4.7
Fluid Resistance 3.6.2.8 4.5.4.8
4.3.1 Qualification Test Samples
Sufficient samples shall be selected to enable the performance of all qualification
tests.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 9 of 13
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4.3.2 Qualification Test Report
The qualification test report shall provide evidence that the products meet all
applicable specification requirements and shall be available to purchasers of couplers
or terminators.
4.4 Acceptance Inspection
Acceptance inspection shall consist of the tests listed in Table III. Acceptance
inspection shall be performed on every lot of items manufactured under this
specification. In-process inspection may be conducted in fulfillment of acceptance
inspection where appropriate.
Table III. 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%
Finished Couplers &
Terminators
3.6.1.2 4.5.3.2 100% -
*Inspection Level and AQL per ANSI/ASQC Z1.4
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.
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-
810.
4.5.1.1 Water Solution
Whenever immersion in a water solution is specified, the solution shall contain
sufficient sodium chloride to make the solution conductive, unless otherwise
specified in the test procedure.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 10 of 13
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4.5.2 Visual Examination
Samples shall be visually examined to ensure conformance with 3.1, 3.4, and 3.5, 3.7
and 3.8 of this specification.
4.5.3 Electrical Tests
4.5.3.1 Internal Components (see 3.6.1.1)
Internal component measurements shall be made in accordance with MIL-STD-
1553B and Specification D-6029.
4.5.3.2 Finished Couplers and Terminators (see 3.6.1.2)
Finished component measurements shall be made in accordance with Specification
D-6029.
4.5.3.3 Functional Test (see 3.6.1.3)
This equipment for this test shall consist of a device capable of transmitting valid
MIL-STD-1553B words and a device for receiving MIL-STD 1553B words. The
receiving device shall be capable of detecting that each word has a valid sync field,
that all bits are a valid Manchester II Code; and that word parity is odd. The number
of good words received and the number of words containing errors received shall be
recorded on counters. For this test bus lines shall be terminated with standard
termination resistances.
4.5.3.4 Voltage Withstand
4.5.3.4.1 Signal Circuits to Shield (see 3.6.1.4.1)
Test the specimens in accordance with MIL-STD-202, Method 301. Apply a test
voltage of 500 V ac for one minute between each conductor and the shield of attached
cables. Apply a test voltage of 100 V ac for 1 minute between bus and stub
conductors of attached cables.
4.5.3.4.2 Shield to Water Bath (see 3.6.1.4.2)
Immerse the specimen in a water bath such that 6-inch at the end of each cable is
above the water. Test the specimens in accordance with MIL-STD-202, Method 301.
Apply a test voltage of 500 V ac for one minute between each the water bath and the
shield of attached cables.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 11 of 13
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4.5.3.5 Insulation Resistance
4.5.3.5.1 Signal Circuits to Shield (see 3.6.1.5.1)
Test the specimens in accordance with MIL-STD-202, Method 302. Use Test
Condition B (500 Volts DC). Measure insulation resistance between the bus and stub
conductors and the shield of attached cables.
4.5.3.5.2 Shield to Water Bath (see 3.6.1.5.2)
Immerse the specimen in a water bath such that 6-inch at the end of each cable is
above the water. Test the specimens in accordance with MIL-STD-202, Method 302.
Use Test Condition B (500 Volts DC). Measure insulation resistance between the
cable shield and the water bath in which the specimen is immersed.
4.5.3.6 EMI Shielding Effectiveness {Surface Transfer Impedance} (see 3.6.1.6)
Test the specimens in accordance with MIL-C-85485. The test specimen shall consist
of a cable assembly with a modified coupler installed near the center. The modified
coupler shall be prepared by cutting off the stub cable near the coupler and enclosing
the cut end by the shield.
4.5.4 Environmental Tests
4.5.4.1 Thermal Cycling (see 3.6.2.1)
Test the specimens in accordance with MIL-STD-202, Method 107, Test Condition B
or F, according to the maximum rated temperature of the part. During the test the
specimen shall be monitored for discontinuities in excess of 1 microsecond. Couplers
shall be functionally tested at high and low temperatures.
4.5.4.2 Altitude Immersion (see 3.6.2.2)
Test the specimens in accordance with MIL-STD-1344, Method 1004. Test
connectors and at least 6-inch of attached cable shall be kept out of the water bath.
4.5.4.3 Moisture Resistance (see 3.6.2.3)
Test the specimens in accordance with MIL-STD-202, Method 106, omitting Step 7b
and Paragraph 3.6.
4.5.4.4 Salt Spray (see 3.6.2.4)
Test the specimens in accordance with MIL-STD-202, Method 101. The exposure
time shall be 1000 hrs.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 12 of 13
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4.5.4.5 Sinusoidal Vibration (see 3.6.2.5)
Test the specimens in accordance with MIL-STD-202, Method 201, using the
frequency range of 5 to 50 Hertz. During the test the specimen shall be monitored for
discontinuities in excess of 1 microsecond.
4.5.4.6 Random Vibration (see 3.6.2.6)
Test the specimens in accordance with MIL-STD-202, Method 214, Test Condition
II, Test Letter H, for 8 hours in each of three mutually perpendicular directions.
During the test the specimen shall be monitored for discontinuities in excess of 1
microsecond.
4.5.4.7 Mechanical Shock (see 3.6.2.7)
Test the specimens in accordance with MIL-STD-202, Method 213, Test Condition
C. During the test the specimen shall be monitored for discontinuities in excess of 1
microsecond.
4.5.4.8 Fluid Resistance (see 3.6.2.8)
The specimens shall be conditioned for 30 minutes in an oven at the temperature
specified. And then immersed in fluid for 5 minutes at room temperature. After
immersion the specimen shall be drained for 1 hour at room temperature. This shall
comprise 1 cycle. Each specimen shall be subjected to 3 cycles.
Table IV. Fluids Resistance Test
Test Fluid Conditioning
Temperature
Coolanol 25 *coolant +135oC
JP-8 jet fuel
(MIL-DTL-5624)
+39oC
JP-5 jet fuel
(MIL-DTL-5624)
+39oC
JET-A1 fuel +39oC
MIL-H-5606 hydraulic
fluid
+135oC
MIL-PRF-7808 lubricating
oil
+135oC
*Synthetic Silicate Ester Base Dielectric Fluid
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
DCR# T-30160
No: D-6020
Rev: C
Date: October 19, 2001
Page: 13 of 13
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4.5.5 Post Test Examination (see 3.6.3)
Visually examine the specimens at 3X magnification for any evidence of damage that
could impair proper functioning.
5.0 Preparation For Delivery
5.1 Packaging and Packing
If not 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.
