ieee standards - draft standard templategrouper.ieee.org/groups/scc20/hiwg/p1505d6d.pdf · 2010. 2....

IEEE P1505/D6, October 2009

Copyright © 2009 IEEE. All rights reserved. This is an unapproved IEEE Standards Draft, subject to change.

IEEE P1505™/D6 1

Draft Standard for Standard for 2

Receiver Fixture Interface 3

Prepared by the IEEE Std 1505 RFI Working Group of under the joint sponsorship of the 4

Instrumentation and Measurement Society, TC-5 Connectors/TC-8 Automated Instruments Committees 5

and the IEEE Standards Coordinating Committee on Test and Diagnosis for Electronic Systems (SCC20) 6

Committee, Hardware Interface Subcommittee. 7

Copyright © 2009 by the Institute of Electrical and Electronics Engineers, Inc. 8 Three Park Avenue 9 New York, New York 10016-5997, USA 10

All rights reserved. 11

This document is an unapproved draft of a proposed IEEE Standard. As such, this document is subject to 12 change. USE AT YOUR OWN RISK! Because this is an unapproved draft, this document must not be 13 utilized for any conformance/compliance purposes. Permission is hereby granted for IEEE Standards 14 Committee participants to reproduce this document for purposes of international standardization 15 consideration. Prior to adoption of this document, in whole or in part, by another standards development 16 organization, permission must first be obtained from the IEEE Standards Activities Department 17 ([email protected]). Other entities seeking permission to reproduce this document, in whole or in part, must 18 also obtain permission from the IEEE Standards Activities Department. 19

IEEE Standards Activities Department 20 445 Hoes Lane 21 Piscataway, NJ 08854, USA 22

23



Abstract: This standard provides a mechanical and electrical specification for implementing a 1 common interoperable mechanical quick disconnect interconnect system for use by industry for 2 interfacing large numbers of electrical signals (digital, analog, RF, power, etc.). These large 3 interface panels (receiver and fixture panels) are employed primarily in test systems between 4 stimulus/measurement assets and a related unit under test (UUT), although any application 5 involving high density contacts requiring a quick disconnect interface could benefit. The Receiver 6 is a receptacle that is mounted to test system mates with multiple Fixtures, which serve as the 7 “buffer” between the UUT and ATE. Fixtures translate standard I/O signal routing offered at the 8 Receiver to a wiring interface that directly connects to the UUT. These UUT interfaces can 9 represent cable connectors, direct plug-in (printed circuit board edge connectors), sensor 10 monitoring, or manual feedback from the test technician. 11

The primary objectives of this standard are: a) to establish interface standards that permit 12 interchangeability of mechanical/electrical receiver/fixture/connector product assemblies from 13 various manufacturers under an “open architecture”; and b) to develop within this framework a 14 defined set(s) of interconnecting connector and mechanical specifications that supports available, 15 accepted, low-cost commercial technology to reduced dependence on proprietary designs, and 16 extend life-cycle availability. 17

Keywords: connector, fixture, framework, interface, interoperability, mass-interconnect, quick 18 disconnect, receiver, specification 19 20

21

22

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iv Copyright © 2009 IEEE. All rights reserved.

This is an unapproved IEEE Standards Draft, subject to change.

Introduction 1

This introduction is not part of IEEE P1505/D6, Draft Standard for Standard for Receiver Fixture Interface. The 2 information provided is informative only. It provides background and general overview of the standard to assist 3 interested parties implementing the specification. 4

Historical Background 5

On September 19, 1996, a group of receiver fixture product vendors/integrators announced the formation of 6 an industry standards group called the RFI Alliance. 7

The organization later sought to gain identity through a standards organization, which ultimately became the 8 Institute of Electrical and Electronic Engineers, Inc. Under the joint sponsorship of the Instrumentation and 9 Measurement Society TC-5 Connectors/TC-8 Automated Instruments Committees and SCC-20 Subcommittee 10 of the Computer Society, Hardware Interface Subcommittee, an PAR IEEE Std 1505 Standard RFI Working 11 Group was developed and authorized by the IEEE Standards Association. Participation in the IEEE Std 1505 12 RFI Working Group is open to vendors, integrators and users. 13

IEEE Std 1505 Receiver Fixture Interface Working Group focus 14

The IEEE Std 1505 RFI Working Group sponsored by the IEEE Instrumentation and Measurement 15 Society and the IEEE SCC-20 Technical Committee was formed to define a common electrical/mechanical 16 interface specifications for applications involving test, production processing, quick-disconnect electrical 17 interfacing, and subassembly mating requirements. The group is made up of technical individuals from 18 industry, government, and academia, which reflect perspective views of a supplier, user, and general interest 19 in the standard. To derive these specifications, the IEEE Std 1505 Working Group utilized the results of a 20 study conducted by the Department of Defense Automatic Test System Research & Development Integrated 21 Product Team (ARI) Critical Interface Working Group (CIWG), which reviewed as part of their tasks the 22 Automatic Test System (ATS) Test Interface and the joint industry/government Common Test Interface 23 (CTI) Working Group. The methodology step process includes: (a) defining the problem, (b) establishing a 24 set of requirements, (c) evaluating available interface designs against a set of parameters that relate to the 25 problem and requirements, and (d) defining a specification that will meet the consensus of the Working 26 Group and industry short- and long-term goals. It was designed upon open standards or functional 27 specifications that are supported by multiple-vendor products. 28

Cooperative relationship with the Common Test Interface (CTI) 29

This IEEE Std 1505document serves as the basis for supplemental pin map configuration standards, such 30 as IEEE Std 1505.1 and others that are expected to meet unique pin map requirements. Future revisions to 31 this document are expected tomay add new connector styles or types that support RFI needs. 32

The IEEE Std 1505 Working Group recognizes industry/government end-user integration and maintenance 33 support of a defined Common Test Interface (CTI), a specific connector/pin map implementation of the 34 standard. This document IEEE Std 1505 provides for these CTI end-users, and for its ATE system and 35 hardware integrators, a defined, standardized framework and connector, and configuration specif ication to 36 enable agency/aerospace interoperability and upward compatibility. The CTI Working Group is alsohas 37 developing developed a Common Test Interface Pin Map Configuration IEEE Std 1505.1 that uses this 38 standard as its basis. 39

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v Copyright © 2009 IEEE. All rights reserved.


Vendor responsibility 1

Users and buyers of the IEEE Std 1505–compliant hardware are forewarned that neither the IEEE nor any other 2 referenced agency has responsibility for the warranty or certification of any RFI product compliance. 3 Therefore, purchasers of RFI products are encouraged to request such information from the manufacturer. 4

Notice to users 5

Laws and regulations 6

Users of these documents should consult all applicable laws and regulations. Compliance with the 7 provisions of this standard does not imply compliance to any applicable regulatory requirements. 8 Implementers of the standard are responsible for observing or referring to the applicable regulatory 9 requirements. IEEE does not, by the publication of its standards, intend to urge action that is not in 10 compliance with applicable laws, and these documents may not be construed as doing so. 11

Copyrights 12

This document is copyrighted by the IEEE. It is made available for a wide variety of both public and 13 private uses. These include both use, by reference, in laws and regulations, and use in private self-14 regulation, standardization, and the promotion of engineering practices and methods. By making this 15 document available for use and adoption by public authorities and private users, the IEEE does not waive 16 any rights in copyright to this document. 17

Updating of IEEE documents 18

Users of IEEE standards should be aware that these documents may be superseded at any time by the 19 issuance of new editions or may be amended from time to time through the issuance of amendments, 20 corrigenda, or errata. An official IEEE document at any point in time consists of the current edition of the 21 document together with any amendments, corrigenda, or errata then in effect. In order to determine whether 22 a given document is the current edition and whether it has been amended through the issuance of 23 amendments, corrigenda, or errata, visit the IEEE Standards Association web site at 24 http://ieeexplore.ieee.org/xpl/standards.jsp, or contact the IEEE at the address listed previously. 25

For more information about the IEEE Standards Association or the IEEE standards development 26 process, visit the IEEE-SA web site at http://standards.ieee.org. 27

Errata 28

Errata, if any, for this and all other standards can be accessed at the following URL: 29 http://standards.ieee.org/reading/ieee/updates/errata/index.html. Users are encouraged to check this URL 30 for errata periodically. 31

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vi Copyright © 2009 IEEE. All rights reserved.


Interpretations 1

Current interpretations can be accessed at the following URL: http://standards.ieee.org/reading/ieee/interp/ 2 index.html. 3

Patents 4

Attention is called to the possibility that implementation of this standard may require use of subject matter 5 covered by patent rights. By publication of this standard, no position is taken with respect to the existence 6 or validity of any patent rights in connection therewith. A patent holder or patent applicant has filed a 7 statement of assurance that it will grant licenses under these rights without compensation or under 8 reasonable rates, with reasonable terms and conditions that are demonstrably free of any unfair 9 discrimination to applicants desiring to obtain such licenses. Other Essential Patent Claims may exist for 10 which a statement of assurance has not been received. The IEEE is not responsible for identifying Essential 11 Patent Claims for which a license may be required, for conducting inquiries into the legal validity or scope 12 of Patents Claims, or determining whether any licensing terms or conditions provided in connection with 13 submission of a Letter of Assurance, if any, or in any licensing agreements are reasonable or non-14 discriminatory. Users of this standard are expressly advised that determination of the validity of any patent 15 rights, and the risk of infringement of such rights, is entirely their own responsibility. Further information 16 may be obtained from the IEEE Standards Association. 17

You can also check the following to see Letters of Assurance on file. 18

http://standards.ieee.org/db/patents/index.html 19

Participants 20

At the time this draft standard was submitted to the IEEE-SA Standards Board for approval, the IEEE Std 21 1505 RFI Working Group had the following membership: 22

Mike Stora, Co-Chair 23

David Droste, Co-Chair 24

25 Bill Ash 26 Larry Boykin 27 Malcolm Brown 28 Kahn Chun 29 Anthony Estrada 30 Anthony Geneva 31 Chris Gorringe 32 David Heck 33 Orman (Bob) Horton 34 Ashley Hulme 35 Mark Kaufman 36

John Knowles 37 Harry Lambert 38 James Langlois 39 William Maciejewski 40 Stephen Mann 41 Alex Meloni 42 Scott Misha 43 Ion Neag 44 Kenney Nordstrom 45 Leslie Orlidge 46 Richard Patrick 47

Ted Ronnenburg 48 William Ross 49 Howard Savage 50 Mike Seavey 51 P. A. Sedberry, Jr. 52 John Sheppard 53 Roger Sowada 54 Rob Spinner 55 Mario Tobias 56 Timothy Wilmering 57 Dave Wilson 58

59

The following members of the individual balloting committee voted on this standard. Balloters may have 60 voted for approval, disapproval, or abstention. 61 62 (to be supplied by IEEE) 63

64

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vii Copyright © 2009 IEEE. All rights reserved.


CONTENTS 1

1. Overview .................................................................................................................................................... 1 2 1.1 Scope ................................................................................................................................................... 1 3 1.2 Purpose ................................................................................................................................................ 2 4

2. Normative references .................................................................................................................................32 5 2.1 Conventions ........................................................................................................................................76 6

3. Definitions .................................................................................................................................................87 7 3.1 Definition of specification terms ........................................................................................................87 8

4. Qualification requirements ......................................................................................................................109 9 4.1 Responsibility for inspection ............................................................................................................109 10 4.2 General requirements ......................................................................................................................1110 11 4.3 Qualification inspections ................................................................................................................1514 12 4.4 Inspection conditions ......................................................................................................................1514 13 4.5 Qualification inspection ..................................................................................................................1615 14 4.6 Method of examination and test......................................................................................................1816 15

5. Framework specification .......................................................................................................................2827 16 5.1 Framework specification introduction ............................................................................................2827 17 5.2 Definitions ......................................................................................................................................2827 18 5.3 Conventions ....................................................................................................................................2927 19 5.4 Framework general specification ....................................................................................................2927 20 5.5 Materials .........................................................................................................................................3332 21 5.6 Restricted materials ........................................................................................................................3332 22 5.7 Dissimilar metals ............................................................................................................................3332 23 5.8 Workmanship..................................................................................................................................3332 24 5.9 Design and construction .................................................................................................................3332 25 5.10 Framework assembly ....................................................................................................................3433 26 5.11 Framework alignment/keying cavities ..........................................................................................5150 27 5.12 Framework ball-lock mechanism..................................................................................................5352 28 5.13 Framework ball-lock/safety-lock pin devices ...............................................................................5453 29 5.14 Framework protective cover .........................................................................................................5554 30 5.15 Method of mounting .....................................................................................................................5554 31 5.16 Interchangeability .........................................................................................................................5756 32 5.17 Framework stroke .........................................................................................................................5756 33 5.18 Framework engagement and separation forces .............................................................................5958 34 5.19 Framework fixture support weight rating .....................................................................................5958 35 5.20 Electrical conditional requirements ..............................................................................................5958 36 5.21 Framework durability ...................................................................................................................6059 37 5.22 Oversize fixture framework ..........................................................................................................6059 38 5.23 Environmental requirements .........................................................................................................6160 39 5.24 Auxiliary parts ..............................................................................................................................6261 40 5.25 Riveting, upsetting, and spinning over .........................................................................................6261 41

6. Connector module specification ............................................................................................................6261 42 6.1 Connector module specification introduction .................................................................................6261 43 6.2 Connector specification system ......................................................................................................6362 44 6.3 Definitions ......................................................................................................................................6362 45 6.4 Conventions ....................................................................................................................................6362 46 6.5 Quality ............................................................................................................................................6463 47 6.6 General and specific connector contact specification relationships ................................................6463 48


viii Copyright © 2009 IEEE. All rights reserved.


6.7 Materials .........................................................................................................................................6564 1 6.8 Reference materials, platings, and processes ..................................................................................6564 2 6.9 Design and construction .................................................................................................................6665 3 6.10 Connector assembly ......................................................................................................................6665 4 6.11 Interchangeability .........................................................................................................................6867 5 6.12 Oversized pin exclusion test .........................................................................................................6968 6 6.13 Contact engagement and separation forces ...................................................................................6968 7 6.14 Connector mating and unmating ...................................................................................................7069 8 6.15 Contact rating ...............................................................................................................................7170 9 6.16 Contact resistance .........................................................................................................................7170 10 6.17 Contact retention ...........................................................................................................................7170 11 6.18 Dielectric withstanding voltage ....................................................................................................7170 12 6.19 Signal low-level circuit .................................................................................................................7170 13 6.20 Insulation resistance......................................................................................................................7271 14 6.21 Contact durability/cycle test .........................................................................................................7271 15 6.22 Environmental requirements .........................................................................................................7271 16 6.23 Contacts supplied in reels .............................................................................................................7372 17 6.24 Contact solderability .....................................................................................................................7372 18 6.25 Contact resistance to soldering heat/flammability ........................................................................7372 19 6.26 Contact crimp tensile strength ......................................................................................................7473 20 6.27 Auxiliary parts ..............................................................................................................................7473 21 6.28 Marking ........................................................................................................................................7473 22 6.29 Workmanship................................................................................................................................7473 23

7. Signal module ........................................................................................................................................7473 24 7.1 Introduction ....................................................................................................................................7473 25 7.2 General specifications .....................................................................................................................7473 26 7.3 Design and construction requirements ............................................................................................8079 27 7.4 Electrical specifications ..................................................................................................................8180 28 7.5 Method of examination and test......................................................................................................8382 29

8. Power size 8 and 16 connector module(s) .............................................................................................8584 30 8.1 Introduction ....................................................................................................................................8584 31 8.2 General specifications .....................................................................................................................8584 32 8.3 Design and construction requirements ............................................................................................8685 33 8.4 Electrical specifications for 23 A power contact ............................................................................9190 34 8.5 Electrical specifications for 45þA power contact ...........................................................................9291 35 8.6 Method of examination and test......................................................................................................9493 36

9. Coax size 16 connector module(s) .........................................................................................................9594 37 9.1 Introduction ....................................................................................................................................9594 38 9.2 General specifications .....................................................................................................................9594 39 9.3 Design and construction requirements ............................................................................................9695 40 9.4 Coax 5 GHz contact electrical specifications ............................................................................. 101100 41 9.5 Coax 3 GHz contact electrical specifications ............................................................................. 103102 42 9.6 Method of examination and test.................................................................................................. 105104 43

10. RFI mixed power connector module, 28-10 A and 16-20 A positions ............................................ 106105 44 10.1 Introduction .............................................................................................................................. 106105 45 10.2 General specifications ............................................................................................................... 106105 46 10.3 Design and construction requirements ...................................................................................... 109108 47 10.4 Electrical specifications ............................................................................................................ 111110 48

11. Universal size 8 connector D-Sub compatible module, 24 position ................................................ 111110 49 11.1 Introduction .............................................................................................................................. 111110 50


ix Copyright © 2009 IEEE. All rights reserved.


11.2 General specifications ............................................................................................................... 111110 1 11.3 Design and construction requirements ...................................................................................... 113112 2 11.4 Coax 40 GHz, size 8, D-Sub compatible, contact ..................................................................... 117116 3 11.5 Power 45-A, size 8, D-Sub compatible contact ........................................................................ 117116 4 11.6 Pneumatic, size 8, D-Sub compatible, contact .......................................................................... 117116 5 11.7 Fiber-optic, size 8, D-Sub compatible, contact specifications .................................................. 117116 6

12. High-speed signal module ............................................................................................................... 117116 7 12.1 Introduction .............................................................................................................................. 117116 8 12.2 General specifications ............................................................................................................... 118117 9 12.3 Design and construction requirements ...................................................................................... 120119 10 12.4 Electrical specifications ............................................................................................................ 122121 11 12.5 Method of examination and test................................................................................................ 123122 12

Annex A (informative) Receiver Fixture Interface (RFI) Tutorial ........................................................ 126125 13 A.1 Scope ......................................................................................................................................... 126125 14 A.2 Receiver fixture interface overview ........................................................................................... 126125 15 A.3 Receiver fixture interface approaches ........................................................................................ 129128 16 A.4 IEEE 1505IEEE STD 1505 RFI framework design ................................................................... 132131 17 A.5 RFI fixture enclosures overview ................................................................................................ 137136 18 A.6 RFI connector modules and contacts ......................................................................................... 140139 19 A.7 Receiver fixture interface assessment and trade-offs ................................................................. 143142 20

Annex B (informative) Critical Interface Working Group (CIWG) report ............................................ 144143 21

Annex C (informative) Bibliography..................................................................................................... 145144 22 23

24


1 Copyright © 2009 IEEE. All rights reserved.


Draft Standard for Standard for 1

Receiver Fixture Interface 2

1. Overview 3

1.1 Scope 4

The scope of this document standard is the development of a common receiver/fixture interface (RFI) 5 specification that is based upon available commercial standards integrated under a common ―open‖ architecture. 6 This mechanical/electrical interface is intended to serve government/commercial interest for applications in test, 7 system integration, manufacturing, monitoring, and other functional requirements that demand large contact 8 densities and quick-disconnect mechanical operation. 9

1.1.1Background 10

A joint technical forum has been operational since 1997 under the auspices of the IEEE Std 1505 RFI 11 Working Group and a recently formed industry/government Common Test Interface (CTI) Working Group. 12

Readers of this document are encouraged to comment on details unclear, contradictory, or undefined to the 13 IEEE 1505IEEE STD 1505 RFI Working Group or the IEEE Standards Association for review and change. 14 These organizations can be contacted at the locations described in the preface of this document. 15

As IEEE Std 1505 evolves, additional revisions may be required and reballoted by the IEEE Standards 16 Association. The RFI Working Group serves to encourage vendors to produce same product class types that 17 are intermatable and interchangeable by adhering to performance specifications of this standard. 18

The document has been developed in accordance with Institute of Electrical and Electronic Engineers 19 (IEEE) Standards Association Policies and Procedures per the IEEE-SA Standards Board Bylaws [B23],

1 20

the IEEE-SA Standards Board Operations Manual [B24], the IEEE-SA Standards Companion [B25], and 21 the IEEE Standards Style Manual [B26]. Additional guidance and reference was utilized from The Authoritative 22 Dictionary of IEEE Standard Terms [B1 5] and SI 10

TM American National Standard for Use of the 23

International System of Units (SI): The Modern Metric System [B35]. 24

1 The number in brackets correspond to those of the bibliography in Annex C.

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1.1.2Annexes overview 1

Included within this document are two informative annexes: (a) Annex A ―Receiver Fixture Interface (RFI) 2 Tutorial, dated 11/1/05,‖ an overview of the RFI description, background, and application use to inform 3 new users; and (b) Annex B ―Automatic Test System Critical Interfaces Report, dated 9/30/96‖ [B27], the 4 results of a study conducted by the Department of Defense Automatic Test System Research and 5 Development Integrated Product Team (ARI) Critical Interface Working Group (CIWG), which reviewed 6 as part of their tasks the ATS test interface, see link 7 http://grouper.ieee.org/groups/scc20/HIWG/index.htmto URL web address.. 8

1.2 Purpose 9

The purpose of this standard is to permit interchangeability of mechanical/electrical receiver/ 10 fixture/connector product assemblies from various manufacturers under an ―open architecture.‖ The 11 standards shall also define within this framework, a set(s) of interconnecting connector and mechanical 12 specifications that supports available, accepted, low-cost commercial technology to reduce dependence on 13 proprietary designs and extend life-cycle availability. Technical requirements incorporated shall be those 14 identified by government and industry, including maximum flexibility, scalability, and range of application. 15

1.3 Background 16

A joint technical forum has been operational since 1997 under the auspices of the IEEE Std 1505 RFI 17 Working Group. 18

Readers of this document are encouraged to comment on details unclear, contradictory, or undefined to the 19 IEEE STD 1505 RFI Working Group or the IEEE Standards Association for review and change. These 20 organizations can be contacted at the locations described in the preface of this document. 21

The RFI Working Group serves to encourage vendors to produce same product class types that are 22 intermatable and interchangeable by adhering to performance specifications of this standard. 23

The document has been developed in accordance with Institute of Electrical and Electronic Engineers 24 (IEEE) Standards Association Policies and Procedures per the IEEE-SA Standards Board Bylaws [B23],

2 25

the IEEE-SA Standards Board Operations Manual [B24], the IEEE-SA Standards Companion [B25], and 26 the IEEE Standards Style Manual [B26]. Additional guidance and reference was utilized from SI 10

TM American 27

National Standard for Use of the International System of Units (SI): The Modern Metric System [B35]. 28

1.4 Annexes overview 29

Included within this document are two informative annexes: (a) Annex A ―Receiver Fixture Interface (RFI) 30 Tutorial, dated 11/1/05,‖ an overview of the RFI description, background, and application use to inform 31 new users; and (b) Annex B ―Automatic Test System Critical Interfaces Report, dated 9/30/96‖ [B27], the 32 results of a study conducted by the Department of Defense Automatic Test System Research and 33 Development Integrated Product Team (ARI) Critical Interface Working Group (CIWG), which reviewed 34 as part of their tasks the ATS test interface, see link http://grouper.ieee.org/groups/scc20/HIWG/index.htm.. 35

2 The number in brackets correspond to those of the bibliography in Annex C.


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2. Normative references 1

The following referenced documents are indispensable for the application of this documentstandard. For dated 2 references, only the edition cited applies. For undated references, the latest edition of the referenced 3 document (including any amendments or corrigenda) applies. 4

ANSI/NCSL Z540-1 Laboratories, Calibration, and Measuring and Test Equipment. 5

ASTM A240, Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and 6 Strip for Pressure Vessels and for General Applications; equivalent to SAE-AMS-QQ-S-766.

3 7

ASTM A342 Indicator, Permeability, Low-Mu (Go–No Go); equivalent to MIL-I-17214. 8

ASTM A484M-03 Stainless Steel Bars, Billets, and Forgings, Standard Specification for. 9

ASTM A581 Steel Wire Free Machining Stainless and Heat Resistant, Standard Specification for General 10 Requirements for 11

ASTM A582M - 05 Free-Machining Stainless Steel Bars Standard Specification for. 12

ASTM A666-00 Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, 13 Strip, Plate, and Flat Bar 14

ASTM A693 - 06 Standard Specification for Precipitation-Hardening Stainless and Heat-Resisting Steel 15 Plate, Sheet, and Strip. 16

ASTM-A967-1999E1 Chemical Passivation Treatments for Stainless Steel Parts, Standard Specification 17 for; supercedes SAE AMS QQ-P-35C Passivation Treatments for Corrosion-Resistant Steel (Cancelled 18 Feb 2005). 19

ASTM B16 Rod, Brass, Free-Cutting, Bar and Shapes for Use in Screw Machines, Standard Specification 20 for. 21

ASTM B103 Phosphor Bronze Plate, Sheet Strip and Rolled , Standard Specification for. 22

ASTM-B121/B121M, Brass, Leaded/Non-Leaded; Rod/Shapes/Forgings/Flat Products with Finished Edges 23 (Bar and Strip); and related Federal Specification for QQ-B-626D Leaded and Non-leaded Brass Forging 24 and Flat Products w/Finished Edges (i.e. Bar and Strip) 25

ASTM B134 Brass Wire, Standard Specification for. 26

ASTM B139 / B139M - 07 Standard Specification for Phosphor Bronze Rod, Bar, and Shapes.; and related 27 Federal Specification QQ-B-750, Phosphor Bronze Bar, Flat Wire, Plate, Sheet, Strip, and Structural Shapes 28

ASTM B159 Wire Phosphor Bronze, Standard Specification for. 29

ASTM B194 Copper-Beryllium Alloy Plate, Sheet, Strip, and Rolled Bar (Copper Alloy Numbers 30 170/172/173), Standard Specification for; and related Federal Specification for QQ-C-530/533 Beryllium-31 Copper (BeCu) Bar, Rod, and Wire/Strip 32

ASTM B196 Copper-Beryllium Alloy Rod and Bar, Standard Specification for. 33

3 ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken,

PA 19428-2959, USA (http://www.astm.org/).

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ASTM B197, Copper-Beryllium Alloy Wire, Standard Specification for. 1

ASTM B206/B206M Copper-Nickel-Zinc (Nickel Silver) Wire and Copper-Nickel Alloy Wire ; and 2 related Federal Specification for QQ-W-321 Copper alloy wire 3

ASTM B209 - 07 Aluminum and Aluminum-Alloy Sheet and Plate, Standard Specification for; related to 4 SAE-AMS-QQ-A-250/1, -250/2, -250/4, -250/8, 250/11, and -250/13 for Aluminum Alloy 3003/ 5 2024/5052/6061/and 7075, Plate and Sheet; 6

ASTM B301/B301M-08 Free Cutting Copper Rod, Bar, Wire and Shapes, Standard Specification for. 7

ASTM B36/B36M-08a Brass Plate, Sheet, Strip, and Rolled Bar, Standard Specification for. 8

ASTM B441 - 04 Copper-Cobalt-Beryllium, Copper-Nickel-Beryllium, and Copper-Nickel-Lead-Beryl-9 lium Rod and Bar (UNS Nos. C17500, C17510, and C17465) , Standard Specification for. 10

ASTM B488 - 01(2006) Electrodeposited Coatings of Gold for Engineering Uses , Standard Specification 11 for; (equivalent to SAE-AMS 2422 and MIL-G-45204) 12

ASTM B740 - 02 Copper-Nickel-Tin Spinodal Alloy Strip , Standard Specification for. 13

ASTM D4067-03 Reinforced and Filled Poly(Phenylene Sulfide) (PPS) Injection Molding and Extrusion 14 Materials, Standard Specification for. 15

ASTM D5927-09 Thermoplastic Polyester (TPES) Injection and Extrusion Materials Based on ISO 16 Test, Methods, Standard Specification for. 17

ASTM D5948 - 05e1 Molding Compounds, Thermosetting, Standard Specification for. 18

ASTM-B121/B12M, QQ-B-626 Brass, Leaded/Non-Leaded; Rod/Shapes/Forgings/Flat Products with Fin-19 ished Edges (Bar and Strip). 20

CPL 02-01-038 [CPL 2-1.38] (2002, October 31) Enforcement of the Electrical Power Generation, 21 Transmission, and Distribution Standard.

4 22

EIA 364-E Electrical Connector/Socket Test Procedures including Environmental Classifications 23

EIA 557B General Standard for Statistical Process Control Systems.5 24

Electrical Safety-Related Work Practices Inspection Procedures and Interpretation Guidelines. STD 01-16-25 007 [STD 1-16.7] (1991, July 1). 26

FED-STD-H28 Screw Thread Standards for Federal Services. 6 27

28 IEC 309-1 Plugs, socket-outlets and couplers for industrial purposes—Part 1.

7 29

4 U.S. Regulatory Guides are available from the Superintendent of Documents, U.S. Government Printing Office, P.O. Box 37082,

Washington, DC 20013-7082, USA (http://www.access.gpo.gov/). 5 EIA publications are available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112, USA

(http://global.ihs.com/). 6 Fed-Std publications are available from the Defense Industrial Supply Center, 700 Robbins Avenue, Bldg 3 (Code DISSC-ETT),

Philadelphia, PA 19111-5096, (www.wbdg.org/ccb/FEDMIL/fedstdh28a.pdf) 7 IEC publications are available from the Sales Department of the International Electrotechnical Commission, Case Postale 131, 3, rue

de Varembé, CH-121 1, Genève 20, Switzerland/Suisse (http://www.iec.ch/). IEC publications are also available in the United States

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IEEE-P1693 Modular Interconnect Packaging for Scalable Systems (MIPSS) Standard 1

IPC-D-275 Design Standard for Rigid Printed Boards and Rigid Printed Board Assemblies. 8 2

ISO 10012-1 Equipment, Quality Assurance Requirements for Measuring, Part 1: Meteorological 3 Confirmation System for Measuring Equipment.

9 4

ISO/IEC 17025:2005/ANSI/NCSL Z540-1 General Requirements for the Competence of Testing and 5 Calibration Laboratories (www.ecalibration.com/Resources/17025b.htm) 6

MIL-F-14072 Finishes for Ground Electronic Equipment.10

7

MIL-C-24308C Connectors, Electric, Rectangular, Nonenvironmental, Miniature, Polarized Shell, Rack, 8 and Panel, General Specification for 9

MIL-C-83517 Connector, Coaxial, RF for Coaxial, Strip or Microstrip Transmission Line. 10

MIL-DTL-16878 Wire, Electrical, Insulated, General Requirements for. 11

MIL-DTL-55302 Connectors, Printed Circuit Subassembly and Accessories, 12

MIL-DTL-55330 Connectors, Electrical and Fiber Optic, Packaging of.. 13

MIL-HDBK-217F Reliability Prediction of Electronic Equipment. 14

MIL-HDBK-454B/4 General Guidelines for Electronic Equipment. 15

MIL-M-24519E, Military Specification for Molding Plastics, Polyester Thermoplastic, Polyarylether 16 Thermoplastic, Plastic Molding Material, Polyphenylene Sulfide, Glass Fiber Reinforced 17

MIL-M-24519/GPT-30F Thermoplastic polyetherimide compound, 30 percent glass reinforced, flame 18 resistant. 19 20 MIL-M-24519/GST-40F Thermoplastic polyphenylene sulfide compound, 40 percent glass reinforced, 21 flame resistant. 22 23 MIL-PRF-31032 Performance Specification Printed Circuit Board/Printed Wiring Board, General 24 Specification for (w/Amendment 1) Revision: A, Dated: 24 February 2006. 25

MIL-PRF-55110 Performance Specification, Printed Wiring Board, Rigid, General Specification for 26 (w/Amendment 1) FSC 5998. 27

MIL-STD-1130 Connections, Electrical, Solderless Wrapped. (Standard has been cancelled with no 28 replacement and should be used for guidance only) 29

from the Sales Department, American National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, USA

(http:// www.ansi.org/). 8 IPC publications are available from the IPC — Association Connecting Electronics Industries, 3000 Lakeside Drive, 309 S,

Bannockburn, IL 60015, or at IPC-D-275 Design Standard for Rigid Printed Boards and. Rigid Printed Board Assemblies. IPC-RB-

276 Qualification and Performance Specification (www.ipc.org/TOC/IPC-ML-960.pdf). 9 ISO publications are available from the ISO Central Secretariat, Case Postale 56, 1 rue de Varembé, CH-121 1, Genève 20,

Switzer¬land/ Suisse (http://www.iso.ch/). ISO publications are also available in the United States from the Sales Department,

American National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, USA (http://www.ansi.org/). 10 Copies of specifications, standards, drawings, and publications required by manufacturers in connection with specific procurement

functions may be obtained from the U.S.Government Printing Office, P.O. Box 37082, Washington, DC 20013-7082, USA

(http://www.access.gpo.gov/) or from other sources that may require additional fees.

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MIL-STD-1285D Marking of Electrical and Electronic Parts. 1

MIL-STD-1344A, EIA 364, Test Methods for Electrical Connectors (equivalent standard EIA 364). 2

MIL-STD-202G Test Method Standard for Electronic and Electrical Component Parts. 3

MIL-STD-2166 Connections, Electrical, Compliant Pin 4

MIL-STD-2166 Connections, Electrical, Compliant Pin, FSC 5935. 5

MIL-STD-275 (replaced by IPC-2221 or IPC-D-2), Printed Wiring for Electronic Equipment. 6

MIL-STD-810F Test Method Standard for Environmental Engineering Considerations and Laboratory 7 Tests. 8

MIL-STD-889B Dissimilar Metals. 9

MS3197 Gage Pin for Socket Contact Engagement Test (equivalent to SAE AMS-3197) 10

OSHA STD 01-16-007 - STD 1-16.7 - Electrical Safety-Related Work Practices -- Inspection Procedures 11 and Interpretation Guidelines.

11 12

OSHA Technical Manual (OTM). TED 01-00-015 [TED 1-0.15A] (1999, January 20). 13

SAE AMS QQ-N-290 Nickel Plating (Electrodeposited).12

14

SAE AMS QQ-S-763 Steel Bars, Wire, Shapes, and Forgings, Corrosion-Resistant. 15

SAE AMS-3197, Gauge Pin for Socket Contact Engagement Test; equivalent to MS-3197 16

SAE AMS-P-81728 Plating, Tin-Lead (Electrodeposited); equivalent to MIL-P-81728 17

SAE-AMS 2422, Gold Plating for Electronic and Electrical Applications; equivalent to ASTM B488 and 18 MIL-G-45204 19

SAE-AMS-2418, , Copper Plating (Electrodeposited); equivalent to ASTM B734, MIL-C-14550 20

SAE-AMS-QQ-A-250/1F Aluminum 1100, Plate and Sheet; related to ASTM B209. 21

SAE-AMS-QQ-A-250/11F Aluminum Alloy 6061, Plate and Sheet; related to ASTM B209 22


SAE-AMS-QQ-A-250/2E Aluminum Alloy 3003, Plate and Sheet; related to ASTM B209 24

SAE-AMS-QQ-A-250/4E Aluminum Alloy 2024, Plate and Sheet; related to ASTM B209 25


11 Occupational Safety & Health Administration (OSHA) publications are available from OSHA, 200 Constitution Avenue, NW Washington, DC 20210, at Safety and Health Topics: Electrical - Standards Electrical Safety-Related Work Practices -- Inspection

Procedures and www.osha.gov/SLTC/electrical/standards.html

12 SAE publications are available from the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096, USA

(http://www.sae.org/).



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http://www.google.com/url?q=http://www.osha.gov/SLTC/electrical/standards.html&ei=L6QvS6GHPNOXtgfg0KmBCQ&sa=X&oi=nshc&resnum=1&ct=result&cd=1&ved=0CAsQzgQoAA&usg=AFQjCNFv9qf29zElDtOPBu7P7rxYZwln9g

http://www.sae.org/




SAE-AMS-QQ-B-613 Brass, Leaded/Non-Leaded; Rod/Shapes/Forgings/Flat Products with Finished 1 Edges (Bar and Strip); equivalent to ASTM B16, 2

SAE-AMS-QQ-B-626 Brass Wire; equivalent to ASTM B16, 3

SAE-AMS-QQ-B-750 Bronze, Phosphor, Bar, Plate, Rod, Sheet, Strip, Flat Wire, and Structural and Special 4 Shaped Sections; equivalent to ASTM-B139, 5

SAE-AMS-QQ-C-530 Copper-Beryllium Alloy Bar/Rod/Wire (Copper Alloy Numbers 172/173); equivalent 6 to ASTM-B196, 7

SAE-AMS-QQ-C-533 Copper-Beryllium Alloy Strip (Copper Alloy Numbers 170 and 172); equivalent 8 to ASTM-B194. 9

SAE-AMS-QQ-P-35 Passivation Treatments for Corrosion-Resistant Steel; equivalent to ASTM-A967, 10

SAE-AMS-QQ-S-766 Steel Plates, Sheets, and Strip, Corrosion Resisting; equivalent to ASTM-A240. 11

SAE-AMS-QQ-W-321 Wire, Metal, Round, Non-Electrical, Copper Alloy 510; equivalent to ASTM-B134. 12

SAE-AS39029 Contacts, Electrical Connector, Socket, Crimp Removable, General Specification for 13

STD 01-16-007 [STD 1-16.7] (1991, July 1), Electrical Safety-Related Work Practices Inspection 14 Procedures and Interpretation Guidelines. 15

2.1 Conventions 16

2.1.1 Order of precedence 17

Rule 2.1.1: In the event of a conflict between the text of this documentspecification and the references 18 cited herein (except for associated detail specifications, specification sheets, or mil-spec standards), the text 19 of this documentspecification shall take precedence. Nothing in this specification, however, shall supersede 20 applicable laws and regulations unless a specific exemption has been obtained. Any change, however, to 21 those references or the specification once approved must follow the IEEE Standards Association 22 Operational Manual to reinitiate a change to the document and subsequent ballot/approval policies (consult 23 IEEE Web site www.ieee.org for current policy requirements). 24

25

2.1.2RFI qualification requirements versus standard specification relationships 26

Rule 2.1.21: Product qualification requirements shall be as specified herein and related to applicable 27 specifications. In the event of any conflict between the qualification requirements and the specification 28 documents, the latter shall govern. 29

2.1.32.1.2 Reference applicability to this standard 30

Observation 2.1.32: This document e IEEE Std 1505 requires a measurement means for evaluating vendor 31 products but does not intend to impose undue rigorous demands on a commercial-off-the-shelf (COTS) 32 product being applied to the RFI specificationis standard. The IEEE Std 1505 will accept any equivalent 33 standard to that referenced, both active or inactive, as long as the vendor applies common criteria referenced 34


Formatted: IEEEStds Paragraph


http://www.ieee.org/




within the respective reference. The goal offered by these references is to give vendors a measurement stick 1 for comparing its product to that of another. It is not the intent of the standard to be so rigorous that vendors 2 qualifying its product under older standards must continue to requalify that product as the reference is 3 superseded, modified, or discontinued. For this reason both are referenced without revision dates. 4

2.1.42.1.3 Responsibility of the vendor and implementer 5

Rule 2.1.43: The IEEE 1505IEEE STD 1505 Working Group and IEEE Standards Organization or its 6 respective representatives shall not accept any liability, either implied or otherwise, for vendors’ products 7 stipulating compliance to this standardthe IEEE 1505 RFI Specification. It shall be understood that integrators 8 have full responsibility to accept product with or without understood limitations and shall have responsibility 9 for soliciting from the supplier any and all certifications that the product meets the specifications. 10

3. Definitions 11

For the purposes of this document, the following terms and definitions apply. Annex C, The Authoritative 12 Dictionary of IEEE Standards Terms, and IEEE Std C37.100

TM [B22] should be referenced for terms not 13

defined in this clause. 14

3.1Definition of specification terms 15

This section describes the specification terms used throughout this documen.t. 16

Rule: Rules shall be followed to ensure compatibility to the standard. A rule is characterized by the use of 17 the words shall and shall not. These words are not used for any other purpose other than stating rules. 18

Recommendation: Recommendations consist of advice to applicants that will affect the usability of the 19 final device. Discussions of particular hardware to enhance throughput would fall under a recommendation. 20 These should be followed to minimize problems and to obtain optimum performance. 21

Suggestion: A suggestion contains advice which is helpful but not vital. The reader is encouraged to 22 consider the advice before discarding it. Suggestions are included to help the novice designer with 23 problematic areas of the design. 24

Permission: Permissions are included to clarify the areas of the specification that are not specifically pro-25 hibited. Permissions inform the reader that a certain approach is acceptable and will minimize potential 26 problems. The word may is reserved for indicating permissions. 27

Observation: Observations spell out implications of rules and bring attention to things that might otherwise 28 be overlooked. They also give the rationale behind certain rules so that the reader understands why the rule 29 must be followed. 30

3.2 ball-lock mechanism: A pin and socket type of mechanical assembly used in the RFI frameworks, that 31 when latched together can withstand considerable push-pull force (maximum 159 kg [350 lb] per ball-lock 32 assembly) applied to engage or disengage their respective attached frames. 33

3.3 connector module body: A dielectric material that holds the contacts in their proper arrangement and 34 electrically insulates them from each other and is secured to the framework as a single slot, two slot, and 35 four slot wide application. 36

3.4 continuous frame interval: An RFI framework segmentation in which a frame can be extended to 9, 37 14, 24, and 29 slots without segmentation or fixture shroud spacing. 38


Formatted: IEEEStds Paragraph





3.5 combination frame interval: An RFI framework segmentation, in which a combination of a 1 segmented frame and representative continuous frame are applied. 2

3.6 eurocard DIN standard: The Eurocard Deutsches Industrie Normal (DIN) Standard (German industry 3 connector standard organization), which establishes a signal pin contact definition and connector footprint 4 standard for RFI mounting, stroke, and interchangeability for RFI connector modules and contact 5 implementation. 6

3.7 end-to-end: description for placing RFI frames in an orientation that aligns the connectors in an end-7 to-end, stacking fashion in either a vertical or horizontal fashion. 8

fixture: An assembly that integrates a fixture frame, fixture enclosure and any other passive and active 9 components or wiring necessary to interconnect the test system to the UUT. 10

3.8 fixture enclosure: Typically a metal encasement that is attached to the fixture frame to contain and 11 protect components and cabling. 12

3.9 fixture frame: RFI framework element that supports fixture connectors, keying, and ball-lock/release 13 subassemblies. 14

3.10 fixture plug/pin header connector module: A connector module mounted to the fixture framework 15 and typically identified as pins protruding from its housing that is encased by a shroud and recessed within 16 the fixture to protect the pins from damage. 17

3.11 frame interval: The mechanical frame width dimension of 76.20 mm (3.00 in.) that identifies with a 18 segmented frame supporting four connector slots and is iterated to create continuous and combination 19 framework. 20

3.12 framework structure: A contoured tongue-and-groove metal or composite structure with different 21 spacing on the top and bottom frame outline for keying and alignment function that supports ball-lock 22 assembly and connector mounting. 23

3.13 mechanical float: The ability of framework, connector housing, or the contact/termination to adjust 24 position within fixed mechanical limits. 25

3.14 mechanical advantage: Mechanical leverage that the receiver drive system is capable of producing, 26 which is represented as the ratio of engagement force versus the force applied by the operator on the manual 27 handle, or motor torque applied to the drive system. 28

3.15 MIL-DTL-55302 military connector standard: A U. S. Defense Department connector standard to 29 meet higher environmental and electrical performance requirements for avionic board connectors based 30 upon the commercial DIN standard. 31

3.16 pin contact: Male mating contact that is applied typically in the fixture module and may be terminated 32 by direct wire, solder post for PCB mounting, or wire-wrap post. 33

3.17 receiver frame: The framework assembly that is fixed to the test system and configured to serve as a 34 common interface for multiple fixtures. It houses the receiver connectors and mechanical actuator 35 subsystem that connects or disconnects the fixture frame to the receiver. 36

3.18 receiver ball-lock receptacle/fixture ball-lock assembly: A mechanical assembly that, when 37 engaged in a pin-and-socket fashion, aligns and automatically latches the receiver and fixture framework 38 together or, when operated upon, can release the frames. 39

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3.19 receiver receptacle connector module: Connector assembly that houses the receptacle contacts, 1 which is normally mounted in the receiver in a recessed manner to protect the contact from damage and 2 operator from potential live circuit condition. 3

3.20 Rreceiver fixture interface (RFI): Represents a mass electrical interconnect system that includes a test 4 interface panel (receiver) mounted to the test system and multiple mating test interface panels (fixtures) that 5 are uniquely designed to adapt the unit-under-test to the receiver. 6

3.21 RFI framework: Consists of two basic mating picture frame halves that support unique multiple 7 functions of the interface, one for the receiver and the other for the fixture. See also Clause 5. 8

3.22 segmented framework: An RFI framework with a width dimension of 76.20 mm (3.00 in.) that 9 supports two ball-lock engagement points, four connector slots 60.96 mm (2.40 in.) representing 4 x 15.24 10 mm (0.60 in.) slot width, and 7.62 mm (0.30 in.) space on each side of the four slots for the mating fixture 11 protective shrouds. 12

side-by-side: description for placing RFI frames in an orientation that aligns the connectors in an side-by-13 side pancake fashion in either a vertical or horizontal fashion. 14

3.23 slot: RFI term representing a connector footprint designated for one connector type with a footprint 15 measuring 15.24 mm (0.60 in.) wide by 0.15 m (5.75 in.) long, based upon a MIL-DTL-55302 military 16 connector standard, DIN type, signal module with 200 positions (4 x 50 pin). 17

3.24 socket contact: Female contact that is applied protectively within the housing of a receiver module 18 and may be terminated by direct wire, solder post for PCB mounting, or wire-wrap post. 19

3.25 stroke: Length of movement or travel necessary to engage or disengage the RFI connectors along an 20 axial dimension of a pin-and-socket contact. 21

3.26 termination: Part of a contact that is attached to the printed wiring board or hookup wire. 22

3.27 two-part connector: Defines a mating pair of a receiver connector module and fixture connector module 23 that contains the respective socket or pin contacts, with integral alignment keying to facilitate proper mat ing 24 of the contacts. 25

3.28 unit-under-test (UUT): The particular equipment being tested (e.g., printed circuit board, electronic 26 device, electrical subassembly, etc.). 27

4. Qualification requirements 28

4.1 Responsibility for inspection 29

Rule 4.1: Unless otherwise specified, the manufacturer shall be responsible for the performance of all 30 inspection requirements as specified herein. The referenced specifications and standards apply to the extent 31 that they are referenced herein. Where references overlap, are revised, or are superseded by other 32 equivalent industry references, either any one may apply to this standard. 33

Permission 4.1: Manufacturers may use their own or any other facilities suitable for the performance of the 34 inspection requirements specified herein. 35




4.1.1 RFI qualification requirements versus standard specification relationships 1

Rule 4.1.1: Product qualification requirements shall be as specified herein and related to applicable 2 specifications. In the event of any conflict between the qualifications requirements and the specification 3 documents, the latter shall govern. 4

4.1.2 Reference applicability to this standard 5

Observation 4.1.2: This document The IEEE Std 1505 requires a measurement means for evaluating 6 vendor products, but does not intend to impose undue rigorous demands on a commercial-off-the-shelf 7 (COTS) product being applied to the RFI specification. This document The IEEE Std 1505 accepts any 8 equivalent standard (i.e. industrial, military specifications, international standards) to that referenced, both 9 active or inactive, as long as the vendor applies common criteria referenced within the respective reference. 10 The goal offered by these references is to give vendors a measurement stick for comparing their products to 11 those of another. It is not the intent of the standard to be so rigorous that vendors qualifying product under 12 older standards must continue to requalify that product as the reference is superseded, modified, or 13 discontinued. For this reason both old and new standards are referenced without revision dates. 14

4.1.3 Inspection conditions 15

Rule 4.1.3: Unless otherwise specified herein, all inspections shall be performed in accordance with the 16 test conditions specified in the general requirements of MIL-STD-202G and MIL-STD-1344A or the 17 equivalent methods of EIA 364. 18

4.1.4 Test equipment and inspection facilities 19

Rule 4.1.4: Test and measuring equipment, ISO calibration and inspection facilities, maintained by 20 inspection facility, shall be of sufficient accuracy, quality, and quantity to permit performance of the 21 required inspection. The establishment and maintenance of a calibration system to control the accuracy of 22 the measuring and test equipment (i.e., ANSI/NCSL Z540-1, ISO 10012-1 part 1, or comparable standards) 23 shall be required. 24

4.1.5 Responsibility of the vendor and implementer 25

Rule 4.1.5: The IEEE and the IEEE Std 1505 Working Group or its respective representatives shall not 26 accept any liability, either implied or otherwise for vendors’ products stipulating compliance to IEEE 1505. 27 It shall be understood that integrators have full responsibility to accept product with or without understood 28 limitations and shall have responsibility for soliciting from the supplier any and all certifications that the 29 product meets the specifications. 30

4.2 General requirements 31

4.2.1 Statistical process control (SPC) 32

Recommendation 4.2.1: It is recommended that the manufacturer implement and use SPC techniques in 33 the manufacturing process for parts covered by this specification. The SPC program should be developed 34 and maintained in accordance with guidelines of EIA-557. Where SPC cannot be utilized because of non-35 continuous production requirements, a lot sampling plan for inspection in accordance with group A lot and 36




sample size with c = 0 is recommended. The SPC and c = 0 programs may be documented and maintained as 1 part of the overall reliability assurance program as specified in EIA-557. 2

4.2.2 Materials 3

Rule 4.2.2: Manufacturer Suppliers shall identify materials used in the manufacturing of the IEEE Std 1505 4 products to the purchaser. When a definite material is not specified, a material shall be used that enables the 5 connectors and accessories to meet the form, fit, function, and performance requirements of this document 6 (see 5-12). Acceptance or approval of any constituent material by the buyer shall not be construed as a 7 guaranty of the acceptance of the finished product from the manufacturer. 8

4.2.2.1 Reference materials, platings and processes 9

Rule 4.2.2.1a: The identified reference materials, platings, and processes described in 4.2.2, 5.3, 5.4, 5.5, 5.6 10 and 6–12, shall be used to enable framework and connectors manufactured to this specification document 11 to mate to similar industry standard or government-specified framework and connector systems with 12 minimal problems related to electrochemical contamination of critical electrical or mechanical interfaces or 13 generation of incompatible mechanical interface surface wear products. 14

Permission 4.2.2.1: The manufacturers of framework and connectors supplied to this specification standard 15 may use alternate recognized industry standard materials, platings, and processes from those identified in 16 4.2.2, 5.3, 5.4, 5.5, 5.6 and 6–12, of this specification. However, use of alternate materials, platings, and 17 processes shall be coordinated with the respective qualifying activity as part of the qualification process. 18

Rule 4.2.2.1b: Use of alternates to those referenced guidance items by the supplier shall not result in 19 inferior short- or long-term performance or reliability of supplied framework and connectors as compared 20 with framework and connectors manufactured using the referenced materials, platings, or processes. Short- 21 or long-term failures or reliability problems due to use of these alternates shall be the responsibility of the 22 supplier. 23

4.2.2.2 Recycled, recovered, or environmentally preferable materials 24

Recommendation 4.2.2.2: Recycled, recovered, or environmentally preferable materials should be used to 25 the maximum extent possible provided that the material meets or exceeds the operational and maintenance 26 requirements, and promotes economically advantageous life-cycle costs. 27

4.2.2.3 Nonmagnetic materials 28

Rule 4.2.2.3: All direct electrical interconnect/contact assembly parts shall be made from materials which 29 are classed as nonmagnetic (permeability 2µ using indicator in accordance with ASTM A342). 30

4.2.2.4 Plastic molded materials 31

Rule 4.2.2.4: Unless otherwise specified (see respective Clauses 76–12), the connector molded body 32 material shall conform to: 33

a) SDG-F or GDI-30F in accordance with ASTM D5948 (see 4.2.2) or 34

b) Type TPES013G30 in accordance with ASTM D5927 or 35




c) PPS000G40A30330E1F01Y1 1 in accordance with ASTM D4067 or 1

d) Type GPT-30F or GST-40F in accordance with MIL-M-24519 2

e) Reground materials shall not be used. 3

4.2.3 Metals 4

4.2.3.1 Aluminum 5

Rule 4.2.3.1: Where applicable, aluminum shall be as specified in SAE-AMS-QQ-A-250/1 (Aluminum 6 1100), SAE-AMS-QQ-A-250/2 (Alloy 3003), SAE-AMS-QQ-A-250/4 (Alloy 2024), SAE-AMS-QQ-A-7 250/8 (Alloy 5052), SAE-AMS-QQ-A-250/11 (Alloy 6061), or SAE-AMS-QQ-A-250/12 (Alloy 7075), and 8 anodized to meet the requirements of MIL-F-14072. 9

4.2.3.2 Corrosion-resistant steel 10

Rule 4.2.3.2: Where applicable, corrosion-resistant steel shall be 300 series, low magnetic permeability in 11 accordance with SAE-AMS-QQ-S-763, ASTM A581, ASTM A582, or ASTM A484 and passivated in 12 accordance with SAE-AMS-QQ-P-35, or to finish E300 as specified in MIL-F-14072. 13

4.2.3.3 Socket contacts, hermaphroditic contacts, and contact terminations 14

Rule 4.2.3.3: Socket contacts, hermaphroditic contacts, and contact terminations shall be copper -nickel-tin 15 alloy C72900 per ASTM B740, or beryllium copper as specified in ASTM B194, ASTM B196 or ASTM 16 B197 or C17500 in accordance with ASTM B441, or phosphor bronze in accordance with ASTM B103 or 17 ASTM B139, or contact terminations of brass alloy in accordance with ASTM B16 or ASTM B134, or 18 thermocouple materials in accordance with SAE-AS39029, or gold plated per 4.2.3.6. 19

4.2.3.4 Pin contacts and contact terminations 20

Rule 4.2.3.4: Pin contacts and contact terminations shall be: 21

a) Copper-nickel-tin alloy C72900 as specified in ASTM B740 or 22

b) Brass as specified in ASTM B16, ASTM B36, ASTM B134, or ASTM B121 or 23

c) Phosphor bronze, in accordance with ASTM B139 or beryllium copper as specified in ASTM B 24 159, ASTM B194, ASTM B196, ASTM B197, or C18700 in accordance with ASTM B301 or 25

d) Thermocouple materials in accordance with SAE-AS39029 or gold plated per 4.2.3.6. 26

4.2.3.5 Connector guide pins and guide bushings 27

Rule 4.2.3.5: Guide pins and guide bushings shall be: 28

a) Free-cutting, half-hard brass as specified in ASTM B36 or ASTM B121 or 29

b) copper alloy as specified in ASTM B134, or ASTM B159, or ASTM B206 or 30

c) Stainless steel as specified in SAE-AMS-QQ-S-763 or ASTM A582 or 31




d) Alternate acceptable materials, which shall be of appropriate physical performance to provide a 1 noncorrosive, nongalling condition and provide adequate wear characteristics in accordance 2 with ASTM-A240, or similar nickel-based materials. 3

4.2.3.6 Plating 4

Rule 4.2.3.6: Unless otherwise specified (see Clause 6, Annex A, and Annex B), contacts shall be gold 5 plated 76 μm (30 μin.) minimum, in accordance with ASTM B488 Type II, Class 1.27, Grade C, or the 6 equivalent SAE AMS 2422 sections, over suitable underplate (see 4.2.3.3). 7

4.2.3.7 Nickel underplate 8

Rule 4.2.3.7: Nickel underplate shall be Class 2, 76 μm (30 μin.) to 381 μm (150 μin.), as specified in 9 SAE-AMS-QQ-N-290. 10

4.2.3.8 Localized finish 11

Rule 4.2.3.8: Localized systems such as selective plating, welded dot, etc., are permitted in lieu of overall 12 plating providing the following conditions are met: 13

a) Contact engagement end shall be gold plated to 0.076 mm (30 μin) minimum in accordance with 14 ASTM B488, Type II, Class 1.27, Grade C, over nickel underplate per 4.2.3.8. 15

b) Contact termination end plating (solderless wrap) shall be tin-lead (95-5%) composition in 16 accordance with SAE-AMS-81728, 254 μm (100 μin.) to 762 μm (300 μin.) thick over nickel 17 underplate in accordance with 4.2.3.8. 18

c) Contact termination end plating (crimp), tin-gold (96%-4%) composition, 0.076 mm (30μin.) 19 minimum over nickel underplate in accordance with 4.2.3.8, or tin-lead (95-5%) composition 254 20 μm (100 μin.) minimum thickness in accordance with SAE-AMS-81728 over nickel underplate in 21 accordance with 4.2.3.8. Solder dipping is permitted, providing it meets procedures and requirements 22 of MIL-STD-202G, Method 208. 23

d) Nonfunctional areas need not be overplated, provided they have a minimum thickness of 127 µm 24 (50 µin.) of nickel in accordance with SAE-AMS-QQ-N-290, Class 2. 25

Permission 4.2.3.8: When contacts have been provided in strip form, the absence of plating in the area 26 where the contact was removed from the strip is acceptable provided it is in a nonfunctional area and any 27 corrosion formed as a result of salt spray testing does not creep into the contact mating area. 28

4.2.4 Restricted materials 29

4.2.4.1 Flammable, explosive, or toxic 30

Rule 4.2.4.1: All mMaterial shall be nonflammable, nonexplosive, and nontoxic over the operating 31 temperature range (5.22.1). 32

4.2.4.2 Corrosion resistance 33

Rule 4.2.4.2: FrameworkThe framework, connectors, and accessories shall be of corrosion-resistant 34 materials or treated to prevent corrosion. 35

Comment [d1]: Shouldn’t all these be +/-%.

Review entire document!




4.2.4.3 Ferrous 1

Rule 4.2.4.3: Material All material containing more than 5% iron shall not be used for current carrying 2 parts. 3

4.2.5 Dissimilar metals 4

Rule 4.2.5: Where dissimilar metals are used in intimate contact with each other, protection against 5 electrolysis and corrosion shall be provided by means of zinc plating, passivation, coatings, or other 6 inhibitors. Dissimilar metals shall be as defined in MIL-STD-889. Dissimilar metals such as brass, copper, or 7 steel (except corrosion-resisting steel, passivated in accordance with 4.2.3.2), shall not be used in intimate 8 contact with aluminum or aluminum alloy. 9

4.2.6 Fungus resistance 10

Rule 4.2.6: Finishes and materials used in the construction of all interface mechanical and electrical 11 components shall be fungus inert in accordance with MIL-STD-810. 12

4.3 Qualification inspections 13

Rule 4.3: Qualification inspections shall be supported by verifying data from the manufacturer that the 14 materials listed in Table 1, used in fabricating the framework, connectors, and accessories, are in 15 accordance with the applicable IEEE Std 1505 conformance definitions, product drawings, and/or referenced 16 specifications and maintained under equivalent IS O-900 1 quality assurance provisions or otherwise agreed 17 by the customer’s quality authority where noncompliance occurs. 18

4.4 Inspection conditions 19

Rule 4.4: Unless otherwise specified herein, all inspections shall be performed in accordance with the test 20 conditions specified or normal manufacturing expected conditions, whichever is more absolute. All 21 products per advertised specifications shall be maintained under ISO-9000 quality assurance provisions or 22 otherwise noted and agreed by the customer’s quality authority. 23




Table 1 —Qualification inspection 1

Component Material

Related RFI

Defined InSpec

Subclause

Applicable Referenced Specifications

Plastic, Molded Materials 5.4, 5.5, 5.6

SDG-F, GDI-30F, GPT-30F, GST-40F, MIL-M-

24519, (equivalent to ASTM-D5927/ D5948),

ASTM-D4067

Framework/Connector Metal Hardware 5.4

Copper Nickel Alloy 5.4, 5.5; 6.7, 6.8 ASTM B740, SAE-AMS-2418, and SAE-AMS-

QQ-N-290

Phosphor Bronze/Beryllium Copper 5.4, 5.5; 6.7, 6.8 SAE-AMS-QQ-B-750, SAE-AMS-QQ-C-530, or

ASTM B139/B194, SAE-AMS-QQ-C-533

Copper Alloy Wire 5.4, 5.5; 6.7, 6.8 SAE-AMS-QQ-W-321, ASTM B206/B740

Brass (Leaded and Nonleaded) 5.4, 5.5; 6.7, 6.8 SAE-AMS-QQ-B-626 and SAE-AMS-QQ-B-613,

ASTM B121, ASTM B134

Aluminum 5.4, 5.5; 6.7, 6.8 SAE-AMS-QQ-A-250/1,/2,/4,/8,/11 and /12;

MIL-F-14072, ASTM-B209

Steel 5.4, 5.5; 6.7, 6.8

SAE-AMS-QQ-P-35, SAE-AMS-QQ-S-763,

SAE-AMS-QQ-S-766, (or equivalent to ASTM

A240, ASTM A666, ASTM A693, and ASTM-

A967), and ASTM-A581/582/484

Dissimilar Metals 5.4, 5.7; 6.10 MIL-STD-889

Fungus Resistance 5.4, 6.11 MIL-HDBK-454A/4

Framework/Connector Body 5.4, 5.9, 5.10;

6.12 FED-STD-H28

2

4.5 Qualification inspection 3

Rule 4.5: Qualification inspection shall be performed on sample units produced with equipment and 4 procedures normally applied in production. 5

4.5.1 Sample 6

Rule 4.5.1: Mating pairs of IEEE 1505the connector product samples and to the required sample size shall 7 be inspected per respective testing requirements per 4.6 and related specifications. 8

4.5.1.1 Sample inspection for RFI product 9

Rule 4.5.1.1: To qualify normally disassembled product elements described by applicable connector and 10 contact clause specification (see Clauses 7–12) and supplied normally disassembled, each Each supplier 11 shall perform compliance testing to the product level it supports (i.e., contacts only to contact specification 12 that it advertises) or certify in accordance with the inspection criteria in Tables 2–4. 13




4.5.1.2 Sample size and measurements 1

Rule 4.5.1.2: Sample The sample size of connectors shall be in accordance with respective product element 2 specifications described in Clause 6. All framework sample units shall undergo full inspection 3 requirements in accordance with 4.6. For connector sample units, a total of 15% of the contact positions 4 shall be measured per connector sample for each subgroup. For connectors with 13 or fewer contacts, all 5 positions shall be measured. This shall apply to the requirements as specified in 4.6. The same contact 6 positions shall be monitored throughout the test sequences. 7

4.5.2 Inspection routine 8

Rule 4.5.2: Sample units shall be subjected to the inspections specified in Tables 2–4. All RFI framework 9 and connector assembly sample units shall be subjected to the visual, dimensional, mechanical, and 10 environmental inspections in accordance with the inspection acceptance criteria in Tables 2, Table 3, and 11 Table –4. RFI Cconnector samples shall further undergo testing in accordance with the connector inspection 12 acceptance criteria in Table 3. 13

4.5.3 Failures 14

Rule 4.5.3: All failures shall be documented and reliability data supplied when requested by a purchaser to 15 verify product conformance to this document, or stipulate any deviations to that stated.product 16 conformance to IEEE Std 1505 or stipulate deviation. 17

Recommendation 4.5.3: MIL-HDBK-217 is the recommended resource for determining reliability for the 18 respective product being supplied under this standard. 19

Suggestion 4.5.3: Failure history collection is suggested by all product manufacturers, to support goals of 20 continuous improvement/product reliability enhancement. 21

Table 2 —Framework and connector mechanical inspection acceptance criteria 22

Inspection Requirement Related RFI Spec.Defined in

Subclause Method Subclause

Visual and mechanical 5.4–5.21; 6.8 4.6.1

Interchangeability and engagement forces* 5.10–5.13, 5.16, 6.12–6.14 4.6.2.1

Mating and unmating conformance 5.10–5.18; 6.12–6.17 4.6.2.2, 4.6.2.3

Durability Cycling 5.21; 6.12–6.17 4.6.2.6, 4.6.2.7

Connector/Contact Conformance* 6.15 4.6.2.4, 4.6.2.5 23 *When applicable (see Subclause 4.3 and Table 14.1) 24

NOTE—All electrical tests may be performed on same sample(s) in one test group. All mechanical tests may be 25 performed on an additional sample(s) in one test group. 26





4.6 Method of examination and test 1

4.6.1 Visual and mechanical examination 2

Rule 4.6.1a: An eExamination shall be made to determine compliance with each of the requirements of 3 4.3. 4

Table 3 —Connector electrical inspection acceptance criteria 5

Inspection Requirement Related RFI Spec.Defined In


Contact resistance 6.19 4.6.3.1

Electrical characteristics 6.8 4.6.3.9

Dielectric withstanding voltage* (sea level) 5

seconds exposure 5.20.1, 6.21 4.6.3.3

Low level contact resistance 6.22 4.6.3.4

Insulation resistance* 5.20.2, 6.23 4.6.3.5

Crimp/Wire-wrap termination 4.6.3.6

Crimp tensile strength 6.29 4.6.3.7

Contact retention 6.20 4.6.3.2

Solderability (contacts only) 6.27–6.28 4.6.3.8

6 *Applicable to connectors furnished with assembled contacts. 7

Table 4 —Framework and connector environmental inspection acceptance criteria 8

Inspection Requirement Defined In Related RFI Spec.


Operating temperature 5.22.1 4.6.4.1

Temperature cycling 5.22.2 4.6.4.2

Humidity 5.22.3 4.6.4.3

Vibration 5.22.5 4.6.4.4

Shock (specified pulse) 5.22.6 4.6.4.5

Salt spray 5.22.7 4.6.4.6

Solvent resistance/ Fluid immersion 5.22.8 4.6.4.7

Flammability 5.22.9 4.6.4.8

9

Formatted Table




Rule 4.6.1b: Connectors Framework, connectors and accessories shall be visually inspected in such a 1 manner as to be uniform in quality and shall be free from burrs, crazing, cracks, voids, pimples, chips, 2 blisters, pinholes, sharp cutting edges, and other defects that adversely affect life, serviceability, or 3 appearance. 4

4.6.2 Framework and connector mechanical specification conformance testing 5

4.6.2.1 Inspection for Interchangeability 6

Rule 4.6.2.1a: All RFI IEEE Std 1505 products shall satisfy interchangeability requirements between 7 common or multiple-manufacturer entities by meeting: 8

a) Physical configuration and dimensional measurements of 4.3 9

b) Related Clause 5 (framework) and Clause 6 (connector) specifications 10

c) Qualification inspections, as referenced in Table 3 11

d) Subsequent applicable requirements in accordance with Methods 2013.1 and 2014 of MIL-STD-12 1344A or equivalent methods of EIA 364. 13

Rule 4.6.2.1b: The following dimensions shall be gauged or measured to determine conformance to the 14 physical interchangeability requirements of applicable specifications (see 4.3). When a listed dimension is 15 not within specified dimensions and tolerances as defined by this specification, it shall be considered a 16 major defect, including. Major defects are: 17

a) External and internal dimensions of cases, covers, and inserted assemblies, when such dimensions 18 affect mating parts 19

b) Dimensions of cavities, when such dimensions affect insertion of items 20

c) c) Location of connectors, locking pins, fasteners, adequacy of connector float/mounting screw 21 implementation, and other mountings, as applicable, which receive mating parts of plug-in assemblies 22 and major units, and location of the mating parts on the plug-in assembly or major unit 23

Recommendation 4.6.2.1: It is recommended that manufacturers utilize opportunities to mate/unmate 24 products with other manufacturers’ products to verify that compatibilities exist. Integrators and/or users may 25 implement their own respective tests with multiple vendors’ products to qualify source acceptance. 26

4.6.2.2 Mating framework conformance specification testing 27

Rule 4.6.2.2a: To meet IEEE Std 1505 requirements,E each manufacturer shall conduct and comply with 28 the mating framework conformance specification as established by Clause 5 and test in accordance with 29 Method 2013.1 of MIL-STD-1344A, EIA 364, or equivalent methods, to verify the specification is being 30 met. An applicable defined/measured compliant mating receiver/fixture test specimen, per 4.6.2.2, is required 31 to perform this test. 32

Rule 4.6.2.2b: Each manufacturer, or third-party test facilitator, shall conduct mating receiver/fixture 33 conformance tests in accordance with Method 2013.1 of MIL-STD-1344A, EIA 364, or equivalent 34 methods, to verify the specification is being met, as described in 5.10 8 and 5.1816 are being met. The test 35 requires that a test specimen receiver or fixture be applied to a compliant mating frame, with a minimum 36 engagement load of 75% of the advertised engagement capability for a period of 5 seconds, through a 500-37 cycle exercise, without causing: 38

Formatted: Font: Not Italic




a) Mechanical interference, binding, push-back by ball-lock spring actions, and/or visible wear to the 1 receiver or fixture 2

b) Misalignment of greater than 0.51 mm (0.02 in.) to preset alignment connector contact points (mini-3 mum of five contact points, four corners and center), per 76.2 mm (3.0 in.) increment of the 4 framework 5

c) Failure to engage, maintain engagement under 75% load of maximum pin load in quantity or force, 6 and disengage the fixture and all related ball-lock mechanisms from their respective receiver 7 receptacles 8

d) Visible connector gap due to coplanar distortion, ball-lock non-engagement, or other mechanical 9 instability that results in contact electrical ―opens‖ or contact electrical/mechanical resistance 10 beyond the specification; 11

e) Failure to maintain parallel relationships between the receiver and fixture framework that would 12 cause a greater than 2.032 mm (0.080 in.) gap between facing surfaces (see 5.10), contact electrical 13 excessive resistance, or contact electrical opens 14

f) Force being applied to the engagement handle by the operator to exceed 20 kg (40.1 pounds), as 15 measured at the end of the handle; and 16

g) Other detrimental impact to mating elements 17

A minimum sample of two units shall be measured on to the conformance test. 18

Rule 4.6.2.2c: Each manufacturer shall, or third-party test facilitator, shall conduct framework maximum 19 fixture support weight tests to verify the that 5.19specification is being met, as described in. 5.19. The test 20 shall require that a compliant test specimen receiver and specified weighted fixture (fixture weight is 21 calculated be applying the specified maximum weight at the center point of the fixture width at 381 mm (15 22 in.) from the face of the fixture framework), with a minimum engagement load of 75% load of maximum 23 pin load in quantity or force, be engaged for a period of 10 seconds through a 100-cycle exercise, without 24 causing any conditions specified in Rule 4.6.2.2b. 25

Rule 4.6.2.2d: Maximum fixture support weight rating of framework shall be as specified based upon com-26 bined drive and ball-lock engagement capability (holding force) not to be less than 45 kg (100 lb) per ball-27 lock, reflecting the amount of fixture weight that can be both supported in a cantilevered fashion while 28 also meeting a specified engagement resistance specifications as tested in accordance with RFI qualification 29 requirements (see 4.6.2). 30

Rule: 4.6.2.2e: Fixture manufacturers that offer large Fixture footprints shall not exceed dimensions 31 described in Clause 5.22 20 (See Figure 350a), that would intrude on the (right side) manual handle and 32 (bottom) lower Fixture fixture support areas. 33

4.6.2.3 Mating contact/receptacle conformance specification testing 34

Rule 4.6.2.3a: To meet IEEE Std 1505 requirements, each manufacturer shall conduct and comply with an 35 mating contact/receptacle conformance specification established within each respective connector/contact 36 specification described in Clauses 7–12. An applicable defined/measured compliant mating pin or receptacle 37 contact test specimen per Clauses 7–12, is required to perform this test. 38

Rule 4.6.2.3b: Each manufacturer, or third-party test facilitator, shall conduct mating contact/receptacle 39 conformance tests as subscribed herein, in which compliant test contact pins are applied to sample contact 40 sockets of the connector, or the reverse for a period of 10 seconds/cycle, through a 500-cycle exercise, 41 without causing: 42

a) Visible wear to the socket or pin 43







b) Loss of memory to spring-loaded receptacle features to maintain surface contact 1

c) Nonconformance to mechanical engagement resistance (per 6.17) across mating surfaces 2

d) Nonconformance to electrical resistance, or reduced parametric performance (per 6.19) across mat-3 ing surfaces 4

e) Mechanical pushback (greater than 15%) within connector housing cavity 5

f) Other detrimental impact to mating elements 6

A minimum sample of seven mating connector sets shall be measured to satisfy conformance tests. 7

Rule 4.6.2.3c: Each manufacturer or third-party test facilitator shall conduct mating connector conformance 8 tests as subscribed in Rule 4.6.2.3b. During 500 cycles of insertion and withdrawal, the force required to 9 fully insert and withdraw a fully populated connector plug from the mating receptacle shall be measured 10 after 25, 100, 250, and 500 cycles. Each fully populated connector plug and receptacle so mated shall be 11 considered as one test specimen, with a minimum of three mated pairs being required to satisfy 12 conformance tests. The measuring equipment shall conform to the following specifications: 13

a) Axis of insertion of the pin contacts and mating receptacle contacts or hermaphroditic contacts as 14 applicable shall coincide during insertion and withdrawal. 15

b) Speed of insertion of the plug into the receptacle contacts shall not exceed 6 cycles per minute for 16 constant speed machines, or the rate of loading shall not exceed 80 pounds per minute for con-17 stant-rate-of-force machines. 18

c) Scale mechanisms shall have no dashpots or other damping devices. 19

d) Scales shall be calibrated in 56.7 g (0.13 lb) steps or less and shall be accurate to within 56.7 g 20 (0.13 lb). 21

NOTE—When mating and unmating tests are required by another test such as contact life, the preconditioning cycles 22 are not required. 23

4.6.2.4 Oversized pin exclusion (pins only) test 24

Rule 4.6.2.4: The oversized pin exclusion (contact pins only) requirement, which determines RFI 25 product pin dimension conformance, shall be met by inserting test sample pin into the mating end of the 26 socket test fixture that excludes the entry of a test sample pin larger than the allowable maximum pin 27 dimensions, as specified in Clause 6 and related detailed specifications in Clauses 7–12. 28

4.6.2.5 Oversized pin/probe damage socket test 29

Rule 4.6.2.5: The oversized pin/probe damage socket test requirement determines RFI connector 30 socket/receptacle test sample ability to maintain dimension conformance when an oversized pin or probe is 31 inserted in accordance with Method 2006-1 of MIL-STD-1344A, EIA 364, or equivalent methods. The 32 connector and mating socket contact entry opening shall prevent an oversized pin or probe that exceeds the 33 tolerances, as specified in Clause 6 and related Annex descriptions, from entering the socket. The 34 receptacle/socket test sample and oversized pin shall be fixtured to verify that concentric relationships are 35 maintained during the insertion test. 36

4.6.2.6 Framework durability cycling 37

Rule 4.6.2.6a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 38 receiver and fixture to a durability cycle test in accordance with Method 2016 of the MIL-STD-39






1344A, EIA 364, or equivalent methods. A minimum durability cycle objective of 25,000 repetitions shall be 1 used. Each manufacturer or third-party test facilitator shall establish a defined mechanical/electrical setup 2 to provide a comprehensive test and data collection that verifies the manufacturer’s product specifications 3 and meets minimum requirements of IEEE Std 1505. The framework cycle test shall validate reliability of 4 the framework to achieve its advertised capabilities under subsequent MIL-STD-1344A requirements. 5

Rule 4.6.2.6b: For the framework durability cycle test of fixture engagement, insertion, and withdrawal, the 6 force shall be sufficient to fully insert and withdraw from the receiver. If the force is manually applied, it 7 shall be measured at the operating handle and shall not exceed 16 kg (35 lb). Each plug and receptacle so 8 mated shall be considered as one test specimen when further testing of the plug or receptacle is indicated. 9 The measuring equipment shall conform to the following specifications: 10

a) Axis of insertion of the pin contacts and mating receptacle contacts or hermaphroditic contacts as 11 applicable shall coincide during insertion and withdrawal. 12

b) Speed of insertion of the plug into the receptacle contacts shall not exceed six cycles per minute for 13 constant speed machines, or the rate of loading shall not exceed 80 pounds per minute for 14 constant-rate-of-force machines. 15

c) Scale mechanisms shall have no dashpots or other damping devices. 16

d) Scales shall be calibrated in 56.7 g (0.13 lb) steps or less and shall be accurate to within 56.7 g 17 (0.13 lb). 18

4.6.2.7 Connector durability cycling 19

Rule 4.6.2.7a: To meet IEEE Std 1505 requirements, each manufacturer shall conduct and comply with an 20 mating contact/receptacle conformance specification established within each respective connector/contact 21 specification described in Clauses 6–12; MIL-STD-1344A, Method 2002.1; EIA 364; or equivalent 22 methods. 23

Rule 4.6.2.7b: Each unit shall be subjected to 10,000 insertion and withdrawal cycles. The following items 24 shall apply: 25

a) Axis of the pin contacts and mating receptacle contacts shall coincide during insertion and 26 withdrawal. 27

b) Durability cycle rate shall not exceed six cycles per minute. 28

c) Contact electrical resistance continuity measurements shall be measured at each 2,500-cycle interval 29 to 5% of the pins in equal pattern across the beam of the mating connectors, maintaining require-30 ments established in 6.19. 31

d) Connector mating and unmating forces shall be measured and maintained in accordance with 32 respective connector requirements (see 6.17 and connector detailed specifications in Clauses 7–12). 33

4.6.3 Connector electrical specification conformance testing 34

Rule 4.6.3: Advertised connector electrical specifications by manufacturers shall be supported by 35 documented test results conducted by the manufacturer, or third-party test labs in accordance with Clause 36 6, and the respective connector detailed specifications in Clauses 7–12). 37




4.6.3.1 Contact electrical resistance 1

Rule 4.6.3.1: The contact electrical resistance shall be measured individually between each mated pair of 2 contacts. A minimum of six mated pairs of contacts shall be measured on each test specimen; in accordance 3 with Method 3004 of MIL-STD-1344A, EIA 364, or equivalent methods. 4

a) Method of connection: Attach current-voltage leads at extreme ends of contacts. For crimp-type 5 contacts, attach current-voltage leads to wires at closest point to contact without touching contact. 6

b) Test current: See respective contact rated current (see Clauses 7–12). 7

4.6.3.2 Contact retention/float within connector housing 8

Rule 4.6.3.2: Connectors shall be tested to meet minimum contact retention requirements per Method 2007 9 of MIL-STD-1344A, EIA 364, or equivalent methods. The following details and exceptions shall apply: 10

a) Number of samples: A minimum of seven contacts per test specimen shall be tested. 11

b) Applied axial load: 1 lb/s until the load specified in individual specification supplements has been 12 reached. Maintain load for 5 seconds. (When hookup wire is used, the wire shall be large enough to 13 withstand the applied load). 14

c) Maximum allowable contact displacement: During application of specified force and after 15 removal of specified force, per respective contact displacement-float tolerance (see the connector 16 specifications in Clauses 6–12). 17

d) Axial direction: Straight. 18

e) Removable type contacts: Shall withstand an axial load (see 4.3) applied in the normal removal 19 direction after 10 insertions and withdrawals from the same contact hole. 20

4.6.3.3 Dielectric withstanding voltage 21

Rule 4.6.3.3: Mated connectors shall be tested to meet dielectric-withstanding-voltage requirements in 22 accordance with Method 3001 of MIL-STD-1344A, EIA 364, or equivalent methods. The following details 23 and exceptions shall apply: 24

a) Preparation: Mated, and may be mounted to printed wiring board. 25

b) Magnitude of test voltage: As specified (see Clauses 6–12). 26

c) Nature of potential: AC (rms). 27

d) Duration of application of test voltage: 60 seconds. 28

e) Points of application of test voltage: Between the closest contacts and between the contacts and 29 all other metallic parts connected together. 30

f) Method of connection of test voltage to specimen: Affix test probes to terminations described in 31 4.6.3.1 by clips or solder. 32

4.6.3.4 Low-Level circuit 33

Rule 4.6.3.4: A minimum of seven mated pairs of contacts on each test specimen shall be individually 34 measured in accordance with Method 3002.1 of MIL-STD-1344A, EIA 364, or equivalent methods. The 35 following details shall apply: 36




a) Method of connection: Attach current-voltage leads at extreme ends of contacts. For crimp-type 1 contacts, attach current-voltage leads to wires, at closest point to contact without touching contact. 2

b) Not to exceed 100 mA at 20 mV DC open circuit. 3

c) Respective specification measured as maximum contact resistance level that is described in 4 associated maximum contact resistance tables. 5

4.6.3.5 Insulation resistance 6

Rule 4.6.3.5: Mated connectors shall be tested in accordance with Method 3003 of MIL-STD-1344A, EIA 7 364, or equivalent methods. The following details and exceptions shall apply: 8

a) Special preparation: 9

1) The connector shall be mated and may be mounted on a printed wiring board. 10

2) The printed wiring board may be conformal coated or otherwise protected. 11

b) Point of measurement: Check between pins and hardware, between pin and pin, and between pins 12 and shell (on shell-constructed connectors). 13

4.6.3.6 Crimp/wire-wrap termination 14

Rule 4.6.3.6: Each terminal, except wire-wrap post and crimp, shall be subjected to Method 208 of MIL-15 STD-202G. 16

4.6.3.7 Crimp tensile strength (applicable to crimp contacts only) 17

Rule 4.6.3.7: The test shall be performed in accordance with Method 2003 of MIL-STD-1344A, EIA 364, 18 or equivalent methods. Samples for test shall be placed in a standard tensile testing machine and the load 19 applied at an approximate rate as specified to pull the wire out of the sample or break the wire sample. 20 Values shall be in accordance with the respective connector clauses (Clauses 6–12. Note that these 21 values are for MIL-DTL-16878 wire used in conjunction with the proper crimp contact. Ten samples of 22 each wire size (both pin and receptacle types) shall be tested. 23

4.6.3.8 Solderability 24

Rule 4.6.3.8: All connectors with solder terminations shall be tested in accordance with Method 210 of 25 MIL-STD-202G, Condition C, except connectors with solder cup terminations shall be tested in accordance 26 with the following details: 27

a) The applicable wire size properly prepared for the solder cup size shall be inserted into the contact 28 termination. A minimum of seven contacts shall be tested. 29

b) An appropriately prepared resistance soldering iron with an appropriate tip shall be applied to the 30 lower portion of the solder cup configuration where the wire enters the termination. 31

c) The solder shall be applied in the normal manner. 32

d) The resistance soldering iron shall be applied to the system. The wattage shall be adjusted as to 33 allow a proper solder fillet to be formed or for a 4 seconds minimum time limit, whichever is more. 34

e) After application, the soldering iron shall be removed and a visual/mechanical inspection 35 performed. 36




f) Visual inspection shall be at magnification power times l0. The connector shall show no evidence 1 of distortion or damage to any area of the connector housing. The contact shall meet the contact 2 retention requirement The contact shall not interfere with normal floating conditions as applicable 3 and shall meet applicable location dimensions. 4

4.6.3.9 Contact electrical characteristics 5

Rule 4.6.3.9a: Coaxial standing wave ratio (SWR) measurements in accordance with Method 3005 of 6 MIL-STD-1344A, EIA 364, or equivalent methods, if applicable, shall be applied on all coaxial connector 7 assemblies and included in any connector specification and contact rating. 8

Rule 4.6.3.9b: Coaxial radio frequency (RF) transmission loss, leakage, and RF high potential withstanding 9 voltage measurements, in accordance with subclauses 4.6.12, 4.6.13, and 4.6.16 of MIL-C-83517, 10 respectively, shall be included in any coaxial connector specification and contact rating. 11

Rule 4.6.3.9c: Power current rating measurements, in accordance with IEC-309-1, shall be included in any 12 power connector specification and contact rating. 13

Rule 4.6.3.9d: Power creepage/dielectric resistance measurements, in accordance with Method 3003.1 of 14 MIL-STD-1344A, EIA 364, or equivalent methods, shall be included in any connector specification and 15 contact rating. 16

4.6.4 Environmental test compliance 17

4.6.4.1 Operating Temperature 18

Rule 4.6.4.1: Conformance to the temperature cycling requirements per applicable specification 19 supplements (see 4.3) shall constitute verification of the product operating temperature. 20

4.6.4.2 Temperature cycling 21

Rule 4.6.4.2: Mated connectors shall be tested in accordance with Method 1003 of MIL-STD-1344A, EIA 22 364, or equivalent methods. The following details shall apply: 23

a) Special mounting: The connector halves shall be mounted on mounting framework 24

b) Test condition: A, except that the minimum temperature shall be 10° +0/–5° C and the maximum 25 temperature shall be 50° +3 /–0° C. 26

c) Test measurement: The connector shall be capable of mating and unmating the temperature 27 extremes (force shall not be monitored) during the fifth cycle. 28

d) After test examination: Connectors shall be examined for evidence of cracking, crazing, or other 29 physical damage, and the contact resistance shall be measured in accordance with 4.6.3.1. 30

4.6.4.3 Humidity 31

Rule 4.6.4.3: Connectors shall be tested in accordance with Method 1002, Type II of MIL-STD-1344A, 32 except Steps 7a and 7b shall not be required. Alternatively, equivalent methods of EIA 364 shall be used. 33 The mated pairs shall be connected as specified in 4.6.2.3. The printed wiring board may be conformal 34 coated or otherwise protected. The loading voltage shall be 100 VDC. Insulation resistance shall be 35 measured in accordance with 4.6.3.5, upon completion of step 6 of the final cycle, after removal of surface 36 moisture from connector. 37





4.6.4.4 Vibration 1

Rule 4.6.4.4a: Framework shall be tested in accordance with Method 2005 of MIL-STD-1344A, EIA 364, 2 or equivalent methods. The following details shall apply: 3

a) Mounting: Specimen mating receiver/fixture connectors shall be mounted in a fully populated four-4 slot receiver and fixture configuration with the receiver framework mounted with standard 5 mounting screws to receiver mounting plate, which is firmly mounted on the vibration table. 6

b) Stabilization: Arrangement of a fully mated receiver and fixture shall be provided, which prevents 7 the mated connectors from mechanically separating, or electrically opening during vibration tests. 8 The resisting medium shall contact the receiver framework mounting surfaces on the test jig 9 only, and no initial load shall be imparted to the connector. 10

c) For connector saver connectors: The mated pairs shall be mounted per integration specifications. 11

d) Monitoring circuit: Shall be provided to detect any interruption greater than 1 µs. 12

e) Electrical load condition: 100 mA. 13

f) Test condition: Frequency requirement for 5 Hz to 55 Hz at a maximum of 29.4 m/s for vibration. 14 (6.86 m/s at 5 Hz to 15 Hz, 12.74 m/s at 16 Hz to 25 Hz, 29.4 m/s at 26 Hz to 55 Hz). 15

g) After test examination: Connectors’ mounting hardware shall be visually examined for loosening, 16 fracture, or other deterioration. 17

Rule 4.6.4.4b: Mated connectors shall be independently tested in accordance with Method 2005 of MIL-18 STD-1344A, EIA 364, or equivalent methods. The following details shall apply: 19

a) Stabilization: Arrangement shall be provided as indicated on Figure 2 of Method 2005 of 20 MIL-STD-1344A, EIA 364, or equivalent methods, such that a resisting force shall exist through a 21 compliant material (rubber with a Shore A durometer of about 25), which prevents the mated 22 connectors from separating during vibration and shock. The resisting medium shall contact the top 23 and side surfaces on the test jig only, and no initial load shall be imparted to the connector other than 24 the weight of the test jig. 25

b) For straight-through connectors: A mated pair shall be mounted an individual parallel wiring 26 boards and secured by bolts and standoffs as indicated on Figure 3 of Method 2005 of MIL-STD-27 1344A, EIA 364, so that the distance between the wiring boards is equal to the height of the 28 assembled connectors. 29

c) Monitoring circuit: Shall be provided to detect any interruption greater than 1 µs. 30

d) Electrical load conditions: 100 mA 31

e) Test condition: III 32

f) After test examination: Connectors and mounting framework shall be visually examined for 33 loosening, fracture, or other deterioration. 34

4.6.4.5 Shock (specified pulse) 35

Rule 4.6.4.5: Mated four-slot receiver and fixture framework with full population of specimen mating 36 connectors shall be tested in accordance with Method 2004 of MIL-STD-1344A, EIA 364, or equivalent 37 methods. The following details shall apply: 38

a) Mounting method and accessories: In accordance with 4.6.4.4a and suitable monitoring circuit to 39 detect any interruption greater than 1 µs. 40

b) Test condition: Pulse requirement for 5 ms of 49 m/s for shock. 41




c) Number of blows: One blow in both directions along each of three mutually perpendicular axes for 1 a total of six shocks. 2

d) Test current: 100 mA 3

e) After test examination: Connectors and mounting framework shall be visually examined for 4 loosening, fracture, or other deterioration. 5

4.6.4.6 Salt spray (corrosion) 6

Rule 4.6.4.6: Mated connectors shall be tested in accordance with Method 1001 of MIL-STD-1344A, EIA 7 364, or equivalent methods. The following details shall apply: 8

a) Applicable salt solution n accordance with MIL-STD-1344 9

b) Test condition: B 10

4.6.4.7 Solvent resistance and fluid immersion 11

Rule 4.6.4.7: Mated connectors shall be tested in accordance with Method 1016 of MIL-STD-1344A, EIA 12 364, or equivalent methods. 13

4.6.4.8 Flammability 14

Rule 4.6.4.8: Mated connectors shall be tested in accordance with Method 1012 of MIL-STD-1344A, EIA 15 364, or equivalent methods. 16

4.6.4.9 Human Safety 17

Rule 4.6.4.9: Mechanical and electrical components shall adhere be reviewed and marked accordingly per 18 to the following Occupational Safety and Health Administration (OSHA) regulations governing human 19 safety and use of IEEE 1505IEEE STD 1505 apparatus during operation. These include: 20

a) OSHA Enforcement of the Electrical Power Generation, Transmission, and Distribution 21 Standard. CPL 02-01-038 [CPL 2-1.38], (2002, October 31). Also available as a 948 KB PDF, 51 22 pages. Provides information to assist compliance personnel in performing inspections in electric 23 power generation, transmission, and installations, including that of distribution lines and other 24 equipment. 25

b) OSHA Technical Manual (OTM). TED 01-00-015 [TED 1-0.15A], (1999, January 20). Assists 26 OSHA Compliance Safety and Health Officers (CSHOs) in hazard recognition and provides guid-27 ance in accident prevention. Serves as a source of advice for CSHOs on safety and health issues. 28

c) Inspection Guidelines for 29 CFR 1910. OSHA STD 01-06-006 [STD 1-6.6], (1995, June 16). 29 Provides inspection assistance related to personal protective equipment (PPE) (29 CFR 1910, 30 Subpart I) to assist OSHA Compliance Safety and Health Officers (CSHOs) performing inspections 31 in general industry. 32

d) Electrical Safety-Related Work Practices—Inspection Procedures and Interpretation Guidelines. 33 OSHA STD 01-16-007 [STD 1-16.7], (1991, July 1). Establishes policies and provides interpretive 34 guidelines for uniform enforcement of the standard for electrical safety-related work practices, 35 29 CFR 1910.331 through 29 CFR 1910.335. 36




5. Framework specification 1

5.1 Framework specification introduction 2

5.1.1 General 3

This clause serves the function of defining framework application, styles, performance, dimensional, and 4 environmental specifications for satisfying IEEE Std 1505. It is presented in two subsections: (a) first as a 5 general definition describing common framework attributes and requirements for meeting the standard and 6 (b) a second, more detailed specification unique to the respective framework style or subset of the RFI 7 system. Within each of those subsections there is a further definition between receiver and fixture 8 elements. The general and specific specifications combine to form the RFI framework definition of the 9 standard, that otherwise could not stand alone. 10

The Table of Contents on page ix describes further its outline and respective page locations. 11

Currently theThe framework specification exists is described in two supplier versions (a), which has been 12 described as IEEE 1505 segmented and (b) IEEE 1505 continuous framework specifications, reflecting 13 differing framework designs. Where under the IEEE 1505 segmented framework specification, the RFI 14 framework may be constructed fabricated or assembled in separate 4 connector slot frame elements with 15 ribs/spacings (voided connector slot) at the mating frame points. Whereas under IEEE 1505 continuous 16 framework, the framework design would may be constructed as an integral unit of multiple connector slots 17 that permits voided substitute connector slot for (the ribs/spacings) required for segmented integration to 18 be used. Integrators/suppliersor may combine both framework designs to support a specific test interface 19 requirement.. In each any approachcase, the body contour, alignment points, hole patterns, surface areas, 20 and actuator elements of either framework shall remain constant with each 76.2 mm (3.0 in.) increment of the 21 framework. The implementation of either version of the IEEE 1505 specification is dependent upon the 22 application being supported. 23

Another descriptive view of the framework specification is related to how multiple frames are integrated to 24 create multiple tier horizontal or vertical implementation. Orientation is first addressed as either End-to-25 End and Side-by-Side integration. Neither approach changes any framework specification, other than 26 illustrate how frames are iterated to create multi-tier system (see Subclause 5.8.3 for more information). 27

End-to-End design describes the placement of RFI frames in an orientation that aligns the connectors in an 28 end-to-end, stacking multi-tier fashion in either a vertical or horizontal fashion (see Subclause 5.8.3 for 29 more information). Side-by-Side design places frames in adjacent fashion to align the connectors in side-30 by-side manner (see Subclause 5.8.3 for more information). Either design can be placed in a Horizontal or 31 Vertical implementation. 32

33

5.2Definitions 34

For purposes of this standard, the terms and definitions found in Clause 2 apply. The Authoritative 35 Dictionary of IEEE Standards Terms, Seventh Edition, should be referenced for terms not defined in this 36 clause. 37

Formatted: Font: Italic

Formatted: Font: Italic








5.3Conventions 1

5.3.1Order of precedence 2

Rule 5.3.1: In the event of a conflict between the text of this specification and the references cited 3 herein, the text of this specification shall take precedence. Nothing in this specification, however, shall 4 supersede applicable laws and regulations unless a specific exemption has been obtained. Any change, 5 however, to those references or the specification once approved shall follow the IEEE Standards 6 Association Operational Manual to reinitiate a change to the document and subsequent ballot/approval 7 policies (consult IEEE Web site www.ieee.org for current policy requirements). 8

5.45.2 Framework general specification 9

Rule 5.4: Critical dimensions and interoperability framework requirements as specified herein and in 10 accordance with related RFI specification sheets, shall be applied to meet general specification compliance. 11 These are further specified in subsequent subclauses and where unique assemblies are provided by supplier may 12 be described in data sheets, or respective specifications. Dimensions are in metric and inches unless otherwise 13 specified. 14

5.4.15.2.1 Framework physical footprint options 15

Rule 5.42.1a: The physical footprint of an segmented framework shall be in accordance with 5, 5.2, and 16 5.8.3.1. The physical footprint of a continuous framework is illustrated in Figure 2, and can be applied as 17 shown by Figure 3'Physical footprint size of the receiver framework shall be in accordance with Clause 5, 18 5.4, and 5.10.3.1 that describes receiver framework layout design under framework specification IEEE 19 1505 segmented framework, see Figure 1, and the alternate variation IEEE 1505 continuous framework 20 layouts, as illustrated in Figure 2, which can be applied as a combination variation as shown in Figure 3. 21




Formatted: Font: Times New Roman, Fontcolor: Auto





1 Figure 1---IEEE 1505R receiver segmented framework layout design 2

design3 Formatted: Font: Bold




1 Figure 2---IEEE 1505R receiver continuous framework layout design 2

Rule 5.42.1b: The framework assembly shall include alignment, keying, securing and mechanical engage-3 ment devices and elements to permit user-friendly operation and to promote safety. Framework shall 4 support: 5

a) Scalable integration of the fixture frames to the receiver frame in connector slot increments of 1, 4, 6 9, 14, 19, 24, and 29 slots based upon 76.2 mm (3.0 in.) wide framework segmentation and 7 15.24 mm (0.6 in.) connector slot widths 8

b) Reconfigurable integration of the multiple type/width connectors (1, 2, and 4 slot wide), at each slot 9 or multiple slots 10

c) Fixture protective shroud intervals at framework/slot intervals 5, 10, 15, 20, and 25, where required 11

Formatted: Font: Bold




1

Figure 3 —IEEE 1505R receiver combination framework layout design 2

Rule 5.42.1c: Under The segmented framework specification (see Figure 1) shall use four the IEEE Std 3 1505 segmented framework specification (detailed herein and illustrated in Figure 1), the framework shall 4 minimally accommodate four connector module mounting slots and a 7.62 mm (0.30 in.) shroud 5 connector module keep-out space on each side. If incremented in four-slot sections under the IEEE 1505 6 segmented specification, a shroud spacing shall be provisioned at slot 5, 10, 15, 20, and 25 in the 7 framework, to accommodate the protective shrouds of two adjoining fixtures. 8

Rule 5.42.1d: Under the The IEEE Std 1505 continuous fixture and receiver framework specification, 9 illustrated in(see Figure 2), the fixture and receiver framework is a side-by-side design implementation of 10 multiple slot frames, that expands connector side-by-side slots without applying shall also use a 11 nonconnector mounting 15.24 mm (0.60 in.) blank spacing (representing combined adjoining fixture 12 frames, 7.62 mm [0.30 in.] fixture shroud connector keep-out space) for connector modules at slot 5, 10, 15, 13 20 and 25 in the framework in accordance with 5.108.3.1. 14

Permission: 5.42.1a: A Integrators may apply a combination of the IEEE Std 1505 segmented and 15 continuous framework specifications, as shown in (see Figure 3), a combination of the two footprints, or 16 any combination of the connector module groups as determined by the specific application may be 17 applied. 18

Rule 5.42.1e: The RFI framework shall be scalable in a side-by-side design from a minimum frame 19 increment (four connector module slots) width of 76.2 mm (3.0 in.), 279.4 mm (11.0 in.) high, and 88.9 20 mm (3.5 in.) deep, as illustrated in Figure 1, in 76.2 mm (3.0 in.) frame increments per Clause 5. Integrators 21 are permitted to increment side-by-side design fixed widths in 152.4 mm (6.0 in.), 228.6 mm (9.0 in.), 22 304.8 mm (12.0 in.), 381 mm (15 in.), up to a maximum 457.2 mm (18.0 in.), (max supports 29 connector 23 module slots including 7.62 mm [0.30 in.] blank spacings [seeas shown in Figure 2]) to meet standard EIA 24 Equipment Rack Specifications. 25







Rule 5.2.1f: The RFI framework shall be scalable in an end-to-end design from a minimum frame 1 increment (four connector module slots) width of 76.2 mm (3.0 in.), 279.4 mm (11.0 in.) high, and 88.9 2 mm (3.5 in.) deep, as illustrated in Figure 7, in 279.4 mm (11.0 in.) high frame increments per Clause 5. 3 Permission 5.2.1b Integrators are permitted to increment end-by-end design in either fixed heights of 279.4 4 mm (11.0 in.) [see Figure 7]), or arbitrary heights to meet system integration requirements. 5

Rule 5.24.1f: IEEE Std 1505 permits integrators or users to may add incremental receiver framework at 6 anytime to satisfy any mix of fixture requirements, as shown in Figure A3, to a maximum of two tiers. 7

5.55.3 Materials 8

Rule 5.53: Manufacturer shall identify materials used and the level of qualification met by the respective 9 materials, as specified in 4.2. When a definite material is not specified, a material shall be used which 10 enables the connectors and accessories to meet the form, fit, function, and performance requirement. 11 Acceptance or approval of any constituent material by the buyer shall not be construed as a guaranty of the 12 acceptance of the finished product from the manufacturer. 13

5.65.4 Restricted materials 14

Rule 5.64: Manufacturer shall restrict use of materials. Manufacturer shall limit the use of restricted 15 materials' identify materials used and the level of qualification met by the respective materials, as specified 16 in 4.2.4. 17

5.75.5 Dissimilar metals 18

Rule 5.75: Where dissimilar metals are used, they shall meet requirements as specified in 4.2.5. 19

5.85.6 Workmanship 20

Rule 5.86: Frameworks and accessories shall be uniform in quality and free from burrs, crazing, cracks, 21 voids, pimples, chips, blisters, pinholes, sharp cutting edges, and other defects that adversely affect 22 functionality or appearance of the product. 23

5.95.7 Design and construction 24

Rule 5.97: Frameworks shall be of the design, construction, and physical dimensions specified herein 25 (see clause 5.108) for detailed product specifications). Compliance is a function of matching dimensional 26 requirements of the standard where noted, and verification by the supplier, or buyer that the product satisfies 27 fit, form, and function interoperability in accordance with RFI qualification with this documentstandard’s 28 requirements (see 4.3). 29

5.9.15.7.1 Threaded parts 30

Rule 5.97.1: Unless otherwise specified, all threaded parts shall be in accordance with FED-STD-31 H28. Where practicable, all threads shall be in conformity with the coarse-thread series. The fine-thread 32 series shall be used only for applications that might show a definite advantage through their use. 33



Formatted: Font: Times New Roman, Fontcolor: Auto








5.9.1.15.7.1.1 Engagement of threaded parts 1

Rule 5.97.1.1: All threaded parts shall engage in accordance with ASME bolt criteria that establishes 1.5 to 2 2 times the diameter of the thread size, or a minimum of three full threads, unless otherwise specified in 3 this document to be greater. 4

5.105.8 Framework assembly 5

5.10.15.8.1 Framework dimensional compliance 6

Rule 5.108.1a: The framework shall be designed to fully comply with the dimensional specifications 7 described in 5.10.3.1 for proper electrical/mechanical operation under alignment (see 5.11), 8 interchangeability (see 5.16), and durability requirements, in accordance with 5.21. 9

Rule 5.108.1b: The framework shall be designed to refine the engagement requirements with minimum 10 dependence on mechanical float, through a telescopic alignment process (described and illustrated in 11 A.4.9 and Figure A1 1Figures 4 through -6, respectively), so that no misalignment or excessive force (see 12 5.18) is transmitted to the mating contact during engagement evolutions, per RFI qualification requirements 13 (see 4.6.2). 14

Rule 5.108.1c: Critical interoperability areas, as illustrated in Figures 4-6, represent key interface points that 15 shall be met in accordance with RFI qualification with this document requirements (see 4.6.2.2) for 16 interoperability between vendor products. These interoperability points shall serve as alignment between the 17 mating surfaces of the receiver and fixture assemblies as previously discussed in 2.1.2. Detail descriptions 18 are shown in subsequent Figures 4-6. 19

20

Figure 4 —IEEE 15S05 segmented receiver/fixture top view, critical interoperability areas 21

Rule 5.108.1d: Dimensional tolerance shall be, unless otherwise stated, understood to be: 22

a) ±0.02 mm (± 0.10 in./± 0.1°), when linear/angular dimensional measurements in inches are to one 23 decimal place 24

b) ±0.013 mm (+ 0.050 in./+ 0.05°), when linear/angular dimensional measurements in inches are to 25 two decimal places 26

c) ±0.0013 mm (+ 0.005 in./+ 0.005°), when linear/angular measurements are to three decimal places. 27






1

Figure 5 —IEEE 15R05 receiver/fixture side view, signal modules disengaged, 2 framework-critical interoperability areas 3

4

Figure 6 —IEEE 15R05 receiver/fixture side view, signal modules engaged, 5 framework-critical interoperability areas 6

5.10.25.8.2 Framework durability compliance 7

Rule 5.108.2: The framework shall be designed for proper operation without dependence on adjustment so 8 that a minimum force is transmitted to the handle during mating and unmating under specified loads and 9 environment conditions through a duration cycle test of 25,000 revolutions, without display of looseness, 10 stroke/alignment dimensional change, or permanent displacement from its original, normal, fitted position at 11 completion of the specified tests. Manufacturers shall validate conformance to this specification this 12 document per RFI qualification requirements in 4.6.2.6, Clause 5, and MIL-STD-1344A, Method 2002.1. 13

5.10.35.8.3 Body design 14

Rule 5.108.3a: Framework bodies shall be designed and constructed with proper sections and radii to 15 prevent cracking, chipping, or breaking in assembly or in normal service. The framework shall be 16 constructed in a side-by-side, a placement of a four slot frame next to another, or end-to-end iteration, a 17 placement of four slot frame on top of another, in accordance with Subclause 5.108.3.1 and 5.108.3.2, to 18 support scalable integration of the test interface as illustrated in Figure 7. 19

Permission 5.108.3: Framework bodies may be separated to accommodate instrument chassis alignment 20 for direct coupling requirements, or building block and adjacent rack mounting schemes (see Figure 8). 21 Implementation should attempt to define the space separating the framework, in acccordance with 22 increments established under the side-by-side and end-to-end iteration rules. 23






Rule 5.108.3b: Side-by-side body integration, which places one four slot frame in row next to one 1 another, or in multiple frames, shall be in accordance with IEEE this document1505 Side-by-side 2 Segmented Framework design having ribs/spacings (voided connector slot), or IEEE 1505 Side-by-side 3 Continuous Framework without ribs, or combination of both. The body contour, alignment points, hole 4 patterns, surface areas, and actuator elements of either framework remain constant. The IEEE 1505 Side-5 by-side Segmented Framework and IEEE 1505 Side-by-side Continuous Framework shall be dimensioned 6 and iterated at 76.2 mm (3.0 inch) intervals, as described in subsequent Subclauses 5.108.3.1, 5.108.3.2, 7 and 5.108.3.3, and utilize materials as specified in Subclause 5.53. As stated earlier, differences in the 8 framework relate only to the presence of a connector at every 15.24 mm (0.60 inch) spacing (slot) under 9 IEEE 1505 Side-by-side Continuous Framework, versus the IEEE 1505 Side-by-side Segmented 10 Framework Specification, that may or may not restrict use of a connector, at 76.2 mm (3.0 inch) frame 11 intervals, to provision for Receiver Frame Side Supports, and/or application of adjacent Fixtures that have 12 protective shroud sidewalls. 13

Rule 5.108.3c: End-to-end multi-tier body, which stacks frames on ends in either a horizontal and 14 vertical integration, as illustrated in Figure 7, shall be in accordance with this document IEEE 1505 End-to-15 end Multi-tier Framework design having all of the side-by-side framework features related to body contour, 16 alignment points, hole patterns, surface areas, actuator elements, and ribs/spacings (voided connector slot), 17 where applicable. IEEE 1505 Multi-Tier Framework shall be dimensioned and iterated at a minimum 18 245.75 mm (9.675 inch) intervals, as described in subsequent Subclauses 5.108.3.2, and utilize materials as 19 specified in Subclause 5.53. 20

21

Figure 7 —IEEE- Std 1505 receiver, end-to-end multi-tier body horizontal and vertical 22 integration based upon minimum increment 245.75 mm (9.675 inch) spacing 23

5.10.3.15.8.3.1 Side-by-side receiver frame layout design 24

Rule 5.108.3.1: Receiver frame side-by-side layout design shall conform to the drawing specification 25 illustrated in either: IEEE 1505this document as either segmented framework (see Figure 8 and Figure 9); 26 IEEE 1505 side-by-side continuous framework (see Figure 12 and Figure 13); and IEEE 1505 side-by-side 27 combination framework (see Figure 14 and Figure 15); IEEE 1505 side view framework, or combination 28 of both, as also described in Figure 10 and Figure 11., Ddetailing contours and draft angles of the frame 29 shall be adhered to in order to support alignment, as described in 5.108.1 casting/molding dimensional 30 provisions. 31

32





1

Figure 8 —IEEE 15S05 segmented framework receiver layout design, perspective view, 2 with connector mount spacing of 15.24 mm (0.60 in.) and nonconnector slot for frame 3

rib at 76.2 mm (3.0 in.) spacings 4




1

Figure 9 —IEEE 15S05 segmented framework receiver layout design, top view, 2 with connector mount spacing of 15.24 mm (0.60 in.) and nonconnector slot for 3

frame rib at 76.2 mm (3.0 in.) spacings 4




1

Figure 10 —IEEE 15S05 segmented, continuous, or combination framework 2 receiver design, sectional view 3

NOTE 1— Nondimensioned features that are shown in the drawing are arbitrary and reflective of one method for 4 actuating the system, or vendor applied for esthetic/functional implementation of nonstandard requirements. These 5 nondimensioned features or illustrations should not be construed as mandatory or recommended as requirements for 6 implementing the standard. 7

NOTE 2— RFI IEEE Std 1505 Framework shall be mounted to a common plate, or multiple plates that maintain a flat 8 planar relationship with all framework elements that does not exceed 2.54 mm (0.10 inch) deviation across the 9 mounting surface(s). 10




1

Figure 11 —IEEE 15S05 segmented, continuous, or combination framework 2 receiver design, cross-sectional view 3

4

Figure 12 —IEEE 15C05 continuous framework receiver layout design, 5 perspective view, with connector mount spacing of 15.24 mm (0.60 in.) and no 6





1

Figure 13 —IEEE 15C05 continuous framework receiver layout design, top view, 2 with connector mount spacing at 15.24 mm (0.60 in.) slot spacings without 3





1

Figure 14 —IEEE 15C05 combination 9-4-4 slot framework receiver layout design, 2 perspective view, connector mount 15.24 mm (0.60 in.) slot spacings with and 3

without frame rib at 76.2 mm (3.0 in.) spacings 4




1

Figure 15 —IEEE 1505C combination framework receiver layout design, top view, 2 with connector mount spacing at 15.24 mm (0.60 in.) slot spacings with or without 3


5.10.3.25.8.3.2 End-to-end, multi-tier receiver frame layout design 5

Rule 5.108.3.2a: Receiver frame End-to-end layout design shall conform to the drawing specificationthis 6 document illustrated in either IEEE 1505 End-to-end Multi-tier Framework, Figure 16. Contours and draft 7 angles of the frame shall be adhered to in order to support alignment, as described in Subclause 3.4.1 and 8 5.10.1 casting/molding dimensional provisions. 9

Rule 5.810.3.2b: Mounting of receiver end-to-end multi-tier framework shall maintain the 245.75 mm 10 (9.675 inch) interval as a minimum requirement, or 491.50 mm [19.35 in] for two tier combined 11 dimensional requirement, or 737.25 mm [29.025in] for three tier combined dimensional requirement. 12

Permission 5.810.3.1: End-to-end, multi-tier receiver frame layout bodies may be separated to 13 accommodate instrument chassis alignment for direct coupling requirements, or building block and 14 adjacent rack mounting schemes, as is being defined under IEEE Std P1693 Modular Interconnect 15 Packaging for Scalable Systems (MIPSS) as further illustrated in Figure 17. Implementation should attempt 16 to define the space separating the framework, in accordance with increments established under the side -by-17 side and end-to-end iteration rules. 18





1

2

3




Figure 16 —IEEE-1505 Eend-to-end multi-tier with side-by side combination framework 1 receiver layout design, top view, with minimum interval spacing of side-by-side, 2

76.2 mm (3.0 inch), and end-to-end 245.75 mm (9.675 inch) spacing spacings. 3

4

Figure 17 —IEEE-1E505 end-to-end multi-tier with side-by side segmented framework 5 receiver layout design, front view, with minimum interval spacing of side-by-side, 6

76.2 mm (3.0 inch), and end-to-end 245.75 mm (9.675 inch) and arbitrary separations 7 between frames. 8

5.10.3.35.8.3.3 Framework mounting surface plate planar requirements 9

Rule 5.108.3.3: RFI IEEE Std 1505 Framework framework shall be mounted to a common plate, or 10 multiple plates that maintain a flat planar relationship with all framework elements that does not exceed 11 2.54 mm (0.10 inch) deviation across the entire mounting surface(s). 12

13

14

Comment [d2]: This is not corrected. It still

needs fixing.





5.8.3.4 5.10.3.4 Fixture frame layout design 1

Rule 5.108.3.4: Fixture frame layout design shall conform to the IEEE 1505this document segmented 2 framework (illustrated in Figures 18-20), or IEEE 1505 continuous framework drawing specifications 3 (shown in Figure 22 and Figure 23), or combination framework in which both designs are implemented 4 (specified in Figure 24 and Figure 25). Connector mount provisions detailed in Figures 18–25 shall be used to 5 satisfy IEEE 1505 segmented framework or IEEE Std 1505 continuous framework drawing specifications. 6

IEEE-P1505

Segmented, 12 Slot

Fixture Frame with

Connector Shroud

7

Figure 18 —IEEE 15S05 segmented 3 x 4 slot framework fixture layout design, 8 perspective view, with connector mount spacing at 15.24 mm (0.60 in.), slot spacings 9

with frame rib at 76.2 mm (3.0 in.) spacings 10






1

Figure 19 —IEEE 15S05 segmented, four-slot fixture frame without connector shroud 2 and with 101.6 mm (4.0 in.) cable strain relief enclosure 3

4




Figure 20 —IEEE 15S05 segmented framework fixture layout design, top view, 1 with connector mount spacing at 15.24 mm (0.60 in.), slot spacings with frame rib 2

at 76.2 mm (3.0 in.) spacings 3

4

Figure 21 —IEEE 15A05 all framework fixture layout design, side view, with 5 connector mount spacing at 15.24 mm (0.60 in.), slot spacings with frame rib at 6

76.2 mm (3.0 in.) spacings 7

8

Figure 22 —IEEE 15C05 continuous 29-slot framework fixture layout design, 9 perspective view, with connector mount spacing at 15.24 mm (0.60 in.), slot spacings 10

with no frame rib at 76.2 mm (3.0 in.) spacings 11




23.4

3m

m[0

.923

in]

23.88 mm [0.940 in]

11.68 mm [0.460 in]

30.23 mm [1.190 in]

134.1

1m

m[5

.280

in]

9.53 mm [0.375 in] HEX

14.22 mm [0.560 in]

198.1

2m

m[7

.800

in]

12.83 mm [0.505 in]

25.65 mm [1.010 in]

R3.18 mm [0.125 in] TYP.

ALL DIMENSIONS APPLY IN 76.20 mm [3.000 in] INCREMENTS

5.2

1m

m[0

.205

in]

191.3

9m

m[7

.535

in]

153.1

6m

m[6

.030

in]

9.5

3m

m[0

.375

in]

5.14 mm [0.203 in]

TYP.

21.43 mm [0.844 in]

138.4

3m

m[5

.450

in]

218.4

4m

m[8

.600

in]

180.9

8m

m[7

.125

in]

13.21 mm [0.520 in]

16.26 mm [0.640 in]

1.27 mm [0.050 in]

18.7

3m

m[0

.738

in]

21.2

7m

m[0

.838

in]

8.5

7m

m[0

.338

in]

EQ SPCS @ 76.20mm [3.000in]

2-56 UNC - 2B

3.25mm [0.128 in] 0.76mm [0.030 in]

EQ SPCS @ 15.24mm [0.600in]

1

Figure 23 —IEEE 15C05 continuous framework fixture layout design, top view, 2 with connector mount spacing at 15.24 mm (0.6 in.) slot spacings with no frame rib 3

at 76.2 mm (3.0 in.) spacings 4




Four (4) Slot Fixture

Segmented Framework

Eight (8) Slot Fixture

Segmented Framework

1

Figure 24 —IEEE 15C05 combination 4-9-4 slot framework fixture layout design, 2 perspective view, with connector mount spacing at 15.24 mm (0.60 in.), slot spacings 3

with or without frame rib at 76.2 mm (3.0 in.) spacings 4




21.43 mm [0.844 in]

43.43 mm [1.710 in]

21.27 mm [0.838 in]

5.21 mm [0.205 in]

138.4

3m

m[5

.450

in]

180.9

8m

m[7

.125

in]

191.3

9m

m[7

.535

in]

198.1

2m

m[7

.800

in]

29.46 mm [1.160 in]

37.08 mm [1.460 in]

13.21 mm [0.520 in]

60.96 mm [2.400 in]

15.24 mm [0.600 in]

73.66 mm [2.900 in]

45.21 mm [1.780 in] 14.22 mm [0.560 in]

134.1

1m

m[5

.280

in]

50.29 mm [1.980 in]

11.68 mm [0.460 in]

18.7

3m

m[0

.738

in]

8.5

7m

m[0

.338

in]

9.53 mm [0.375 in] HEX

23.4

3m

m[0

.923

in]

5.14 mm [0.203 in]

3 EQ SPCS @

15.24mm [0.600in]

76.20 mm [3.000 in] INCREMENT

1.27 mm [0.050 in]

25.65 mm [1.010 in]

153.1

6m

m[6

.030

in]

12.83 mm [0.505 in]

2-56 UNC - 2B

3.25mm [ 0.128 in]

0.76mm [0.030 in]

R3.18 mm [0.125 in] TYP.

76.20 mm [3.000 in] INCREMENT

ALL DIMENSIONS APPLY IN 76.20 mm [3.000 in] INCREMENTS

9.5

3m

m[0

.375

in]

218.4

4m

m[8

.600

in]

1

Figure 25 —IEEE 15C05 combination framework fixture layout design, top view, 2 with connector mount spacing at 15.24 mm (0.60 in.), slot spacings with or without 3


5.115.9 Framework alignment/keying cavities 5

5.11.15.9.1 Framework alignment cavities 6

Rule 5.119.1: Alignment/keying cavities shown in Figure 26, Detail Design Views A, B, and C, shall be 7 provided within the body of frameworks as specified (see 5.108, 5.119.2, and Figures 18-25 for further 8 detail). Each alignment/keying cavity shall align the receiver and fixture assembly in a confined manner, 9 as to prevent any accidental engagement of the fixture in an improper position with the receiver. 10





Detail A Detail C Detail E

22.352 (0.88)6.35 (0.250)

6.35 (0.250)

36.068

(1.42)

+0.127 (0.005)

- 0.051 (0.002)0.203 (0.008)

1

Figure 26 —RFI Fframe alignment cavity/keying design 2

5.11.25.9.2 Framework keying devices 3

Rule 5.119.2: A six-position hex split keying device shall be provided within the body of frameworks as 4 specified in the drawing specification, illustrated in Figures 27 (see 5.10 8 and 5.11 9 for further 5 specification definitions), in a confined manner, as to prevent any accidental engagement of the fixture in 6 an improper position. Each keying device shall be reconfigurable to support the minimum number of 12 7 unique positions for each four-slot receiver/fixture framework intervals that may be applied by the receiver 8 assembly. 9

24.892 (0.98)

22.352 (0.88)

1.524 (0.06)

6.35 (0.250)

28.702 (1.13)

4.775 (0.188)

9.525 (0.375)

HEX STOCK

4.826 (0.19)

5.08 (0.20)

10

Figure 27 — SRFI six position hex split keying device 11

Recommendation 5.119.2: Keying configuration is not mandatory and is at the discretion of the User. 12 However, where no specific alternative keying is required, it is recommended that the User apply the 13 configuration described in Figure 28 in which a four frame slot fixture can be placed in only one position in 14 a two tier system. 15





1

Figure 28 — VRFI vertical two tier end-to-end framework implementation keying device 2 recommended configuration 3

NOTE—The above configuration is one application of an End-To-End implementation. Description of Tier One and 4 Two and Slot Identification is arbitrary. However it is recommended, that where it can be implemented, the tiers should 5 be applied in a vertical application as shown (one on bottom and two on top). with slots 1 through 29, beginning from 6 left and sequentially to the right. In a horizontal application this may be implemented differently. 7

5.125.10 Framework ball-lock mechanism 8

Rule 5.1210: A ball-lock mechanism, illustrated in Figure 29, functions as the primary engagement device 9 that locks the fixture to the receiver and locking-pin mechanism and shall be supported within the body of 10 frameworks as specified in the drawing specification (see 5.108). The critical dimensional attributes of the 11 ball-lock, shown in Figure 30, shall be supported. 12





1

Figure 29 — BRFI ball-lock mechanism, perspective view 2

33.2 (0.13) x 20 degrees

+.0.00

-1.54 (0.06)11.3 (0.44)

+0.0059

(0.0015)

-0.00

7.861 (0.3095)

9.53 (0.375) +.0.13 (0.005)

3.31 (0.13) x 20 degrees

3.81 (0.150) +.0.0508 (0.002)

3.556 (0.140)

2.515 (0.099)

11.43 (0.450)ø8.23 (0.324)

+.0.0508 (0.002)10.312 (0.406)

16.51 (0..65)

3

Figure 30 — BRFI ball-lock mechanism, detail view 4

5.135.11 Framework ball-lock/safety-lock pin devices 5

Rule 5.1311: The framework shall provide a ball-lock and locking-pin mechanism within the body of 6 frameworks as specified in the drawing specification (Figure 31) to: 7

a) Prevent engagement when receiver mechanism is not positioned to accept the fixture 8

b) Initially latch the fixture to the receiver in preparation for engagement of the connectors 9

c) Lock fixture to the receiver to prevent an inadvertent release of the ball-lock 10

d) Support the mechanical push/pull force of the engagement mechanism to the framework 11

e) Ultimately connect and disconnect the electrical contacts of the IEEE Std 1505RFI system 12





1

Figure 31 — BRFI ball-lock/safety lock pin devices 2

5.145.12 Framework protective cover 3

Rule 5.1412: A framework protective cover shall be provided for each framework assembly to maximize 4 operator safety and protection of the connectors. Each device can be constructed or implemented under 5 vendor discretion. 6

5.155.13 Method of mounting 7

Rule 5.15a13a: A method of mounting receiver frames and fixture frames to their mounting panels (see 8 Figure 32) mounted to a common plate, or multiple plates that maintain a flat planar relationship with all 9 framework elements without distorting or effecting framework operation, not to exceed 2.54 mm (0.10 10 inch) deviation across the mounting surface(s). 11

Permission 5.1513: Mounting method can be constructed or implemented in vertical, horizontal, 12 separated, or otherwise under vendor discretion, providing requirements specified in Rule 5.15b 13b are 13 adhered to. 14

Rule 5.15b13b: Each receiver framework interval shall provide mounting points as specified in Figure 33, using 15 standard 10-32 machine screws and mounting points capable of supporting receiver and fixture support 16 weight requirements per 5.179. 17








2 .10503 .5000

TYP IC A L2.0140

T YPIC AL

0 .7500

2 .5000

6.3800

0.6250

8 .5750

6 .1700 0 .6000

2 .6370T YPIC AL

2.5000

7.4403

0.2500

0 .7500

n 0 .2010 T H RU

w n 0 .4000 X 82 .00 °

10X

n 0 .2010 T HR U

24X

R 0.12508X

19 .0000

17 .4690

0 .9703 TYP IC A L

3.0000TY PIC AL

5.2597TY PIC AL

2 .9450

1.1100T YPIC AL

1.25002X

1 .75002X

0.2340 0 .2840

0 .23402X

0.2840

18.3120T YPIC AL

R 0.140016X T H RU 0.1200

6 .1700

R 0 .12504X

2.7500

1

Figure 32 —Twenty-nine slot receiver rack mounting plate implementation example 2

3

Figure 33 —Receiver framework interval mounting point specifications 4




5.165.14 Interchangeability 1

Rule 5.1614: Receivers of a given scale shall be capable of being mated with associated fixtures meeting 2 the requirements of this specification. The mated frameworks and individual fixtures and receivers having 3 related part numbers shall be directly and completely interchangeable with each other with respect to instal-4 lation and performance as specified in RFI qualification requirements (see 4.6.2). 5

5.175.15 Framework stroke 6

Rule 5.1715: The framework shall provide a minimum stroke of 14.986 mm (0.59 in.) for full 7 disengagement and engagement of the receiver and fixture contacts across the diagonal aspects of the 8 frameworks. The subsequent illustration, Figure 34, details dimensional information and requirements 9 necessary to meet contact mechanical engagement. 10






15.01 (0.590)

15.01 (0.590)

6.35 (0.250)

6.35 (0.250)

2.55 (0.100)

1.28

(0.050)

1

Figure 34 — FRFI framework and connector stroke requirements 2




5.185.16 Framework engagement and separation forces 1

5.18.15.16.1 General requirements 2

Rule 5.1816.1: When tested as specified in RFI qualificationthis document requirements (see 4.5 and 4.6) 3 framework forces shall conform to that defined in drawing specification (see 5.108). 4

5.18.25.16.2 Engagement mechanism mechanical advantage 5

Observation 5.1816.2: The mechanical advantage of a receiver mechanism is the ratio of force applied to 6 the receiver ball-lock actuators via the drive subsystem employed to overcome the engagement resistance 7 of the connector/contacts. In a manual system this force is applied by the operator to operating handle, and a 8 motor is substituted in an electrical-mechanical drive. 9

Rule 5.1816.2: When tested as specified in accordance with this document RFI qualification requirements 10 (see 4.6.2.2b), the framework engagement mechanism mechanical advantage shall support a minimum 11 force to the handle not to exceed 16 kg (35 lb), to achieve engagement forces required by the application 12 employed. The manufacturer of the receiver product shall specify the mechanical advantage of the product. 13

5.18.35.16.3 Framework mating and unmating forces 14

Rule 5.1816.3: When tested in accordance with this document RFI qualification requirements (see 4.6.2.2), 15 the maximum and minimum mating and unmating forces shall be as specified to vendor-stipulated 16 specification data for user information. 17

Connectors assembled to frameworks shall not move or display looseness after assembly, or during and after 18 mate and unmate cycles, or add resistance to engagement process due to framework dimensional instability, 19 torquing, bowing, or other mechanical anomalies. 20

5.195.17 Framework fixture support weight rating 21

Rule 5.1917: Maximum fixture support weight rating of framework shall be as specified based upon combined 22 drive and ball-lock engagement capability (holding force) not to be less than 45 kg (100 lb) per ball -lock, 23 reflecting amount fixture weight that can be both supported in a cantilevered fashion while also meeting a 24 specified engagement resistance specifications as tested in accordance with RFI qualification with this 25 document requirements (see 4.6.2). 26

5.205.18 Electrical conditional requirements 27

5.20.15.18.1 Dielectric withstanding voltage 28

Rule 5.2018.1: When tested in accordance with this document RFI qualification requirements (see 4.6.3.3), 29 there shall be no evidence of breakdown of insulation or flashover. 30











5.20.25.18.2 Insulation resistance 1

Rule 5.2018.2: When tested in accordance with this document RFI qualification requirements (see 4.6.3.5), 2 the initial insulation resistance shall be not less than 5,000 M3/4. 3

5.215.19 Framework durability 4

Rule 5.2119: To meet this document IEEE Std 1505 requirements, each manufacturer shall subject the test 5 specimen receiver and fixture to a durability cycle test in accordance with RFI qualification requirements in 6 4.6.2.6. A minimum durability cycle objective of 25,000 repetitions is required. Each manufacturer or third-7 party test facilitator shall establish a defined mechanical/electrical set -up to provide a comprehensive 8 test and data collection that verifies the manufacturer’s product specifications and meets minimum 9 requirements of IEEE Std 1505. The framework cycle test shall validate reliability of the framework to achieve 10 its advertised capabilities under Clause 4 requirements (MIL-STD-1344A, EIA 364, or equivalent methods). 11

5.225.20 Oversize fixture framework 12

Rule 5.2220: Fixture manufacturers that offer large Fixture footprints shall not exceed dimensions 13 described in Clause 5, Figures 18-25, that would intrude on the (right side) manual handle and (bottom) 14 lower Fixture support areas, as stated in Rule 4.6.2.2e and further illustrated illustrated in Figure 35. Fixture 15 design may be extended beyond the right side and upper side of the Receiver, without interfering with 16 handle and support functions. 17

CAUTION 18

Manufacturers should be cognizant of cantilevered weight and other surrounding interference factors that 19 may impact implementation when standard footprints are exceeded. 20

21

22

Figure 35 —Oversize fixture keep-out areas 23









5.235.21 Environmental requirements 1

Rule 5.2321: FRFI framework shall meet the environmental tests in accordance with this document RFI 2 qualification requirements (see 4.6.4) 3

5.23.15.21.1 Operating temperature 4

Rule 5.2321.1: Unless otherwise specified, frameworks shall have an operating temperature of a 5 minimum 10°C, as deviated +0 and –5° C, and the maximum temperature shall be 50°C, as deviated +3° 6 and –0°C, in accordance with this document RFI qualification requirements (see 4.6.4.1) 7

5.23.25.21.2 Temperature cycling 8

Rule 5.2321.2: When a mated pair of frameworks undergo temperature cycle testing in accordance with RFI 9 qualification This document requirements (see 4.6.4.2), there shall be no evidence of cracking, crazing or 10 warping of the framework body or other physical damage to the framework assembly. 11

5.23.35.21.3 Humidity 12

Rule 5.2321.3: When tested in accordance with RFI qualification this document requirements (see 4.6.4.3), 13 insulation resistance shall be greater than 1,000 M3/4. 14

5.23.45.21.4 Metal Surfaces and environmental exposure protection 15

Rule 5.2321.4: When mated framework pairs are environmentally tested in accordance with RFI qualification 16 this document requirements (see 4.6.4.1 through 4.6.4.4), there shall be no peeling, chipping, or blistering of 17 metal surfaces or corrosion/rusting of exposed base metal. 18

5.23.55.21.5 Vibration 19

Rule 5.2321.5: When tested in accordance with RFI qualification with this document requirements (see 20 4.6.4.4), there shall be no physical or mechanical damage to the framework body or contacts. During 21 vibration tests the framework shall maximize dampening of vibration transmission to connector assembly 22 and prevent interruption in continuity greater than 1 µs of the test circuit that incorporates mated contacts. 23 After the vibration test, the framework and related mounting hardware shall show no signs of loosening, 24 fracture, or other deterioration. 25

5.23.65.21.6 Shock (specified pulse) 26

Rule 5.2321.6: When shock tested in accordance with RFI qualification with this document requirements 27 (see 4.6.4.5), the framework and related mounting hardware shall show no signs of loosening, fracture or 28 other deterioration. During shock tests the framework shall maximize dampening of shock transmission to 29 connector assembly and prevent interruption in continuity greater than 1 µs of the test circuit that incorporates 30 mated contacts. 31











5.23.75.21.7 Salt spray (corrosion) 1

Rule 5.2321.7: When mated connector pairs are tested in accordance with RFI qualification with this 2 document requirements (see 4.6.4.6), there shall be no peeling, chipping, or blistering of metal surfaces or 3 exposure of base metal. 4

5.23.85.21.8 Solvent resistance and fluid immersion 5

Rule 5.2321.8: Mated framework shall be tested in accordance with RFI qualification with this document 6 requirements (see 4.6.4.7 and Method 1016 of MIL-STD-1344A, EIA 364, or equivalent methods). 7

5.23.95.21.9 Flammability 8

Rule 5.2321.9: Mated framework shall be tested in accordance with RFI qualification with this document 9 requirements (see 4.6.4.8 and Method 1012 of MIL-STD-1344A, EIA 364, or equivalent methods). 10

5.245.22 Auxiliary parts 11

Rule 5.2422: Mechanical, nonelectrical parts, such as polarizing keys, keying accessories, covers, cable 12 clamps, etc., shall be as specified on the individual specification sheet. 13

5.255.23 Riveting, upsetting, and spinning over 14

Rule 5.2523: When riveting, upsetting, or spinning-over processes are employed, there shall be no 15 evidence of fatigue or deformation of noninvolved surfaces of the material being riveted, upset, or spun 16 over. 17

6. Connector module specification 18

6.1 Connector module specification introduction 19

The connector specification is a primary element of this standardIEEE Std 1505. This specific specification 20 is presented in two subsections: (a) first as a general definition describing common connector attributes and 21 requirements for meeting the standard, and (b) a second, more detailed specification unique to the 22 respective connector style or subset of the RFI system. The general and specific specifications combine to form 23 the RFI connector definition of the standard, that otherwise could not stand alone. The Table of Contents on 24 page ix describes further its outline and respective page locations. 25

This section serves the function of defining common connector application, styles, performance, dimen-26 sional, and environmental specifications for satisfying this standardIEEE Std 1505. 27

The connector/module subelement houses and electrical mates the signal paths between the automatic test 28 system (ATS) and unit-under-test (UUT), as illustrated in Figure 36. It shall also identify with many of the 29 design performance objectives defined previously. The following describes the specific dimensional and 30 parametric requirements for producing and conforming to the IEEE Std 1505. 31









1

Figure 36 —RFI IEEE Std 1505 connector module interface 2

6.2 Connector specification system 3

As tIEEE Std 1505he standard evolves, additional connector types may be qualified adopted and 4 sanctioned included to this document by the IEEE Std 1505 RFI Working Group and subsequently 5 approved by the IEEE ballot organizationprocess. IEEE Std 1505 RFI system application and use of these 6 connectors is intended to be arbitrary for the integrator and user. The RFI standards organization intends to 7 minimize connector proliferation by maintaining open architecture, generic connector type classes (signal, 8 power, low RF, high RF, etc.), and performance specifications under the subsequent clauses defined herein. 9 This serves to encourage vendors to produce the same class types that are intermatable. Where user need and 10 technology dictate alternate connector type classes, connector vendors may apply to the IEEE Std 1505 RFI 11 standards Working Ggroup for inclusion of a new connector type class and specification. 12

6.3Definitions 13

For purposes of this standard, the terms and definitions found in Clause 3 apply. The Authoritative 14 Dictionary of IEEE Standards Terms, Seventh Edition, should be referenced for terms not defined in this 15 clause. 16

6.4Conventions 17

6.4.1Order of precedence 18

Rule 6.4.1: In the event of a conflict between the text of this specification and the references cited herein 19 (except for associated detail specifications, specification sheets, or military specification standards), the text 20 of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable 21 laws and regulations unless a specific exemption has been obtained. Any change, however , to those refer-22 ences or the specification once approved shall follow the IEEE Standards Association Operational Manual, 23 to reinitiate a change to the document and subsequent ballot/approval policies (see IEEE Web site 24 www.ieee.org for current policy requirements). 25







6.56.3 Quality 1

Permission 6.35: The contractor may implement and use statistical process control (SPC) techniques in the 2 manufacturing process for parts covered by this specification. The SPC program should apply guid elines 3 specified with EIA-557. Where SPC cannot be utilized because of noncontinuous production requirements, 4 a lot-sampling plan for inspection in accordance with group A lot and sample size with c = 0 can be utilized. 5 The SPC and c = 0 programs shall be documented and maintained as part of the overall reliability assurance 6 program as specified in EIA-557. Evidence of such compliance shall be verified by the qualifying activity of 7 this specification this document as a prerequisite for qualification. 8

6.66.4 General and specific connector contact specification relationships 9

6.6.16.4.1 Specification Relationships 10

Rule 6.64.1: The individual connector type style requirements shall be as specified in the general connector 11 requirements in 6.46 and in accordance with the respective specification in Clauses 7–11. In the event of any 12 conflict between the general connector requirements in Clause 6 of this specification this document and the 13 respective connector/contact specifications in subsequent Clauses 7–11, the latter shall govern. 14

6.6.26.4.2 Selected connector footprint 15

Observation 6.46.2: The Eurocard DIN/MIL-DTL-55302 standard signal connector design, shown in 16 Figure 37 and Figure 38, was selected as the basic footprint for all IEEE 1505IEEE Std 1505 RFI connector 17 designs. It was selected because of its prequalification as a rugged, highly durable design under MIL-18 DTL-55302/179-1 80 and ―open system availability.‖ 19

20

Figure 37 —Eurocard DIN/MIL-DTL-55302 four-row signal connector 21 design specifications 22

Rule 6.46.2: The connector footprint establishes outer dimensional envelopes that shall not exceeded 23 length, width, and mounting points for UNC 2-56 screws as specified in Figure 39. 24







138.43

(5.45)

146.05

(5.75)133.35

(5.25)

2x ø 3.05

(0.12)138.43

(5.45)14.73

(0.58)

1

Figure 38 —Eurocard DIN/MIL-DTL-55302/four-row signal connector 2 design specifications 3

6.76.5 Materials 4

Rule 6.57: Manufacturer shall identify materials used. When a definite material is not specified, a material 5 shall be used that enables the connectors and accessories to meet the form, fit, function, and performance 6 requirement. Acceptance or approval of any constituent material by the buyer shall not be construed as a 7 guaranty of the acceptance of the finished product from the manufacturer. 8

6.86.6 Reference materials, platings, and processes 9

Rule 6.68a: The identified reference materials, platings, and processes described in 4.2.2 shall be used to 10 enable proper interfacing of connectors manufactured to this specification this document to similar industry 11 standard or government-specified connector systems with minimal problems related to electrochemical 12 contamination of critical electrical, mechanical interfaces, or generation of incompatible mechanical 13 interface surface-wear products. 14

Permission 6.68: The manufacturers of connectors supplied to this specification this document may use 15 alternate recognized industry standard materials, platings, and processes from those identified in 4.2.2 of 16 this specification. However, use of alternate materials, platings, and processes shall be coordinated with the 17 qualifying activity as part of the qualification process. 18

Rule 6.68b: Use of alternates to those referenced guidance items by the supplier shall not result in inferior 19 short- or long-term performance or reliability of supplied connectors as compared with connectors 20 manufactured using the referenced materials, platings, or processes. Short- or long-term failures or 21 reliability problems due to use of these alternates shall be the responsibility of the supplier. 22






6.96.7 Design and construction 1

Rule 6.79: Connectors shall be of the design, construction, and physical dimensions as specified by the 2 respective connector clause in Clauses 7–12. 3

6.9.16.7.1 Threaded parts 4

Rule 6.79.1: Unless otherwise specified, all threaded parts shall be in accordance with FED-STD-H28. 5 Where practicable, all threads shall be in conformity with the coarse-thread series. The fine-thread series 6 shall be used only for applications that might show a definite advantage through their use. 7

6.9.1.16.7.1.1 Engagement of Threaded Parts 8

Rule 6.79.1.1: All threaded parts shall engage by at least three full threads, unless otherwise specified. 9

6.106.8 Connector assembly 10

Rule 6.108: No parts of the connector assembly shall be permanently displaced from their original, normal, 11 fitted position at completion of the specified tests. 12

6.10.16.8.1 Contact compliance 13

Rule 6.108.1: The contact shall be designed for proper operation without dependence on mechanical float, 14 so that minimum force is transmitted to the connection joining the contact to the interconnecting media 15 during mating and unmating. Contacts assembled to printed circuit boards shall not move or display 16 looseness after assembly, or during and after mate and unmate cycles. 17

6.10.26.8.2 Contact cavities 18

Rule 6.108.2: The arrangement of contact cavities in the insulator body of connectors shall be as specified 19 by the respective connector clause. Each contact cavity shall be fitted with a contact assembly so confined 20 within the cavity that accidental removal is prevented, and positive alignment of the respective contacts, 21 Including the contact termination, is effected. 22

6.10.36.8.3 Contact clearance 23

Rule 6.108.3: The tops of the pins and sockets, in their uppermost position, shall be below the upper edge 24 of the pin header shroud and contact cavity wall, respectively. 25

6.10.46.8.4 Printed wiring terminations 26

Rule 6.108.4: Printed wiring terminations for both plug and receptacle shall be as specified by the 27 respective connector clause. The termination layout shall be in accordance with the printed wiring 28 requirements of MIL-STD-275, MIL-PRF-55110, IPC-D-275 and MIL-PRF-31032. 29












6.10.56.8.5 Hookup wire termination 1

Rule 6.108.5: The form factor and dimensions of wire termination contacts for those connectors shall be as 2 specified by the respective connector clause. 3

6.10.66.8.6 Contact identification 4

Rule 6.108.6: Contact positions shall be identified by legible letters, numbers, or symbols, molded or 5 stamped on the front face of the connector body adjacent to each contact and on the front and back of wire 6 type terminals or on the side where front/rear provisions are not accommodated. 7

6.10.76.8.7 Body design 8

Rule 6.810.7a: Connector bodies shall be designed and constructed with proper sections and radii to 9 provide for no cracking, chipping, or breaking in assembly or in normal service. The insulator body of each 10 plug and receptacle shall be of molded or bonded one-piece construction. Depressions, when used to achieve 11 longer creepage paths, shall not cause structural weakness. Construction shall support engagement 12 resistance without causing contact mating. 13

Rule 6.810.7b: Connector bodies shall be designed and constructed as defined by the respective 14 connector/contact requirements (see Clauses 7–12) to support contact: mounting/securing, axial concentricity, 15 axial movement tolerances, mating pre-alignment, and float tolerances during engagement/disengagement. 16 Where rear-mount printed board mounted connectors are applied, the connector housings shall be secured 17 to the printed wiring board by additional means other than the circuit solder connections. 18

6.10.86.8.8 Polarization 19

Rule 6.810.8: A polarization feature shall be incorporated in each connector housing assembly as defined by 20 the respective connector/contact requirements (see Clauses 7–12) for correct insertion and prevent mis-21 orientation, or to prevent non-mating connector engagement. 22

6.10.96.8.9 Alignment 23

Rule 6.810.9: Each IEEE 1505 RFI connector shall provide housing and contact features, as defined by the 24 respective connector/contact requirements (see Clauses 7–12) to support pre-alignment of the connector 25 housings and contacts prior to mating. 26

6.10.106.8.10 Method of mounting/connector float 27

Rule 6.810.10a: A method of mounting connectors to the IEEE 1505 receiver/fixture framework shall be 28 limited to the footprint and connector mounting dimensional provisions established by the receiver/fixture 29 framework body design specifications per 5.108.3, mounting methods described in 5.135, and by the 30 respective connector/contact requirements (see Clauses 7–12). 31

Rule 6.810.10b: Respective receiver and fixture shoulder screws as specified in Figure 39 shall be used to 32 secure the connector modules to the framework and provision 0.08mm (0.003 in.) minimum axial float for 33 alignment adjustment. 34

Rule 6.810.10c: The alignment and float of mating modules on respective connector mounting dimensional 35 locations (0.600 in. spacings), shall be sufficient to satisfy engagement force, contact electrical resistance, 36










and eliminate contact stubbing and push-outs caused by mounting/rigid connector misalignment, when 1 tested to RFI qualifications to this document requirements (see 4.6.2.3). 2


Rule 6.119: Receptacle connectors of a given type shall be capable of being mated with associated plug con-4 nectors meeting the requirements of this specification, and as defined by the respective connector/contact 5 requirements (see Clauses 7–12). The mated connectors and individual plugs and receptacles having related 6 part numbers shall be directly and completely interchangeable with each other with respect to installation 7 and performance as specified in the RFI qualification is document requirements (see 4.6.2.1). 8

9

Figure 39 —Receiver and fixture connector module mounting screw specification 10





6.126.10 Oversized pin exclusion test 1

6.12.16.10.1 Oversized pin exclusion (pins only) test 2

Rule 6.1210.1: Contact pins shall be constructed to meet the oversized pin exclusion (per 4.6.2.4) of the RFI 3 qualifications this document requirements so that contact pins do not damage mating sockets by excluding 4 entry of a pin larger than the maximum allowable pin dimensions, as further specified by Clause 6 and 5 related connector clause descriptions. 6

6.12.26.10.2 Oversized pin exclusion (sockets only) test 7

Rule 6.1210.2: The mating end of the socket contacts shall exclude the entry of a test pin larger than the 8 allowable maximum pin diameter tolerance, as defined by the respective connector/contact requirements 9 (see Clauses 7–12), in the connector when tested in accordance with RFI qualifications with this 10 document requirements (see 4.6.2.5). 11

6.12.2.16.10.2.1 Oversized pin/probe damage socket test 12

Rule 6.1210.3: When testing the socket contact in accordance with the oversized pin/probe damage socket 13 test requirement of the RFI qualifications this document requirements (see 4.6.2.5), the connector and 14 mating socket contact entry opening shall prevent an oversized pin or probe that exceeds the specified 15 tolerance of the test sample specification from entering the socket, as further related in Clause 6 and related 16 connector Clauses 7–12 descriptions. 17

6.136.11 Contact engagement and separation forces 18

Rule 6.1311: When tested as specified in the RFI qualifications this document requirements (see 4.6.2.3), 19 contact forces shall conform to the forces defined in the respective connector/contact requirements (see 20 Clauses 7–12), unless otherwise specified. The maximum contact engagement and separation force for 21 the respective pin and related pin size shall not exceed force requirements defined in Table 5, unless 22 specified otherwise by the respective connector/contact requirements (see Clauses 7–12). 23








Table 5 — Contact engagement/separation force requirements 1

Contact Type Maximum Engagement Force Maximum Separation Force

Signal Pin/Receptacle 113 g (4 oz) 99 g (3.5 oz)

Size 8 Coax Pin/Receptacle 1,361 g (36 oz) 1,134 g (30 oz)

Size 16 Coax Pin/Receptacle 680 g (24 oz) 510 g (18 oz)

Size 8 Power Pin/Receptacle 1,361 g (36 oz) 1,134 g (30 oz)

Size 16 Power Pin/Receptacle 680 g (24 oz) 510 g (18 oz)

Fiber Optic Pin/Receptacle 680 g (24 oz) 567 g (20 oz)

Pneumatic Pin/Receptacle 680 g (24 oz) 567 g (20 oz)

2

6.146.12 Connector mating and unmating 3

Rule 6.124: When tested in accordance with in RFI qualifications this document requirements (see 4.6.2.3), 4 connector module forces shall conform to the forces defined in the respective connector/contact 5 requirements (see Clauses 7–12), unless otherwise specified. The maximum fully populated connector 6 module mating and unmating forces shall be as defined by Table 6, unless specified otherwise by the 7 respective connector/contact requirements (see Clauses 7–12). 8

Table 6 —Connector engagement/separation force requirements 9

Connector Type Maximum Engagement Force Maximum Separation Force

Signal Module 22.7 kg (50 lb) 20.4 kg (45 lb)

Size 8 Universal Module, 1 Slot 22.7 kg (50 lb) 20.4 kg (45 lb)



Size 16 Coax/Power Module, 1 Slot 27.2 kg (60 lb) 22.7 kg (50 lb)



Fiber Optic Module 22.7 kg (50 lb) 20.4 kg (45 lb)

10





6.156.13 Contact rating 1

Rule 6.135: Maximum current rating of contacts shall be as specified by the respective connector/contact 2 requirements (see Clauses 7–12). 3

6.166.14 Contact resistance 4

Rule 6.146: When tested in accordance with RFI qualifications with this document requirements (see 4.6.3.1), 5 the contact resistance requirements shall be as defined by Table 7, unless specified otherwise by the 6 respective connector/contact requirements (see Clauses 7–12). 7

Table 7 —Contact resistance 8

Wire Size, AWG Type E

Per MIL-W-16878

Test

Current (A)

Maximum

Contact Resistance (m3/4)

Maximum

Potential Drop (mV)

8 to 14 7.5 5.0 37.5

16.18 5.0 8.0 40.0

20 to 22 3.0 10.0 30.0

26 2.0 14.0 28.0

28 1.5 16.0 24.0

30 1.0 20.0 20.0

6.176.15 Contact retention 9

Rule 6.157: When tested as specified in RFI qualifications in this document requirements (see 4.6.3.2), 10 unless otherwise specified, contacts shall withstand an axial load in accordance with the respective 11 connector/contact requirements (see Clauses 7–12), without damage to the contact, insert, or contact 12 retaining clip, if applicable. 13

6.186.16 Dielectric withstanding voltage 14

Rule 6.168: When tested in accordance with RFI qualifications with this document requirements (see 15 4.6.3.3), there shall be no evidence of breakdown of insulation or flashover. 16

6.196.17 Signal low-level circuit 17

Rule 6.179: When tested in accordance with RFI qualifications with this document requirements (see 4.6.3.4), 18 the contact resistance shall be in accordance with the respective connector/contact requirements (see 19 Clauses 7–12), unless otherwise specified. 20









6.206.18 Insulation resistance 1

Rule 6.2018: When tested in accordance with RFI qualifications with this document requirements (see 2 4.6.3.5), the initial connector module insulation resistance shall be not less than 5000 M3/4, unless 3 otherwise defined by the respective connector/contact requirements (see Clause 7–12). 4

6.216.19 Contact durability/cycle test 5

Rule 6.21a19a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 6 receiver and fixture connector to a durability cycle test in accordance with RFI qualifications with this 7 document requirements (see 4.6.2.7). A minimum durability cycle objective of 10,000 repetitions is 8 required, unless otherwise defined in the respective connector/contact requirements (see Clauses 7–12). 9

Rule 6.21b19b: When tested in accordance with RFI qualifications with this document requirements (see 10 4.6.2.6), connectors shall show no evidence of cracking or breaking, the contact resistance requirements 11 (see 6.19) shall not be exceeded, and mating and unmating requirements (see 6.17) shall be met. 12

6.226.20 Environmental requirements 13

Rule 6.2220: RFI connectors as further defined in shall meet the environmental tests in accordance with 14 RFI qualifications with this document requirements (see 4.6.4). 15

6.22.16.20.1 Operating temperature 16

Rule 6.2220.1: Unless otherwise defined in the respective connector/contact requirements (see Clauses 7–12), 17 connectors shall have an operating temperature of +100°C maximum and –10°C minimum in accordance 18 with RFI qualifications with this document requirements (see 4.6.4.1). 19

6.22.26.20.2 Temperature cycling 20

Rule 6.2220.2: When a mated pair of connectors undergo temperature cycle testing in accordance with RFI 21 qualification with this document requirements (see 4.6.4.2), there shall be no evidence of cracking, crazing 22 or warping of the connector body or other physical damage to the connector assembly. 23

6.22.36.20.3 Humidity 24

Rule 6.2220.3: When tested in accordance with RFI qualification with this document requirements (see 25 4.6.4.3), insulation resistance shall be greater than 1000 M3/4, unless otherwise defined in the respective 26 connector/contact requirements (see Clauses 7–12). 27

6.22.46.20.4 Metal surfaces and environmental exposure protection 28

Rule 6.2220.4: When mated connector pairs are environmentally tested in accordance with RFI 29 qualification with this document requirements (see 4.6.4.1–4.6.4.4), there shall be no peeling, chipping, or 30 blistering of metal surfaces or corrosion/rusting of exposed base metal. 31











6.22.56.20.5 Vibration 1

Rule 6.2220.5: When tested in accordance with RFI qualification with this document requirements (see 2 4.6.4.4), there shall be no physical or mechanical damage to the connector body or contacts. During vibration 3 there shall be no interruption in continuity greater than 1 µs of the test circuit that incorporates mated 4 contacts. After the vibration test, the mounting hardware shall show no signs of loosening, fracture, or other 5 deterioration. 6

6.22.66.20.6 Shock (specified pulse) 7

Rule 6.202.6: When shock tested in accordance with RFI qualifications with this document requirements 8 (see 4.6.4.5), there shall be no physical damage to the connector. During the test there shall be no 9 interruption in continuity greater than 1 µs of the test circuit that incorporates mated contacts. 10

6.22.76.20.7 Salt spray (corrosion) 11

Rule 6.2220.7: When mated connector pairs are tested in accordance with RFI qualification with this 12 document requirements (see 4.6.4.6), there shall be no peeling, chipping, or blistering of metal surfaces or 13 exposure of base metal. 14

6.22.86.20.8 Connector module solvent resistance and fluid immersion 15

Rule 6.2220.8: Mated connectors shall meet solvent/fluid immersion requirements established by RFI 16 qualification by this document requirements (see 4.6.4.7) and Method 1016 of MIL-STD-1344A. 17

6.22.96.20.9 Connector module flammability 18

Rule 6.2220.9: Mated connectors shall not exhibit flammability conditions when tested in accordance with 19 RFI qualification with this document requirements (see 4.6.4.8) and Method 1012 of MIL-STD-1344A. 20

6.236.21 Contacts supplied in reels 21

Rule 6.2321: When contacts are separated from the carrier strip, base metal may be exposed. Following 22 the salt spray test any corrosion that may occur in the region of the separation shall not interfere with the 23 ability of the contacts to meet the subsequent test requirements, either for contacts tested separately, or as 24 part of the connector, including the ability to mate or unmate the connectors. 25

6.246.22 Contact solderability 26

Rule 6.2422: Contact terminations shall withstand the test specified in RFI qualifications in this document 27 requirements (see 4.6.3.8), and MIL-STD-1344A, Method 1016. 28

6.256.23 Contact resistance to soldering heat/flammability 29

Rule 6.2523: Contacts shall withstand the test specified in RFI qualifications in this document 30 requirements (see 4.6.3.8) and MIL-STD-1344A, Method 1016. 31












6.266.24 Contact crimp tensile strength 1

Rule 6.2624: When any type contacts are tested as specified in RFI qualifications in this document 2 requirements (see 4.6.3.7), the contact-to-wire crimp shall not break nor pull out at less than the minimum 3 tensile strength specified in the respective connector/contact requirements (see Clauses 7–12) for the 4 applicable wire size. 5

6.276.25 Auxiliary parts 6

Rule 6.2725: Mechanical, nonelectrical parts, such as polarizing keys, keying accessories, covers, cable 7 clamps, etc., shall be as specified on the individual specification sheet. 8

6.286.26 Marking 9

Rule 6.2826: Connectors and accessories shall be marked in accordance with MlL-STD-1285. 10

6.296.27 Workmanship 11

Rule 6.2927: Connectors and accessories shall be processed in such a manner as to be uniform in quality 12 and shall be free from burrs, crazing, cracks, voids, pimples, chips, blisters, pinholes, sharp cutting edges, 13 and other defects that adversely affects life, serviceability, or appearance. 14

6.29.16.27.1 Riveting, upsetting, and spinning-over 15

Rule 6.2927.1: When riveting, upsetting, or spinning-over processes are employed, there shall be no 16 evidence of fatigue or deformation of noninvolved surfaces of the material being riveted, upset, or spun 17 over. 18

7. Signal module 19

7.1 Introduction 20

Clause 7 and the related Clause 6 of this standard describe specifications for developing and integrating 21 RFI signal module receptacle and pin connector assembly, (Connector Saver) Receiver Module, Contacts 22 and Accessories for: (a) four (4) row by fifty (50) pin configuration, 200 contact positions; (b) ten (10) row 23 by fifty (50) pin configuration, 500 contact positions, with DIN contact layout 2.54 mm [0.10 inch] center 24 spacing with 0.64mm [0.025 inch] square post, or 0.60mm (0.024inch) circular post, for discrete wire or 25 two-wire coaxial wiring, in vertical mount or printed wiring board (PWB) scheme. 26

7.2 General specifications 27

Rule 7.2: The RFI signal module receptacle receiver and fixture pin connector assembly shall conform to 28 the following subclauses and illustrations. These design specifications provide address connector/contact 29 physical dimensions, vertical interconnect scheme implementations, electrical and environmental perfor-30









mance specifications, and applicable PCB layout requirements. The information presented in Clause 7 is 1 not stand-alone and shall coexist with the information presented in Clause 6 and conform to the related 2 sections of Clause 4. 3

The following Figure 40 presents implementations of the RFI signal module connector pin and receptacle 4 assembly under the specifications described herein. Figures 41-45 reflect detailed dimensions required. 5

6

Figure 40 — SRFI square-post signal module connector pin and receptacle assembly 7 implementation 8




1

Figure 41 — SRFI square-post signal module receiver receptacle connector assembly 2 dimensional specifications 3

NOTE—Dimensions shown in Figure 35 41 are shown as inches with metric measurements in millimeters in 4 parentheses. 5

6

Figure 42 — SRFI square-post signal module fixture pin connector assembly dimensional 7 specifications 8




NOTE—Dimensions shown in Figure 36 42 are shown as inches with metric measurements in millimeters in 1 parentheses. 2

3

Figure 43 — CRFI circular-post signal module 500 pin connector assembly dimensional 4 specifications 5




1

Figure 44 — CRFI circular-post signal module 200 pin connector assembly dimensional 2 specifications 3




1

Figure 45 —RFI Mmixed circular-post signal and size 18 (i.e.coax/power) module connector 2 assembly dimensional specifications 3




7.2.1 Specification relationships 1

Rule 7.2.1: The individual connector-type style requirements shall be as specified within this Clause 6 and 2 in accordance with the applicable specification sheets listed in Clause 7 of this specification. In the event of 3 any conflict between the requirements of this specification this document and the specification sheets, 4 the latter shall govern. 5

7.3 Design and construction requirements 6

7.3.1 General requirements 7

Rule 7.3.1: Each connector shall meet all applicable connector specifications described in Clause 6 and the 8 related qualification requirements in Clause 4, unless otherwise specified hereafter. 9

7.3.2 Materials 10

Rule 7.3.2a: The identified reference materials, platings, and processes described in 4.2.2 shall be used to 11 enable connectors manufactured to this specification this document to mate to similar industry standard or 12 government-specified connector systems with minimal problems related to electrochemical contamination 13 of critical electrical or mechanical interfaces or generation of incompatible mechanical interface surface wear 14 products. 15

Permission 7.3.2: The manufacturers of connectors supplied to this specification this document may use 16 alternate recognized industry standard materials, platings, and processes from those identified in 4.2.2 of 17 this specification. However, use of alternate materials, platings, and processes shall be coordinated with the 18 qualifying activity as part of the qualification process. 19

Rule 7.3.2b: Use of alternates to those referenced guidance items by the supplier shall not result in inferior 20 short- or long-term performance or reliability of supplied connectors as compared with connectors 21 manufactured using the referenced materials, platings, or processes. Short- or long-term failures or reliabil-22 ity problems due to use of these alternates shall be the responsibility of the supplier. 23

7.3.3 Dimensions 24

Rule 7.3.3: Dimensions shall be shown in metric and referenced to inches in parentheses. 25

7.3.4 Tolerances 26

Rule 7.3.4: Unless otherwise specified, tolerance is 0.13 mm (0.005 in.) on decimals and ±2° on angles. 27

7.3.5 Related mating connector 28

Rule 7.3.5: Each connector described herein provides mating male (pin header), and female (receptacle) 29 connector elements specified within this clause. 30




7.3.6 Locator pin markings 1

Rule 7.3.6: Location indicators shall be marked with permanent paint or etched markings on surface. Num-2 bers indicating end cavities, letters indicating row nearest to polarizing feature, and markings every 10 3 positions stamped on this surface, in lettering orientation as shown in Figure 46. 4

Pin 50 ---------------------------------------------------------25 ----------------------------------------------------------1

Row A - B - C - D -

5

Figure 46 —Front view receiver signal module connector 200 position markings 6

7.3.7 Chamfers 7

Rule 7.3.7: Chamfers shall be 0.015mm (0.38 in.) minimum at a 45° angle (see Figure 44 and Figure 45). 8

7.3.8 Mating and unmating 9

Rule 7.3.8: The maximum mating force shall be 22.7 kg (50 lb). The maximum separation force of 20.4 kg 10 (45 lb). 11


Rule 7.3.9: Contact retention shall be 1.36 kg (3 lb) at a minimum. 13

7.3.10 Compliant pin design 14

Rule 7.3.10: Compliant pins shall meet the requirements of MIL-STD-2166, Type III. For use with 15 2.362mm (0.093 in.) minimum thick printed wiring boards. Sequence of tests and number of samples shall 16 be in accordance with MIL-STD-2166, Table III. 17

7.3.11 Wire-wrap post contact design 18

Rule 7.3.11: Wire-wrap post contacts shall be in accordance with MIL-STD-1130. 19

7.4 Electrical specifications 20

7.4.1 Current rating 21

Rule 7.4.1: Current rating of the pin shall be based upon amperes continuous per contact at ambient room 22 temperature with no more than two adjacent contacts carrying this current without exceeding a 10° Celsius 23 rise in temperature surrounding the contacts. See Table 8 for related wire gauge conditions/current rating. 24





Rule 7.4.2: No individual contact pair shall have a resistance exceeding maximum level after testing, as 2 described Table 9 for related wire gauge conditions/contact signal pin. 3

7.4.3 Contact dielectric withstanding voltage 4

Rule 7.4.3: Contact dielectric withstanding voltage shall be as follows: 5

At sea level: 900 V rms 6

At 21,336 m (70,000 ft): 200 V rms 7

Maximum leakage current: 2 mA 8

Table 8 —Signal contact current rating 9

Wire Size, AWG

Type E per MIL-W-16878

Max Current (A) continuous

at room temperature

20 5.0

22 3.0

24 2.0

26 1.5

28 1.0

30 0.75

10

Table 9 —Signal contact resistance 11

Wire Size, AWG

Type E Per

MIL-W-16878

Test Current

(mA)

Maximum

Contact Resistance

(m3/4)

Maximum

Voltage Drop

(mV)

20 100 9 9.0

22 100 15 15.0

24 100 20 20.0

26 100 24 25.0

28 100 40 40.0

30 100 50 50.0

12






Rule 7.5.1: Examination shall be made to determine compliance with 4.5. 3

7.5.1.1 Interchangeability 4

Rule 7.5.1.1: Physical configuration and dimensional measurements shall meet the requirements of 4.6.2.1, 5 and as specified in the related supplemental paragraphs. 6

7.5.2 Oversized signal pin exclusion 7

Rule 7.5.2: The applicable steel pin, shown in Figure 47, for the signal pin size contacts to be tested shall 8 be applied to the sockets of the connector for a period of 10 seconds without the pin causing damage when 9 entering the socket. A minimum of seven contacts shall be measured on each specimen. 10

11

Figure 47 —Signal socket test pin gauge 12


Rule 7.5.3: Sockets (contacts) shall be mounted in a suitable position or fixture (see Figure 48 and 14 Figure 49) for applying gradually increasing loads for the engagement and separation of the test pin from 15 the sockets (contacts). Maximum and minimum test pins shall be in accordance with MS3197. Insertion of 16 test pins shall be to a minimum depth of 3.556 mm (0.140 ±.020 in.) when measured from the front of the 17 socket contact. The test pin shall not bottom in the socket contact. This test shall be performed in the sequence 18 as specified in Method 2014 of MIL-STD-1344A. 19

20

Figure 48 —Stabilizing arrangement 21




1

Figure 49 —Bolts and standoffs 2


Rule 7.5.4: After three cycles of insertion and withdrawal, the force required to fully insert and withdraw a 4 plug from the receptacle shall be measured. Each plug and receptacle so mated shall be considered as 5 one test specimen where further testing of the plug or receptacle is indicated. The measuring equipment 6 shall conform to the following. 7

a) Rule 7.5.4a: The axis of insertion of the pin contacts and mating receptacle contacts or hermaphro-8 ditic contacts as applicable shall coincide during insertion and withdrawal. 9

b) Rule 7.5.4b: The speed of insertion of the plug into the receptacle contacts shall not exceed 10 10 cycles per minute for constant speed machines, or the rate of loading shall not exceed 36.3 kg 11 (80 lb) per minute for constant-rate-of-force machines. 12

c) Rule 7.5.4c: Scale mechanisms shall have no dashpots or other damping devices. 13

d) Rule 7.5.4.d: Scales shall be calibrated in 0.057 kg (2 oz) steps or less, and shall be accurate to 14 within 0.057 kg (2 oz). 15


Table 10 —Signal contact engagement and separation force test requirements 18

Signal Contact Tolerance

Signal Pin Standard Diameter 0.635 mm (0.025 in.) ±0.025 mm (0.00 1 in.)

Maximum Engagement Force 113 g (4 oz) ±2.8 g (0.1 oz)

Maximum Separation Force 99 g (3.5 oz) ±2.8 g (0.1 oz) 19


Rule 7.6.5a: To meet IEEE Std 1505this document requirements, each manufacturer shall subject the 21 test specimen receiver and fixture connector to a durability cycle test in accordance with 4.6.2.7. A 22




minimum durability cycle objective of 10,000 repetitions is required, unless otherwise defined in the 1 respective connector! contact requirements (see Clauses 7–12). 2

Rule 7.6.5b: When tested in accordance with RFI qualifications with this document requirements (see 3 4.6.2.6), connectors shall show no evidence of cracking or breaking, the contact resistance requirements 4 (see 6.19) shall not be exceeded, and mating and unmating requirements (see 6.17) shall be met. 5

8. Power size 8 and 16 connector module(s) 6

8.1 Introduction 7

Clause 8 and the related Clause 6 of this standard document describe specifications for developing and 8 integrating RFI power size 8 and 16 module connector, receptacle, and pin assembly, connector saver, 9 contacts, and accessories for multiple module configurations including: 10

a) Mixed size 8 and !16 power module single slot with 45 positions of 23 A contacts in three rows and 11 four positions of 45 A contacts with two on each end of the connector 12

b) Size 16 power module single slot with 59 positions of 23 A contacts in three rows 13

c) c) Size 16 power module dual slot with 152 positions of 23 A contacts in eight rows 14

NOTE—Size 16 connector saver power module four-slot assembly with 307 positions of 23 A contacts in 17 rows, 15 which support discrete wiring and printed wiring board (PCB) applications. 16


Rule 8.2: The RFI power module receptacle receiver and fixture pin connector assemblies described herein 18 shall conform to the following subclauses and illustrations. These design specifications provided address 19 connector/contact physical dimensions, vertical interconnect scheme implementations, electrical and envi-20 ronmental performance specifications, and applicable PCB layout requirements. The information presented 21 in Clause 8 is not stand-alone and shall coexist with the information presented in Clause 6 and conform to 22 the related requirements in Clause 4. 23

The following Figure 50 presents implementations of the RFI signalpower module connector pin and 24 receptacle assembly under the specifications described herein. Figures 51-56 reflect detailed dimensions 25 required. 26

Formatted: Font color: Auto




1

Figure 50 — PRFI power module receiver and fixture assembly 2


Rule 8.2.1: The individual connector type style requirements shall be as specified within this standard and in 4 accordance with the applicable specification sheets listed in this clause. In the event of any conflict between 5 the requirements of this specification this document and the specification sheets, the latter shall govern. 6



Rule 8.3.1: Each connector, as shown in Figures 51-56, shall meet all applicable connector specifications 9 described in Clause 6 and the related qualification requirements in Clause 4, unless otherwise specified 10 hereafter. 11

8.3.2 Materials 12


18




Permission 8.3.2: The manufacturers of connectors supplied to this specification this document may use 1 alternate recognized industry standard materials, platings, and processes from those identified in 4.2.2 of this 2 specification. However, use of alternate materials, platings, and processes shall be coordinated with the 3 qualifying activity as part of the qualification process. 4

Rule 8.3.2b: Use of alternates to those referenced guidance items by the supplier shall not result in inferior 5 short- or long-term performance or reliability of supplied connectors as compared with connectors 6 manufactured using the referenced materials, platings, or processes. Short- or long-term failures or 7 reliability problems due to use of these alternates shall be the responsibility of the supplier. 8

8.3.3 Dimensions 9


8.3.4 Tolerances 11




131.166 (5.164)

146.05 (5.75)

119.507 (4.705)

106.502 (4.193)

28.727

(1.131) 21.973

(.858)18.593

(.733)

14.732

(.580)

31.902

(1.256)

3.81 (.15)

3.175

(.125)

16

Figure 51 —RFI Mmixed power module, 45-23 A/4-45 A position-rating, 17 receiver housing physical layout 18




1

Figure 52 — —RFI Mmixed power module, 45-23 A/4-45 A position-rating, 2 fixture housing physical layout 3




1

Figure 53 —Power module, 59 position for 23 A contact, receiver housing 2 physical layout 3

4

Figure 54 —Power module, 59 position for 23 A contact, fixture housing 5 physical layout 6




1

Figure 55 —Power module, 2 slot, 152 position for 23 A contact, receiver housing 2 physical layout 3

4

Figure 56 —Power module, 2 slot, 152 position for 23 A contact, fixture housing 5 physical layout 6





Rule 8.3.6: Location indicators shall be marked with permanent paint or etched markings on surface. Num-2 bers indicating end cavities, letters indicating row nearest to polarizing feature, and markings at each posi-3 tion shall be stamped or permanently labeled on this surface. 4

8.3.7 Chamfers 5

Rule 8.3.7: Chamfers shall be 0.38 mm (0.015 in.) minimum at a 45° angle (see Figures 51-56). 6

8.3.8 Keying 7

Permission 8.3.8: Two keys, Part or Identifying Number (PIU) MS5530Z/31-04, and two .086-56 UNC-8 2A mounting screws may be applied. 9

8.3.9 Jackscrews 10

Permission 8.3.9: Use M55302/182-1 1, -12, -13, -14, -15, or -16. Jackscrews may be applied. 11


Rule 8.3.10: Contact retention shall be 4.5 kg (10 lb at a minimum. 13

8.3.11 Connector part or identifying number 14

Rule 8.3.11: Suffix to any manufacturing part number shall include the respective connector Clause 8 spec-15 ification RFI.2. 1 .A. Example: 555302/RFI.8.3. 16

8.4 Electrical specifications for 23 A power contact 17


Rule 8.4.1: Current rating of the pin, as described in Figure 57, shall be 23.0 A maximum per contact in 19 free air, and 18.0 A continuous per contact with no more than six adjacent contacts carrying this current 20 when applied to 14AWG stranded wire and not exceed a 10° Celsius temperature rise from ambient. 21


Rule 8.4.2: No individual contact pair shall have a resistance exceeding 4 mΩ% initial and 5 mΩ% after 23 testing. 24







At 21,336 m (70,000 ft): 200 V rms 2



Rule 8.4.4: The maximum mating/unmating force in kilograms (pounds) shall be the number of contacts 5 multiplied by 680 g (24 oz) for connector engagement force and 510 g (18 oz) for separation force. 6

7

Figure 57 —Power receiver/fixture size 16, 23 A contact, physical layout 8

8.5 Electrical specifications for 45þA power contact 9


Rule 8.5.1: Current rating of the pin, as described in Figure 58, shall be 45.0 A maximum per contact and 11 40 A continuous per contact at room ambient with no more than one adjacent contacts carrying this current, 12 when applied to 8AWG stranded wire and not exceed a 10° Celsius temperature rise from ambient. 13


Rule 8.5.2: No individual contact pair shall have a resistance exceeding 3 mΩ% initially and 5 m%Ω after 15 testing. 16







At 21,336 m (70,000 ft): 200 V rms 4



Rule 8.5.4: The maximum mating/unmating force in kilograms (pounds) shall be the number of contacts 7 multiplied by 1,361 g (36 oz) for connector engagement force and 1,134 g (30 oz) for separation force. 8

9

Figure 58 —Power receiver/fixture size 8, 45 A contact, physical layout 10






Rule 8.6.1: Examination shall be made to determine compliance with 4.5. 3


Rule 8.6.1.1: Physical configuration and dimensional measurements shall meet the requirements of 4.6.2.1, 5 and as specified in the related supplemental paragraphs. 6

8.6.2 Oversized signal pin exclusion 7

Rule 8.6.2: The applicable steel pin, shown in Figure 59, for the signal pin size contacts to be tested, shall 8 be applied to the sockets of the connector for a period of 10 seconds without the pin causing damage when 9 entering the socket. A minimum of seven contacts shall be measured on each specimen. 10

“A” Dia

0.914 + 0.13

(.360 + .005)

• �

!

"

Pin

Pin; Tool Steel, Harden and Draw To Rockwell C50-55.

Handle; Shape Optional, Size To Be Determined by Speci!ed Total Weight.

“A” DIA Applied Force Contact

+0.03 (.001) kg (lbs) Size

1.65 (.065) 0.907 (2.0) 16

3.25 (.128) 1.814 (4.0) 8

!HandleFull

Radius##

11

Figure 59 —Signal socket test pin gauge 12


Rule 8.6.3: Sockets (contacts) shall be mounted in a suitable position or fixture for applying gradually 14 increasing loads for the engagement and separation of the test pin from the sockets (contacts). Maximum 15 and minimum test pins shall be in accordance with MS3 197. Insertion of test pins shall be to a minimum 16 depth of 5.08 mm ±0.508 mm (0.200 in. ±0.020 in.) when measured from the front of the socket contact. 17 The test pin shall not bottom in the socket contact. This test shall be performed in the sequence as specified 18 in Method 2014 of MIL-STD-1344A. 19


Rule 8.6.4: After three cycles of insertion and withdrawal, the force required to fully insert and withdraw a 21 plug from the receptacle shall be measured and conform to the requirements listed in Table 11. Each plug 22 and receptacle so mated shall be considered as one test specimen where further testing of the plug or recep -23 tacle is indicated. The measuring equipment shall conform to the following rules: 24







d) Rule 8.6.4d: Scales shall be calibrated in 0.057 kg (2 oz) steps or less and shall be accurate to 5 within 0.057 kg (2 oz). 6

Table 11 —Power contact size, engagement, and separation force test requirements 7

Contact Size Pin Maximum

Diameter mm (in.) Tolerance

Engagement

Max Force kg (lbs)

Separation

Max Force kg (lbs)

8 3.25 (0.128) ± 0.0762 (0.003) 1361 g (36 oz) 1134 g (30 oz)

16 1.65 (0.065) ±0.0254 (0.001) 680 g (24 oz) 113 g (18 oz)

8

NOTE—When mating and unmating tests are required by another test such as contact life, the preconditioning cycles are 9 not required. 10


Rule 8.6.5a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 12 receiver and fixture connector to a durability cycle test in accordance with 4.6.2.7. A minimum durability 13 cycle objective of 10,000 repetitions is required, unless otherwise defined in the respective connector/contact 14 requirements (see Clauses 7–12). 15


9. Coax size 16 connector module(s) 19

9.1 Introduction 20

Clause 9 and the related Clause 6 of this standard describe specifications for developing and integrating RFI 21 coax size 16 module connector, receptacle and pin assembly, connector saver, contacts and accessories for 22 multiple module configurations including: 23

a) Size 16 coax module single slot with 59 positions of 5 GHz contacts in three rows 24

b) Size 16 coax module dual slot with 152 positions of 3 GHz or 5 GHz contacts in eight rows 25

NOTE—Size 16 connector saver coax module four-slot assembly with 307 positions of 3 GHz or 5 GHz contacts in 17 26 rows, which support discrete wiring and printed wiring board (PCB) applications 27


Rule 9.2: The RFI Coax Module Receptacle Receiver and Fixture Pin Connector Assemblies described 29 herein shall conform to the following subclauses and illustrations. These design specifications provided 30




address connector/contact physical dimensions, vertical interconnect scheme implementations, electrical 1 and environmental performance specifications, and applicable PCB layout requirements. The information 2 presented in Clause 9 is not stand-alone and shall coexist with the information presented in Clause 6 and 3 conform to the related qualification to this document requirements in Clause 4. 4

The following Figure 60 presents implementations of the RFI signalcoax module connector pin and 5 receptacle assembly under the specifications described herein. Figures 61-64 reflect detailed dimensions 6 required. 7

8

Figure 60 — CRFI coax module receiver and fixture assembly implementation 9


Rule 9.2.1: The individual connector-type style requirements shall be as specified within this standard and 11 in accordance with the applicable specification sheets, listed in Clause 9 of this specification. In the event 12 of any conflict between this document e requirements of this specification and the specification sheets, the 13 latter shall govern. 14



Rule 9.3.1: Each connector module and related contact, as described in Figures 61-64, shall meet all 17 applicable connector specifications described in Clause 6, and the related qualification requirements in 18 Clause 4 unless otherwise specified hereafter. 19




9.3.2 Materials 1



Rule 9.3.2b: Use of alternates to those referenced guidance items by the supplier shall not result in inferior 11 short- or long-term performance or reliability of supplied connectors as compared with connectors 12 manufactured using the referenced materials, platings, or processes. Short- or long-term failures or reliability 13 problems due to use of these alternates shall be the responsibility of the supplier. 14

9.3.3 Dimensions 15

Rule 9.3.3: Dimensions shall be in metric and referenced to inches where applicable. 16

9.3.4 Tolerances 17







1

Figure 61 —Coax module, 59 position for 5 GHz contact, 2 receiver housing physical layout 3

4

Figure 62 —Coax module, 59 position for 5 GHz contact, fixture 5 housing physical layout 6




1

Figure 63 —Coax module, 2 slot, 152 position for 5 GHz contact, fixture 2 housing physical layout 3




1

Figure 64 —Coax module, 2 slot, 152 position for 5 GHz contact, 2 receiver housing physical layout 3


Rule 9.3.6: Location indicators shall be marked with permanent paint or etched markings on surface. 5 Numbers indicating end cavities, letters indicating row nearest to polarizing feature, and markings at each 6 position shall be stamped or permanently labeled on this surface. 7

9.3.7 Chamfers 8

Rule 9.3.7: Chamfers shall be 0.38 mm (0.015 in.) minimum at a 45° angle (see Figures 61-64). 9

9.3.8 Keying 10


9.3.9 Jackscrews 13

Permission 9.3.9: Use M55302/182-1 1, -12, -13, -14, -15, or -16. Jackscrews may be applied. 14







Rule 9.3.11: Suffix to any manufacturing part number shall include the respective connector specification 2 from Clause 7, 8, 9, 10, 11, or 12. Example: 555302/RFI.9.3. 3

9.4 Coax 5 GHz contact electrical specifications 4

9.4.1 General 5

Rule 9.4.1: The coax 5 GHz size 16 contact shall meet the following specifications described in Table 12 6 and physical dimensions illustrated in Figure 65 and Figure 66. Deviations from these definitions shall be 7 noted by the vendor. 8

Table 12 —Coax receiver/fixture size 16 contact specifications 9

Frequency range DC to 5 GHz

Bandwidth loss <0.1dB @ 2 GHz

RF leakage (mated pair) 0.1dB @ 2 GHz

Crosstalk >65dB @ 100 MHz >60dB @ 500 MHz

>55dB @ 1.3 GHz

VSWR (mated pair) <1.15:1 @ 2 GHz

Characteristic impedance 50Ω

Insulation resistance > 5000 MΩ

Dielectric withstanding voltage 750 V

Contact resistance Initial After environmental test

Center contact (mΩ) 3.5 4.2

Outer contact (mΩ) 0.45 0.6

Voltage rating 500 V

Rise time degradation (corrected for board effects) at 300 ps 6 ps

Difference in propagration delay between shortest and longest line 26 ps

Near end crosstalk at 300 ps 0.2%

Mechanical:

Typical engagement force Typical disengagement force

680 g (24 oz) nominal 510 g (18 oz)

nominal

Temperature range –25°C to + 125°C

Material:

Bodies

Insulators Spring tabs

Brass or bronze PTFE

Beryllium copper

Plating Gold plated for contact zone

10




1

Figure 65 —Coax receiver size 16 contact, physical layout 2

3

Figure 66 —Coax receiver size 16 contact, physical layout 4




9.5 Coax 3 GHz contact electrical specifications 1

9.5.1 General 2

Rule 9.5.1: The coax 3 GHz size 16 contact shall meet the following specifications described in Table 13 3 and physical dimensions illustrated in Figure 67 and Figure 68. Deviations from these definitions shall be 4 noted by the vendor. 5

6

Figure 67 —Coax fixture size 16 contact, physical layout 7




Table 13 —Coax receiver/fixture size 16 contact, 3 GHz specifications 1

Frequency range DC to 3 GHz

Bandwidth loss <0.1 dB @ 2 GHz

RF leakage (mated pair) 0.1 dB @ 2 GHz

Crosstalk >65 dB @ 100 MHz >60 dB @ 500 MHz >55 dB @ 1.3 GHz

VSWR (mated pair) <1.15:1 @ 2 GHz;

Characteristic impedance 50 Ω

Insulation resistance > 5000 MΩ

Dielectric withstanding voltage 750 V

Contact resistance

Center contact (mΩ) Outer contact (mΩ)

Initial After environmental test

3.5 4.2

0.45 0.6

Voltage rating 500 V

Rise time degradation

(corrected for board effects) at 300 ps 6 ps

Difference in propagation delay between shortest

and longest line 26 ps

Near end crosstalk at 300 ps 0.2%

Mechanical:

Typical engagement force Typical disengagement

force

680 g (24 oz) nominal 567 g (20 oz) nominal

Temperature range –25°C to +125°C

Material:

Bodies

Insulators Spring tabs

Brass or bronze PTFE

Beryllium copper

Plating Gold plated for contact zone

2




1

Figure 68 —Coax fixture size 16 contact, physical layout 2



Rule 9.6.1: Examination shall be made to determine compliance with 4.5 in the RFI qualifications this 5 document requirements. 6


Rule 9.6.1.1: Physical configuration and dimensional measurements shall meet the requirements of 4.6.2.1, 8 and as specified in the related specification supplemental paragraphs. 9

9.6.2 Contact pin size, engagement and separation force measurement 10

Rule 9.6.2: Sockets (contacts) shall be mounted in a suitable position or fixture for applying gradually 11 increasing loads for the engagement and separation of the test pin from the sockets (contacts). Maximum 12 and minimum size test pins as specified in Table 14 shall be in accordance with MS3 197. Insertion of test 13 pins shall be to a minimum depth of 2.54 ±0.508 mm (0.100 ±0.020 in.) when measured from the front of the 14 socket contact. The test pin shall not bottom in the socket contact. This test shall be performed in the 15 sequence as specified in method 2014 of MIL-STD-1344A. 16


Rule 9.6.3: After three cycles of insertion and withdrawal, the force required to fully insert and withdraw a 18 plug from the receptacle shall be measured and conform to the requirements listed in Table 14. Each plug 19




and receptacle so mated shall be considered as one test specimen where further testing of the plug or recep-1 tacle is indicated. The measuring equipment shall conform to the following rules: 2




d) Rule 9.6.3d: Scales shall be calibrated in 57 g (2 oz) steps or less, and shall be accurate to within 9 57 g (2 oz). 10


Table 14 —Coax contact size, engagement, and separation force test requirements 13 14

Contact

Size

Pin Diameter

mm (in.) Tolerance Engagement Max Force Separation Max Force

16 1.65mm (.065in.) +0.0254 mm (.001 in.) 680 g (24 oz) 510 g (18 oz) 15


Rule 9.6.4a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 17 receiver and fixture connector to a durability cycle test in accordance with 4.6.2.7. A minimum durability 18 cycle objective of 10,000 repetitions is required, unless otherwise defined in the respective connector/contact 19 requirements (see Clauses 7–12). 20

Rule 9.6.4b: When tested in accordance with the RFI qualifications this document requirements (see 21 4.6.2.6), connectors shall show no evidence of cracking or breaking, the contact resistance requirements 22 (see 6.19) shall not be exceeded, and mating and unmating requirements (see 6.17) shall be met. 23

10. MRFI mixed power connector module, 28-10 A and 16-20 A positions 24

10.1 Introduction 25

Clause 10 and the related Clause 6 of this standard describe specifications for developing and integrating 26 RFI mixed power module connector, receptacle, and pin assembly; contacts and accessories with mixed con-27 figuration of 28 positions, 10A contacts in three rows; and 16 positions, 20A contacts in two rows that support 28 discrete wiring applications. 29


Rule 10.2: The following subclauses and illustrations describe general specifications for the RFI mixed 31 power module connector, receptacle, and pin assembly. The information presented in Clause 10 is not 32




standalone and shall coexist with that presented in Clause 6 and conform to the related qualification to this 1 document requirements in Clause 4. 2

The design and physical layout of the RFI mixed power module connector, receptacle, and pin assembly are 3 shown in Figure 69 and Figure 70. The design and physical layout of the RFI mixed power module contacts 4 are shown in Figure 71 and Figure 72. 5

SECTION A-A

SCALE 2 : 1

SECTION B-B

SCALE 2 : 1

A A

B B

n 2.06 mm [0.081 in]

n 1.83 mm [0.072 in]

OPTIONAL

2.06 mm[0.081 in]

5.5

9m

m[0

.220

in]

5.27 mm[0.208 in]

LEAD-IN

OPTIONAL

n 4.24 mm [0.167 in]

OPTIONAL

n 4.65 mm

[0.183 in]

3.4

9m

m[0

.138

in]

11.3

3m

m[0

.446

in]

3.1

8m

m[0

.125

in]

3.1

8m

m[0

.12

5in

]

138.4

3m

m[5

.45

0in

]3

.81

mm

[0.1

50

in]

5.8

4m

m[0

.230

in]

126.7

5m

m[4

.99

0in

]

14.73 mm [0.580 in]

7.37 mm [0.290 in]

1.98 mm [0.078 in]

3.96 mm [0.156 in]3.05mm [0.120in] THRU

v 5.08mm [0.200in] x 1.52mm [0.060in]

7S

PS

@1

0.2

6m

m[0

.404

in]

5.1

3m

m[0

.202

in]

2.1

8m

m[0

.086

in]

9SP

S@

4.3

7m

m[0

.172in

]

11.43 mm [0.450 in]

5.72 mm [0.225 in]

7.62 mm [0.300 in]

3.81 mm [0.150 in]

13

3.3

5m

m[5

.250

in]

3.18 mm [0.125 in]

10.16 mm [0.400 in]

22.67 mm [0.893 in]

6

Figure 69 —MRFI mixed power module connector, 28-10 A/1 6-20 A position, 7 receiver housing physical layout 8




SECTION A-A

SCALE 2 : 1

SECTION B-B

SCALE 2 : 1

A A

B B

7.37 mm [0.290 in]

14.73 mm [0.580 in]

3.05mm [0.120in] THRU

v 5.08mm [0.200in] x 0.79mm [0.031in]

138.4

3m

m[5

.450

in]

3.8

1m

m[0

.150

in]

132.5

9m

m[5

.220

in]

6.7

3m

m[0

.265

in]

n 2.08 mm [0.082 in]

n 2.92 mm [0.115 in]

n 2.92 mm [0.115 in]

6.3

5m

m[0

.250

in]

7.6

2m

m[0

.300

in]

0.9

9m

m[0

.039

in]

11.7

3m

m[0

.462

in]

11.73 mm[0.462 in]

133.3

5m

m[5

.250

in]

ARBITRARY2.2

1m

m[0

.087

in]

11.7

3m

m[0

.462

in]

6.7

3m

m[0

.265

in]

9.0

2m

m[0

.355

in]

n 6.10 mm [0.240 in]

n 4.60 mm [0.181 in]

n 6.10 mm

[0.240 in]

2.9

2m

m[0

.115

in]

12.95 mm [0.510 in]

6.48 mm [0.255 in]

2.1

8m

m[0

.086

in]

9SPS

@4.3

7m

m[0

.172in

]

2.1

8m

m[0

.086

in]

7.62 mm [0.300 in]

3.81 mm [0.150 in]

7SPS

@10.2

6m

m[0

.404in

]

5.1

3m

m[0

.202

in]

3.96 mm [0.156 in]

1.98 mm [0.078 in]

R0.76 mm [0.030 in] 4X

1

Figure 70 —MRFI mixed power module connector, 28-10 A/1 6-20 A position, 2 fixture housing physical layout 3

4

Figure 71 —RFI Mmixed power module connector, 28-10 A/1 6-20 A position, 5 receiver receptacle contact 6




1

Figure 72 —MRFI mixed power module connector, 28-10 A/1 6-20 A position, 2 fixture pin contact 3



Rule 10.3.1: Each connector shall meet all applicable connector specifications described in 6.6 and related 6 qualifications, unless otherwise specified hereafter. 7

10.3.2 Materials 8


Permission 10.3.2: The manufacturers of connectors supplied to this specification this document may use 14 alternate recognized industry standard materials, platings, and processes from those identified in 4.2.2 of 15 this specification. However, use of alternate materials, platings, and processes shall be coordinated with the 16 qualifying activity as part of the qualification process. 17


10.3.3 Dimensions 22

Rule 10.3.3: Dimensions are shown in metric and referenced to inches in parentheses per Figures 68-72 23

10.3.4 Tolerances 24






Rule 10.3.5: These connectors shall mate as a mating set only with connector assemblies and contacts 2 defined within this specific clause. 3



10.3.7 Chamfers 8

Rule 10.3.7: Chamfers shall be 0.38 mm (.015 in.) minimum at a 45° angle (see Figures 68-72). 9

10.3.8 Keying 10



Rule 10.3.9: The maximum mating/unmating force shall be the number of contacts multiplied by: 14

a) For 10 A contact, the engagement force of 680 g (24 oz), and the separation force of 510 g (18 oz) 15

b) For 20 A contact, the engagement force of 1,361 g (36 oz), and the separation force of 1,134 g 16 (30 oz) 17



10.3.11 Wire-wrap post and contact design 20

Rule 10.3.11 Wire-wrap post and contacts shall be in accordance with MIL-STD-1130. 21


Rule 10.3.12: Suffix to any manufacturing part number shall include the respective connector Clause 10 23 specification. Example: 555302/RFI 10.3. 24





10.4.1 Current rating 10/20 A contact 2

Rule 10.4.1: Current rating of the contacts shall be at a maximum of 10.0 A and 20.0 A respectively per 3 contact and 2.25 A and 10.0 A continuous per contact at room ambient with no more than two adjacent contacts 4 carrying this current without exceeding a 10° Celsius rise in temperature surrounding the contacts. 5


Rule 10.4.2: No individual contact pair shall have a resistance exceeding 8 m%Ω initially and 10 m%Ω 7 after testing. 8




At 21,336 m (70,000 ft): 200 V rms 12



Rule 10.4.4a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 15 receiver and fixture connector to a durability cycle test in accordance with 4.6.2.7. A minimum durability 16 cycle objective of 10,000 repetitions is required, unless otherwise defined in the respective connector/con-17 tact requirements (see Clause 7–12). 18


11. Universal size 8 connector D-Sub compatible module, 24 position 22


Clause 11 and the related Clause 6 in this standard describe specifications for developing and integrating 24 RFI uuniversal ssize 8 D-Sub compatible module connector, receptacle and pin assembly, contacts and 25 accessories with 24 positions, in two staggered rows that support mixed coaxial, power, pneumatic, or fiber 26 discrete wiring applications. 27


The following subsections and illustrations describes general specifications for the uRFI universal ssize 8 29 D-Sub compatible module connector, receptacle and pin assembly. 30





Rule 11.2: The information presented in Clause 11 is not stand-alone and shall coexist with that presented 1 in Clause 6 and conform to the related qualification to this document requirements in Clause 4. 2

The design and physical layout of the RFI uuniversal ssize 8 D-Sub compatible module connector, receptacle, 3 and pin assembly are shown in Figure 73 and Figure 74. 4

5

Figure 73 —URFI universal ssize 8 D-Sub compatible module connector, 24 position, 6 receiver housing physical layout 7




1

Figure 74 —RFI uUniversal ssize 8 D-Sub compatible module connector, 24 position, 2 fixture housing physical layout 3



Rule 11.3.1: Each connector shall meet all applicable connector specifications described in 6.6, Figure 73, 6 Figure 74, and related qualifications, unless otherwise specified hereafter. 7

11.3.2 Materials 8


Permission 11.3.2: The manufacturers of connectors supplied to this specification this document may use 14 alternate recognized industry standard materials, platings, and processes from those identified in 4.2.2 of 15




this specification. However, use of alternate materials, platings, and processes shall be coordinated with the 1 qualifying activity as part of the qualification process. 2


11.3.3 Dimensions 7

Rule 11.3.3: Dimensions shall be in inches and referenced to (metric) per Figure 73 and Figure 74, and in 8 accordance with applicable MIL-C-24308. 9


Rule 11.3.4: Unless otherwise specified, tolerance shall be 0.13 mm (0.005 in.) on decimals and ±2° on 11 angles. 12


Rule 11.3.5: These connectors shall mate as a mating set only with connector assemblies and contacts 14 defined within this specific standard. 15



11.3.7 Chamfers 20

Rule 11.3.7: Chamfers shall be 0.38 mm (0.015 in.) minimum at a 45° angle (see Figure 73 and Figure 74). 21

11.3.8 Keying 22





Rule 11.3.10: Suffix to any manufacturing part number shall include the respective connector Clause 11 28 specification. Example: 555302/RFI 11.3 29




11.3.11 Electrical specifications 1

11.3.11.1 Contact resistance 2

Rule 11.3.11.1a: No individual coax contact shall have a resistance exceeding 5 m%Ω for center contact 3 and 3 m%Ω for outer contact; and 8 m%Ω and 10 m%Ω after testing. 4

Rule 11.3.11.1b: No individual power contact shall have a resistance exceeding 3 m%Ω for contact; and 8 m%Ω 5 after testing. 6

11.3.11.2 Contact dielectric withstanding voltage 7

Rule 11.3.11.2: Contact dielectric withstanding voltage shall be as shown in the following table. 8

At Sea Level At 21,336 m (70,000 ft) Maximum Leakage Current

RG-402/U Cable

3.58 mm (0.141 in) O.D.) 500 V rms at 60 Hz 125 V rms 2 mA

RG-405/U Cable

(2.18 mm (0.086 in) O.D.) 335 volts rms at 60 Hz 85 V rms at 60 Hz 2 mA

9

11.3.11.3 Coax contact impedance/insulation resistance 10

Rule 11.3.11.3: Coax contact shall maintain a 50 ~ nominal impedance and insulation resistance of 5000 ~ 11 minimum. 12

11.3.11.4 Coax contact frequency bandwidth/standing wave ratio (SWR) 13

Rule 11.3.11.4: Coax contact shall provide a 0 GHz to 40.0 GHz frequency bandwidth and voltage 14 standing wave ratio from 20.0 GHz for straight connector using semi-rigid or RG-402/U or FLL cable or 15 FLL cable: 1.15 GHz +.02F GHz on RG-316 cable and straight connector: 1.15 GHz +.01F GHz on 3.58 mm 16 (0.141 in.) diameter semi-rigid cable. 17

11.3.12 Environmental 18

Rule 11.4.3.12: Contact shall meet environmental requirements: 19

Operating Temperature: –55°C to +125°C 20

Vibration: MIL-STD-202, Method 204, Test Condition D 21

Shock: MIL-STD-202, Method 213, Test Condition I 22

Corrosion Resistance: MIL-STD-202, Method 101, Condition B 23

Formatted: Font color: Auto





Rule 11.3.13: Examination shall be made to determine compliance with the RFI qualifications this 2 document requirements in 4.5. 3


Rule 11.3.14: Physical configuration and dimensional measurements shall meet the requirements of 4.6.2.1 5 and those specified in the related specification requirements. 6

11.3.15 Contact pin size, engagement, and separation force measurement 7

Rule 11.3.15: Sockets (contacts) shall be mounted in a suitable position or fixture for applying gradually 8 increasing loads for the engagement and separation of the certified test pin from the sockets (contacts). 9 Maximum and minimum size test pins as specified in Table 15 shall be in accordance with MS3 197. 10 Insertion of test pins shall be to a minimum depth of 2.54 mm (0.100 in.) ±0.5 mm (0.020 in.) when measured 11 from the front of the socket contact. The test pin shall not bottom in the socket contact. This test shall be 12 performed in the sequence as specified in Method 2014 of MIL-STD-1344A. 13

Table 15 —Coax contact size, engagement, and separation force test requirements 14 15

Contact Size Pin Diameter Pin Tolerance Engagement Max

Force

Separation Max

Force

8 5.72 mm (0.225 in.) ±0.076 mm (0.003 in.) 1.36 kg (3.0 lb) 1.13 kg (2.5 lb) 16


Rule 11.3.16: After three cycles of insertion and withdrawal, the force required to fully insert and withdraw 18 a plug from the receptacle shall be measured and conform to the requirements listed in Table 15. Each plug 19 and receptacle so mated shall be considered as one test specimen where further testing of the plug or recep-20 tacle is indicated. The measuring equipment shall conform to the following rules: 21

a) Rule 11.3.16a: The axis of insertion of the pin contacts and mating receptacle contacts or hermaph-22 roditic contacts as applicable shall coincide during insertion and withdrawal. 23

b) Rule 11.3.16b: The speed of insertion of the plug into the receptacle contacts shall not exceed 24 10 cycles per minute for constant-speed machines, or the rate of loading shall not exceed 36.3 kg 25 (80 lb) per minute for constant-rate-of-force machines. 26


d) Rule 11.3.16d: Scales shall be calibrated in 57 g (2 oz) steps or less, and shall be accurate to within 28 57 g (2 oz). 29






Rule 11.3.17a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 2 receiver and fixture connector to a durability cycle test in accordance with 4.6.2.7. A minimum durability 3 cycle objective of 10,000 repetitions is required, unless otherwise defined in the respective connector/ 4 contact requirements (see Clauses 7–12). 5


11.4 Coax 40 GHz, size 8, D-Sub compatible, contact 9

The coax size 8, D-Sub compatible contact may be integrated into the DIN cavity of the universal modules 10 provides a 40-GHz capability to meet a wide range of RF requirements. Using a blind-mate, spring-loaded 11 design, the mating contacts can be consistently mated and maintained a constant interconnect under varying 12 stroke conditions. 13

11.5 Power 45-A, size 8, D-Sub compatible contact 14

The coax size 8, D-Sub compatible contact as referenced in 8.5 may be integrated into the DIN cavity of 15 the universal modules provides a 45-A capability to meet high performance power requirements. All 16 applicable references related to 8.5 power contacts shall be adhered to within the Clause 11 requirements. 17

11.6 Pneumatic, size 8, D-Sub compatible, contact 18

The pneumatic size 8, D-Sub compatible contact may be integrated into the DIN cavity of the universal 19 modules provides 10 cfm at 50-psi capability to meet a wide range of pneumatic requirements. Using a 20 blind-mate, double-grommet design, the mating contacts can be consistently mated and with a constant 21 interconnect under varying stroke conditions. 22

11.7 Fiber-optic, size 8, D-Sub compatible, contact specifications 23

The fiber-optic size 8, D-Sub compatible contact may be integrated into the DIN cavity of the universal 24 modules is a MU (single mode) (multi-mode) design, employing 2 mm, 900 µm fiber type capability to 25 meet a wide range of fiber-optic requirements. Using a blind-mate, spring-loaded design, the mating 26 contacts can be consistently mated and with a constant interconnect under varying stroke conditions. 27

12. High-speed signal module 28


Clause 12 and Clause 6 of this IEEE 1505document RFI standard describe specifications for developing 30 and integrating RFI high-speed signal module receptacle and pin connector assembly, connector saver 31 receiver module, contacts, and accessories. Each module houses two connector plugs, with each plug 32





having 6 rows by 25 pins for a 150-pin configuration, for a total of 300 contact positions per connector 1 module, supporting discrete wire or two-wire coaxial wiring, in vertical mount, or right-angle printed 2 wiring board (PWB) scheme. 3


Rule 12.2: The RFI high-speed signal module receptacle receiver and fixture plug connector assembly shall 5 conform to the following subclauses and illustrations. These design specifications provided address connec-6 tor/contact physical dimensions, vertical interconnect scheme implementations, electrical and 7 environmental performance specifications, and applicable PCB layout requirements. The information 8 presented in Clause 12 is not stand-alone and shall coexist with the information presented in Clause 6, and 9 conform to the related RFI qualification requirements in Clause 4. 10

The following Figure 75 presents implementations of the RFI high-speed signal module connector plug and 11 receptacle assembly under the specifications described herein. Figures 76-78 reflect detailed dimensions 12 required. 13

14

Figure 75 —RFI hHigh-speed signal module connector pin and receptacle assembly 15 implementation 16




1

Figure 76 —RFI hHigh-speed signal module receiver receptacle connector assembly 2 dimensional specifications 3

4

Figure 77 — RFI Hhigh-speed signal module receiver receptacle connector assembly 5 PCB pin tail layout dimensional specifications 6




1

Figure 78 —RFI hHigh-speed signal module fixture plug connector assembly 2 dimensional specifications 3


Rule 12.2.1: The individual connector-type style requirements shall be as specified within this standard and 5 in accordance with the applicable specification sheets, listed in Clause 12 of this specification. In the event 6 of any conflict between the requirements of this specification this document and the specification sheets, 7 the latter shall govern. 8



Rule 12.3.1: Each connector shall meet all applicable connector specifications described in Clause 6 and 11 the related qualification requirements in Clause 4, unless otherwise specified hereafter. 12

12.3.2 Materials 13

Rule 12.3.2a: The identified reference materials, platings, and processes described in 4.2.2 shall be used to 14 enable connectors manufactured to this specification this document to mate to similar industry standard or 15 government-specified connector systems with minimal problems related to electrochemical contamination 16




of critical electrical or mechanical interfaces or generation of incompatible mechanical interface surface wear 1 products. 2



12.3.3 Dimensions 11





Rule 12.3.5: Each connector described herein provides mating male (pin header) and female (receptacle) 16 connector elements specified within this clause. 17


Rule 12.3.6: Location indicators shall be marked with permanent paint or etched markings on surface. 19 Numbers indicating end cavities, letters indicating row nearest to polarizing feature, and markings every 10 20 positions stamped on this surface, in lettering orientation as shown in Figure 79. 21

Pin 1 ----------------------------------------25 -------26----------------------------------------50Row A - B - C - D - E- F-

22

Figure 79 —Front view receiver high-speed signal module connector 200 23 position markings 24

12.3.7 Chamfers 25

Rule 12.3.7: Chamfers shall be 0.015 mm (0.006 in.) at a minimum at a 45° angle (see Figures 76-78). 26





Rule 12.3.8: The maximum mating force in pounds shall be 22.7 kg (50.0 lb); the withdrawal force in 2 pounds shall be a minimum of 20.4 kg (45 lb) and shall not exceed the measured insertion force. 3


Rule 12.3.9: Contact retention shall be 1.36 kg (3.00 lb) at a minimum. 5

12.3.10 Wire-wrap post contact design 6

Rule 12.3.10:Wire-wrap post contacts shall be in accordance with MIL-STD-1130. 7

12.3.11 Rear-mount connector PCB implementation through-hole layout 8

Rule 12.3.11: Holes for solder type shall be 1.07 mm to 1.27 mm (0.042 in. to 0.050 in.). Holes for compli-9 ant pin shall be manufactured as follows: 10

a) 1.15 1 ±0.025 mm (0.0453 ±0.001 in.) hole drilled with a 1.15-mm drill 11

b) 0.03 mm to 0.08 mm (0.00 1 in. to 0.003 in.) thick copper on wall 12

c) 0.008 mm (0.0003 in.) minimum tin lead plating 13

d) Finished hole diameter 0.94 mm to 1.09 mm (0.037 in. to 0.043 in.) after plating 14

e) 0.91 mm to 1.09 mm (0.036 in. to 0.043 in.) after reflow 15

f) Copper hardness (knoop) 150 maximum 16


Rule 12.3.13: Suffix to any manufacturing part number shall include the respective connector clause speci-18 fication. Example: 555302/RFI 12.3 19



Rule 12.4.1: Current rating of the pin based upon 24 AWG wire size shall be 2.0 A maximum per contact 22 and 1.5 A continuous per contact at room ambient with no more than two adjacent contacts carrying this 23 current. See Table 16 for related wire gauge conditions/current rating. 24




Table 16 —Signal contact current rating 1


per MIL-W-1687 Test Current (A)

Maximum Test

Contact Resistance (m%Ω)

Maximum Test

Voltage Drop (mV)

24 3.0 8.7 26.0

26 2.0 12.0 24.0

28 1.5 14.7 22.0

30 1.0 20.0 20.0

2


Rule 12.4.2: No individual contact pair shall have a resistance exceeding 0.015 ~ for initial test and 0.020 ~ 4 after testing. See Table 17 for related wire gauge conditions/contact signal pin. 5

Table 17 —Signal contact resistance 6


per MIL-W-16878

Test Current

(A)

Maximum Contact

Resistance (m%Ω)

Maximum Voltage Drop

(mV)

24 0.001 20 20.0

26 0.001 24 25.0

28 0.001 40 40.0

30 0.001 50 50.0 7



At sea level: 1000 V rms @ 60 Hz 10

At 21,336 m (70,000 ft): 250 V rms @ 60 Hz 11

Maximum leakage current: 2mA 12



Rule 12.5.1: Examination shall be made to determine compliance with the RFI qualification requirements 15 in 4.4–4.6. 16





Rule 12.5.1.1: Physical configuration and dimensional measurements shall meet the requirements of 2 4.6.2.1, and as specified in the related specification supplemental paragraphs. 3


Rule 12.5.2: Sockets (contacts) shall be mounted in a suitable position or fixture for applying gradually 5 increasing loads for the engagement and separation of the test pin from the sockets (contacts). Maximum 6 and minimum test pins shall be in accordance with MS3 197 except as specified herein for flat-blade type 7 contacts (see 12.3). Insertion of test pins shall be to a minimum depth of 0.036 mm (0.140 ±0.020 in.), when 8 measured from the front of the socket contact. The test pin shall not bottom in the socket contact. This test 9 shall be performed in the sequence as specified as in Method 2014 of MIL-STD-1344A. 10


Rule 12.5.3: After three cycles of insertion and withdrawal, the force required to fully insert and withdraw 12 a plug from the receptacle shall be measured. Each plug and receptacle so mated shall be considered as 13 one test specimen where further testing of the plug or receptacle is indicated. The measuring equipment 14 shall conform to the following. 15

a) Rule 12.5.4. a: The axis of insertion of the pin contacts and mating receptacle contacts or hermaph-16 roditic contacts as applicable shall coincide during insertion and withdrawal. 17

b) Rule 12.5.4.b: The speed of insertion of the plug into the receptacle contacts shall not exceed 18 10 cycles per minute for constant speed machines, or the rate of loading shall not exceed 36.3 kg 19 (80 lb) per minute for constant-rate-of-force machines. 20

c) Rule 12.5.4.c: Scale mechanisms shall have no dashpots or other damping devices. 21

d) Rule 12.5.4.d: Scales shall be calibrated in 0.057 kg (2 oz) steps or less and shall be accurate to 22 within 0.057 kg (2 oz). 23


Table 18 —Signal contact engagement and separation force test requirements 26

Signal Pin Standard Diameter 0.6 mm (0.024 in.)

Tolerance ±0.025 mm (0.001 in.)

Maximum Engagement Force 113 g (4 oz)

Maximum Separation Force 99 g (3.5 oz)

27


Rule 12.5.4a: To meet IEEE Std 1505 requirements, each manufacturer shall subject the test specimen 29 receiver and fixture connector to a durability cycle test in accordance with 4.6.2.7. A minimum durability 30 Formatted: Font: Not Italic




cycle objective of 10,000 repetitions is required, unless otherwise defined in the respective connector/con -1 tact requirements (see Clauses 7–12). 2

Rule 12.5.4b: When tested in accordance with RFI qualification with this document requirements (see 3 4.6.2.6), connectors shall show no evidence of cracking or breaking, the contact resistance requirements 4 (see 6.19) shall not be exceeded, and mating and unmating requirements (see 6.17) shall be met. 5




Annex A 1

(informative) 2

Receiver Fixture Interface (RFI) Tutorial 3

A.1 Scope 4

The information provided within this annex is informative only and is not part of the IEEE Std 1505. RFI 5 specification. It provides general overview ,of IEEE Std 1505, background, and application use to inform 6 new users or interested individuals about IEEE Std 1505. 7

A.2 Receiver fixture interface overview 8

A.2.1 General description 9

Receiver/fixture interfaces provide a mechanical quick-disconnect for connecting large numbers of signals 10 (digital, analog, RF, power, etc.), while also serving as a common electrical link between source and recipi-11 ent of those connections. The following illustration, Figure A1, describes the elements involved in a typical 12 automatic test system (ATS) application and the respective interface points coming to the receiver from a 13 system/subsystem and going to a system/subsystem/unit-under-test (UUT), by means of a fixture. Because 14 the vast majority of applications and complexity of an IEEE Std 1505 RFI system are related to the test 15 system, the material will be slanted towards testing use. However, integrators/users of mass electrical 16 interconnects can be assured that the IEEE Std 1505 RFI does apply to quick-disconnect requirements in 17 factory, field, and general applications demanding such interfaces. 18





Mainframe Rear Bulkhead To Instrument

Mainframe Rear Bulkhead To Receiver

Fixture Component To UUT Interface of the Fixture

UUT Interface of the Fixture To UUT Interface

Fixture Interface To UUT Interface

Fixture Jumper To / From UUT

Fixture Jumper To / From Test System

B Instrument To Receiver

J

A

C

D

E

F

G

H

I

Instrument To Instrument Jumper

CABLE ASSEMBLIES

ITA / UUT Cable or Edge-Card Interface3

Mainframe Rear Bulkhead4

Rack-and-Stack Instrument Front/Rear Panels5

Instrument Front Panels1

Receiver / ITA Mass Quick Disconnect2

INTERFACE PLANES

Mainf rame

PowerSupply

CoolingSystem

Cable Tray

InstrumentModules Receiv er

A

B

C D

L

Rack-Mounted Instrumentsand Benchtop Equipment

Fixture

Unit Under Test (UUT)

Embedded PCMCIA Modules, Active Eurocard Modules, or Active/Passive Circuitry (e.g., switching, terminations, filtering, buffering)

E F

I

J

Fixture Test InterfaceEngagement Assembly

G

H

Backplane

• Power Supplies • Data Comm• Electronic Loads • Controllers• Frequency Standards • Monitors• Synthesizers • Keyboard• Spectrum Analyzers

K

L

Mainframe Rear Bulkhead To Rack-and-Stack Instrument

Mainframe/Rack Instrument To PC Control

K

4

5

Fixture Interface To Fixture Component

1

Figure A.1 —ATS receiver fixture interface diagram 2

A.2.2 Receiver fixture basic structure description 3

The basic structure of the IEEE 1505IEEE Std 1505 receiver fixture interface segmented framework 4 configuration is illustrated by Figure A2. The specific elements shown serve to make the signal connection 5 possible through first the mechanical alignment features of the receiver and fixture frame, followed by the 6 contact modules, and finally the electrical contacts that transmit the signals across the junction of the 7 interface. The IEEE 1505IEEE Std 1505 receiver fixture interface continuous framework configuration 8 removes the rib framework to allow higher slot density and greater connector access (see Clause 5 for more 9 details). 10




4/12 Slot

Fixture

Enclosure

Receiver

Framework

Receiver Engagement

Operator’s Handle

Receiver

Connector Modules

with ContactsFixture

Connector Modules

with Contacts

Fixture Framework

1

Figure A.2 —Receiver fixture interface IEEE 1505 typical segmented 2 framework configuration 3

A.2.2.1 RFI relationship in an automatic test system application 4

Many interrelationships exist between the receiver fixture interface and its related subsystems, as shown by 5 the automatic test systems (ATS) interface diagram in Figure A1. Generally, it includes the receiver 6 mechanism/connectors/contacts, the fixture/internal components/internal cabling/enclosure, and the respec -7 tive input/output (I/O) cabling that connects the receiver fixture to the respective test assets, and mating 8 recipient of those signals. 9

A.2.3 Receiver fixture interface subassemblies 10

The term receiver fixture interface describes the overall assembly that provides a quick-disconnect mass 11 termination between two electrical units. It is assembled from two major subassemblies (as shown in 12 Figure A3): the receiver, which serves as the receptacle part of the interface, that is typically hardmounted 13 to the automatic test system (ATS) and the fixture, the mating subassembly or mass termination plug that 14 connects to the receiver. In the test community, the fixture is uniquely designed for a specific test program 15 set (TPS) to adapt a unit-under-test (UUT) to the ATS. In any application of the receiver fixture interface, 16 the architecture performs the same function of quickly blindmating thousands of contacts and their related 17 electrical signals. 18




A.2.4 RFI system scalability 1

The receiver fixture interface (RFI) system supports a broad number of scalable interface options. To illustrate 2 this capability, Figure A3 shows how a 29-slot single-tier and 58 (2 x 29)-slot double-tier receiver with 3 continuous framework can support 1, 4, 9, 14, 19, 24, and 29 single-tier fixtures. This allows the integrator 4 to grow the configuration without rendering already built fixtures obsolete. 5

6

Figure A.3 —IEEE 1505IEEE STD 1505 RFI scalable configurations 7

A.3 Receiver fixture interface approaches 8

A.3.1 Receiver trade-offs 9

The architecture of the receiver fixture interface varies with the application of wiring techniques, an 10 electrical switch, the signal type/functional needs of the units being interfaced, and the mechanical fixture 11




interface requirements. This may be further driven by the user’s desire to have greater flexibility and 1 capabilities to support multiple interface requirements. 2

A.3.2 Receiver-resource interface choices 3

Assuming the need for an interface has been established, a number of interface approaches can be employed, 4 as illustrated in Figure A4. The approaches identified provide advantages and disadvantages for the user to 5 evaluate. The following list outlines those aspects: 6

a) The typical direct cable interface approach represents the lowest cost solution and most flexible. 7 Although the receiver configuration is fixed, the instrumentation, which can be VMEbus [B37] 8 eXtension for Instrumentation (VXI) [B38], or PCIbus [B33] eXtensions for Instrumentation (PXI) 9 [B34], and wiring can be adjusted easily by the user to the application. This recognizes of course 10 that any change or substitution may affect the test program application. 11

b) An integrated cable/PCB and receiver module interface is similar to the typical direct cable inter-12 face approach but applies a mechanical link between the instrument and receiver module. This 13 approach results in a shortened wire length and may include an EMI-shielding scheme. It primarily 14 benefits users who desire high signal integrity and an integrated cable and instrument-packaged 15 assembly, but who are not pin limited. This approach constrains the user to define a fixed instrument 16 configuration at the start and stay with that approach through the test system’s life. 17

18

Figure A.4 —Receiver interfacing approaches 19

c) The typical cable-switch module-receiver module integrated approach employs a switch module to 20 facilitate switching between the instrument and receiver. This approach enhances the flexibility of 21 the test system in routing signals to/from the UUT with a minimum number of pin interfaces. 22 Although more expensive than the previous approaches, due to added switch module costs, it 23 affords more capability to the user than any other approach. 24

d) The integrated switch-receiver module approach combines a dedicated switching matrix and a 25 receiver module interface in a single card assembly. This approach is often applied by digital ATS, 26 that interconnects each digital/analog signal channel to any of the receiver module contacts. The 27 benefits of this approach is the ability to reroute a signal to multiple points with minimum wire 28

a)




length. However, like the integrated cable/PCB and receiver module interface approach, it is 1 inflexible to change without disrupting the receiver configuration. 2

A.3.3 Receiver product designs 3

A.3.3.1 Basic receiver elements 4

The receiver is the common element of any ATS approach that accepts a wide variety of connector designs 5 in support of unique UUTs. Because of its commonality with the fixture, the receiver must be capable of 6 accepting the highest pin configuration of any of the fixtures being supported. Specific elements of the tradi-7 tional receiver, as shown in Figure A5, include: 8

a) Receiver holding/alignment/operating mechanism 9

b) Receiver contact module 10

c) Receiver connector contact pin with or without patchcord 11

12

Figure A.5 —Receiver/fixture framework and subelements 13

A.3.3.2 Receiver mechanism design concepts 14

The receiver is offered in various sizes to accommodate the needs of the user and associated test system. 15 Although this sometimes changes the dimensions of the receiver, as well as the number of contact modules 16




and pins that can be accommodated, it does not change the basic mechanical concept used. The various 1 concepts for mechanically mating the fixture connectors to the receiver connectors are shown in Figure A6. 2

a. CAM Receiver b. Claw/CAM Action Receiver c. Inclined Plane/CAM Receiver d. Ball Lock/Gear Receiver

Claw

Receiver

Fixture

Disengaged

Cam Actuator

Engaged

Fixture

Receiver

Cam

Actuator

Fixture

Receiver

Fixture Receiver

3

Figure A.6 —Receiver mechanism design concepts 4

The differences shown involve either the pin contact methods or mechanical alignment and closure subas-5 sembly. The CAM receiver (see Figure A6a), moves the fixture vertically until contact is made by the pin 6 with the spring-loaded tab connector. This permits zero-insertion force of the fixture into receiver and a min-7 imum amount of CAM action force to press the contact pins of the fixture against the receiver connector 8 tabs. These types of assemblies were used heavily in an earlier period of interface development. 9

The typical receiver used today implements either the claw linkage identified in Figure A6b, or the inclined 10 plane/CAM actuator design shown in Figure A6c. Both apply a picture frame fixture design with a perimeter 11 roller assembly. This approach utilizes a mechanical linkage assembly to apply lever action of the opera tor 12 handle to the CAM or receiver claw of the alignment and closure assembly. Either the two slide plates of 13 the inclined plane/CAM receiver, or the four receiver claws of the claw/CAM action receiver are used to 14 engage four rollers of the fixture frame. 15

This engagement initially aligns and holds the fixture onto the receiver until the handle is actuated to pull or 16 push the fixture from the receiver. Other mechanisms are employed to lock the fixture into position and 17 electrically indicate the existence or absence of an fixture in the receiver. The latter serves as a safety 18 feature. The ball lock/gear receiver (see Figure A6d) provides unique distributed pull/push engagement system 19 that permits users to apply scalable fixture designs. Mechanical force to pull or push the receiver and fixture 20 framework together is also distributed to minimize bowing of the framework. 21

A.4 IEEE 1505IEEE STD 1505 RFI framework design 22

A.4.1 Framework overview 23

The IEEE 1505IEEE STD 1505 RFI framework (segmented example shown in Figure A7), represents the 24 mechanical element that: 25

a) First support and mount the electrical connector modules and contacts 26

b) Align the respective receiver and fixture subassemblies to each other 27

c) Connect and disconnect the electrical contacts through mating mechanical engagement subelements 28 found within the respective receiver and fixture subassemblies 29




1

Figure A.7 —RFI framework design 2

The receiver and fixture framework body, shown in Figure A7, serves initially as a keying and alignment 3 function, in which the different tongue and groove spacings of the top and bottom frame outline validate 4 that mating frames are right side up and aligned for ball-lock engagement. Sufficient mechanical float must be 5 offered in the framework mounting relationships to maintain initial accurate alignment. A telescopic align-6 ment process, discussed in A.4. 1, is implemented within the framework design to refine alignment as ele-7 ments are engaged. 8

Each framework element supports unique multiple functions of the interface, including: 9

a) Integral tongue-grooved alignment between mating frames 10

b) Respective receiver and fixture connectors mounting 11

c) Six-position hex keying 12

d) Respective ball-lock assemblies and engaging/disengaging hardware 13

e) Sensor/locking hardware assemblies to detect and secure against inadvertent release 14

f) Mounting attachment points for rack/chassis plates 15

The RFI framework is also designed to be produced in multiple variations (see Figure A8): 16

a) 3-in. segmented frame that supports only four connector slots (see Figure A8a.) or 17

b) Continuous frame that supports 4, 9, 14, 19, 24, or 29 connector slots in 3-in. intervals (see Figure 18 A8b) or 19

c) Combination frame that can integrate segmented and continuous intervals into their framework (see 20 Figure A8c) 21

To achieve a highly reliable and robust design, the RFI system employs an unique telescopic alignment and 22 distributed engagement architecture that minimizes contact misalignment and framework loading problems. 23 Support surfaces are recommended for supporting heavy fixtures. Protective covers for both the receiver 24 and fixture are recommended for protecting the connector contacts. 25




1

Figure A.8 —RFI framework types 2

A.4.2 Segmented frame interval 3

The segmented frame with two ball-lock engagement points, as shown in Figure A8a., supports four 4 connector slots 60.96 mm (2.40 in.) representing 4 x 15.24 mm (0.60 in.) slot width), and 7.62 mm (0.30 in.) 5 space on each side of the four slots to support the mating fixture protective shrouds. These segments can be 6 integrated to form receiver interfaces with 4, 8, 12, 16, 20, and 24 connector slots with fixture shroud spacings 7 at each 76.20 mm (3.00 in.) increment. 8

A.4.3 Continuous frame interval 9

The continuous frame interval (see Figure A8b) extends the segment incrementally from four connector 10 slots to 9, 14, 19, 24, and 29 slots. This increases the number of connector slots within each interval by 11 using the fixture shroud spacings as a dedicated connector slots. In using the shroud spacing as connector 12 slots, standard shrouded fixture will not be matable to the receiver at that specific interval. 13




A.4.4 Combination frame interval 1

The combination frame interval is employed where test applications may dictate variations in the connector 2 slot intervals and fixture shroud spacings. Presented in Figure A8c is a combination of a segmented frame 3 and representative continuous frame that expands from the four-slot segment. 4

A.4.5 RFI receiver framework loading 5

One aspect of receiver design that impacts life-cycle durability and dictates scalability of fixture is the 6 framework loading concept. When the fixture frame or modules flex under the force caused by engagement 7 resistance of the contacts, bowing occurs, a fundamental problem for receivers. The RFI receiver designs 8 distribute the load over segmented pull/push points so that the load is distributed evenly over the fixture 9 frame, minimizing bowing, whereas a traditional receiver design, as reflected in Figure A9, utilizes a perim-10 eter framework to engage the fixture to the receiver. This places the load of the pull or push of the mecha-11 nism on the outside framework that ultimately distributes that force to the modules and in turn to the 12 contacts that are encountering the force as resistance. Greater bowing occurs with perimeter-loading designs 13 than distributed-loaded framework. 14

15

Figure A.9 —Framework loading receiver concepts 16

A.4.6 RFI receiver framework loading 17

The resultant impact of bowing on the interface is that contacts may not mate, limiting performance 18 because of reduced mating surface contact area. Where alignment becomes affected, there is added 19 resistance, wear, and eventually reduced cycle life. To counteract this effect, perimeter loading receivers 20 have included robust metal structure to reduce bowing under significant force. 21

A.4.7 Receiver ball-lock receptacle/fixture ball-lock assembly 22

The receiver ball-lock receptacle in conjunction with the fixture ball-lock assembly, shown in Figure A10, 23 serve to align and latch the receiver/fixture framework together. Once latched, the receiver by means of the 24 handle/drive assembly operation pulls the fixture with a piston action into the receiver. This action in turn 25 engages the fixture connector pin contacts with their respective receiver connector socket contacts. 26




Fixture

Framew ork

Ball-lock

Assembly

Ball-lock

Receptacle

Receiver

Framew orkFixture

Engaged

Position

Fixture

Disengaged

Position

1

Figure A.10 —Receiver ball-lock receptacle/fixture ball-lock assembly 2

A.4.8 Ball-lock mechanism 3

A ball-lock mechanism, detailed in 5.12, is used in the RFI frameworks as a pin-and-socket-type of 4 mechanical engagement that when latched together can withstand considerable force (maximum 159 kg [350 5 lb] per ball-lock assembly) applied to engage or disengage their respective attached frames. 6

A.4.9 RFI telescopic alignment process 7

The RFI architecture provides an alignment process through four levels of telescopic alignment (see Figure 8 A.11). 9

Level 1Fixture Alignment

Frame To Receiver Outer

Shroud

Level 2

Fixture Ball-Lock Pin

To Receiver Socket

Engagement Cavity

Level 3

Connector Shroud Male-

To-Female Interface

Engagement

Level 4Connector Pin to

Female Socket

Interface Engagement

10

Figure A.11 —RFI telescopic alignment process 11




A.4.10 Receiver mechanical advantage 1

The mechanical advantage of the receiver represents the ratio of force at the fixture to that placed on the 2 drive system to overcome engagement resistance of mating the interface connectors. In a manual system this 3 represents the ratio of engagement force to that force applied by the operator to the handle. In an electro-4 mechanical system it is the ratio of the engagement force to the torque applied by the drive motor. Limita-5 tions imposed upon the amount of force that be applied at handle or motor determines the effectiveness of 6 the drive system. 7

Where coax and power pins are employed demanding as much as 454 g (1 lb) of force per contact and high-8 density application on a single-tier receiver the engagement force can exceed 545 kg (1200 lb). This places 9 consider stress on a receiver drive system demanding high receiver mechanical advantage to minimize force 10 being exerted by an operator or motor to engage/disengage the system. For example, under a constraint of a 11 maximum force of 9 kg (20 lb) upon the handle by an operator, the engagement mechanism would require a 12 60:1 mechanical advantage to engage an interface exhibiting 545 kg (1200 lb) of insertion force. To increase 13 mechanical advantage suppliers usually apply handle extensions to reduce the force within the ability of an 14 operator to perform the effort. In electrical-mechanical operation the motor size may increase to meet the 15 higher torque requirements. 16

A.5 RFI fixture enclosures overview 17

The fixture enclosure and internal packaging structure subelement of the receiver fixture interface serves as 18 the structural/housing system for fixture connectors/modules and the supporting interfaces to the UUT. The 19 fixture enclosure and internal structure provides direct wiring signal paths between the receiver of the ATS 20 and the UUT, as shown in Figure A12. It also typically supports wide variety of active and passive compo-21 nents, printed circuit boards, secondary connectors, and/or any other support function that the ATS could not 22 perform to test the UUT. 23

24

Figure A.12 —Internal Packaging Structure 25




A.5.1 Fixture product design approaches 1

A.5.1.1 Fixture elements 2

The fixture, presented in Figure A13, serves as a mechanical and electrical link between the receiver inter -3 face of the test system and the unit-under-test. It is composed of the fixture frame, with 4

a) Connector modules 5

b) Contact pins 6

c) Enclosure 7

d) UUT interface 8

The following sections describe several fixture types employed by the industry and its respective 9 application. 10

11

Figure A.13 —Fixture basic elements 12

A.5.1.2 Device adapter board (DAB) fixture 13

The device level interface or device adapter board (DAB) fixture (shown in Figure A14) is used to test 14 semiconductor devices. This type of test application would be applied at incoming inspection or repair 15 centers. 16




1

Figure A.14 —Device adapter board (DAB) fixture 2

A.5.1.3 Bed-of-nails fixture 3

The bed-of-nails fixture (shown in Figure A15) is used to conduct in-circuit and functional testing through 4 needle like spring-loaded probes that make contact to the under or top side of a printed circuit board. These 5 fixtures can be employed at both the factory and depot where conformal coatings are not used. 6

7

Figure A.15 —Bed-of-nails fixture 8

A.5.1.4 Cable/printed circuit board plug-in interface fixture 9

The combined cable/printed circuit board plug-in interface fixture (shown in Figure A16) illustrates both 10 cable connections between the ATS and the UUT, and/or standard interface of a printed circuit card using a 11 compatible mating connectors and supports. Applying multiple ports/interface modules, a broad mix of 12 UUTs can be supported with a single fixture. 13




1

Figure A.16 —Cable/printed circuit board fixture interface 2

A.6 RFI connector modules and contacts 3

A.6.1 Overview 4

Both the receiver and the fixture subassemblies are modularized further into a receiver/fixture frames, 5 connector modules, and contacts, as was illustrated in Figure A2, to support the mechanical and electrical 6 connection. Typically, there are four class types of connections: 7

a) Signal Connections: For digital and general low-level signal applications 8

b) Power Connections: To interface high amperage/voltage (20 A to 50 A) levels signals 9

c) Coax Connections: For RF signals 10

d) Special: For fiber optic, pneumatic, cooling, etc. 11

Examples are illustrated in Figure A17 and Figure A18. 12

A.6.2 RFI connector implementation based on Eurocard DIN Standards 13

An open architecture connector footprint is described within IEEE Std 1505, based upon Eurocard/ DIN and 14 commercial contact standards for each slot. This permits the user to select a number of standard connectors 15 types to form the interface. Multiple types and connector modules (see Figure A1 7 and Figure A1 8) cur -16 rently being offered by industry include: 17

a) 200 position high-density signal connector module 18




b) Rear mount 100-position high-speed digital, 0 MHz to 750 MHz signal connector module 1

c) Optical 24-position connector module 2

d) Pneumatic 24-position connector module 3

e) 4/45-59-152-307 position 45 A/23 A power/5 GHz coax connector module 4

f) 24-65-170 position 7GHz RF coax connector modules 5

g) 12 to 24 position 40 GHz high-RF coax connector module 6

h) 26-position RF 60 GHz coax connector module 7

A blank module is supplied when none of the other connector modules are used. The power and coax 8 connector module houses respective power or coax contacts that can be independently installed to the 9 configuration desired. Each contact can be provided with a built -in piggyback, quick-disconnect 10 feature that eliminates cutting/crimping in the field to repair failed interface contacts. 11

12

Figure A.17 —Receiver fixture interface connector assemblies 13




(E) Power/RF High Density Modules:1 Slot Mix 23A/5Ghz;45A/7Ghz -45/4 pos

1 Slot Pow er 23A/RF 5GHz -59 pos



Fixture

Receiver

(F) RF 7GHz Connector Modules:1 Slot RF 7GHz -24 positions

2 Slot RF 7GHz -65 positions

4 Slot RF 7GHz -170 positions

Receiver

Fixture

(G) RF 40 GHz w/K Conn-12 pos

Receiver

Fixture

(H) RF 60 GHz w/K Conn-26 pos

Fixture

Receiver

Connector Saver

1 Figure A.17 (continued)—Receiver fixture interface connector assemblies 2




A.7 Receiver fixture interface assessment and trade-offs 1

A.7.1 General background of the RFI assessment 2

The development of the Receiver Fixture Interface specification by the IEEE Std 1505 RFI Working Group 3 sponsors was derived from many sources representing general industry needs, government-COTS interests, 4 government open-system directives, industry technology trends, government/aerospace test requirements 5 (functional test requirements), and test industry/connector/packaging standards. 6

The Working Group also utilized the results of a study conducted by the Department of Defense Automatic 7 Test System Research & Development Integrated Product Team (ARI) Critical Interface Working Group 8 (CIWG) that reviewed as part of their tasks the ATS Test Interface. They are described in the Automatic Test 9 System Critical Interfaces Report, which has been included as an informative reference in Annex B. A direct 10 response to the receiver fixture interface is addressed in subclause 4.4.3 of the report. The methodology 11 step process used by the RFI Working Group includes: 12

a) Defining the problem 13

b) Establishing a set of requirements 14

c) Evaluating available interface designs against a set of parameters that relate to the problem and 15 requirements 16

d) Defining a specification that will meet the consensus of the Working Group and industry short and 17 long-term goals 18

It was based upon ―open standards‖ or functional specifications that are supported by multiple-vendor 19 products. 20




Annex B 1

(informative) 2

Critical Interface Working Group (CIWG) report 3

Automatic Test System Critical Interfaces Report, dated 9/30/96, is the results of a study conducted by the 4 Department of Defense Automatic Test System Research and Development Integrated Product Team (ARI) 5 Critical Interface Working Group (CIWG), which reviewed as part of their tasks the Automatic Test 6 System (ATS) Test Interface. A copy of the CIWG Report can be found at the following link: 7

http://grouper.ieee.org/groups/scc20/HIWG/CIWG%20Report.doc 8

9

10

http://grouper.ieee.org/groups/scc20/HIWG/CIWG%20Report.doc




Annex C 1

(informative) 2

Bibliography 3

The following list of documents and references were applied in the development of IEEE Std 1505. 4

[B1] ANSI Y32.9, American National Standard Graphic Symbols for Electrical Wiring and Layout 5 Diagrams.

13 6

[B2] ANSI/ASQC M-1, MIL-STD-45662 Calibration Systems Requirements. 7

[B3] ANSI/IEEE Std 260.3' American National Standard for Mathematical Signs and Symbols for Use in 8 Physical Sciences and Technology. 9

[B4] ANSI/IEEE Std 260.4', American National Standard Letter Symbols and Abbreviations for 10 Quantities Used in Acoustics. 11

[B5] ASME B46. 1-78 Surface Texture (Surface Roughness Waviness and Lay).14

12

[B6] ASTM B734 Electrodeposited Copper for Engineering Uses, Standard Specification for.15

13

[B7] ASTM-D4080 Trichloroethylene, Technical. 14

[B8] ASTM-E32 Standard Practices for Sampling Ferroalloys and Steel Additives for Determination of 15 Chemical Composition. 16

[B9] EIA RS-3 10-C Racks, Panels and Associated Equipment.16

17

[B10] EIA Standard 60796-3, Racks, Panels and Associated Equipment; EIA-Arlington, VA. 18

[B11] IEC 1010-1 Safety requirements for electrical equipment for measurement, control, and laboratory 19 use Part I, General Requirements. 20

[B12] IEC 60068-1 Environmental testing. 21

[B13] IEC 61326-1 Electrical equipment for measurement, control, and laboratory use EMC Requirements 22 Part I, General Requirements. 23

[B14] IEEE Std 91', IEEE Standard Graphic Symbols for Logic Functions.17

24

[B15] IEEE Std 100', The Authoritative Dictionary of IEEE Standards Terms, Seventh Edition, New 25 York, Institute of Electrical and Electronics Engineers, Inc.; URL: http://standards.ieee.org. 26

[B16] IEEE Std 260.1', American National Standard Letter Symbols for Units of Measurement (SI Units, 27 Customary Inch-Pound Units, and Certain Other Units). 28

[B17] IEEE Std 280', IEEE Standard Letter Symbols for Quantities Used in Electrical Science and Electri -29 cal Engineering. 30

[B18] IEEE Std 31 5', IEEE Standard Graphic Symbols for Electrical and Electronics Diagrams (Including 31 Reference Designation Letters). 32

13

ANSI Standards are available through the ANSI website at: http://webstore.ansi.org/ 14 ASME publications are available from the American Society of Mechanical Engineers, 3 Park Avenue, New York, NY 10016-5990,

USA (http://www.asme.org/). 15 ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West

Conshohocken, PA 19428-2959, USA (http://www.astm.org/). 16 EIA and IEC Standards are available through the ANSI website at: http://webstore.ansi.org 17

Available from the IEEE Service Center, 445 Hoes Lane, Piscataway, NJ 08854, USA (http://standards.ieee.org)


Formatted: IEEEStds Footnote









[B19] IEEE Std 945', IEEE Recommended Practice for Preferred Metric Units for Use in Electrical and 1 Electronics Science and Technology. 2

[B20] IEEE Std 991', IEEE Standard for Logic Circuit Diagrams. 3

[B21] IEEE Std 1014'; Piscataway, NJ; URL: http://standards.ieee.org. 4

[B22] IEEE Std C37. 1 00', New York: Institute of Electrical and Electronics Engineers, Inc.; URL: 5 http://standards.ieee.org. 6

[B23] IEEE-SA Standards Board Bylaws, New York: Institute of Electrical and Electronics Engineers, 7 Inc.; URL: http://standards.ieee.org. 8

[B24] IEEE-SA Standards Board Operations Manual, New York: Institute of Electrical and Electronics 9 Engineers, Inc.; URL: http://standards.ieee.org. 10

[B25] IEEE-SA Standards Companion, New York: Institute of Electrical and Electronics Engineers, Inc.; 11 URL: http://standards.ieee.org. 12

[B26] IEEE Standards Style Manual, New York: Institute of Electrical and Electronics Engineers, Inc.; 13 URL: http://standards.ieee.org. 14

[B27] ISO 9001 Quality Systems Model for quality assurance in design/development, production, 15 installation and servicing

18 16

[B28] Joint Service Automatic Test Systems Research and Development Integrated Product Team (ARI), 17 government/industry Critical Interfaces Working Group; USAF-CIWG Contract Report, Washington, DC, 18 6/1/98. 19

[B29] MIL-C-83733 Rectangular Rack and Panel Connectors.19

20

[B30] MIL-G-45204 Gold Plating, Electrodepositing (equivalent standard AMS 2422). 21

[B31] MIL-PRF-2 8800 General Specification for Test Equipment for Use with Electrical and Electronic 22 Equipment. 23

[B32] MIL-STD-1916 Sampling Procedures and Tables for Inspection by Attributes (equivalent standard 24 ASQ Z1.4). 25

[B33] MIL-STD-961 Defense and Program Unique Spec Format and Content. 26

[B34] PCIbus; Wakefield, MA; URL: http://picmg.com. 27

[B35] PXIbus; Austin, TX; URL: http://vxipnp.org. 28

[B36] SI 10'American National Standard for Use of the International System of Units (SI): The Modern 29 Metric System, Co-Sponsorship IEEE/ASTM SI 10'-2002, New York, Institute of Electrical and 30 Electronics Engineers, Inc./ West Conshohocken, PA, ASTM International; URL: http://standards.ieee.org. 31

[B37] Society of Automotive Engineers; Aerospace Material Specification (AMS); Warrandale, PA. 32

[B38] VMEbus; VITA, Scottsdale, AZ; URL: http://vita.com; ANSI, Washington, DC; URL: http://ansi.org. 33

[B39] VXIbus; San Diego, CA; URL: http://vxi.org. 34

[B40] VXIbus IEEE 1155 Eurocard Mechanical Packaging; VXIbus-San Diego, CA; URL: http://vxi.org; 35 Piscataway, NJ; URL: http://standards.ieee.org. 36

18

ISO publications are available from the ISO Central Secretariat, Case Postalė 56, 1 rue de Varembė, CH-1211, Genevė 20,

Switzerland/.Suissė (http://www.iso.ch/). ISO publications are also available in the United States from the Sales Department,

American National Standards Institute, 25 West 43rd Street, 4th floor, New York, NY 10036, USA (http://www.ansi.org/). 19

MIL Standards and MIL Specifications are available through Document Automation and Production Service, Building 4/D, 700

Robbins Avenue, Philadelphia, PA 19111-5094. URL https://assist.daps.dla.mil/quicksearch/









http://picmg.com/

http://vxipnp.org/


http://vita.com/

http://ansi.org/

http://vxi.org/

http://vxi.org/
