Raychem

ICD
PRODUCT B ULLETIN

MIL-STD-1553B Data Bus Microcouplers

Raychem has developed a very compact, in-line, spliceterminated data bus microcoupler. This new lightweight design meets the MIL-STD-1553B requirements for hardware configuration and performance. The low-profile configuration enables avionics system designers to plan for optimum coupler locations. The Raychem data bus microcoupler features: J Environmental sealing. J No connectors. JVery small size, light weight - 1 stub: 10 g (max.) - 2 stub: 15 g (max.) JIn-line profile to enable wire bundle mounting. J 360 continuous low-impedance cable shield terminations. JReliable solder termination of all components, JPotted circuit elements for maximum durability and in-use reliability. J Ease of installation. J Altitude immersion resistance. JOptional eyelet configurations for bulkhead mounting. J MTBF > l,000,000 hours. Raychems data bus microcouplers are qualified to Raychem Specification D-6020, and are supplied with Raychem SPEC 55 data bus cables, including EMP-hardened versions. All of these products are available assembled with other components into a complete data bus harness.
Microcouplers with Internal Terminator

Old-Design Coupler vs. New Microcoupler

Raychem Microcoupler Part Numbers:

(see the back of this Product Bulletin for microcoupler configurations)

D-500-04WW-X-61Y-ZZZ Boot
5 = w/o eyelet 6 = with eyelet

Cable Length
012 = 12 in (1 ft) 078 = 78 in (6.5 ft) 079 = 79 in (2m) 120 = 120 in (10 ft) 236 = 236 in (6m) 240 = 240 in (20 ft) 360 = 360 in (30 ft)

Design
Optional Eyelet Configuration
5 6 7 8 = w/o internal terminator = same as 5 with reverse bus = with internal terminator = same as 7 with reverse bus

Cable Type
612 = 10612 613 = 10613 614 = 10614

Number of Stubs
1 or 2

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.
SPEC 55 is a trademark of Raychem Corporation.

1996 Raychem Corporation

DB0003 10/96

Microcoupler Part Numbers and Configurations

Single Stub Double Stub

D-500-0455-1-XXX-YYY

D-500-0455-2-XXX-YYY

D-500-0465-1-XXX-YYY

D-500-0465-2-XXX-YYY

D-500-0456-1-XXX-YYY

D-500-0456-2-XXX-YYY

D-500-0466-1-XXX-YYY

D-500-0466-2-XXX-YYY

D-500-0457-1-XXX-YYY

D-500-0457-2-XXX-YYY

D-500-0467-1-XXX-YYY

D-500-0467-2-XXX-YYY

D-500-0458-1-XXX-YYY

D-500-0458-2-XXX-YYY

D-500-0468-1-XXX-YYY

D-500-0468-2-XXX-YYY

Bus Cable Stub Cable

Raychem

ICD
PRODUCT B ULLETIN

SPEC 55 Data Bus Cables and TMS Marker Sleeves

Raychem manufactures a line of SPEC 55* data bus cables that meet or exceed the performance requirements of MIL-STD-1553B. These cables are :
J Lightweight J Highly flexible J Flame-resistant J Chemical-resistant to all known aircraft fluids J Solder-iron-resistant J Made with optimized shielding providing three levels

of defined EMI/EMP protection.

Raychem Cable Part Numbers

24 AWG Single Optimized Shield 24 AWG Double Optimized Shield 24 AWG EMP Hardened 10612 10613 10614

*SPEC 55 insulation is a high-temperature, radiation-crosslinked, modified ETFE material that can be used in wire constructions rated up to 200C. This insulation is qualified to MIL-W-22759/32-/35 and /41-/46.

TMS ldentification Cable Marker Sleeves:

For identification of data bus networks and components, Raychem also manufactures TMS marker sleeves that meet MIL-M-81531 requirements for print adherence. TMS marker sleeves are rugged, heat-shrinkable, and flame-retardant. Marks, made permanent on the sleeve with infrared heat applied by the TMS permatizer, remain legible even after exposure to fuels, lubricants, and solvents.

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.
SPEC 55 and TMS are trademarks of Raychem Corporation DB0003 6/95

Raychem

ICD
PRODUCT B ULLETIN

Data Bus Discrete Connectors

Raychems D-621 series connectors are designed specifically For MIL-STD-1553B data bus applications. In addition to utilizing Raychems heat-shrink technology, the D-621 series connectors also feature: J Compliance to MIL-STD-1553B hardware requirements. J Light weight. J Removable pin or socket contacts. J Termination with Raychem MIL-STD-1553B data bus cables, including EMP-hardened versions. J Continuous 360 shield coverage. J Rugged constructions. J Termination time of 1 to 2 minutes. J Inspectable solder terminations. J Low-skill assembly. JReworkable and repairable terminations. J Strain relief built into the design. JLow voltage drop and high reliability due to precisely controlled solder terminations. JThreaded coupling, with safety wire holes and bayonet coupling styles. J Low total installed cost. J 1000-hour salt spray resistance. J Lower-cost connectors for benchtop and mock-up. The D-621 connector was designed to be a perfect match for the Raychem airworthy data bus cable. Together they provide durable, reliable, and workable interconnection hardware for the MIL-STD-1553B market. Raychem D-621 connectors are qualified to Raychem Specification D-6025.
Bayonet Connector Mates

Threaded Connector Mates

Raychem Connector Part Numbers: DK-621-04XX-XX

D-621 Connector, kitted with accessories Basic Connector Configurations
Threaded Styles:
11 = Plug 12=Jack 35 = Plug, B polarization 36 = Jack, B polarization 37 = Plug, C polarization 38 = Jack, C polarization 39 = Plug, D polarization 40 = Jack, D polarization

Contact (installed, DK-621 kits only)

P = Pin* S = Socket*
*May be ordered separately as D-602-0126 (pin) and D-602-0127 (socket).

Bayonet Styles:
33 = Plug, A polarization 34 = Jack, A polarization

Polarization (bayonet styles only)

1=A 2=B 3=C 4=D

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.
D-621 is a trademark of Raychem Corporation DB0004 6/95

Raychem
MIL-STD-1553B Data Bus System Air Force Components

Part Spliced Terminators

Outline (not to scale)

Air Force Drawing Number 84215031

Threaded
Plug Jack Single Shield Double Shield Cable EMP Hardened Low Capacitance Stub Spliced In Couplers 8421524 8421525 8421526 8421527 8421528

Bayonet 8912009
8912010

8912011
1 84215051, 8912026

Threaded
Connectorized Box 8912005 8912007

Bayonet
8912006 8912008

Threaded
Connectors Plug Jack Triaxial Contacts (for MIL-C-38999 connectors, size 8 cavity) Splices Connector Caps
1 2 3

Bayonet
89120032 89120042

8340709

83407112

Interchangeable Inner Contacts

Outer Pin Outer Socket 83407123 8340708

MIL-STD-1760 Applications
89120203

Threaded 8912012
See Air Force Drawing 8912023 for termination instructions See Air Force Drawing 8912021 for termination instructions See Air Force Drawing 8912022 for termination instructions

Bayonet 8912013

Raychem

ICD
PRODUCT B ULLETIN

MIL-STD-1553B Data Bus Accessories

Raychem manufactures all the products needed to build a MIL-STD-1553B data bus network. In addition to the main components (couplers, connectors, contacts and cables), Raychem supplies the accessory components that may be necessary to complete a data bus system, such as:
J Bus and stub terminators (spliced-in and connectorized

D-621 series)
J Cable splice kits J EMI/environment-resistant connector caps J Braid terminators and strain relief tubing (for rework

applications)
Bus and Stub Terminators

Raychem Accessory Part Numbers:

See the back of this product bulletin.

Cable Splice Kits

Connector Caps

Braid Terminators and Strain Relief Tubing

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.

D-621 Is a trademark of Raychem Corporation.

DB0006

6/95

DATA BUS ACCESSORIES PRODUCT SELECTION

Bus and Stub Terminators

Spliced-in D-621 Plug
D-621 Jack

Spliced-in
78-ohm 10612 Cable 78-ohm 10613 Cable 78-ohm 10614 Cable

12-lnch Cable
D-500-0463-612 D-500-0463-613 D-500-0463-614

D-621 Series - Plug

78-ohm Pin Contact 78-ohm Socket Contact 3000-ohm Pin Contact 3000-ohm Socket Contact

Threaded
D-621-0413 D-621-0415 D-621-0417 D-621-0407

Bayonet A
D-621-0453 D-621-0469 D-621-0457 D-621-0473

Bayonet B
D-621-0454 D-621-0470 D-621-0458 D-621-0474

Bayonet C
D-621-0455 D-621-0471 D-621-0459 D-621-0475

Bayonet D
D-621-0456 D-621-0472 D-621-0476 D-621-0460

D-621 Series - Jack

78-ohm Pin Contact 78-ohm Socket Contact 3000-ohm Pin Contact 3000-ohm Socket Contact

Threaded
D-621-0418 D-621-0406 D-621-0423 D-621-0424

Bayonet A
D-621-0477 D-621-0461 D-621-0481 D-621-0465

Bayonet B
D-621-0478 D-621-0462 D-621-0482 D-621-0466

Bayonet C
D-621-0479 D-621-0463 D-621-0483 D-621-0467

Bayonet D
D-621-0480 D-621-0464 D-621-0484 D-621-0468

Connector Caps
D-621 Series
Plug Cap for Jack Connector

Threaded
D-600-0083

Bayonet A
D-600-0068

Bayonet B
D-600-0068

Bayonet C
D-600-0068

Bayonet D
D-600-0065

Braid Terminators and Strain Relief Tubing

Connectors
All D-621 Series

Braid Terminator
D-600-0030

Strain Relief Tubing

D-600-0019

Cable Splice Kits

Cables
All Data Bus Cables

Flexible Crimp
D-150-0708-5

Raychem

ICD
PRODUCT B ULLETIN

MIL-STD-14553B Data Bus Components

Connectorized System Spliced-In Line

Dematable Bus Terminator 78 Threaded and Bayonet Sealed, 1000-hr Salt Spray Resistant, D-621-04XX (Ref. USAF 8421524, 8912009)

Raychem Data Bus Cables 24 AWG Single Shield 10612 (Ref. USAF 8421526) 10613 24 AWG Double Shield (Ref. USAF 8421527) 24 AWG EMP Hardened 10614 (Ref. USAF 8421528)

Spliced-In Lightweight Bus Terminator Sealed D-500-0463-XXX

BUS Box Coupler with D-621 Discrete Connectors, 1-to 8-Stub Sealed, 1000-hr Salt Spray Resistant, D-500-0255-5XX-X (Ref. USAF 8912007, 8912009) CONTROLLER

Spliced-In-Line Lightweight Bus Coupler. 1- or 2-Stub, Sealed, D-500-04-XXX (Ref. USAF 8912026)

or
DK-621-041X-X Discrete Connectors Threadad and Bayonet, Sealed, 1000-hr Salt Spray Resistant (Ref. USAF 8340709, 8340711)

R/T SolderShield Splice with MiniSeal Crimp or SolderSleeve Splice with In-Line Splice Kit. Sealed, D-150-0706-X (Ref. USAF 8340708)

R/T MIL-C-38999 Size 8 Cavity Triaxial Contacts D-602-1108/1109, D-602-1112/1113 (Ref. USAF 8340712, 8340713) DK-602-0156/0157, DK-602-0169/0170 (Ref. USAF 8912019, 8912020) Spliced-In Flat-Pack Bus Coupler D-500-F4XX-X

R/T

Dematable Stub Terminator D-621-04XX, Threaded and Bayonet Sealed, 1000-hr Salt Spray Resistant (Ref. USAF 8421525, 8912010) R/T Box Coupler with Dematable Bus Terminator D-500-0255-XXX TYPICAL REMOTE TERMINAL (R/T) Weapon Delivery System Attack Radar P.I.U. Fire Control Radar RF/lR Warning Nav. Radar Terrain following Radars Air Data Computer E W Systems Alt. Heading Ref. Radar Warning Receiver Mass Memory Mission Computers Heads-up Display Flight Control Functions Stores Mgmt. Systems Spliced-ln Coupler with Internal Terminator. Sealed, D-500-0457-X

D-621, MiniSeal, SolderShield. and SolderSleeve are trademarks of Raychem Corporation.

1996 Raychem Corporation

DB0001

7/96

ICD

Raychem

PRODUCT B ULLETIN

MIL-STD-1553B Data Bus Box Couplers

Raychem's data bus box couplers provide light, robust coupler modules with connector versatility. Up to eight stub connectors can be arrayed on the "face" of the box coupler. The bus connectors can also be on the "face" or on the "side" of the box. Box couplers are designed with Raychem D-621 series corrosion-resistant threaded- or bayonet-type connectors and are qualified to Raychem Specification D-6021. The following box coupler configurations are currently readily available. Raychem also designs and manufactures customized data bus box couplers.
Box Couplers: 4-Stub "Face and 1 -Stub Side

Raychem Data Bus Box Coupler Part Numbers

Coupler Type Face - 1 Stub Face - 2 Stub Face - 3 Stub Face - 4 Stub Face - 5 Stub Face - 6 Stub Face - 7 Stub Face - 8 Stub Side - 1 Stub Side - 2 Stub Side - 3 Stub Side - 4 Stub Side - 5 Stub Side - 6 Stub Side - 7 Stub Side - 8 Stub Threaded D-500-0255-511-1 D-500-0255-521-1 D-500-0255-531-1 D-500-0255-541-1 D-500-0255-551-1 D-500-0255-561-1 D-500-0255-571-1 D-500-0255-581-1 D-500-0255-512-1 D-500-0255-522-1 D-500-0255-532-1 D-500-0255-542-1 D-500-0255-552-1 D-500-0255-562-1 D-500-0255-572-1 D-500-0255-582-1 Bayonet A* D-500-0255-513-1 D-500-0255-523-1 D-500-0255-533-1 D-500-0255-543-1 D-500-0255-553-1 D-500-0255-563-1 D-500-0255-573-1 D-500-0255-583-1 D-500-0255-513-2 D-500-0255-523-2 D-500-0255-533-2 D-500-0255-543-2 D-500-0255-553-2 D-500-0255-563-2 D-500-0255-573-2 D-500-0255-583-2 Bayonet B* D-500-0255-515-1 D-500-0255-525-1 D-500-0255-535-1 D-500-0255-545-1 D-500-0255-555-1 D-500-0255-565-1 D-500-0255-575-1 D-500-0255-585-1 D-500-0255-515-2 D-500-0255-525-2 D-500-0255-535-2 D-500-0255-545-2 D-500-0255-555-2 D-500-0255-565-2 D-500-0255-575-2 D-500-0255-585-2 Bayonet C* D-500-0255-517-1 D-500-0255-527-1 D-500-0255-537-1 D-500-0255-547-1 D-500-0255-557-1 D-500-0255-567-1 D-500-0255-577-1 D-500-0255-587-1 D-500-0255-517-2 D-500-0255-527-2 D-500-0255-537-2 D-500-0255-547-2 D-500-0255-557-2 D-500-0255-567-2 D-500-0255-577-2 D-500-0255-587-2

*The bayonet polarization listed is for the bus connector. All stub connectors are Bayonet D polarization. Polarizations are depicted as follows:

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.

Raychem

ICD
PRODUCT B ULLETIN

MIL-C-38999-Type Triaxial Contacts for Data Bus Applications

Now, both high-density packaging and full shield coverage are available with a simple, quick, and reliable termination system. AWG 24 twisted-pair data bus cables are terminated with triaxial SolderTact contacts, which fit size 8 cavities of MIL-C-38999, Series 1, 3, or 4 connectors. Raychems triaxial 38999-type data bus contact delivers the signals with:
J One-step termination. JTermination time of 1 to 2 minutes. JNo requirements for special termination tools. JNo requirements for special skills. JReworkable and repairable terminations.
Pin and Socket Contact Mates

J Strain relief that is built into the design. J Continuous 360 shield coverage. J Triaxial mating face for least susceptibility to damage. JRugged construction, because only 2 parts are being

soldered together.
J Inspectable solder terminations. J Low voltage drop and high reliability due to precisely

controlled solder termination. Raychems size 8 triaxial data bus contacts for MIL-C-38999 connectors have interfaces that comply with MIL-C-39029/90 and /91 to provide ease of termination and intermatability with more cumbersome crimp contacts. These contacts provide a fast and convenient method of implementing MIL-STD-1553B connections in MIL-STD-1760 applications.
MIL-C-38999 Connector

Raychem Triaxial Contact Part Numbers

Cable Type
10612 10613 10614

Pin
DK-602-0156-1 DK-602-0156-2 DK-602-0156-3

Socket
DK-602-0157-1 DK-602-0157-2 DK-602-0157-3

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.
SolderTact is a trademark of Raychem Corporation D80005 6/95

Raychem

ICD
PRODUCT B ULLETIN

Raychem Offers a Complete MIL-STD-15538 Data Bus System

Based on unique material technologies, the Raychem family of data bus components offers innovative solutions to todays aerospace data bus requirements. Raychems data bus component selection provides one-stop shopping for MIL-STD-1553B networks. Available components include:
J Variety of couplers (micros, boxes, flat-packs). JVariety of data bus cables. J Triax connectors and contacts with strain relief. J One-piece triaxial contacts for ML-C-38999

connectors (size 8 cavity).

J Bus and stub terminators. J Cable marker sleeves (TMS). J Complete network testing.

All Raychem data bus components offer:

J High packaging density and weight savings. J Design flexibility. J High performance (to 150C rating).

In addition to extensive field experience, Raychems MIL-STD-1553B data bus components are also specified in the Air Force drawings listed in Air Force Drawing 8340707. Raychems full line of data bus productscables, couplers, matched impedance terminators, D-621 discrete connectors, and MIL-C-38999-type size 8 triaxial contactsoffer a complete system of interconnection hardware for all MIL-STD-1553B multiplexing needs. Raychem also, supplies complete data bus networks in accordance with customer harness drawings. Using factory-built harnesses eliminates unnecessary splices and connectors, reducing the cost and increasing the reliability of the networks.

All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Raychem makes no warranties as to the accuracy of completeness of the information, and disclaims any liability regarding its use. Raychems only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Raychem reserves the right to make changeswithout notification to Buyerto materials or processing that do not affect compliance with any application specification.
D-621 and TMS are trademarks of Raychem Corporation DB0009 6/95