1、 MIL-J-L7LILb 57 7777706 0037573 3 MILITARY SPECIFICATION JUNCTION BOX MARK 41 MOD O -07-/5- MIL- J-19416 ( NOrU 6 April 1956 ISSUED IN LIEU OF NAVORD OS 5418 r/ 1. SCOPE 1.1 This specification governs the manufacture,. assembly and preparation for delivery of Junction Box Mark 41 Mod O and the meth
2、ods of inspection and tests upon which product acceptance will be based. 2. APPLICABLE DOCUMENTS 2.1 The following specifications, standards, drawings and publications, of the issue in effect on the date of invitation for bids, form a part of this document: SPECIFICATIONS MIL-R-25018. - Relays, Mini
3、aturized, Hermetically sealed, airborne equipment NAVY DEPARTMENT General Specifications for Inspection of Material STANDARDS MILITARY MIL-STD-129 - Marking for Shipment and Storage DRAWINGS BUREAU OF ORDNANCE LD 295581 - Junction Box Mark 41 Mod O LD 413162 - Packaging Assembly List for Component L
4、D 412909 - Packaging Assembly List for Component Container Mark 20 Mod O Container Mark 10 Mod O - 1/ When publications, etc. , refer to NAVORD OS 5418., this specification applies. i THIS DOCUMENT CONTAINS /b PAGES , - I -. . - Provided by IHSNot for ResaleNo reproduction or networking permitted wi
5、thout license from IHS-,-,-MIL-J-1941b 59 7797906 0017572 3 W PUB LICATIONS BUREAU OF ORDNANCE OP 400 - General instructions for the Design, Manufacture and inspection of Naval Ordnance Equipment (Copies of specifications, standards, drawings, and publications required by contractors in connection w
6、ith specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer. ) 3. REQUIREMENTS 3.1 General. - The Junction Box Mark 41 Mod O shall be manufactured, assembled and prepared for delivery in accordance with the requirements of documents lis
7、ted on LD 295581. 3.1.1 in Bureau of Ordnance publication OP 400 shall be complied with, as applicable . The general requirements and procedures established 3.2 Continuity 3.2.1 Continuity, sub-assemblies. - All circuits connected by diagram on the cable assembly and receptacle assembly (Drawings 13
8、79501 and 1379500 of LD 295581) shall have a resistance of O. 1 ohm or less with a current of one (1) ampere flowing. This requirement on the receptacle assembly shall be met when the assembly and plug housing are mounted to the junction box body. 3.2.2 Continuity, junction box. - All circuits conne
9、cted by diagram (Drawing 1262262 of LD 295581) shall have resistance values given in the schedule in 4.3.1.2 when a current of one (1) ampere is flowing. indicate a resistance value within this document when tested in accordance with 4.3.2. 3.3 Resistance. - All resistors in the junction box shall 3
10、.4 insulation resistance. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-J-19LILb 57 7797906 0037573 5 -, MIL- J- 194 16 (-Nord 3.4.1 insulation resistance, sub-assemblies. - All pins on connector shells of the cable assembly and receptacle asse
11、mblv shall . indicate an insulation resistance of 50 megohms-or more with respect to every other non-connected pin shorted to all other non-connected pins and connector shells. This requirement on the receptacle assembly shall be met when the assembly and plug housing are mounted to the junction box
12、 body. 3.4.2 insulation resistance, junction box. - All pins on P1, J1, 52, and 53 not connected by diagram (Drawing 1262262 of LD 295581) shall indicate an insulation resistance of 50 megohms or mor when tested in accordance with 4. 3. 3. 3. 5 Capacitor. - Capacitor-Cl (Drawing 1262262 of LD 295581
13、) shall indicate a capacitance value of I. O f O. 2 microfarad when tested in accordance with 4.3.4.1. insulation resistance of this capacitor shall be 50 megohms or greater when tested in accordance with 4.3.4.2. 3.6 Relay 3.6.1 Acceptance tests. - Acceptance tests shall be performed at the discret
14、ion of the Government either at the place of manufacture by the contractor under Government supervision ir by an agency and at a place to be designated by the Government. The acceptance test shall consist of Group A and Group B Acceptance Tests of MIL-R-25018 as detailed in 4. 3. 5.1 of this documen
15、t. These tests shall be run prior to acceptance of each lot of relays for assembly in Junction Box Mark 41 Mod O. Drawing 1262292 shall be used in lieu of a Military Standard for the relay. 3.6.2 Assembly tests. 3.6.2.1 At the applicable stage of Junction Box Mark 41 Mod O assembly each relay shall
16、be tested in accordance with 4. 3. 5.2.1 3. 6.2. 2 Following the completion of the tests of 3. 6.2.1 the following requirements shall be met. 3. 6.2.2.1 The relay (K-1) shall operate with the application of 26. 5 * 2 volts in accordance with 4.3. 5.2.2 of this document. 3.6.2.2.2 Circuits completed
17、through relay contacts shall have a resistance of not more than O. 2 ohm, and open contacts shall show an insulation resistance of 50 megohms or more with the relay energized or de-energized, Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3.7 Mechan
18、ical requirements 3.7.1 Case strength. - The cable hook (refer to Drawing 1362936 of LD 295581) shall withstand a shearing force of 1000 pounds without causing fracture or deformity of the case, when tested in accordance with 4.3.6.1. 3.7.2 Plug housing. - The application of 35 pound-inches torque t
19、o the plug housing shall provide 160 degree rotation of this housing with respect to the case. The application of 18 pound-inches or less torque shall not cause rotation of the plug housing from its closed position. 3.8 Durability. - The junction box shall withstand extremes of shock and vibration.
20、After being subjected to these environmental conditions the junction box shall meet all the requirements of 3.2 through3. 7.2 excluding 3. 6.1. 3.8.1 Shock. - The junction box shall withstand shocks simulating careless handling during transportation as specified in 4. 3.7.1. 3. 8.2 Transportation vi
21、bration. - The junction box shall withstand simulated transportation vibrations as specified in 4.3.7.2. 3.8.3 Aircraft vibration. - The junction box shall withstand simulated aircraft vibrations as specified in 4. 3. 7. 3. 3.9 Wor kmans hip 3.9.1 Cleanliness. - Necessary precautions shall be taken
22、to protect the junction box components from moisture, solder splashes, chips, and other foreign matter during assembly processes. 3.9.2 Soldering. - Where soldering is employed, only non-corrosive and non-volatile fluxes shall be used. Rosin shall be used when soldering wires to coils, contacts, or
23、terminals. Solder shall not be used primarily for obtaining mechanical strength; el ectrical connections shall be mechanically secure and electrically continuous before soldering. Sufficient heat shall be applied during the soldering process to avoid ffcoldf solder joints. 4. QUALITY ASSURANCE PROVI
24、SIONS AND TEST REQUIREMENTS 4.1 Preproduction sample. - At the start of pilot production(or prior to full production, if there is no pilot production) a preproduction sample of five (5) Junction Boxes Mark 41 Mod O shall be delivered by the contractor to the Government inspector. These junction boxe
25、s shall be 4 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-J-LSLI116 57 7977706 00117575 7 ,- MIL-J-l9416(Nrd ) manufactured by the same procedures and processes and at the same location proposed by the contrastor for full production, using the
26、 same tooling, fixtures, and equipment as for full production. The Government inspector shall perform, witness, or participate in such inspections and tests on the samples as are required for full production, Upon acceptance by the inspector, the preproduction sample shall be forwarded together with
27、 a report of inspection to an activity designated by the procuring agency for final inspection and acceptance. When the sample has proved to be satisfactory, the contractorwill be notified and will be authorized by the procuring agency to proceed with the submission of the product for acceptance. Th
28、e preproduction sample shall be prepared for delivery in accordance with the applicable section of this document. Accepted samples shall become the property of the Government and shall be included in the number called for in the contract schedule. 4. i. 2 Preproduction sample for a subsequent contra
29、ct. - The necessity for a preproduction sample will be determined by the Bureau of Ordnance when production under a new contract by the same contractor at the same location follows the manufacture of satisfactory material as covered by this document. . 4.2 inspection. - The general inspection proced
30、ures shall be in accordance with General Instructions for the Design, Manufacture, and Inspection of Naval Ordnance Equipment, OP 400. In addition, there shall be 100% inspection of all junction boxes on tests described in 4. 3.1 through 4. 3.4.2 and 4. 3. 5. 2 through 4. 3. 5. 2.2. 4.3 Test methods
31、 4.3.1 Continuity 4.3.1.1 Continuity tests, sub-assemblies. - Using the circuit of Figure 1, measure the resistance of each conductor on the cable assembly and receptacle assembly. The receptacle assembly, with plug housing, shall be attached to .he body of the junction box but wires left unconnecte
32、d for these measurements. For each measurement, adjust R2 for a one (1) ampere current flow as indicated on the ammeter. The resistance shall be O. 1 ohm or less as indicated by a voltmeter reading of O. 1 volt or less. 4. 3.-1. 2 Continuity tests, junction box. - The resistance between appropriate
33、pins on J1, 52, 53 and P1 shall be measured by the ammeter- voltmeter method using the circuit of Figure 1. For each measurement listed below, adjust R2 for a one (1) ampere current flow as indicated on the ammeter. The voltmeter shall indicate voltages equal to or less than the falues shown in the
34、following schedule: Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIE-J-l9416(NOrd) MEASURE BETWEEN ACCEPTABLE VOLTAGES Pin A on P1 and Pin R on P1 S on P1 D on J1 C on J1 D on 52 C on 52 B on 53 C on 53 A on P1 S on P1 S on P1 S on P1 S on P1 H on
35、 P1 P on P1 O. 1 Vor less O. 1 Vor less O. 1 V or less O. 1 V or less O. 1 V or less O. 1 Vor less O. 2 V or less O. 2 V or less The resistance shall not be greater than O. 1 ohm for measurements on P1, J1 and 52 nor greater than O. 2 ohm for measurements on 53 as indicated by the maximum voltmeter
36、readings above. FIGURE 1. i D. C. SUPPLY 24 V. own resistance 1 r Supply - Variable d-c supply to be set for 24 V. output R1 R2 A V - 20 ohms 25 watt resistor - 20 ohms 5 watt variable resistor - Ammeter 0-1. 5 amperes d-c 1% accuracy - Voltmeter, with ranges of 0-1 and 0-30 volts d-c with 1% accura
37、cy and a resistance of at least 1000 ohms per volt, 4.3.2 Resistance tests 4.3.2.1 One-half ohm resistors. - All resistors having a nominal resistance of O. 5 ohm shall be measured at appropriate pins on Pl, J1, and 52 by the ammeter-voltmeter. method using the circuit of Figure 1. For each measurem
38、ent below, adjust R2 for a one (1) ampere current flow as indicated on the ammeter. The voltmeter shall indicate O. 5 + O. 1 - O volt for each measurement below: Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Provided by IHSNot for ResaleNo reproduc
39、tion or networking permitted without license from IHS-,-,-_ - VIL-J-LSYLh 57 H 9999906 0037578 4 M MIL-J-l9416(NOrd) 4. 3. 3.2 insulation resistance tests, junction box. - Insulation resistance of each pin on J1, 52, 53 and P1 shall be measured with respect to every other non-connected pin shorted t
40、o all other non-connected pins and grounded. Use the megohmmeter (4.3.8, item a) and make measure- ments according to the following schedule: MEASURE BETWEEN and - Pin F on P1 - E on P1 H on P1 P on P1 B on P1 C on Pi G on P1 M on P1 N on P1 The following pins shorted together and Grounded S, E, H,
41、P, B, C, G, M, N, T, V, U, D on P1 A on Ji A on 53 F, S, H, P, B, C, G, M, N, T, V, U, D on P1 A on J1 A on 53 F, S, E, B, C, G, M, N, T, V, U, D on P1 A on J1 A on 53 F, S, E, B, C, G, M, N, T, V, U, D on P1 A on J1 A on 53 F,S,E,H,P,C,G,M,N,T,V,U,DonPl A on J1 A on 53 F, S, E, H, P, B, G, M, N, T,
42、 V, U, D on P1 A on J1 A on 53 F, S, E, H, P, B, C, M, N, T, V, U, D on Pl A on Ji A on 53 F, S, E, H, P, B, C, G, N, T, V, U, D on P1 A on J1 A on 53 F, S, E, H, P, B, C, G, M, T, V, U, D on P1 A on J1 A on 53 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from
43、 IHS-,-,-MIL-J-1741b 57 77777Ob 0017577 b P and - Pin T on P1 - V on P1 U on P1 D on P1 A on J1 A on 53 MIL- 5-194 16 ( Nord ) MEASURE BETWEEN (cont) The following pins shorted together and Grounded F, S, E, H, P, B, C, G, M, N, V, U, D on P1 A on J1 A on 53 F, S, E, H, P, B, C, G, M, N, T, U, D on
44、P1 A on J1 A on 53 F, S, E, H, P, B, C, G, M, N, T, V, D on P1 A on J1 A on 53 F,S,E,H,P,B,C,G,M,N,T,V,U onP1 A on J1 A on 53 A on 53 F, S, E, H, P, B, C, G, M, N, T, V, U, D on P1 All measurements shall indicate insulation resistance of 50 megohms or greater. 4.3.4 Capacitor 4.3.4.1 Capacitance tes
45、t. - The capacitance of C1 shall be measured by connecting a capacitance bridge (4.3.8, item b) across pins H and P on P1. The indicated value of Ci shall be 1. O f O. 2 microfarad. 4.3.4.2 Capacitor insulation resistance. - Connect the d-c supply (4.3.8, item C) to pins J (POSITIVE) and S (NEGATIVE
46、) on P1 and apply 26. 5 * 2 volts so as to energize K-l. Measure the insulation resistance between pins H and P on P1 at a test potential of 100 f 1OV. d-c, using the megohm bridge (4.3.8, item d). The insulation resistance shall be 50 megohms or more when tested in an ambient temperature of 25 degr
47、ees Centrigrade. Repeat the measurement with the relay de-energized. 4.3. 5 Relay test _. . 4.3. 5.1 Acceptance Tests. _7_c 9 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,- MIL-J-LSLILh 57 7777706 0037580 2 _- 4.3. 5.1.1 The sampling, rejection and
48、 disposition procedures of section 4.3, of MIL-R-25018 shall be followed. 4.3.5.1.2 Group A Acceptance Tests. - The relays shall be subjected to the tests in Table I in the order listed: TABLE I-GROUP A ACCEPTANCE TESTS (Paragraph references are to MIL-R-25018) Requirement Test Test Paragraph Paragr
49、aph Visual and Mechanical Inspection 3.2, 3.3.6, 3.3.11 4. 5.1 Electrical Character istics 3.4 4. 5.3 a. Dielectric Strength 3.4.9 4. 5.3. i. 1 3.13, 3.14, 3.15 b. Pull-in voltage 3.4. 3.1 4. 5.3.3 C. Drop-out voltage 3.4. 3.1 4. 5. 3.4 d. Contact resistance 3.4.1 4.5.3.6 e. Coil Current 3.4. 5 4.5.3.8 f. DIRECT Current Coil Resistance 3.4.6 4.5. 3.9 Seal Test 2 3.3.10 4. 5.2.2 4.3. 5.1.3
