TRANSFORMERS AND INDUCTORS, HIGH RELIABILITY, SPACE USE, GENERAL SPECIFICATION FOR

Transcription

1 Registration No JAXA-QTS-2110B Superseding JAXA-QTS-2110A Cancelled TRANSFORMERS AND INDUCTORS, HIGH RELIABILITY, SPACE USE, GENERAL SPECIFICATION FOR JAXA JAPAN AEROSPACE EXPLORATION AGENCY

2 This document is the English version of JAXA QTS/ADS which was originally written and authorized in Japanese and carefully translated into English for international users. If any question arises as to the context or detailed description, it is strongly recommended to verify against the latest official Japanese version.

3 Page i Revision Record Rev. Date Revised Contents A 18 Nov. 05 1) Reflected the revision of NASDA-HDB-4. NASDA-HDB-4 JERG ) Specified a provision to allow using specifications prepared by acquisition officers as a product specification. 3) For Appendix B, clarified the qualification coverage and added a check sheet. B 30 Sep. 11 1) Paragraph : Corrected the test temperature of 3rd step in thermal shock test to the maximum operating temperature. 2) Added gull wing terminal and the corresponding test method. 3) Added and corrected wordings to explain or clarify the requirements.

4 Page ii Contents 1. GENERAL Scope Terms and Definitions Classification Part Number APPLICABLE DOCUMENTS Applicable Documents Reference Documents Order of Precedence Detail Specification Detail Specification Number Revision Letter of Detail Specification Independency of Detail Specification Format of Detail Specification Product Specification REQUIREMENTS Certification Qualification Coverage Initial Qualification Retention of Qualification Effective Period of Certification Change of Qualification Coverage Quality Assurance Program Establishment of a Quality Assurance Program TRB Formation Materials Outgassing Design and Construction Externals, Dimension, Mass and Marking Workmanship Rating Electrical Performance Mechanical Performance Environmental Performance Durability Performance QUALITY ASSURANCE PROVISIONS General Requirements Classification of Test and Inspection In-Process Inspection Qualification Test Sample Manufacturing Records Test Items and Sample Size Criteria for Pass/Fail... 9

5 Page iii Disposition after Inspections Quality Conformance Inspection Quality Conformance Inspection (Group A) Quality Conformance Inspection (Groups B and C) Method for Test or Inspection Externals, Dimension, Mass, and Marking Workmanship Electrical Performance Mechanical Performance Environmental Performance Durability Performance Long-Term Storage Disposition of Lots Stored for a Long-Term at the Manufacturer s Site Storage by Purchasers Change to Tests and Inspections PREPARATION FOR DELIVERY Packaging Marking on Package NOTES Notes for Manufacturer Preparation and Registration of Application Data Sheet Notes for Purchasers Items to be Specified for Procurement Preparing Product Specification Format Example Appendix A Inductors Low Frequency, Transformers Power, and Low Frequency Appendix B Transformers Power, and Inductors Power, (for manned missions)

6 Page 1 TRANSFORMERS AND INDUCTORS, HIGH RELIABILITY, SPACE USE, GENERAL SPECIFICATION FOR 1. GENERAL 1.1 Scope This specification establishes the general requirements and quality assurance provisions for space use, high reliability, transformers and inductors (hereinafter referred to as "transformers/inductors ") used for electronic equipment installed on space systems. Assemblies consisting of transformers or inductors combined with other parts shall be excluded from application of this specification. This specification complies with JAXA-QTS-2000 (Common Parts/Materials, Space Use, General Specification for) which was recently established to transition to the qualified manufacturing line system and replaces the following specifications. a) NASDA-QTS-39013C Inductors Low Frequency, Transformers Power, and Low Frequency, High Reliability, Space Use, General Specification For b) NASDA-QTS-1050 Transformers and Coils, High Reliability, Space Use, General Specification for 1.2 Terms and Definitions The definitions for terms used herein are as specified in JAXA-QTS-2000, JIS C 5301 and JIS C Classification Transformers/inductors covered by this specification shall be classified as specified in Table 1. Table 1. Classification Type Appendix Previous specifications Low frequency inductors and low frequency and power transformers A NASDA-QTS-39013C Power transformers and power inductors (for manned missions) B NASDA-QTS Part Number The part number shall be as specified in Appendix A, paragraph A of JAXA-QTS Details shall be as specified in each appendix.

7 Page 2 2. APPLICABLE DOCUMENTS 2.1 Applicable Documents The documents listed below form a part of this specification. These documents are the latest issues available at the time of contract award or application. If it is necessary to designate an issue, the issue shall be specified in the detail specification. a) JAXA-QTS-2000 Common Parts/Materials, Space Use, General Specification for b) JIS B ISO general purpose metric screw threads -- Part 1: Basic profile c) JIS B ISO general purpose metric screw threads -- Part 2: General plan d) JIS B ISO general purpose metric screw threads -- Part 3: Selected sizes for screws, bolts and nuts e) JIS B ISO general purpose metric screw threads -- Part 4: Basic dimensions f) JIS B ISO general purpose metric screw threads -- Tolerances -- Part 1: Principles and basic data g) JIS B ISO general purpose metric screw threads -- Tolerances -- Part 2: Limits of sizes for general purpose external and internal screw threads -- Medium quality h) JIS B ISO general purpose metric screw threads -- Tolerances -- Part 3: Deviations for constructional screw threads i) JIS C 3202 Enamelled winding wires j) JIS C 5301 General rules of low frequency transformer for electronic equipment k) JIS C 5310 Generic specification of transformers for electronic equipment l) JIS C 6435 Testing methods for low frequency transformers and inductors m) ASTM E 595 Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment n) MIL-HDBK-454 General Guidelines for Electronic Equipment o) MIL-STD-202 Test Method Standard, Electronic and Electrical Component Parts 2.2 Reference Documents The followings are reference documents of this specification. a) JERG NASDA Parts Application Handbook b) JIS C 5311 Testing methods of power transformers for electronic equipment c) MIL-PRF-27 Transformers and Inductors (Audio, Power, and High-Power Pulse), General Specification for 2.3 Order of Precedence In the event of a conflict between the text of this specification and the applicable documents, the following order of precedence shall apply. a) Detail specification

8 Page 3 b) This specification c) JAXA-QTS-2000 d) Applicable documents of this specification (paragraph 2.1, except for JAXA-QTS-2000) 2.4 Detail Specification Detailed requirements for the configuration and performance of transformers/inductors are specified in each detail specification and product specification. The detail specification shall be prepared and established by a manufacturer in accordance with Appendix A, Section A.4 of JAXA-QTS The detail specification shall also be registered with the Japan Aerospace Exploration Agency (hereinafter referred to as JAXA ) Detail Specification Number The detail specification number shall be indicated in the following form in accordance with Appendix A, paragraph A of JAXA-QTS (Example) JAXA-QTS-2110 / A A This specification number Appendix letter Individual Identification Revision letter Revision Letter of Detail Specification A revision letter in the detail specification number shall be assigned in accordance with Appendix A, paragraph A of JAXA-QTS Independency of Detail Specification The detail specification shall be a stand-alone document with a unique number defined in accordance with paragraph Format of Detail Specification The detail specification format shall be in accordance with Appendix A, paragraph A.6, item b) of JAXA-QTS-2000, and shall specify each requirement in accordance with Appendix A, Section A.4 of JAXA-QTS Product Specification When specifying requirements for special applications within the qualification coverage defined in the detail specification, purchasers and/or certified manufacturers shall prepare a product specification in accordance with paragraph 6.3 and verify its compliance with the qualification coverage specified in paragraph The product specification shall be readily available upon request from JAXA. Certified manufacturers shall attach a list of part numbers assigned to each product as a part of TRB status report in accordance with paragraph of JAXA-QTS-2000.

9 Page 4 3. REQUIREMENTS 3.1 Certification Qualification Coverage Qualification coverage shall be as specified in each appendix Initial Qualification To acquire certification of the transformers/inductors in compliance with this specification, a manufacturer shall establish a quality assurance program in accordance with paragraph 3.2.1, perform the qualification tests specified in paragraph 4.4, and acquire a certification status from JAXA as specified in paragraph of JAXA-QTS The manufacturer shall be listed on the Qualified Manufacturer List of the Japan Aerospace Exploration Agency (JAXA QML) Retention of Qualification To continue supplying transformers/inductors in accordance with this specification, a manufacturer must apply for QML certification retention in accordance with paragraph of JAXA-QTS-2000 commencing between 30 and 60 days prior to the expiration date of the certification period (paragraph 3.1.4). If products were not shipped during the effective period of certification and a quality conformance inspection was not conducted, the manufacturer may apply for retention of certification without conducting the quality conformance inspection Effective Period of Certification The effective period of certification granted in compliance with this specification shall be three years Change of Qualification Coverage To change the qualification coverage, a manufacturer shall perform procedures for re-certification in accordance with paragraph of JAXA-QTS Quality Assurance Program Establishment of a Quality Assurance Program To acquire certification status, a manufacturer shall be responsible for establishing a quality assurance program that satisfies the requirements specified in paragraph of JAXA-QTS-2000 and this specification. The manufacturer shall generate a Quality Assurance Program Plan in accordance with paragraph of JAXA-QTS-2000 and provide the plan to JAXA for review in accordance with paragraph of JAXA-QTS TRB Formation To acquire a certification status in compliance with this specification, the manufacturer shall form and operate the Technical Review Board (TRB) in accordance with paragraph of JAXA-QTS-2000.

10 Page Materials Materials used for manufacturing transformers/inductors shall be as specified in this specification. If a specific material is not specified, a material which enables the transformers/inductors to satisfy the requirements of this specification shall be used and the material shall be specified in the document defining the manufacturing conditions of the quality assurance program including the attached documents from a material manufacturer or receiving inspection data at the time of purchase Outgassing Organic materials used for transformers/inductors shall meet the following requirements when tested in accordance with ASTM E 595. a) Total Mass Loss (TML): 1.0% or less b) Collected Volatile Condensable Material (CVCM): 0.1% or less 3.4 Design and Construction The design and construction shall be in accordance with each appendix. The configurations, mounting constructions and terminal types shall be as specified in Tables 2 through 4, respectively. Detailed requirements shall be specified in the detail specification. 3.5 Externals, Dimension, Mass and Marking The externals, dimensions, mass and markings of transformers/inductors shall be as specified in each appendix. 3.6 Workmanship The workmanship of transformers/inductors shall be as specified in each appendix. 3.7 Rating The ratings of transformers/inductors shall be as specified in each appendix. 3.8 Electrical Performance Requirements for the electrical performance of transformers/inductors shall be in accordance with each appendix. 3.9 Mechanical Performance Requirements for the mechanical performance of transformers/inductors shall be in accordance with each appendix Environmental Performance Requirements for the environmental performance of transformers/inductors shall be in accordance with each appendix Durability Performance Requirements for the durability performance of transformers/inductors shall be in accordance with each appendix.

11 Page 6 Table 2. Configuration of Transformers/Inductors Grade Configuration Example Remark 4 Metal case Sealed type Glass or ceramic sealed terminal shall be used. 5 Synthetic resin case Filled type 5 Molded type Cast type 5 Coated type 6 Open type 7 Metal case, Semi-sealed type

12 Page 7 Table 3. Mounting Construction of Transformers/Inductors Mounting construction Example Remark With leads or pin terminals With studs With screw holes With holes on a mounting bracket By a mounting bracket tab By adhesion, screwing through a central mounting hole, or their combination

13 Page 8 Table 4. Terminal Construction of Transformers/Inductors Terminal type Construction Example Solid wire lead Contains a single wire (copper alloy wire etc.) to tie up terminals. Rod Metal rods, plates or tubes are embedded in an insulator, and wires are soldered to them (turret type or hook type, etc.). Soldered terminals Lug Wires are soldered to lugs mounted to an insulator (tub type, or flat type, etc.). Pin Leads (copper alloy wire etc.) are extended and to be soldered to a printed wiring board. Gull wing Leads are extended from the package body and flatten towards the end of the leads. Insulating lead Flexible insulated strand wires are pulled out outside the transformer or inductor for external connection (including direct wiring wire). Screw Wires are clinched to an insulator with a screw clamp or an embedded screw. Others Other than above.

14 Page 9 4. QUALITY ASSURANCE PROVISIONS 4.1 General Requirements The manufacturer shall be responsible for implementing the quality assurance program as specified in paragraph 3.2 and operating the TRB. 4.2 Classification of Test and Inspection The tests and inspections shall be classified into the following three categories in accordance with paragraph 4.3 of JAXA-QTS a) In-process inspection b) Qualification test c) Quality conformance inspection 4.3 In-Process Inspection The manufacturer shall perform the in-process inspections during the manufacturing process to detect any failure which could seriously affect the reliability and quality of the products, assure the workmanship, and characterize properties which cannot be measured using the finished products. Some examples are shown below. The manufacturing flowchart in the quality assurance program plan shall define the inspection process. a) Internal visual inspection of semi-finished products (non-destructive, 100% or sampled inspection) b) Physical and chemical inspection of semi-finished products (destructive or non-destructive, 100% or sampled inspection) c) Characterization of semi-finished products (non-destructive, 100% or sampled inspection) 4.4 Qualification Test Sample Samples shall be manufactured using the process and control specified in the quality assurance program and shall also typify the qualification coverage Manufacturing Records The manufacturer, which intends to acquire certification status, shall archive material certification, receiving inspection data or test data of materials used, work records related to sample preparation and the in-process inspection data. These records shall be readily available upon request Test Items and Sample Size Test items, test sequence and sample size of the qualification test shall be in accordance with each appendix Criteria for Pass/Fail A failure of any test in the qualification tests specified in each appendix shall constitute failure of the qualification tests. If the failure mode of the defects is catastrophic such

15 Page 10 as an open- or short-circuiting where the function of the transformers/inductors might be lost, the transformer and inductors fail the qualification test Disposition after Inspections The samples used in the qualification test shall not be delivered. The products in the same inspection lot that have passed the qualification test may be delivered after passing the Group A inspection of the quality conformance inspection. 4.5 Quality Conformance Inspection Quality Conformance Inspection (Group A) Group A inspections shall be performed at the time of production for all products Sample Selection of test samples for Group A inspections lots shall be defined as a part of the manufacturing conditions in the quality assurance program Inspection Items and Sample Size Inspection items, inspection sequence and sample size in the Group A inspection shall be as specified in each appendix Criteria for Pass/Fail A failure of any test in Group A inspections specified in each appendix shall constitute failure of Group A of quality conformance inspections. If the failure mode of the defects is catastrophic such as an open- or short-circuiting where the function of the transformers/inductors might be lost, the transformers/inductors fail Group A inspections Disposition after Inspections The lots rejected in Group A inspection shall not be delivered. Details shall be specified in each appendix Quality Conformance Inspection (Groups B and C) Groups B and C inspections shall be performed in accordance with the following schedule. a) Group B inspection shall be performed on the first lot manufactured within the certification period. b) When retention of certification is granted, Group C inspection shall be performed prior to the restart of production when no products were manufactured within the previous certification period and no quality conformance inspection was performed Sample Samples for Groups B and C inspection lots shall be taken from inspection lots that have passed Group A inspections.

16 Page Inspection Items and Sample Size Inspection items, inspection sequence and sample size of the Group B and C inspections shall be as specified in each appendix Criteria for Pass/Fail A failure of any inspection specified in the Group B or C inspections shall constitute failure of the quality conformance inspection of each group Disposition after Inspections The samples used for the Group B and C inspections shall not be delivered. If the samples fail in the Group B or C inspections, the manufacturer shall conduct a failure analysis on the defects and take corrective action. Delivery of the products shall be suspended until JAXA approves the corrective actions. 4.6 Method for Test or Inspection Externals, Dimension, Mass, and Marking Test methods for externals, dimensions, mass, and marking of the transformers/inductors shall be as specified in each appendix Workmanship Test methods regarding workmanship of the transformers/inductors shall be as specified in each appendix Electrical Performance Test methods regarding the electrical performance of the transformers/inductors shall be as specified in each appendix Mechanical Performance Test methods regarding the mechanical performance of the transformers/inductors shall be as specified in each appendix Environmental Performance Test methods regarding the environmental performance of the transformers/inductors shall be as specified in each appendix Durability Performance Test methods regarding the durability performance of the transformers/inductors shall be as specified in each appendix. 4.7 Long-Term Storage Disposition of Lots Stored for a Long-Term at the Manufacturer s Site When products have been stored at the manufacturer s site for 24 months or longer after the Group A inspections of the quality conformance inspection, the manufacturer shall perform 100% inspection for test items specified in each appendix prior to delivery.

17 Page 12 Only the transformers/inductors which have passed such inspections can be shipped as products Storage by Purchasers Instructions for storage by purchasers shall be as specified in the detail specification. 4.8 Change to Tests and Inspections Any change in the in-process inspection and quality conformance inspection specified in this specification shall be made in accordance with paragraphs 4.4 and 6.1 of JAXA-QTS PREPARATION FOR DELIVERY Preparation for delivery shall be as follows and as specified in Section 5 of JAXA-QTS Packaging The transformers/inductors shall be appropriately packaged as high reliability parts at the time of delivery from the manufacturer to the purchaser. Package specifications shall be included in the quality assurance program. a) Individual packaging A group of transformers/inductors shall be individually packaged in a proper manner. The group shall contain a practical quantity of transformers/inductors such as 5, 10, or 20. b) Packaging Transformers/inductors shall be individually packaged with cushioning materials to protect the products. Additional requirements for packaging shall be specified in procurement documents, if necessary. 5.2 Marking on Package Each shipping package shall have the following markings. a) Part name b) Part number (part number in this specification or that assigned by a purchaser) c) Applicable specification number d) Lot identification code e) Purchaser s name f) Manufacturer s name g) Quantity of packages h) Date of inspection i) Inspection result 6. NOTES 6.1 Notes for Manufacturer Preparation and Registration of Application Data Sheet The manufacturer shall prepare the Application Data Sheet in accordance with Appendix G of JAXA-QTS-2000 and register it with JAXA. 6.2 Notes for Purchasers Refer to the Application Data Sheet for detailed data of the products and notes.

18 Page Items to be Specified for Procurement To purchase transformers/inductors manufactured in accordance with this specification, the purchaser shall provide the following information. a) Part number (both specified in this specification and assigned by a purchaser) b) This specification number c) Detail specification number d) Indication of test data or source inspection results to be submitted for delivery e) Others For item e), requirements other than those defined in this specification may be specified by preparing a product specification (See paragraph 6.3.). However, if the requirements conflict with the existing requirements in this specification, the purchaser shall not request that the manufacturer indicate that the transformers/inductors comply with this specification. 6.3 Preparing Product Specification A purchaser and/or manufacturer shall prepare a product specification to specify requirements for special applications. The format of product specification shall be in accordance with Format Example - 1. For description of paragraph 3 and subsequent paragraphs of the format example, a specification prepared by the purchaser may be used as the product specification provided that such specification covers the contents of product specification.

19 Page 14 Format Example - 1 (1/5) Established on: October 10, 2005 Manufacturer: XXXXXXXXXX PRODUCT SPECIFICATION NASDA 2110/A114 T001 (to T003) JAXA Purchaser Manufacturer Part number (Control number) N2110/A114-T001 ABC A001 N2110/A114-T002 (skip) (skip) N2110/A114-T003 (skip) (skip) 1. Rating The rating shall be as shown in Table 1. Table 1. Rating Item N2110/A114-T001 N2110/A114-T002 N2110/A114-T003 Operating ambient temperature -55 to +100 C Maximum operating temperature +130 C Operating frequency 20kHz±10% (sine wave) (skip) (skip) Maximum operating voltage 175V Power voltage 50Vrms Output 253VA

20 Page 15 Format Example - 1 (2/5) 2. Qualification Coverage The qualification coverage shall be as shown in Table 2. Qualification coverage by similarity including certified transformers/inductors Table 2. Qualification Coverage Description of individual transformer and inductor Detail specification no.: JAXA-QTS-2110/A114 Product specification: NASDA2110/A114-T0010 (to T003) a) b) c) d) e) f) g) h) i) Typical part no.: N2110/A114-T000 N2110/A114-T001 N2110/A114-T002 N2110/A114-T003 Class (max. operating temperature) External/internal mounding structure S (130 C) max. Combination of adhesion and screwing S (130 C) Combination of adhesion and screwing External dimension (mm) φ80 x 60 H max. φ80 x 48 H Total volume (cm 3 ) max Operating voltage 200Vpeak max. 175Vpeak Insulation Polyester equivalent or better Polyester Magnet wire diameter (mm) φ0.14 min. φ0.14 Coating material Polyester equivalent or better Polyester Grade 6 6 Insulating, impregnating, and filling materials Epoxy impregnation Epoxy impregnation Construction and material of terminal PTFE lead: AWG28 min. Direct wiring wire: φ0.4mm min. Terminal strength PTFE lead: 13.7N max. Direct wiring wire: 9.8N max. Shock 1,000G, 0.5ms, semi sine wave max. High frequency: MIL-STD-202, test method 204, Vibration test condition D max. Random: MIL-STD-202, test method 214, test condition II-H max. Core material MPP MPP Core shape Toroidal Toroidal Dielectric withstanding voltage AC500V PTFE leads: AWG18, 20, 28 Direct wiring wire: φ1.0 x 5mm, φ0.4mm PTFE lead wire: 13.7N Direct wiring wire: 9.8N 840G, 0.6ms, semi sine wave High frequency: MIL-STD-202, test method 204, test condition D Random: MIL-STD-202, test method 214, test condition II-H AC500V (skip) (skip) j) Outline drawing

21 Page 16 Format Example - 1 (3/5) 3. Product Inspection External, construction, dimensions, marking and mass shall be as shown in Figures 1, 2 and Lead wire length: 100mm min. AWG 18 for terminals 5, 6 AWG 20 for terminals 3, 4, 7, 8, 9, 10, 11, 12 AWG 28 for terminals 15, 16 Direct wiring wires of φ1.0mm x 5 for terminals 1, 2 Direct wiring wires of φ0.4mm for terminals 13, 14 Coating removed for length of approximately 10mm at end 2. Mass: 900g max. Figure 1. External, Construction, Dimension, Marking and Mass (N2110/A114-T001) (Skip the rest)

22 Page 17 Format Example - 1 (4/5) 4. Performance The performance shall be as shown in Table 3. Table 3. Performance JAXA-QTS-2110, Appendix A Performance Item Paragraph no. N2110/A114-T001 N2110/A114-T002 N2110/A114-T003 Electrical characteristics A As specified in Table 4. As specified in Table 5. As specified in Table 6. Interlayer withstanding voltage A kHz, sine wave of 100Vrms for 5±0.5s between (1-2) Insulation resistance A a) 10,000MΩ Corona discharge A N/A Temperature rise A Up to 30 C (ambient temperature: 100 C) Solderability A N/A Resistance to soldering heat A N/A Seal A N/A (Skip) (Skip) Thermal shock A Test condition A-1 (temperature of 3rd step: 115 C) Immersion A N/A Flammability A N/A Resistance to solvents A N/A Life A Ambient temperature: 130 C measured temperature rise

23 Page 18 Format Example - 1 (5/5) 5. Electrical Characteristic The electrical characteristics shall be as shown in Tables 4, 5 and 6. Table 4. Electrical Characteristic (N2110/A114-T001) Item Rating Operating frequency Power voltage Winding ratio Inductance DC resistance (at 20 C) Output Polarity 20kHz±10% (sine wave) 50Vrms ( 3 4) / (1 2) = ± 3% ( 5 6) / (1 2) = ± 3% ( 7 8) / (1 2) = ± 3% ( 9 10) / (1 2) = ± 3% (11 12) / (1 2) = ± 3% (13 14) / (1 2) = ± 3% (15 16) / (1 2) = ± 4% (1 2) = 90μH min. at 10kHz, 0.1V, DC10A (1 2) = 0.03Ω max., ( 9 10) = 0.30Ω max (3 4) = 0.40Ω max., (11 12) = 0.35Ω max (5 6) = 0.20Ω max., (13 14) = 0.90Ω max (7 8) = 0.45Ω max., (15 16) = 5.00Ω max 253VA Test points 1, 3, 5, 7, 9, 11, 13, and 15 shall have same polarity. Test circuit (Skip the rest)

24 Page i APPENDIX A INDUCTORS, LOW FREQUENCY, TRANSFORMERS, POWER, AND LOW FREQUENCY A.1 GENERAL... A-1 A.1.1 Scope... A-1 A.1.2 Part Number... A-1 A Characteristic Identifier... A-1 A.2 APPLICABLE DOCUMENTS... A-1 A.2.1 Applicable Documents... A-1 A.2.2 Reference Document... A-2 A.3 REQUIREMENTS... A-2 A.3.1 Certification... A-2 A Qualificaiton Coverage... A-2 A.3.2 Materials... A-4 A Flammable Materials... A-4 A Corrosive Materials... A-4 A Antibacterial Materials... A-4 A Core Materials... A-4 A Molded Resins and Impregnating Materials... A-4 A Solder and Flux... A-4 A Screws, Nuts and Washers... A-4 A Magnet Wires... A-4 A Temrinal Materials... A-4 A.3.3 Design and Construction... A-5 A Mounting, Embedded, and Terminal Screws... A-5 A Terminals... A-5 A Mounting Studs... A-5 A Internal Lead Wires... A-5 A Core and Coil Mounting... A-6 A Coating and Plating... A-6 A Potting, Filling or Encapsulating Materials... A-6 A Grades... A-6 A.3.4 Externals, Dimension, Mass and Marking... A-7 A Externals and Marking... A-7 A Dimension, Total Volume and Mass... A-7 A Visual and Mechanical Inspection (Post-Test)... A-7 A.3.5 Workmanship... A-8 A.3.6 Rating... A-8 A Class... A-8 A.3.7 Electrical Performance... A-8 A Electrical Characteristics... A-8 A Dielectric Withstanding Voltage... A-8 A Interlayer Withsanding Voltage... A-8

25 Page ii A Insulating Resistance... A-8 A Corona Discharge (if required)... A-9 A Temperature Rise... A-9 A Overload... A-9 A Electrical Continuity... A-9 A.3.8 Mechanical Performance... A-9 A Terminal Strength... A-9 A Solderability... A-9 A Resistance to Soldering Heat (if required)... A-9 A Seal (Grade 4)... A-9 A.3.9 Environmental Performance... A-10 A Vibration... A-10 A Shock... A-10 A Thermal Shock... A-10 A Immersion... A-10 A Moisture Resistance... A-10 A Flammability (Grade 5)... A-10 A Resistance to Solvents... A-10 A.3.10 Durability... A-11 A Life... A-11 A.4 QUALITY ASSURANCE PROVISIONS... A-11 A.4.1 In-Process Inspection... A-11 A.4.2 Qualification Test... A-11 A Samples... A-11 A Manufacturing Records... A-11 A Test Items and Sample Size... A-11 A Criteria for Pass/Fail... A-11 A.4.3 Quality Conformance Inspection... A-13 A Quality Conformance Inspection (Group A)... A-13 A Quality Conformance Inspection (Groups B and C)... A-14 A.4.4 Test and Inspection Methods... A-16 A Test and Inspection Conditions... A-16 A Externals, Dimension and Marking... A-16 A Workmanship... A-16 A Electrical Performance... A-17 A Mechanical Performance... A-29 A Environmental Performance... A-35 A Durability... A-37 A.4.5 Long-Term Storage... A-38 A Disposition of Products Stored for a Long Term at the Manufacturer s SiteA-38 A.4.6 Changes to Tests and Inspections... A-38 A.5 PREPARATION FOR DELIVERY... A-38 A.6 NOTES... A-38 A.6.1 Notes for Manufacturures... A-38 A Prepration and Registration of Application Data Sheet... A-38 A.6.2 Notes for Acquisition Officers... A-39

26 Page iii A Items to be Specified for Procurement... A-39 A.6.3 Notes for Designning... A-39 A Phenolic Laminate... A-39 A Size of Transformers/inductors... A-39 A Test Circuits for Electrical Characteristics... A-40 A Ambient Temperature Rise... A-40 A Dielectric Withstanding Voltage... A-40 A Simplification of Dielectric Withstanding Voltage Test... A-40 A Interlayer Withstanding Voltage for Inductors... A-40 A Notes for Equipment Deisgners... A-40 A Center-Tapped Secondary Windings... A-43

27 This document is the English version of JAXA QTS/ADS which was originally written and authorized in Japanese and carefully translated into English for international users. If any question arises as to the context or detailed description, it is strongly recommended to verify against the latest official Japanese version.

28 Page A-1 APPENDIX A INDUCTORS, LOW FREQUENCY, TRANSFORMERS, POWER AND LOW FREQUENCY A.1 GENERAL A.1.1 A.1.2 Scope This specification establishes the general requirements and quality assurance provisions for power transformers, low frequency transformers and low frequency inductors (hereinafter referred to as "transformers/inductors"). Part Number The part number shall be indicated as follows. The details shall be as specified in the detail specification. (Example) JAXA (1) 2110 / A Appendix letter Individual identification Characteristic identifier (A.1.2.1) Note: (1) "JAXA" indicates the part is for space use and may be abbreviated J. If the part number is defined as NASDA in the detail specification, it may be abbreviated N. A Characteristic Identifier The characteristic identifier shall indicate characteristics of transformers/inductors such as electrical characteristics and shall be composed of a single capital letter followed by a 3-digit number. The letter distinguishes whether the product is Transformer (T) or Inductor (C) and the 3-digit number identifies transformers/inductors in the qualification coverage. A purchaser and/or manufacturer shall define the characteristic identifier in a product specification in accordance with paragraph 6.3. The characteristic identifier shall differ from those of samples subjected to the qualification test. A.2 APPLICABLE DOCUMENTS A.2.1 Applicable Documents Applicable documents for this appendix shall be as specified in paragraph 2.1 and as follows. a) MIL-W-16878D Wire, Electrical, Insulated General Specification for b) MIL-W-22759/17A Wire, Electric, Fluoropolymer-Insulated, Extruded ETFE, Medium Wight, Silver-Coated High Strength Copper Alloy Conductor, 600-Volt, 150 C

29 Page A-2 A.2.2 Reference Document Reference documents of this appendix shall be as specified in paragraph 2.2 and as follows. a) JIS C Environmental testing -- Part 2-21: Tests -- Test U: Robustness of terminations and integral mounting devices A.3 REQUIREMENTS A.3.1 A A Certification Qualificaiton Coverage The qualification coverage shall be limited to transformers/inductors produced by the manufacturing line that conforms to materials, designs, constructions, ratings and performance specified in paragraphs A.3.2 to A Transformers/inductors covered by this specification shall be fully represented by samples that have passed the qualification test (paragraph A.4.2.1), or shall conform to criteria for the extent of qualification by similarity. Within this coverage, the manufacturer is allowed to supply qualified products in accordance with the detail specification and the product specification (paragraph 2.4.5). If necessary, additional definitions of qualification coverage shall be specified in the detail specification or the product specification. Qualification by Similarity Qualification can be granted by similarity for transformers/inductors represented by samples that have passed the qualification test (paragraph A.4.2), and that are produced by the certified manufacturer using the design and manufacturing process stipulated in the quality assurance program without adversely affecting the performance, quality and reliability. In addition, such transformers/inductors shall meet the following items a) to i). Table A-1 shall be used to determine if the products can be qualified by similarity. a) The class (the maximum operating temperature: Table A-4) shall be the same or lower. b) The external and internal mounting constructions shall be the same or mechanically more robust against vibration and shock. The external linear (or diagonal) dimensions shall not exceed the corresponding dimensions and the total volume shall not exceed the corresponding volume. In the case of Grade 4, the case configuration shall be the same and the plate thickness shall be between 50 and 200%. c) The operating voltage shall be the same or lower and the insulations shall be equivalent or better, and the electric field strength per unit thickness of the insulating material shall be the same or lower, except when the requirement for dielectric withstanding voltage is 500V or lower. d) The electric wire dimension (cross section) shall be the same or greater, and the coating materials of the magnet wire for corresponding windings shall be equivalent or better. e) The grade shall be the same. The processing and materials for insulating, impregnating, and filling shall be the same, or shall have been verified to meet the required performance.

30 Page A-3 f) The construction and materials of terminals shall be the same, and the terminal strength required for the same or wider terminals shall be the same. g) The requirements for shock and vibration shall be the same or lower. h) The core materials shall be the same and the core shape shall be similar. i) When the requirement for dielectric withstanding voltage is 500V or lower, the transformer/inductor may be considered similar. Table A-1. Table for Transformer/Inductor Similarity Evaluation Item Transformer/inductor certified Transformer/inductor under evaluation Remark Detail specification/product specification number JAXA-QTS-2110/A Part Number a) b) Class (max. operating temperature) External/internal mounting construction External dimension Total volume Paragraph A of JAXA-QTS-2110 c) d) e) f) g) Operating voltage Insulations Magnet wire diameter Coating material Grade Insulating, impregnation, and filling material Construction and material of terminal Terminal strength Shock Vibration h) Core material Core shape i) Dielectric withstanding voltage j) Outline drawing

31 Page A-4 A.3.2 A A A A A A A A A Materials The materials shall be as follows and as specified in paragraph 3.3. Flammable Materials Unless otherwise specified, materials used for the transformers/inductors shall be nonflammable or nonexplosive. Corrosive Materials Corrosive materials used in the manufacturing processes shall be completely removed or neutralized to avoid corrosions. Unless otherwise specified, materials used in the transformers/inductors shall be noncorrosive. Antibacterial Materials External materials of the transformers/inductors shall be non-nutrient to bacteria growth or proper measures shall be taken for the materials to prevent bacteria growth. Core Materials Unless otherwise specified, MPP (Molybdenum Permalloy Powder), ferrite or amorphous shall be used for the core material. Molded Resins and Impregnating Materials Epoxy shall be used as the molded resin. Silicon or epoxy shall be used as the impregnating material. Solder and Flux The solder and flux specified in the detail specification shall be used and shall satisfy the requirements defined in MIL-STD-454. Screws, Nuts and Washers Screws, nuts, and washers shall be noncorrosive, or shall be protected against corrosions. Unless otherwise specified, screws and nuts shall be selected from those specified in JIS B to -4. Magnet Wires Magnet wires shall be selected from those types defined in JIS C 3202 with the conductor diameter of 0.1 mm or greater, and shall be capable for accommodating the maximum temperature of internal windings. The manufacturer shall obtain advance approval from JAXA to use other types or conductor diameters. Temrinal Materials Phosphor bronze, brass, copper or kovar shall be used for the pin and rod terminals. Insulated electrical wires specified in MIL-W-16878D or MIL-W-22759/17A shall be used for the insulated lead terminals other than direct wiring wires. The manufacturer shall obtain advance approval from JAXA in to use insulated electrical wires of other types or sizes as insulated lead terminals.

32 Page A-5 A.3.3 A Design and Construction Mounting, Embedded, and Terminal Screws Allowable limit sizes and tolerances for the mounting, embedded and terminal screws shall conform to JIS B After the finishing process is completed for the male and female screws, the mating torques shall not exceed the values shown in Table A-2. Table A-2. Torque Screw nominal (Unit: N m) Torque M M M M M M A A A Terminals a) Soldering Terminals Soldering terminals shall be easily soldered regardless of their shapes. Terminal height shall be considered as the maximum distance from the terminal mounting surface to the highest point of the terminal. This definition is applicable to straightened semi flexible terminals and hook-type terminals in the normal position. The shapes and dimensions of terminals and lead wires shall be as specified in the detail specification. b) Screw Terminals Unless otherwise specified, a screw terminal shall be composed of two nuts, two flat washers, and one tooth lock washer. The terminal height shall be the distance from the terminal mounting surface to the top end of the screw. Mounting Studs When specified, a mounting stud shall be composed of a flat washer and a lock nut or with a flat washer, a tooth lock washer, and a nut. Internal Lead Wires Internal lead wires shall be securely attached to coils or other internal parts, terminals, or case by soldering, welding, brazing, or other means. When soldered for electrical connectivity, the lead wires shall be mechanically secured prior to soldering.

33 Page A-6 A A A A Core and Coil Mounting Cores and coils shall be firmly mounted to prevent any change in the relative position of parts. When the total volume of the case or inner case of multiple-cased units (e.g. multiple-shielded units) exceeds 100cm 3, the mechanical strength of junctions between the cores and coils and the mounting devices (e.g. studs, lugs, inserts, brackets) shall not be solely provided by soldering. When rigid thermosetting resin is used or when the total volume of the case or inner case is 100cm 3 or less, potting or filling compound may be used as a method to mechanically secure the cores and coils provided that outflow of the softened compound does not occur at the specified maximum operating temperature. Coating and Plating Transformers/inductors shall be surface-treated such as coating or plating to prevent corrosions, if required. Unless otherwise specified, coating on the mounting surface and the terminal surface may be exempted. Potting, Filling or Encapsulating Materials Potting, filling, or encapsulating materials shall not outflow from the case of the transformer or inductor by any test. Grades Configurations of transformers/inductors shall be classified in the following four grades. Each grade shall satisfy environmental tests defined in Table A-3. a) Grade 4 (sealed metal case type) Grade 4 units are sealed, metal encased with separately fabricated headers or terminals. This grade does not include units encapsulated in a metal case with open end or side faces, or with insulated lead wires extending through the metal case. b) Grade 5 (encapsulated type) Grade 5 units are encapsulated, including molded or embedded constructions, or encased in a metal case with one face or both faces being open filled with encapsulation materials. c) Grade 6 (open type) Grade 6 units are of an open type, generally installed in a circuit board and embedded with other components covered with synthetic resin through processes such as potting or molding. d) Grade 7 (semi-sealed metal case type) Grade 7 units are encased in a metal case, with lead wires extending through a sidewall hole or with terminal plates. Sealing is not required.

34 Page A-7 Table A-3. Grades Test Grade 4 Sealed metal case type Grade 5 Encapsulated type Grade 6 Open type Grade 7 Semi-sealed metal case type Seal Thermal shock Immersion Humidity Vibration Shock Flammability A.3.4 A A A Externals, Dimension, Mass and Marking Externals and Marking Transformers/inductors shall be free of defects such as peeled coatings, cracks, scratches, compound leakages, or corrosions. The following items shall be marked on the surface of transformers or inductors in a manner which cannot be erased easily. a) Part number (part number of this specification or that assigned by purchaser) (1) b) Terminal identification c) Lot identification code Lot identification code shall be assigned as specified by the manufacturer. d) Serial number e) Manufacturer name or abbreviation Note: (1) As specified in the detail specification or product specification. If the marking area on the transformers/inductors is limited, items a) and e) may be omitted in the following order. a) Part number of this specification b) Manufacturer name or abbreviation Dimension, Total Volume and Mass Dimension, total volume, and mass shall be as specified in the detail specification. The total volume shall be calculated based on the external dimensions. Visual and Mechanical Inspection (Post-Test) When tested in accordance with paragraph A , protective coating damages such as peeled coatings, cracks, scratches, which will adversely affect the electrical or mechanical performance, shall not exceed 10% of the surface area. There shall not be any leakage of filling materials, physical damage such as cracks, crazing, or bulging of the case, or corrosion which will adversely affect the mechanical or electrical performance.

35 Page A-8 A.3.5 A.3.6 A Workmanship Transformers/inductors shall be manufactured based on a good design and in accordance with the quality assurance program defined in paragraph Rating Class Class shall be identified by a single capital letter as shown in Table A-4 below denoting the maximum operating temperature (measured temperature rise + the maximum ambient temperature) Table A-4. Class Symbol Maximum operating temperature ( C) Q 85 R 105 S 130 V 155 T 170 U >170 (Details shall be specified in the detail specification.) A.3.7 A A A A Electrical Performance Transformers/inductors shall meet the following requirements. Electrical Characteristics When tested as specified in paragraph A , transformers/inductors shall meet the electrical characteristics and tolerance specified in the detail specification. Dielectric Withstanding Voltage When tested as specified in paragraph A , there shall not be any arcing, flashover, dielectric breakdown or mechanical damage. Interlayer Withsanding Voltage When tested as specified in paragraph A , there shall not be continuous arcing or dielectric breakdown. Input current or Q shall not exhibit any abrupt change. Insulating Resistance When tested as specified in paragraph A , the insulation resistance shall exceed one of the following values specified in the test item table which is defined in the detail specification. a) 10,000MΩ b) 7,500MΩ c) 1,000MΩ

36 Page A-9 A A A A A.3.8 A A A Corona Discharge (if required) When tested as specified in paragraph A , the corona voltage shall not exceed 0.1V p-p when observed using oscilloscope. Temperature Rise When tested in accordance with paragraph A , the winding temperature rise shall not exceed the values specified in the detail specification (allowable temperature rise). Transformers/inductors shall be free of any physical damage. Overload When tested in accordance with paragraph A , there shall not be any leakage of filling materials, physical damage such as crack, crazing or bulging of the case, or corrosion which will adversely affect the mechanical or electrical performance. Electrical Continuity When tested in accordance with paragraph A , all windings shall maintain electrical continuity. Mechanical Performance Transformers/inductors shall meet the following requirements. Terminal Strength When tested in accordance with paragraph A , the terminals shall not have any loosening, breakage or other mechanical damage. Terminal bending is not considered damage provided that the surface is free of any crazing. Terminals other than flexible terminals shall not rotate. Permanent rotation angle of hook-type terminals shall not exceed 10 at the metal part. Solderability When tested in accordance with paragraph A , the dipped lead surfaces of the leads shall be at least 95% covered with a new, smooth, solder coating. Although the remaining 5% may contain only small pinholes or rough spots, they shall not be concentrated in one area. Resistance to Soldering Heat (if required) There shall not be any softening of insulation materials, or loosening of windings or terminals when tested in accordance with paragraph A A Seal (Grade 4) a) Liquid-filled units There shall not be any liquid leakage when tested as specified in item a) of paragraph A b) Gas-filled units The gas leak rate shall not exceed x 10-9 Pa m 3 /s when tested in accordance with item b) of paragraph A

37 Page A-10 c) All other units There shall not be any continuous air bubble or compound leakage when tested in accordance with item c) of paragraph A A.3.9 A A A A A Environmental Performance Transformers/inductors shall satisfy the following requirements. Vibration When tested in accordance with paragraph A , there shall not be any leakage of filling materials, or physical damage such as crazing, crack, or bulging of the case. Shock When tested in accordance with paragraph A , there shall not be any leakage of filling materials, or physical damage such as crazing, crack, or bulging of the case. Thermal Shock When tested in accordance with paragraph A , there shall not be any leakage of filling materials, physical damage such as crack, crazing or bulging, of the case, or corrosion which will adversely affect the mechanical or electrical performance. Immersion When tested as specified in paragraph A , there shall not be any leakage of filling materials, physical damage such as crack, crazing, or bulging of the case, or corrosion which will adversely affect the mechanical or electrical performance. Moisture Resistance When tested in accordance with paragraph A , there shall not be any leakage of filling materials, physical damage such as crack, crazing, or bulging of the case, or corrosion which will adversely affect the mechanical or electrical performance. A Flammability (Grade 5) When tested as specified in paragraph A , transformers/inductors shall not produce intense combustions that will cause explosive fires. The coating materials used on the transformers/inductors shall be self-extinguishable. Even if burned out by an ignition source in the test, the transformers/inductors shall not be considered failed unless dripping of burning materials or an explosive fire occurs. The transformers/inductors shall be considered failed if explosions, dripping of burning material or explosive fires occur, or if burning continues more than 3 minutes after removal of the ignition source. The material shall be considered self-extinguishing if the following conditions are satisfied. a) Burning shall not continue more than 3 minutes after removal of the ignition source. b) The material shall neither explode nor burn explosively. c) Burning materials shall not drip from the transformers/inductors. A Resistance to Solvents When tested as specified in paragraph A , there shall not be any mechanical damage and the marking shall remain legible.

38 Page A-11 A.3.10 A Durability Transformers/inductors shall meet the following requirements. Life Transformers/inductors shall be free of physical or electrical damage such as wire breaking or short-circuiting (between layers, windings, windings and case or cores, windings and shield, etc.) when tested in accordance with paragraph A In addition, the transformers/inductors shall satisfy the following requirements. a) Insulation resistance shall be as specified in paragraph A b) Dielectric withstanding voltage shall be as specified in paragraph A c) Interlayer withstanding voltage shall be as specified in paragraph A d) Electrical characteristics shall be within the tolerance specified in the detail specification. A.4 QUALITY ASSURANCE PROVISIONS A.4.1 A.4.2 A A A A In-Process Inspection The manufacturer shall define the following in-process inspection in the manufacturing flowchart and perform it. a) Pre-cap internal visual inspection (100% non-destructive) Qualification Test The qualification test shall be as follows and as specified in paragraph 4.4. Samples Samples for the qualification test shall be as specified in paragraph Multiple samples may be used if a single sample is not sufficient to include critical design and construction verification. Manufacturing Records The manufacturing records shall be as specified in paragraph When there is a specific product covered in the qualification coverage at the time of the qualification test, the manufacturer shall prove that the product satisfies the requirements specified in paragraph A Test Items and Sample Size Test items and sample size of the qualification test shall be as specified in Table A-5. All samples shall be subjected to Groups I and II tests and shall be divided for Groups III and IV tests. Criteria for Pass/Fail A failure of any test in the qualification tests except for Group I shall constitute failure of the qualification tests. If the failure mode of the defects is catastrophic such as open- or short-circuiting where the function of transformer/inductor might be lost, the transformers/inductors fail the qualification test.

39 Page A-12 Table A-5. Qualification Test Sub group I II III IV Test item Grade Requirement paragraph Test method paragraph Thermal shock (25 cycles) A A Electrical continuity A A Materials, design, construction, external, dimension, marking, workmanship A to A.3.2.3, A to A.3.3.3, A.3.3.6, A.3.4.1, A.3.4.2, A.3.5 A.4.4.2, A Electrical characteristics A A Seal A A Dielectric withstanding voltage (barometric pressure) A A Dielectric withstanding voltage (reduced barometric pressure) A A Interlayer withstanding voltage A A Insulation resistance A a) A Resistance to bacteria (1) A Solderability (2) A A Life A A Dielectric withstanding voltage (reduced voltage) A A Insulation resistance A b) A Interlayer withstanding voltage A A Visual and mechanical inspection (post-test) A A Electrical characteristics A A Corona discharge (if required) A A Resistance to soldering heat (if required) A A Terminal strength A A Temperature rise (2 samples) A A Vibration A A Shock A A Dielectric withstanding voltage (reduced voltage) A A Interlayer withstanding voltage A A Electrical continuity A A Immersion A A Moisture resistance A A Dielectric withstanding voltage (reduced voltage) A A Interlayer withstanding voltage A A Insulation resistance A c) A Electrical continuity A A Overload A A Dielectric withstanding voltage (reduced voltage) A A Interlayer withstanding voltage A A Insulation resistance A c) A Electrical continuity A A Electrical characteristics A A Visual and mechanical inspection (post-test) A A Resistance to solvent (3 samples) A A Flammability (2 samples) A A DPA (3 samples) (3) A.3.2, A.3.3.4, A.3.3.5, A.3.3.7, A.3.5 A Sample size No. of defectives permissible 100% 1 100% Notes: (1) This test may be exempted if all external materials are verified to be antibacteria. (2) This test shall be applicable only to soldered terminals which are specified in Table 4. (3) For Grades 4 and 5, DPA shall be performed with the samples submitted to the resistance to solvent.

40 Page A-13 A.4.3 Quality Conformance Inspection A Quality Conformance Inspection (Group A) Group A inspection shall be as follows and as specified in paragraph A Test Items and Sample Size Test items and sample size of the Group A inspections shall be as specified in Table A-6. Inspections shall be performed in the order of subgroups listed. Sub group A1 A2 Table A-6. Quality Conformance Inspection (Group A) Inspection item Requirement paragraph Test method paragraph Thermal shock (5 cycles) (1) A A Electrical continuity A A Material, design, construction, external, dimension, marking and workmanship A to A.3.2.3, A to A.3.3.3, A.3.3.6, A.3.4.1, A.3.4.2, A.3.5 A , A Seal (Grade 4) A A Dielectric withstanding voltage A A Interlayer withstanding voltage A A Insulation resistance A a) A Electrical characteristics (2) A A Transformation ratio A Polarity A No load A Rated load (3) A Insertion loss-frequency characteristic DC resistance and resistive unbalanced Inductance and inductive unbalanced A A A Winding unbalanced A Other electrical characteristics Sample size 100% No. of defectives permissible 10% or less or 1unit or less 100% 0 Notes: (1) 25 cycles for samples to be submitted to Groups B and C inspections. (2) Only items specified in the detail specification shall be performed. Actual circuit may be used for the test. (3) This inspection may be exempted if existing data is accepted by JAXA.

41 Page A-14 A A Criteria for Pass/Fail Criteria for pass/fail shall be as specified in paragraph Disposition after Inspections Products in the lot that have passed the Group A inspection may be delivered provided that the terminals are clean and smooth. A Quality Conformance Inspection (Groups B and C) Groups B and C of the quality conformance inspection shall be as follows and as specified in paragraph A A Samples Inspection lot for Group B or C inspection shall be made of the most critical products that have passed the Group A inspection. If the transformer/inductor is manufactured per multiple detail specifications or product specifications and is unable to be represented by the most critical product alone, multiple products may be used as the samples. The manufacturer shall determine the most critical product based on the minimum wire diameter, volume or other specifications which will affect environmental resistance, and shall stipulate in the document defining the manufacturing conditions of the quality assurance program. Test Items and Sample Size Test items and sample size of the Groups B and C inspections shall be as specified in Table A-7 and Table A-8, respectively.

42 Page A-15 Table A-7. Quality Conformance Inspection (Group B) Sub group Inspection item Grade Requirement paragraph Test method paragraph Sample size No. of defectives permissible Dielectric withstanding voltage (reduced barometric pressure) A A Corona discharge (if required) A A Resistance to soldering heat (if required) A A Terminal strength A A Temperature rise A A Vibration A A Shock A A Dielectric withstanding voltage (reduced voltage) A A Interlayer withstanding voltage A A Electrical continuity A A Immersion A A B1 Moisture resistance A A Dielectric withstanding voltage (reduced voltage) A A Interlayer withstanding voltage A A Insulation resistance A c) A Electrical continuity A A Overload A A Dielectric withstanding voltage (reduced voltage) A A Interlayer withstanding voltage A A Insulation resistance A c) A Electrical continuity A A Electrical characteristics A A Visual and mechanical inspection (post-test) A A Resistance to solvent A A Flammability (2 samples) A A DPA A.3.2, A.3.3.4, A.3.3.5, A.3.3.7, A.3.5 A

43 Page A-16 Table A-8. Quality Conformance Inspection (Group C) Subgroup Inspection item Requirement paragraph Test method paragraph Sample size No. of defectives permissible Solderability (1) A A Life A A Dielectric withstanding voltage (reduced voltage) A A C1 Interlayer withstanding voltage A A Insulation resistance A b) A Electrical characteristics A A Visual and mechanical inspection (post-test) A A Note: (1) Applicable only to the soldered terminals shown in Table A-4. A.4.4 A A A A Test and Inspection Methods Test and Inspection Conditions Test and inspection conditions shall be in accordance with Section 4 of MIL-STD-202. The following details and exceptions shall apply. a) Measurements shall be made at a temperature between 15 and 35 C. b) Reference measurement When measurements are made before and after the tests and inspections, the latest values measured under the measurement condition shall be used as the reference value. If the reference value has been made 30 days prior to the beginning of test or inspection, or is possibly affected by measuring jigs, the measurement shall be repeated to refresh the reference value. c) Power supply voltage Fluctuation in the power supply voltage for the life test shall be within ±3%. Externals, Dimension and Marking Transformers/inductors shall be examined for materials, external design, construction, dimensions, mass, and markings to verify compliance with the detail specification. Visual and Mechanical Inspection (Post-Test) Upon completion of all environmental tests, protective coating, filling material, and case construction shall be examined to verify compliance with the detail specification. Workmanship Workmanship shall be examined to verify compliance with paragraph A.3.5.

44 Page A-17 A A A A DPA Transformers/inductors shall be disassembled and/or dissected after radiography and examined visually or with a microscope of about 10-times magnification for the following items to verify that the materials, internal lead wires, internal mounting construction, impregnation, filling, and workmanship conform to the requirements specified in the detail specification and quality assurance program. Procedures for radiography, disassembling, and dissecting examination and control shall be stipulated in the quality assurance program. DPA results shall be photographed or captured in other physical media. a) Gaps between filling materials and internal elements which will affect relative positions of the internal elements. b) Crazing or cracks of the sintered core c) Free foreign objects such as solder particles and other metallic objects in the transformers/inductors d) Compatibility between the solder melting point for internal connections and the transformer/inductor class e) Types and dimensions of the windings, internal wires, and core f) Mounting methods of the windings and internal wires g) Insulating methods between the windings and internal wires and the case and core h) Adhesiveness of the filling materials with the case or lead wires i) Softening or outflow of the impregnating, filling, or encapsulating materials j) Appropriateness of materials of internal elements, internal construction and processes that are not covered by a) through i) k) Any other defect that adversely affects the reliability of transformers/inductors Electrical Performance Electrical performance tests shall be performed as follows. Electrical Characteristics Electrical characteristics specified in the detail specification shall be tested using the methods defined in this specification. Electrical tests not covered in this specification shall be defined in the detail specification. No Load The rated voltage shall be applied to the primary winding at the specified frequencies with the secondary winding being open. The following items shall be measured. a) No-load RMS current (I n1 ) b) No-load power (P n1 ) c) Primary-tap and RMS secondary voltages d) Neutral point voltage unbalanced = (V 1-V 2 ) x 100 (%) (V 1 +V 2 ) Voltage unbalance shall be computed as shown above. V 1 and V 2 are the voltages between the neutral point and each terminal of the winding, and V 1 V 2. (V 1 - V 2 ) shall be directly measured by a bridge or equivalent method.

45 Page A-18 A A Rated Voltage a) Unrectifired output The secondary rated output voltages shall be measured with the rated voltage at the specified frequency applied to the primary windings of the transformer, and with the rated load currents flowing in the secondary winding. b) Rectified output RMS output voltages at the secondary winding terminals shall be measured with the rated voltage at the specified frequency applied to the primary windings of the transformer. The output shall be rectified and filtered using specified rectifiers and filters to produce the rated DC current and shall be terminated with a resistive load. DC Resistance and Resistive Unbalance Winding DC resistance may be measured at ambient temperature and converted to a value at 20 C, if required. The resistive unbalance of windings having a neutral point shall be calculated as follows. (R 1 -R 2 ) R 1 x 100(%) Where, R 1 and R 2 are DC resistance values between the neutral point and each winding terminal, and R 1 R 2. Kelvin bridge shall be used to measure resistance values equal to or less than 1Ω. A Inductance and Inductive Unbalance Winding inductance shall be measured at the specified test voltage and frequency. For transformers/inductors that superimpose DC currents, measurements shall be made with the specified DC currents superimposed in the specified windings. The inductive unbalance of windings having a neutral point shall be calculated as follows. (L 1 -L 2 ) L 1 x 100(%) Where, L 1 and L 2 are inductance values between the neutral point and each winding terminal, and L 1 L 2. A Harmonic Distortion The transformer shall be connected to a proper power supply and load impedance. A sine-wave voltage of the specified frequency shall be applied in order to obtain the specified output conditions, and the total harmonic distortion shall be measured or computed.

46 Page A-19 A A Primary Impedance Transformer primary impedance shall be measured between the primary terminals at the specified frequency with all secondary windings loaded with the specified impedance loads. When DC currents are superimposed, the specified DC currents shall be superimposed in the specified windings. The resistance and reactance values seen from the primary side shall be measured at the specified frequency and voltage by a bridge or equivalent method approved by JAXA. Loss Frequency Response Using the circuit shown in Figure A-1, the transformer shall be terminated with the specified impedance. The power supply voltage with the reference frequency shall be adjusted to obtain the specified voltage across the load. While the constant power supply voltage is maintained, the output voltages shall be measured at the specified frequencies. For applications where DC currents are superimposed, the measurements shall be made with the rated DC currents superimposed in the specified windings. The measurements shall be made using a vacuum-tube voltmeter or equivalent instrument having a high input impedance. The same measurement instrument type shall be used to measure the power supply voltage and the output voltage. Loss deviation d 1 in decibels (db) at f f for reference frequency f r shall be computed as follows. d 1 = 20 log 10 E f E r (db) Where, E r is output voltage at the reference frequency f r, and E f is output voltage at any other specified frequency f f. Unless otherwise specified, the measurement may be made in accordance with paragraph 5.13 of JIS C 6435 or using a spectrum analyzer. Figure A-1. Test Circuit for Loss Frequency Response

47 Page A-20 A Insertion Loss Using the circuit shown in Figure A-1, output voltage at the specified frequency shall be measured at the specified power supply voltage, power supply impedance, and load impedance. Insertion loss bd in decibels (db) shall be calculated as follows. bd = 10 log 10 E S 2 Z L 4V o 2 Z a (db) Remark: This measurement is accurate only when the image impedance precisely matches the power supply impedance. A A A Resonance a) Transformers The specified load shall be connected to all secondary windings and the maximum rated voltage shall be applied to the primary windings. The power supply frequency shall be changed over the specified frequency range maintaining the constant primary voltage, and the secondary voltage shall be observed. The load impedance shall be set at the minimum frequency in the range and shall not be changed during this test. The resonance frequency shall be determined by this test. All resonance frequencies in the specified frequency band shall be recorded. b) Inductors RMS inductor terminal voltage shall be observed with constant AC and DC currents in the inductors. Cross Talk (Coupling among individual trasfomers of multiple transformer module) Frequency and voltage specified in the detail specification shall be applied to one of the transformers in the multiple transformer module and measure the voltage induced on the winding having the highest voltage or impedance in the multiple transformer module. Electrostatic Shielding All windings shall be short-circuited and those on the same side of the electrostatic shield shall be connected together. The circuit shown in Figure A-2 shall be used. The signal generator output voltage shall be set at the specified frequency to generate a definite indication on the detector while switch S is in the open position. Then switch S shall be turned to the closed position. The generator voltage shall be increased until the detector comes to indicate the same reading. The ratio of the generator voltages shall be computed to obtain the electrostatic shielding effectiveness. The detector shall have a minimum input impedance of 1MΩ.

48 Page A-21 Figure A-2. Test Circuit for Electrostatic Shielding A A Electromagnetic Shielding The transformer/inductor shall be coaxially placed 300±10mm apart in the approximate center of a Hermholz structure consisting of two additively seriesconnected test coils. Each coil shall be a 1,500 turn copper wire of 0.2mm diameter which is wound around a bobbin of 300±10mm in radius and 25±0.5mm in axial length. 115V of 50 or 60Hz shall be applied across the series-connected coils. The transformer/inductor shall be rotated until the voltage induced in the winding having highest voltage or highest impedance reaches the maximum value that shall be recorded. The detector shall have a minimum impedance of 1MΩ. Winding Unbalance Transformer winding unbalance shall be measured using the circuit shown in Figure A-3. Variable attenuator ATT shall be adjusted so that the voltmeter V indicates the same reading in both positions of switch K. Where the attenuation in this adjustment is bo, the winding unbalance bw in decibels (db) shall be calculated as follows. bw = bo 20log 10 n 1 n (db) Where, n 1 /n 2 shall be the turn ratio of power supply side winding to load side winding. The voltmeter input impedance shall be high enough compared to R 2 and R 0, and the load resistors shall have a minimum balance of 80dB.

49 Page A-22 OSC: Oscillator T: Sample transformer ATT: Variable resistance attenuator W 1 : Power supply side windings K: Transfer switch W 2 : Load side windings V: Voltmeter R 2 : Load resistor R0: Resistor equivalent to ATT characteristic impedance Figure A-3. Test Circuit for Winding Unbalance A Polarity Using the circuit shown in Figure A-4, one end of the primary and secondary windings shall be connected together. With an AC voltage applied at the high voltage terminal, the voltage V 3 between terminals 1 and 3 shall be measured. If V 3 is equal to the difference between V 1 and V 2, terminals 1 and 3 are of the same polarity. If V 3 is equal to the sum of V 1 and V 2, terminals 1 and 3 are of the opposite polarity. Other methods are allowed as long as polarity is properly measured. Figure A-4. Test Circuit for Polarity A Q (Storage Factor) Q shall be measured using a Q meter or other proper methods under the specified conditions.

50 Page A-23 A A A A A A Waveform Output waveforms shall be observed using an oscilloscope with the power supply and the load connected under the specified conditions. Transformer Turn Ratio Transformer turn ratio shall be measured in accordance with paragraph 5.6 of JIS C 6435 or other appropriate manner. Phase Characterstics Transformer phase characteristics shall be measured in accordance with paragraph 5.16 of JIS C Short Circuit With the secondary windings shorted in turn, the voltage applied to the primary shall be increased until the secondary winding current reaches the rated current. Current flowing in the primary winding, voltages across the primary winding, and power supplied to the primary side shall then be measured. Leakage Inductance Leakage inductance of low frequency transformers shall be measured in accordance with paragraph 5.10 of JIS C Overload The overload test shall be performed at a minimum duration of 48 hours in the qualification test and 8 hours in the quality assurance inspection. If the operating temperature of transformers/inductors is lower than the maximum operating temperature for the class in the temperature-rise test specified in paragraph A , the ambient temperature in the overload test shall be raised until the operating temperature reaches the maximum operating temperature for the class. The test conditions shall be as specified item a), b), or c) shown below. At the completion of the test, the transformers/inductors shall be examined for leakages of filling compounds and other visible damages. The transformers/inductors may be cooled for approximately 8 hours at the standard conditions before conducting subsequent tests. a) Transformers 1) Output of less than 0.8W 112% of the DC and AC rated voltage shall be applied without any load at an ambient temperature equal to the maximum operating temperature for the class. This test shall not be performed for Grades 4 and 7 transformers. 2) Output of 0.8W or greater The rated voltage at the minimum frequency of the specified frequency band shall be applied to the primary windings at the specified duty cycle. The rated load shall be connected to the secondary windings. The input voltage shall then be raised to 112% of the rated voltage. When specified, the rated DC current shall be superimposed during the test.

51 Page A-24 b) Inductors 1) Rated power (=DC resistance x rated current 2 ) of less than 0.2W The rated AC and DC voltages applied at an ambient temperature equivalent to the maximum operating temperature for the class. This test shall not be performed for Grades 4 and 7 inductors. 2) Rated power (=DC resistance x rated current 2 ) of 0.2W or greater 112% of the rated DC current and AC voltage shall be applied at the minimum frequency of the specified frequency band and at the specified duty cycle. c) Saturable core transformers/inductors The test shall be performed in accordance with item a) or b) above. The required load shall be adjusted so that 112% of the rated currents flow in the control windings and output windings. A A Dielectric Withstanding Voltage At Atmospheric Pressure Transformers/inductors shall be tested in accordance with test method 301 of MIL-STD-202. The following details shall apply. a) Test voltage For windings not internally grounded, the test voltage shall be as specified in Table A-9. When there are high-voltage center-tapped windings or adjacent windings operating with DC potentials, the predicted peak voltage between the windings shall be considered in calculating the test voltage. Test voltage which exceeds 1,000V RMS shall be gradually applied at a rate equal to or less than 500V per second. b) Voltage Type: AC c) Duration of application 1) For qualification test: 1 minute 2) Group A inspection of quality conformance inspection: 5 seconds as a minimum d) Points of application 1) Between winding and case or core The test voltage shall be applied between each winding and the case or core with all windings not under test grounded to the case (if cased) or to the normal mounting bracket (if uncased) and core (if accessible). 2) Between windings The test voltage shall be applied between each winding and each of the other windings with all windings not under test grounded to the case (if cased), the normal mounting bracket (if uncased), or core (if accessible). This test is not required if the test voltage between the winding and case or core is equal to or greater than the test voltage between the windings. Two power supply units shall be used to perform the dielectric withstanding voltage test between the windings. These power supply units shall be in-phase and well-balanced to supply test voltages as specified in Table A-9, and one terminal of each power supply unit shall be grounded to the case (if cased), the normal

52 Page A-25 mounting bracket (if uncased), or the core (if accessible). The test voltages shall not exceed the required test voltages between each of the windings and ground, and shall be applied so that the required test voltages appear between the windings. Multi-section windings designed only for series or parallel operations shall be considered a single winding. Test voltage between the windings shall never exceed the sum of the test voltages between each of the windings and the case (if cased), the normal mounting bracket (if uncased), or the core (if accessible). e) A high voltage power supply unit shall have a minimum of 1KVA capacity for voltage tests over 1KV. f) Inspection during and after test Transformers/inductors shall be examined for evidence of arcing, flashovers, dielectric breakdowns, and mechanical damages. Table A-9. Test Voltage in Barometric Pressure Operating voltage (1) (Unit: V) RMS test voltage (94.6 to 108.4kPa) 25 or less 50 Over 25 to Over 50 to Over 100 to Over 175 to x operating voltage Over x operating voltage + 1,000 Note: (1) The operating voltage is defined as the maximum instantaneous voltage stress that may appear under the normal rated operation across the insulation under test. This insulation may exist between the windings or between the winding and the case or core. A For Special Designs For transformers/inductors windings which are internally grounded or part of which is designed to operate at or near the ground potential, the interlayer withstanding voltage test or a combination of the DC dielectric withstanding voltage test on the low-voltage terminal and the interlayer withstanding voltage test shall be performed. Windings with special dielectric features such as graded insulation shall be subjected to the dielectric withstanding voltage test at the specified test voltage or to the interlayer withstanding voltage test.

53 Page A-26 A At Reduced Barometric Pressure Transformers/inductors designed to operate at an altitude of 3,000m or higher shall be tested in accordance with test method 105 of MIL-STD-202 and as specified in paragraph A above. The following details shall apply. a) Test condition: D (1.1kPa), or as specified in the detail specification for the altitude of 9.000m or lower. b) Test voltage As specified in Table A-10. The supplier may choose to use a higher voltage. c) Inspection during and after test Transformers/inductors shall be examined for evidence of arcing, flashovers, dielectric breakdowns, and mechanical damages. Table A-10. Test Voltage for Reduced Pressure Operating voltage (1) RMS test voltage (Unit: V) 25 or less 50 Over 25 to Over 50 Either 300 or 1.25 x operating voltage, whichever is greater Note: (1) The operating voltage is defined as the maximum instantaneous voltage stress that may appear under the normal rated operation across the insulation under test. This insulation may exist between windings or between the winding and the case or core. A A A For Special Designs The interlayer withstanding voltage test shall be performed under reduced barometric pressure conditions equivalent to the altitude for which the transformer or inductor is rated. The test voltage shall be adjusted so that 125% of the rated voltage is generated across the windings. At Reduced Voltage Transformers/inductors shall be tested as specified in paragraph A % (65% in life test) of the test voltages specified in Table A-9 shall be applied for 5 seconds. Interlayer Withstanding Voltage Transformers/inductors whose terminal voltages exceed 25V shall be subjected to the interlayer withstanding voltage test. There shall not be any continuous arcing, dielectric breakdown, or abrupt change in the input current. Methods shall be provided to detect input voltage shifts or Q changes. Voltage shall be applied to the transformers/inductors to generate 200% of rated voltage across the windings. The test voltage may be applied to any winding. The windings shall be grounded in the same way as the actual application. The test frequency, which is sufficiently apart

54 Page A-27 from the resonance frequency, shall be specified by the supplier. The test voltage shall be applied for either 7,200±200 cycles or 5±1/2 seconds, whichever is longer. A A Insulation Resistance Transformers/inductors shall be tested in accordance with test method 302 of MIL-STD-202. The following details shall apply. a) Test conditions Test condition B shall apply for the qualification test. In the quality conformance inspection, DC500 to 1,000V shall be used and pass/fail shall be determined based on measurements made at 500V. Test voltage shall be 100V if the operating voltage is 175V or lower, and 50V if 25V or lower. b) Points of measurement 1) Windings to case or core The voltage shall be applied between each winding and the case or core. All windings not under test shall be grounded to the case (if cased), the normal mounting bracket (if uncased), or the core (if accessible). 2) Between windings (for Grade 5 and if the mounting brackets or core are inaccessible) The voltage shall be applied between each winding and all other windings connected together. c) The measurements may be made at any temperature above 20 C in ambient humidity. The pass/fail shall be determined based on measurements made at C in a relative humidity of 80% or lower. Corona Discharge Unless otherwise specified, transformers/inductors shall be tested as specified in item a) or b) below. Oscilloscopes shall have the minimum sensitivity of approximately 40mV P-P /cm and shall have adequately flat frequency responses up to 200kHz. Unless otherwise specified, oil-filled transformers/inductors shall be inclined and tested at various angles. a) Insulation between windings Transformers/inductors shall be tested using Circuit 1 of Figure A-5. The peak test voltage shall be 130% of the applied peak terminal voltage under pressures equivalent to those in the range from sea level to the specified altitudes. b) Insulation between windings, and Insulation between windings and core or ground Transformers/inductors shall be tested using c) Circuit 2 of Figure A-5. The peak test voltage shall be 130% of the operating voltage under pressures equivalent to those in the range from sea level to the altitude specified.

55 Page A-28 Circuit 1. Primary Excited Notes: 1. Unless otherwise specified, when circuit 1 or 2 is used, the case and all windings other than those under tested shall be grounded. 2. C = 200pF, L = 20 to 30mH, Q 50 at 100kHz. HV = high voltage power supply, corona free Circuit 2. External High Voltage Power Supply Figure A-5. Test Circuit for Corona Discharge

56 Page A-29 A Temperature Rise Unless otherwise specified, the temperature rise test shall be applicable to transformers rated at 0.8W or greater average output and for inductors for which the product of the DC resistance and the square of the rated current is 0.2W or greater. The temperature rise of each winding shall be based on the change in winding resistance and computed by the following formula. θ =θ 2 θ a = R 2 R 1 1 α +θ 1 1 α + θ a Where, θ θ 2 θ a θ 1 R 1 R 2 α : Temperature rise ( C) : Final winding temperature ( C) : Final ambient temperature ( C) : Initial ambient temperature ( C) : Winding resistance at temperature θ 1 (Ω) : Winding resistance at temperature θ 2 (Ω) : Resistance temperature coefficient ( C -1 ) ( for copper) Transformers/inductors shall be left in an air-flow free location at least 3 hours preceding the test without excitation. For transformers, the rated voltage at the rated frequency shall be applied to the primary windings with the specified load connected to the secondary windings. For inductors, the rated DC and AC currents shall be applied to the windings. Transformers/inductors shall be operated until two consecutive resistance readings taken on the highest resistance winding at 30 minute interval become equal. The resistance shall be measured as soon as the power is turned off. The transformer/inductor shall then be examined for any physical damage. Unless otherwise specified, transformers/inductors shall be tested in an air-flow free atmosphere. Ambient temperature shall be the average of at least 3 thermometer readings which shall be measured at locations which are 1 to 2 meters apart from the transformer/inductor at the same height as the transformer/inductor. The final ambient temperature shall be the average of readings measured in the last hour of the test. A A A Winding Continuity All windings shall be tested using an appropriate method. Mechanical Performance Mechanical performance tests shall be performed as follows. Terminal Strength Transformers/inductors shall be tested as specified in paragraphs A through A for items specified in the detail specification. After completion of each test, the terminal shall be examined for looseness, cracks, and other mechanical damages. Unless otherwise specified, all terminals shall be tested. For the same terminal type, the maximum of four terminals shall be tested per sample.

57 Page A-30 A Pull Test a) Pin terminals and gull wing terminals Transformers/inductors shall be tested in accordance with test method 211 of MIL-STD-202. The following details shall apply. 1) Test condition: A 2) Applied force The force shall be gradually increased until it reaches 9.8N in the axial direction of each pin terminal as shown in Figure A-6. Figure A-6. Force Direction Applied to Each Pin Terminal b) Other terminal types Transformers/inductors shall be performed in accordance with test method 211 of MIL-STD-202. The following details shall apply. 1) Test condition: A 2) Points of measurement The force shall be applied in the axial direction for solid-wired, rod, and screw-thread types, in the terminal direction for lug type, and in the terminal pulled-out direction for insulating lead type. Force shall be gradually increased until it reaches the value shown in Table A-11. The terminals shall withstand the force for 5 to 10 seconds. Table A-11. Pull Test Cross section of the terminal at its smallest point where the lead from the external circuit is connected in mm 2 (equivalent circular diameter, mm) (Unit: N) Force 1.0 ( 1.14) 9.8 >1.0 ( 1.14) 19.6

58 Page A-31 A Twist or Bend Test a) Solid-wire lead terminals Following the test specified in item b) of paragraph A , transformers/inductors shall be tested in accordance with test method 211 of MIL-STD-202. The following exceptions shall apply. 1) Test condition: D 2) Application of torsion A terminal fixed to the body or clamp shall be bent and rotated 360 degrees around the original axis, which is counted as the first rotation. Rotate the terminal in the opposite direction, which is the second rotation. Perform a total of 5 rotations at the rate of approximately 3 seconds per rotation. b) Lug terminals For terminals that indicated permanent metal deformations exceeding 15 degrees during the pull test specified in paragraph A , the following test shall be performed in accordance with test method 211 of MIL-STD-202. This test is not applicable to terminals which can be bent up to 45 degrees by design even if they indicated permanent deformations. 1) Test condition: B 2) Number of bending: 5 times of 90 degree bent (45 degree bent in two opposite directions with respect to the center) c) Gull wing terminals Fix the part body so as to make the terminal axis perpendicular to the horizontal axis and weight on the end of the terminal as specified in table A- 12 unless otherwise specified. Tilt the part body to a 90 degree angle in 2 to 3 minutes and set back to the original position in the same period of time. A set of this operation shall be counted as one bending. 1) Number of bending: 3 times 2) Bending direction: bend the part body to the direction of larger terminal area as shown in Figure A-7. W W Figure A-7. Bending Direction