High-Reliability Interconnect Solutions

Active Optical
Connectors & Cables

Complete Electronic

Solutions

AirBorn is an employee owned company whose core businessis engineering & manufacturing specialized connectors &electronic components for OEMs worldwide. We serve customers
across many industries including: Commercial Air, Industrial, Medical, Military/Defense, & Space Exploration.
Companies today are looking for more than a supplier, they’re looking for a strategic partner to collaborate& grow with. AirBorn products are trusted to perform in extreme conditions, where mission-critical reliability isvital to success. Customers trust AirBorn products, and have for over 60 years.

®

AirBorn Engineering = Problem Solved

AirBorn’s engineering group specializes in new product design and development for OEMs across the globe.
Our team of 50+ degreed engineers are the most innovative and committed to solving our customer’s
challenges, but that’s only the beginning of where we can help! Leverage our design and manufacturingexpertise throughout the entire product development process. From conceptual design, prototyping, pilotruns through to mass production, our teams work efficiently to cut down your program’s time to market.

Solution Engineering

Cable vs. Flex Assemblies

Signal Integrity Expertise

Lab & Test Services

AirBorn has a dedicatedteam of experienced anddegreed solution engineers
on staff to help solve yourmost pressing electronic
challenges.

We manufacture cableand flex assemblies andcan provide an impartial
recommendation of which
solution is best for yourdistinct application.

Whether a new design
retrofit, or a field issue, let us
help you design an end-toend interconnect solution
to support your high-speed
signal integrity design.

We'll test against the highest
standards imaginable toensure your products standup to the rigors of space,
military, commercial air, andindustrial applications.

3500 AirBorn Circle — Georgetown, TX 78626•

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Connectors

Micro D
M Series

Rectangular 25Gbps
verSI

Z Axis Interposer
Z Series

Hybrid-Keyed Micro D

High-Speed Micro D

Nano D

Stackable

Rectangular

Rectangular

Circular

Strip Connector

Macro D

Cable Assemblies

FUZE Assemblies

Active Optical Assemblies

microQUAD

RC & RCII Series

Series 360

microSI

N Series

R Series

W Series

AirStrip

RocKetAssemblies

Flexible Circuit Assemblies

Embedded Systems

Rugged Power Systems

AirBorn’s FOCuS Active Optical Connectors & Cables

Photonics/Optoelectronics•

airborn.com/AOC

1

AirBorn In Action
Voyager Program

AirBorn Solutions Are "In-Action" Inside Many
Important & Famous Applications
AirBorn Connectors, Inc. was founded in 1958 to manufacture electronic connectors for aviation applications,hence our company name. By 1960, our 12 employees engaged with customers including Motorola Inc., Texas
Instruments (now Raytheon), Lockheed Aircraft, Boeing and Burroughs. In the time since our founding, we'vemanaged to be a part of many famous and important projects in human history. The Voyager I & II program,launched in 1977 and still traveling interstellar space today, is emblematic of how customers view AirBorn
parts: rugged, reliable and long lasting.
We're proud to be a part of America's, and our allies', vast military and defense initiatives too. AirBorn parts
were designed into the Apache & Blackhawk Helicopters, F-16 & F-35 Jets, Abram's & Bradley Tanks and OhioClass Attack Subs just to name a few. Our solutions are also part of Patriot, Javelin, Hellfire, Tomahawk and
THAAD missile programs. We excel at providing unfailing quality to mission-critical applications.
While military/defense and aviation applications are our specialty, we by no means stop there. AirBorn parts
are an integral part of commercial aircraft, MRI machines, defibrillators as well as pain management systems.
From deep sea to deep space, AirBorn connectors are ready for any challenge.

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Space Shuttle
ProgramMars Rovers

Commercial Airliners

Military Communications & Rifle Scopes

Pain Management Systems

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

3

Active Optical Cables

Overview

Revolutionary
Data Communications
The FOCuS Active Optical Cable product line is designed to meet the requirements for high-speed/signal
integrity applications while delivering the quality and reliability customers have come to expect from AirBorn.
FOCuS affords design flexibility by offering vertical board-mount, right angle board-mount, AOC cable I/O,
and Copper Cable I/O. The copper and AOC cables have the exact same pin-out to offer the flexibility ofusing either a copper cable for shorter lengths and easily changed to an Active Optic cable as needed.

Key Features & Benefits:•

Patented design•

EMI immune•

Distances up to 100 meters•

No fiber cleaning concerns•

Data rates of 12.5 Gbps/channel•

Fast installation: mate & go•

4 Channels•

No transceiver needed•

Rugged, light-weight and low-profile cable•

Evaluation kit available (see page 37)

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A: Any
Application
Requiring
One Of
These:

Q: WhatApplications
Are AOCsBest Suited
For?

More Rugged Than FiberHigh Speed

Copper interface provides
multiple points of contact andmore rugged housing and overall
makeup.

Supports speeds up to 12.5Gbps
per channel.

More Reliable Than Fiber

Longer Distances

Copper interface eliminates thepotential for fiber contaminationfrom dust and dirt.

Delivers reliable high speeds up
to 100m.

Easier MaintenanceThan Fiber

Weight Savings
Significant weight savings overcopper.

Copper interface eliminates themaintenance required for fiberconnectors.

Reduced Space

Hybrid Power & Optics

Much smaller cable bundles andno need for transceiver on PCB.

Easily accommodate power andoptics in a single assembly.

Design Flexibility

Improved EMI Protection

Design 1 box with both copper &AOC assembly options.
No need to incorporate fibertransceiver design into box.

Fiber cable and shell design are
critical for EMI reduction.

The Time Is NOW: Active Optical Connectors & Assemblies
We engineered these fiber cable assemblies with Space, Military, Industrial, and Commercial Aviation
applications in mind — but their practical uses extend into many industries. When you need dependability
as well as performance, AirBorn's FOCuS AOCs are the answer for your toughest applications.

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

5

Critical to Success

Applications

Ingenuity, Toughness, & Quality:
Keys To Surviving Harsh Environments
Our FOCuS® active optical cable technology now embodies a fully-qualified, Space-Rated Active Optical
Cable (SAOC®) and a Rugged Active Optical Cable (RAOC®). Built on our proven, high-speed verSI
connector platform, both versions exemplify all the benefits of fiber with the ease & reliability of copper with adesign that operates 4 channels at 12.5 Gbps per channel (50 Gbps aggregate).
The SAOC® is radiation-hardened and non-outgassing components are used throughout the assembly toassure complete reliability. Optimizing size and weight factors in the design, we made certain the SAOC® isideal for spaceflight and the extreme conditions that come to bear during a launch.
Features such as multiple points-of-contact, optimal material tensile strength, and metal backshells ensure that
RAOC® is tested for complete reliability when the ride is rough in industrial and mil/aero applications.

Applications•

Satellite Systems•

Commercial Aircraft•

Launch Vehicles•

Avionics•

Missile Systems•

Helicopters•

High-Speed Rail•

Submarines

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FOCuS AOCs Are Designed Into:

Avionics

Helicopters

And More...
Satellites

MissilesLaunch Vehicles

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

7

AV4M2 — Active Optical Cable Assembly
AirBorn’s FOCuS Active Optical Cable is a 4 channel, 12.5
Gbps offering, available in both space-rated and rugged
models. AV4M2 cables mate to the VTF and VTRAF boardmount connectors and VPD panel-mount cables.
This is a Class I laser product compliant with 21CFR1040.10.

Sample Part Number Format: AV4M2-RN2-010-LS00-000

4AV
SeriesAV – AOC
verSI Cable
AssemblyM

Lanes
Gender4 – 4 BiM – Plug
Directional
Optical
Links

2
Shell
Material
2 – Nickel
PlatedAluminum000
Application Optical
PackageS – Space
H – Hermetic
R – Rugged
N – NonHermetic

Fiber Type1 – Radiation Hardened,
50/125 OM3Multimode Fiber
2 – Non-Radiation
Hardened, 50/125
OM3 Multimode Fiber

HardwareJS – Jacking Screw
LS – Locking Screw

Fiber Length005 – 16.40 Feet
(5 Meters)
010 – 32.81 Feet
(10 Meters)
020 – 65.62 Feet
(20 Meters)
030 – 98.43 Feet
(30 Meters)

Notes:

Testing
000 – Rugged:
ESL6153
Specification	Space: ESL6015
Specification

KeyingPolarization*
00 – Option 'A' - Standard
01 – Option 'B'
02 – Option 'C'
03 – Option 'D'
04 – Option 'E'
05 – Option 'F'
06 – Option 'G'
07 – Option 'H'*See ESL6133 for keying
details and dimensions–

Mates with connector series: VTF, VTRAF, & VPD.

–

Packaging: Cable to be packaged with dust cover installed (not shown). Cable supplied fully assembled in ESD safe box.

NOTE: Please consult airborn.com to configure your part number and for the latest revision controlled drawing and technical data.

Marking Detail83500 AirBorn Circle — Georgetown, TX 78626•

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Dimensions

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.
CLASS I Laser Product compliant with 21CFR1040.10

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

9

VTF — Vertical Board-Mount Connector
VTF models are thermal interface connectors designed
to mate with AV4M2 active optical cables and CV4M2
copper cables. VTF connectors are offered with multiple
termination options including press-fit, paste-in-hole,and plated-thru-hole. EMI gaskets are standard with thismodel connector.

Sample Part Number Format: VTF-05-10-50-00-00-N

VTF

05

10

50

SeriesVTF – V ertical
ThermalFemaleRows
05 – 5 Rows

Columns
10 – 10 Columns

Contact
Plating
50 – 50μIN Au

Notes:

Termination
00 – Press-Fit
01 – Paste-In-Hole (PIH)
02 – Plated-Thru-Hole(PTH) .078" Length
03 – PTH .109" Length
04 – PTH .140" Length05 – PTH .156" Length
06 – PTH .172" Length–

Mates with AV4MX & CV4MX cables–

Packaging: parts supplied in thermoformed trays, hardware supplied uninstalled–

See AirBorn spec ESL5001 for additional application information

KeyingPolarization*
00 – Option 'A' - Standard
01 – Option 'B'
02 – Option 'C'
03 – Option 'D'
04 – Option 'E'
05 – Option 'F'
06 – Option 'G'
07 – Option 'H'*See ESL6133 for keying
details and dimensions

Hardware Options
N – Fixed Jacknut (.125" Max.
Board Thickness)
N1 – Fixed Jacknut (.250" Max.
Board Thickness)

NOTE: Please consult airborn.com to configure your part number and for the latest revision controlled drawing and technical data.

Marking Detail10

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Dimensions

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

11

VTRAF — Right-Angle, Board-Mount Connector
VTRAF models are thermal interface connectors designed tomate with AV4M2 active optic cables and CV4M2 copper cables.
VTRAF connectors are offered with multiple termination options
including press-fit, paste-in-hole and plated-thru-hole options.
EMI gaskets are standard with this model connector.

Sample Part Number Format: VTRAF-05-10-50-00-0-N

VTRAF

05

10

SeriesVTRAF – Vertical Thermal
Right-Angle
FemaleRows
05 – 5 Rows

Columns
10 – 10 Columns

Notes:

50
Contact Plating
50 – 50μIN Au

Termination
00 – Press-Fit
01 – Paste-In-Hole (PIH)
02 – Plated-Thru-Hole(PTH) .078" Length
03 – PTH .109" Length
04 – PTH .140" Length05 – PTH .156" Length
06 – PTH .172" Length–

Mates with cable series: AV4MX-XXX-XXX-XXXX-XXX & CV4MX-XXX-XXXX-X–

Packaging: parts supplied in thermoformed trays, hardware supplied uninstalled–

See AirBorn spec ESL5001 for additional application information

KeyingPolarization*
00 – Option 'A' - Standard
01 – Option 'B'
02 – Option 'C'
03 – Option 'D'
04 – Option 'E'
05 – Option 'F'
06 – Option 'G'
07 – Option 'H'*See ESL6133 for keying
details and dimensions

Hardware Options
N – Fixed Jacknut
NE – Fixed Jacknut
With Panel Mount

NOTE: Please consult airborn.com to configure your part number and for the latest revision controlled drawing and technical data.

Marking Detail12

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Dimensions

Panel Mount Option

Board Mount Option

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

13

CV4M2 — Copper Cable Assembly
AirBorn’s CV4M2 is a 4 channel, 12.5 Gbps copper
verSI cable assembly. CV4M2 cables mate with
VTF and VTRAF board-mount connects and VPD
panel-mount cables.

Sample Part Number Format: CV4M2-040-JS00-1

4

CV
SeriesCV – Copper
verSI Cable
AssemblyM

Lanes
Gender4 – 4 BiM – Plug
Directional
Links

Notes:

2
Shell
Material
2 – Nickel
PlatedAluminum

Length (Dim A)
030 – .98 Feet (0.30 Meters)
040 – 1.31 Feet (0.40 Meters)
050 – 1
 .64 Feet (0.50 Meters)
060 – 1
 .96 Feet (0.60 Meters)
070 – 2
 .29 Feet (0.70 Meters)
080 – 2
 .62 Feet (0.80 Meters)
090 – 2
 .95 Feet (0.90 Meters)
100 – 3
 .28 Feet (1.00 Meters)

HardwareJS – Jacking Screw
LS – Locking Screw

KeyingPolarization*
00 – Option 'A' - Standard
01 – Option 'B'
02 – Option 'C'
03 – Option 'D'
04 – Option 'E'
05 – Option 'F'
06 – Option 'G'
07 – Option 'H'*See ESL6133 for keying
details and dimensions–

Cable mates with connector series: VTF, VTRAF, & VPD.

–

Packaging: Cable to be packaged with dust cover installed (not shown). Cable supplied fully assembled in ESD safe box.

–

Cable ends A & B have identical pin outs and pin assignments.

Braiding
1 – No Braid2 – Metal Braid3 – Halar Braid4 – Halar Over Metal Braid

NOTE: Please consult airborn.com to configure your part number and for the latest revision controlled drawing and technical data.

Marking Detail14

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Dimensions

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

15

VPD — Vertical Panel-Mount Connector
VPD models are single-ended, thermal interface, panelmounted cables designed to mate with AV4M2 active
optical cables and CV4M2 copper cables. Dust covers
come standard with this model cable.

Sample Part Number Format: VPD-05-10-03N-000-00-1-030

05

10

03N

000

Rows
05 – 5 Rows

Columns
10 – 10 Columns

Connector 1:
verSI Panel
Mount
03N – F emaleWith
ThreadedJacknut#4-40

Connector 2000 – Flying
Leads

VPD
Series
VPD – Vertical
PanelMount
FemaleNotes:

KeyingPolarization*
00 – Option 'A' Standard
01 – Option 'B'
02 – Option 'C'
03 – Option 'D'
04 – Option 'E'
05 – Option 'F'
06 – Option 'G'
07 – Option 'H'*See ESL6133
for keying details
and dimensions–

Mates with AV4MX & CV4MX cables–

Packaging: cable to be packaged with dust covered installed (not shown) and in ESD safe packaging

Code
1 – No Braid2 – Braid

Length030 – .98 Feet (0.30 Meters)
040 – 1.31 Feet (0.40 Meters)
050 – 1.64 Feet (0.50 Meters)
060 – 1.96 Feet (0.60 Meters)
070 – 2.29 Feet (0.70 Meters)
080 – 2.62 Feet (0.80 Meters)
090 – 2.95 Feet (0.90 Meters)
100 – 3.28 Feet (1.00 Meters)

NOTE: Please consult airborn.com to configure your part number and for the latest revision controlled drawing and technical data.

Marking Detail16

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Dimensions

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

17

AV4M2 Materials, Finishes, & Cable Performance

Materials & Finishes
Pin Contacts (Male)
Molded Insulator
Shell
HardwareMaterial

BeCu per ASTM B194

Finish50µ IN min localized Au per ASTM B 488 Type 11, code C over SOµIN min Ni per ASTM
B689 Type I

Material

Glass-filled liquid crystal polymer (LCP) per ASTM D5138

Material

Aluminum alloy 6061-T6 per SAE AMS-4027 or 6061-T6511 per SAE AMS-QQ-A-200/8

Finish500µ IN min electroless Ni per SAE AMS-2404, class 3

Material

Stainless steel per ASTM A484/A484M, ASTM A582/A582M, or ASTM A320

FinishPassivate per SAE AMS-2700

Cable Performance
SymbolUnit

Min

Storage Temperature Range

Parameter

Ts

C

-55

125

Case Operating Temp. Range

Ta

C

-40

90

Operating Relative Humidity(Non-Condensing)

%

0

95

Pressurization

torr

10-9

775

TID Radiation Hardening

krad

>40

Fiber Tension

N

Fiber Bend Radius

in

30
2.5

Operating Voltage

Vdd

3.15

Data Rate Per Channel

Gbps

1.25

Power ConsumptionW

Bit Error Rate

BER

Return LossdB

OutgassingMax

30 kradSee MeVcm2/mg

Rx Differential Output Voltage

Typical

7
3.3

3.45
12.5

0.850

1.1
10-12

-8

mVp-p

250

900

Max TML of 1% and max CVCM of .1% per MIL-DTL-83513

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VTF Materials, Finishes, & Performance

Materials & Finishes

Socket Contacts

Molded Insulators
Shell
Embedment
HardwareWashers
EMI Spira Gasket

Material

BeCu per ASTM B194

Finish Socket End

50μin min localized Au per ASTM B488 Type II, code C, over 50μin min Ni per
ASTM B689 Type I

Finish Termination End

PIH & PTH: 10μin min localized Au flash per ASTM B488 Type i, code A or C
over 50μin min ni per ASTM B689 Type I Press-fit: 50μin min localized Au per
ASTM B488 Type II, code C over 50μin min Ni per ASTM B689 Type I

Material

Glass-filled liquid crystal polymer (LCP) per ASTM D5138

Material

Aluminum alloy 6061-T6 per SAE AMS-4027 or 6051-t6511 Per SAE AMSQQ-A-200/8

Finish500μin min electroless Ni per SAE AMS-2404, class 3

Material

Frey Eng. Co. Insulating compound CF3003-80 or equivalent

Material

Stainless steel per ASTM A484/A484m, ASTM A582/A582m, or ASTM A320

FinishPassivated per SAE AMS-2700

Material

Stainless steel per SAE NASM35333 (ASTM A240)

FinishPassivate per NASM35333 (SAE AMS-2700)

Material

Beryllium copper

FinishElectroplated, 90% tin, 10% lead per AMS-P-81728

Performance
Contact Rating 2

2 Amperes Max, see AirBorn PTB66 for more info

Operating Temperature-55°C TO 125°C, see AirBorn PTB66 for more info

Contact Engagement Force

6.0oz max*

Contact Separation Force

0.5oz min*Connector Mating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

Connector Unmating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

Dwv (Sea Level)

600V, RMS, 60Hz, see AirBorn PTB61 for more info

Recommended Max Operating Voltage

200V, RMS, 60Hz, see AirBorn PTB61 for more info

Insulation Resistance

5,000 MEGAOHMS minimum @ 500 VDC, tested per MIL-DTL-83513

Durability

2,500 connector mating cycles, exceeds MIL-DTL-83513

Sinusoidal Vibration

20g, tested per MIL-DTL-83513

Shock50g, tested per MIL-DTL-83513

Outgassing

Max TML of 1% and max CVCM of .1% per MIL-DTL-83513*Max pin size used for contact engagement force and min pin size used for contact separation force.

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

AirBorn’s FOCuS Active Optical Connectors & Cables•

airborn.com/AOC

19

VTRAF Materials, Finishes, & Performance

Materials & Finishes
Material

BeCu per ASTM B194

Finish Socket End

50μin min localized Au per ASTM B488 type II, code C, over 50μin min Ni per
ASTM B689 Type I

Finish Termination End

PIH & PTH: 10μin min localized Au flash per ASTM B488 Type I, code A or C
over 50μin min ni per ASTM B689 Type I Press-fit: 50μin min localized Au per
ASTM B488 Type II, code C over 50μin min Ni per ASTM B689 Type I

Material

Glass-filled liquid crystal polymer (LCP) per ASTM D5138

Material

Aluminum alloy 6061-T6 per SAE AMS-4027 or 6051-t6511 Per SAE AMSQQ-A-200/8

Finish500μin min electroless Ni per SAE AMS-2404, class 3

Material

Frey Eng. Co. Insulating compound CF3003-80 or equivalent

Material

Stainless steel per ASTM A484/A484m, ASTM A582/A582m, or ASTM A320

FinishPassivated per SAE MAS-2700

Material

Stainless steel per SAE NASM35333 (ASTM A240)

FinishPassivate per NASM35333 (SAE AMS-2700)

Material

Beryllium copper

FinishElectroplated, 90% tin, 10% lead per AMS-P-81728

Thread Insert

Material

NAS1130-02-10

Thermal Electrical
GasketMaterial

Silver-Copper filled silicon, acrylic, electrically conductive, pressure sensitiveadhesive (PSA) backing

Socket Contacts

Molded Insulators
Shell
Embedment
HardwareWashers
EMI Spira Gasket

Performance
Contact Rating 2

2 Amperes max, see AirBorn PTB66 for more info

Operating Temperature-55°C to 125°C, see AirBorn PTB66 for more info

Contact Engagement Force

6.0oz max*

Contact Separation Force

0.5oz min*Connector Mating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

Connector Unmating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

DWV (Sea Level)

600V, RMS, 60Hz, see AirBorn PTB61 for more info

Recommended Maximum Operating Voltage

200V, RMS, 60Hz, see AirBorn PTB61 for more info

Insulation Resistance

5,000 MEGAOHMS minimum @ 500 VDC, tested per MIL-DTL-83513

Durability

10,000 connector mating cycles, exceeds MIL-DTL-83513

Sinusoidal Vibration

20g, tested per MIL-DTL-83513

Shock50g, tested per MIL-DTL-83513

Outgassing

Max TML of 1% and max CVCM of .1% per MIL-DTL-83513*Max pin size used for contact engagement force and min pin size used for contact separation force.

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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CV4M2 Materials, Finishes, & Cable Performance

Materials & Finishes
Pin Contacts (Male)
Molded Insulator
Shell

HardwareSpira Gasket

Material

BeCu per ASTM B194

FinishPhos bronze per ASTM B103, 50μin min localized Au per ASTM B488 Type II, code C
over 50μin min Ni per ASTM B689 Type I

Material

Glass-filled liquid crystal polymer (LCP) per ASTM D5138

Material

Aluminum alloy 6061-T6 per SAE AMS-4027 or 6051-T6511 Per SAE AMSQQ-A-200/8

Finish500μin min electroless Ni per SAE AMS-2404, class 3

Material

Stainless steel per ASTM A484/A484M, ASTM A582/A582M, or ASTM A320

FinishPassivated per SAE AMS-2700

Material

BeCu

FinishElectroplated, 90% tin, 10% lead per AMS-P-81728

Cable: 26 AWG Twinax

Parallel, 100 ohm impedanceCable: 26 AWG Buss Wire

Electroplated, 90% tin, 10% lead per AMS-P-81728

Heatshrink Tubing

AA59551-H26S1B per A-A-59551, plating: eclectrodeposited tin alloy coating per ASTM B545, class
C. 90 ± 5% tin, remainder lead

Lacing (Braid Option Only)

Per A-A-52081

Tape

Acrylic adheasive polymide film (Kaption)

Metal Braid Only (Option 2)

Silver-plated copper braid per aa59569r30soxxx. Secured to backshell with micro band. Potting
compound shall be frey engineering CF-3003-80 (fullpot) and L-II-49 (prepot) or equivalent.

Halar Braid (Option 3)

Halar braid secured to backshell with micro band. Potting compound shall be frey engineering
CF-3003-80 (fullpot) and L-II-49 (prepot) or equivalent.

Halar Over Metal Braid(Option 4)

Halar over silver-plated copper braid per AA59569R30SOXXX secured to backshell with micro
band. Potting compound shall be frey engineering CF-3003-80 (fullpot) and L-II-49 (prepot) or
equivalent.

Performance
Contact Rating

2 Amperes max, see AirBorn PTB66 for more info

Operating Temperature-55°C to 125°C, see AirBorn PTB66 for more info

Contact Engagement Force

6.0oz max*

Contact Separation Force

5.0oz min*Connector Mating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

Connector Unmating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

DWV (Sea Level)

600V, RMS, 60Hz, see AirBorn PTB61 for more info

Recommended Max. Operating Voltage

200V, RMS, 60Hz, see AirBorn PTB61 for more info

Insulation Resistance

5,000 MEGAOHMS minimum @ 500 VDC, tested per MIL-DTL-83513

Durability

2,500 connector mating cycles, exceeds MIL-DTL-83513

Sinusoidal Vibration

20g, tested per MIL-DTL-83513

Shock50g, tested per MIL-DTL-83513

Outgassing

Max TML of 1% and max CVCM of .1% per MIL-DTL-83513*Max pin size used for contact engagement force and min pin size used for contact separation force.
Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VPD Materials, Finishes, & Performance

Materials & Finishes
Material

6061-T6, 6061-T651, or 6061-T6511 aluminum
SAE AMS 4027 or SAE AMS-QQ-A-200/8

Finish500μin min electroless Ni per SAE AMS-2404, class 3

Socket Material

BeCu per ASTM B194

Finish50μin min localized gold finish per ASTM B488, over 50μin min Ni per ASTM
B689 Type I

Cable

Finish26 AWG, 100 OHM twinax cable

Wire

Material

24 AWG, M22759/33-24, black

Molded Insulator

FinishGlass-filled liquid crystal polymer (LCP) per ASTM D5138

Material

Stainless steel per ASTM A582/A582M or ASTM A320

FinishPassivate per SAE MAS-2700

Embedment

Material

Frey Eng. Co. Insulating compound CF3003-80 and L-II-49 or equivalent

SolderMaterial

SN/PB solder, 63% PB, 37% SN

Material

ISOLA 185HR PCB laminate

FinishElectroless nickel immersion gold per IPS-6012/DS

Material

Beryllium copper

FinishElectroplated, 90% tin, 10% lead per AMS-P-81728

Material

Silver-Copper filled silicon, acrylic, electrically conductive, pressure sensitiveadhesive (PSA) backing

ShellContacts

Hardware

PCB
Spira Gasket
Thermal Electrical
GasketPerformance
Contact Rating

2 Amperes max, see AirBorn PTB66 for more info

Operating Temperature-55°C to 125°C, see AirBorn PTB66 for more info

Contact Engagement Force

6.0oz max*

Contact Separation Force

0.5oz min*Connector Mating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

Connector Unmating Force

10oz X (# of contacts) max tested per MIL-DTL-83513

DWV (Sea Level)

600V, RMS, 60Hz, see AirBorn PTB61 for more info

Recommended Maximum Operating Voltage

200V, RMS, 60Hz, see AirBorn PTB61 for more info

Insulation Resistance

5,000 MEGAOHMS minimum @ 500 VDC, tested per MIL-DTL-83513

Durability

10,000 connector mating cycles, exceeds MIL-DTL-83513

Sinusoidal Vibration

20g, tested per MIL-DTL-83513

Shock50g, tested per MIL-DTL-83513

Outgassing

Max TML of 1% and max CVCM of .1% per MIL-DTL-83513*Max pin size used for contact engagement force and min pin size used for contact separation force.

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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AV4M2 Hardware Options

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VTF Hardware Options

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VTRAF Recommended Hardware (Mounting Hardware Not Included)

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CV4M2 Hardware Options

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VPD Connector 1 Hardware Options

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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AV4M2 Wire Connect Chart & Pin Out

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VTF Recommended PCB Layout

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VTRAF Recommended PCB Layout

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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CV4MX Wire Chart

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VTF Termination Dimensions

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VTRAF Termination Dimensions

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33

VTRAF Mounting Instructions

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VPD Pinout & Connector 1 Panel Cutout

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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VPD Twinax Properties

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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CDGV01649 Evaluation Kit

Order Your Evaluation Kit Today!
Want to try our SAOC or RAOC out in your own lab and in your unique product design? Order a kit
today and run the product through its paces and you'll discover AirBorn quality and design ingenuity inyour own time.

Please consult the AirBorn website for the latest revision of this document prior to beginning any design work.

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37

38

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Space-Rated Active Optical
Cable Qualifications Review
CLASS I laser product compliant with 21CFR1040.10.

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Qualification Testing
The cables in Qualification testing go through the following verification testing. Each cable is fully functional
throughout all tests, with bit error monitoring, as well as power, and telemetry checks throughout. Passing
criteria for each test includes: BER better than 1x10-12. Telemetry interface responds without error. Nochanges in current draw greater than 5% from baseline. No signs of physical damage.

Thermal Life Testing
134 thermal cycles of +95°C to -34°C, 1 hour dwells on all plateaus, ramp rate ≤ 6°C.

Thermal Vacuum Testing
24 thermal cycles of +95°C to -34°C, 6 hour dwells on all hot plateaus, 1 hour dwells on all cold dwells, ramp
rate ≤ 6°C, chamber pressure of 1x10-4 torr.

Vibration Testing
Vibration testing is meant to simulate the environment the cablewould experience as it is rocketed into orbit. 60.26 Grms total, 3minutes per axis. Vibration profile and test images shown below.

Vibration Testing

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Pyroshock
Pyroshock testing is meant to simulate the high-magnitude shock waves propagated through a structureduring an explosive event, such as when an explosive charge is used to separate a multistage rocket. Each
cable undergoes the following pyroshock profile, applied three times in each direction of each orthogonalaxis. The cables are not powered for this test.

Additional Verification Testing
The following tests are performed outside of the official
Qualification test plan, and verify that additional design criteria
have been met.

Radiation Testing
Radiation testing has been performed on all AirBorn Active Optical
Cable designs. A high flux, continuous 200MeV proton beam was
focused on the cable end, while power, telemetry and bit error
rate were measured and recorded for all four channels. No latchup
events nor permanent degradation in functionality were observed,
with a total ionizing dose of over 95 kRad (TID Si) delivered to theoptical engine components. Test setup shown below.

AirBorn’s FOCuS Active Optical Connectors & Cables•

Radiation Testing

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41

EMC Testing
EMC testing per MIL-STD-461F has been performed on alllegacy AirBorn Active Optical Cable designs. The test results
indicate that the cable’s external interfaces and enclosures
successfully contained all EMC emissions. EMC testing will be
performed on all future cable configurations. The same robust
design features which made the legacy product so effectiveat mitigating EMC emissions are incorporated into each new
product configuration.

Cable Pullout Testing
The FOCuS cables have been tested and verified to meet a
10lbf axial pull force on the cable jacket without separationfrom the cable end body. Test setup shown below.

VCSEL and Photodiode Extended Life Testing
Each unique VCSEL and Photodiode lot used in FOCuS
Cable Pull Testingproduction assemblies undergo extended life testing before they
are approved for use. Three subgroups of 30 pieces each run
through spectrum analysis, LIV curve testing, burn in, and a life test of up to 2,500hrs at 150°C. This testing
provides confidence thatour products will withstandextreme operating
conditions over theirlifespan.

Element Evaluation
Testing
All microcircuit andsemiconductor die lots
used in the FOCuS productare tested per MIL-PRF38534J, Appendix C, Table
C-II, before being used in
production assemblies. The
testing is tailored to ourexact usage case. Testing
includes the following:

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Design Analysis
Several design analyses were performed on the FOCuS 4X verSI cable throughout the design process, in orderto provide insight for how to optimize the design. These optimizations greatly improve the ability of the cableto successfully pass Qualification testing and perform in the field.

FEA Modal and Stress Analysis
A finite-element analysis using Nastran has been performed on the cable and mating interface to determine
natural frequencies and Von Mises stress levels developed during Vibration testing. Positive margins of safety
are maintained throughout this test, both in Yield and Ultimate Strength, for all mechanical components.
Additionally, fastener torque levels have been analyzed to assure preload is maintained. When paired withvibration testing, this analysis provides a high confidence level that the cable can withstand extreme vibration
environments. An excerpt from the report can be seen below, as well as images of the FEA model.

Y-Displacement(RMS)

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Structural and Thermal Fatigue Analysis
A structural and thermal fatigue analysis has been performed on all legacy AirBorn Active Optical Cable
designs, to ensure structural integrity throughout the mission. The structural fatigue analysis accounted fordamage due to vibration as well as thermal cycling.

Heat Transfer Analysis
The FOCuS PCBA has been optimized to enhance thermal transfer from high-power-consuming-die onboard,
into the host assembly, thereby minimizing the temperature rise of these die. A complete finite element modelof the PCBA and thermal path has been generated, to predict maximum case and junction temperatures forall onboard die. In conjunction with thermal vacuum testing, this analysis provides high confidence that thecable will continue to perform within our stated operating temperature range.

CAD Geometry

Temperature Distribution

Venting Analysis
A venting analysis has been performed of the cable backshell and all inner semi-enclosed cavities, to ensure
the pressure change due to rapid ascent or descent through Earth’s atmosphere does not cause structural
damage. The analysis follows the approach of NASA Memorandum 85016 to determine pressure differentials,
and utilizes structural FEA analysis to show margins of safety.

Parts & Materials list and Outgassing
A complete parts and materials list has been generated to identify every unique material utilized within thecable assembly, with the exception of board-mounted electronics. All non-metallic materials have beenoutgas tested per ASTM-E-595.
CLASS I laser product compliant with 21CFR1040.10.

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Failure Mode, Effects and Criticality Analysis
A Failure Mode, Effects and Criticality Analysis (FMECA) has been performed on all legacy AirBorn Active
Optical Cable designs to identify and eliminate single point failures, in an effort to reduce the possibility of
mission failure.

Reliability Analysis
A Reliability Analysis has been performed on all legacy AirBorn Active Optical Cable designs to calculate thepredicted probability of success for a mission. This analysis accounts for all components in the data transfer
path, from one end of the cable to the other.

Worst Case Analysis
A Worst Case Analysis has been performed on all legacy AirBorn Active Optical Cable designs. This analysis
provides a method for analytically verifying circuit performance and derating requirements have been met
over a program specified environment and design life. It is an effective tool in validating electrical circuitdesign stress and estimated performance margins, to a customer’s specific operating environment.

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The

Advantage
RuggedPower
Systems

Model-To-Market
Solutions

Flexible
Circuit
Assemblies

Rectangular
W Series

Hybrid-Keyed
Micro D
microQUAD

Rectangular
R Series

High-Speed
Micro D
microSI

Photonics/
Optoelectronics

Micro D
M Series

Stackable

RC & RCII Series

ActiveOpticalAssemblies

FUZE
Assemblies

Cable
Assemblies

Nano D
N Series

Circular

Series 360

Rectangular
25GbpsZ Axis Interposer

verSI

Z Series

Strip Connector

Macro D

AirStrip

RocKet

AOCC-4.21

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