MIL-DTL-83538 Connectors And Accessories, Electrical, Circular, Umbilical, Environment Resistant, Removable Crimp Contacts For Mil-Std-1760 Applications \(Metric\), General Specification ForThis specification covers connectors and accessories, electrical, circular, umbilical. The connector assembly provides the necessary connections required to meet MIL-STD-1760, class I electrical interface between stores and their associated launchers using a "blind mating" mechanism. The connector assembly consists of a receptacle installed on the launcher, a receptacle installed on the store, and a buffer plug installed between the two receptacles. This specification also includes the required mounting adapters and nut, accessory adapter, cable bushing, and protective covers \(see 6.1 for details on intended use and application\). The connectors covered by this specification are intended for use with launcher mechanisms with an applied holding force in the range 271 Newtons \(61 lbs\) to 427 Newton \(96 lbs\).

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MIL-DTL-83538D

4.4.2 Sample size. The following test samples, manufactured by normal production methods, shall be

provided. Tested and untested connectors, accessories and materials may be required at no cost to the

Government for qualification verification by the responsible qualification activity (see 6.3).

a. Each test group (except groups 4 and 5) in table VI shall consist of four mating sets as follows:

For each buffer style being qualified, 2 sets shall contain the MIL-DTL-83538/3 buffer plug and 2

sets shall contain the MIL-DTL-83538/11 buffer plug (see 4.4.2e) of the combined launcher

receptacle, buffer plug and store receptacle. Connectors shall be fitted with SAE-AS85049

straight strain relief accessories. Where buffer adapter connectors (MIL-DTL-83538/11) are used,

the mating store receptacle shall be of the AIM-120 receptacle style or the test fixture as specified

in 4.6.1.2, which mates with the store end of the adapter. Any failure of this connector or the test

fixture shall not be considered a failure of MIL-DTL-83538 parts.

b. Test group 4 in table VI shall consist of 10 mating sets of the combined launcher

receptacle /buffer plug and store receptacle. Where qualification by similarity is claimed for the

receptacle inserts (20-25 insert), the samples for this test can be reduced to buffer plugs only. In

the case of the MIL-DTL-83538/11 buffer, 10 samples of the individual or standalone

MIL-DTL-83538/11 buffer plug shall be tested.

c. Test group 5 in table VI shall consist of 10 (20-25) inserts. Where qualification by similarity is

claimed for the receptacle inserts, the samples for this test can be reduced to buffer plugs only.

In the case of the MIL-DTL-83538/11 buffer, 10 samples of the individual or standalone

MIL-DTL-83538/11 buffer plug shall be tested.

d. Test group 7 in table VI shall consist of 4 mating sets (2 sets containing the MIL-DTL-83538/3

buffer plug and 2 sets containing the MIL-DTL-83538/11 buffer plug, see 4.4.2e) of the combined

launcher receptacle, buffer plug and store receptacle.

e. Test assemblies shall consist of the following:

(1) The first 2 assemblies shall comprise:

A clamp (JN1092HS23) or a suitable straight clamp in accordance with SAE-AS85049

(where applicable).

An adapter in accordance with MIL-DTL-83538/9, style C (where applicable).

A launcher receptacle in accordance with MIL-DTL-83538/4, style A or style B.

A hybrid buffer plug in accordance with MIL-DTL-83538/11.

A store receptacle in accordance with 4.4.2a.

(2) The second 2 assemblies shall comprise:

A clamp (PIN: JN1092HS23) or a suitable straight clamp in accordance with

SAE-AS85049 (where applicable).

An adapter in accordance with MIL-DTL-83538/9, style C (where applicable).

A launcher receptacle in accordance with MIL-DTL-83538/4, style A or style B.

A buffer plug in accordance with MIL-DTL-83538/3.

A store receptacle in accordance with MIL-DTL-83538/1

4.4.3 Test routine. Samples provided in accordance with 4.4.2 shall be subjected to each test group in

table VI in the order shown.

4.4.3.1 Failures. One or more failures shall be cause for refusal to grant qualification.