MIL-DTL-83538D
4.6.38.1 Lightning strike - current pulse test. The current pulse will be a slow pulse Waveform
(see figure 15), to simulate the effect of an indirect lightning signal arising from the voltage differences
across the airframe. A typical test arrangement is shown on figure 17. The power generator used shall
be capable of producing the current waveform show on figure 16. The test shall be carried out on two
mated connector sets, one for each buffer adapter type. Connectors must be tested as a complete
connector set, ie. Launcher receptacle, buffer plug, and store receptacle. The connector set shall be
fully coupled and held together using a non-conductive fixture. The launcher receptacle is to be
assembled with a SAE-AS85049/19 backshell to ensure that the test current is injected into the shell via
its rear accessory thread. A cable bundle with a large cross-sectional area of screen must be used to
ensure that it will carry the test currents. The non- conductive fixture and cable bundle shall be approved
by the qualifying activity. The full amplitude signal (see figure 15) at 10 kA amplitude shall be a total of 5
times in the positive and negative directions of current flow.
4.6.38.2 Lightning strike - voltage pulse test. A typical test method is shown on figure 17. The power
generator used shall be capable of producing the voltage waveform shown on figure 18. The test
performed shall be between contacts, and between contacts and shell, for a mated connector set. For
the contact to contact test, only the two adjacent contacts closest together are to be tested, and for the
contact to shell test, only the contact closest to the shell is tested. If there is no difference in the contact
spacing, any contact is acceptable. The full amplitude signal is to be applied 5 times for each contact to
contact, and each contact to shell test.
4.6.39 Electrical resistance. Wired and mated connectors shall be subjected to the requirements of
test procedure EIA 364-06. The applied dc current shall be 100mA, and the maximum voltage of the
current source shall be 2 volts. All paths through the connector shall be measured and recorded (see
3.39.1).
4.6.40 Applied high current. Qualifications only. Applicable to the MIL-DTL-83538/11 buffer plug only
(see 3.39.2). The applied high current test shall be conducted as follows: Test 10 size 16 contacts only.
The test current and duration shall be 20 amps for 1 minute respectively. The contacts should be tested
individually. The temperature shall be at ambient. The ratio of the resistance level (see 4.6.39) from
before to after the test shall be not less than 95% computed as follows:
(Resistance before the test) / (Resistance after the test) X 100% ≥ 95%.
A full connector stack shall be used in the test and a tested contact should be allowed to cool down
before a new contact is tested.
4.6.41 Biological and chemical certification. A connector manufacturer shall submit a list of non-
metallic materials used in his connector to be qualified, to a certifying organization acceptable to the
DSCC qualification activity for certification. The certification shall state that the non-metallic materials
used in the connector meet the requirements of 3.3.7. If a material is unknown to the certifying
organization, then a test sample shall be submitted to the certifying organization for testing and
certification. The sample's mechanical properties for the purposes of testing shall be decided by the
certifying organization.
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