B08 SPECIFICATIONS REQUIREMENTS FOR MIS-23393Y _10MAR2021.pdf

CUI

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MIS-23393Y

09 FEB 2021

Superseding

MIS-23393W

CODE IDENT 18876

MISSILE COMMAND SPECIFICATION

CRITICAL ITEM PRODUCTION FUNCTION SPECIFICATION

FOR CONNECTOR ASSEMBLY, ELECTRICAL, IFF

1. SCOPE

1.1 This specification establishes the performance, design, test, manufacture, and acceptance requirements for the Identification Friend or Foe (IFF) electrical connector assembly critical item, hereinafter referred to as the connector assembly (see 6.1).

2. APPLICABLE DOCUMENTS

2.1 Government documents. The following documents of the issue in effect on date of invitation for bids or request for proposal, form a part of the specification to the extent specified herein.

SPECIFICATION:

Federal

QQ-A-225 Aluminum and Aluminum Alloy Bar, Rod, Wire, or Special Shapes; Rolled, Drawn, or Cold Finished;

General Specification for

QQ-P-416 Plating, Cadmium (Electrodeposited)

QQ-S-764 Steel Bars, Corrosion Resisting, Free Machining

Military

MIL-S-5002 Surface Treatments and Inorganic Coatings for Metal Surfaces of Weapons Systems

MIL-S-5059 Steel, Corrosion-Resistant (18-8) Plate, Sheet and Strip

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense and U.S. DoD contractors only; Critical Technology, Export Controlled; 09 July 2018. Other requests shall be referred to Program Executive Officer, Missiles and Space, Short and Intermediate Effectors for Layered Defense (SHIELD) Project Office, SFAE-MSL-SDM, Redstone Arsenal, AL 35898-5000.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

Controlled By: US Army PEO MS Controlled By: SFAE-MSL-SDM CUI Category: OPSEC Distribution Statement D POC: James Smith, james.w.smith26.civ@mail.mil

MIS-23393Y CUI

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MIL-S-7742 Screw Threads, Standard, and Optimum Selected Series: General Specification for

MIL-C-14550 Copper Plating (Electrodeposited)

MIL-C-24308 Connectors, Electric, Rectangular, Miniature Polarized Shell, Rack and Panel, General Specification for

MIL-R-25988 Rubber, Fluorosilicone Elastomer, Oil- and Fuel- Resistant, Sheets, Strips, Molded Parts, and Extruded Shapes

MIL-C-26074 Coating, Electroless Nickel, Requirements for

MIL-C-39029 Contacts, Electric General, Specifications for

MIL-C-39029/63 Contacts, Electrical Connector, Socket, Crimp Removable, (for MIL-C-24308 Connectors)

MIL-C-39029/64 Contacts, Electrical Connector, Pin, Crimp Removable, (for MIL-C-24308 Connectors)

MIL-G-45204 Gold Plating, Electrodeposited

MIL-P-46161 Plastic Molding Material, Polyterephthalate Thermoplastic, Glass Fiber Reinforced

MIL-W-83420 Wire Rope, for Aircraft Control

MIL-C-83723 Connector, Electric, Circular, Environment Resisting, General Specification for

STANDARDS

Federal

FED-STD-595 Colors

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Military

MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes

MIL-STD-129 Marking for Shipment and Storage

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-186 Protective Finishing for Army Missile Weapon Systems

MIL-STD-202 Test Methods for Electronic and Electrical Component Parts

MS-27488 Plug, Grommet Sealing, Electrical Connector

MIL-STD-454 Standard General Requirements for Electronic Equipment

MIL-STD-1250 Corrosion Prevention and Deterioration Control in Electronic Components and Assemblies

MIL-STD 1344 Test Methods for Electrical Connectors

MIL-STD-45662 Calibration System Requirements

MS-27981 Fastener, Snap, Style 2a (Small Wire Spring Clamp Type)

Other Publications

U.S. Army Missile Command

PDS- MIS-23393 Packaging Data Sheet for Connector Assembly, Electrical, IFF

QAP-MIS-23393 Quality Assurance Provision, Production Lot Test Requirements for Protective Plug

(Copies of specifications, standards, drawings, and publications required by suppliers in connection with specified procurement functions should be obtained from the procuring activity or as directed by the contracting officer.)

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2.2. Non-Government documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of invitation for bids or request for proposal shall apply.

Society of Automotive Engineers

AMS 3651 Polytetrafluoroethylene

(Application for copies should be addressed to Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096).

Uniform Classification Committee

Uniform Freight Classification Rating, Rules and Regulations

(Application for copies should be addressed to the Uniform Classification Committee, Agent:

Tariff Publishing Officer, Room 1106, 222 South Riverside Plaza, Chicago, Illinois 60606.)

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3. Requirements

3.1 Item definition. The connector assembly (see figure 1) is a two-piece item which consists of a plug (see 3.1.1 and figures 2a through 2e) and receptacle (see 3.1.2, figures 3a through 3c, and 10a through 10c). The plug and receptacle are designed for direct mating to each other.

The connector assembly is designed to facilitate electrical connection and interface between the separable gripstock and the IFF beltpack interrogator.

3.1.1 IFF plug. The IFF plug is primarily an electrical fitting with push-pull coupling. The plug is equipped with a lanyard used for disengaging the plug from the receptacle. A rubber handgrip covers the cable entry providing orientation for quick mating lineup. There are provisions for two crimp socket coaxial contacts (see 3.1.3 and figure 4) and seven, size 20, crimp pin contacts (see 3.1.4). The rear grommet is a resilient (see 3.3.1.6.1.2) dielectric material acting as a seal around each wire for environmental performance. The mating face is a resilient dielectric material providing a moisture tight seal when mated to the receptacle. The plug is designed for use on the end of a cable. It is capable of being independently replaced.

3.1.2 IFF receptacle. The IFF receptacle (see figures 3a through 3c and 10a through 10c) is primarily an electrical fitting with a flange type of mounting. There are provisions for two crimp pin coaxial contacts (see 3.1.3 and figure 4) and seven size 20 crimp socket contacts (see 3.1.4).

The rear grommet is a resilient dielectric material acting as a seal around each wire for environmental performance. The mating face is a rigid (see 3.3.1.6.1.1) material providing a seal when mated to the plug. The receptacle is designed to be mounted to the separable gripstock.

It is capable of being independently replaced.

3.1.3 Contact, coaxial. The coaxial contacts are designed for use in the connector assembly as follows:

(a) Type: pin, size 12 coaxial (see figure 4) for use in the IFF receptacle.

(b) Type: socket, size 12 coaxial (see figure 4) for use in the IFF plug.

(c) Coaxial cable: RG-178/U or equivalent.

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(d) Termination: The center conductor and the outer conductor shall be crimped using the specified crimp tools.

(e) Crimp tools: (see 6.1.6).

(f) Insertion and removal tool (see 6.1.6). Insertion and removal of contacts are performed from the rear of the connector.

3.1.4 Contact, size 20. The size 20 contacts to be used in the connector assembly are as follows:

(a) Socket contact for installation in the receptacle (see 6.1.4.1).

(b) Pin contact for installation in the plug (see 6.1.4.2).

(c) Sealing plug: The connector assembly shall accept the sealing plugs specified in

6.1.7. Sealing plugs shall be used to seal vacant contact cavities.

(d) Crimp tool: (see 6.1.6).

(e) Insertion and removal tool (see 6.1.6). Insertion and removal of contacts are performed from the rear of the connector.

3.1.5 Cover, protective, plug. The protection cover is designed to seal and protect the mating end of the plug from the environment when the plug and receptacle are not mated (see 6.1.5.1 and figure 5a) and (see QAP MIS-23393-11).

3.1.6 Cover, protective, receptacle. The protective cover is designed to seal and protect the mating end of the receptacle from the environments when the plug and receptacle are not mated (see 6.1.5.2 and figure 6).

3.2 Characteristics.

3.2.1 Performance. The connector assembly shall meet the performance requirements of this specification under conditions specified herein.

3.2.1.1 Dielectric withstanding voltage. The dielectric strength of the unmated connector assembly shall be no less than 500 volts, root mean square (rms). The connector assembly shall show no evidence of breakdown or flashover during testing.

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3.2.1.2 Insulation resistance. The unmated connector assembly shall have an insulation resistance greater than 50 mega ohms initially and 2 mega ohms thereafter (post conditioning), when applying no less than 500 volts direct current (vdc). The mated connector assembly shall have a shell-to-shell resistance no greater than 1.0 ohm.

3.2.1.3 Contact resistance. Contacts used in the mated connector assembly and the coaxial cable outer conductor shall meet the resistance values specified in table I.

Table I. Contact resistance limits

Pin Size Number Test Current Amperes

Maximum millivolt drop at rated amperes:

Initial Post Conditioning

Center Coaxial Conductor

1.0 135 145

Outer Coaxial Conductor

3.0 45 55

20 7.5 55 65

3.2.1.4 Contact Voltage Standing Wave Ratio. The VSWR of the coaxial contacts in the connector assembly shall be not more than 1.30:1.00 within frequency range of 0.9 to 1.5 gigahertz (GHz) when terminated with a nominal 50 ohm-load.

3.2.2 Physical characteristics.

3.2.2.1 Weight. The weight of the connector assembly (see 3.1) shall not be more than 0.401 pounds. The weight of the component parts of the connector assembly and the protective covers shall be as follows:

(a) IFF plug (see 3.1.1): 0.300 pound maximum

(b) IFF receptacle (see 3.1.2): 0.140 pound maximum

(c) Contacts (see 3.1.4): 0.001 pound, maximum, each

(d) Contacts, coaxial (see 3.1.3): 0.003 pound, maximum, each

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(e) Cover, protective, plug (see 3.1.5): 0.30 pound, maximum

(f) Cover, protective, receptacle (see 3.1.6): 0.08 pound, maximum

3.2.2.2 Dimensional limitations. The dimensional limitations of the connector assembly shall be in accordance with figures 1 through 3c, 10a through 10c and to the extent specified herein.

The dimensional limitations of the contacts shall be in accordance with figure 4 and the dimensional limitations of the protective covers shall be in accordance with figures 5a through 6.

3.2.2.3 Contact insertion and removal forces. Contact insertion force shall be 15 pounds maximum. Contact removal force shall be 15 pounds maximum.

3.2.2.4 Engaging force and separating impulse. The engaging force, the separating impulse (separating impulse applied to lanyard) and the retention force of the connector assembly and protective covers shall meet the force and impulse requirements of table II.

Table II. Engaging force and separating impulse axial (pounds)

Connector maximum engagement force

Quick disconnect connector retention maximum force

Quick disconnect connector separating maximum impulse

20 pounds

5 pounds

0.39 pound-seconds with a peak force not to exceed 60 pounds

3.2.2.5 Insert retention. Inserts of the connector assembly shall not be dislocated from the specified insert position as shown (see figures 2a through 3c and l0a through l0c) when an effective pressure differential of 75 pounds per square inch is applied.

3.2.2.6 Contact retention. Contacts of the connector assembly shall be retained in their inserts when subjected to an axial load of 9.0 pounds, minimum for size 20 contacts, and 15 pounds minimum for coax contacts. The axial displacement of the contacts shall not exceed 0.012 inch while under load with the accessory rear hardware removed.

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3.2.2.7 Survival (mating durability). The connector assembly shall show no mechanical or electrical defects detrimental to the operation of the connector assembly as a result of no less than 3000 mating and unmating cycles. Survival performance of the connector assembly shall not degrade the post-conditioning requirements of 3.2.1.3 and the requirements of 3.2.2.4.

3.2.2.8 Lanyard strength. The lanyard connected to the plug shall withstand an axial pull of no less than 288 pounds.

3.2.2.9 Cable pull-out. Each configuration, the wired plug, wired receptacle, and the mated connector assembly, shall withstand an axial force of no less than 30 pounds when applied to the cables, and no less than 75 pounds when applied to the mated connector bodies without loss of continuity, pullout, damage to the contacts, or fracturing of the shield or jacket. The cable stretch shall not degrade the wires, shield grounding or contact crimped termination. The mated plug and receptacle shall remain locked. Wiring shall consist of seven number 20 American Wire Gauge (AWG) wires and two RG-178/U coaxial cables. The cable shall be covered with an overall shield and jacket.

3.2.3 Environmental conditions. The connector assembly shall meet the requirements of 3.2.1 and 3.2.2 after exposure to the non-operating environments and during and after exposure to the operating environments except as specified herein. The connector assembly shall be unmated unless otherwise specified.

3.2.3.1 Non-operating environments. The non-operating environments shall consist of the conditions specified herein.

3.2.3.1.1 High temperature (storage). The high temperature (storage) conditions shall consist of exposure to a temperature of plus 71 (plus or minus 3) degrees Centigrade [plus 160 (plus or minus 5) degrees Fahrenheit] for a period of no less than 10 hours.

3.2.3.1.2 Low temperature (storage). The low temperature (storage) conditions shall consist of exposure to a temperature of minus 46 (plus or minus 3) degrees Centigrade [minus 50 (plus or minus 5) degrees Fahrenheit] for a period of no less than 10 hours.

3.2.3.1.3 Thermal shock. The thermal shock conditions shall consist of exposure to five complete cycles of temperature extremes as follows:

(a) A low temperature for no less than 30 minutes at minus 46 (plus 3, minus 0) degrees Centigrade [minus 50 (plus 5, minus 0) degrees Fahrenheit], followed by

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(b) A high temperature for no less than 30 minutes at plus 71 (plus or minus 3) degrees Centigrade [plus 160 (plus or minus 5) degrees Fahrenheit]; and that

(c) No more than a five-minute delay shall be permitted between the transfer of the connector assembly from one temperature extreme to the other.

3.2.3.1.4 Humidity. The humidity conditions shall consist of exposure to relative humidity in the range from 80 to 98 percent, at temperatures ranging from plus 21 to plus 71 degrees Centigrade (plus 70 to plus 160 degrees Fahrenheit) for no less than 240 hours.

3.2.3.1.5 Immersion. The immersion conditions shall consist of preheating the IFF connector plug or receptacle to 33o Centigrade minimum above the water temperature and immersing them, unmated, and without the protective covers, into a 5% (by volume) salt (sodium chloride) and water solution, to a minimum depth of 4 feet, for 10 minutes minimum, without degradation to the connectors, or reducing any insulation resistance below 2 mega ohms.

3.2.3.1.6 Salt spray. The salt spray conditions shall consist of a 48-hour exposure to a 5-percent salt (sodium chloride) water solution with pH value of 6.5 to 7.2 at plus 35 degrees Centigrade (plus 95 degrees Fahrenheit) without evidence of corrosion of the connector assembly. The requirements specified in 3.2.1 shall not apply to connector assemblies exposed to salt spray environments.

3.2.3.1.7 Sand and dust. The sand and dust conditions shall consist of a 6-hour exposure to blowing dust with particle sizes up to 150 microns, density of 0.3 gram per cubic foot, and wind of 1750 feet per minute.

3.2.3.1.8 Non-operating Shock. The non-operating shock conditions shall consist of shocks applied parallel to two mutually-perpendicular axes (see Figures 7 and 8) as follows:

(a) Acceleration: 100 gravity units (one-half sine wave shock pulse)

(b) Duration: 10 milliseconds each

(c) Amblent-temperture range and number of shocks: Plus 18 degrees to plus 35 degrees Centigrade (plus 65 degrees to plus 95 degrees Fahrenheit); total of 4 shocks.

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3.2.3.1.9 Fixed frequency vibration. The fixed frequency vibration conditions shall consist of the following:

(a) Frequency: 50 (plus or minus 5) Hertz (Hz)

(b) Amplitude: 15 gravity units peak (filtered)

(c) Duration: Not less than 1.0 hour in each axis

(d) Application: Parallel to the AB and CD axes (see figure 7)

3.2.3.2 Operating environment. The operating environments shall consist of the conditions specified herein.

3.2.3.2.1 High temperature (operating). The high temperature (operating) conditions shall consist of exposure to a temperature of plus 60 (plus or minus 3) degrees Centigrade [plus 140 (plus or minus 5) degrees Fahrenheit] for a period of 24 hours, or until temperature stabilized (see 6.3.2), whichever occurs first.

3.2.3.2.2 Low temperature (operating). The low temperature (operating) conditions shall consist of exposure to a temperature of minus 40 (plus or minus 3) degrees Centigrade [minus 40 (plus or minus 5) degrees Fahrenheit] for a period of 24 hours or until temperature stabilized (see 6.3.2), whichever occurs first.

3.3 Design and construction. The design and construction of the connector assembly and the protective covers shall be as specified herein.

3.3.1 Materials. Materials used in the connector assembly shall be as specified herein. However, when a definite material is not specified herein, a material shall be used which will enable the connector assembly to meet the performance requirements of this specification. Unless necessary for the design application, critical and strategic materials shall not be used.

3.3.1.1 Dissimilar metals. The use of dissimilar metals in the connector assembly shall be in accordance with MIL-STD-454, requirement 16.

3.3.1.2 Moisture and fungus resistance. Materials resistant to moisture and fungus shall be used whenever practical. If nonresistant materials are used, they shall be treated in accordance with

MIL-STD-1250.

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3.3.1.3 Corrosion of metal parts. Corrosion-resistant materials shall be used whenever practical.

Cleaning methods, surface treatment, metal coating, or other metal finishes shall be in accordance with MIL-STD-186.

3.3.1.4 Screw threads. Screw threads shall be in accordance with MIL-S-7742.

3.3.1.5 Contacts.

3.3.1.5.1 Materials, contact. The material of the contacts specified in figure 4 shall be as follows:

(a) Outer body, crimp sleeve, and inner conductor shall be made of suitable conductive copper alloys.

(b) Outer body sleeve shall be stainless steel, passivated.

(c) Dielectric shall be polytetrafluoroethylene.

3.3.1.5.2 Plating contact. Gold plating shall be in accordance with MIL-G-45204, type II, class I, applied to a suitable undercoating copper flash in accordance with MIL-C-14550, class 4.

Accessory members of the contacts need not be plated but shall comply with the requirements for dissimilar metals specified in 3. 3.1.1.

3.3.1.5.3 Ductility of materials, plating. There shall be no cracks in the parent material or in the plating of either pin or socket contacts after termination of wire, using the specified crimp tool (see 6.1.6), which could have deleterious effect on the performance of the contacts.

3.3.1.5.4 Contact alignment. With all the contacts in place, the alignment of pin and socket contacts shall permit engagement regardless of buildup of tolerances on hole locations, distortion of contacts due to soldering, crimping, or insert location in the shell.

3.3.1.6 Dielectric materials.

3.3.1.6.1 Insert and grommet. Insert and grommet materials shall be high grade dielectric having hardness, electrical, and mechanical characteristics suitable for the purpose intended.

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3.3.1.6.1.1 Rigid. Rigid dielectric material shall be in accordance with MIL-P-46161 grade B, class 3 or equivalent.

3.3.1.6.1.2 Resilient. The resilient dielectric material shall be fluorosilicone in accordance with MIL-R-25988, class 1, with a suitable Shore A durometer hardness to meet the requirements of this specification.

3.3.1.6.1.3 Insert design and construction. Inserts shall be of voidless construction and shall be secured to prevent rotation within the connector shell. The inserts shall be non-removable from the shell and shall be installed in normal clocking position. The insert and wire sealing grommet shall be one integral part. The design shall permit the removal and reinsertion of individual contacts without damage to any parts of the insert, including contact retention members, adjacent contacts, or the sealing members, using the specified insertion and removal tool (see 6.1.6). The individual contacts shall be positively retained when reinstalled in the insert.

3.3.1.7 Shells and accessories material and design. The shells of the connector assembly and the coupling nut of the plug shall be 303 stainless steel in accordance with QQ-S-764. Finish shall be passivated in accordance with MIL-S-5002. Accessory members of the connector assembly may be a high grade of aluminum alloy in accordance with QQ-A-255, suitably protected with a finish of electroless nickel in accordance with MIL-C-26074, class 3, Grade A, 0.0010 to 0.0014 inch thick. The protective covers for the plug and the receptacle shall be made of a high grade of rubber composition suitable for the purpose specified herein. Lanyard materials, used for the receptacle cover, shall be corrosion-resistant steel wire rope covered with polyvinylchloride (PVC). The plug and receptacle shall be of a single-piece shell design, constructed to positively retain the insert in the specified position in the shell.

3.3.1.7.1 Finish, connector housings. The plug coupling device and plug cover shall be cadmium plated in accordance with QQ-P-416, 0.000040 to 0.000080 inch thick. The color of the plug coupling device (see figure 2a) and plug cover shall be olive drab as specified in FED-STD-595, color chip 24087. The color of all other plug component surfaces shall be optional. The receptacle cover shall be colored olive drab as specified herein. The synthetic rubber handgrip (part of the plug) shall be black. The finish of the receptacle housing and plug housing shall be passivated in accordance with MIL-S-5002.

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3.3.1.8 Shell polarization. Polarization of the connector assembly shall be accomplished by three matched keys and keyways of the plug and receptacle. The polarization of the connector assembly shall take place before engagement and before any pin contacts of the plug can touch any opposing socket of the receptacle. Shell polariza-tion of the connector assembly shall be as shown in figures 2 and 3.

3.3.1.8.1 Engagement seal. The connector assembly shall contain sealing means so that the engaged connectors comply with the requirements specified herein. The design of the seal shall be similar to MIL-C-83723 and shall be such that, in the mated condition, all air paths between adjacent contacts and between contacts and shells are eliminated.

3.3.1.9 Wire sealing. The connector assembly shall be provided with an integral grommet and insert capable of sealing the 12 AWG (coaxial) and the 20 AWG wire sizes.

3.3.1.10 Protective covers. When mated to either the plug or receptacle, the protective covers (see 3.1.5 and 3.1.6) shall maintain the connector free of moisture, prevent contamination of contacts, and conform to the requirements of figures 5 and 6.

3.3.1.11 Lanyard. The lanyard shall conform to the requirements of MIL-W-83420, 1/16-inch, nominal diameter 7 by 7 construction requirements with polyvinylchloride (PVC) coating.

3.3.2 Identification and marking.

3.3.2.1 Identification marking. Unless otherwise specified by the procuring activity, the identification marking of each connector, contact, and each protective cover (see figures 2, 3, 5, 6, and 10) shall be in accordance with MIL-STD-130.

3.3.2.2 Date code. A four-digit code shall be marked on each connector and on each protective cover (see figures 2, 3, 5, 6, and 10) to indicate the year and week of manufacture as follows:

(a) The first two digits of the four-digit code shall be the last two digits of the year; for example for "1974" the first two digits shall be “74”.

(b) The last two digits of the four-digit code shall identify the week of the year of manufacture ("01 through "52').

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3.3.2.3 Package identification. The lowest level of packaging shall include MIS-23393 plus applicable dash number and revision letter to which the part has been manufactured.

3.3.3 Contact arrangement identification. Contact locations shall be designated by identifiable characters of contrasting color on the front and rear faces of the insert grommet assembly as illustrated in figures 2, 3, and 10. Positioning and arrangement of the characters shall be such that the appropriate contact cavities are identifiable and remain identifiable after completion of tests specified in section 4. Raised or depressed characters shall not be used on mating faces.

3.3.4 Workmanship. Workmanship shall be In accordance with MIL-STD-454, requirements 9.

3.4 Qualification inspection.

3.4.1 Qualification. When specified by the contract, the connector assembly furnished under this specification shall be a product which has been tested for design approval and which has passed the qualification inspection (see 4.l.2.1).

3.4.2 Qualification sample. For purposes of this specification, qualification sample shall refer to a prescribed number of connector assemblies manufactured by the methods and procedures intended for the production lot.

3.4.3 Qualification lot. Unless otherwise specified in the contract or order (see 6.2), a qualification lot shall be manufactured using the processes, methods, and procedures intended for production connector assemblies. The lot shall comply with the requirements specified herein and shall be subjected to the inspection specified in 4.1.2.l. Further production of the connector assemblies prior to approval of the qualification lot shall be at the supplier's risk. No design change shall be made after acceptance of the qualification lot without the approval of the procuring activity.

3.4.4 Qualification repeatability. The requirements for the performance of repeat qualification shall be the same as for the initial qualification (see 4.l.2.1). Unless otherwise specified in the contract or order, qualification shall be repeated in the event of any of the following occurrences:

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(a) Any design changes.

(b) Changes in the supplier's processing.

(c) If the supplier's plant or facilities are relocated.

3.5 Precedence. When the requirements of the contract, this specification, or applicable subsidiary specifications, standards, or other publications are in conflict, the following precedence shall apply.

(a) Contract. The contract shall have precedence over any other requirements.

(b) This specification. This specification shall have precedence over all referenced documents except the contract. Any deviation from this specification, or from referenced documents where applicable, shall have the specific written approval of the procuring activity before adoption (see 6.2.1).

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4. Quality Assurance Provisions

4.1 General. This section establishes the requirements for verifying connector assembly conformance to the requirements of sections 3 and 5 by test, analysis, demonstration, or examination. The quality assurance provisions shall consist of the following classification of inspections.

(a) Qualification inspection: (see 4.1.2.1)

(b) Quality conformance inspections: (see 4.2)

(c) Production Lot Test Requirements (see QAP MIS-23393-11)

4.1.1 Responsibility for inspection. Unless otherwise specified in the contract or order, the supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier may use his own facilities or any commercial laboratory acceptable to the Government. The Government reserves the right to perform any of the inspections set forth in this specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1.1 Inspection equipment, facilities, and conditions. Inspection equipment and facilities shall be of the quality and quantity necessary to permit performance of the required examinations and tests.

Unless otherwise specified, all quality conformance inspections shall be performed within the following conditions:

(a) Temperature range: Plus 18 to plus 35 degrees Centigrade (plus 65 to plus 95 degrees Fahrenheit)

(b) Relative humidity: 10 to 95 percent

(c) Barometric pressure: Local average plus or minus 2 inches of mercury

4.1.1.2 Test equipment accuracy. All test equipment required for the quality conformance inspections of

4.2 shall have an accuracy of one-tenth the tolerance of the parameter being tested, or better. Where the state-of-the-art does not permit this, every effort shall be made to keep the equipment accuracy to one-fourth the tolerance of the parameter or better. The equipment utilization shall require approval of the procuring activity prior to the performance of inspections. Test equipment calibration shall comply with the requirements of MIL-STD-45662.

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4.1.1.3 Precautions. Adequate precautions shall be taken during inspection to prevent condensation of moisture on connector assemblies except when performing the humidity, thermal, shock and immersion tests specified herein.

4.1.2 Special tests and examinations.

4.1.2.1 Qualification Inspection. Qualification inspection (see 3.4) shall be performed as specified herein.

4.1.2.1.1 Qualification sample. The qualification sample (see 3.4.2) shall consist of nine connector assemblies (see 3.1) one additional connector assembly shall be supplied with the qualification sample.

This connector assembly will be a spare for use in the event of an allowable subgroup I failure (see table

III).

4.1.2.1.2 Qualification test inspection. Specimens (connector assemblies) shall subjected to the tests specified in table III in the sequence listed. Nine specimens shall be subjected to subgroup I examination and tests. A sample of nine specimens shall then be divided into three subgroups of three specimens each. A separate subgroup of three specimens each shall be used for each of the subgroups II, III and IV examinations and test. Approval of the qualification test samples by the procuring activity shall be based on the successful completion of the tests specified in table III.

Table III. Qualification sampling and tests (subgroups I through IV)

Examination in Test Requirement Test Method Defectives allowed

Subgroup I. 9-connector assemblies 1/

Visual and mechanical examination

Dielectric withstanding voltage

Insulation resistance (initial)

Engaging force and separating impulse

Insertion retention

Contact insertion and removal forces

Contact retention

3.2.2.1 3.2.2.2

3.3.1 thru

3.3.4 and 5

3.2.1.1

3.2.1.2

3.2.2.4

3.2.2.5

3.2.2.3

3.2.2.6

4.3.1.1 thru

4.3.1.6 and 4.3.1.14

4.3.2.1

4.3.2.2

4.3.1.8

4.3.1.9

4.3.1.7

4.3.1.10

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Lanyard strength

Subgroup II. 3-connector assemblies from subgroup I

Test 1

Contact resistance (initial)

Test 2 (in sequence shown)

Thermal Shock

Dielectric withstanding voltage

Insulation resistance (post conditioning)

3.2.2.8

3.2.1.3

3.2.3.1.3

3.2.1.1

3.2.1.2

4.3.1.12

4.3.2.3

4.4.1.3

Examination in Test Requirements Test Method Defective allowed

Subgroup II. 3-connector assemblies from subgroup I (Continued)

Test 3 (in sequence shown)

Sand and dust

Contact resistance (post conditioning)

Test 4 (in sequence shown)

Humidity

Dielectric withstanding voltage

3.2.3.1.7

3.2.2.4

3.2.3.1.4

4.4.1.7

4.3.1.8

4.4.1.4

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Installation resistance (post conditioning)

Test 5 (in sequence shown)

Engagement seal test

Immersion

Dielectric withstanding voltage

Installation resistance (post conditioning)

Test 6 (in sequence shown)

Salt Spray

Contact identification

3.3.1.8.1

3.2.3.1.5

3.2.3.1.6

3.3.3

4.3.1.15

4.4.1.5

4.4.1.6

4.3.1.5

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Examination in Test Requirements Test Method Defective allowed

Subgroup III. 3-connector assemblies from subgroup I

Test 1 (in sequence shown)

Survival (mating durability)

Engaging Force and separating impulse

Test 2 Cable pull-out

Contact resistance (post conditioning)

Subgroup IV. 3-connector assemblies from subgroup I

First Specimen (test in sequence as shown)

High temperature (storage)

High temperature (operating)

Engaging force and separating impulse 2/

Non-operating shock

Fixed frequency vibration

Contact resistance (post conditioning)

Contact VSWR

Second Specimen (test in sequence shown)

Non-operating Shock

3.2.2.7

3.2.2.9

3.2.3.1.1

3.2.3.2.1

3.2.3.1.8

3.2.3.1.9

3.2.1.4

4.3.1.11

4.3.1.13

4.4.1.1

4.4.2.1

4.4.1.8

4.4.1.9

4.3.2.4

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1/ Connectors which fail subgroup I examination shall not be included in samples of other subgroups. A single specimen failing more than one examination or test shall be regarded as a single defective.

2/ Run test at high temperature (see 3.2.3.2.1)

3/ Run test at low temperature (see 3.2.3.2.2)

4.1.2.1.3 Action in case of qualification inspection failure. Defectives in excess of those specified in table II shall constitute a qualification inspection failure and shall be cause for refusal of qualification approval. In the event of qualification failure, inspection shall be discontinued, and

Fixed frequency vibration

4.3.1.8

Examination in Test Requirements Test Method Defective allowed

Subgroup IV. 3-connector assemblies from subgroup I

Third Specimen (test in sequence shown)

Low temperature (storage)

Low temperature (operating)

Engaging force and separating impulse 3/

Non-operating shock

Fixed frequency vibration

Contact VSWR

3.2.3.1.2

3.2.3.2.2

3.1.2.4

4.4.1.2

4.4.2.2

23 of 66 CUI the procuring activity shall be notified. The supplier shall determine the cause of failure and propose corrective action.

4.2 Quality conformance inspection. Quality conformance inspection (QCI) shall consist of groups A, B, and C inspections, as specified herein. The QCI lot (see 6.3.3) shall consist of connector assemblies which are manufactured in continuous production (see 6.3.4).

4.2.1 Mating parts required for quality conformance inspection. When both the connector and mating halves (see 3.1) are furnished under the contract or purchase order, any mating parts required for inspection shall be selected from production under that contract or order. When separating halves only are furnished the mating halves for inspection shall be furnished as specified in the contract or purchase order (see 6.2)

However, mating parts (see 3.1) required for tests shall be new, unused parts manufactured in accordance with all requirements of this specification. To ascertain the quality of mating parts used for inspection, the mating parts shall be inspected together with the test specimens under group A inspection herein.

4.2.2 Groups A and B inspections. Groups A and B inspections shall consist of inspections specified in table IV for verification of the requirements by the methods noted therein. The classification of characteristics (see 6.3.5) specified in table IV shall be as follows:

(a) Critical characteristics: 001-099

(b) Major characteristics: 101-199

(c) Minor characteristics: 201-299

4.2.2.1 Group A inspection sampling. Group A inspection shall be performed on each lot (see 6.3.) both on a 100-percent basis and sample inspected to MIL-STD-105 acceptable quality level (AQL) specified in table IV.

4.2.2.2 Group B inspection sampling. Group B inspection shall be performed on lots of connector assemblies that have passed Group A inspection. Specimens shall be sample inspected to MIL-STD-105 AQL specified in table IV.

4.2.2.3 Inspection, AQL. The requirements of MIL-STD-105 shall apply for acceptance and rejection.

4.2.2.4 Inspection, 100 percent. Where 100-percent inspect1on is specified, only defective connector assemblies shall be rejected.

4.2.3 Group C sampling and testing. Group C inspection shall consist of the tests listed in table V preformed in the sequence shown.

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Table IV. Groups A and B inspections

Examination or Test Requirement Paragraph

Inspection Method

AQL or percent inspection

Classification of Characteristics

Group A

Weight Dimensional limitations Identification and marking Contact arrangement identification Workmanship Preparation for delivery

3.2.2.1 3.2.2.2 3.3.2 3.3.3 3.3.4

4.3.1.1 4.3.1.2 4.3.1.4 4.3.1.5 4.3.1.6 4.3.1.14

1.0 1.0 1.0 1.0

100% 2.5

Group B

Dielectric withstanding voltage Insulation resistance (initial) Engaging force and separating impulse

0.4

100%

Group B (Continued)

Contact insertion and removal forces Insertion retention Contact retention Lanyard strength

3.2.2.3 3.2.2.5 3.2.2.6 3.2.2.8

4.3.1.7 4.3.1.9 4.3.1.10 4.3.1.12

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4.2.3.1 Frequency of group C inspection. All group C tests shall be performed on the first lot submitted after 6 months from the successful completion of qualification testing. Thereafter, no lot shall be shipped without first running all group C tests if over 12 months has elapsed since the previous group C tests were performed.

4.2.3.2 Group C sampling. Nine connector assemblies (see 3.1.) shall be selected from specimens which have passed groups A and B inspections. The nine specimens shall be subjected to the tests in table V. Different specimens shall be used for each subgroup inspection.

4.2.3.3 Action in case of failure (Group C). If any specimen fails any group C test, the supplier shall take corrective action on all connector assemblies (see 3.1) which were manufactured under essentially the same conditions and which are considered subject to the same failure.

Acceptance of subsequent connector assemblies shall be withheld until corrective action has been taken, and specimens which incorporate the corrective action have passed the test failed by the preceding specimens.

4.3 Inspection methods. The inspection methods specified herein are for demonstrating compliance with the requirements of sections 3 and 5. Alternate inspection methods may be proposed by the supplier but shall be approved by the procuring activity prior to use in acceptance testing.

4.3.1 Physical, visual, and analytical inspections.

4.3.1.1 Weight. The weight of the connector assembly shall in be verified for compliance with the weight requirements specified in 3.2.2.1.

4.3.1.2 Dimensional limitations. The configuration, limiting dimensions, and mechanical tolerances of the connector assembly shall be verified for compliance with the requirements specified in 3.2.2.2.

4.3.1.3 Materials, processes, and parts. It shall be ascertained by the inspection of data that all materials, processes, and parts have been inspected and found to comply with their respective specifications and applicable drawings, and that all specified manufacturing processes have been followed during production, to verify compliance with 3.3.1.

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Table V. Group C inspection (subgroups I through III)

Paragraph

Inspection Method Paragraph

Subgroup I - 3-connector assemblies

Test 1.

Contact resistance (Initial)

Test 2. (in sequence shown):

Thermal shock Dielectric withstand voltage Insulation resistance (post conditioning)

Test 3. (in sequence shown):

Sand and dust Contact resistance (post conditioning) Engaging force and separating impulse

Test 4. (in sequence shown):

Humidity Dielectric withstanding voltage Insulation resistance (post conditioning)

Test 5. (in sequence shown):

Immersion Dielectric Withstanding Voltage Insulation resistance (post conditioning)

Test 6. (in sequence shown):

Salt Spray

Subgroup II - 3-connector assemblies

3.2.3.1.3

3.2.3.1.7

3.3.2.1.4

3.2.3.1.5

3.2.3.1.6

4.4.1.3

4.4.1.7

4.4.1.4

4.4.1.5

4.4.1.6

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Test 1 (in sequence shown):

Survival (mating durability) Contact resistance (post conditioning) Engaging force and separating impulse

Test 2.

Cable pull-out

3.2.2.7

3.2.2.9

4.3.1.11

4.3.1.13

Paragraph

Inspection Method Paragraph

Subgroup III - 3-comector assemblies

First specimen (test in sequence shown):

High temperature (storage) Non-operating shock Fixed frequency vibration Contact resistance (post conditioning) Contact VSWR Engaging force and separating Impulse

Second specimen (test in sequence shown):

Non-operating shock Fixed frequency vibration Contact resistance (post conditioning) Engaging force and separating impulse

Third specimen (test in sequence shown):

Low temperature (storage) Non-operating shock Fixed frequency vibration Contact resistance (post conditioning) Contact VSWR

3.2.3.1.1

3.2.3.1.9 3.2.1.3

3.2.3.1.2

3.2.3.1.9 3.2.1.3

4.4.1.1

4.4.1.9 4.3.2.3

4.4.1.2

4.4.1.9 4.3.2.3

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4.3.1.4 Identification and marking. The connector assembly shall be examined to determine compliance with the identification and marking requirements of 3.3.2.

4.3.1.5 Contact arrangement identification. The connector assembly shall be examined to determine compliance with the identification and marking requirements of 3.3.3.

4.3.1.6 Workmanship, The connector assembly shall be examined to determine compliance with the workmanship requirements of 3.3.4.

4.3.1.7 Contact insertion and removal forces test. The connector assembly shall be tested in accordance with the maintenance aging requirements specified In MIL-STD-1344, method 2002, The insertion and removal tools shall be as specified in 6.1.6. The contact insertion and removal forces shalt not exceed those specified in 3.2.2.3.

4.3.1.8 Engaging force and separating impulse test. An engaging force, retention force and separating impulse test shall be performed on the connector assembly and protective covers in accordance with MIL-STD-1344, method 2013. The following details shall apply.

(a) The force shall be applied to the shell of the connectors and protective covers within 20 degrees of the axial centerline.

(b) Twenty AWG stranded insulated wires at least 6 Inches long shall be used.

(c) With a 5 pound maximum static applied to the lanyard, the connector shall remain engaged.

(d) For groups B and C testing, the unmating impulse shall be produced by dropping a

2.4 pound weight maximum, a distance of 5.0 Inches maximum to the lanyard. For group C testing, the unmating impulse shall also be measured to verify that the peak force did not exceed 60 pounds.

4.3.1.9 Insert retention test. Inserts In the connector assembly shall be subjected to axial loads in each direction in accordance with MIL-STD-1344, method 2010. The connector shall not be wired for this test. Prior to applying the specified load, the location of the inserts shall be measured and noted. After the axial loads have been applied in each direction, the location of the inserts shall be measured. These measurements shall be compared to the original measurements to verify that no change occurred during the load test. The connector shall withstand these loads without showing differences in measurements, evidence of cracking, breaking, or separation from the shell.

4.3.1.10 Contact retention test. The connector assembly shall be tested in accordance with the contact retention requirements specified In MIL-STD-1344, method 2007. The axial load specified in 3.2.2.6 shall be applied to individual test gages in both directions. All contacts in each connector shall be tested.

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4.3.1.11 Survival (mating durability) test. The connector assembly shall be tested for no less than 3000 mating and unmating cycles. The normal mounting means shall be used. The test shall be performed at a maximum rate of 200 cycles per hour and shall be performed manually.

Upon completion of the survival test, the contact resistance (post conditioning) and the connector assembly engaging and separating forces shall be measured as specified in 4.3.2.3 and 4.3.1.8, respectively.

4.3.1.12 Lanyard strength test. The lanyard connected to the plug shall withstand an axial pull of no less than 288 pounds.

4.3.1.13 Cable pull-out test. The mated connector assembly shall withstand the specified force in the axial direction (tending to pull the cable out of the connector, and tending to separate the mating halves) in accordance with Mll-STD-1344, method 2009. Verify compliance with the requirements of paragraph 3.2.2.9 herein. Post condition (of the pull test) contact resistance shall not exceed the requirements specified in 3.2.1.3 herein.

4.3.1.14 Inspection of preparation for delivery. Inspection for compliance with the requirements of section 5 shall be performed on packages of connectors that have been prepared for delivery.

4.3.1.15 Engagement seal test. The IFF plug and receptacle shall be tested as a mated assembly for Insulation Resistance in accordance with paragraph 3.2.1.2 herein while subjected to the immersion environment as described in paragraph 3.2.3.1.5 herein. All pins shall have wires of sufficient length to permit voltage application while the connector assembly is submerged.

4.3.2 Performance inspections.

4.3.2.1 Dielectric withstanding voltage. The unmated connector assembly shall be tested in accordance with MIL-STD-1344, method 3001. The specified test voltages shall be applied between all adjacent contacts and between the shell and each contact closest to the shell.

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4.3.2.2 Insulation resistance test. The unmated and mated connector assembly shall be tested for insulation resistance in accordance with MIL-STD-1344, method 3003 for compliance with 3.2.1.2.

4.3.2.3 Contact resistance test. The mated connector assembly shall be tested in accordance with the contact resistance test specified in MIL-STD-1344, method 3004. Number 20 AWG stranded wire and RC-178/U or equivalent coaxial wire shall be used.

4.3.2.4 Contact VSWR test. The VSWR of the coaxial contacts in the mated connector assembly shall be tested in accordance with the following:

(a) Terminate one end of the coaxial contacts with a 50-ohm characteristic impedance.

(b) Apply an input at a frequency of 1.00 (plus or minus 0.05) GHZ.

(c) Determine that the VSWR meets the requirements of 3.2.1.4

4.4 Environmental inspection methods. The connector assembly shall be tested after or during exposure to the environments of 4.4.1 and 4.4.2 as specified herein.

4.4.1 Non-operating environmental inspection methods.

4.4.1.1 High temperature storage test. The unmated connector assembly shall be subjected to the high temperature (storage) conditions specified in 3.2.3.1.1. During the test, the plug and the receptacle shall be protected by the covers, After the high temperature exposure, the connector assembly shall be tested for compliance with the requirements specified In table III for the qualification inspection and table V for the quality conformance inspection.

4.4.1.2 Low temperature (storage) test. The unmated connector assembly shall be subjected to the low temperature (storage) conditions specified in 3.2.3.1.2. During the test, the plug and recep-tacle shall be protected by their covers. After the low temperature exposure, the connector assembly shall be tested for compliance with the requirements specified in table Ill for the Qualification Inspection and table V for the quality conformance Inspection.

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4.4.1.3 Thermal shock test. The unmated and wired connector assembly shall be tested ln accordance with MIL-STD-1344, method 1003. The following details and exceptions shall apply with tests performed in the sequence Indicated after cycling:

(a) During the test, protect the plug by its protective cover. Protect the receptacle by its protective cover (see 3.3.1.10).

(b) Use test condition A, except use the temperature specified in 3.2.3.1.3.

(c) Measurements in MIL-STD-1344, method 1003, before the tests are not applicable.

(d) For the qualification inspections, test for compliance with the requirements specified in table III.

(e) For the quality conformance Inspection, test for compliance with the requirements specified in table V.

4.4.1.4 Humidity test. The unmated connector assembly shall be subjected to the requirements of MIL-STD-1344, method 1002.1, type II with the following conditions, and exceptions:

(a) During tests, protect the plug by its protective cover. Protect the receptacle by its protective cover (see 3.3.1.10).

(b) Wire the connector assembly.

(c) Replace step 7 by a repeat of steps 4, 5, and 6 of MIL-STD-202, method 106, with temperatures as specified in 3.2.3.1.4 during each 24-hour cycle.

(d) After high humidity exposure, remove the protective covers and perform the following tests:

(1) For the qualification Inspection, test for compliance with the requirements specified in table III.

(2) For the quality conformance inspection, test for compliance with the requirements specified in table V.

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4.4.1.5 Immersion test. The IFF connector plug and receptacle (-014 receptacle shall have wires trunked as shown in figure 11) without protective covers shall be subjected to the immersion test specified in MIL-STD-202, method 104A, test condition B. The following conditions and exceptions apply:

(a) The connector plug and receptacle shall be fully wired.

(b) Depth of immersion shall be 4 feet minimum for 10 minutes minimum.

(c) One immersion at a water temperature of 25o +10, -5 centigrade with the connector preheated to 33° Centigrade minimum above the water temperature.

(d) The connector assembly, shall be tested for compliance with requirements specified in table III for qualification and table V for QCI. Measurements shall be performed within

1.0 hour after the immersion test. No artificial drying of the connector shall be permitted.

4.4.1.6 Salt spray (corrosion test). The unmated connector assembly and individual contacts shall be tested in accordance with MIL-STD-1344, method 1001. The following condition shall apply:

(a) During the test, cover the plug and receptacle with their protective covers.

(b) Use test condition B of MIL-STD-202, method 101.

(c) Prior to all subsequent testing, engage and disengage the corrosion tested connector for one cycle to remove free salt deposits.

(d) Subject the connector assembly to the…