D38999

D38999 ETC2

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36 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III – – M IL-D TL-38 9 9 9 Features and A pplication Series III w w w .conesys.com sales @ aero-electric.com Features and A pplication M IL-DTL-3 89 9 9 Series III is the new est cylindrical connector designed for highest perform ance capabilities used in both general purpose and severe environm ent applications. These connectors feature an im proved “one-turn” coupling system , utilizing self-locking acm e thread. A cm e threads provide coupling durability, w hile thicker w all sections and greater coupling surface area im prove strength and shock resistance. Blunting of the threads on both receptacle and plug coupling nut elim inates cross threading. Elongated m ounting holes perm it the Series III C onnector to interm ount w ith various existing M il-spec flange m ounted receptacles, giving it a design replacem ent advantage. W all m ount receptacle, jam nut receptacle and straight self-locking RFI plug are offered in 9 shell sizes and 54 insert arrangem ents utilizing M 3 9 029 contacts in sizes 22D, 20, 16 , 12, 10 pow er and 8 tw inax. These connectors are available in w ide range of shell m aterials and finishes. A lum inum shells are offered in electroless nickel and olive drab cadm ium . O ther finishes such as anodic and zinc nickel are available upon request to com m ercial callouts only. In addition, w e offer stainless steel shells (both passivated and electro-deposited nickel plated) w ith firew all inserts, and for highly corrosive environm ents, nickel-alum inum -bronze shells w ith standard environm ent-resisting inserts (com m er - cial callouts only). M IL-STD -1 560 Insert A rrangem ents – Series III connectors use insert patterns and contacts com m on to Series I, m aking for an easy transition from bayonet to triple-lead, acm e-thread, self-locking coupling. M etal-to-M etal Bottom ing – This feature precludes relative shell-to-shell m otion, w hich m ay result in ordinary connector w ear and m oisture entrapm ent. Lockw iring Elim inated – Self-locking quick coupling plug elim inates the need for lockw iring. Firew all Capability - Stainless steel shells in both K and S firew all classes are offered. U niversal I/R Tool – A single, expendable plastic tool is used for both insertion and rem oval of contacts. Scoop-Proof D esign – Recessed pins in elongated shells m inim ize the possibility for contact dam age. In a blind m ating application, m ating shells cannot “scoop” the pins, and cause a shorting or bending of contacts. Closed-Entry Socket Insert – H ard dielectric socket face has lead-in cham fers for positive alignm ent of pins (even partially bent w ithin pre-established lim its) w ith sockets. Interfacial Pin Insert Seal – R aised m oisture barriers around each pin, w hich m ate into lead-in cham fers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. Elastom er W ire Sealing G rom m et – Sealing over a w ide range of w ire diam eters is assured by a triple w ire seal in each cavity at the rear of the connector. Superior Contact Stability – Rear release crim p contact system features a stam ped beryllium -copper retaining clip captivated by m olded-in shoulders of each contact cavity in the insulator. A rear-inserted M 819 6 9 plastic tool expands the tines beyond the shoulder, releasing the contact. M etric A ccessory Thread – M etric thread results in additional w all thickness giving greater strength and shock resistance .

37 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III M IL-D TL-38 9 9 9 Perform ance Specifications Series III – – Perform ance Specifications O perating Tem perature Range C lasses F, K , S and BZ*: -6 5°C to +200°C (-85°F to +3 9 2°F) C lasses W and ZC *: -6 5°C to +17 5°C (-85°F to +3 47 °F) M aterial and Finish D ata (Class) F – alum inum shell, electroless nickel finish K – stainless steel shell, passivated, firew all S – stainless steel shell, electrodeposited nickel, firew all W – alum inum shell, olive drab cadm ium over nickel base BZ *– alum inum nickel bronze shell, std insert Z*– alum inum shell, zinc nickel finish Corrosion Resistance C lasses K , W , BZ* and Z* w ithstand 500-hour salt spray. C lasses F and S w ithstand 48-hour salt spray. D urability M inim um of 500 m ating cycles. Fluid Resistance C onnectors resist specified im m ersions in M IL -PR F -7 808, M IL-PRF -23 6 9 9 , M I L-PRF-56 06 , M 2 -V C hevron oil, C oolanol 25, M IL-DT L-83 13 3 (JP-8), M IL-DTL-56 24 (JP-4, JP-5), SA E-A M S1424 Type I, and other solvents and cleaning agents. Shielding Effectiveness R FI and EM I attenuation at the specified frequencies m eet the requirem ents of M IL-DTL-3 89 9 9 . G R FI shielding effectiveness of m ated connectors w ith R FI backshells is m easured in a triaxial radio frequency leakage fixture. G EM I shielding effectiveness is m easured at the interface of m ated connectors and tested by the m ode-stirred technique specified in m ethod 3 008 of M IL-STD-13 44. Voltage Rating Environm ental Seal W ired, m ated connectors w ith specified accessories attached, shall m eet the altitude-im m ersion test specified in M IL-DTL-3 89 9 9 . Shell-to-Shell Conductivity M axim um potential drop shall not exceed: G C lasses F and S = 1.0 m illivolt. G C lass W = 2.5 m illivolts, C lass K = 10.0 m illivolts Shock and Vibration Requirem ents W ired, m ated connectors shall not be dam aged, nor shall there be a current interruption longer than one m icrosecond w hen subjected to the follow ing: Shock Pulse of approxim ate half sine w ave of 3 00 G ± 15 percent m ag - nitude w ith duration of 3 ± 1 m illiseconds applied in three axes. H igh Im pact Shock W hen m ounted as specified in M IL-S-9 01, grade A , a drop of a 400 lb. H am m er from 1 foot, 3 feet and 5 feet applied to connector in three axes, totaling nine im pacts. Vibration W ired and m ated connectors w ithstand the follow ing vibration levels: G Sine vibration w here connector sam ples w ith sim ulated accessory load are subjected to sim ple harm onic m otion from 10 to 2,000 H z in three m utually perpendicular axes, in 20 m inute sw eeps, for 12 hours in each axis at velocity of 254 m m /sec from 10-50 H z, displacem ent of 1.5 m m from 50-140H z and acceleration of 6 0G from 140-2,000H z. G R andom V ibration per M IL-STD-13 44, m ethod 205, test condition V at am bient tem perature and test condition V I, Letter “J” at elevated tem perature. * N ot on Q PL, can be supplied to Aero-Electric part num ber only. Service Rating Suggested O perating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft. AC (RM S) D C V RM S V RM S V RM S V RM S M 400 550 13 00 550 3 50 200 N 3 00 450 1000 400 26 0 200 I 6 00 8 50 18 00 6 00 400 200 II 900 1250 23 00 8 00 500 200 N ote: The establishm ent of electrical safety factors is left entirely to the designer, as he is in the best position to know exactly w hat peak voltages, sw itching currents, transients, etc., can be expected in a particular circuit.

38 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III M IL-D TL-38 9 9 9 Part N um ber D evelopm ent Series III M ilitary and Aero-Electric Part N um ber D evelopm ent – – * N ot on Q PL, can be supplied to Aero-Electric part num ber only. N ote 1 : Each connector is furnished w ith contacts unless ordered less contacts (L/C ) as follow s: O ne spare contact for inserts requiring 2 through 26 of each contact and tw o spares for inserts w ith 27 or m ore contacts, and a m inim um of one sealing plug up to 10% of the num ber contacts. Spare C oax and Tw inax contacts are not supplied. O ne insertion/extraction tool for each contact size is also included. N ote 2: Proper part num ber m arking has no “0” in front of single digit layout. Exam ple: JD3 89 9 9 /20W B5SN . “N ” for norm al is included. In addition, J or JA N m ust be m arked im m ediately in front of M IL part num ber. M il. Prefix D 38 9 9 9 / 2 0 W C 35 P N A ero Prefix A E3 2 0 W C 35 P N -340 Shell Type (Specification Sheet N um ber) 2 0 = W all m ount receptacle 2 4 = Jam nut receptacle 2 6 = Self-locking, RFI grounding plug Class (M aterial & Finish) F = Alum inum shell, electroless nickel finish W = Alum inum shell, olive drab cadm ium over electroless nickel base K = Stainless steel shell, passivated, w ith firew all insert S = Stainless steel shell, electrodeposited nickel, w ith firew all insert B Z * = Alum inum nickel bronze shell w ith standard insert (Aero p/n only) Z* = Alum inum shell, zinc nickel plating (Aero p/n only) Shell Size A , B , C, D , E, F, G , H or J Insert A rrangem ent See pages 15 thru 19 Contact Style P = Pin S = Socket A = Pin connector less pins (w ith intent to use non-std pin contacts) B = Socket connector less sockets (w ith intent to use non-std socket contacts) Polarization (Keying) N = N orm al (Included in part num ber) A , B , C, D , or E M odification (applies to A ero part num bers only) 0 1 = Less contacts (is not m arked on the part) 340 = Connector kitted w ith M 8 5049/14-XXX 341 = Connector kitted w ith M 8 5049/3 8 -XXX straight clam p 342 = Connector kitted w ith M 8 5049/3 9-XXX right angle clam p Consult factory for other m odifications

39 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III D 38 9 9 9 /2 0 W all M ounting Receptacle A E32 0 Triple Start Threaded Coupling, Crim p Rem ovable, Rear Release, Scoop-Proof – – BLUE COLOR BAND (REAR RELEASE) B

4 MINOR KEYWAYS

E C D LOCKING INDICATOR BAND COLOR: RED F MATING THREAD MASTER KEYWAY G MAX 31.50(1.240) MAX 2.16(.085) MAX GROMMET EXTENSION J NUMBER OF TEETH K ACCESSORY THREAD 7.11(.280) MIN FULL THREAD H MAX A /H11083 L MAX GROMMET Page 3 8 Com pleted Part N um ber Page 44 Contacts, Sealing Plugs and Tools Pages 17–19 Insert Arrangem ents Page 3 7 Perform ance Specifications Pages 15, 16 Insert Availability and Contact Inform ation Page 42 Polarization N ote 1 : “K ” A ccessory Thread for A E3 20 is sam e as A E3 26 (“D” A ccessory Thread) on page 41. N ote 2: “F” M ating Thread for A E3 20 is sam e as A E3 26 (“E” M ating Thread) on page 41 except it is C lass 2A . N ote 3: M axim um G rom m et Extension for insert layouts incorporating size 8 and 10 contacts = 5.95 (.23 4). Shell Size A B C D E G H J /H11083 L N o. of inch m m inch m m inch m m inch m m inch m m inch m m inch m m inch m m

40 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III D 38 9 9 9 /2 4 Jam N ut Receptacle A E32 4 Triple Start Threaded Coupling, Crim p Rem ovable, Rear Release, Scoop-Proof – – "O" RING SEAL HEX NUT PER D38999/28 MASTER KEYWAY B FLAT A E MATING THREAD C J THREAD LOCKING INDICATOR BAND COLOR: RED 32.50 (1.280) MAX PANEL THICKNESS 3.20(.126) 1.58(.062) K ACCESSORY THREAD F NUMBER OF TEETH /H11083 H MAX GROMMET 2.16(.085) MAX GROMMET EXTENSION BLUE COLOR BAND (REAR RELEASE) GD Page 3 8 Com pleted Part N um ber Page 44 Contacts, Sealing Plugs and Tools Pages 17–19 Insert Arrangem ents Page 3 7 Perform ance Specifications Pages 15, 16 Insert Availability and Contact Inform ation Page 42 Polarization N ote 1 : “K ” A ccessory Thread for A E3 24 is sam e as A E3 26 (“D” A ccessory Thread) on page 41. N ote 2: “E” M ating Thread for A E3 24 is sam e as A E3 26 (“E” M ating Thread) on page 41 except it is C lass 2A . N ote 3: M axim um G rom m et Extension for insert layouts incorporating size 8 and 10 contacts = 5.95 (.23 4). Shell Size A B C D F G /H11083H J inch m m inch m m inch m m inch m m inch m m inch m m 0.1 00R

41 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III D 38 9 9 9 /2 6 Self-Locking, RFI G rounding Plug A E32 6 Triple Start Threaded Coupling, Crim p Rem ovable, Rear Release, Scoop-Proof – – MASTER KEY RFI STRIP

4 MINOR KEYS

E MATING THREAD BLUE COLOR BAND LOCATION OPTIONAL (REAR RELEASE) 31.00(1.220) MAX D ACCESSORY THREAD T NUMBER OF TEETH 2.16(.085) MAX GROMMET EXTENSION 7.11(.280) MIN FULL THREAD /H11083 A MAX COUPLING NUT /H11083 B MAX GROMMET N ote : M axim um G rom m et Extension for insert layouts incorporating size 8 and 10 contacts = 5.95 (.23 4). Page 3 8 Com pleted Part N um ber Page 44 Contacts, Sealing Plugs and Tools Pages 17–19 Insert Arrangem ents Page 3 7 Perform ance Specifications Pages 15, 16 Insert Availability and Contact Inform ation Page 42 Polarization Shell Size /H11083A /H11083B D E T Accessory Thread M ating Thread N o. of M axim um M axim um M etric Class 2B Teeth inch m m inch m m

42 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III M IL-D TL-38 9 9 9 Polarization Series III Keying Positions – – MASTER KEYWAY NORMAL N otes: 1. M ating face of receptacle show n (plug is opposite). 2. A ll m inor keyw ays (keys) are rotated to provide shell polarization w hile m aster keyw ay (key) rem ains fixed as show n. 3 . The angles for a given connector are the sam e w hether it contains pin or socket inserts. 4. Insert arrangem ent does not rotate relative to the m aster keyw ay (key). Shell Size Key/Keyw ay Key/Keyw ay Positions BSC Identification Letter A ° B ° C° D ° A (9) N 105 140 215 26 5 A 102 13 2 248 3 20 B 8 0 118 23 0 3 12 C 3 5 140 205 275 D 6 4 155 23 4 3 04 E 91 13 1 197 240 B (11) C (13 ) D (15) N 95 141 208 23 6 A 113 156 18 2 292 B 90 145 195 252 C 53 156 220 255 D 119 146 176 298 E 51 141 18 4 242 E (17) F (19) G (21) H (23 ) J (25) N 8 0 142 196 293 A 13 5 170 200 3 10 B 49 16 9 200 244 C 6 6 140 200 257 D 6 2 145 18 0 28 0 E 79 153 197 272

43 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III M IL-D TL-38 9 9 9 Series III Flange and Jam N ut Receptacles Panel Cutouts Panel Cutouts – – N ote: Diam eter B cutout dim ensions are listed separately for back and front of panel m ounting. A /H11083 E 4x /H11083 C /H11083 B MIN FLANGE MOUNT 3.20(.126) 1.58(.062) PANEL THICKNESS D JAM NUT Shell Size A /H11083B /H11083B /H11083C D /H11083E For Back M ounting For Front M ounting +.000 +.00 +.010 +.25 inch m m inch m m inch m m inch m m inch m m inch m m

44 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III M IL-D TL-38 9 9 9 Contacts, Tools and Seal Plugs Series III Contacts, Plastic Insertion/Rem oval Tools and Seal Plugs Crim ping and M etal Insertion/Extraction Tools Contact and W ire D ata – – † M S3 3 48 bushing required w ith 12 gauge w ire. * W hen tested w ith silver-plated w ire. Insertion tool is not required. * D um m y contact, used in lieu of unw ired contact and seal plug. **** D aniels M anufacturing part num ber. N ote: Size 8 coax contacts are used w ith M 17 /09 5-RG 180 cable, w hile size 8 Tw inax contacts are used w ith M 17 /17 6 -00002 cable. Contact Size A pplication Pin Contacts Socket Contacts Seal Plugs Insertion/Rem oval Tools Plastic Type M ilitary N o. M ilitary N o. M ilitary N o. M ilitary N o. 22D Pow er/Signal M 3 9029/58 -3 6 0 M 3 9029/56 -3 48 M S2748 8 -2 2-1 M 8 196 9/14 -01

20 Pow er/Signal M 3 9029/58 -3 6 3 M 3 9029/56 -3 51 M S2748 8 -2 0 -1 M 8 196 9/14- 10

16 Pow er/Signal M 3 9029/58 -3 6 4 M 3 9029/56 -3 52 M S2748 8 -1 6 -1 M 8 196 9/14 -03

12 Pow er/Signal M 3 9029/58 -3 6 5 M 3 9029/56 -3 53

M S2748 8 -12-1 M 8 196 9/14 -04 12 Coax Coax M 3 9029/28 -211 M 3 9029/75-416

12 Coax Coax M 3 9029/102-558 M 3 9029/103 -559

10 (Pow er) Pow er M 3 9029/58 -528 M 3 9029/56 -527 M 8 5049/8 1- 10** * M 8 196 9/14 -05

8 Coax Coax M 3 9029/6 0 -3 6 7 M 3 9029/59-3 6 6 M S2748 8 - 8 -1 M 8 196 9/14 -06

8 Tw inax Tw inax M 3 9029/9 0 -529 M 3 9029/91-53 0 M S2748 8 - 8 -1 M 8 196 9/14- 12

Crim p Tool Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts M etal M etal 22D M 22520/2 -01 M 22520/2 -09 M 22520/2 -07 M 8 196 9/8 -01 M 8 196 9/8 -02 20 M 22520/1 -01 M 22520/1 -04 M 22520/1 -04 M 8 196 9/8 -05 M 8 196 9/8 -06 M 22520/2 -01 M 22520/2-10 M 22520/2 -10

16 M 22520/1 -01 M 22520/1 -04 M 22520/1 -04 M 8 196 9/8 -07 M 8 196 9/8 -08

12 M 22520/1 -01 M 22520/1 -04 M 22520/1 -04

M 8 196 9/8 -09 M 8 196 9/8 -10 12 Coax Inner M 22520/2 -01 M 22520/2-3 4 M 22520/2-3 4

12 Coax O uter M 22520/ 31-01 M 22520/3 1 -02 M 22520/3 1 -02

10 ( Pow er) 17 16 P -1**** N /A N /A M 8 196 9/ 8 -1 1 M 8 196 9/8 - 12

8 Coax Inner M 22520/2 -01 M 22520/2-3 1 M 22520/2-3 1

M 8 196 9/ 8-13 ** M 8 196 9/8 -14 8 Coax O uter M 22520/5 -01 M 22520/5 -05 M 22520/5 -05 D ie Closure B D ie Closure B

8 Tw inax Center M 22520/2 -01 M 22520/2-3 7 M 22520/2-3 7

— —8 Tw inax O uter & Interm ediate M 22520/5 -01 M 22520/5-200 M 22520/5-200 Contact Size Test Current* Voltage* Crim p W ell D ata W ire Range Finished W ire /H11083 Range D C Test M ax. D rop W ell D ia. M inim um W ell D ept M inim um M axim um Am ps M illivolts inch inch m m AW G m m 2 inch m m inch m m

45 w w w .conesys.com sales @ aero-electric.com MIL–DTL– 38999 S III M IL-D TL-38 9 9 9 Contact Installation Instructions Series III – – Contact Installation Instructions Crim ping Contacts 1. Select the appropriate crim p tool and ensure that the proper crim p head positioner is used. 2. C ycle the tool to be sure the indentors are open. 3 . Determ ine the correct selector setting for the w ire size from the data plate on the positioner (turret head assem bly) and set the selector knob on the crim p tool to m atch. 4. Place the contact, m ating end first, into the tool. 5. Insert the stripped w ire into the hollow end of the contact. Be sure the w ire is inserted as far as it w ill go. 6 . C lose the tool com pletely to crim p. U nless the tool is closed com pletely, the tool w ill not release the contact. 7 . Rem ove the crim ped contact from the tool. C heck the inspection hole to verify that the w ire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clam ps, backshells or adapters) from rear of plug or receptacle. Slide the hardw are over the w ire bundle in the proper order for reassem bly after all the contacts are inserted. 2. T o assist insertion of contacts, lubricate insulator (grom m et) cavities w ith isopropyl alcohol. A lcohol w ill evaporate and w ill not leave a conductive film . C aution : N ever use any lubrican t other than isopropyl alcohol. 3 . Place the correct insertion tool on the contact so that the w ire runs along the groove in the tool. (T ool tip w ill butt against the shoulder.) H old the plug or receptacle body firm ly. 4. Beginning w ith a center cavity, insert the contact into the insulator w ith a slow , even pressure until the contact snaps into position. M ake sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grom m et could be dam aged.

4.1 If contacts are not inserted all the w ay prior to

rem oving insertion tool, do not try to reinsert the insertion tool. Instead, rem ove the contact and try again; otherw ise reinserting the insertion tool m ay dam age the inside of the contact cavity. 5. Rem ove tool and check the face of the connector for proper contact installation. Proper installation m ay also be checked by pulling back lightly on the w ire to m ake sure the contact is properly seated. Com pletion A fter all the cavities have been filled, slide the hardw are back into position on the connector and tighten. Extraction of Contacts (Rew ork) 1. Slide the hardw are back over the w ire bundle. 2. Select the appropriate tool. Place the w ire into the extraction tool of the pin or socket. 3 . Slow ly slide the extraction tool dow n w ire into the contact cavities until the tool tip bottom s against the contact shoulder, expanding the clip retaining tines. H old the w ire firm ly in the tool and pull the w ired contact and tool straight out of the rear of the insulator. Size Pin Contact Socket Contact B asic Crim p Tool Pin Positioner Socket Positioner Insertion/Rem oval Tool 22D M 3 9029/58 -3 6 0 M 3 9029/56 -3 48 M 22520/2 -01 M 22520/2 -09 M 22520/07 M 8 196 9/ 14- 01 20 M 3 9029/58 -3 6 3 M 3 9029/56 -3 51 M 22520/1 -01 M 22520/1 -04 Red M 22520/1 -04 red M 8 196 9/ 14-10 M 22520/2 -01 M 22520/2-10 M 22520/2 -10 16 M 3 9029/58 -3 6 4 M 3 9029/56 -3 52 M 22520/1 -01 M 22520/1 -04 Blue M 22520/1 -04 Blue M 8 196 9/ 14- 03 12 M 3 9029/58 -3 6 5 M 3 9029/56 -3 53 M 22520/1 -01 M 22520/1 -04 Yellow M 22520/1 -04 Yellow M 8 196 9/ 14- 04

10 M 3 9029/58 -528 M 3 9029/56 -527 * * * M 8 196 9/ 14- 05

For Coax and Tw inax contacts refer to instructions that are supplied w ith contacts. * Contact D aniels M anufacturing for crim p tool/positioner.