Aero-Electric Connector Military Aerospace Geophysical Industrial Transportation conesys.com Circular Connectors With roots dating back to 1983, Conesys Inc. is focused on the Design and Manufacturing of Quality Interconnect Products. We are an ISO 9001 and AS9100- Certified vertically integrated manufacturer of Circular and Rectangular Connectors for the Military, Industrial, Transportation and Commercial Markets. Our companies Design, Manufacture and supply High Performance, EMI Filter & Transient Devices, Copper & High Frequency Interconnect Systems, Hermetically Sealed, PCB, RF and Application - Specific Interconnects to a wide range of Military, Aerospace, Commercial Aviation, Heavy Equipment, Rail & Mass Transit, Geophysical and Machine Automation sectors. We are committed to being a Global Interconnect Organization. Servicing our Customers throughout Conesys World Headquarters Aero Industrial Products Manufacturer of Connectors and Cable Assemblies for the industrial marketplace Conesys Europe Sales, Engineering, and Connector Assembly of MIL Spec, Hermetic, and custom connectors, supporting International Customers the America's and Asia from our headquarters in Torrance, California, serving the needs of our European, African and Middle East Customers from our Conesys Europe facility in Toulouse, France and serving the local market in China from our Conesys Asia Ltd. facility in Beijing China. Conesys Inc. combines excellent financial strength with the flexibility and responsiveness of an entrepreneurial firm to supply our valued Customers Quality Products, Cost-efficiency and On-Time Delivery, while meeting a full range of your requirements from Standard Applications to Customized Solutions Engineering. Our Mission is to be a World-Class supplier of Electronic Connector Products through Customer Satisfaction, Quality, Innovation and Leading-Edge Technology. Aero-Electric Connector A High Volume, Mil Spec Connector Manufacturer J-Tech & EMP Manufacturers of Custom Connectors, fiber optic assemblies, and filter connectors ATI Interco Sales and Engineering for Printed Circuit Board and Custom Connectors, Backshells and Cabling Components Products Conesys/Aero Electric Connector is a first-rate designer and cost competitive manufacturer of high performance environmental and firewall-rated cylindrical connectors machined from aluminum, carbon steel, stainless steel, and aluminum nickel bronze. Conesys/J-Tech specializes in front and rear release 5015 connectors as well as customer-specific applications for customized connectors and fiber optic assemblies. Conesys/EMP Connectors designs and manufactures EMI filter and EMP transient suppression devices. Conesys Europe markets and assembles product for Aero-Electric, J-Tech and EMP. Conesys/Aero Industrial Products sells and manufactures connectors and cable assemblies intended for the industrial marketplace. Markets Our connectors are widely used in all types of applications spanning markets such as: Military/Aerospace, Commercial Aviation, Business Aviation, Aircraft Engines, Marine Applications, Heavy Equipment, Rail Mass Transit, Geophysical, Machine Automation/Motion Control, Medical Equipment, General Industrial and Telecommunications. Machining In house, using state-of-the-art double spindle, double turret CNC machines allowing for flexibility, and faster cycle times. Molding In house, using internally built molds allowing for tighter controls and improved cycle times. Plating In house, using state-of-the-art equipment and processes with environmentally friendly results. Excellence Conesys' manufacturing process is vertically integrated, ISO 9001:2008 and AS9100C: 2009 - 01 certified and most importantly focused on continuous improvement through prevention of defects and reduction in variation and waste. Quality Policy Assembly In house, using cellular concepts for better efficiency, cost control and reduced cycle times. "We are committed to Customer Satisfaction by meeting Quality and Delivery requirements while continuously measuring and improving our processes." Warranty: Conesys warrants to the first user that it will correct any proven defect in product purchased from Conesys without charge. This correction will be by repair or replacement, F.O.B. factory. Correction will made as long as product was used in accordance with good engineering practices. Any claims for warranty replacement must be made in writing within 365 days of the original delivery date. Claims made after this time will not be recognized. This warranty is in lieu of all other expressed or implied warranties, including warranties of merchantability, and it does not include consequential damages. New Products from Conesys X-line Multipin Connectors The heavy duty X-line multi-pin series of connectors are environmentally sealed plugs and receptacles providing power for control and instrumentation connectivity across a wide spectrum of harsh environments. These devices are used in a variety of industrial applications, including onshore and offshore drilling operations, factories, refineries, marine, machine tool and land transportation applications. EN2997 Integrated Backshell Coming soon, Conesys will be releasing our new ASD certified EN2997 Integrated Backshell connector. This innovative design eliminates the need for an additional backshell making it ideal for compact and lightweight applications. The EN2997 series offers improved high temperature, shock and vibration resistance combined with interfacial sealing. These environments are typically seen in aircraft engines, landing gear and sensor systems. MIL-DTL-26482 Series I Solder Look for the new Conesys Aero Electric brand MIL-DTL-26482 series I solder cup connectors early 2015. By employing a proprietary insert molding technology we will achieve industry leading assembly performance, best in class sealing and contact alignment productivity. Available in both commercial and MIL versions, 26482 will also support MIL\Aero and the vast industrial markets that have adopted this product in factory automation, traffic signal, rail \mass transit etc. MIL-DTL-38999 III Composite (Class M and J) Having supplied Qualified D38999 series III class W, F, K, and S for decades, Aero Electric is expanding this product offering to include Qualified class M and J in 2015. The patented coupling mechanism will offer the first product of this kind to be free from metal components, which with other proprietary attributes to the product line, will make this the lightest D38999 III composite product in the market. Alternate Plating Due for release early 2015, Conesys will launch its Aero Electric brand Class Z and Class T codes conforming to the latest D38999 series III specification. Along with Class Z and T, Black Nickel is already commercially available. All of these plating's are RoHS compliant, offer excellent electrically conductive, and meet the 500 hour salt spray testing for corrosion resistance. EN3645 In 2015, Conesys will be releasing an ASD certified EN3645 connector. This is a subminiature circular connector series, compatible to the D38999 III connectors. These connectors offer the highest performance capabilities for both general duty and severe - high vibration- environment applications, including ground vehicles, airframe, and avionics communication systems. www.conesys.com sales@aero-electric.com 38999 S I MIL-DTL-38999 Series I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 MS27466 (AE166) Front Wall Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MS27656 (AE156) Rear Wall Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MS27496 (AE196) Front Box Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MS27505 (AE105) Rear Box Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MS27468 (AE168) Jam Nut Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MS27467 (AE167) RFI Grounding Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dummy Stowage Receptacle (AE109) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 38999 S II MIL-DTL-38999 Series II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 - 43 MS27472 (AE272) Front Wall Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 MS27497 (AE297) Rear Wall Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 MS27499 (AE299) Front Box Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 MS27508 (AE208) Rear Box Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 MS27513 (AE213) Front Box Mount Receptacle, Long Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 MS27474 (AE274) Jam Nut Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 MS27473 (AE273) Straight Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 MS27484 (AE284) RFI Grounding Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 MS27500 (AE200) Plug with 90 Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Dummy Stowage Receptacle (AE210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 38999 S III MIL-DTL-38999 Series III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44- 62 D38999/20 (AE320) Wall Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 D38999/24 (AE324) Jam Nut Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 D38999/26 (AE326) Self-Locking, RFI Grounding Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Part Number Development Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54 Dummy Stowage Receptacle (AE322) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Protective Cover, Plug (AE332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Protective Cover, Receptacle (AE333) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5015 S III MIL-DTL-5015 (Series III) Rear Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63- 87 MS3450 (AE550) Wall Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 MS3451 (AE551) Cable Connecting Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 MS3452 (AE552) Box Mount Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 MS3454 (AE554) Jam Nut Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MS3456 (AE556) Straight Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 MS3459 (AE559) Self-Locking Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MS25042 (AE542) Protective Cover Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 MS25043 (AE543) Protective Cover Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Integrated Rear Accessories Aero-Electric Connector, Inc. Table of Contents Mil Spec Catalog (AE101) Integrated Rear Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88- 107 MIL-DTL 5015 Series III Wall Mount Receptacle (MS3450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Jam Nut Receptacle (MS3454) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Straight Plug (MS3456). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 MIL-DTL 26482 Series II. Narrow Flange Receptacle (MS3470). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Cable Connecting Receptacle (MS3471). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Wide Flange Receptacle (MS3472). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Jam Nut receptacle (MS3474). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 RFI Grounding Plug (MS3475). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Straight Plug (MS3476). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 MIL-DTL 38999 Series I Integrated Rear Banding Platform (AE45-475). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Integrated Rear Banding Platform (AE45-476). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Integrated Rear Banding Platform (AE45-477). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Integrated Rear Banding Platform (AE45-478. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Integrated Rear Banding Platform (AE65-377). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Integrated Rear Banding Platform (Plug Connector, RFI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Integrated Rear Banding Platform (AE65-379). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 www.conesys.com - 1 - sales@aero-electric.com Aero-Electric Connector, Inc. Table of Contents Mil Spec Catalog (AE101) MIL-DTL-26482 Series 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108- 126 MS3470 (AE770) Narrow Flange Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 MS3471 (AE771) Cable Connecting Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 MS3472 (AE772) Wide Flange Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 MS3474 (AE774) Jam Nut Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 MS3476 (AE776) Straight Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 MS3475 (AE775) RFI Grounding Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 AC3475 Arctic Coupling Nut, RFI Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 26482 S II MIL-DTL-83723 Series III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127-149 M83723/71, 72 (AE83371, 72) Wall Mount Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 M83723/73, 74 (AE83373, 74) Jam Nut Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 M83723/75, 76 (AE83375, 76) Straight Plug, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 M83723/77, 78 (AE83377, 78) RFI Grounding Plug, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 M83723/82, 83 (AE83382, 83) Wall Mount Receptacle, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 M83723/84, 85 (AE83384, 85) Jam Nut Receptacle, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 M83723/86, 87 (AE83386, 87) Straight Plug, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 M83723/91, 92 (AE83391, 92) RFI Grounding Plug, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 M83723/95, 96 (AE83395, 96) Self-Locking Plug, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 M83723/97, 98 (AE83397, 98) Self-Locking RFI Plug, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 M83723/68, 69 (AE83368, 69) Lanyard Release Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 M83723/70 (AE83370) Receptacle Adapter for Lanyard Release Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 83723 S III MIL-DTL-26500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150-164 MS24264R**B (AE664R**B) Wall Mount Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 MS24265R**B (AE665R**B) Jam Nut Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 MS24266R**B (AE666R**B) Straight Plug, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 MS24264R**T (AE664R**T) Wall Mount Receptacle, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 MS24265R**T (AE665R**T) Jam Nut Receptacle, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 MS24266R**T (AE666R**T) Straight Plug, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 26500 Printed Circuit Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-234 MIL-DTL 38999 Series III Rear Wall Mount Receptacle (AEP65-101, AEP65-102) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Rear Wall Mount Receptacle (AEP65-103, AEP65-104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Rear Wall Mount Receptacle (AEP65-105, AEP65-106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Rear Jam Nut Receptacle (AE65-505) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Rear Jam Nut Receptacle (AE65-255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Wall Mount Receptacle (AEP6520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Single Hole Mount Receptacle (AEP6524) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 MIL-DTL 38999 Series I Rear Wall Mount Receptacle (AEP45-101, AEP45-102) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Rear Wall Mount Receptacle Dual Flange (AEP45-103, AEP45-104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Jam Nut Receptacle (AEP45-105, AEP45-106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 MIL-DTL 38999 Series II Rear Wall Mount Receptacle (AEP55-101, AEP55-102) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Rear Wall Mount Receptacle (AEP55-103, AEP55-104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Rear Jam Nut Receptacle (AEP55-105, AEP55-106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Insert Arrangements (MIL-DTL 38999 Series I, II, III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Insert Arrangements (MIL-DTL 26482 Series II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 PC Tail Lengths (MIL-DTL 38999 Series I, II, III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 MIL-DTL 26482 Series II Wall Mount Receptacle (AEP15-101, AEP15-102) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Wall Mount Receptacle (AEP15-103, AEP15-104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Jam Nut Receptacle (AEP15-105, AEP15- 106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Printed Circuit Board Connectors Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235-240 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241-243 www.conesys.com - 2 - sales@aero-electric.com MIL-DTL-38999 Features and Application Series I Features and Application 38999 S I Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. MIL-DTL-38999 Series I is a bayonet coupling subminiture configuration with high contact density, ideal for smaller wire gauge, general-purpose applications. These environmentresisting connectors are 100% "scoop-proof." Pins are recessed in elongated shells to prevent the possibility of bending contacts when plugs are scooped into the mating receptacles. Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. This family of connectors is offered in 5 receptacle-mounting styles. They include square flange receptacles, for both front and rear panel (wall) mounting; square flange receptacles, for both front and rear box mounting; and jam nut receptacles which incorporate "O" ring seals, designed for rear panel "D" hole mounting. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. Standard plugs provide RFI protection by incorporating a continuous strip of attached grounding fingers attenuating interference up to 1 GHz. Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having identical insert arrangement. Fifty-seven insert arrangements per MIL-STD-1560 are tooled and qualified to MIL-DTL-38999 Series I, utilizing 2 to 128 contacts. Contacts come in sizes 22M, 22D, 20, 16, 12, and 8 (coax and twinax), terminating wire sizes from 28 gauge to 12 gauge including coaxial cable. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel, olive drab cadmium and bright cadmium. Other finishes such as anodic and zinc cobalt are available upon request to commercial callouts only. In addition, we offer passivated stainless steel shells with standard environment-resisting inserts (commercial callouts only), and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. Scoop-Proof Design - Recessed pins in elongated shells minimize the possibility for contact damage. In a blind mating application, mating shells cannot "scoop" the pins, and cause a shorting or bending of contacts. www.conesys.com - 3 - sales@aero-electric.com MIL-DTL-38999 Performance Specifications Series I Performance Specifications * Finish S* = 10.0 millivolts maximum potential drop Shielding Effectiveness RFI and EMI attenuation at the specified frequencies meet the requirements of MIL-DTL-38999. * RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture. * EMI shielding effectiveness is measured at the interface of mated connectors and tested by the mode-stirred technique specified in method 3008 of MIL-STD-1344. Material and Plating Data (Finish) B - aluminum shell, olive drab cadmium over nickel base F - aluminum shell, electroless nickel finish A - aluminum shell, silver to light iridescent yellow color (bright) cadmium over electroless nickel BN* - aluminum shell, black nickel finish (Aero p/n only)(RoHS) Z* - Aluminum shell, Black Zinc Nickel Finish (Aero p/n only) Shock and Vibration Requirements Wired, mated connectors shall not be damaged, nor shall there be a current interruption longer than one microsecond when subjected to the following: (RoHS) S* - stainless steel shell, passivated (Aero p/n only) (RoHS) *Only commercial version available via AE p/n Corrosion Resistance Finishes A,B, S* and Z* withstand 500-hour salt spray. Finish BN* withstands 400 hour salt spray.Finish F withstands 48-hour salt spray. Standard Shock Mated connectors withstand a pulse of approximate half sine wave of 300 G 15 percent magnitude with duration of 3 1 milliseconds applied in three axes per MIL-STD-1344, method 2004. Durability Minimum of 500 mating cycles High Impact Shock When mounted as specified in MIL-S-901, grade A, a drop of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to connector in three axes, totaling nine impacts. Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-38999. Vibration Mated connectors, with proper accessories, withstand the following vibration levels: * Sine Vibration per MIL-STD-202, method 204, test condition G. * Random Vibration per MIL-STD-1344, method 2005, test condition V and test condition VI, Letter "J" at ambient temperature. Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808, MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol 25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5), SAE-AMS1424 Type I, and other solvents and cleaning agents. Shell-to-Shell Conductivity * Finish F & BN* = 1.0 millivolt maximum potential drop * Finishes A, B & Z* = 2.5 millivolts maximum potential drop Voltage Rating Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS M 400 550 1300 550 350 200 N 300 450 1000 400 260 200 I 600 850 1800 600 400 200 II 900 1250 2300 800 500 200 Note: The establishment of electrical safety factors is left entirely to the designer, as he is in the best position to know www.conesys.com exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 4 - sales@aero-electric.com 38999 S I Operating Temperature Range Finish B, BN* & Z*: -65C to +175C (-85F to +347F) Finish F & S*: -65C to +200C (-85F to +392F) Finish A: -65C to +150C (-85F to +302F) MIL-DTL-38999 Part Number Development Series I Military and Aero-Electric Part Number Development 38999 S I Mil. Prefix Aero Prefix MS AE 27467 167 T T 13 13 B B 35 35 P P A A -340 Shell Type 27466 = Front, wall mount receptacle = 166 (Aero p/n) 27467 = RFI grounding plug = 167 (Aero p/n) 27468 = Jam nut receptacle = 168 (Aero p/n) 27496 = Front, box mount receptacle = 196 (Aero p/n) 27505 = Rear, box mount receptacle = 105 (Aero p/n) 27656 = Rear, wall mount receptacle = 156 (Aero p/n) Class T = With acc. thread (MS27466, MS27467, MS27468 & MS27656) E = Same as T in line above but is not approved for new design (E-nut is not included) E = No acc. thread, box mount (MS27496 & MS27505) Shell Size 9, 11, 13, 15, 17, 19, 21, 23 or 25 Finish (Material & Plating) A = Aluminum shell, silver to light iridescent yellow color (bright) cadmium over nickel base B = Aluminum shell, olive drab cadmium over electroless nickel base F = Aluminum shell, electroless nickel finish S = Stainless steel shell, passivated (Aero p/n only) BN = Aluminum shell, Black Nickel Finish (Aero p/n only)(RoHS) (n/a for AE167) Z = Aluminum shell, Black Zinc Nickel Finish (Aero p/n only)(RoHS) (n/a for AE167) Insert Arrangement See page 19 thru 21 Contact Style P = Pin S = Socket A = Pin connector less pins (with intent to use non-standard pin contacts) B = Socket connector less sockets (with intent to use non-standard socket contacts) Polarization (Keying) N = Normal (Omitted in part number) A, B, C, or D (B & C keyways are not available in shell size 9) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/27-XXX E-nut 341 = Connector kitted with M85049/49-2-XXX straight clamp Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 1 through 26 of each contact and two spares for inserts with more than 26 contacts and a minimum of one sealing plug up to 10% of the number of contacts. Spare Coax and Twinax contacts are not supplied. One insertion/ removal tool for each contact size is also included. www.conesys.com Note 2: Proper part number marking has no "0" in front of single digit shell size (9) and no "0" in front of single digit layout. Example of each: J MS27466T9B35S and J MS27466T11B5S. In both, "N" for normal is omitted. In addition, J or JAN must now be marked in front of the MS part number. - 5 - sales@aero-electric.com MS27466 Front, Wall Mounting Receptacle AE166 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.323(33.60) MAX D 38999 S I A MASTER KEYWAY F B .219(5.56) MIN. FULL THREAD .060(1.52) MAX GROMMET EXTENSION H E MAX GROMMET J ACCESSORY TEETH G ACCESSORY THREAD 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size B .020 .51 inch mm OC (TP) inch mm D OE F G OH J Maximum No. of Teeth +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 Accessory Thread inch mm inch mm inch mm inch mm UNEF-2A inch mm 9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 7/16-28 .299 7.59 12 11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 9/16-24 .427 10.85 16 13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 11/16-24 .541 13.74 20 15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 13/16-20 .666 16.92 24 17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28 19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32 21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36 23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40 25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44 www.conesys.com - 6 - sales@aero-electric.com MS27656 Rear, Wall Mounting Receptacle AE156 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.350 (34.29) MAX 38999 S I A MASTER KEYWAY D B F .219 (5.56) MIN FULL THREAD .060 (1.52) MAX GROMMET EXTENSION H E MAX GROMMET J ACCESSORY TEETH G ACCESSORY THREAD 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size B .020 .51 inch mm OC (TP) inch mm Note: See page 14 for panel thickness. D OE F G OH J Maximum No. of Teeth +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 Accessory Thread inch mm inch mm inch mm inch mm UNEF-2A inch mm 9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 7/16-28 .299 7.59 12 11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 9/16-24 .427 10.85 16 13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 11/16-24 .541 13.74 20 15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 13/16-20 .666 16.92 24 17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28 19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32 21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36 23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40 25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44 www.conesys.com - 7 - sales@aero-electric.com MS27496 Front, Box Mounting Receptacle AE196 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.104(28.04) MAX D B 38999 S I A MASTER KEYWAY F .060(1.52) MAX GROMMET EXTENSION H G MAX GROMMET MAX E .312(7.93) MAX 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B OC D OE F OG +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 OH Shell Size .020 .51 inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm 9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 .469 11.91 .299 7.59 11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 .594 15.09 .427 10.85 13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 .719 18.26 .541 13.74 15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 .844 21.44 .666 16.92 (TP) Maximum Maximum 17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 .969 24.61 .791 20.09 19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1.078 27.38 .897 22.78 21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1.203 30.56 1.022 25.96 23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1.328 33.73 1.147 29.13 25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1.453 36.91 1.272 32.31 www.conesys.com - 8 - sales@aero-electric.com MS27505 Rear, Box Mounting Receptacle AE105 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.100(27.94) MAX 38999 S I A MASTER KEYWAY D B F .060(1.52) MAX GROMMET EXTENSION H E G MAX MAX GROMMET 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size B .020 .51 inch mm inch OC Note: See page 14 for panel thickness. D OE F OG OH +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 mm inch mm inch mm inch mm inch mm inch mm inch (TP) Maximum Maximum mm 9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 .547 13.89 .299 7.59 11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 .656 16.66 .427 10.85 13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 .828 21.03 .541 13.74 15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 .953 24.21 .666 16.92 17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 1.078 27.38 .791 20.09 19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1.203 30.56 .897 22.78 21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1.328 33.73 1.022 25.96 23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1.453 36.91 1.147 29.13 25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1.578 40.08 1.272 32.31 www.conesys.com - 9 - sales@aero-electric.com MS27468 Jam Nut Receptacle AE168 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof E 1.308 (33.22) MAX 38999 S I B .920 (23.37) .910 (23.11) .615 (15.62) .598 (15.19) MASTER KEYWAY .060 (1.52) MAX GROMMET EXTENSION K OC OA FLAT MAX GROMMET G No. OF TEETH OD 4X MINOR KEYWAYS 3X BAYONET PINS EQUALLY SPACED Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 "O"-RING J THREAD BLUE COLOR BAND HEX NUT PER MS3186 PANEL THICKNESS .125(3.18) .062(1.57) Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA Shell Size F ACCESSORY THREAD BLUE COLOR BAND B OC +.001 -.005 +.03 -.13 +.011 -.010 +.28 -.25 inch mm inch mm OD Maximum inch mm E F .016 .41 .016 .41 Accessory Thread inch mm inch mm UNEF- 2A G J K No. of Jam Nut Thread Flat Teeth Class 2A .005 .13 inch mm 9 .572 14.53 .109 2.77 .299 7.59 1.188 30.18 1.062 26.97 7/16-28 12 11/16-24UNEF .650 16.51 11 .700 17.78 .109 2.77 .427 10.85 1.375 34.93 1.250 31.75 9/16-24 16 13/16-20UNEF .750 19.05 13 .850 21.59 .109 2.77 .541 13.74 1.500 38.10 1.375 34.93 11/16-24 20 1-20UNEF .937 23.80 15 .975 24.77 .109 2.77 .666 16.92 1.625 41.28 1.500 38.10 13/16-20 24 1-1/8-18UNEF 1.061 26.95 17 1.100 27.94 .109 2.77 .791 20.09 1.750 44.45 1.625 41.28 15/16-20 28 1-1/4-18UNEF 1.186 30.12 19 1.207 30.66 .140 3.56 .897 22.78 1.938 49.23 1.812 46.02 1-1/16-18 32 1-3/8-18UNEF 1.311 33.30 21 1.332 33.83 .140 3.56 1.022 25.96 2.062 52.37 1.938 49.23 1-3/16-18 36 1-1/2-18UNEF 1.436 36.47 23 1.457 37.01 .140 3.56 1.147 29.13 2.188 55.58 2.062 52.37 1-5/16-18 40 1-5/8-18UNEF 1.561 39.65 25 1.582 40.18 .140 3.56 1.272 32.31 2.312 58.72 2.188 55.58 1-7/16-18 44 1-3/4-18UNS 1.686 42.82 www.conesys.com - 10 - sales@aero-electric.com MS27467 RFI Grounding Plug AE167 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.294 (32.87) MAX F MAX. COUPLING NUT 38999 S I MASTER KEY E ACCESSORY THREAD RFI STRIP .060(1.52) GROMMET MAX EXTENSION A C MIN MAX GROMMET D No. OF TEETH .219(5.56) MIN FULL THREAD 4 MINOR KEYS BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA OC D E Minimum Maximum No. of Teeth Accessory Thread Class 2A Shell Size inch mm inch mm OF Maximum inch mm 9 .417 10.59 .299 7.59 12 7/16-28UNEF .859 21.82 11 .545 13.84 .427 10.85 16 9/16-24UNEF .984 24.99 13 .657 16.69 .541 13.74 20 11/16-24UNEF 1.156 29.36 15 .782 19.86 .666 16.92 24 13/16-20UNEF 1.281 32.54 17 .907 23.04 .791 20.09 28 15/16-20UNEF 1.406 35.71 19 1.012 25.70 .897 22.78 32 1-1/16-18UNEF 1.516 38.51 21 1.137 28.88 1.022 25.96 36 1-3/16-18UNEF 1.641 41.68 23 1.262 32.05 1.147 29.13 40 1-5/16-18UNEF 1.766 44.86 25 1.387 35.23 1.272 32.31 44 1-7/16-18UNEF 1.891 48.03 www.conesys.com - 11 - sales@aero-electric.com M38999/9 Dummy Stowage Receptacle AE109 Dummy Stowage Receptacle, Bayonet Coupling 38999 S I Part Number Configuration MIL. Prefix Aero Prefix M38999 AE10 9/ 9- XX XX B B Shell Type 9 = receptacle, dummy stowage, bayonet coupling Shell Size 9 THRU 25 (Note: single digit for shell size 9) Material Finish B = Aluminum, Cadmium Olive Drab A = Aluminum, Bright Cadmium over Nickel base (Aero p/n only) F = Aluminum shell, Electroless Nickel finish (Aero p/n only) S = Stainless steel shell, passivated (Aero p/n only) BN = Aluminum, Black Nickel (Aero p/n only) BZ = Bronze (Aero p/n only) Z = Aluminum shell, Black Zinc Nickel (Aero p/n only) SHELL SIZE OA +.001 -.005 K +.015 -.000 M .010 OT +.010 -.005 S .020 J +.010 -.015 9 .572 .085 .727 .128 .938 .567 11 .700 .085 .727 .128 1.031 .567 13 .850 .085 .727 .128 1.125 .567 15 .975 .085 .727 .128 1.219 .567 17 1.100 .085 .727 .128 1.312 .567 19 1.207 .085 .727 .128 1.438 .567 21 1.332 .115 .697 .128 1.562 .567 23 1.457 .115 .697 .147 1.688 .567 25 1.582 .115 .697 .147 1.812 .567 www.conesys.com - 12 - sales@aero-electric.com MIL-DTL-38999 Polarization Series I Keying Positions 38999 S I NORMAL C N MASTER KEYWAY A B D 5 DATUM F Notes: 1. Mating face of receptacle shown (plug is opposite). 2. The master keyway (key) has various positions relative to DATUM F; the minor keyways (keys) remain fixed as shown. In the Normal position, the master keyway (key) is at 95 from DATUM F. 3. The angles for a given connector are the same whether it contains pin or socket inserts. 4. The insert arrangement does not rotate relative to master keyway (key). Keying Positions BSC Shell Size N A B C D 9 95 77 - - 113 11 95 81 67 123 109 13 95 75 63 127 115 15 95 74 61 129 116 17 95 77 65 125 113 19 95 77 65 125 113 21 95 77 65 125 113 23 95 80 69 121 110 25 95 80 69 121 110 www.conesys.com - 13 - sales@aero-electric.com MIL-DTL-38999 Series I Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts D MAX PANEL THICKNESS 4x C 38999 S I JAM NUT MOUNT FLANGE MOUNT .125(3.18) .062(1.57) PANEL THICKNESS B MIN b =F A Note 1: Flange Mounting Dimensions (O B cutout and D MAX) listed only for back of panel mounting (MS27505 and MS27656). Note 2: D MAX includes mounting hardware. Flange and Jam Nut Mounting Dimensions A OB (TP) Minimum Shell Size inch mm inch OC D .005 .13 mm inch mm inch E OF +.000* -.010 +.00* -.25 +.010 -.000 +.25 -.00 mm inch mm inch mm Maximum 9 .719 18.26 .656 16.66 .128 3.25 .234 5.94 .657* 16.70* .693 17.60 11 .812 20.62 .796 20.22 .128 3.25 .234 5.94 .771 19.59 .825 20.96 13 .906 23.01 .922 23.42 .128 3.25 .234 5.94 .955 24.26 1.010 25.65 15 .969 24.61 1.047 26.59 .128 3.25 .234 5.94 1.085 27.56 1.135 28.83 17 1.062 26.97 1.219 30.96 .128 3.25 .234 5.94 1.210 30.73 1.260 32.01 19 1.156 29.36 1.297 32.94 .128 3.25 .234 5.94 1.335 33.91 1.385 35.18 21 1.250 31.75 1.422 36.12 .128 3.25 .204 5.18 1.460 37.08 1.510 38.35 23 1.375 34.93 1.547 39.29 .154 3.91 .204 5.18 1.585 40.26 1.635 41.53 25 1.500 38.10 1.672 42.47 .154 3.91 .193 4.90 1.710 43.43 1.760 44.70 * Tolerance .10mm (.004") www.conesys.com - 14 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series I Contacts, Plastic Insertion/Removal Tools and Seal Plugs 38999 S I Contact Size 22D 22M* 22* 20 16 12 12 Coax 12 Coax 8 Coax 8 Twinax Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Power/Signal Power/Signal Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Coax Twinax Military No. M39029/58-360 M39029/58-361 M39029/58-362 M39029/58-363 M39029/58-364 M39029/58-365 M39029/28-211 M39029/102-558 M39029/60-367 M39029/90-529 Military No. M39029/56-348 M39029/56-349 M39029/56-350 M39029/56-351 M39029/56-352 M39029/56-353 M39029/75-416 M39029/103-559 M39029/59-366 M39029/91-530 Military No. Plastic Military No. Positioner Positioner Insertion Tool Extraction Tool For Socket Contacts Military No. M22520/2-07 M22520/2-07 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 Metal Military No. M81969/8-01 M81969/8-03 Metal Military No. M81969/8-02 M81969/8-04 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M81969/8-13** M81969/8-14 M81969/14-01 MS27488-22-1 MS27488-20-1 MS27488-16-1 -- M81969/14-10 M81969/14-03 MS27488-12-1 M81969/14-04 MS27488-8-1 MS27488-8-1 M81969/14-06 M81969/14-12 Crimping and Metal Insertion/Extraction Tools Contact Size/ Type Crimp Tool 16 12 12 Coax Inner 12 Coax Outer 8 Coax Inner Military No. M22520/2-01 M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 M22520/2-01 8 Coax Outer M22520/5-01 8 Twinax Center 8 Twinax Outer & Intermediate M22520/2-01 For Pin Contacts Military No. M22520/2-09 M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 M22520/5-01 M22520/5-200 22D, 22M* 22* 20 -- M22520/5-200 -- Contact and Wire Data Test Current Voltage Contact Size 22D 22M* 22* 20 16 12 DC Test Amps 5.0 3.0 5.0 7.5 13.0 23.0 Max. Drop Millivolts 73 45 73 55 49 42 Crimp Well Data AWG 28-22 28-24 26-22 24-20 20-16 14-12 mm2 .08-.33 .08-.20 .13-.33 .20-.52 .52-1.31 2.08-3.31 Finished Wire O Range Minimum inch mm .030 .76 .030 .76 .034 .86 .040 1.02 .065 1.65 .097 2.46 Maximum inch mm .054 1.37 .050 1.27 .060 1.52 .083 2.11 .109 2.77 .142 3.61 Note 3: Size 8 coax contacts are used with M17/095-RG180 cable, while size 8 Twinax contacts are used with M17/176-00002 cable. Note 4: Size 8 Power contacts available with various crimp wells - 5265244-08xx and 5065-246-08xx - please consult factory for sales drawing that includes various tooling needed * Inactive for new design ** Insertion tool is not required. Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. Note 2: Size 12 coax contacts purchased in bulk. www.conesys.com Wire Range Well Dia. Minimum Well Dept inch inch mm .0345 .0010 .141 3.58 .028 .001 .141 3.58 .0365 .0010 .141 3.58 .047 .001 .209 5.31 .067 .001 .209 5.31 .100 .002 .209 5.31 - 15 - sales@aero-electric.com MIL-DTL-38999 Contact Installation Instructions Series I Contact Installation Instructions Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. Size Pin Contact Socket Contact Basic Crimp Tool 22D 22M 22 M39029/58-360 M39029/58-361 M39029/58-362 M39029/56-348 M39029/56-349 M39029/56-350 20 M39029/58-363 M39029/56-351 20 12 M39029/58-364 M39029/58-365 M39029/56-352 M39029/56-353 M22520/2-01 M22520/2-01 M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 For coax and twinax contacts refer to instructions that are supplied with contacts. www.conesys.com - 16 - Pin Positioner Socket Positioner Insertion/Removal Tool M81969/14-01 M81969/14-01 M81969/14-01 M22520/2-09 M22520/2-07 M22520/2-09 M22520/2-07 M22520/2-09 M22520/2-07 M22520/1-04 Red M22520/1-04 Red M81969/14-10 M22520/2-10 M22520/2-10 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04 Note 4: Size 8 Power contacts available with various crimp wells - 5265-244-08xx and 5065-246-08xx - please consult factory for sales drawing that includes various tooling needed sales@aero-electric.com 38999 S I 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. MIL-DTL-38999 Series I Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information Insert Arrangement Aero-Electric Service Status Total Quantity of Contacts No. of (by Size) 38999 S I Series I QPL'd Tooled Rating Contacts 9-6* 9-35 9-98 11-2 11-4 11-5 11-13* 11-35 11-98 11-99 13-4 13-8 13-22* 13-35 13-98 15-5 15-15 15-18 15-19 15-35 15-37* 15-97 17-6 17-8 17-26 17-35 17-55* 17-99 19-11 19-28 19-30 19-32 19-35 19-66* Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M M I I I I M M I I I I M M I II I I I M M I I II I M M I II I I I M M 6 6 3 2 4 5 13 13 6 7 4 8 22 22 10 5 15 18 19 37 37 12 6 8 26 55 55 23 11 28 30 32 66 66 See next page for Shell Sizes 21 thru 25 layouts. www.conesys.com 22D 22M 22 20 16 12 10 8 6 6 3 2 4 5 13 13 6 7 4 8 22 22 10 14 18 19 5 1 37 37 8 4 6 8 26 55 55 21 26 29 32 2 11 2 1 66 66 * Not approved for new design. Tooled and qualified but their separate pictorials are not shown on pages 19 thru 21, as they are the same as corresponding (-35) layouts that take the same quantity of 22D contacts, but are supplied with 22M contacts instead. - 17 - sales@aero-electric.com MIL-DTL-38999 Series I Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information (continued) Insert Arrangement Aero-Electric Service Total Status Quantity of Contacts No. of QPL'd Tooled Rating Contacts 21-1* 21-11 21-16 21-35 21-39 21-41 21-48** 21-75 23-1* 23-2*** 23-21 23-32 23-35 23-53 23-55 25-1* 25-4 25-19 25-24 25-29 25-35 25-43 25-46 25-61 Yes Yes Yes Yes Yes Yes N/A Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M I II M I I I Twinax M M II I M I I M I I I I M I I, Coax I 79 11 16 79 39 41 4 4 100 85 21 32 100 53 55 128 56 19 24 29 128 43 46 61 (by Size) 22D 22M 22 20 16 12 10 8 79 11 16 79 37 41 2 4 (Power) 4 (Twinax) 100 85 21 32 100 53 55 128 48 8 12 29 19 12 128 23 40 61 20 4 2 (Coax) * Not approved for new design. Tooled and qualified but their separate pictorials are not shown on pages 19 thru 21, as they are same as corresponding (-35) layouts that take the same quantity of 22D contacts, but are supplied with 22M contacts instead. ** 21-48 layout is not to MIL-STD-1560. It is tooled and intended for commercial use only. *** Not approved for new design. Pictorial is shown on page 20. www.conesys.com - 18 - sales@aero-electric.com 38999 S I Series I MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I Connectors Insert Arrangements Views 38999 S I 1 C 5 D A B 1 6 A E A 10 A 2 11 9 4 3 B 2 8 3 B C 13 B D 5 7 C 4 12 6 9-35 9-98 11-2 11-4 11-5 11-35 6 # 22D, M 3 # 20, I 2 # 16, I 4 # 20, I 5 # 20, I 13 # 22D, M A A E F D F B A G A H F E C G B D 1 15 22 C D C C J K B B G B E A H 14 21 F D C D E 11-98 11-99 13-4 13-8 13-35 13-98 6 # 20, I 7 # 20, I 4 # 16, I 8 # 20, I 22 # 22D, M 10 # 20, I L A L K B A E J B C J D P T H E G C A L B N M M A B N P 1 U S G R F K C P U J D T H E D R V S G K C 31 N H D K M R B 21 H E C M G F F F D E 15-5 15-15 15-18 15-19 15-35 15-97 5 # 16, II 1 # 16, 14 # 20, I 18 # 20, I 19 # 20, I 37 # 22D, M 4 # 16, 8 # 20, I A A A E G B F B S T H C M L C 17-6 6 # 12, I www.conesys.com 17-8 8 # 16, II 40 Z V E 53 C F W X G H 17-26 26 # 20, I - 19 - Z U D N V X 55 3 T S P Y M c J B R 47 D U Y D A 32 25 1 b K E 17 4 C N F 10 B R P a D A L J 52 9 46 16 24 31 39 17-35 55 # 22D, M E W L F G K J H 17-99 2 # 16, 21 # 20, I sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I Connectors Insert Arrangements Views A T S A J B G C Y g L G K E J Y K J L F G H 19-30 19-32 32 # 20, I 34 J 43 51 L A 63 24 33 42 j h Z m r p F R H f P M 21-39 2 # 16, 37 # 20, I 29 20 39 48 58 b c G 5 75 J N A M B W R V K C Z 11 81 28 38 47 57 66 74 U J D K T G 23-2* 23-21 85 # 22, M 21 # 16, II Y J E H h g 21-75 4 # 8 Twinax, Twinax S c 16 25 35 46 56 67 77 86 1 94 2 C 95 3 T d i 8 B R 96 4 97 98 S 85 B A P b a L X 4 C C 21-48** 4 # 8 Power, I P L 82 1 19 B D K L N M A H 21-41 41 # 20, I 67 D F d e N K 12 p q E a n r g J L m t S G 21-35 79 # 22D, M A D Z s h E c d e M T a n f F C Y k i 11 E B X j U D b q P D G 21-16 16 # 16, II A W V C Y 61 41 B k i R 21-11 11 # 12, I X 71 79 P D E A W 31 C F 50 19-35 66 #22D, M V N H C 57 16 J L 66 9 S 21 G 3 B 51 B M H K 1 A K 58 64 N Z 1 # 16, 29 # 20, I 4 g a 19-28 25 E b M G H X 2 # 16, 26 # 20, I 1 S R E D g h 19-11 17 T c C W f j 11 # 16, II 10 U N F Y J d X Z K V e P f W F Z D B U R C V a L a U e M E A T S B T b D X M A d c N W e D F C b N L V c P P 38999 S I K H d R S R B U D f e X U V H G 99 6 10 0 7 W F E 5 F 15 24 34 45 55 66 76 85 23-32 23-35 32 # 20, I 100 # 22D, M 93 * Inactive for new design. ** Not MIL-STD-1560 layout (not QPL'd.). www.conesys.com - 20 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I Connectors Insert Arrangements Views S T R 38999 S I GG EE f t w e K v d J a b c i G g L C Y X D P n m N M 15 25 36 48 59 K 94 105 X 115 122 125 4 E m F 7 G 24 H J 35 47 5870 81 93 104 11 4 Z A p w k v h u R 121 14 G Y U S W X F G n W V K E 25-19 19 # 12, I 1 V D R S H L 8 d Y V T J J k 71 82 C H h U e L g B b x r c t s d f e P N M 25-35 25-43 20 # 16, 23 # 20, I AA X X C Y v W Z D V E z w c m h M g L K F G e f H J u t GG s FF r HH q T KK CC P N M L 25-46 25-61 40 # 20, 4 # 16, 2 # 8 Coax, I / Coax 61 # 20, I www.conesys.com H i j k F G h AA BB m E g z LL D f y MM n C e x JJ DD P R d PP EE J B c w NN G H A b v U S d x y k Z a Y B F L 128 # 22D, M A E K 25-29 u D q 29# 16, I W t C a 25-24 a N p P G D F q P AA BB CC U B 12 # 12, 12 # 16, I s n KK K f g DD q R B f Z b R G LL N 25-4 8 # 16, 48 # 20, I c M p S S C E U r T r T H T N T V U F EE L F z JJ s E e y A M D T a V c e S a H U J b Z J E C d HH FF A P S W Z b u K R R K V 23-55 55 # 20, I B N D B c x GG t Y a d f H u t v A P L DD EE w 23-53 55 # 20, I M CC s FF x N H M Z u HH y P F C r A b w v W X q BB GG j R W p AA z E Y x m S k D X s DD g L CC HH W r X B V n C V q FF y M p BB A T B U AA z h N n m P k A a Z Y U J K - 21 - sales@aero-electric.com MIL-DTL-38999 Features and Application Series II Features and Application Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. MIL-DTL-38999 Series II connectors feature a bayonet coupling mechanism with lower profile design and rear-removable crimp contact retention system. Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. Reduction of both size and weight were achieved through the use of thinner shell walls and length restrictions. These design restrictions reduced the RFI attenuation characteristics and the "scoop" protection, while yielding an excellent general purpose, lightweight connector. Compared to Series I, Series II connectors achieve up to 20% reduction in mated pair length, up to 39% reduction in outside diameter and up to 40% reduction in weight (128 pin mated pair). This family of connectors is offered in six receptacle-mounting styles. They include square flange receptacles, for both front and rear panel (wall) mounting; square flange receptacles, for both front and rear panel (box) mounting; square flange receptacle with extended grommet, for front of panel (box) mounting; and jam nut receptacles which incorporate "O" ring seals, designed for rear panel "D" hole mounting. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having same insert arrangement. Plugs are available in two designs, with and without RFI grounding. Fifty-two insert arrangement per MIL-STD-1560 are tooled and qualified to MIL-DTL-38999 Series II, utilizing 3 to 128 M39029 contacts. Contacts come in sizes 22D, 22M, 22, 20, 16 and 12, terminating wire sizes from 28 to 12 gauge. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel, bright cadmium, anodized, and olive drab cadmium. Other finishes such as zinc cobalt are available upon request to commercial callouts only. In addition, we offer passivated stainless steel shells with standard environment-resisting inserts (commercial callouts only). Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. www.conesys.com - 22 - sales@aero-electric.com 38999 S II These connectors were designed for military and commercial applications where the prime requirements are lower profile and lighter weight. MIL-DTL-38999 Performance Specifications Series II Performance Specifications Shell-to-Shell Conductivity Maximum potential drop shall not exceed: * With RFI spring fingers, finish F & BN* = 1.0 millivolt, while finishes A, B & Z* = 2.5 millivolts. Finish E* = 10.0 millivolts * Without spring fingers = 200 millivolts. * Finish C = nonconductive. Operating Temperature Range Finish B ,Z* and BN*: -65C to +175C (-85F to +347F) Finishes C, F & E*: -65C to +200C (-85F to +392F) Finish A: -65C to +150C (-85F to 302F) 38999 S II Material and Plating Data (Finish) B - aluminum shell, olive drab cadmium over nickel base C - aluminum shell, black anodized finish F - aluminum shell, electroless nickel finish A - aluminum shell, silver to light iridescent yellow color (bright) cadmium over electroless nickel base BN* - aluminum shell, black nickel finish (Aero p/n only)(RoHS) Z* - Aluminum shell, Black Zinc Nickel Finish (Aero p/n only) Shielding Effectiveness RFI and EMI attenuation at the specified frequencies meet the requirements of MIL-DTL-38999. * RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture. * EMI shielding effectiveness is measured at the interface of mated connectors and tested by the mode-stirred technique specified in method 3008 of MIL-STD-1344. (RoHS) E* - stainless steel shell, passivated (Aero p/n only) (RoHS) Corrosion Resistance Finishes A, B ,C, E* & Z* withstand 500-hour salt spray. Finish BN* withstands 400 hour salt spray. Finish F withstands 48-hour salt spray. Shock and Vibration Requirements Wired, mated connectors shall not be damaged, nor shall there be a current interruption longer than one microsecond when subjected to the following: Durability Mated connectors withstand a minimum of 250 mating cycles for RFI plug (MS27484) and 500 cycles for MS27473 and MS27500 plugs. Standard Shock Mated connectors withstand a pulse of approximate half sine wave of 300 G magnitude with duration of three milliseconds applied in three axes per MIL-STD-1344, method 2004. Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified by MIL-DTL-38999. Vibration Mated connectors withstand the following vibration levels: * Random vibration per MIL-STD-1344, method 2005 test condition VI, Letter "J". Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808, MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol 25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5), SAE-AMS1424 Type I, and other solvents and cleaning agents. Voltage Rating Service Rating *NotQPL'd, order via Aero part number only Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft. V RMS V RMS V RMS V RMS AC (RMS) DC M 400 550 1300 550 350 200 N 300 450 1000 400 260 200 I 600 850 1800 600 400 200 II 900 1250 2300 800 500 200 Note: The establishment of electrical safety factors is left entirely to the designer, as he is in the best position to know www.conesys.com exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 23 - sales@aero-electric.com MIL-DTL-38999 Part Number Development Series II Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS AE 27473 273 T T 12 12 B B 35 35 P P A A -340 Class 38999 S II Shell Type 27472 = Front, wall mount receptacle = 272 (Aero p/n) 27473 = Straight plug = 273 (Aero p/n) 27474 = Jam nut receptacle = 274 (Aero p/n) 27484 = RFI grounding plug = 284 (Aero p/n) 27497 = Rear, wall mount receptacle = 297 (Aero p/n) 27499 = Front, box mount receptacle = 299 (Aero p/n) 27500 = Standard plug with 90 backshell = 200 (Aero p/n) 27508 = Rear, box mount receptacle = 208 (Aero p/n) 27513 = Front, box mount rec. (long grommet) = 213 (Aero p/n) T = With accessory thread (MS27472, 27473, 27474, 27484 & 27497) E = Same as T in line above except connector is kitted with E-Nut = No accessory thread, box mount (MS27499 & MS27508) = No accessory thread, box mount, long grommet (MS27513) P = Supplied with ring and potting boot (same shell types as "T" class) Shell Size 8, 10, 12, 14, 16, 18, 20, 22 or 24 Finish (Material & Plating) A = Aluminum shell, silver to light iridescent yellow (bright) cadmium over electroless nickel base B = Aluminum shell, olive drab cadmium over electroless nickel base C = Aluminum shell, black anodized finish (not available in MS27484) F = Aluminum shell, electroless nickel finish E = Stainless steel shell, passivated (Aero p/n only, n/a in AE284) BN = Aluminum shell, Black Nickel Finish (Aero p/n only)(RoHS) Z = Aluminum shell, Black Zinc Nickel Finish (Aero p/n only)(RoHS) Insert Arrangement See page 41-43 Contact Designator P = Pin A = Pin connector less pins (with intent to use non-std pin contacts) S = Socket B = Socket connector less sockets (with intent to use non-std socket contacts) Polarization (Keying) N = Normal (Omitted in part number) A, B, C, or D (B & C keyways are not available in shell size 8) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/27-XXX E-nut 341 = Connector kitted with M85049/49-2-XXX straight clamp 342 = Connector kitted with M85049/47XXX right angle clamp Consult factory for other modifications Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 through 26 of each contact and two spares for inserts with 27 or more contacts, and a minimum of one sealing plug up to 10% of the number contacts. One insertion/extraction tool for each contact size is also included. www.conesys.com Note 2: Proper part number marking has no "0" in front of single digit shell size (8) and no "0" in front of single digit layout. Example of each: J MS27472T8B35S and J MS27472T10B5S. In both "N" for normal is omitted. Please note that JAN or J marking is required immediately in front of MS number. - 24 - sales@aero-electric.com MS27497 Rear, Wall Mount Receptacle AE297 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight D MAX A .447(11.35) .442(11.23) MAX .069(1.75) .058(1.47) B MASTER KEYWAY .219(5.56) MIN FULL THREAD K GROMMET EXTENSION 38999 S II H E MAX GROMMET MAX Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 A B Maximum (TP) inch mm inch F ACCESSORY THREAD 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization Shell Size G NO. OF TEETH BLUE COLOR BAND 4x C OC Note: See page 36 for panel thickness. D OE F G OH K Maximum Maximum Accessory Thread No. of Teeth Maximum Grommet Extension +.010 -.005 +.25 -.13 mm inch mm inch mm inch mm UNEF-2A inch mm inch mm 8 .828 21.03 .594 15.09 .120 3.05 .988 25.10 .547 13.89 7/16-28 12 .299 7.59 .150/.090 3.81/2.29 10 .954 24.23 .719 18.26 .120 3.05 .988 25.10 .672 17.07 9/16-24 16 .427 10.85 .150/.090 3.81/2.29 12 1.047 26.59 .812 20.62 .120 3.05 .988 25.10 .844 21.44 11/16-24 20 .541 13.74 .150/.090 3.81/2.29 14 1.141 28.98 .906 23.01 .120 3.05 .988 25.10 .969 24.61 13/16-20 24 .666 16.92 .150/.090 3.81/2.29 16 1.234 31.34 .969 24.61 .120 3.05 .988 25.10 1.094 27.79 15/16-20 28 .791 20.09 .150/.090 3.81/2.29 18 1.328 33.73 1.062 26.97 .120 3.05 .988 25.10 1.219 30.96 1-1/16-18 32 .897 22.78 .150/.090 3.81/2.29 20 1.453 36.91 1.156 29.36 .120 3.05 .988 25.10 1.344 34.14 1-3/16-18 36 1.022 25.96 .150/.090 3.81/2.29 22 1.578 40.08 1.250 31.75 .120 3.05 .988 25.10 1.469 37.31 1-5/16-18 40 1.147 29.13 .150/.090 3.81/2.29 24 1.703 43.26 1.375 34.93 .147 3.73 1.056 26.82 1.594 40.49 1-7/16-18 44 1.272 32.31 .140/.040 3.56/1.02 www.conesys.com - 25 - sales@aero-electric.com MS27472 Front, Wall Mount Receptacle AE272 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight D MAX A .069(1.75) .058(1.47) .322(8.18) .317(8.05) MAX B MASTER KEYWAY .219(5.56) MIN FULL THREAD K GROMMET EXTENSION Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 MAX GROMMET G NO. OF TEETH BLUE COLOR BAND 4x C 38999 S II H E F ACCESSORY THREAD 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum (TP) Shell Size inch mm inch OC D +.010 -.005 +.25 -.13 mm inch mm inch OE F G OH K No. of Teeth Maximum Grommet Extension .003 .08 Accessory Thread mm inch mm UNEF-2A Maximum inch mm inch mm 8 .828 21.03 .594 15.09 .120 3.05 .932 23.67 .471 11.96 7/16-28 12 .299 7.59 .150/.090 3.81/2.29 10 .954 24.23 .719 18.26 .120 3.05 .932 23.67 .588 14.94 9/16-24 16 .427 10.85 .150/.090 3.81/2.29 12 1.047 26.59 .812 20.62 .120 3.05 .932 23.67 .748 19.00 11/16-24 20 .541 13.74 .150/.090 3.81/2.29 14 1.141 28.98 .906 23.01 .120 3.05 .932 23.67 .873 22.17 13/16-20 24 .666 16.92 .150/.090 3.81/2.29 16 1.234 31.34 .969 24.61 .120 3.05 .932 23.67 .998 25.35 15/16-20 28 .791 20.09 .150/.090 3.81/2.29 18 1.328 33.73 1.062 26.97 .120 3.05 .932 23.67 1.123 28.52 1-1/16-18 32 .897 22.78 .150/.090 3.81/2.29 20 1.453 36.91 1.156 29.36 .120 3.05 .932 23.67 1.248 31.70 1-3/16-18 36 1.022 25.96 .150/.090 3.81/2.29 22 1.578 40.08 1.250 31.75 .120 3.05 .932 23.67 1.373 34.87 1-5/16-18 40 1.147 29.13 .150/.090 3.81/2.29 24 1.703 43.26 1.375 34.93 .147 3.73 1.000 25.40 1.498 38.05 1-7/16-18 44 1.272 32.31 .140/.040 3.56/1.02 www.conesys.com - 26 - sales@aero-electric.com MS27508 Rear, Box Mount Receptacle AE208 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight .757(19.23) MAX A .447(11.35) .442(11.23) MAX B MASTER KEYWAY 38999 S II MAX Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 .069(1.75) .058(1.47) .322(8.18) .317(8.05) F 4x C .250(6.35) MAX .060(1.52) MAX GROMMET EXTENSION H E MAX F GROMMET MAX BLUE COLOR BAND 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum (TP) Shell Size inch mm inch Note: See page 36 for panel thickness. OC OE OF OH +.010 -.005 +.25 -.13 .003 .08 mm inch mm inch mm inch mm inch Maximum Maximum mm 8 .828 21.03 .594 15.09 .120 3.05 .471 11.96 .547 13.89 .299 7.59 10 .954 24.23 .719 18.26 .120 3.05 .588 14.94 .672 17.07 .427 10.85 12 1.047 26.59 .812 20.62 .120 3.05 .748 19.00 .844 21.44 .541 13.74 14 1.141 28.98 .906 23.01 .120 3.05 .873 22.17 .969 24.61 .666 16.92 16 1.234 31.34 .969 24.61 .120 3.05 .998 25.35 1.094 27.79 .791 20.09 18 1.328 33.73 1.062 26.97 .120 3.05 1.123 28.52 1.219 30.96 .897 22.78 20 1.453 36.91 1.156 29.36 .120 3.05 1.248 31.70 1.344 34.14 1.022 25.96 22 1.578 40.08 1.250 31.75 .120 3.05 1.373 34.87 1.469 37.31 1.147 29.13 24 1.703 43.26 1.375 34.93 .147 3.73 1.498 38.05 1.594 40.49 1.272 32.31 www.conesys.com - 27 - sales@aero-electric.com MS27499 Front, Box Mount Receptacle AE299 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight .763(19.38) MAX A MAX .069(1.75) .058(1.47) .322(8.18) .317(8.05) B MASTER KEYWAY .312(7.92) MAX H E 4x C Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 38999 S II .060(1.52) MAX GROMMET EXTENSION F MAX MAX GROMMET BLUE COLOR BAND 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum (TP) Shell Size inch mm inch OC OE OF OH +.010 -.005 +.25 -.13 .003 .08 mm inch mm inch mm inch mm inch Maximum Maximum mm 8 .828 21.03 .594 15.09 .120 3.05 .471 11.96 .453 11.51 .299 7.59 10 .954 24.23 .719 18.26 .120 3.05 .588 14.94 .578 14.68 .427 10.85 12 1.047 26.59 .812 20.62 .120 3.05 .748 19.00 .703 17.86 .541 13.74 14 1.141 28.98 .906 23.01 .120 3.05 .873 22.17 .828 21.03 .666 16.92 16 1.234 31.34 .969 24.61 .120 3.05 .998 25.35 .953 24.21 .791 20.09 18 1.328 33.73 1.062 26.97 .120 3.05 1.123 28.52 1.062 26.97 .897 22.78 20 1.453 36.91 1.156 29.36 .120 3.05 1.248 31.70 1.188 30.18 1.022 25.96 22 1.578 40.08 1.250 31.75 .120 3.05 1.373 34.87 1.312 33.32 1.147 29.13 24 1.703 43.26 1.375 34.93 .147 3.73 1.498 38.05 1.438 36.53 1.272 32.31 www.conesys.com - 28 - sales@aero-electric.com MS27474 Jam Nut Receptacle AE274 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight D G MAX. MASTER KEYWAY "O" RING A .105(2.67) .084(2.13) SS 8-22 .150(3.81) .090(2.29) GROMMET SS 24 .140(3.56) EXTENSION .040(1.02) 38999 S II B J F FLAT MAX GROMMET H NO. OF TEETH M ACCESSORY THREAD HEX NUT PER MS3186 E THREAD 3 BAYONET PINS 4 MINOR KEYWAYS BLUE COLOR BAND Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size PANEL THICKNESS .109(2.77) .062(1.57) B D E OF .005 .13 +.001 -.006 +.03 -.15 .016 .41 Jam Nut Thread Class 2A .003 .08 inch mm inch mm inch mm inch mm G H OJ M Maximum No. of Teeth Maximum Accessory Thread inch mm inch mm UNEF-2A 8 .438 11.13 .817 20.75 1.250 31.75 7/8-20UNEF .471 11.96 .937 23.80 12 .299 7.59 7/16-28 10 .438 11.13 .941 23.90 1.375 34.93 1-20UNEF .588 14.94 .937 23.80 16 .427 10.85 9/16-24 12 .438 11.13 1.065 27.05 1.500 38.10 1-1/8-18UNEF .748 19.00 .937 23.80 20 .541 13.74 11/16-24 14 .438 11.13 1.190 30.23 1.625 41.28 1-1/4-18UNEF .873 22.17 .937 23.80 24 .666 16.92 13/16-20 16 .438 11.13 1.320 33.53 1.781 45.24 1-3/8-18UNEF .998 25.35 .937 23.80 28 .791 20.09 15/16-20 18 .438 11.13 1.440 36.58 1.890 48.01 1-1/2-18UNEF 1.123 28.52 .937 23.80 32 .897 22.78 1-1/16-18 20 .464 11.79 1.565 39.75 2.016 51.21 1-5/8-18UNEF 1.248 31.70 .931 23.65 36 1.022 25.96 1-3/16-18 22 .464 11.79 1.690 42.93 2.140 54.36 1-3/4-18UNS 1.373 34.87 .931 23.65 40 1.147 29.13 1-5/16-18 24 .464 11.79 1.815 46.10 2.265 57.53 1-7/8-16UN 1.498 38.05 .984 24.99 44 1.272 32.31 1-7/16-18 www.conesys.com - 29 - sales@aero-electric.com MS27513 Long Grommet, Front, Box Mount Receptacle AE213 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight .907(23.04) MAX A MAX B MASTER KEYWAY .069(1.75) .058(1.47) .516(13.11) MAX .322(8.18) .317(8.05) .312(7.92) MAX MAX GROMMET 38999 S II H E F MAX BLUE COLOR BAND 4x C 4 MINOR KEYWAYS Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum (TP) Shell Size inch mm inch OC OE OF OH +.010 -.005 +.25 -.13 .003 .08 mm inch mm inch mm inch mm inch Maximum Maximum mm 8 .828 21.03 .594 15.09 .120 3.05 .471 11.96 .453 11.51 .299 7.59 10 .954 24.23 .719 18.26 .120 3.05 .588 14.94 .578 14.68 .427 10.85 12 1.047 26.59 .812 20.62 .120 3.05 .748 19.00 .703 17.86 .541 13.74 14 1.141 28.98 .906 23.01 .120 3.05 .873 22.17 .828 21.03 .666 16.92 16 1.234 31.34 .969 24.61 .120 3.05 .998 25.35 .953 24.21 .791 20.09 18 1.328 33.73 1.062 26.97 .120 3.05 1.123 28.52 1.062 26.97 .897 22.78 20 1.453 36.91 1.156 29.36 .120 3.05 1.248 31.70 1.188 30.18 1.022 25.96 22 1.578 40.08 1.250 31.75 .120 3.05 1.373 34.87 1.312 33.32 1.147 29.13 24 1.703 43.26 1.375 34.93 .147 3.73 1.498 38.05 1.438 36.53 1.272 32.31 www.conesys.com - 30 - sales@aero-electric.com MS27473 Straight Plug AE273 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight 38999 S II Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA OC D E OF G H Minimum Maximum No of Teeth Accessory Thread Maximum Maximum Grommet Extension Shell Size inch mm inch mm UNEF-2A inch mm inch mm inch mm 8 .337 8.56 .299 7.59 12 7/16-28 .750 19.05 .916 23.27 .150/.090 3.81/2.29 10 .465 11.81 .427 10.85 16 9/16-24 .859 21.82 .916 23.27 .150/.090 3.81/2.29 12 .557 14.15 .541 13.74 20 11/16-24 1.031 26.19 .916 23.27 .150/.090 3.81/2.29 14 .702 17.83 .666 16.92 24 13/16-20 1.156 29.36 .916 23.27 .150/.090 3.81/2.29 16 .827 21.01 .791 20.09 28 15/16-20 1.281 32.54 .916 23.27 .150/.090 3.81/2.29 18 .927 23.55 .897 22.78 32 1-1/16-18 1.406 35.71 .916 23.27 .150/.090 3.81/2.29 20 1.052 26.72 1.022 25.96 36 1-3/16-18 1.531 38.89 .916 23.27 .150/.090 3.81/2.29 22 1.177 29.90 1.147 29.13 40 1-5/16-18 1.641 41.68 .916 23.27 .150/.090 3.81/2.29 24 1.302 33.07 1.272 32.31 44 1-7/16-18 1.766 44.86 .984 24.99 .140/.040 3.56/1.02 www.conesys.com - 31 - sales@aero-electric.com MS27484 RFI Grounding Plug AE284 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight 38999 S II Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA OC D E OF G H Minimum Maximum No of Teeth Accessory Thread Maximum Maximum Grommet Extension Shell Size inch mm inch mm UNEF-2A inch mm inch mm inch mm 8 .337 8.56 .299 7.59 12 7/16-28 .750 19.05 .916 23.27 .150/.090 3.81/2.29 10 .465 11.81 .427 10.85 16 9/16-24 .859 21.82 .916 23.27 .150/.090 3.81/2.29 12 .557 14.15 .541 13.74 20 11/16-24 1.031 26.19 .916 23.27 .150/.090 3.81/2.29 14 .702 17.83 .666 16.92 24 13/16-20 1.156 29.36 .916 23.27 .150/.090 3.81/2.29 16 .827 21.01 .791 20.09 28 15/16-20 1.281 32.54 .916 23.27 .150/.090 3.81/2.29 18 .927 23.55 .897 22.78 32 1-1/16-18 1.406 35.71 .916 23.27 .150/.090 3.81/2.29 20 1.052 26.72 1.022 25.96 36 1-3/16-18 1.531 38.89 .916 23.27 .150/.090 3.81/2.29 22 1.177 29.90 1.147 29.13 40 1-5/16-18 1.641 41.68 .916 23.27 .150/.090 3.81/2.29 24 1.302 33.07 1.272 32.31 44 1-7/16-18 1.766 44.86 .984 24.99 .140/.040 3.56/1.02 www.conesys.com - 32 - sales@aero-electric.com MS27500 Plug with 90 Backshell AE200 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight F MAX COUPLING NUT BLUE COLOR BAND MASTER KEY 38999 S II A MIN SHELL Y MAX W MAX 4 MINOR KEYS L MAX Page 24 Page 37 Pages 41-43 Page 23 Pages 39, 40 Page 35 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA OF Minimum Shell Size inch L Maximum W Maximum Y Maximum Maximum mm inch mm inch mm inch mm inch mm 8 .337 8.56 .750 19.05 1.859 47.22 1.000 25.40 .828 21.03 10 .465 11.81 .859 21.82 1.859 47.22 1.032 26.21 .891 22.63 12 .557 14.15 1.031 26.19 1.938 49.23 1.094 27.79 1.016 25.81 14 .702 17.83 1.156 29.36 2.125 53.98 1.219 30.96 1.141 28.98 16 .827 21.01 1.281 32.54 2.281 57.94 1.281 32.54 1.255 31.88 18 .927 23.55 1.406 35.71 2.312 58.72 1.344 34.14 1.469 37.31 20 1.052 26.72 1.531 38.89 2.375 60.33 1.375 34.93 1.550 39.37 22 1.177 29.90 1.641 41.68 2.531 64.29 1.438 36.53 1.675 42.55 24 1.302 33.07 1.766 44.86 2.828 71.83 1.719 43.66 1.800 45.72 www.conesys.com - 33 - sales@aero-electric.com M38999/10 Dummy Stowage Receptacle AE210 Dummy Stowage Receptacle, Bayonet Coupling 38999 S II Part Number Configuration MIL. Prefix Aero Prefix M38999/ AE2 10 10- XX XX B B Shell Type 10 = receptacle, dummy stowage, bayonet coupling Shell Size 8 THRU 24 (Note: single digit for shell size 8) Material Finish B = Aluminum, Cadmium Olive Drab A = Aluminum, Bright Cadmium over Nickel base (Aero p/n only) F = Aluminum shell, Electroless Nickel finish (Aero p/n only) S = Stainless steel shell, passivated (Aero p/n only) BN = Aluminum, Black Nickel (Aero p/n only) BZ = Bronze (Aero p/n only) Z = Aluminum shell, Black Zinc Nickel (Aero p/n only) C= Aluminum shell, black anodized (Aero part # only) SHELL SIZE www.conesys.com OA +.001 -.005 OT +.010 -.005 S MAX 8 .473 .120 .828 10 .590 .120 .954 12 .750 .120 1.047 14 .875 .120 1.141 16 1.000 .120 1.234 18 1.125 .120 1.328 20 1.250 .120 1.453 22 1.375 .120 1.578 24 1.500 .147 1.703 - 34 - sales@aero-electric.com MIL-DTL-38999 Polarization Series II Keying Positions NORMAL C 38999 S II N A MASTER KEYWAY B D 10 DATUM F Notes: 1. Mating face of receptacle shown (plug is opposite). 2. The master keyway (key) has various positions relative to DATUM F; the minor keyways (keys) remain fixed as shown. In the Normal position, the master keyway (key) is 100 from DATUM F. 3. The angles for a given connector are the same whether it contains pin or socket inserts. 4. The insert arrangement does not rotate relative to master keyway (key). Keying Positions BSC Shell Size N A B C D 8 100 82 - - 118 10 100 86 72 128 114 12 100 80 68 132 120 14 100 79 66 134 121 16 100 82 70 130 118 18 100 82 70 130 118 20 100 82 70 130 118 22 100 85 74 126 115 24 100 85 74 126 115 www.conesys.com - 35 - sales@aero-electric.com MIL-DTL-38999 Series II Flange and Jam Nut Receptacle Panel Cutouts Panel Cutouts JAM NUT FLANGE MOUNT D MAX PANEL THICKNESS 38999 S II 4x C .109(2.77) .062(1.57) PANEL THICKNESS B MIN F E A Note 1: Flange Mounting Dimensions (O B cutout and D max) listed only for back of panel mounting (MS27497 and MS27508). Note 2: D max includes mounting hardware. Flange and Jam Nut Mounting Dimensions A OB (TP) Minimum Shell Size inch mm inch OC D OE .005 .13 mm inch mm inch mm Maximum F +.010 -.000 +.25 -.00 +.000 -.010 +.00 -.25 inch mm inch mm 8 .594 15.09 .557 14.15 .128 3.25 .146 3.71 .885 22.48 .830 21.08 10 .719 18.26 .682 17.32 .128 3.25 .146 3.71 1.010 25.65 .955 24.26 12 .812 20.62 .854 21.69 .128 3.25 .146 3.71 1.135 28.83 1.085 27.56 14 .906 23.01 .979 24.87 .128 3.25 .146 3.71 1.260 32.01 1.210 30.73 16 .969 24.61 1.104 28.04 .128 3.25 .146 3.71 1.385 35.18 1.335 33.91 18 1.062 26.97 1.229 31.22 .128 3.25 .146 3.71 1.510 38.35 1.460 37.08 20 1.156 29.36 1.354 34.39 .128 3.25 .168 4.27 1.635 41.53 1.585 40.26 22 1.250 31.75 1.479 37.57 .128 3.25 .168 4.27 1.760 44.70 1.709 43.42 24 1.375 34.93 1.604 40.74 .154 3.91 .168 4.27 1.885 47.88 1.835 46.61 www.conesys.com - 36 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series II Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Insertion/Removal Tools Plastic Contact Size 38999 S II Type Military No. Military No. 22D Power/Signal M39029/58-360 M39029/57-354 22M* Power/Signal M39029/58-361 M39029/57-355 22* Power/Signal M39029/58-362 M39029/57-356 20 Power/Signal M39029/58-363 M39029/57-357 16 Power/Signal M39029/58-364 M39029/57-358 Coax M39029/76-424 M39029/78-432 Power/Signal M39029/58-365 16 Coax 12 Seal Plugs Military No. Military No. M81969/14-01 MS27488-22-1 -- MS27488-20-1 M81969/14-10 MS27488-16-1 M81969/14-03 M39029/57-359 MS27488-12-1 M81969/14-04 Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size/Type Military No. Military No. Military No. Military No. Military No. 22D, 22M* M22520/2-01 M22520/2-09 M22520/2-06 M81969/8-01 M81969/8-02 22* M22520/2-01 M22520/2-09 M22520/2-06 M81969/8-03 M81969/8-04 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M22520/1-01 M22520/1-04 M22520/1-04 M22520/2-01 M22520/2-10 M22520/2-10 16 M22520/1-01 M22520/1-04 M22520/1-04 16 Coax Inner M22520/2-01 M22520/2-35 M22520/2-35 16 Coax Outer M22520/4-01 M22520/4-02 M22520/4-02 12 M22520/1-01 M22520/1-04 M22520/1-04 20 Contact and Wire Data Test Current Voltage Contact Size DC Test Max. Drop Crimp Well Data Well Dia. Wire Range Finished Wire O Range Minimum Well Dept Minimum 2 Maximum Amps Millivolts inch inch mm AWG mm inch mm inch mm 22D 5.0 73 .0345 .0010 .141 3.58 28-22 .08-.33 .030 .76 .054 1.37 22M* 3.0 45 .028 .001 .141 3.58 28-24 .08-.20 .030 .76 .050 1.27 22* 5.0 73 .0365 .0010 .141 3.58 26-22 .13-.33 .034 .86 .060 1.52 20 7.5 55 .047 .001 .209 5.31 24-20 .20-.52 .040 1.02 .083 2.11 16 13.0 49 .067 .001 .209 5.31 20-16 .52-1.31 .065 1.65 .109 2.77 12 23.0 42 .100 .002 .209 5.31 14-12 2.08-3.31 .097 2.46 .142 3.61 * Inactive for new design Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com Note 2: Size 16 coax contacts purchased in bulk. - 37 - sales@aero-electric.com MIL-DTL-38999 Contact Installation Instructions Series II Contact Installation Instructions 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool 22D M39029/58-360 M39029/57-354 M22520/2-01 M22520/2-09 M22520/2-06 M81969/14-01 22M M39029/58-361 M39029/57-355 M22520/2-01 M22520/2-09 M22520/2-06 M81969/14-01 22 M39029/58-362 M39029/57-356 M22520/2-01 M22520/2-09 M22520/2-06 M81969/14-01 M22520/1-01 M22520/1-04 Red M22520/1-04 Red M22520/2-01 M22520/2-10 M22520/2-10 20 M39029/58-363 M39029/57-357 M81969/14-10 16 M39029/58-364 M39029/57-358 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03 12 M39029/58-365 M39029/57-359 M22520/1-01 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04 For coax contacts refer to instructions supplied with contacts. www.conesys.com - 38 - sales@aero-electric.com 38999 S II 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. MIL-DTL-38999 Series II Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information Insert Arrangement Aero-Electric Service Status Total Quantity of Contacts No. of (by Size) 38999 S II Series II QPL'd Tooled Rating Contacts 8-6* 8-35 8-98 10-5 10-13* 10 -35 10-98 10-99 12-3 12-4 12-8 12-22* 12-35 12-98 14-5 14-15 14-18 14-35 14-37* 14-97 16-6 16 -8 16 -26 16 -35 16-55* 16-99 18-11 18-28 18-30 18-32 18-35 18-53** 18-66* Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M M I I M M I I II I I M M I II I I M M I I II I M M I II I I I M M M 6 6 3 5 13 13 6 7 3 4 8 22 22 10 5 15 18 37 37 12 6 8 26 55 55 23 11 28 30 32 66 53 66 22D 22M 22 20 16 12 6 6 3 5 13 13 6 7 3 4 8 22 22 10 14 18 5 1 37 37 8 4 6 8 26 55 55 21 26 29 32 2 11 2 1 66 53 66 See next page for Shell Sizes 20 thru 24 layouts. * Not approved for new design. Tooled and qualified but their separate pictorials are not shown on pages 41 thru 43, as they are the same as corresponding (-35) layouts that take the same quantity of 22D contacts, but are supplied with 22M contacts instead. ** Not approved for new design. Pictorial is shown on page 42. www.conesys.com - 39 - sales@aero-electric.com MIL-DTL-38999 Series II Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information (continued) Insert Arrangement Aero-Electric Service Status Total Quantity of Contacts No. of (by Size) QPL'd Tooled Rating Contacts 20-1* 20-16 20-35 20-39 20-41 22-1* 22-2*** 22-21 22-32 22-35 22-53 22-55 24-1* 24-4 24-19 24-24 24-29 24-35 24-61 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M II M I I M M II I M I I M I I I I M I 79 16 79 39 41 100 85 21 32 100 53 55 128 56 19 24 29 128 61 22D 22M 22 20 16 12 79 16 79 37 41 2 38999 S II Series II 100 85 21 32 100 53 55 128 48 8 12 29 19 12 128 61 * Not approved for new design. Tooled and qualified but their separate pictorials are not shown on pages 41 thru 43, as they are same as corresponding (-35) layouts that take the same quantity of 22D contacts, but are supplied with 22M contacts instead. www.conesys.com - 40 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series II Connectors Insert Arrangements Views 5 C 1 6 4 3 A E A 1 A 10 2 11 9 B 2 D 8-98 3 # 20, I 8-35 6 # 22D, M 38999 S II C 10-5 5 # 20, I A A 8 B C G D H F 13 12 7 6 14 1 21 15 12-3 3 # 16, II 10-98 6 # 20, I L A L K B M R J K N H C J D P H E G T U S R G F 31 B J F 12-35 22 # 22D, M K A E C B D M G F F A A E G D D F A S P T J E F W X G H 16-26 26 # 20, I www.conesys.com 32 C H F D 47 P 53 Y 55 3 52 9 16 24 31 39 46 16-35 55 # 22D, M 16-8 8 # 16, II C Z K H U B V X M E W J H F G G C L E 16-99 2 # 16, 21 # 20, I - 41 - 18-11 11 # 16, II V C W e D X b N E Y a M D F d c P B U R D K A T S A J N L D E 16-6 6 # 12, I B T S C E 14-97 4 # 16, 8 # 20, I A R 40 1 V c Y K 25 D U Z 17 4 C b a N M L 10 B R 14-35 37 # 22D, M 14-18 18 # 20, I B B C 14-5 1 # 16, 14 # 20, I C 14-5 5 # 16, II B H E D 12-98 10 # 20, I A L J 21 C P 10-99 7 # 20, I E 1 B B C C D A N M A H G K 12-8 8 # 20, I 12-4 4 # 16, I A G E D B E C F B C 5 22 B F D 4 10-35 13 # 22D, M A B E 3 F Z L G K J 18-28 2 # 16, 26 # 20, I sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series II Connectors Insert Arrangements Views S R P d U e b M g f W a L D V E J a 24 U 31 N C 21 29 39 N 58 67 12 75 W R L K 11 C S 28 38 47 57 U J 81 19 66 S R P k h N n m z AA f K HH FF q CC DD J s t w d v c u a b n C W X Y x e r EE g L V BB GG y M p S k D E F Z G H 22-53 53 # 20, I m z R P j AA GG q N H M x FF DD EE v f L Y Z a d e K G J 94 97 5 99 6 10 0 15 24 T S q LL p E 55 66 76 85 KK AA BB n m N M f 24-4 B K U P V C D R H J K N G h k L A L F z g DD CC 45 93 D e y HH JJ EE r 34 M C d 8 # 16, 48 # 20, I - 42 - 86 B c x GG P 22-55 55 # 20, I A s U R H 77 22-35 100 # 22D, M b FF E b c 67 96 F w t V t u 56 95 7 a Z u D F 46 4 E v W X HH w g X C r 35 3 U V Y CC s K L 2 T e X B BB H J 1 C d 25 16 8 B S G W G 20-41 41 # 20, I D f A p c d e M 22-32 32 # 20, I y i P N c H * Inactive for new design. ** Not MIL-STD-1560 layout (not QPL'd.). www.conesys.com Y F V p q f b 98 K J G U U g R F n r W T B G R i 22-21 21 # 16, II A T D T H 22-2* 85 # 22, M S E a t A P g E 74 s H D Z m h K h Z V 85 F T J b a X 4 b c N M B P L 82 1 E C Y k i 20-39 2 # 16, 37 # 20, I A M 5 a B X j U D d e M 20-35 79 # 22D, M 48 p L 20-16 16 # 16, 11 20 n f 11 E F m q N 41 Z r A W V C Y k g D G j P 61 R 11 18-53* 53 #22, M B X h S R 71 79 P A W i T S 50 42 38999 S II 51 B 33 18-35 66 #22D, M V M 31 57 16 H A K H 63 1 L 52 66 9 18-32 32 # 20, I 18-30 1 # 16, 29 # 20, I J 3 F G J K G H 51 53 E Y Z L 64 1 b M 21 58 X h F Y 1 51 D g c N X Z K j 43 C W f d P 34 4 V e R C 25 10 B U T c N S B 17 A T A T J H E S G F 24-19 19 # 12, I sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series II Connectors Insert Arrangements Views A P B N R C Y M D T 38999 S II W J H G 24-24 12 # 12, 12 # 16, I www.conesys.com L F d 94 105 1 Y V X 122 W V 125 4 K 7 G 24 H J 35 47 5870 81 93 24-35 128 # 22D, M 24-29 29# 16, I - 43 - 104 11 4 FF A b B c v GG s d w HH NN JJ KK MM CC n P N k M L H i j F G h AA BB m E g z LL DD D f y EE P C e x PP q R 121 14 t r S F u U T W X Z a Y 115 E e Z E U V 71 82 D f M a 36 48 59 U c N 25 8 C a X 15 B T b S K S P Z L A R J K 24-61 61 # 20, I sales@aero-electric.com MIL-DTL-38999 Features and Application Series III Features and Application Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. MIL-DTL-38999 Series III is the newest cylindrical connector designed for highest performance capabilities used in both general purpose and severe environment applications. Scoop-Proof Design - Recessed pins in elongated shells minimize the possibility for contact damage. In a blind mating application, mating shells cannot "scoop" the pins, and cause a shorting or bending of contacts. These connectors feature an improved "one-turn" coupling system, utilizing self-locking acme thread. Acme threads provide coupling durability, while thicker wall sections and greater coupling surface area improve strength and shock resistance. Blunting of the threads on both receptacle and plug coupling nut eliminates cross threading. Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. Elongated mounting holes permit the Series III Connector to intermount with various existing Mil-spec flange mounted receptacles, giving it a design replacement advantage. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. Wall mount receptacle, jam nut receptacle and straight self-locking RFI plug are offered in 9 shell sizes and 54 insert arrangements utilizing M39029 contacts in sizes 22D, 20, 16, 12, 10 power and 8 twinax. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel and olive drab cadmium. Other finishes such as anodic and zinc cobalt are available upon request to commercial callouts only. In addition, we offer stainless steel shells (both passivated and electro-deposited nickel plated) with firewall inserts, and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). Metric Accessory Thread - Metric thread results in additional wall thickness giving greater strength and shock resistance. Twinax Contacts - Aero Electric is Qualified to make and supply M39029/90-529 and M39029/91-530 size 8 Twinax contacts used in 38999 III connectors. Please consult factory even when needing to buy just the contacts. MIL-STD-1560 Insert Arrangements - Series III connectors use insert patterns and contacts common to Series I, making for an easy transition from bayonet to triple-lead, acme-thread, self-locking coupling. Metal-to-Metal Bottoming - This feature precludes relative shell-to-shell motion, which may result in ordinary connector wear and moisture entrapment. Lockwiring Eliminated - Self-locking quick coupling plug eliminates the need for lockwiring. Firewall Capability - Stainless steel shells in both K and S firewall classes are offered. www.conesys.com - 44 - sales@aero-electric.com 38999 S III Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. MIL-DTL-38999 Performance Specifications Series III Performance Specifications Operating Temperature Range Classes F, K, S, RN*, BZ*: -65C to +200C (-85F to +392F) Classes W, T, Z, & BN*: -65C to +175C (-85F to +347F) Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-38999. Material and Finish Data (Class) F - aluminum shell, electroless nickel finish K - stainless steel shell, passivated, firewall S - stainless steel shell, electrodeposited nickel, firewall T *- aluminum shell, nickel flourocarbon polymer finish W- aluminum shell, olive drab cadmium over nickel base Z - aluminum shell, zinc nickel finish(RoHS) BN* -aluminum shell, black nickel finish(RoHS) BZ* - aluminum nickel bronze shell, std insert RN* - aluminum shell, electroless nickel finish (RoHS) Shell-to-Shell Conductivity Maximum potential drop shall not exceed: * Classes F and S = 1.0 millivolt. * Class W & Z = 2.5 millivolts, Class K = 10.0 millivolts 38999 S III Shock and Vibration Requirements Wired, mated connectors shall not be damaged, nor shall there be a current interruption longer than one microsecond when subjected to the following: Corrosion Resistance Military Classes K, W, Z, and S withstand 500-hour salt spray. Military Class F withstands 48-hour salt spray. Commercial RoHS compliant Class RN* withstands 48-hour salt spray. Commercial RoHS compliant Classes BZ* and T* withstand 500-hour salt spray. Commercial RoHS compliant Class BN* withstands 400-hour salt spray. Shock Pulse of approximate half sine wave of 300 G 15 percent magnitude with duration of 3 1 milliseconds applied in three axes. High Impact Shock When mounted as specified in MIL-S-901, grade A, a drop of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to connector in three axes, totaling nine impacts. Durability Minimum of 500 mating cycles. Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808, MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol 25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5), SAE-AMS1424 Type I, and other solvents and cleaning agents. Vibration Wired and mated connectors withstand the following vibration levels: * Sine vibration where connector samples with simulated accessory load are subjected to simple harmonic motion from 10 to 2,000 Hz in three mutually perpendicular axes, in 20 minute sweeps, for 12 hours in each axis at velocity of 254 mm/sec from 10-50 Hz, displacement of 1.5 mm from 50-140Hz and acceleration of 60G from 140-2,000Hz. * Random Vibration per MIL-STD-1344, method 2005, test condition V at ambient temperature and test condition VI, Letter "J" at elevated temperature. Shielding Effectiveness RFI and EMI attenuation at the specified frequencies meet the requirements of MIL-DTL-38999. * RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture. * EMI shielding effectiveness is measured at the interfaceof mated connectors and tested by the mode-stirred technique specified in method 3008 of MIL-STD-1344. Voltage Rating Service Rating M N I II * Not on QPL, can be supplied to Aero-Electric part number only. Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level V RMS 1300 1000 1800 2300 50,000 Ft. V RMS 550 400 600 800 70,000 Ft. V RMS 350 260 400 500 100,000 Ft. V RMS 200 200 200 200 AC (RMS) 400 300 600 900 DC 550 450 850 1250 Note: The establishment of electrical safety factors is left entirely to the designer, as he/she is in the best position to www.conesys.com know exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 45 - sales@aero-electric.com MIL-DTL-38999 Part Number Development Series III Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix D38999/ AE3 20 20 W W C C 35 35 P P N N -340 Shell Type (Specification Sheet Number) 20 = Wall mount receptacle 24 = Jam nut receptacle 26 = Self-locking, RFI grounding plug Class (Material & Finish) F = Aluminum shell, electroless nickel finish W = Aluminum shell, olive drab cadmium over electroless nickel base T = Aluminum shell, nickel flourocarbon polymer finish (consult factory for availability) Z = Aluminum shell, zinc nickel finish (black) K = Stainless steel shell, passivated, with firewall insert 38999 S III S = Stainless steel shell, electrodeposited nickel, with firewall insert BN* = Aluminum shell, black nickel finish, (RoHS), (Aero p/n/ only) BZ* = Aluminum nickel bronze shell with standard insert (Aero p/n only) Shell Size ZC* = Aluminum shell, zinc cobalt plating, (RoHS), (Aero p/n only)(black) L* = Stainless steel shell, electrodeposited nickel, non-firewall/standard insert (Aero p/n only) A, B, C, D, E, F, G, H or J Insert Arrangement See pages 60 thru 62 Contact Style P = Pin S = Socket A = Pin connector less pins (with intent to use non-std pin contacts) B = Socket connector less sockets (with intent to use non-std socket contacts) Polarization (Keying) N = Normal (Included in part number) A, B, C, D, or E Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/15-XXX 341 = Connector kitted with M85049/38-XXX straight clamp 342 = Connector kitted with M85049/39-XXX right angle clamp Consult factory for other modifications * Not on QPL, can be supplied to Aero-Electric part number only. Note 2: Proper part number marking has no "0" in front of single digit layout. Example: J D38999/20WB5SN. "N" for normal is included. In addition, J or JAN must be marked immediately in front of MIL part number. Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 through 26 of each contact and two spares for inserts with 27 or more contacts, and a minimum of one sealing plug up to 10% of the number contacts. Spare Coax and Twinax contacts are not supplied. One insertion/extraction tool for each contact size is also included. www.conesys.com - 46 - sales@aero-electric.com D38999/20 Wall Mount Receptacle AE320 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof 31.50(1.240) MAX A G MASTER KEYWAY H MAX MAX 7.11(.280) MIN FULL THREAD 2.16(.085) MAX GROMMET EXTENSION D L MAX GROMMET J NUMBER OF TEETH F 38999 S III E MATING THREAD 4 MINOR KEYWAYS LOCKING INDICATOR BAND COLOR: RED C BLUE COLOR BAND (REAR RELEASE) K ACCESSORY THREAD B Page 46 Page 52 Pages 60-62 Page 45 Pages 58, 59 Page 50 A B C (TP) (TP) .012 .30 inch mm inch mm inch A .937 23.80 .719 18.26 B 1.031 26.20 .812 20.62 C 1.126 28.60 .906 D 1.220 31.00 E 1.311 33.30 Shell Size Note 1: "K" Accessory Thread for AE320 is same as AE326 ("D" Accessory Thread) on page 49. Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization Note 2: "F" Mating Thread for AE320 is same as AE326 ("E" Mating Thread) on page 49 except it is Class 2A. Note 3: Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). D E G H J Maximum Maximum No. of Teeth OL .008 .20 .008 .20 mm inch mm inch mm inch mm inch mm .594 15.09 .216 5.49 .128 3.25 .820 20.83 .098 2.50 12 .299 7.59 .719 18.26 .194 4.93 .128 3.25 .820 20.83 .098 2.50 16 .427 10.85 23.01 .812 20.62 .194 4.93 .128 3.25 .820 20.83 .098 2.50 20 .541 13.74 .969 24.61 .906 23.01 .173 4.39 .128 3.25 .820 20.83 .098 2.50 24 .666 16.92 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 .820 20.83 .098 2.50 28 .791 20.09 Maximum inch mm F 1.437 36.50 1.156 29.36 1.062 26.97 .194 4.93 .128 3.25 .820 20.83 .098 2.50 32 .897 22.78 G 1.563 39.70 1.250 31.75 1.156 29.36 .194 4.93 .128 3.25 .790 20.07 .126 3.20 36 1.022 25.96 H 1.689 42.90 1.375 34.93 1.250 31.75 .242 6.15 .154 3.91 .790 20.07 .126 3.20 40 1.147 29.13 J 1.811 46.00 1.500 38.10 1.375 34.93 .242 6.15 .154 3.91 .790 20.07 .126 3.20 44 1.272 32.31 www.conesys.com - 47 - sales@aero-electric.com D38999/24 Jam Nut Receptacle AE324 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof A D 32.50 (1.280) MAX BLUE COLOR BAND (REAR RELEASE) G LOCKING INDICATOR BAND COLOR: RED MASTER KEYWAY 2.16(.085) MAX GROMMET EXTENSION H B MAX GROMMET FLAT F NUMBER OF TEETH C K ACCESSORY THREAD E MATING THREAD HEX NUT PER D38999/28 38999 S III J THREAD 4 MINOR KEYWAYS "O" RING SEAL PANEL THICKNESS 3.20(.126) 1.58(.062) Page 46 Page 52 Pages 60-62 Page 45 Pages 58, 59 Page 50 Note 1: "K" Accessory Thread for AE324 is same as AE326 ("D" Accessory Thread) on page 49. Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Note 2: "E" Mating Thread for AE324 is same as AE326 ("E" Mating Thread) on page 49 except it is Class 2A. Note 3: Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). C Shell Size .016 .40 +.004 -.006 +.10 -.15 inch mm inch mm A 1.063 27.00 .651 16.53 B 1.252 31.80 .751 19.07 C 1.374 34.90 .938 23.82 D 1.500 38.10 1.062 E 1.626 41.30 1.187 D F G inch mm Maximum Jam Nut Thread +.60 -.00 mm inch mm .945/.859 24.00/21.82 .555 14.10 12 .087 2.20 .299 7.59 M17x1-6g 1.063/.984 27.00/24.99 .555 14.10 16 .087 2.20 .427 10.85 M20x1-6g 1.260/1.172 32.00/29.77 .555 14.10 20 .087 2.20 .541 13.74 M25x1-6g 26.97 1.417/1.296 36.00/32.91 .555 14.10 24 .087 2.20 .666 16.92 M28x1-6g 30.15 1.457/1.422 37.00/36.12 .555 14.10 28 .087 2.20 .791 20.09 M32x1-6g inch +.90 -.10 J +.024 -.000 No. of Teeth +.035 -.004 OH mm inch 0.100R F 1.811 46.00 1.312 33.32 1.614/1.546 41.00/39.26 .555 14.10 32 .118 3.00 .897 22.78 M35x1-6g G 1.937 49.20 1.437 36.50 1.811/1.672 46.00/42.47 .555 14.10 36 .118 3.00 1.022 25.96 M38x1-6g H 2.063 52.40 1.562 39.67 1.969/1.796 50.00/45.61 .555 14.10 40 .118 3.00 1.147 29.13 M41x1-6g J 2.189 55.60 1.687 42.85 2.017/1.939 51.23/49.25 .555 14.10 44 .118 3.00 1.272 32.31 M44x1-6g www.conesys.com - 48 - sales@aero-electric.com D38999/26 Self-Locking, RFI Grounding Plug AE326 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof 31.00(1.220) MAX [A BLUE COLOR BAND LOCATION OPTIONAL (REAR RELEASE) MASTER KEY MAX COUPLING NUT 2.16(.085) MAX GROMMET EXTENSION 7.11(.280) MIN FULL THREAD [B MAX GROMMET RFI STRIP 38999 S III E MATING THREAD 4 MINOR KEYS Page 46 Page 52 Pages 60-62 Page 45 Pages 58, 59 Page 50 T NUMBER OF TEETH Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization D ACCESSORY THREAD Note : Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). OA OB D E T Maximum Maximum Accessory Thread Metric Mating Thread Class 2B No. of Teeth Shell Size inch mm inch A .858 21.80 .299 7.59 M12x1.0-6g 0.100R .6250-0.1P-0.3L 12 B .984 25.00 .427 10.85 M15x1.0-6g 0.100R .7500-0.1P-0.3L 16 C 1.157 29.40 .541 13.74 M18x1.0-6g 0.100R .8750-0.1P-0.3L 20 mm D 1.280 32.50 .666 16.92 M22x1.0-6g 0.100R 1.0000-0.1P-0.3L 24 E 1.406 35.70 .791 20.09 M25x1.0-6g 0.100R 1.1875-0.1P-0.3L 28 F 1.516 38.50 .897 22.78 M28x1.0-6g 0.100R 1.2500-0.1P-0.3L 32 G 1.642 41.70 1.022 25.96 M31x1.0-6g 0.100R 1.3750-0.1P-0.3L 36 H 1.768 44.90 1.147 29.13 M34x1.0-6g 0.100R 1.5000-0.1P-0.3L 40 J 1.890 48.00 1.272 32.31 M37x1.0-6g 0.100R 1.6250-0.1P-0.3L 44 www.conesys.com - 49 - sales@aero-electric.com MIL-DTL-38999 Polarization Series III Keying Positions D NORMAL MASTER KEYWAY A B C 38999 S III Notes: 1. Mating face of receptacle shown (plug is opposite). 2. All minor keyways (keys) are rotated to provide shell polarization while master keyway (key) remains fixed as shown. Shell Size A (9) B (11) C (13) D (15) E (17) F (19) G (21) H (23) J (25) www.conesys.com 3. The angles for a given connector are the same whether it contains pin or socket inserts. 4. Insert arrangement does not rotate relative to the master keyway (key). Key/Keyway Key/Keyway Positions BSC Identification Letter N A B C D E N A B C D E N A B C D E A 105 102 80 35 64 91 95 113 90 53 119 51 80 135 49 66 62 79 - 50 - B 140 132 118 140 155 131 141 156 145 156 146 141 142 170 169 140 145 153 C 215 248 230 205 234 197 208 182 195 220 176 184 196 200 200 200 180 197 D 265 320 312 275 304 240 236 292 252 255 298 242 293 310 244 257 280 272 sales@aero-electric.com MIL-DTL-38999 Series III Flange and Jam Nut Receptacle Panel Cutouts Panel Cutouts JAM NUT MOUNT FLANGE MOUNT 3.20(.126) 1.58(.062) PANEL THICKNESS 4x O C OB MIN 38999 S III D OE A Note: Diameter B cutout dimensions are listed separately for back and front of panel mounting. Shell Size inch A OB OB (TP) For Back Mounting Minimum For Front Mounting Minimum mm inch mm inch OC mm D OE .005 .13 +.000* -.010 +.00* -.25 +.010 -.000 +.25 -.00 inch mm inch mm inch mm A (9) .719 18.26 .656 16.66 .516 13.11 .128 3.25 .657* 16.70* .700 17.78 B (11) .812 20.62 .796 20.22 .625 15.88 .128 3.25 .771 19.59 .825 20.96 C (13) .906 23.01 .922 23.42 .750 19.05 .128 3.25 .955 24.26 1.010 25.65 D (15) .969 24.61 1.047 26.59 .906 23.01 .128 3.25 1.085 27.56 1.135 28.83 E (17) 1.062 26.97 1.219 30.96 1.016 25.81 .128 3.25 1.210 30.73 1.260 32.01 F (19) 1.156 29.36 1.297 32.94 1.141 28.98 .128 3.25 1.335 33.91 1.385 35.18 G (21) 1.250 31.75 1.422 36.12 1.266 32.16 .128 3.25 1.460 37.08 1.510 38.35 H (23) 1.375 34.93 1.547 39.29 1.375 34.93 .154 3.91 1.585 40.26 1.635 41.53 J (25) 1.500 38.10 1.672 42.47 1.484 37.69 .154 3.91 1.710 43.43 1.760 44.70 * Tolerance .10mm (.004") www.conesys.com - 51 - sales@aero-electric.com D38999 Accessories Part Number Development Dummy Stowage Receptacle Part Number Configuration MIL. Prefix Aero Prefix D38999/ AE3 22 22 C C W W Shell Type 22 = receptacle, dummy stowage, threaded Shell Size** A, B, C, D, E, F, G, H or J 38999 S III Material Finish W = Aluminum Shell, Olive Drab Cadmium Finish F = Aluminum, Electroless Nickel Finish K = Stainless Steel, Passivated S = Stainless Steel, Electrodeposited Nickel BN* = Aluminum Shell, Black Nickel Finish (Aero p/n only) * Not on QPL, can be supplied to Aero-Electric part number only. * * Shell size code A is for use with plugs with mating key polarizations "C", "E" or "N". Shell size code AA is for use with plugs with mating key polarizations "A", "B" or "D". Protective Metal Caps Part Number Configuration MIL. Prefix Aero Prefix D38999/ AE3 32 32 W W- 11 11 R R Shell Type 32 = cover, protective, plug 33 = cover, protective, receptacle Material Finish W = Aluminum Shell, Olive Drab Cadmium Finish F = Aluminum, Electroless Nickel Finish K = Stainless Steel, Passivated S = Stainless Steel, Electrodeposited Nickel BN* = Aluminum Shell, Black Nickel Finish (Aero p/n only) Shell Size 9,11,13, 15, 17, 19, 21, 23, 25 Style R = Wire Rope Assembly N = Wire Rope/Ring Assembly * Not on QPL, can be supplied to Aero-Electric part number only. www.conesys.com - 52 - sales@aero-electric.com D38999/22 Dummy Stowage Receptacle AE322 AE322 Threaded Dummy Stowage Receptacle 38999 S III SHELL SIZE SHELL SIZE CODE 9 OB PP R1 R2 S V W MM INCH MM .20 INCH .008 MM INCH MM INCH MM .3 INCH .012 MM .00 -.13 INCH .000 -.005 MM .3 INCH .012 A 12.63 12.47 .497 .491 5.49 .216 18.26 .719 15.09 .594 23.8 .937 20.83 .820 2.5 .098 11 B 15.88 15.73 .625 .619 4.93 .194 20.62 .812 18.26 .719 26.2 1.031 20.83 .820 2.5 .098 13 C 19.63 19.49 .773 .767 4.93 .194 23.01 .906 20.62 .812 28.6 1.126 20.83 .820 2.5 .098 15 D 22.84 22.69 .899 .893 4.39 .173 24.61 .969 23.01 .906 31.0 1.220 20.83 .820 2.5 .098 17 E 25.99 25.84 1.023 1.017 4.93 .194 26.97 1.062 24.61 .969 33.3 1.311 20.83 .820 2.5 .098 19 F 28.63 28.48 1.127 1.121 4.93 .194 29.36 1.156 26.97 1.062 36.5 1.437 20.83 .820 2.5 .098 21 G 31.83 31.68 1.253 1.247 4.93 .194 31.75 1.250 29.36 1.156 39.7 1.563 20.07 .790 3.2 .126 23 H 35.03 34.88 1.379 1.373 6.15 .242 34.93 1.375 31.75 1.250 42.9 1.689 20.07 .790 3.2 .126 25 J 38.18 38.03 1.503 1.497 6.15 .242 38.10 1.500 34.93 1.375 46.0 1.811 20.07 .790 3.2 .126 www.conesys.com - 53 - sales@aero-electric.com D38999/32 Protective Cover, Plug AE332 Protective Cover Plug 38999 S III www.conesys.com OB MAX OD MAX OE MAX G SHELL SIZE A THREAD CLASS 2A TRIPLE START INCH MM INCH MM INCH MM INCH +.512 -.276 MM +13.0 -7.0 9 .6250-0.1P-0.3L .906 23.0 .945 24.0 .512 13.0 5.000 127.00 11 .7500-0.1P-.03L 1.024 26.0 1.063 27.0 .709 18.0 5.000 127.00 13 .8750-0.1P-.03L 1.221 31.0 1.181 30.0 .787 20.0 5.000 127.00 15 1.0000-0.1P-.03L 1.299 33.0 1.221 31.0 .906 23.0 5.000 127.00 17 1.1875-0.1P-.03L 1.457 37.0 1.457 37.0 1.024 26.0 5.000 127.00 19 1.2500-0.1P-.03L 1.575 40.0 1.575 40.0 1.142 29.0 5.000 127.00 21 1.3750-0.1P-.03L 1.732 44.0 1.732 44.0 1.260 32.0 5.000 127.00 23 1.5000-0.1P-.03L 1.811 46.0 1.811 46.0 1.339 34.0 5.000 127.00 25 1.6250-0.1P-.03L 1.969 50.0 1.929 49.0 1.535 39.0 5.000 127.00 - 54 - sales@aero-electric.com D38999/33 Protective Cover, Receptacle AE333 Protective Cover Receptacle 38999 S III OB MAX OD MIN OC MAX F SHELL SIZE A THREAD CLASS 2B TRIPLE START INCH MM INCH MM INCH MM INCH +.512 -.276 MM +13.0 -7.0 9 .6250-0.1P-0.3L .906 23.0 1.063 27.0 .695 17.64 5.000 127.00 11 .7500-0.1P-0.3L 1.102 28.0 1.260 32.0 .865 21.97 5.000 127.00 133 .8750-0.1P-0.3L 1.221 31.0 1.457 37.0 .989 25.12 5.000 127.00 15 1.0000-0.1P-0.3L 1.260 32.0 1.575 40.0 1.178 29.92 5.000 127.00 17 1.1875-0.1P-0.3L 1.457 37.0 1.732 44.0 1.260 32.00 5.000 127.00 19 1.2500-0.1P-0.3L 1.535 39.0 1.811 46.0 1.428 36.27 5.000 127.00 21 1.3750-0.1P-0.3L 1.654 42.0 1.929 49.0 1.506 38.25 5.000 127.00 23 1.5000-0.1P-0.3L 1.772 45.0 2.126 54.0 1.678 42.62 5.000 127.00 25 1.6250-0.1P-0.3L 1.929 49.0 2.205 56.0 1.750 44.45 5.000 127.00 www.conesys.com - 55 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series III Contacts, Plastic Insertion/Removal Tools and Seal Plugs Contact Size 22D 20 16 12 12 Coax 12 Coax 10 (Power) 8 Coax 8 Twinax**** Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Power Coax Twinax Military No. M39029/58-360 M39029/58-363 M39029/58-364 M39029/58-365 M39029/28-211 M39029/102-558 M39029/58-528 M39029/60-367 M39029/90-529 Military No. M39029/56-348 M39029/56-351 M39029/56-352 M39029/56-353 M39029/75-416 M39029/103-559 M39029/56-527 M39029/59-366 M39029/91-530 Military No. MS27488-22-1 MS27488-20 -1 MS27488-16 -1 Plastic Military No. M81969/14-01 M81969/14-10 M81969/14-03 MS27488-12-1 M81969/14-04 M85049/81-10*** MS27488-8-1 MS27488-8-1 M81969/14-05 M81969/14-06 M81969/14-12 Positioner Positioner Insertion Tool Extraction Tool For Socket Contacts Military No. M22520/2-07 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 -- M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 Metal Military No. M81969/8-01 Metal Military No. M81969/8-02 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M81969/8-11 M81969/8-12 M81969/8-13** M81969/8-14 M22520/5-200 -- -- Crimping and Metal Insertion/Extraction Tools 16 12 12 Coax Inner 12 Coax Outer 10 ( Power) 8 Coax Inner Military No. M22520/2- 01 M22520/1- 01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 -- M22520/2-01 8 Coax Outer M22520/5-01 8 Twinax Center 8 Twinax Outer & Intermediate M22520/2-01 For Pin Contacts Military No. M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 -- M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 M22520/5-01 M22520/5-200 22D 20 Contact and Wire Data Test Current* Voltage* DC Test Amps 5.0 7.5 13.0 23.0 33.0 Max. Drop Millivolts 73 55 49 42 33 Contact Size 22D 20 16 12 10 Crimp Well Data Well Dia. inch .0345 .0010 .047 .001 .067 .001 .100 .002 .137 .003 MS3348 bushing required with 12 gauge wire. * When tested with silver-plated wire. ** Insertion tool is not required. *** Dummy contact, used in lieu of unwired contact and seal plug. **** Aero Electric is Qualified for Twinax contacts, consult factory for a quote. www.conesys.com Wire Range Minimum Well Dept inch mm .141 3.58 .209 5.31 .209 5.31 .209 5.31 .355 9.02 - 56 - AWG 28-22 24-20 20-16 14-12 12-10 mm2 .08-.33 .20-.52 .52-1.31 2.08-3.31 3.31-5.26 Finished Wire O Range Minimum inch mm .030 .76 .040 1.02 .065 1.65 .097 2.46 .135 3.42 Maximum inch mm .054 1.37 .083 2.11 .109 2.77 .142 3.61 .162 4.12 Note: Size 8 coax contacts are used with M17/095-RG180 cable, while size 8 Twinax contacts are used with M17/176-00002 cable. Note 2: Size 8 Power contacts available with various crimp wells - 5265244-08xx and 5065-246-08xx - please consult factory for sales drawing that includes various tooling needed. sales@aero-electric.com 38999 S III Crimp Tool Contact Size/Type MIL-DTL-38999 Contact Installation Instructions Series III Contact Installation Instructions 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 38999 S III 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool 22D M39029/58-360 M39029/56-348 M22520/2-01 M22520/2-09 M22520/07 M81969/14-01 20 M39029/58-363 M39029/56-351 M22520/1-01 M22520/1-04 Red M22520/1-04 red M22520/2-01 M22520/2-10 M22520/2-10 16 M39029/58-364 M39029/56-352 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03 12 M39029/58-365 M39029/56-353 M22520/1-01 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04 10 M39029/58-528 M39029/56-527 * * * M81969/14-05 For Coax and Twinax contacts refer to instructions that are supplied with contacts. www.conesys.com M81969/14-10 * Contact Daniels Manufacturing for crimp tool/positioner. - 57 - sales@aero-electric.com MIL-DTL-38999 Series III Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information Insert Arrangement Aero-Electric Service Status Total Quantity of Contacts No. of (by Size) Series III QPL'd Tooled Rating Contacts 22D A35 A98 B2 B4 B5 B35 B98 B99 C4 C8 C35 C98 D5 D15 D18 D19 D35 D97 E6 E8 E26 E35 E99 F11 F28 F30 F32 F35 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M I I I I M I I I I M I II I I I M I I II I M I II I I I M 6 3 2 4 5 13 6 7 4 8 22 10 5 15 18 19 37 12 6 8 26 55 23 11 28 30 32 66 6 20 16 12 10 8 3 2 4 5 13 6 7 4 38999 S III 8 22 10 14 18 19 5 1 37 8 4 6 8 26 55 21 26 29 32 2 11 2 1 66 See next page for Shell Sizes G thru J layouts. www.conesys.com - 58 - sales@aero-electric.com MIL-DTL-38999 Series III Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information (continued) Insert Arrangement Aero-Electric Service Total Status Quantity of Contacts No. of 38999 S III Series III QPL'd Tooled Rating Contacts G11++ G16 G35 G39 G41 G48** G75 H21 H32 H35 H53 H55 J4 J8 J11 J19 J20 J24 J29 J35 J37 J43 J46*** J61 J90 Yes Yes Yes Yes Yes N/A Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes I II M I I I Twinax II I M I I I Twinax N I N, Coax, Twinax I I M II I I, Coax I I, Twinax 11 16 79 39 41 4 4 21 32 100 53 55 56 8 11 19 30 24 29 128 37 43 46 61 46 ** G48 layout is not to MIL-STD-1560. It is tooled and intended for comm'l use only. *** Not approved for new design. Pictorial is shown on page 62. ++ G11 insert arrangement cannot be ordered with A or B sufix, as certifying agency does not want non-standard contacts used in these connectors. (by Size) 22D 20 16 12 10 8 11 16 79 37 41 2 4 (Power) 4 (Twinax) 21 32 100 53 55 48 8 8 (Twinax) 2 10 9 13 12 29 19 4 (Coax) 12 3 (Twinax) 128 23 40 61 40 37 20 4 2 (Coax) 4 2 (Twinax) Note 1: J20P uses 4 size 12 coax contacts as follows: 2 ea M39029/28-211 and 2 ea of M39029/102-558; J20S uses 4 size 12 coax contacts as follows: 2 ea M39029/75416 and 2 ea of M39029/103-559. Note 2: Layouts (G75, J8, J20, J46 and J90) that take twinax or coax contacts should not be used for firewall applications (Classes K & S) in Series III. Note 3: H and J contact styles (in lieu of P & S) are meant for Composite (classes J & M) Series III only. Aluminum (classes F & W) and Firewall (classes K & S) are rated for 500 cycles regardleess what contacts are used. www.conesys.com - 59 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series III Connectors Insert Arrangements Views 5 4 C 1 6 A A98, 3 # 20, I B 1 A 10 E C C E L R J B N H J D A T U S G K C P R F L B N M H E G C K C P 15 A B N P U J D T H E G A H G B C J F C35, 22 # 22D, M D C98, 10 # 20, I K 1 S 5 E C 31 D R V 6 4 C D M 7 K C8, 8 # 20, I C4, 4 # 16, I B M 1 B E C L A K 14 21 12 B35, 13 # 22D, M 22 B99, 7 # 20, I A C 3 13 38999 S III B98, 6 # 20, I A H F B D 2 11 8 B B5, 5 # 20, I G B D A G D B4, 4 # 20, I A F B D E 9 B2, 2 # 16, I A F D A C A35, 6 # 22D, M E D A B 2 3 B 21 A L J B H E M G F F C D E F D15, 1 # 16, 14 # 20, I D5, 5 # 16, II A D F E6, 6 # 12, I www.conesys.com P B T N H E C D E8, 8 # 16, II M L E F W X J G H E26, 26 # 20, I - 60 - 32 D97, 4 # 16, 8 # 20, I A 40 R 47 P 1 V c Y K 25 D U Z 17 4 C b a B F C S 10 B R G D35, 37 # 22D, M D19, 19 # 20, I A A E D18, 18 # 20, I 53 55 3 52 9 16 24 31 39 46 E35, 55 # 22D, M Y B T S C Z U D N V X M E W L K J H F G E99, 2 # 16, 21 # 20, I sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series III Connectors Insert Arrangements Views A T S A J K H d R B G K E 17 25 34 J F28, 2 # 16, 26 # 20, I J 43 51 4 K 38999 S III 63 24 33 42 Y k i T R j h Z m r g n f N p H d e M f K M G39, 2 # 16, 37 # 20, I N L W R L C Z V S U J D T G B D J G48**, 4 # 8 Power, I F H21, 21 # 16, II g S Y 16 25 35 46 56 67 77 f e S R 94 96 4 97 5 G 10 0 7 W H 99 6 E F 15 24 34 45 55 66 76 85 H35, 100 # 22D, M H32, 32 # 20, I P k 95 3 U V B 86 2 C D X C G75, 4 # 8 Twinax, Twinax 1 T d i 8 B R c A C 98 K J E H G A h D H K P b a X K b c L N M B P A G41, 41 # 20, I A M G35, 79 # 22D, M F d e N F E a n p q P J L m r g R 11 E D Z t S 71 79 61 C Y k h G c 31 B s S F b q P F G H 41 A i T E J C D G X j U D a Y 51 G16, 16 # 16, II W V C E F32, 32 # 20, I N R G11, 11 # 12, I B X K P H D E A W V Z B F 50 F35, 66 #22D, M U a 21 C 57 16 J X b M L M S L 66 9 B D g h A H 3 c 1 L 58 G N C W f j F30, 1 # 16, 29 # 20, I A 64 E G H K 1 d F Y J P X Z K G V e R D B U f W F Z F11, 11 # 16, II g a L a L C V M E S U e A T B T b D X M D 10 W e A d c N Y L F C b N C P V c P S R B U 93 h N m z f K p V q BB GG HH FF CC DD J t w d C W X Y x e r s EE g L B U AA y M A T n v c u a b D E F Z G H H53, 53 # 20, I * Inactive for new design. ** Not MIL-STD-1560 layout (not QPL'd.). www.conesys.com - 61 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series III Connectors Insert Arrangements Views A T AA z R i x N H M DD FF v c d f L b u LL q S G n P H55, 55 # 20, I C V D R E S H 6 7 L 15 25 94 105 8 X 115 1 V 125 4 m 24 35 47 5870 104 81 93 W t V s U v h u g a D q b r c E AA X C W Z q D a p S s f e G d R V E H M w c m P J h M g L K F G e f H J J46, 40 # 20, 4 # 16, 2 # 8 Coax, I / Coax u t s FF d w HH NN KK MM CC n m P N k M L H i j F G h AA BB E g z LL DD D f y EE P C e x JJ PP q R B c v U T A b GG r S d x y k N L J43, 20 # 16, 23 # 20, I z n Z a Y B Y v H J29, 29# 16, I b t G J A X F X Y G u r T F W t s U K N J K J61, 61 # 20, I A u AA X C Y v r B Z q D a p R p V C W K J24, 12 # 12, 12 # 16, I B P 11 4 J35, 128 # 22D, M S k R 121 14 A x S 7 Z w U T T n W 122 Y L V E e Z F H d M V J J20 10 # 20,13 # 16, 4 # 12, 3 # 8 Twinax, N / Coax / Twinax 71 82 36 48 59 D f E U K J J19, 19 # 12, I T W H C U c N a a L G K D B T b S X V S P Z F 2 C Y A R R M E J11 9 # 10, 2 # 20, N B D U W F G 1 3 X D E A P N T 4 Y N M T J B 5 Z F D E C P K L J8 8 # 8 Twinax, Twinax R P U F J E z n b w c m P k N h M g L K F d x y G e f H J J90, 40 # 20, 4 # 16, 2 # 8 Twinax, I / Twinax www.conesys.com - 62 - sales@aero-electric.com 38999 S III K h k A S B N G C L M C G H K m N H J4, 8 # 16, 48 # 20, I A L BB CC p R J M AA J f g KK DD H e K EE r T t w g U F G F z B H E e y JJ B D d HH FF s E a EE V D Z CC s y P Y r HH t X q C x GG A A B c v u W C BB GG j W p A b w X B V n m S k a Z Y U MIL-DTL-5015 /AS50151 Features and Application Series III Features and Application Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. The threaded coupling, environmentally sealed MIL-DTL-5015 Series III connector with rear-removable crimp contacts was developed to replace the earlier solder type. This redesigned connector is intermateable and intermountable with the MIL-DTL-5015 Series I solder type (MS310*) as well as the MIL-DTL- 83723 Series II (USAF) crimp type and MIL-DTL-5015 Series II Front Release (MS340*). Thus, it provides for a minimum effort and high economy upgrade for existing applications. Insert Polarization - Alternate insert clocking positions aid in mating of adjacent connectors having identical insert arrangement. Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. These connectors are recommended for a wide range of applications, from commercial/industrial and mass transportation systems to the most stringent high reliability defense and aerospace requirements. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. 5015 S III This family of connectors is offered in four receptacle mounting configurations. They include two square flange receptacles, both wall and box mounting; cable connecting receptacles; and jam nut receptacles which incorporate "O" ring seals, designed for rear panel "D" hole mounting. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. Two plug styles are offered - standard plug with free rotating coupling nut with safety wire holes, and a self-locking, anti-decoupling plug, which eliminates the need for safety wiring. Eighty-eight insert arrangements per MIL-STD-1651 are tooled and qualified to MIL-DTL-5015, utilizing 1 to 85 contacts. Contacts come in sizes 16, 12, 8, 4 and 0, terminating wire sizes from 20 gauge to 0 gauge. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in both electroless nickel and olive drab cadmium to both commercial and MS callouts. Other finishes such as anodic and zinc cobalt are available upon request to commercial callouts only. In addition, we offer passivated stainless steel shells with both standard and firewall-rated inserts, and carbon steel shells with firewall inserts. Lockwiring Eliminated - Self-locking plug eliminates the need for lockwiring. www.conesys.com - 63 - sales@aero-electric.com MIL-DTL-5015 /AS50151 Performance Specifications MS345*/AE55* Performance Specifications Shock and Vibration Requirements Wired, mated connectors shall not be damaged, coupling ring shall not loosen, and there shall be no interruption of electrical continuity longer than 10 microseconds when subjected to the following: Operating Temperature Range Classes KS and LS: -55C to +200C (-67F to +392F) Classes KT,W & Z* : -55C to +175C (-67F to +347F) Class L: -55C to +200C (-67F to +392F) Class A*: -55C to +200C (-67F to +392F) Shock Mated connectors withstand a pulse of approximate half sine wave of 50 G magnitude with duration of 11 milliseconds applied in three axes per MIL-STD-1344, method 2004, test condition A. Material and Finish Data (Class) KT - carbon steel shell, olive drab cadmium, firewall KS - stainless steel shell, passivated, firewall (RoHS) L - aluminum shell, electroless nickel finish LS - stainless steel shell, passivated W - aluminum shell, olive drab cadmium over nickel base A* - aluminum shell, black anodized finish Z* - Aluminum Shell, black zinc nickel finish (RoHS) Vibration Mated connectors withstand the following vibration levels: * Random vibration per MIL-STD-1344, method 2005, and test condition VI, letter J. Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808 (lubricating oil), MIL-PRF-23699 (lubricating oil), MIL-PRF-5606 (hydraulic fluid), M2-V Chevron oil, Coolanol 25, MIL-DTL-83133 (turbine fuel JP-8), MIL-DTL-5624 (turbine fuels JP-4 and JP-5), SAE-AMS1424 Type I (defrosting fluid), and other solvents and cleaning agents. Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-5015. Durability Minimum of 100 mating cycles Voltage Rating Service Rating Maximum Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft 70,000 Ft. 110,000 Ft. V RMS V RMS V RMS V RMS AC (RMS) DC Inst. 200 250 1000 400 260 200 A 500 700 2000 600 360 200 D 900 1250 2800 675 400 200 E 1250 1750 3500 750 440 200 B 1750 2450 4500 825 480 200 C 3000 4200 7000 975 560 200 * Not MS approved, available to Aero-Electric part number only. **To be used by designer only as a guide. www.conesys.com - 64 - sales@aero-electric.com 5015 S III Shell-to-Shell Conductivity Maximum potential drop shall not exceed: * Class W = 5 millivolts * All other classes (except A*) = 50 millivolts Corrosion Resistance Classes KS and LS withstand 1,000 hour salt spray. Class KT withstands 96-hour salt spray. Class L withstands 96-hour salt spray. Class W withstands 1,000-hour salt spray. Classes A* and Z* withstand 500 hour salt spray. MIL-DTL-5015 Series III /AS50151 Part Number Development Rear Release Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS34 AE5 50 50 L L 14S 14S - 5 5 P P X X -340 Shell Type 50 = Wall mount receptacle 51 = Cable connecting receptacle 52 = Box mount receptacle 54 = Jam nut receptacle 56 = Straight plug 59 = Self-locking plug Class (Material and Finish) A = Aluminum shell, black anodized finish (Aero part number only) KS = Stainless steel shell, passivated, firewall (n/a in MS3451, MS3452, MS3454) KT = Carbon steel shell, cadmium finish, firewall (n/a in MS3451, MS3452, MS3454) LS = Stainless steel shell, passivated L = Aluminum shell, electroless nickel finish W = Aluminum shell, olive drab cadmium over electroless nickel base Z = Aluminum Shell, black zinc nickel finish (Aero p/n only) (RoHS) 5015 S III Shell Size 8S, 10S, 10SL, 12, 12S, 14, 14S, 16, 16S, 18, 20, 22, 24, 28, 32, 36 or 40 Insert Arrangement See pages 82 thru 87 Contact Style P = Pin S = Socket A = Pin connector less pins (with intent to use non-std contact) B = Socket connector less sockets (with intent to use non-std contacts) Polarization N = Normal (not included in part number) W, X, Y or Z = Alternate insert polarizations (see pages 77 thu 81 for position availability) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/31-XXX E-nut 341 = Connector kitted with M85049/52-1-XXX straight clamp 342 = Connector kitted with M85049/51-1-XXX right angle clamp Consult factory for other modifications Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 to 26 of each contact and two spares for inserts with 27 or more of each size, and a minimum of one sealing plug up to 15% of the number contacts. No spares or seal plugs are provided with one contact layouts. No spares or seal plugs for contact sizes 0 and 4 are provided. For contact size 8, no contact spares are provided, but seal plugs are included. In addition, one insertion/removal tool of each size is included. www.conesys.com Note 2: KS and KT firewall classes are only available to Military part numbers for shell types MS3450, MS3456 and MS3459. KS and KT classes are available to Aero callouts for AE551 and 554, but not for AE552 (box mount receptacle). - 65 - Note 3: Proper part number marking has no "0" in front of single digit (numeric) shell size (8S) and no "0" in front of single digit layout. Examples: J MS3450W8S-1S and J MS3450W24-2PW. Please note that J or JAN marking is required immediately in front of MS part number. sales@aero-electric.com MS3450 per AS34501 Wall Mount Receptacle AE550 Threaded Coupling, Crimp Removable, Rear Release L G MAX F D POLARIZING KEY A MATING THREAD B MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS 3 ACCESSORY TEETH J ACCESSORY THREAD 4x H HOLES BLUE COLOR BANDS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size 8S 10S 10SL 12 12S 14 14S 16 16S 18 20 22 24 28 32 36 40 Mating Thread Class 2A 1/2-28 UNEF 5/8-24 UNEF 5/8-24 UNEF 3/4-20 UNEF 3/4-20 UNEF 7/8-20 UNEF 7/8-20 UNEF 1-20 UNEF 1-20 UNEF 1 1/8-18 UNEF 1 1/4-18 UNEF 1 3/8-18 UNEF 1 1/2-18 UNEF 1 3/4-18 UNS 2-18 UNS 2 1/4-16 UN 2 1/2-16 UN www.conesys.com B .015 inch .083 .083 .083 .083 .083 .083 .083 .083 .083 .125 .125 .125 .125 .125 .125 .125 .125 D .38 mm 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 3.18 3.18 3.18 3.18 3.18 3.18 3.18 3.18 +.031 -.000 inch .562 .562 .562 .750 .562 .750 .562 .750 .562 .750 .750 .750 .812 .812 .875 .875 .875 Note 1: L max is same as L max for AE551 on next page. Note 2: Maximum grommet O.D. is same as O E max for AE551 on next page. F +.79 -.00 mm 14.27 14.27 14.27 19.05 14.27 19.05 14.27 19.05 14.27 19.05 19.05 19.05 20.62 20.62 22.23 22.23 22.23 (TP) inch mm .594 15.09 .719 18.26 .719 18.26 .812 20.62 .812 20.62 .906 23.01 .906 23.01 .969 24.61 .969 24.61 1.062 26.97 1.156 29.36 1.250 31.75 1.375 34.93 1.562 39.67 1.750 44.45 1.938 49.23 2.188 55.58 - 66 - G .031 inch .875 1.000 1.000 1.094 1.094 1.188 1.188 1.281 1.281 1.375 1.500 1.625 1.750 2.000 2.250 2.500 2.750 OH .79 mm 22.23 25.40 25.40 27.79 27.79 30.18 30.18 32.54 32.54 34.93 38.10 41.28 44.45 50.80 57.15 63.50 69.85 Classes L, LS, W +.010 +.25 -.005 -.13 inch mm .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .147 3.73 .147 3.73 .173 4.39 .173 4.39 .173 4.39 J Classes KS, KT +.010 +.25 -.005 -.13 inch mm .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .177 4.50 .177 4.50 .177 4.50 .177 4.50 .177 4.50 .209 5.31 .209 5.31 .209 5.31 Accessory Thread Class 2A 1/2-20UNF 5/8-24UNEF 5/8-24UNEF 3/4-20UNEF 3/4-20UNEF 7/8-20UNEF 7/8-20UNEF 1-20UNEF 1-20UNEF 1-1/16-18UNEF 1-3/16-18UNEF 1-5/16-18UNEF 1-7/16-18UNEF 1-3/4-18UNS 2-18UNS 2-1/4-16UN 2-1/2-16UN sales@aero-electric.com 5015 S III Page 65 Page 75 Pages 82-87 Page 64 Pages 77-81 Page 77 MS3451 per AS34511 Cable Connecting Receptacle AE551 Threaded Coupling, Crimp Removable, Rear Release L MAX R ACROSS FLATS .083.015(2.11.38) FOR 8S-16S .125.015(3.18.38) FOR 18-40 M A POLARIZING KEY MATING THREAD MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 E S MAX GROMMET 3 ACCESSORY TEETH .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS BLUE COLOR BANDS 5015 S III Page 65 Page 75 Pages 82-87 Page 64 Pages 77-81 Page 77 V GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS ACCESSORY THREAD Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Mating Thread Class 2A OE 16 & 12 Contacts inch mm M 8, 4 & 0 Contacts inch mm R +.031 -.000 inch +.79 -.00 mm OS .79 mm V Accessory Thread Class 2A inch mm .031 inch 1/2-28 UNEF .305 7.75 2.031 51.59 - - .562 14.27 .504/.496 12.80/12.60 .729 18.52 1/2-20UNF 10S 5/8-24 UNEF .405 10.29 2.031 51.59 - - .562 14.27 .629/.621 15.98/15.77 .854 21.69 5/8-24UNEF 10SL 5/8-24 UNEF .405 10.29 2.031 51.59 - - .562 14.27 .629/.621 15.98/15.77 .854 21.69 5/8-24UNEF 12 3/4-20 UNEF .549 13.94 2.125 53.98 - - .750 19.05 .754/.746 19.15/18.95 .974 24.74 3/4-20UNEF 12S 3/4-20 UNEF .549 13.94 2.031 51.59 - - .562 14.27 .754/.746 19.15/18.95 .974 24.74 3/4-20UNEF 14 7/8-20 UNEF .665 16.89 2.125 53.98 - - .750 19.05 .879/.871 22.33/22.12 1.099 27.91 7/8-20UNEF 14S 7/8-20 UNEF .665 16.89 2.031 51.59 - - .562 14.27 .879/.871 22.33/22.12 1.099 27.91 7/8-20UNEF 16 1-20 UNEF .790 20.07 2.125 53.98 2.500 63.50 .750 19.05 1.005/.996 25.53/25.30 1.224 31.09 1-20UNEF 16S 1-20 UNEF .790 20.07 2.031 51.59 - - .562 14.27 1.005/.996 25.53/25.30 1.224 31.09 1-20UNEF 18 1 1/8-18 UNEF .869 22.07 2.125 53.98 2.500 63.50 .750 19.05 1.131/1.121 28.73/28.47 1.349 34.26 1-1/16-18UNEF 1-3/16-18UNEF Shell Size 8S Maximum inch mm L MAX 20 1 1/4-18 UNEF .994 25.25 2.125 53.98 2.500 63.50 .750 19.05 1.256/1.246 31.90/31.65 1.474 37.44 22 1 3/8-18 UNEF 1.119 28.42 2.125 53.98 2.500 63.50 .750 19.05 1.381/1.371 35.08/34.82 1.599 40.61 1-5/16-18UNEF 24 1 1/2-18 UNEF 1.244 31.60 2.125 53.98 2.500 63.50 .812 20.62 1.506/1.496 38.25/38.00 1.715 43.56 1-7/16 -18UNEF 28 1 3/4-18 UNS 1.465 37.21 2.125 53.98 2.500 63.50 .812 20.62 1.756/1.746 44.60/44.35 1.974 50.14 1-3/4-18UNS 32 2-18 UNS 1.715 43.56 2.125 53.98 2.500 63.50 .875 22.23 2.007/1.996 50.98/50.70 2.224 56.49 2-18UNS 36 2 1/4-16 UN 1.930 49.02 2.125 53.98 2.500 63.50 .875 22.23 2.257/2.246 57.33/57.05 2.474 62.84 2-1/4-16UN 40 2 1/2-16 UN 2.145 54.48 2.125 53.98 2.500 63.50 .875 22.23 2.511/2.496 63.78/63.40 2.724 69.19 2-1/2-16UN www.conesys.com - 67 - sales@aero-electric.com MS3452 per AS34521 Box Mount Receptacle AE552 Threaded Coupling, Crimp Removable, Rear Release L S MAX R .083.015(2.11.38) FOR 8S-16S .125.015(3.18.38) FOR 18-40 M POLARIZING KEY A MATING THREAD GG 4x T HOLES BLUE COLOR BAND A Mating Thread Class 2A O GG L MAX M R S +.031 -.000 inch +.79 -.00 mm inch mm - .562 14.27 .594 - - .562 14.27 42.21 - - .562 42.21 - - .750 1.662 42.21 - - .016 inch .41 mm 16 & 12 Contacts inch mm 1/2-28 UNEF .500 12.70 1.662 42.21 - 10S 5/8-24 UNEF .625 15.88 1.662 42.21 10SL 5/8-24 UNEF .625 15.88 1.662 12 3/4-20 UNEF .750 19.05 1.662 12S 3/4-20 UNEF .750 19.05 Shell Size 8S Note 1: The insulation material shall be above, flush with, or no more than .015 inches (.38 mm) below the metal shell. Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization 8, 4 & 0 Contacts inch mm OT .031 inch .79 mm +.010 -.005 inch +.25 -.13 mm 15.09 .875 22.23 .120 3.05 .719 18.26 1.000 25.40 .120 3.05 14.27 .719 18.26 1.000 25.40 .120 3.05 19.05 .812 20.62 1.094 27.79 .120 3.05 .562 14.27 .812 20.62 1.094 27.79 .120 3.05 3.05 (TP) 14 7/8-20 UNEF .875 22.23 1.662 42.21 - - .750 19.05 .906 23.01 1.188 30.18 .120 14S 7/8-20 UNEF .875 22.23 1.662 42.21 - - .562 14.27 .906 23.01 1.188 30.18 .120 3.05 16 1-20 UNEF 1.000 25.40 1.662 42.21 1.937 49.20 .750 19.05 .969 24.61 1.281 32.54 .120 3.05 16S 1-20 UNEF 1.000 25.40 1.662 42.21 - - .562 14.27 .969 24.61 1.281 32.54 .120 3.05 18 1 1/8-18 UNEF 1.062 26.97 1.662 42.21 1.937 49.20 .750 19.05 1.062 26.97 1.375 34.93 .120 3.05 3.05 20 1 1/4-18 UNEF 1.187 30.15 1.662 42.21 1.937 49.20 .750 19.05 1.156 29.36 1.500 38.10 .120 22 1 3/8-18 UNEF 1.312 33.32 1.662 42.21 1.937 49.20 .750 19.05 1.250 31.75 1.625 41.28 .120 3.05 24 1 1/2-18 UNEF 1.437 36.50 1.662 42.21 1.937 49.20 .812 20.62 1.375 34.93 1.750 44.45 .147 3.73 28 1 3/4-18 UNS 1.750 44.45 1.662 42.21 1.937 49.20 .812 20.62 1.562 39.67 2.000 50.80 .147 3.73 32 2-18 UNS 2.000 50.80 1.662 42.21 1.937 49.20 .875 22.23 1.750 44.45 2.250 57.15 .173 4.39 36 2 1/4-16 UN 2.250 57.15 1.662 42.21 1.937 49.20 .875 22.23 1.938 49.23 2.500 63.50 .173 4.39 40 2 1/2-16 UN 2.500 63.50 1.662 42.21 1.937 49.20 .875 22.23 2.188 55.58 2.750 69.85 .173 4.39 www.conesys.com - 68 - sales@aero-electric.com 5015 S III Page 65 Page 75 Pages 82-87 Page 64 Pages 77-81 Page 77 MS3454 per AS34541 Jam Nut Receptacle AE554 Threaded Coupling, Crimp Removable, Rear Release E B MAX D POLARIZING KEY SPRING PIN MS171430 .180(4.57) .165(4.19) MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS .196(4.98) .186(4.72) GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS 3 ACCESSORY TEETH A C H BLUE COLOR BAND ACCESSORY THREAD "O" RING BLUE COLOR BAND F MATING THREAD PANEL THICKNESS .128(3.25) MAX .032(.81) MAX SAFETY WIRE HOLE (3 EQALLY SPACED) 5015 S III Page 65 Page 75 Pages 82-87 Page 64 Pages 77-81 Page 77 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B .13 mm .010 inch OC .25 mm .005 inch Note: Maximum grommet O.D. is same as O E max on next page. D .13 mm .005 inch E MAX .13 mm 16 & 12 Contacts inch mm 8, 4 & 0 Contacts inch mm F H Mating Thread Class 2A Accessory Thread Class 2A Shell Size 8S .005 inch 1.187 30.15 .687 17.45 1.272 32.31 .720 18.29 2.031 51.59 - - 1/2-28 UNEF 1/2-20UNF 10S 1.312 33.32 .812 20.62 1.397 35.48 .720 18.29 2.031 51.59 - - 5/8-24 UNEF 5/8-24UNEF 10SL 1.312 33.32 .812 20.62 1.397 35.48 .720 18.29 2.031 51.59 - - 5/8-24 UNEF 5/8-24UNEF 12 1.437 36.50 .937 23.80 1.522 38.66 .970 24.64 2.125 53.98 - - 3/4-20 UNEF 3/4-20UNEF 12S 1.437 36.50 .937 23.80 1.522 38.66 .720 18.29 2.031 51.59 - - 3/4-20 UNEF 3/4-20UNEF 14 1.562 39.67 1.125 28.58 1.647 41.83 .970 24.64 2.125 53.98 - - 7/8-20 UNEF 7/8-20UNEF 14S 1.562 39.67 1.125 28.58 1.647 41.83 .720 18.29 2.031 51.59 - - 7/8-20 UNEF 7/8-20UNEF 16 1.687 42.85 1.250 31.75 1.772 45.01 .970 24.64 2.125 53.98 2.500 63.50 1-20 UNEF 1-20UNEF 16S 1.687 42.85 1.250 31.75 1.772 45.01 .720 18.29 2.031 51.59 - - 1-20 UNEF 1-20UNEF 18 1.812 46.02 1.375 34.93 1.897 48.18 .970 24.64 2.125 53.98 2.500 63.50 1 1/8-18 UNEF 1-1/16-18UNEF 20 1.937 49.20 1.500 38.10 2.022 51.36 .970 24.64 2.125 53.98 2.500 63.50 1 1/4-18 UNEF 1-3/16-18UNEF 22 2.156 54.76 1.625 41.28 2.241 56.92 .970 24.64 2.125 53.98 2.500 63.50 1 3/8-18 UNEF 1-5/16-18UNEF 24 2.281 57.94 1.750 44.45 2.366 60.10 .970 24.64 2.125 53.98 2.500 63.50 1 1/2-18 UNEF 1-7/16-18UNEF 28 2.531 64.29 2.000 50.80 2.616 66.45 .970 24.64 2.125 53.98 2.500 63.50 1 3/4-18 UNS 1-3/4-18UNS 32 2.781 70.64 2.375 60.33 2.866 72.80 .970 24.64 2.125 53.98 2.500 63.50 2-18 UNS 2-18UNS 36 3.031 76.99 2.625 66.68 3.116 79.15 .970 24.64 2.125 53.98 2.500 63.50 2 1/4-16 UN 2-1/4-16UN 40 3.281 83.34 2.875 73.03 3.366 85.50 .970 24.64 2.125 53.98 2.500 63.50 2 1/2-16 UN 2-1/2-16UN www.conesys.com - 69 - sales@aero-electric.com MS3456 per AS34561 Straight Plug AE556 Threaded Coupling, Crimp Removable, Rear Release H MAX A MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 MAX POLARIZING KEYWAY .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS B E MAX GROMMET 3 TEETH EQUALLY SPACED C MATING THREAD F ACCESSORY THREAD BLUE COLOR BAND Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA OB .005 inch 5015 S III Page 65 Page 75 Pages 82-87 Page 64 Pages 77-81 Page 77 3x .035(.89) SAFETY WIRE HOLES EQUALLY SPACED C .13 mm Mating Thread Class 2B OE F Maximum inch mm Accessory Thread Class 2A H MAX 16 & 12 Contacts inch mm 8, 4 & 0 Contacts inch mm Shell Size 8S Maximum inch mm .844 21.44 .360 9.14 1/2-28 UNEF .305 7.75 1/2-20UNF 2.031 51.59 - - 10S .969 24.61 .435 11.05 5/8-24 UNEF .405 10.29 5/8-24UNEF 2.031 51.59 - - 10SL .969 24.61 .443* 11.25* 5/8-24 UNEF .405 10.29 5/8-24UNEF 2.031 51.59 - - 12 1.062 26.97 .550 13.97 3/4-20 UNEF .549 13.94 3/4-20UNEF 2.125 53.98 - - 12S 1.062 26.97 .550 13.97 3/4-20 UNEF .549 13.94 3/4-20UNEF 2.031 51.59 - - 14 1.156 29.36 .670 17.02 7/8-20 UNEF .665 16.89 7/8-20UNEF 2.125 53.98 - - 14S 1.156 29.36 .670 17.02 7/8-20 UNEF .665 16.89 7/8-20UNEF 2.031 51.59 - - 16 1.250 31.75 .800 20.32 1-20 UNEF .790 20.07 1-20UNEF 2.125 53.98 2.500 63.50 16S 1.250 31.75 .800 20.32 1-20 UNEF .790 20.07 1-20UNEF 2.031 51.59 - - 18 1.344 34.14 .925 23.50 1 1/8-18 UNEF .869 22.07 1-1/16-18UNEF 2.125 53.98 2.500 63.50 20 1.469 37.31 1.045 26.54 1 1/4-18 UNEF .994 25.25 1-3/16-18UNEF 2.125 53.98 2.500 63.50 22 1.594 40.49 1.170 29.72 1 3/8-18 UNEF 1.119 28.42 1-5/16-18UNEF 2.125 53.98 2.500 63.50 24 1.719 43.66 1.295 32.89 1 1/2-18 UNEF 1.244 31.60 1-7/16-18UNEF 2.125 53.98 2.500 63.50 28 1.969 50.01 1.515 38.48 1 3/4-18 UNS 1.465 37.21 1-3/4-18UNS 2.125 53.98 2.500 63.50 32 2.219 56.36 1.765 44.83 2-18 UNS 1.715 43.56 2-18UNS 2.125 53.98 2.500 63.50 36 2.469 62.71 1.975 50.17 2 1/4-16 UN 1.930 49.02 2-1/4-16UN 2.125 53.98 2.500 63.50 40 2.719 69.06 2.225 56.52 2 1/2-16 UN 2.145 54.48 2-1/2-16UN 2.125 53.98 2.500 63.50 * Tolerance for this dimension is .003(.08) www.conesys.com - 70 - sales@aero-electric.com MS3459 per AS34591 Self-Locking Plug AE559 Threaded Coupling, Crimp Removable, Rear Release C MAX POLARIZING KEYWAY L .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS MAX GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS D E MAX GROMMET 3 ACCESSORY TEETH A MATING THREAD MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 BLUE COLOR BAND B ACCESSORY THREAD 5015 S III Page 65 Page 75 Pages 82-87 Page 64 Pages 77-81 Page 77 Shell Size 8S Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Mating Thread Class 2B Accessory Thread Class 2A OC OD Maximum inch mm .005 inch OE L MAX .13 mm Maximum inch mm 16 & 12 Contacts inch mm 8, 4 & 0 Contacts inch mm 1/2-28 UNEF 1/2-20UNF .963 24.46 .360 9.14 .305 7.75 2.031 51.59 - - 10S 5/8-24 UNEF 5/8-24UNEF 1.088 27.64 .435 11.05 .405 10.29 2.031 51.59 - - 10SL 5/8-24 UNEF 5/8-24UNEF 1.088 27.64 .443* 11.25* .405 10.29 2.031 51.59 - - 12 3/4-20 UNEF 3/4-20UNEF 1.213 30.81 .550 13.97 .549 13.94 2.125 53.98 - - 12S 3/4-20 UNEF 3/4-20UNEF 1.213 30.81 .550 13.97 .549 13.94 2.031 51.59 - - 14 7/8-20 UNEF 7/8-20UNEF 1.358 34.49 .670 17.02 .665 16.89 2.125 53.98 - - 14S 7/8-20 UNEF 7/8-20UNEF 1.358 34.49 .670 17.02 .665 16.89 2.031 51.59 - - 16 1-20 UNEF 1-20UNEF 1.463 37.16 .800 20.32 .790 20.07 2.125 53.98 2.500 63.50 16S 1-20 UNEF 1-20UNEF 1.463 37.16 .800 20.32 .790 20.07 2.031 51.59 - - 18 1 1/8-18 UNEF 1-1/16-18UNEF 1.588 40.34 .925 23.50 .869 22.07 2.125 53.98 2.500 63.50 20 1 1/4-18 UNEF 1-3/16-18UNEF 1.713 43.51 1.045 26.54 .994 25.25 2.125 53.98 2.500 63.50 22 1 3/8-18 UNEF 1-5/16-18UNEF 1.788 45.42 1.170 29.72 1.119 28.42 2.125 53.98 2.500 63.50 24 1 1/2-18 UNEF 1-7/16-18UNEF 1.963 49.86 1.295 32.89 1.244 31.60 2.125 53.98 2.500 63.50 28 1 3/4-18 UNS 1-3/4-18UNS 2.213 56.21 1.515 38.48 1.465 37.21 2.125 53.98 2.500 63.50 32 2-18 UNS 2-18UNS 2.463 62.56 1.765 44.83 1.715 43.56 2.125 53.98 2.500 63.50 36 2 1/4-16 UN 2-1/4-16UN 2.713 68.91 1.975 50.17 1.930 49.02 2.125 53.98 2.500 63.50 40 2 1/2-16 UN 2-1/2-16UN 2.963 75.26 2.225 56.52 2.145 54.48 2.125 53.98 2.500 63.50 * Tolerance for this dimension is .003(.08) www.conesys.com - 71 - sales@aero-electric.com MIL-DTL-5015 Series III, Rear Release Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts .100(2.54) DIA. .095(2.41) C B E D MS3454 (AE554) CUTOUT A 5015 S III Flange and Jam Nut Mounting Dimensions A OB OC OD E .010 .25 Classes L, LS, W +.010 +.25 -.005 -.13 mm inch mm inch mm inch mm inch mm inch mm .594 15.09 .562 14.27 .120 3.05 .150 3.81 .505 12.83 .323 8.20 10S, 10SL .719 18.26 .688 17.48 .120 3.05 .150 3.81 .630 16.00 .385 9.78 12, 12S .812 20.62 .812 20.62 .120 3.05 .150 3.81 .755 19.18 .448 11.38 14, 14S .906 23.01 .938 23.83 .120 3.05 .150 3.81 .880 22.35 .510 12.95 (TP) Shell Size inch 8S Classes KS, KT +.010 +.25 -.005 -.13 +.015 -.000 +.38 -.00 .005 .13 16, 16S .969 24.61 1.062 26.97 .120 3.05 .150 3.81 1.005 25.53 .573 14.55 18 1.062 26.97 1.188 30.18 .120 3.05 .177 4.50 1.130 28.70 .635 16.13 20 1.156 29.36 1.312 33.32 .120 3.05 .177 4.50 1.255 31.88 .698 17.73 22 1.250 31.75 1.438 36.53 .120 3.05 .177 4.50 1.380 35.05 .760 19.30 24 1.375 34.93 1.562 39.67 .147 3.73 .177 4.50 1.505 38.23 .823 20.90 28 1.562 39.67 1.812 46.02 .147 3.73 .177 4.50 1.755 44.58 .948 24.08 32 1.750 44.45 2.062 52.37 .173 4.39 .209 5.31 2.005 50.93 1.073 27.25 36 1.938 49.23 2.312 58.72 .173 4.39 .209 5.31 2.255 57.28 1.198 30.43 40 2.188 55.58 2.562 65.07 .173 4.39 .209 5.31 2.505 63.63 1.323 33.60 www.conesys.com - 72 - sales@aero-electric.com MS25042 Protective Cover, PLUG AE542 Protective Cover, Plug Part Number Configuration MIL. Prefix Aero Prefix MS25042AE542- XX XX XX XX 5015 S III Shell Size 8 THRU 44 (Note: single digit for shell size 8) Material Finish DA = Aluminum, Hard Black Anodize D = Aluminum, Cadmium Olive Drab L = Aluminum, Electroless Nickel Plate (Aero p/n only) LS = Stainless Steel, Passivated (Aero p/n only) KT = Carbon Steel, Cadmium Olive Drab (Aero p/n only) BN = Aluminum, Black Nickel Plate (Aero p/n only) BZ = Bronze (Aero p/n only) Z = Aluminum Shell, black zinc nickel finish (RoHS)(Aero p/n only) E OD +.010 -.005 1 Link F .016 OG .016 H Min. L Max. .562 .156 4.000 .562 .375 .380 .969 .844 .687 .156 4.000 .562 .469 .380 .969 .844 .812 .156 4.500 .750 .562 .530 1.156 SHELL SIZE Coupling Shell Size A Thread Class 2A B Max. Max. 8 8S .500-28 UNEF .656 10 10S, 10SL .625-24 UNEF 12 12, 12S .750-20 UNEF OC 14 14, 14S .875-20 UNEF .844 0.937 .156 4.500 .750 .688 .530 1.156 16 16, 16S 1.000-20 UNEF .844 1.062 .156 4.500 .750 .812 .530 1.156 18 18 1.125-18 UNEF .844 1.187 .156 4.500 .750 .938 .530 1.156 20 20 1.250-18 UNEF .844 1.312 .187 5.000 .750 1.062 .530 1.156 22 22 1.375-18 UNEF .844 1.437 .187 5.000 .750 1.188 .530 1.156 24 24 1.500-18 UNEF .844 1.562 .187 5.500 .750 1.312 .530 1.156 28 28 1.750-18 UNS .844 1.812 .187 7.750 .750 1.531 .530 1.156 32 32 2.000-18UNS .844 2.062 .218 7.750 .750 1.781 .530 1.156 36 36 2.250-16 UN .844 2.312 .218 7.750 .750 2.000 .530 1.156 40 40 2.500-16 UN .844 2.562 .218 7.750 .750 2.250 .530 1.156 44 44 2.750-16 UN .844 2.812 .218 7.750 .750 2.500 .590 1.156 www.conesys.com - 73 - sales@aero-electric.com MS25043 Protective Cover, Receptacle AE543 Protective Cover, Receptacle Part Number Configuration MIL. Prefix Aero Prefix MS25043AE543- XX XX XX XX 5015 S III Shell Size 8 THRU 44 (Note: single digit for shell size 8) Material Finish DA = Aluminum, Hard Black Anodize D = Aluminum, Cadmium Olive Drab L = Aluminum, Electroless Nickel Plate (Aero p/n only) LS = Stainless Steel, Passivated (Aero p/n only) KT = Carbon Steel, Cadmium Olive Drab (Aero p/n only) BN = Aluminum, Black Nickel Plate (Aero p/n only) BZ = Bronze (Aero p/n only) Z = Aluminum Shell, black zinc nickel finish (RoHS) (Aero p/n only) E Coupling Shell Size A Thread Class 2B B Max. OC Max. OD +.010 -.005 1 Link L Max. 8 8S .500-28 UNEF .469 .688 .140 4.000 .750 10 10S, 10SL .625-24 UNEF .469 .813 .140 4.000 .750 SHELL SIZE 12 12, 12S .750-20 UNEF .469 1.000 .140 4.500 .750 14 14, 14S .875-20 UNEF .469 1.125 .140 4.500 .750 16 16, 16S 1.000-20 UNEF .469 1.188 .140 4.500 .750 18 18 1.125-18 UNEF .469 1.344 .140 4.500 .750 20 20 1.250-18 UNEF .469 1.469 .140 5.000 .750 22 22 1.375-18 UNEF .469 1.594 .140 5.000 .750 24 24 1.500-18 UNEF .469 1.719 .171 5.500 .750 28 28 1.750-18 UNS .531 1.969 .171 7.750 .812 32 32 2.000-18UNS .531 2.219 .187 7.750 .812 36 36 2.250-16 UN .531 2.469 .187 7.750 .812 40 40 2.500-16 UN .531 2.718 .187 7.750 .812 44 44 2.750-16 UN .531 2.969 .187 7.750 .812 www.conesys.com - 74 - sales@aero-electric.com MIL-DTL-5015 series III/AS50151 Contacts, Tools and Seal Plugs MS345*/AE55* Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Plastic Contact Size Type Military No. Military No. 16S Power/Signal N/A M39029/30-217 16 Power/Signal M39029/29-212 M39029/30-218 12 Power/Signal M39029/29-213 8 Power 4 0 Military No. Military No. MS27488-16-1 M81969/14-03 M39029/30-219 MS27488-12-1 M81969/14-04 M39029/29-214* M39029/30-220* MS27488-8-1 M81969/14-06 Power M39029/29-215* M39029/30-221* MS27488-4-1** M81969/14-07 Power M39029/29-216* M39029/30-222* MS27488-0-1** M81969/14-08 Locator Extraction Tool * No spare size 0, 4 and 8 contacts are provided in connector contact packages. ** Not supplied as part of connector contact packages. Crimping and Metal Insertion/Extraction Tools Crimp Tool Positioner Die Set Pin & Socket Contacts Pin & Socket Contacts Pin & Socket Contacts Metal 5015 S III Contact Size Military No. Military No. Military No. Military No. Military No. 16/16S M22520/1-01 M22520/1-02 N/A N/A M81969/8-208 12 M22520/1-01 M22520/1-02 N/A N/A M81969/8-210 8 M22520/23-01 N/A M22520/23-02 M22520/23-09 M81969/15-01 4 M22520/23-01 N/A M22520/23-03 M22520/23-11 M81969/15-02 0 M22520/23-01 N/A M22520/23- 04 M22520/23-13 M81969/15-03 Contact and Wire Data Contact Size 16/16S Test Current Voltage DC Test Max. Drop Crimp Well Data Well Dia. Wire Range Minimum Well Dept Finished Wire O Range Minimum Amps Millivolts inch inch mm AWG mm2 13 49 .067 .001 .250 6.35 20-16 0.52-1.31 Maximum inch mm inch mm .053 1.35 .103 2.62 12 23 42 .100 .002 .250 6.35 14-12 2.08-3.31 .085 2.16 .158 4.01 8 46 26 .181 .002 .485 12.32 10-8 5.26-8.37 .132 3.35 .255 6.48 4 80 23 .281 .002 .485 12.32 6-4 13.30-21.15 .237 6.02 .370 9.40 0 150 21 .453 .002 .580 14.73 2-0 33.63-53.48 .360 9.14 .550 13.97 MS3348 bushings required in crimp barrel to accommodate 10, 6 and 2 wire gauges. Bushings are ordered separately. Note 1: 16S socket contacts are only used in shell sizes 8S, 10S, 10SL, 12S, 14S and 16S. Note 3: Metal Insertion tool is not req'd for size 8, 4 and 0 contacts. Metal insertion tool for size 16 contacts = M81969/8-207. Metal insertion tool for size 12 contacts = M81969/8-209. Note 2: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com - 75 - sales@aero-electric.com MIL-DTL-5015 series III/AS50151 Contact Installation Instructions MS345*/AE55* Contact Installation Instructions 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. Size Pin Contact Socket Contact Crimp Tool Positioner Die Set Locator I/R Tool 16S* -- M39029/30-217 M22520/1-01 M22520/1-02 Blue -- -- M81969/14-03 16 M39029/29-212 M39029/30-218 M22520/1-01 M22520/1-02 Blue -- -- M81969/14-03 12 M39029/29-213 M39029/30-219 M22520/1-01 M22520/1-02 Yellow -- -- M81969/14-04 8 M39029/29-214 M39029/30-220 M22520/23-01 -- M22520/23-02 M22520/23-09 M81969/14-06 4 M39029/29-215 M39029/30-221 M22520/23-01 -- M22520/23-04 M22520/23-11 M81969/14-07 0 M39029/29-216 M39029/30-222 M22520/23-01 -- M22520/23-05 M22520/23-13 M81969/14-08 I/R = Insertion/Removal * 16S socket contact is only used in shell sizes 8S, 10S, 10SL, 12S, 14S and 16S. www.conesys.com - 76 - sales@aero-electric.com 5015 S III 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. MIL-DTL-5015 series III/AS50151 Polarization, Insert Availability & Contact Information per MIL-STD-1651 Polarization (Insert Clocking) 1. In the normal insert clocking position (position N), the insert centerline coincides with the centerline of the master keyway (key) of the shell: L = 0. L MASTER KEYWAY(KEY) OF A SHELL 2. In the alternate clocking positions (W, X, Y and Z), the pin insert (viewing from mating side) is rotated clockwise relative to the centerline of the master keyway (key) of the shell. 3. The socket insert is rotated counter-clockwise. 4. Plugs have keyways; receptacles have keys. INSERT VERTICAL CENTERLINE Note: Be careful with alternate positions. See table below for position availability on layouts of interest. PIN INSERT MATING FACE (SOCKET INSERT IS OPPOSITE) Insert Availability, Contact Information and Clocking Positions 5015 S III Shell Size & Insert Arrangement Aero-Electric Status Contacts Total Insert Positions Service Contact QPL'd Tooled Number Qty Quantity by Size Size Rating Location N W "L" Degrees X Y Z 8S-1 Yes Yes 1 1 16/16S** A All 0 -- -- -- -- 10S-2 Yes Yes 1 1 16/16S** A All 0 -- -- -- -- 10SL-3*** Yes Yes 3 3 16/16S** A All 0 -- -- -- -- 10SL-4 Yes Yes 2 2 16/16S** A All 0 -- -- -- -- 12-5 Yes Yes 1 1 12 D All 0 -- -- -- -- 12S-3 Yes Yes 2 2 16/16S** A All 0 70 145 215 290 12S-4 Yes Yes 1 1 16/16S** D All 0 -- -- -- -- 14-3 Yes Yes 1 1 8 A All 0 -- -- -- -- 14S-1* Yes Yes 3 3 16/16S** A All 0 -- -- -- -- 14S-2 Yes Yes 4 4 16/16S** Inst. All 0 -- 120 240 -- 14S-5 Yes Yes 5 5 16/16S** Inst. All 0 -- 110 -- -- 14S-6 Yes Yes 6 6 16/16S** Inst. All 0 -- -- -- -- 14S-7 Yes Yes 3 3 16/16S** A All 0 90 180 270 -- 14S-9* Yes Yes 2 2 16/16S** A All 0 70 145 215 290 16-10 Yes Yes 3 3 12 A All 0 90 180 270 -- 16-11 Yes Yes 2 2 12 A All 0 35 110 250 325 16-12 Yes Yes 1 1 4 A All 0 -- -- -- -- 16S-1 Yes Yes 7 7 16/16S** A All 0 80 -- -- 280 16S-4 Yes Yes 2 2 16/16S** D All 0 35 110 250 325 16S-5* Yes Yes 3 3 16/16S** A All 0 70 145 215 290 16S-8 Yes Yes 5 5 16/16S** A All 0 -- 170 265 -- * Inactive for new design ** Pin contact is size 16, socket contact is size 16S *** Service Rating = Inst. for classes KS and KT only. www.conesys.com - 77 - sales@aero-electric.com MIL-DTL-5015 series III/AS50151 Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Shell Size & Insert Arrangement Contacts Aero-Electric Status QPL'd Total Tooled Number 18-1 Yes Yes 10 18-4 Yes Yes 4 18-5 Yes Yes 3 18-6 Yes Yes 1 18-8 Yes Yes 8 18-9 Yes Yes 7 18-10* Yes Yes 18-11 Yes Yes 18-12 Yes Yes Insert Positions Quantity by Size Service Contact Qty Size Rating Location 4 16 A B,C,F,G 6 16 Inst. All others D 4 16 1 16 2 12 1 4 7 16 1 12 "L" Degrees N W X Y Z 0 70 145 215 290 All 0 35 110 250 325 D All 0 80 110 250 280 D -- 0 -- -- -- -- A All 0 70 -- -- 290 Inst. All 0 80 110 250 280 -- 5 16 2 12 4 4 12 A All 0 -- 120 240 5 5 12 A All 0 -- 170 265 -- 6 6 16 A All 0 80 -- -- 280 Yes Yes 5 5 16 A All 0 90 180 270 -- Yes Yes 1 1 0 D --- 0 -- -- -- -- 20-3* Yes Yes 3 3 12 D All 0 70 145 215 290 20-4 Yes Yes 4 4 12 D All 0 45 110 250 -- 4 16 D A,B,G,H 4 16 A All others 0 80 110 250 280 Inst. All 0 80 110 250 280 Inst. All 0 -- -- -- -- A All 0 80 110 250 280 A All 0 80 -- -- 280 A All 0 80 110 250 280 A All 0 90 180 270 -- A All 0 35 110 250 325 A All 0 80 110 250 280 A All 0 35 110 250 325 20-7 Yes Yes 8 20-8 Yes Yes 6 20-11* Yes Yes 13 20-14 Yes No 5 20-15 Yes Yes 7 20-16 Yes Yes 9 20-17 Yes Yes 6 20-18 Yes Yes 9 20-22 Yes Yes 6 20-24* Yes Yes 4 4 16 2 8 13 16 3 12 2 8 7 12 7 16 2 12 1 16 5 12 6 16 3 12 3 16 3 8 2 16 2 8 20-27 Yes Yes 14 14 16 A All 0 35 110 250 325 20-29 Yes Yes 17 17 16 A All 0 80 -- -- 280 20-33 Yes Yes 11 11 16 A All 0 -- -- -- -- 22-1* Yes Yes 2 2 8 D All 0 35 110 250 325 * Inactive for new design www.conesys.com - 78 - sales@aero-electric.com 5015 S III 18-20* 20-2 MIL-DTL-5015 series III/AS50151 Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Shell Size & Insert Arrangement 22-2 Aero-Electric Status Contacts Service Contact QPL'd Tooled Number Qty Size Rating Location N W X Y Z Yes Yes 3 3 8 D All 0 70 145 215 290 22-9 Yes Yes 3 3 12 E All 0 70 145 215 290 22-12 Yes Yes 5 3 16 2 8 D All 0 80 110 250 280 22-13* Yes Yes 5 0 35 110 250 325 22-14** Yes Yes 19 0 80 110 250 280 0 80 110 250 280 22-18 Yes Total Insert Positions Yes 8 Quantity by Size 1 16 D E 4 12 A All others 19 16 A All 3 16 A C,D,E 5 16 D All others "L" Degrees 5015 S III 22-19 Yes Yes 14 14 16 A All 0 80 110 250 280 22-20* Yes Yes 9 9 16 A All 0 35 110 250 325 22-22 Yes Yes 4 4 8 A All 0 -- 110 250 -- 1 12 D H 7 12 A All others 0 35 -- 250 -- 1 8 D J 8 16 A All others 0 80 -- 250 280 0 80 110 250 280 22-23 Yes Yes 8 22-27 Yes Yes 9 22-33* Yes Yes 7 24-2 Yes Yes 7 24-4 Yes Yes 4 24-6 Yes Yes 8 24-7 Yes Yes 16 24-9* Yes Yes 24-10 Yes Yes 24-11 Yes Yes 9 24-12 Yes Yes 5 24-20 Yes Yes 11 24-21 Yes No 10 3 16 A E,F,G 4 16 D All others D All 0 80 -- -- 280 D All 0 80 110 250 280 0 80 110 250 280 0 80 110 250 280 7 12 3 16 1 0 3 12 D A,G,H 5 12 A All others A All 14 16 2 12 2 2 4 A All 0 35 110 250 325 7 7 8 A All 0 80 -- -- 280 6 12 3 8 A All 0 35 110 250 325 3 12 2 4 A All 0 80 110 250 280 D All 0 80 110 250 280 D All 0 80 110 250 280 9 16 2 12 9 16 1 8 24-22 Yes Yes 4 4 8 D All 0 45 110 250 -- 24-27 Yes Yes 7 7 16 E All 0 80 -- -- 280 24-28 Yes Yes 24 24 16 Inst. All 0 80 110 250 280 * Inactive for new design ** Alternate positions X, Y are cancelled after June 26, 1968. www.conesys.com - 79 - sales@aero-electric.com MIL-DTL-5015 series III/AS50151 Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Shell Size & Insert Arrangement 28-1 Aero-Electric Status QPL'd Yes Contacts Total Tooled Yes Number 9 Insert Positions Quantity by Size Service Contact Qty Size Rating Location 2 12 D A,E 4 12 A B,D,F,H 1 8 D J A G,C D 2 8 12 16 2 12 8 "L" Degrees N W X Y Z 0 80 110 250 280 All 0 35 110 250 325 E All 0 70 145 215 290 D All 0 35 110 250 325 L,M 0 80 110 250 280 Yes Yes 14 28-3 Yes Yes 3 3 2 16 28-5 Yes Yes 5 1 12 2 4 2 12 E 1 16 D B 9 16 A All others D All 0 80 110 250 280 A All 0 80 110 250 280 28-8 Yes Yes 12 28-9 Yes Yes 12 28-11 Yes Yes 22 6 16 6 12 18 16 4 12 28-12 Yes Yes 26 26 16 A All 0 90 180 270 -- 28-15 Yes Yes 35 35 16 A All 0 80 110 250 280 28-16* Yes Yes 20 20 16 A All 0 80 110 250 280 2 16 B H,M D A,B 0 80 110 250 280 A All others A All 0 80 110 250 280 A All 0 80 110 250 280 D All 0 70 145 215 290 0 80 110 250 280 28-19 Yes Yes 10 28-20 Yes Yes 14 28-21 Yes Yes 37 28-22 Yes Yes 6 32-1 Yes Yes 5 32-3 Yes Yes 9 32-5* Yes Yes 2 32-6 Yes Yes 23 2 16 2 16 4 12 4 16 10 12 37 16 3 16 3 4 1 12 2 12 2 0 4 16 2 12 2 4 1 0 2 0 16 16 2 12 3 8 2 4 E D A D,C B,E D All 0 80 110 250 280 D All 0 80 110 250 325 A All 0 80 110 250 280 * Inactive for new design www.conesys.com - 80 - sales@aero-electric.com 5015 S III 28-2 MIL-DTL-5015 series III/AS50151 Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Shell Size & Insert Arrangement 32-7 32-8* 32-10* 32-15 Aero-Electric Status QPL'd Yes Yes Yes Yes Contacts Total Tooled Yes Yes Yes Yes Number 35 30 7 8 Insert Positions Quantity by Size Service Contact Qty Size Rating Location 4 16 Inst. A,B,h,j 24 16 7 12 A All others A All A,F 24 16 6 12 "L" Degrees N W X Y Z 0 80 125 235 280 0 80 125 235 280 0 80 110 250 280 280 2 16 E 1 16 B G 2 8 D B,E 2 4 A C,D 6 12 2 0 D All 0 35 110 250 5015 S III 32-17 Yes Yes 4 4 4 D All 0 45 110 250 --- 32-22** Yes Yes 54 54 16 A All 0 80 110 250 280 32-63 Yes Yes 5 5 4 D All 0 -- -- -- -- 32-73 Yes Yes 46 46 16 A All 0 36 -- -- -- 36-3 Yes No 6 3 12 3 0 D All 0 70 145 215 290 36-5 Yes Yes 4 A All 0 -- 120 240 -- A All 0 35 110 250 325 A All 0 80 110 250 280 A All 0 80 110 250 280 A All 0 80 125 235 280 A All 0 80 125 235 280 A All 0 65 125 225 310 A All 0 72 144 216 288 36-6 Yes Yes 6 36-7 Yes Yes 47 36-8 Yes Yes 47 36-9 36-10 40-10 40-56 Yes Yes Yes Yes Yes Yes Yes Yes 31 48 29 85 4 0 4 4 2 0 40 16 7 12 46 16 1 12 14 16 14 12 2 8 1 4 48 16 16 16 9 8 4 4 85 16 * Inactive for new design ** Alternate positions U (100 degrees) and V (260 degrees) are also available per MIL-STD-1651. www.conesys.com - 81 - sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangement Views C A C A A B B A B B 8S-1 1- #16 10S-2 1- #16 10SL-3 3- #16 A D 12S-3 2- #16 14-3 1- #8 12S-4 1- #16 E A B C A C A B B A C D E B C B D 14S-2 4- #16 14S-1* 3- #16 A F A C 12-5 1- #12 10SL-4 2- #16 14S-5 5- #16 B B 14S-6 6- #16 14S-7 3- #16 16-10 3- #12 14S-9* 2- #16 16-11 2- #12 H E F A A D G E B B A B C J D 16S-1 7- #16 16S-4 2- # 16 16S-5* 3- #16 18-1 10- #16 16S-8 5- #16 G F A D A F A E C B 18-5 1- #16, 2- #12 18-6 1- #4 C D C B 18-8 7- #16, 1- #12 A 18-9 5- #16, 2- #12 18-10* 4- #12 F E A B B D 18-4 4- #16 D B G H C C E A B A E D A A E B C C B D B C D C 18-11 5- #12 18-12 6- #16 18-20* 5- # 16 20-2 1- #0 20-3* 3- #12 * Inactive for new design www.conesys.com - 82 - sales@aero-electric.com 5015 S III C F B C E 16-12 1- #4 B A C D A I G MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangement Views A D L C B A G E C B E B F A E M F D H G F C C B 20-8 4- #16, 2- #8 20-11* 13- #16 F G G E B 20-14 3- #12, 2- #8 E F G B C J D 20-7 8- #16 A E A D 20-4 4- #12 F A D E K H N D A E A D B A F H I H F I B D A C D C C B 5015 S III 20-15 7- #12 20-16 7- #16, 2- #12 20-17 1- #16, 5- #12 A M A J K H L C 20-22 3- #16, 3- #8 A B J M D K C H E D H E 20-27 14- #16 D F F G E 20-29 17- #16 20-33 11- #16 22-1* 2- #8 A A A B L R J M F 20-24* 2- #16, 2- #8 K P S C B B N G 20-18 6- #16, 3- #12 C T B C N L I D C A D E B L D A M A A U K E C B B B C 22-9 3- #12 V S B P R C D B C 22-12 3- #16, 2- #8 N T H C D 22-2 3- #8 J E G 22-13* 1- #16, 4- #12 F E 22-14 19- #16 * Inactive for new design www.conesys.com - 83 - sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangement Views G A G B K A G L A F M P B H A D A C J F H F J H B B N H D C E G E E C D E B C C F D 22-18 8- #16 D 22-19 14- #16 22-20* 9- #16 22-22 4- #8 22-23 8- #12 C A F D B H A G A D B A F J E C B H G G B C B E A D F 22-33* 7- #16 24-2 7- #12 A 24-4 3- #16, 1- #0 A A F B M J C D 22-27 1- #8, 8- #16 K E C D 5015 S III E L F G B 24-6 8- #12 C A E C N P E B D B A D E F G B I E O D H F C D G G 24-7 14- #16, 2- #12 24-9* 2- #4 A 24-10 7- #8 24-11 6- #12, 3- #8 A J B A L E B F G K A A D C 24-12 3- #12, 2- #4 G K J K F D C E 24-20 9- #16, 2- #12 G F L B E 24-21 9- #16, 1- #8 C E M H N S R F D C J C G D B B H H C J H W U T X Y Q P V Z D 24-22 4- #8 24-27 7- #16 24-28 24- #16 * Inactive for new design www.conesys.com - 84 - sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangement Views K H A A J J G A A B L H C B P M C E G F E F 28-1 6- #12, 3- #8 28-2 12- #16, 2- #12 G G L 5015 S III E P K L S R X Y a Z e d M U T V W S H R E E G D P h G F C M U a E 28-19 6- #16, 4- #12 28-16* 20- #16 V A E A C R n p X e d k r 28-21 37- #16 D f E F B Z D m J G s D B 28-22 3- #16, 3- #4 C 32-1 3- #12, 2- #0 * Inactive for new design www.conesys.com B C J P W j h 28-20 4- #16, 10- #12 A F H N c b g D F H D G F T C L G J E E S P m B L B K M 28-15 35- #16 A H N K N A J C k l K U V G 28-12 26- #16 B L C M F H M c g j A E W J 28-11 18- #16, 4- #12 B L T I M N b f A K J J T X K D D G F D Y L H X 28-9 6- #16, 6- #12 B E U V L S C A H C W F 28-8 2- #12, 10- #16 T b Z M C a d K D B G R C B S N F K V B B M C A P A P U J D R E N K E C 28-5 2- #16, 1- #12, 2- #4 J A H F D 28-3 3- #8 J A L B C E H M D N D B - 85 - H 32-3 4- #16, 2- #12, 2- #4, 1- #0 sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangement Views E B A C A d h R P S S Y e k V f T g V 32-6 16- #16, 2- #12, 3- #8, 2- #4 32-5* 2- #0 C N J a W P X R I b G S 32-8* 24- #16, 6- #12 A D N E b C P U T X Y c j AD 32-15 6- #12, 2- #0 21 20 E 17 22 37 B 33 46 2 32-63 5- #4 B 7 28 30 12 6 27 40 D 8 13 C B D E 26 3 41 31 14 5 38 42 32 15 F 4 24 25 45 43 16 3 23 34 AC AE AG A 35 44 AA v A 2 36 18 r y 32-22 54- #16 1 1 A D 32-17 4- #4 k u x f q p AF 32-10* 3- #16, 2- #8, 2- #4 e t w W a d z G R V Z h n s AB B J M C 11 C 10 32-73 46- #16 36-3 3- #12, 3- #0 36-5 4- #0 * Inactive for new design www.conesys.com - 86 - sales@aero-electric.com 5015 S III F C D E H O g m H L K S D G A C B B C D E C F L U 32-7 28- #16, 7- #12 B B K D F G E V d e A I O A A F H O b X W G M a U c Z B B U L D N F j Z T Y K A M L O N J R H T E X H I K M J c F G P W D MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangement Views A A B E F M Z Y e n C x b v A M C U I Y d w v y z 36-8 46- #16, 1- #12 A C D B E G F E F H G D J H K L 5015 S III d V E J P Y H O A V B W e M N W Y U T K a Z I c b X L R T L M O N Q P f C F b c S R X e d K f Q P j r t J a e h p x B D a Z u s R V k n y z L U c g m 36-7 40- #16, 7- #12 O Z H P T f p w r 36-6 4- #4, 2- #0 S K s u D M X m g k t J O W c f j E S b a d h N X W F I T S V D G N R P U E J I L O C B G H K B F A D C R U S G T W V X Y N b Z 36-9 14- #16, 14- #12, 2- #8, 1- #4 36-10 48- #16 A E N X h F P Y j i t AC AP k m v w AD AE AF AR AS AT BA BJ BL BS d y W q z AA AB AN AK AL AM AV AW AX BE BN BU s r AJ BD g f AU BM BT M V p x BC BB BK c n AH L U b u AZ K T a Z D J S R 40-10 16- #16, 9- #8, 4- #4 C B H a c BF BP AY BH BR BV 40-56 85- #16 www.conesys.com - 87 - sales@aero-electric.com MIL-DTL-5015 Series III Integrated Rear Banding Platform Part Number Development Part Number Configuration Aero Prefix AE05- 440- L 24- 10 P W INTEGRATED REAR Shell Type 440 = Wall Mount Receptacle (Ref: MS3450) 442 = Jam Nut Receptacle (Ref: MS3454) 443 = Straight Plug (Ref: MS3456) Material & Finish A = Aluminum Shell, Black Anodized Finish KS = Stainless Shell, Passivated Finish, Firewall (RoHS) KT = Ferrous Alloy Shell, Olive Drab Cadmium Finish, Firewall L = Aluminum Shell, Electroless Nickel Finish LS = Stainless Steel, Passivated Finish (RoHS) W = Aluminum Shell, Olive Drab Cadmium Finish BN = Aluminum Shell, black nickel finish (RoHS) Z = Aluminum shell, Black Zinc Nickel finish (RoHS) Shell Size 8S, 10S, 10SL, 12, 12S, 14, 14S, 16, 16S, 18, 20, 22, 24, 28, 32, 36, 40 Insert Arrangement Per MIL-STD-1651 Contact Style P = Pin S = Socket Polarization (Keying) N = Normal = Blank Alternative Polarization = W, X, Y and Z www.conesys.com - 88 - sales@aero-electric.com MIL-DTL-5015 Series III Integrated Rear Banding Platform Wall Mount Receptacle (MS3450) AE05-440 Receptacle Connector, Wall Mount, with integrated Rear Banding Platform INTEGRATED REAR SHELL SIZE A COUPLING THREAD CLASS 2A B .015 C MAX D +.031 -.000 OE MAX F (T.P.) OH +.010 -.005 G .031 ALUMINUM STEEL 8S .500-28 UNEF .083 2.031 .562 .505 .594 .875 .120 .150 10S .625-24 UNEF .083 2.031 .562 .632 .719 1.000 .120 .150 10SL .625-24 UNEF .083 2.031 .562 .632 .719 1.000 .120 .150 12 .750-20 UNEF .083 2.125 .750 .755 .812 1.094 .120 .150 12S .750-20 UNEF .083 2.031 .562 .755 .812 1.094 .120 .150 14 .875-20 UNEF .083 2.125 .750 .880 .906 1.188 .120 .150 14S .875-20 UNEF .083 2.031 .562 .880 .906 1.188 .120 .150 16 1.000-20 UNEF .083 2.500 .750 1.005 .969 1.281 .120 .150 16S 1.000-20 UNEF .083 2.031 .562 1.005 .969 1.281 .120 .150 18 1.125-16 UNEF .125 2.500 .750 1.065 1.062 1.375 .120 .177 20 1.250-18 UNEF .125 2.500 .750 1.190 1.156 1.500 .120 .177 22 1.375-18 UNEF .125 2.500 .750 1.315 1.250 1.625 .120 .177 24 1.500-18 UNEF .125 2.500 .812 1.440 1.375 1.750 .147 .177 28 1.750-18 UNS .125 2.500 .812 1.750 1.562 2.000 .147 .177 32 2.000-18 UNS .125 2.500 .875 2.000 1.750 2.250 .173 .209 36 2.250-16 UN .125 2.500 .875 2.250 1.938 2.500 .173 .209 40 2.500-16 UN .125 2.500 .875 2.500 2.188 2.750 .173 .209 www.conesys.com - 89 - sales@aero-electric.com MIL-DTL-5015 Series III Integrated Rear Banding Platform Jam Nut Receptacle (MS3454) AE05-442 Receptacle Connector, Jam Nut, with integrated rear banding platform INTEGRATED REAR www.conesys.com SHELL SIZE A B .010 OC D OE MAX F THREAD-2A G MAX 8S 1.187 .687 1.272 .720 .505 .500-28 UNEF 2.031 10S 1.312 .812 1.397 .720 .632 .625-24 UNEF 2.031 10SL 1.312 .812 1.397 .720 .632 .625-24 UNEF 2.031 12 1.437 .937 1.522 .970 .755 .750-20 UNEF 2.125 12S 1.562 .937 1.522 .720 .755 .750-20 UNEF 2.031 2.125 14 1.562 1.125 1.647 .970 .880 .875-20 UNEF 14S 1.562 1.125 1.647 .720 .880 .875-20 UNEF 2.031 16 1.687 1.250 1.772 .970 1.005 1.000-20 UNEF 2.500 16S 1.687 1.250 1.772 .720 1.005 1.000-20 UNEF 2.031 18 1.812 1.375 1.897 .970 1.065 1.125-18 UNEF 2.500 20 1.937 1.500 2.022 .970 1.190 1.250-18 UNEF 2.500 22 2.156 1.625 2.241 .970 1.315 1.375-18 UNEF 2.500 24 2.281 1.750 2.366 .970 1.440 1.500-18 UNEF 2.500 28 2.531 2.000 2.616 .970 1.750 1.750-18 UNS 2.500 32 2.781 2.375 2.866 .970 2.000 2.000-18 UNS 2.500 36 3.031 2.625 3.116 .970 2.250 2.250-16 UN 2.500 40 3.281 2.875 3.366 .970 2.500 2.500-16 UN 2.500 - 90 - sales@aero-electric.com MIL-DTL-5015 Series III Integrated Rear Banding Platform Straight Plug (MS3456) AE05-443 Straight Plug Connector, with integrated Rear Banding Platform INTEGRATED REAR www.conesys.com SHELL SIZE A COUPLING THREAD CLASS 2B OB MAX C MAX OD MAX 8S .500-28 UNEF .844 2.031 .505 10S .625-24 UNEF .969 2.031 .632 10SL .625-24 UNEF .969 2.031 .632 12 .750-20 UNEF 1.062 2.125 .755 12S .750-20 UNEF 1.062 2.031 .755 14 .875-20 UNEF 1.156 2.125 .880 14S .875-20 UNEF 1.156 2.031 .880 16 1.000-20 UNEF 1.250 2.500 1.005 16S 1.000-20 UNEF 1.250 2.031 1.005 18 1.125-18 UNEF 1.344 2.500 1.065 20 1.250-18 UNEF 1.469 2.500 1.190 22 1.375-18 UNEF 1.594 2.500 1.315 24 1.500-18 UNEF 1.719 2.500 1.440 28 1.750-18 UNS 1.969 2.500 1.750 32 2.000-18 UNS 2.219 2.500 2.000 36 2.250-16 UN 2.469 2.500 2.250 40 2.500-16 UN 2.719 2.500 2.500 - 91 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform Part Number Configuration Part Number Configuration Aero Prefix AE15- 469- L 18- 8 P W INTEGRATED REAR Shell Type 469 = Rear, narrow flange (Ref: MS3470) 470 = Rear, cable connecting receptacle (Ref: MS3471) 471= Rear, wide flange receptacle (Ref: MS3472) 472= Rear, jam nut receptacle (Ref: MS3474) 473= Rear, RFI plug (Ref: MS3475) 474= Rear, straight plug (Ref: MS3476) Material Finish L = Aluminum Shell, Electroless Nickel Finish W = Aluminum Shell, Olive Drab Cadmium Finish BN = Aluminum Shell, black nickel finish (RoHS)(not available for AE15-473 (ref: MS3475)) Z = Aluminum shell, Black Zinc Nickel finish (RoHS), (not available for AE15473, ref: MS3475) Shell Size 8, 10, 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL -STD-1669 Contact Style P = Pin S = Socket Polarization (Keying) Normal = Blank Alternative Polarization = W, X, Y and Z www.conesys.com - 92 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform Narrow Flange Receptacle (MS3470) AE15-469 Receptacle Connector, Narrow Flange, with integrated Rear Banding Platform INTEGRATED REAR www.conesys.com SHELL SIZE A MAX B OC D MAX E F OG MAX 8 .828 .599/.589 .120 1.410 .078/.046 .462/.431 .505 10 .964 .724/.714 .120 1.410 .078/.046 .462/.431 .632 12 1.047 .817/.807 .120 1.410 .078/.046 .462/.431 .755 14 1.141 .911/.901 .120 1.410 .078/.046 .462/.431 .880 16 1.234 .974/.964 .120 1.410 .078/.046 .462/.431 1.005 18 1.328 1.067/1.057 .120 1.410 .078/.046 .462/.431 1.065 20 1.453 1.161/1.151 .120 1.475 .110/.078 .587/.556 1.190 22 1.578 1.255/1.245 .120 1.475 .110/.078 .587/.556 1.315 24 1.703 1.380/1.370 .147 1.475 .110/.078 .587/.556 1.440 - 93 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform Cable Connecting Receptacle (MS3471) AE15-470 Receptacle Connector, Cable Connecting, with integrated rear banding platform INTEGRATED REAR www.conesys.com SHELL SIZE A MAX OB C MAX D E OF MAX 8 .828 .958/.918 1.410 .078/.046 .462/.431 .505 10 .964 1.082/1.042 1.410 .078/.046 .462/.431 .632 12 1.047 1.176/1.136 1.410 .078/.046 .462/.431 .755 14 1.141 1.270/1.230 1.410 .078/.046 .462/.431 .880 16 1.234 1.364/1.324 1.410 .078/.046 .462/.431 1.005 18 1.328 1.458/1.418 1.410 .078/.046 .462/.431 1.065 20 1.453 1.582/1.542 1.475 .110/.078 .587/.556 1.190 22 1.578 1.708/1.668 1.475 .110/.078 .587/.556 1.315 24 1.703 1.832/1.792 1.475 .110/.078 .620/.589 1.440 - 94 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform Wide Flange Receptacle (MS3472) AE15-471 Receptacle Connector, Wide Flange, with integrated Rear Banding Platform INTEGRATED REAR www.conesys.com SHELL SIZE A MAX B OC MAX D MAX E F MAX 8 1.065 .734 .505 1.410 .078/.046 .493/.462 10 1.141 .812 .632 1.410 .078/.046 .493/.462 12 1.266 .938 .755 1.410 .078/.046 .493/.462 14 1.360 1.031 .880 1.410 .078/.046 .493/.462 16 1.453 1.125 1.005 1.410 .078/.046 .493/.462 18 1.532 1.203 1.065 1.410 .078/.046 .493/.462 20 1.688 1.297 1.190 1.475 .110/.078 .587/.556 22 1.766 1.375 1.315 1.475 .110/.078 .587/.556 24 1.891 1.500 1.440 1.475 .110/.078 .587/.556 - 95 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform Jam Nut Receptacle (MS3474) AE15-472 Receptacle Connector, Jam Nut, with integrated Rear Banding Platform INTEGRATED REAR J SHELL SIZE A OB C MAX D E F FLAT THREAD-2A G OH MAX RECOMMENDED PANEL THICKNESS 8 .954/.923 1.078/1.047 1.410 .113/.086 .707/.658 .525 .562-24 .505 .187/.062 10 1.078/1.047 1.203/1.172 1.410 .113/.086 .707/.658 .650 .687-24 .632 .187/.062 12 1.266/1.235 1.391/1.360 1.410 .113/.086 .707/.658 .813 .875-40 .755 .187/.062 14 1.391/1.360 1.516/1.485 1.410 .113/.086 .707/.658 .937 1.000-20 .880 .187/.062 16 1.516/1.485 1.641/1.610 1.410 .113/.086 .707/.658 1.061 1.125-18 1.005 .187/.062 18 1.641/1.610 1.766/1.735 1.410 .113/.086 .707/.658 1.186 1.250-18 1.065 .187/.062 20 1.828/1.797 1.954/1.923 1.475 .148/.096 .772/.721 1.311 1.375-18 1.190 .250/.062 22 1.954/1.923 2.078/2.047 1.475 .148/.096 .772/.721 1.436 1.500-18 1.315 .250/.062 24 2.078/2.047 2.203/2.172 1.475 .148/.096 .772/.721 1.561 1.625-18 1.440 .250/.062 www.conesys.com - 96 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform RFI Grounding Plug (MS3475) AE15-473 Plug Connector, RFI, with integrated Rear Banding Platform INTEGRATED REAR www.conesys.com SHELL SIZE OA MAX OB MAX 8 .782 .505 10 .926 .632 12 1.043 .755 14 1.183 .880 16 1.305 1.005 18 1.391 1.065 20 1.631 1.190 22 1.656 1.315 24 1.777 1.440 - 97 - sales@aero-electric.com MIL-DTL-26482 Series II Integrated Rear Banding Platform Straight Plug (MS3476) AE15-474 Plug Connector, Straight, with integrated Rear Banding Platform INTEGRATED REAR www.conesys.com SHELL SIZE OA MAX OB MAX 8 .782 .505 10 .926 .632 12 1.043 .755 14 1.183 .880 16 1.305 1.005 18 1.391 1.065 20 1.631 1.190 22 1.656 1.315 24 1.777 1.440 - 98 - sales@aero-electric.com MIL-DTL-38999 Series I Integrated Rear Banding Platform Part Number Development Part Number Configuration Aero Prefix AE45- 475- T 15 B 15 P A INTEGRATED REAR Shell Type 475 = Front, wall mount (Ref: MS27466) 476 = Plug Connector, RFI (Ref: MS27467) 477 = Jam Nut Connector (Ref: MS27468) 478 = Rear, wall mount (Ref: MS27656) Class T for reference only Shell Size 9, 11, 13, 15, 17, 19, 21, 23, 25 Material Finish A = Aluminum, Bright Cadmium B = Aluminum, Cadmium/Olive Drab F = Aluminum, Electroless Nickel S = Stainless Steel, Passivated (RoHS) RN = Aluminum Shell, Electroless nickel finish (RoHS) Insert Arrangement Per MIL-STD-1560 Contact Style P = Pin S = Socket Polarization (Keying) Normal = Blank Alternative Polarization = A, B, C & D www.conesys.com - 99 - sales@aero-electric.com MIL-DTL-38999 Series I Integrated Rear Banding Platform (MS27466) AE45-475 Front Wall Mount Receptacle with integrated Rear Banding Platform INTEGRATED REAR A B SHELL SIZE www.conesys.com OC D OE F OG MAX .020 BASIC +.010 -.005 +.000 -.005 +.001 -.005 +.015 -.000 9 .938 .719 .128 .820 .572 .085 .453 11 1.031 .812 .128 .820 .700 .085 .571 13 1.125 .906 .128 .820 .850 .085 .690 15 1.219 .969 .128 .820 .975 .085 .847 17 1.312 1.062 .128 .820 1.100 .085 .965 19 1.438 1.156 .128 .820 1.207 .085 1.083 21 1.562 1.250 .128 .790 1.332 .115 1.201 23 1.688 1.375 .147 .790 1.457 .115 1.319 25 1.812 1.500 .147 .790 1.582 .115 1.447 - 100 - sales@aero-electric.com MIL-DTL-38999 Series I Integrated Rear Banding Platform (MS27467) AE45-476 Plug Connector, RFI, with integrated Rear Banding Platform INTEGRATED REAR www.conesys.com SHELL SIZE OA MAX OB MAX 9 .859 .453 11 .984 .571 13 1.156 .690 15 1.281 .847 17 1.406 .965 19 1.516 1.083 21 1.641 1.201 23 1.766 1.319 25 1.891 1.447 - 101 - sales@aero-electric.com MIL-DTL-38999 Series I Integrated Rear Banding Platform (MS27468) AE 45-477 Jam Nut Receptacle with integrated Rear Banding Platform INTEGRATED REAR A OB SHELL SIZE www.conesys.com C D FLAT OE F Thread-2A OG MAX .687-24 .453 +.011 -.010 +.001 -.005 .655 .109 .572 1.375 .755 .109 .700 .812-20 .571 1.500 .942 .109 .850 1.000-20 .690 1.500 1.625 1.066 .109 .975 1.125-18 .847 17 1.625 1.750 1.191 .109 1.100 1.250-18 .965 19 1.812 1.938 1.316 .140 1.207 1.375-18 1.083 21 1.938 2.062 1.441 .140 1.332 1.500-18 1.201 23 2.062 2.188 1.566 .140 1.457 1.625-18 1.319 25 2.188 2.312 1.691 .140 1.582 1.750-18 1.447 .016 .016 +.001 -.010 9 1.062 1.188 11 1.250 13 1.375 15 - 102 - sales@aero-electric.com MIL-DTL-38999 Series I Integrated Rear Banding Platform (MS27656) AE45-478 Rear Wall Mount Receptacle with integrated Rear Banding Platform INTEGRATED REAR A B SHELL SIZE www.conesys.com OC D OE F OG MAX .020 BASIC +.010 -.005 +.000 -.005 +.001 -.005 +.015 -.000 9 .938 .719 .128 .820 .572 .085 .453 11 1.031 .812 .128 .820 .700 .085 .571 13 1.125 .906 .128 .820 .850 .085 .690 15 1.219 .969 .128 .820 .975 .085 .847 17 1.312 1.062 .128 .820 1.100 .085 .965 19 1.438 1.156 .128 .820 1.207 .085 1.083 21 1.562 1.250 .128 .790 1.332 .115 1.201 23 1.688 1.375 .147 .790 1.457 .115 1.319 25 1.812 1.500 .147 .790 1.582 .115 1.447 - 103 - sales@aero-electric.com MIL-DTL-38999 Series III Integrated Rear Banding Platform Part Number Development Part Number Configuration Aero Prefix AE65- 379- W B 98 S N INTEGRATED REAR Shell Type 377 = Rear, Narrow Flange (Ref: D38999/20) 378 = Rear, Jam Nut receptacle (Ref: D38999/24) 379= Plug Connector, RFI (Ref: D38999/26) Material Finish W = Aluminum, Olive Drab Cadmium over Nickel F = Aluminum, Electroless Nickel G = Stainless Steel, Passivated, Non-Firewall K = Stainless Steel, Passivated, Firewall BN = Aluminum, Black Nickel (RoHS) Shell Size A = 9, B= 11, C = 13, D = 15, E = 17, F = 19, G = 21, H = 23, J = 25 Insert Arrangement Per MIL-STD-1560 Contact Style P = Pin S = Socket A = Pin (Connectors used with other than Standard Contacts) B = Socket Polarization (Keying) N = Normal A, B, C, D and E Note = All minor keys are rotated to provide shell polarization, the master key remains fixed. www.conesys.com - 104 - sales@aero-electric.com MIL-DTL-38999 Series III Integrated Rear Banding Platform D38999/20 AE65-377 Wall Mount Receptacle with integrated Rear Banding Platform INTEGRATED REAR SHELL SIZE SHELL CODE A TYP B TYP C TYP D TYP E INCH .012 MM 0.26 INCH .010 MM 0.26 INCH .010 MM 0.26 INCH .008 MM 0.20 INCH .008 MM 0.20 G MAX H MAX OJ MAX F THREAD TRIPLE START INCH MM INCH MM INCH MM OK REF. 9 A .937 23.80 .719 18.26 .594 15.09 .216 5.49 .128 3.25 .6250-.1P-.3L .820 20.83 .099 2.50 .453 11.50 .476 11 B 1.031 26.20 .812 20.62 .719 18.26 .194 4.93 .128 3.25 .7500-.1P-.3L .820 20.83 .099 2.50 .571 14.50 .594 13 C 1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 3.25 .8750-.1P-.3L .820 20.83 .099 2.50 .690 17.53 .713 15 D 1.220 31.00 .969 24.61 .906 23.01 .194 4.93 .128 3.25 1.000-.1P-.3L .820 20.83 .099 2.50 .847 21.51 .870 17 E 1.311 33.30 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 1.187-.1P-.3L .820 20.83 .099 2.50 .965 24.51 .988 19 F 1.437 36.50 1.156 29.36 1.062 26.97 .194 4.93 .128 3.25 1.250-.1P-.3L .820 20.83 .099 2.50 1.083 27.51 1.104 21 G 1.563 39.70 1.250 31.75 1.156 29.36 .194 4.93 .128 3.25 1.375-.1P-.3L .790 20.07 .126 3.20 1.201 30.51 1.226 23 H 1.689 42.90 1.375 34.93 1.250 31.75 .242 6.15 .154 3.91 1.500-.1P-.3L .790 20.07 .126 3.20 1.319 33.50 1.342 25 J 1.811 46.00 1.500 38.10 1.375 34.93 .242 6.15 .154 3.91 1.625-.1P-.3L .790 20.07 .126 3.20 1.447 36.75 1.460 www.conesys.com - 105 - sales@aero-electric.com MIL-DTL-38999 Series III Integrated Rear Banding Platform D38999/24 AE65-378 Jam Nut Receptacle with integrated Rear Banding Platform INTEGRATED REAR A SHELL SIZE SHELL CODE B MTG. FLAT .016 +.004 -.006 D C HEX +.028 -.004 E THREAD TRIPLE START G +.028 -.004 H REF. J THREAD OL MAX OM REF. 9 A 1.063 .651 .945 .859 .555 .6250-.1P-.3L .087 1.580 M17x1.0-6g.100R .453 .476 11 B 1.252 .751 1.063 .984 .555 .7500-.1P-.3L .087 1.580 M20x1.0-6g.100R .571 .594 13 C 1.374 .983 1.260 1.172 .563 .8750-.1P-.3L .087 1.580 M25x1.0-6g.100R .690 .713 15 D 1.500 1.062 1.417 1.296 .563 1.000-.1P-.3L .087 1.580 M28x1.0-6g.100R .847 .870 17 E 1.626 1.187 1.457 1.422 .563 1.187-.1P-.3L .087 1.580 M32x1.0-6g.100R .965 .988 19 F 1.811 1.312 1.614 1.546 .563 1.250-.1P-.3L .087 1.615 M35x1.0-6g.100R 1.083 1.104 21 G 1.937 1.437 1.811 1.672 .563 1.375-.1P-.3L .118 1.615 M38x1.0-6g.100R 1.201 1.226 23 H 2.063 1.562 1.969 1.796 .563 1.500-.1P-.3L .118 1.615 M41x1.0-6g.100R 1.319 1.342 25 J 2.189 1.687 2.017 1.939 .563 1.625-.1P-.3L .118 1.615 M44x1.0-6g.100R 1.447 1.460 www.conesys.com - 106 - sales@aero-electric.com MIL-DTL-38999 Series III Integrated Rear Banding Platform D38999/26 AE65-379 Plug Connector, RFI, with integrated Rear Banding Platform INTEGRATED REAR SHELL SIZE MS SHELL CODE OA MAX OB MAX OC REF. INCH MM INCH MM D THREAD TRIPLE START OE OF INCH +.005 -.009 MM +0.13 -0.25 INCH +.005 -.001 MM +0.13 -0.03 9 A .858 21.8 .453 11.50 .476 .625-.1P-.3L .285 7.24 .387 9.83 11 B .984 25.0 .571 14.50 .594 .750-.1P-.3L .412 10.49 .514 13.06 13 C 1.157 29.4 .690 17.53 .713 .875-.1P-.3L .527 13.39 .628 15.95 15 D 1.279 32.5 .847 21.51 .870 1.000-.1P-.3L .651 16.56 .753 19.13 17 E 1.405 35.7 .965 24.51 .988 1.187-.1P-.3L .777 19.74 .878 22.30 19 F 1.515 38.5 1.083 27.51 1.104 1.250-.1P-.3L .866 22.00 .972 24.69 21 G 1.641 41.7 1.201 30.51 1.226 1.375-.1P-.3L .990 25.17 1.097 27.86 23 H 1.767 44.9 1.319 33.50 1.342 1.500-.1P-.3L 1.116 28.35 1.222 31.04 25 J 1.889 48.0 1.447 36.75 1.460 1.625-.1P-.3L 1.240 31.52 1.347 34.21 www.conesys.com - 107 - sales@aero-electric.com MIL-DTL-26482 Features and Application Series 2 Features and Application MIL-DTL-26482 Series 2, bayonet coupling, rear-removable crimp contact connectors were designed as an upgrade to MIL-DTL-26482 Series 1. Series 2 connectors are intermountable and interchangeable with both solder and front-release crimp Series 1. They are also identical to the inactivated MIL-DTL- 83723 Series I connectors. Series 2 connectors are widely used on commercial, military and aerospace systems requiring general-purpose, miniature cylindrical bayonet coupling connectors. This family of connectors is offered in 4 receptacle-mounting styles. They include narrow flange wall mounting receptacles, wide flange wall mounting receptacles, cable connecting receptacles and jam nut mounting receptacles which incorporate "O" ring seals, designed for rear panel "D" hole mounting. Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. Plugs are available in two designs, with and without RFI grounding. 26482 S 2 Thirty-three insert arrangements per MIL-STD-1669 are tooled and qualified to MIL-DTL-26482 Series 2, utilizing 3 to 61 M39029 contacts. Contacts come in sizes 20, 16 and 12, terminating wire sizes from 24 to 12 gauge. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel, olive drab cadmium and black anodic. Other finishes such as zinc cobalt are available upon request to commercial callouts only. In addition, we offer passivated stainless steel shells with standard environment-resisting inserts (commercial callouts only), and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. Insert Polarization - Alternate insert clocking positions aid in mating of adjacent connectors having identical insert arrangement. www.conesys.com - 108 - sales@aero-electric.com MIL-DTL-26482 Performance Specifications Series 2 Performance Specifications Durability Mated connectors withstand a minimum of 250 mating cycles for RFI plug (MS3475) and 500 cycles for standard plug (MS3476). Operating Temperature Range Classes A, L and S*: -55C to +200C (-67F to +392F) Classes W, Z* and BN*: -55C to +175C (-67F to +347F) Shock and Vibration Requirements Wired, mated connectors shall not be damaged, coupling ring shall not loosen, and there shall be no interruption of electrical continuity longer than one microsecond when subjected to the following: Material and Finish Data (Class) A - aluminum shell, black anodized finish (RoHS) L - aluminum shell, electroless nickel finish W - aluminum shell, olive drab cadmium over nickel base S* - stainless steel shell, passivated (RoHS) BN*- aluminum shell, black nickel finish (Aero P/N only) Z* = Aluminum shell, Black Zinc Nickel finish (RoHS) (Aero p/n only) Shock Mated connectors withstand a pulse of approximate half sine wave of 300 G magnitude with duration of three milliseconds applied in each direction of the three major axes. Corrosion Resistance Classes A, S*, W and Z* withstand 500-hour salt spray. Class BN* withstands 350-hours salt spray. Class L withstands 48-hour salt spray. Vibration Mated connectors withstand the following vibration levels: * Random vibration per MIL-STD-202, method 214, test condition II, letter J. Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-26482 Series 2. 26482 S 2 Shielding Effectiveness RFI attenuation at the specified frequency meets the requirements of MIL-DTL-26482 Series 2. * RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture. Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808 (lubricating oil), MIL-PRF-23699 (lubricating oil), MIL-PRF-5606 (hydraulic fluid), M2-V Chevron oil, Coolanol 25, ASTM D4814 (gasoline), SAE-AMS1424 Type I (defrosting fluid), MIL-DTL-5624 (JP-5), and solvents specified in Method 215 of MIL-STD-202. Shell-to-Shell Conductivity * With RFI spring fingers, the maximum potential drop shall not exceed 5 millivolts. * Without spring fingers, the maximum potential drop shall not exceed 200 millivolts. * Not on QPL, can be supplied to Aero-Electric P/N only. Voltage Rating Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Service Rating Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft. AC (RMS) DC V RMS V RMS V RMS V RMS I 600 850 1,500 500 375 200 II 1,000 1,275 2,300 750 500 200 ** To be used by designer only as a guide. www.conesys.com - 109 - sales@aero-electric.com MIL-DTL-26482 Part Number Development Series 2 Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS34 AE7 70 70 L L 12 12 - 10 10 P P W W -340 Shell type 70 = Narrow flange receptacle 71 = Cable connecting receptacle 72 = Wide flange receptacle 74 = Jam nut receptacle 75 = RFI grounding plug 76 = Straight plug Class (Material and Finish) A = Aluminum shell, black anodized finish (not available in RFI plug) (RoHS) L = Aluminum shell, electroless nickel finish W = Aluminum shell, olive drab cadmium over electroless nickel base S* = Stainless steel shell, passivated (Aero part number only) (RoHS) BN* = Aluminum shell,Black Nickel finish, (RoHS), (Aero part number only) (N/A for AE775) Z* = Aluminum shell, Black Zinc Nickel finish (RoHS) (Aero p/n only) (N/A for AE775) Shell Size 8, 10, 12, 14, 16, 18, 20, 22 or 24 Insert Arrangement See pages 125 thru 126 Contact Style P = Pin 26482 S 2 S = Socket A = Pin connector less pins (with intent to use non-std contact) B = Socket connector less sockets (with intent to use non-std contacts) Polarization N = Normal (not included in part number) W, X, Y or Z = Alternate insert polarizations (see pages 123 for position availability) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/31-XXX E-nut 341 = Connector kitted with M85049/52-1-XXX straight clamp 342 = Connector kitted with M85049/51-1-XXX right angle clamp * Not on QPL, can be supplied to Aero part number only. Consult factory for availability. Note 2: Proper part number marking has no "0" in front of single digit shell size ( 8) and no "0" after the dash between shell size and single digit layout. Example of each: MS3470W8-33P and MS3470W10-6P. In both "N" for normal was omitted. Note 3: Insert layouts 8-2, 8-3 and 8-4 can only be ordered to Aero-Electric part number. Non standard contacts are required and to avoid confusion are sold "with contacts" only. See page 121 for the correct contact part numbers. Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 to 26 of each contact and two spares for inserts with 27 or more of each size, and a minimum of one sealing plug up to 15% of the number of contacts. In addition, one plastic insetion/removal tool of each size is included. www.conesys.com - 110 - sales@aero-electric.com MS3470 Narrow Flange Receptacle AE770 Bayonet Coupling, Crimp Removable, Rear Release D MAX A MAX PANEL THICKNESS .125(3.18) MAX B E F MASTER KEYWAY .290 (7.37) MIN FULL THREAD .190 (4.83) .130 (3.30) GROMMET EXTENSION 3 ACCESSORY TEETH 4x C H 3 BAYONET PINS MOUNTING HOLES G ACCESSORY THREAD 4 MINOR KEYWAYS BLUE COLOR BAND BLUE COLOR BAND MAX PANEL THICKNESS & SCREWHEAD .087(2.21) S.S. 8-18 .212(5.38) S.S. 20-24 26482 S 2 Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization A B Maximum (TP) Shell Size inch mm inch OC Note: Maximum grommet O.D. is same as O C max on page 113. D .005 .13 mm inch mm inch E F G .016 .41 +.016 -.015 +.41 -.38 mm inch mm inch mm Maximum OH Accessory Thread Class 2A .003 .08 inch mm 8 .828 21.03 .594 15.09 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 1/2-20UNF .471 11.96 10 .954 24.23 .719 18.26 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 5/8-24UNEF .588 14.94 12 1.047 26.59 .812 20.62 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 3/4-20UNEF .748 19.00 14 1.141 28.98 .906 23.01 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 7/8-20UNEF .873 22.17 16 1.234 31.34 .969 24.61 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 1-20UNEF .998 25.35 18 1.328 33.73 1.062 26.97 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 1-1/16-18UNEF 1.123 28.52 20 1.453 36.91 1.156 29.36 .120 3.05 1.275 32.39 .094 2.39 .571 14.50 1-3/16-18UNEF 1.248 31.70 22 1.578 40.08 1.250 31.75 .120 3.05 1.275 32.39 .094 2.39 .571 14.50 1-5/16-18UNEF 1.373 34.87 24 1.703 43.26 1.375 34.93 .147 3.73 1.275 32.39 .094 2.39 .604 15.34 1-7/16-18UNEF 1.498 38.05 www.conesys.com - 111 - sales@aero-electric.com MS3471 Cable Connecting Receptacle AE771 Bayonet Coupling, Crimp Removable, Rear Release C A MAX MAX .290 (7.37) MIN FULL THREAD D E MASTER KEYWAY .190 (4.83) .130 (3.30) GROMMET EXTENSION 3 ACCESSORY TEETH F B 4 MINOR KEYWAYS 3 BAYONET PINS G ACCESSORY THREAD BLUE COLOR BANDS A OB Maximum Shell Size inch mm Note: Maximum grommet O.D. is same as O C max on page 113. C .020 .51 inch mm inch D E OF G .016 .41 +.016 -.015 +.41 -.38 .003 .08 mm inch mm inch mm inch mm Maximum Accessory Thread Class 2A 8 .828 21.03 .938 23.83 1.215 30.86 .062 1.57 .446 11.33 .471 11.96 1/2-20UNF 10 .954 24.23 1.062 26.97 1.215 30.86 .062 1.57 .446 11.33 .588 14.94 5/8-24UNEF 12 1.047 26.59 1.156 29.36 1.215 30.86 .062 1.57 .446 11.33 .748 19.00 3/4-20UNEF 14 1.141 28.98 1.250 31.75 1.215 30.86 .062 1.57 .446 11.33 .873 22.17 7/8-20UNEF 16 1.234 31.34 1.344 34.14 1.215 30.86 .062 1.57 .446 11.33 .998 25.35 1-20UNEF 18 1.328 33.73 1.438 36.53 1.215 30.86 .062 1.57 .446 11.33 1.123 28.52 1-1/16-18UNEF 20 1.453 36.91 1.562 39.67 1.275 32.39 .094 2.39 .571 14.50 1.248 31.70 1-3/16-18UNEF 22 1.578 40.08 1.688 42.88 1.275 32.39 .094 2.39 .571 14.50 1.373 34.87 1-5/16-18UNEF 24 1.703 43.26 1.812 46.02 1.275 32.39 .094 2.39 .604 15.34 1.498 38.05 1-7/16-18UNEF www.conesys.com - 112 - sales@aero-electric.com 26482 S 2 Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization MS3472 Wide Flange Receptacle AE772 Bayonet Coupling, Crimp Removable, Rear Release D A MAX MAX PANEL THICKNESS .125(3.18) MAX B F MASTER KEYWAY E .190 (4.83) .130 (3.30) GROMMET EXTENSION .290 (7.37) MIN FULL THREAD 3 ACCESSORY TEETH C H .150.005 ( 3.81.13) MOUNTING HOLES MAX GROMMET 3 BAYONET PINS G ACCESSORY THREAD 4 MINOR KEYWAYS BLUE COLOR BAND BLUE COLOR BAND MAX PANEL THICKNESS & SCREWHEAD .118(3.00) S.S. 8-18 .212(5.38) S.S. 20-24 26482 S 2 Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization A B OC D Maximum (TP) Maximum Maximum Shell Size inch mm inch mm inch E F G OH .016 .41 +.016 -.015 +.41 -.38 Accessory Thread Class 2A .003 .08 inch mm mm inch mm inch mm inch mm 8 1.065 27.05 .734 18.64 .305 7.75 1.215 30.86 .062 1.57 .477 12.12 1/2-20UNF .471 11.96 10 1.141 28.98 .812 20.62 .405 10.29 1.215 30.86 .062 1.57 .477 12.12 5/8-24UNEF .588 14.94 12 1.266 32.16 .938 23.83 .531 13.49 1.215 30.86 .062 1.57 .477 12.12 3/4-20UNEF .748 19.00 14 1.360 34.54 1.031 26.19 .665 16.89 1.215 30.86 .062 1.57 .477 12.12 7/8-20UNEF .873 22.17 16 1.453 36.91 1.125 28.58 .790 20.07 1.215 30.86 .062 1.57 .477 12.12 1-20UNEF .998 25.35 18 1.532 38.91 1.203 30.56 .869 22.07 1.215 30.86 .062 1.57 .477 12.12 1-1/16-18UNEF 1.123 28.52 20 1.688 42.88 1.297 32.94 .994 25.25 1.275 32.39 .094 2.39 .571 14.50 1-3/16-18UNEF 1.248 31.70 22 1.766 44.86 1.375 34.93 1.119 28.42 1.275 32.39 .094 2.39 .571 14.50 1-5/16-18UNEF 1.373 34.87 24 1.891 48.03 1.500 38.10 1.244 31.60 1.275 32.39 .094 2.39 .604 15.34 1-7/16-18UNEF 1.498 38.05 www.conesys.com - 113 - sales@aero-electric.com MS3474 Jam Nut Receptacle AE774 Bayonet Coupling, Crimp Removable, Rear Release C MAX A E D MASTER KEYWAY .290(7.37) MIN FULL THREAD "O" RING .190 (4.83) .130 (3.30) GROMMET EXTENSION F 3X REAR ACCESSORY TEETH FLAT B 3 BAYONET PINS G BLUE COLOR BAND ACCESSORY THREAD (SAME AS FOR MS3472 ON PREVIOUS PAGE) H THREAD HEX NUT PER MS3186 EXCEPT FOR THICKNESS BLUE COLOR BAND .125(3.18) .108(2.74) PANEL THICKNESS .187(4.75) S.S. 8-18 .062(1.57) .250(6.35) S.S. 20-24 .062(1.57) A Shell Size OB C +.000 -.031 +.00 -.79 +.000 -.031 +.00 -.79 inch mm inch mm Note: Maximum grommet O.D. is same as O E max on page 113. D E Maximum inch mm mm inch inch mm F H Flat .005 .13 Jam Nut Thread mm UNEF-2A inch 8 .954 24.23 1.078 27.38 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .525 13.34 9/16-24 10 1.078 27.38 1.203 30.56 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .650 16.51 11/16-24 12 1.266 32.16 1.391 35.33 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .813 20.65 7/8-20 14 1.391 35.33 1.516 38.51 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .937 23.80 1-20 16 1.516 38.51 1.641 41.68 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 1.061 26.95 1-1/8-18 18 1.641 41.68 1.766 44.86 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 1.186 30.12 1-1/4-18 20 1.828 46.43 1.954 49.63 1.275 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.311 33.30 1-3/8-18 22 1.954 49.63 2.078 52.78 1.275 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.436 36.47 1-1/2-18 24 2.078 52.78 2.203 55.96 1.275 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.561 39.65 1-5/8-18 www.conesys.com - 114 - sales@aero-electric.com 26482 S 2 Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization MS3475 RFI Grounding Plug AE775 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX .320(8.13) MIN C MAX COUPLING NUT MASTER KEY RFI STRIP .290 (7.37) MIN FULL THREAD BLUE COLOR BAND 3 ACCESSORY TEETH EQUALLY SPACED A B E MAX INSERT MAX GROMMET .190 (4.83) .130 (3.30) GROMMET EXTENSION 4 MINOR KEYS D ACCESSORY THREAD 26482 S 2 Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization OB OA Maximum Shell Size OC Maximum D Accessory Thread Class 2A OE Maximum inch mm .003 inch .08 mm inch mm 8 .285 7.24 .355 9.02 .782 19.86 1/2-20UNF 10 .402 10.21 .483 12.27 .926 23.52 5/8-24UNEF .405 10.29 12 .516 13.11 .595 15.11 1.043 26.49 3/4-20UNEF .531 13.49 14 .641 16.28 .720 18.29 1.183 30.05 7/8-20UNEF .665 16.89 16 .766 19.46 .845 21.46 1.305 33.15 1-20UNEF .790 20.07 18 .855 21.72 .945 24.00 1.391 35.33 1-1/16-18UNEF .869 22.07 20 .980 24.89 1.070 27.18 1.531 38.89 1-3/16-18UNEF .994 25.25 22 1.105 28.07 1.195 30.35 1.656 42.06 1-5/16-18UNEF 1.119 28.42 24 1.229 31.22 1.320 33.53 1.777 45.14 1-7/16-18UNEF 1.244 31.60 www.conesys.com - 115 - inch mm .305 7.75 sales@aero-electric.com MS3476 Straight Plug AE776 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX .320(8.13) MIN C MAX COUPLING NUT .290 (7.37) MIN FULL THREAD BLUE COLOR BAND MASTER KEY 3 ACCESSORY TEETH EQUALLY SPACED E A B MAX MAX GROMMET INSERT .190 (4.83) .130 (3.30) GROMMET EXTENSION 4 MINOR KEYS D ACCESSORY THREAD OA Maximum Shell Size inch 26482 S 2 Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization OC Maximum OB mm .003 inch .08 mm inch OE Maximum D mm Accessory Thread Class 2A inch mm 8 .285 7.24 .355 9.02 .782 19.86 1/2-20UNF .305 7.75 10 .402 10.21 .483 12.27 .926 23.52 5/8-24UNEF .405 10.29 12 .516 13.11 .595 15.11 1.043 26.49 3/4-20UNEF .531 13.49 14 .641 16.28 .720 18.29 1.183 30.05 7/8-20UNEF .665 16.89 16 .766 19.46 .845 21.46 1.305 33.15 1-20UNEF .790 20.07 18 .855 21.72 .945 24.00 1.391 35.33 1-1/16-18UNEF .869 22.07 20 .980 24.89 1.070 27.18 1.531 38.89 1-3/16-18UNEF .994 25.25 22 1.105 28.07 1.195 30.35 1.656 42.06 1-5/16-18UNEF 1.119 28.42 24 1.229 31.22 1.320 33.53 1.777 45.14 1-7/16-18UNEF 1.244 31.60 www.conesys.com - 116 - sales@aero-electric.com AC3475 Arctic Coupling Nut, RFI Plug Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX C MAX COUPLING NUT MASTER KEY .290 (7.37) MIN FULL THREAD RFI STRIP 3 ACCESSORY TEETH EQUALLY SPACED E A B MAX GROMMET MAX INSERT .190 (4.83) .130 (3.30) GROMMET EXTENSION 4 MINOR KEYS D ACCESSORY THREAD AC3475 - 10- 7 Aero Prefix P N Polarization N = Normal (N included in part number marking) A, B, C, D, E or F (Alternate key positions) and W, X, Y or Z (Alternate insert clocking positions) Class (Material and Finish) - = Aluminum shell, cadmium olive drab for the plug shell - aluminum shell, hard anodized, black plating for the coupling nut L = Aluminum shell, electroless nickel Contact Style P = Pin S = Socket Shell Size 8, 10, 12, 14, 16, 18, 20, 22 or 24 Layout See pages 125 and 126 26482 S 2 Note: AC3475 Arctic Coupling Nut, RFI Plug is available to Aero-Electric part number only. Mating part is AC3474 which is same as AE774 on page 114. Additional mates are AC3470 (same as AE770 on page 111), AC3471 (same as AE771 on page 112)and AC3472 (same as AE772 on page 113). Page 110 Completed Part Number Page 121 Contacts, Sealing Plugs and Tools Pages 125, 126 Insert Arrangements Page 109 Performance Specifications Pages 123, 124 Insert Availability and Contact Information Page 123 Polarization OA Shell Size OB Maximum inch mm .003 inch OC .08 mm D Maximum inch mm Accessory Thread Class 2A OE Maximum inch mm 8 .285 7.24 .355 9.02 .900 22.86 1/2-20UNF .305 7.75 10 .402 10.21 .483 12.27 1.010 25.65 5/8-24UNEF .405 10.29 12 .516 13.11 .595 15.11 1.180 29.97 3/4-20UNEF .531 13.49 14 .641 16.28 .720 18.29 1.310 33.27 7/8-20UNEF .665 16.89 16 .766 19.46 .845 21.46 1.510 38.35 1-20UNEF .790 20.07 18 .855 21.72 .945 24.00 1.620 41.15 1-1/16-18UNEF .869 22.07 20 .980 24.89 1.070 27.18 1.740 44.20 1-3/16-18UNEF .994 25.25 22 1.105 28.07 1.195 30.35 1.850 46.99 1-5/16-18UNEF 1.119 28.42 24 1.229 31.22 1.320 33.53 1.980 50.29 1-7/16-18UNEF 1.244 31.60 www.conesys.com - 117 - sales@aero-electric.com MIL-DTL-26482 Series 2 Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts C A A F E B G MS3470(AE770) MS3474(AE774) D MS3472(AE772) 26482 S 2 Flange and Jam Nut Mounting Dimensions OA B .13 OC (TP) .010 D .25 OE F .25 .005 inch mm .150 3.81 20.62 .150 23.83 .150 1.031 26.19 3.05 1.125 3.05 1.203 OG .13 .005 inch mm inch mm .536 13.61 .572 14.53 3.81 .661 16.79 .697 17.70 3.81 .824 20.93 .895 22.73 .150 3.81 .948 24.08 1.010 25.65 28.58 .150 3.81 1.072 27.23 1.135 28.83 30.56 .150 3.81 1.197 30.40 1.260 32.00 Shell Size .005 (TP) .010 inch mm inch mm inch mm inch mm 8 .568 14.43 .594 15.09 .120 3.05 .734 18.64 10 .685 17.40 .719 18.26 .120 3.05 .812 12 .864 21.95 .812 20.62 .120 3.05 .938 14 .989 25.12 .906 23.01 .120 3.05 16 1.113 28.27 .969 24.61 .120 18 1.238 31.45 1.062 26.97 .120 .13 20 1.363 34.62 1.156 29.36 .120 3.05 1.297 32.94 .150 3.81 1.322 33.58 1.385 35.18 22 1.488 37.80 1.250 31.75 .120 3.05 1.375 34.93 .150 3.81 1.447 36.75 1.510 38.35 24 1.615 41.02 1.375 34.93 .147 3.73 1.500 38.10 .150 3.81 1.572 39.93 1.635 41.53 Note: For O C and O E, MS3470 and MS3472 call out for tolerance of .010 (.25), however we recommend .005 (.13). www.conesys.com - 118 - sales@aero-electric.com MS3180 Protective Cover, Plug AE1580 Protective Cover, Plug Part Number Configuration MIL. Prefix Aero Prefix MS3180AE1580- XX XX X X A A X X Shell Size 8 THRU 24 (Note: single digit for shell size 8) Style C = Chain R = Wire Rope Assembly 26482 S 2 Material Finish A = Aluminum, Hard Black Anodized (RoHS) W = Aluminum, olive drab cadmium (Aero part # only) L = Aluminum, electroless nickel (Aero part # only) S = Stainless steel, passivated (Aero part # only) (RoHS) BN = Aluminum, Black Nickel finish (Aero part # only) (RoHS) Z = Aluminum, Black Zinc Nickel finish (Aero part # only) (RoHS) Chain/Wire Rope Lengh Blank - for standard length "H" L= 5.000 +500 -.250 SHELL SIZE OA +.001 -.005 OB +.006 -.002 OC +.000 -.016 OD +.005 -.001 OF MAX. H +.500 -.250 J +.010 -.020 L Max. M +.031 -.000 OQ +.005 -.006 W X MAX 8 .473 .078 .563 .362 .719 3.000 .328 .562 .368 .412 .100 .781 10 .590 .078 .680 .490 .844 3.000 .328 .562 .368 .540 .100 .781 12 .750 .078 .859 .607 1.000 3.500 .328 .562 .368 .689 .100 .781 14 .875 .078 .984 .732 1.125 3.500 .328 .562 .368 .814 .100 .781 16 1.000 .078 1.108 .857 1.250 3.500 .328 .562 .368 .939 .100 .781 18 1.125 .078 1.233 .962 1.375 3.500 .328 .562 .368 1.039 .100 .781 20 1.250 .078 1.358 1.087 1.500 4.000 .390 .625 .430 1.164 .100 .844 22 1.375 .078 1.483 1.212 1.625 4.000 .390 .625 .430 1.289 .100 .844 24 1.500 .078 1.610 1.337 1.750 4.000 .390 .625 .430 1.414 .109 .875 www.conesys.com - 119 - sales@aero-electric.com MS3181 Protective Cover, Receptacle AE1581 Protectice Cover, Receptacle Part Number Configuration MIL. Prefix Aero Prefix MS3181- XX AE1581- XX X X A A X X Shell Size 8 THRU 24 (Note: single digit for shell size 8) Style 26482 S 2 C = Chain R = Wire Rope Assembly N = Chain/Ring Assembly Material Finish A = Aluminum, Hard Black Anodized (RoHS) W = Aluminum, olive drab cadmium (Aero part # only) L = Aluminum, electroless nickel (Aero part # only) S = Stainless steel, passivated (Aero part # only) (RoHS) BN = Aluminum, Black Nickel finish (Aero part # only) (RoHS) Z = Aluminum, Black Zinc Nickel finish (Aero part # only) (RoHS) Chain/Wire Rope Lengh Blank - for standard length "H" L= 5.000 +500 -.250 SHELL SIZE OA +.001 -.005 B +.006 -.002 OG +.005 -.006 H +.500 -.250 J +.010 -.020 L Max. ON MIN. OQ +.005 -.006 OK MAX X MAX 8 .481 .149 .576 3.000 .115 .562 .578 .734 .812 .844 10 .602 .149 .697 3.000 .115 .562 .703 .859 1.000 .844 12 .761 .149 .871 3.500 .115 .562 .891 1.000 1.188 .844 14 .885 .149 .995 3.500 .115 .562 1.016 1.125 1.438 .844 16 1.010 .149 1.120 3.500 .115 .562 1.141 1.250 1.562 .844 18 1.136 .149 1.245 3.500 .115 .562 1.266 1.375 1.688 .844 20 1.260 .149 1.370 4.000 .115 .562 1.391 1.500 1.812 .844 22 1.385 .149 1.495 4.000 .115 .562 1.516 1.625 1.938 .844 24 1.510 .087 1.624 4.000 .147 .602 1.641 1.750 2.062 .875 www.conesys.com - 120 - sales@aero-electric.com MIL-DTL-26482 Contacts, Tools and Seal Plugs Series 2 Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Contact Size Type Military No. Military No. Military No. Military No. 20 Power/Signal M39029/4-110 M39029/5-115 MS27488-20-1 M81969/14-11 16 Power/Signal M39029/4-111 M39029/5-116 MS27488-16-1 M81969/14-03 12 Power/Signal M39029/4-113 M39029/5-118 MS27488-12-1 M81969/14-04 20* Power/Signal 5291-022-204H 5091-022-204H MS27488-20-1 M81969/39-01 Extraction Tool Plastic * Size 20 contacts for 8-2, 8-3 and 8-4 layouts are only available to Aero-Electric part numbers. Connectors incorporating these three layouts are only sold to Aero-Electric callouts (AE770, AE771, AE772, AE774, AE775, AE776, AC3470, AC3471, AC3472, AC3474 and AC3475). Standard size 20 contacts M39029/4-110 and M39029/5-115 will not work in these 3 layouts. Crimping and Metal Insertion/Extraction Tools Contact Size 20 Crimp Tool Positioner Positioner Insertion Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. Military No. Military No. Military No. M22520/1-01 M22520/1-02 M22520/1-02 M22520/2- 01 M22520/2-02 M22520/2-02 M81969/8-205 M81969/8-206 26482 S 2 16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-207 M81969/8-208 12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-209 M81969/8-210 20* M22520/2-01 M22520/2-08 M22520/2-08 M81969/8-205 M81969/8-206 Contact and Wire Data Contact Size Test Current Voltage DC Test Max. Drop Well Dia. Amps Millivolts inch inch mm AWG mm2 inch mm inch mm 7.5 55 .049 .001 .155 3.94 24-20 .20-.52 .040 1.02 .083 2.11 20 Crimp Well Data Wire Range Minimum Well Dept Finished Wire O Range Minimum Maximum 16 13.0 49 .067 .001 .250 6.35 20-16 .52-1.31 .053 1.35 .103 2.62 12 23.0 42 .100 .002 .250 6.35 14-12 2.08-3.31 .097 2.46 .158 4.01 Note: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com - 121 - sales@aero-electric.com MIL-DTL-26482 Contact Installation Instructions Series 2 Contact Installation Instructions 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner 20 M39029/4-110 M39029/5-115 M22520/1-01 M22520/1-02 Red M22520/1-02 Red M22520/2-01 M22520/2-02 M22520/2-02 16 M39029/4-111 M39029/5-116 M22520/1-01 M22520/1-02 Blue M22520/1-02 Blue 12 M39029/4-113 M39029/5-118 M22520/1-01 20* 5291-022-204H 5091-022-204H M22520/2-01 M22520/1-02 Yellow M22520/1-02 Yellow M22520/2-08 M22520/2-08 Insertion/Removal Tool M81969/14-11 M81969/14-03 M81969/14-04 M81969/39-01 * Aero-Electric proprietary size 20 contacts used in 8-2, 8-3 and 8-4 layouts only. www.conesys.com - 122 - sales@aero-electric.com 26482 S 2 Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. MIL-DTL-26482 Series 2 Polarization, Insert Availability & Contact Information per MIL-STD-1669 Polarization (Insert Clocking) 1. In the normal insert clocking position (position N), the insert centerline coincides with the centerline of the master keyway (key) of the shell: L = 0. L MASTER KEYWAY (KEY) OF A SHELL 2. In the alternate clocking positions (W, X, Y and Z), the pin insert (viewing from mating side) is rotated clockwise relative to the centerline of the master keyway (key) of the shell. 3. The socket insert is rotated counter-clockwise. 4. Plugs have keys; receptacles have keyways. INSERT VERTICAL CENTERLINE Note: Be careful with alternate positions. See table below for position availability on layouts of interest. PIN INSERT MATING FACE (SOCKET INSERT IS OPPOSITE) Insert Availability, Contact Information and Clocking Positions Aero-Electric Total Contact Quantity Status No. of By Size Service Insert Positions In Degrees 26482 S 2 Insert Arrangement QPL'd Tooled Contacts 20 Rating N W X Y Z 8-2* No Yes 2 2 I 0 58 122 -- -- 8-3* No Yes 3 3 I 0 60 210 -- -- 8-4* No Yes 4 4 I 0 45 -- -- -- 8-33 Yes Yes 3 3 I 0 90 -- -- -- 8-98 Yes Yes 3 3 I 0 -- -- -- -- 10-6 Yes Yes 6 6 I 0 90 -- -- -- 10-7** N/A Yes 7 7 -- 12-3 Yes Yes 3 12-8 Yes Yes 8 8 10 16 12 3 I 0 90 -- -- II 0 -- -- 180 -- I 0 90 112 203 292 12-10 Yes Yes 10 I 0 60 155 270 295 14-2** N/A Yes 2 2 I 0 -- -- -- -- 14-4 Yes Yes 4 4 I 0 45 -- -- -- 14-5 Yes Yes 5 II 0 40 92 184 273 14-9 Yes Yes 9 5 I 0 15 90 180 240 14-12 Yes Yes 12 8 4 I 0 43 90 -- -- 14-15 Yes Yes 15 14 1 I 0 17 110 155 234 14-18 Yes Yes 18 18 I 0 15 90 180 270 14-19 Yes Yes 19 19 I 0 30 165 315 -- 5 4 * Not qualified to MIL-DTL-26482 Series 2. These layouts were designed to mate with solder Series 1 connectors using proprietary Aero-Electric contacts (not QPL'd to M39029) and to avoid confusion are sold only "with contacts". www.conesys.com ** Non MIL-STD-1669 layouts, available to Aero-Electric part numbers only and utilize standard M39029 contacts. These layouts were originally designed for use in AC3475 Arctic Coupling RFI plugs and AC3474 jam nut receptacles. - 123 - sales@aero-electric.com MIL-DTL-26482 Series 2 Polarization, Insert Availability & Contact Information per MIL-STD-1669 Insert Availability, Contact Information and Clocking Positions Aero-Electric Status Total Contact Quantity No. of Insert Arrangement QPL'd Tooled Contacts Insert Positions By Size 20 Yes Yes 8 Yes Yes 14 8 16-23 Yes Yes 23 22 16-26 Yes Yes 26 26 18-8 Yes Yes 8 18-11 Yes Yes 11 18-30 Yes Yes 30 29 18-32 Yes Yes 32 32 20-16 Yes Yes 16 20-24 Yes Yes 24 24 20-39 Yes Yes 39 37 20-41 Yes Yes 41 41 22-12 Yes Yes 12 22-21 Yes Yes 21 22-41 Yes Yes 41 27 22-55 Yes Yes 55 55 22-95 Yes Yes 32 26 24-19 Yes No 19 24-31 Yes Yes 31 24-61 Yes Yes 61 16 In Degrees 12 Rating N W X Y Z II 0 54 152 180 331 I 0 25 78 180 240 I 0 158 270 -- -- I 0 60 -- 275 338 I 0 180 -- -- -- 11 II 0 62 119 241 340 1 I 0 180 193 285 350 I 0 85 138 222 265 16 II 0 238 318 333 347 I 0 70 145 215 290 I 0 63 144 252 333 I 0 45 126 225 -- 8 6 1 8 2 I 0 -- -- -- -- 21 12 II 0 16 135 175 349 14 I 0 39 135 264 -- I 0 30 142 226 314 6 I 0 26 180 266 -- 19 II 0 30 165 315 -- I 0 90 225 255 -- I 0 90 180 270 324 31 61 - 124 - sales@aero-electric.com 26482 S 2 16-8 16-14 www.conesys.com Service MIL-STD-1669 Insert Arrangements (Pin Front View) for MIL-DTL-26482 Series 2 Connectors Insert Arrangement Views B A C A B 8-2* 2 # 20, I F 8-3* 3 # 20, I B C C F H 26482 S 2 B L N C L T L Z D B V U a Z g f M Z H C P R F Y X K J G C D P B H W F E V C F E E N M c L L X b Y a Z J H G A K B M D g h K 18-8 8 # 12, I C W J D G B f d S J N 18-32 32 # 20, I C E F H R D P G E F 18-30 1 # 16, 29 # 20, I F D U H V D E 14-19 19 # 20, I A U S G H E R V T J C P U D 16-26 26 # 20, I e N K B A L B c L F R G M B D G F X Y U S T b S W N A A S N T U 14-4 4 # 12, I 14-18 18 # 20, I R E W A M G P T * Not on QPL, available to Aero-Electric part number only. www.conesys.com E C L T H B C V J E J A B e a D 18-11 11 # 16, II A d c K F S b M C 16-23 1 # 16, 22 # 20, I R B K D F S H 16-14 8 # 20, 6 # 12, I K Y J F P P R X E A N K D M D G M C G P N L B 14-15 1 # 16, 14 # 20, I B P A G A N H J A 14-2** 2 # 12, I D 14-12 4 # 16, 8 # 20, I J H 10-6 6 # 20, I B C R J C E K A 16-8 8 # 16, II C D D M H L D 14-9 5 # 20, 4 # 12, I E J L M F E C B B E K B K C F H E 8-98 3 # 20, I 12-10 10 # 20, I J G G F K F A B J G A G B 12-8 8 # 20, I A 14-5 5 # 16, II B A C H C 8-33 3 # 20, I C D 12-3 3 # 16, II B B F A H B E C A A E A C A H A C 10-7** 7 # 20, I D B G A D D 8-4* 4 # 20, I G E A 20-16 16 # 16, II ** Non MIL-STD-1669 layout, available in AC3470 through AC3475 shell styles only. - 125 - sales@aero-electric.com MIL-STD-1669 Insert Arrangements (Pin Front View) for MIL-DTL-26482 Series 2 Connectors Insert Arrangement Views L K A M W N X Y a J B Z U T G D R S X B W R U H T G C m b c m P r R H z R P F N e g P F N f M L e K N C Z U R V D N a Y X S E J W V H G F T H F 24-31 31 # 16, I - 126 - L 22-95 6 # 12, 26 # 20, I Z V T PP MM x CC p F y m AA BB z h i k M H J j P N g G n R E f KK LL DD D e JJ NN C d w HH EE q B c v GG r U A b a u t FF S E J K M W s D H d N Q S G c P Y U G 24-19 19 # 12, II G c d F b e H X C E a j R J R g e T J P D Z f F B b f K K b S A M B P g T E 22-55 55 # 20, I L L D c d f L C Y h U 26482 S 2 A u v M J B a t w 22-41 14 # 16, 27 # 20, I M DD A V Y Z EE x C s FF g K X CC HH y h X W B r GG l E G H d q E 22-12 12 # 12, I W q BB D F A V p AA k D n t T D 22-21 21 # 16, II www.conesys.com U n T S i E L G J K 20-41 41 # 20, I B C K G H d L s S U N a i p c A j V C S V J q e M H F b M Z k E a f P J Y A X K R G H B D n r K L m t g J Z s h 20-39 2 # 16, 37 # 20, I P W c d C Y k S F A B X j i E a n P e M N L q f N 20-24 24 # 20, I T b P E F M m r D Z g R V H h U Y k i S C P C A W V B X J T A W V U K L 24-61 61 # 20, I sales@aero-electric.com MIL-DTL-83723 Series III Features and Application Bayonet and Threaded Coupling Features and Application Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having same insert arrangement. MIL-DTL-83723 Series III family offers connectors with bayonet and threaded coupling including lanyard-release quick-disconnects. These connectors combine the best features of MIL-DTL-26500 and NAS 1599 miniature connector specifications. They are intermateable with both bayonet and threaded 26500 connectors (exception: shell size 8, threaded coupling only) and have the added advantage provided by the rear-release contact retention system. Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. AE833 connectors are widely used on commercial, military and aerospace systems requiring general-purpose, miniature cylindrical bayonet or threaded coupling connectors. In addition, Series III threaded connectors with self-locking plugs are well suited for engine applications. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. This family of connectors (bayonet as well as threaded) is offered in wall mount receptacles as well as jam nut mounted receptacles which incorporate "O" ring seals, designed for rear panel "D" hole mounting. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. Series III bayonet-coupling plugs are available in two designs - with and without RFI grounding. Threaded coupling plugs are offered with and without RFI grounding, self-locking and RFI/self-locking. In addition we offer quick-disconnect (lanyard release) plugs, which mate with threaded receptacles via an adapter. 83723 S III Thirty-one insert arrangements per MIL-STD-1554 are tooled and qualified to MIL-DTL-83723 Series III, utilizing 2 to 61 M39029 contacts. Contacts come in sizes 20, 16 and 12, terminating wire sizes from 24 to 12 gauge. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel, olive drab cadmium and black anodic. Other finishes such as zinc cobalt are available upon request to commercial callouts only. In addition, we offer passivated stainless steel shells with both standard and firewall-rated inserts, and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. www.conesys.com - 127 - sales@aero-electric.com MIL-DTL-83723 Series III Performance Specifications Bayonet and Threaded Coupling Performance Specifications Voltage Rating Durability Mated connectors withstand a minimum of 500 mating cycles for bayonet coupling straight plug (M83723/75, 76); 250 mating cycles for bayonet coupling RFI plug (M83723/77, 78); and 250 cycles for all threaded coupling plugs (M83723/86, 87, 91, 92, 95, 96, 97, 98). Operating Temperature Range Classes A and R: -65C to +200C (-85F to +392F) Class W: -65C to +175C (-85F to +347F) Classes G and K: -65C to +200C (-85F to +392F) Classes N and S: -65C to +200C (-85F to +392F) Shock and Vibration Requirements Wired, mated connectors shall not be damaged, coupling ring shall not loosen, and there shall be no interruption of electrical continuity longer than one microsecond when subjected to the following: Material and Finish Data (Class) A - aluminum shell, black anodized finish(RoHS) G - stainless steel shell, passivated (RoHS) K - stainless steel shell, passivated, firewall (RoHS) R - aluminum shell, electroless nickel finish S - stainless steel shell, passivated, firewall, and 360 teeth Shock Mated connectors withstand a pulse of approximate half sine wave of 300 G 15 percent magnitude with duration of 3 1 milliseconds applied in three axes. ( RoHS) W- aluminum shell, olive drab cadmium over nickel base N - stainless steel shell, electrodeposited nickel, firewall, and 360 teeth Vibration Mated connectors withstand the following vibration levels: * Random vibration per MIL-STD-1344, method 2005, test condition VI, letter J. Corrosion Resistance Classes A, N, G, K, S & W withstand 500-hour salt spray. Class R withstands 48-hour salt spray. Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified by MIL-DTL-83723 Series III. Shielding Effectiveness RFI attenuation at the specified frequency meets the requirements of MIL-DTL-83723 Series III. * RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture. Service Rating Shell-to-Shell Conductivity (Except class A) * With RFI spring fingers, the maximum potential drop shall not exceed 5 millivolts. * Without spring fingers, the maximum potential drop shall not exceed 200 millivolts. Suggested Operating Voltage* Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft. V RMS V RMS V RMS V RMS AC (RMS) DC I 600 850 1500 500 375 200 II 900 1250 2300 750 500 200 * To be used by designer only as a guide. www.conesys.com - 128 - sales@aero-electric.com 83723 S III Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808 (lubricating oil), MIL-PRF-23699 (lubricating oil), MIL-PRF-5606 (hydraulic fluid), M2-V Chevron oil, Coolanol 25, MIL-DTL-83133 (turbine fuel JP-8), MIL-DTL-5624 (turbine fuels JP-4 and JP-5), SAEAMS1424 Type I (defrosting fluid), and other solvents and cleaning agents. MIL-DTL-83723 Series III Part Number Development Bayonet Coupling Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix M83723/ AE833 71 71 R R 12 12 12 12 N N -340 Shell type 71 = Wall mount receptacle with socket contacts 72 = Wall mount receptacle with pin contacts 73 = Jam nut receptacle with socket contacts 74 = Jam nut receptacle with pin contacts 75 = Straight plug with socket contacts 76 = Straight plug with pin contacts 77 = RFI grounding plug with socket contacts 78 = RFI grounding plug with pin contacts Class (Material and Finish) A = Aluminum shell, black anodized finish (not available in 77 and 78 RFI plugs) G = Stainless stell shell, passivated R = Aluminum shell, electroless nickel finish W = Aluminum shell, olive drab cadmium over electroless nickel finish Shell Size (SS) 8, 10, 12, 14, 16, 18, 20, 22 or 24 Insert Arrangement See pages 148 and 149 Polarization (Keying) N = Normal 6, 7, 8, 9 or Y (Alternate keyed positions, Y is not availabe in SS 8) 1, 2, 3, 4 or 5 (Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in shell size 8) Modification (applies to Aero part numbers only) 01 = Less contacts (Part is bagged and tagged, but not marked with 01) 340 = Connector kitted with M85049/31-XXX E-nut 83723 S III 341 = Connector kitted with M85049/52-1-XXX straight clamp 342 = Connector kitted with M85049/51-1-XXX right angle clamp Consult factory for other modifications Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 to 26 of each contact and two spares for inserts with 27 or more of each size, and a minimum of one sealing plug up to 15% of the number of contacts of each size. In addition, one insertion/removal tool of each size is included. www.conesys.com Note 2: Proper part number marking has no "0" in front of single digit shell size (8), but it does include the "0" in front of single digit layout. Examples: M83723/72W803N and M83723/77G10056. Please note that in this series "N" for normal is included in part number marking. - 129 - sales@aero-electric.com M83723/71, 72 Wall Mounting Receptacle AE83371, 72 Bayonet Coupling, Crimp Removable, Rear Release 1.300(33.02) MAX A .728(18.49) .708(17.98) B .072(1.83) .052(1.32) .290(7.37) MIN FULL THREAD 3x BAYONET PINS EQUALLY SPACED MASTER KEYWAY .190(4.83) GROMMET .130(3.30) EXTENSION 3 ACCESSORY TEETH EQUALLY SPACED D F MAX GROMMET E 4x MINOR KEYS 4x C MOUNTING HOLES Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B .005 .13 inch mm OC (TP) inch mm OD E .005 .13 +.000 -.005 +.00 -.13 inch mm inch mm Accessory Thread Class 2A OF Maximum inch mm 8 .812 20.62 .594 15.09 .120 3.05 .536 13.61 1/2-20UNF .305 7.75 10 .937 23.80 .719 18.26 .120 3.05 .659 16.74 5/8-24UNEF .405 10.29 12 1.031 26.19 .812 20.62 .120 3.05 .829 21.06 3/4-20UNEF .531 13.49 14 1.125 28.58 .906 23.01 .120 3.05 .898 22.81 7/8-20UNEF .665 16.89 16 1.250 31.75 .969 24.61 .120 3.05 1.025 26.04 1-20UNEF .790 20.07 18 1.343 34.11 1.062 26.97 .120 3.05 1.131 28.73 1-1/16-18UNEF .869 22.07 20 1.437 36.50 1.156 29.36 .120 3.05 1.256 31.90 1-3/16-18UNEF .994 25.25 22 1.562 39.67 1.250 31.75 .120 3.05 1.381 35.08 1-5/16-18UNEF 1.119 28.42 24 1.703 43.26 1.375 34.93 .149 3.78 1.506 38.25 1-7/16-18UNEF 1.244 31.60 www.conesys.com - 130 - sales@aero-electric.com 83723 S III Shell Size ACCESSORY THREAD BLUE COLOR BANDS M83723/73, 74 Jam Nut Receptacle AE83373, 74 Bayonet Coupling, Crimp Removable, Rear Release A MAX 1.300(33.02) MAX .190(4.83) GROMMET .130(3.30) EXTENSION E MOUNTING FLAT .781(19.84) .761(19.33) MASTER KEYWAY "O" RING 3 ACCESSORY TEETH EQUALLY SPACED C D MAX GROMMET F JAM NUT G ACCESSORY THREAD B THREAD MAX 4x MINOR KEYWAYS HEX NUT PER MS3186 BLUE COLOR BAND BLUE COLOR BAND PANEL THICKNESS: .125(3.18) .062(1.58) Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 83723 S III Shell Size Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A OB OC Maximum Maximum Maximum inch mm inch mm inch OD E +.000 -.005 +.00 -.13 .003 .08 mm inch mm inch mm F G Jam Nut Thread Class 2A Accessory Thread Class 2A 8 .979 24.87 1.068 27.13 .305 7.75 .536 13.61 .593 15.06 5/8-20UN 1/2-20UNF 10 1.104 28.04 1.192 30.28 .405 10.29 .659 16.74 .718 18.24 3/4-20UNEF 5/8-24UNEF 12 1.291 32.79 1.380 35.05 .531 13.49 .829 21.06 .905 22.99 15/16-20UNEF 3/4-20UNEF 14 1.391 35.33 1.505 38.23 .665 16.89 .898 22.81 .968 24.59 1-20UNEF 7/8-20UNEF 16 1.516 38.51 1.630 41.40 .790 20.07 1.025 26.04 1.093 27.76 1-1/8-20UN 1-20UNEF 18 1.641 41.68 1.756 44.60 .869 22.07 1.131 28.73 1.217 30.91 1-1/4-18UNEF 1-1/16-18UNEF 20 1.766 44.86 1.860 47.24 .994 25.25 1.256 31.90 1.342 34.09 1-3/8-18UNEF 1-3/16-18UNEF 22 1.954 49.63 2.086 52.98 1.119 28.42 1.381 35.08 1.467 37.26 1-1/2-18UNEF 1-5/16-18UNEF 24 2.079 52.81 2.160 54.86 1.244 31.60 1.506 38.25 1.592 40.44 1-5/8-18UNEF 1-7/16-18UNEF www.conesys.com - 131 - sales@aero-electric.com M83723/75, 76 Straight Plug AE83375, 76 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX F 3x BAYONET HOLES EQUALLY SPACED MAX COUPLING NUT .290(7.37) MIN FULL THREAD .190(4.83) GROMMET .130(3.30) EXTENSION MASTER KEY 3 ACCESSORY TEETH EQUALLY SPACED E G MAX GROMMET 4 MINOR KEYS H ACCESSORY THREAD BLUE COLOR BAND Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization inch OF OG Maximum Maximum H +.005 -.004 +.13 -.10 mm inch mm inch mm Accessory Thread Class 2A 8 .305 7.75 .776 19.71 .419 10.64 1/2-20UNF 10 .405 10.29 .906 23.01 .521 13.23 5/8-24UNEF 12 .531 13.49 1.078 27.38 .691 17.55 3/4-20UNEF 14 .665 16.89 1.141 28.98 .760 19.30 7/8-20UNEF 16 .790 20.07 1.266 32.16 .887 22.53 1-20UNEF 18 .869 22.07 1.375 34.93 .993 25.22 1-1/16-18UNEF 20 .994 25.25 1.510 38.35 1.118 28.40 1-3/16-18UNEF 22 1.119 28.42 1.625 41.28 1.243 31.57 1-5/16-18UNEF 24 1.244 31.60 1.760 44.70 1.368 34.75 1-7/16-18UNEF www.conesys.com - 132 - sales@aero-electric.com 83723 S III Shell Size OE M83723/77, 78 RFI Grounding Plug AE83377, 78 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX F 3x BAYONET HOLES EQUALLY SPACED MAX COUPLING NUT MASTER KEY .290(7.37) MIN FULL THREAD .190(4.83) GROMMET .130(3.30) EXTENSION R.F.I SPRING 3 ACCESSORY TEETH EQUALLY SPACED E G MAX GROMMET 4 MINOR KEYS H ACCESSORY THREAD BLUE COLOR BAND Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization 83723 S III Shell Size inch OE OF Maximum Maximum mm inch OG mm H +.005 -.004 +.13 -.10 inch mm Accessory Thread Class 2A 8 .305 7.75 .776 19.71 .419 10.64 1/2-20UNF 10 .405 10.29 .906 23.01 .521 13.23 5/8-24UNEF 12 .531 13.49 1.078 27.38 .691 17.55 3/4-20UNEF 14 .665 16.89 1.141 28.98 .760 19.30 7/8-20UNEF 16 .790 20.07 1.266 32.16 .887 22.53 1-20UNEF 18 .869 22.07 1.375 34.93 .993 25.22 1-1/16-18UNEF 20 .994 25.25 1.510 38.35 1.118 28.40 1-3/16-18UNEF 22 1.119 28.42 1.625 41.28 1.243 31.57 1-5/16-18UNEF 24 1.244 31.60 1.760 44.70 1.368 34.75 1-7/16-18UNEF www.conesys.com - 133 - sales@aero-electric.com MIL-DTL-83723 Series III Part Number Development Threaded Coupling Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix M83723/ AE833 95 95 R R 12 12 12 12 N N -340 Shell type 82 = Wall mount receptacle with socket contacts 83 = Wall mount receptacle with pin contacts 84 = Jam nut receptacle with socket contacts 85 = Jam nut receptacle with pin contacts 86 = Straight plug with socket contacts 87 = Straight plug with pin contacts 91 = RFI grounding plug with socket contacts 92 = RFI grounding plug with pin contacts 95 = Self-locking plug with socket contacts 96 = Self-locking plug with pin contacts 97 = Self-locking, RFI grounding plug with socket contacts 98 = Self-locking, RFI grounding plug with pin contacts 68 = Lanyard release, quick-disconnect plug, pin (not available in K & S classes) 69 = Lanyard release, quick-disconnect plug, socket (not available in K & S classes) Class (Material and Finish) A = Aluminum shell, black anodized finish (Not available in 91, 92, 97 & 98 RFI plugs) G = Stainless steel shell, passivated (n/a in 97 & 98) K = Stainless steel shell, passivated, with firewall rated insert (n/a in 91, 92, 97 & 98) R = Aluminum shell, electroless nickel finish (n/a in 97 & 98 to mil number) W = Aluminum shell, olive drab cadmium over nickel base (n/a in 97 & 98 to mil number) S = Stainless steel shell, passivated, full teeth, firewall insert (n/a in 86, 87, 91, 92, 95 & 96) Shell Size (SS) 8, 10, 12, 14, 16, 18, 20, 22 or 24 (and shell size 28 available in Aero p/n only) Insert Arrangement See pages 148 and 149 Polarization (Keying) N = Normal 6, 7, 8, 9 or Y (Alternate keyed positions, Y is not availabe in SS 8) 1, 2, 3, 4 or 5 (Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in SS 8) Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 to 26 of each contact and two spares for inserts with 27 or more of each size, and a minimum of one sealing plug up to 15% of the number of contacts of each size. In addition, one insertion/removal tool of each size is included. www.conesys.com 83723 S III Modification (applies to Aero part numbers only) 01 = Less contacts (Part is bagged and tagged, but not marked with 01) 340 = Connector kitted with M85049/31-XXX E-nut 341 = Connector kitted with M85049/52-1-XXX straight clamp 342 = Connector kitted with M85049/51-1-XXX right angle clamp Consult factory for other modifications Note 2: Proper part number marking has no "0" in front of single digit shell size (8), but it does include the "0" in front of single digit layout. Examples: M83723/95G803N and M83723/98S10056. Please note that in this series "N" for normal is included in part number marking. Note 3: Shell type M83723/70 (AE83370 Receptacle Adapter) is not listed above, - 134 - sales@aero-electric.com M83723/82, 83 Wall Mounting Receptacle AE83382, 83 Threaded Coupling, Crimp Removable, Rear Release 1.248(31.70) MAX .072(1.83) .728(18.49) .052(1.32) .708(17.98) A B MASTER KEYWAY 1.340(34.04) MAX CLASS "S" ONLY .290(7.37) MIN FULL THREAD .190(4.83) GROMMET .130(3.30) EXTENSION .290(7.37) MIN FULL THREAD .160(4.06) GROMMET .010(0.25) EXTENSION 3 ACCESORY TEETH E U ALLY S ACED OF OF MAX GROMMET H No. OF TEETH CLASSES: "N" & "S" ONLY E ACCESSORY THREAD D MATING THREAD 4 MINOR KEYWAYS MAX GROMMET E ACCESSORY THREAD BLUE COLOR BANDS 4x OC MOUNTING HOLES FULL MATE INDICATOR COLOR: RED PANEL THICKNESS: .125(3.18) MAX Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B 83723 S III .13 OC +.005 -.004 (TP) +.13 -.10 D E Mating Thread Class 2A Accessory Thread Class 2A OF H Maximum No. of Teeth Shell Size .005 inch mm inch mm inch mm inch mm 8 .812 20.62 .594 15.09 .120 3.05 9/16-24UNEF 1/2-20UNF .305 7.75 12 10 .937 23.80 .719 18.26 .120 3.05 11/16-24UNEF 5/8-24UNEF .405 10.29 15 12 1.031 26.19 .812 20.62 .120 3.05 7/8-20UNEF 3/4-20UNEF .531 13.49 21 14 1.125 28.58 .906 23.01 .120 3.05 15/16-20UNEF 7/8-20UNEF .665 16.89 24 16 1.250 31.75 .969 24.61 .120 3.05 1-1/16-18UNEF 1-20UNEF .790 20.07 30 18 1.343 34.11 1.062 26.97 .120 3.05 1-3/16-18UNEF 1-1/16-18UNEF .869 22.07 33 20 1.437 36.50 1.156 29.36 .120 3.05 1-5/16-18UNEF 1-3/16-18UNEF .994 25.25 36 22 1.562 39.67 1.250 31.75 .120 3.05 1-7/16-18UNEF 1-5/16-18UNEF 1.119 28.42 39 24 1.703 43.26 1.375 34.93 .149 3.78 1-9/16-18UNEF 1-7/16-18UNEF 1.244 31.60 42 28 2.000 50.80 1.562 39.67 .149 3.78 1-13/16-16UN 1-3/4-18UNS 1.475 37.47 54 www.conesys.com - 135 - sales@aero-electric.com M83723/84, 85 Jam Nut Receptacle AE83384, 85 Threaded Coupling, Crimp Removable, Rear Release 1.340(34.04) MAX CLASS "S" ONLY A 1.240(31.50) MAX G HEX NUT PER MS3186 MOUNTING FLAT MASTER KEYWAY "O" RING FULL MATE INDICATOR COLOR: RED .290(7.37) MIN FULL THREAD .290(7.37) MIN FULL THREAD .190(4.83) .130(3.30) GROMMET EXTENSION .160(4.06) GROMMET .010(0.25) EXTENSION CLASSES: "N" & "S" OC MAX GROMMET OC MAX GROMMET 3 ACCESSORY TEETH 120 APART F No. OF TEETH H ACCESSORY THREAD OB CLASSES: "N" & "S" ONLY H ACCESSORY THREAD E JAM NUT BLUE COLOR BAND THREAD D 4 MINOR KEYWAYS MATING THREAD .781(19.84) .761(19.33) BLUE COLOR BAND PANEL THICKNESS: .125(3.18) .062(1.57) Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A 8 +.016 -.015 +.41 -.38 +.016 -.015 +.41 -.38 OC D E F Maximum Mating Thread Class 2A Jam Nut Thread Class 2A No. of Teeth inch mm Class 2A 5/8-20UN 12 .593 15.06 1/2-20UNF inch mm inch mm inch mm .964 24.49 1.062 26.97 .305 7.75 9/16-24UNEF G .003 H .08 Accessory Thread 10 1.088 27.64 1.176 29.87 .405 10.29 11/16-24UNEF 3/4-20UNEF 15 .718 18.24 5/8-24UNEF 12 1.275 32.39 1.364 34.65 .531 13.49 7/8-20UNEF 15/16-20UNEF 21 .905 22.99 3/4-20UNEF 14 1.375 34.93 1.545 39.24 .665 16.89 15/16-20UNEF 1-20UNEF 24 .968 24.59 7/8-20UNEF 16 1.500 38.10 1.625 41.28 .790 20.07 1-1/16-18UNEF 1-1/8-18UNEF 30 1.093 27.76 1-20UNEF 18 1.625 41.28 1.750 44.45 .869 22.07 1-3/16-18UNEF 1-1/4-18UNEF 33 1.217 30.91 1-1/16-18UNEF 20 1.750 44.45 1.938 49.23 .994 25.25 1-5/16-18UNEF 1-3/8-18UNEF 36 1.342 34.09 1-3/16-18UNEF 22 1.938 49.23 2.062 52.37 1.119 28.42 1-7/16-18UNEF 1-1/2-18UNEF 39 1.467 37.26 1-5/16-18UNEF 24 2.063 52.40 2.166 55.02 1.244 31.60 1-9/16-18UNEF 1-5/8-18UNEF 42 1.592 40.44 1-7/16-18UNEF 28 2.314 58.78 2.428 61.67 1.475 37.47 1-13/16-16UN 1-7/8-20UN 54 1.840 46.74 1-3/4-18UNS www.conesys.com - 136 - sales@aero-electric.com 83723 S III Shell Size OB M83723/86, 87 Straight Plug AE83386, 87 Threaded Coupling, Crimp Removable, Rear Release 1.180(29.97) MAX 3x .035(.89) SAFETY WIRE HOLES B MAX COUPLING NUT MASTER KEY .290(7.37) MIN FULL THREAD .190(4.83) .130(3.30) GROMMET EXTENSION A C MAX GROMMET 3 ACCESSORY TEETH EQUALLY SPACED D MATING THREAD 4 MINOR KEYS Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 BLUE COLOR BAND Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA 83723 S III Shell Size E ACCESSORY THREAD +.005 -.004 O +.13 -.10 B O Maximum C Maximum D E Mating Thread Class 2B Accessory Thread Class 2A inch mm inch mm inch mm 8 .400 10.16 .776 19.71 .305 7.75 9/16-24UNEF 1/2-20UNF 10 .521 13.23 .906 23.01 .405 10.29 11/16-24UNEF 5/8-24UNEF 12 .691 17.55 1.078 27.38 .531 13.49 7/8-20UNEF 3/4-20UNEF 14 .760 19.30 1.141 28.98 .665 16.89 15/16-20UNEF 7/8-20UNEF 16 .887 22.53 1.266 32.16 .790 20.07 1-1/16-18UNEF 1-20UNEF 18 .993 25.22 1.375 34.93 .869 22.07 1-3/16-18UNEF 1-1/16-18UNEF 20 1.118 28.40 1.510 38.35 .994 25.25 1-5/16-18UNEF 1-3/16-18UNEF 22 1.243 31.57 1.625 41.28 1.119 28.42 1-7/16-18UNEF 1-5/16-18UNEF 24 1.368 34.75 1.760 44.70 1.244 31.60 1-9/16-18UNEF 1-7/16-18UNEF 28 1.618 41.10 2.050 52.07 1.475 37.47 1-13/16-16UN 1-3/4-18UNS www.conesys.com - 137 - sales@aero-electric.com M83723/91, 92 RFI Grounding Plug AE83391, 92 Threaded Coupling, Crimp Removable, Rear Release 1.180(29.97) MAX 3X .035(.89) SAFETY WIRE HOLES B MAX COUPLING NUT MASTER KEY .290(7.37) MIN FULL THREAD .190(4.83) .130(3.30) GROMMET EXTENSION RFI STRIP C A MAX GROMMET 3 ACCESSORY TEETH EQUALLY SPACED D MATING THREAD 4 MINOR KEYS Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 BLUE COLOR BAND ACCESSORY THREAD Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA +.005 -.004 OB +.13 -.10 Maximum OC D E Maximum Mating Thread Class 2B Accessory Thread Class 2A inch mm inch mm inch mm 8 .400 10.16 .776 19.71 .305 7.75 9/16-24UNEF 1/2-20UNF 10 .521 13.23 .906 23.01 .405 10.29 11/16-24UNEF 5/8-24UNEF 12 .691 17.55 1.078 27.38 .531 13.49 7/8-20UNEF 3/4-20UNEF 14 .760 19.30 1.141 28.98 .665 16.89 15/16-20UNEF 7/8-20UNEF 16 .887 22.53 1.266 32.16 .790 20.07 1-1/16-18UNEF 1-20UNEF 18 .993 25.22 1.375 34.93 .869 22.07 1-3/16-18UNEF 1-1/16-18UNEF 20 1.118 28.40 1.510 38.35 .994 25.25 1-5/16-18UNEF 1-3/16-18UNEF 22 1.243 31.57 1.625 41.28 1.119 28.42 1-7/16-18UNEF 1-5/16-18UNEF 24 1.368 34.75 1.760 44.70 1.244 31.60 1-9/16-18UNEF 1-7/16-18UNEF 28 1.618 41.10 2.050 52.07 1.475 37.47 1-13/16-16UN 1-3/4-18UNS www.conesys.com - 138 - sales@aero-electric.com 83723 S III Shell Size E M83723/95, 96 Self-Locking Plug AE83395, 96 Threaded Coupling, Crimp Removable, Rear Release 1.180(29.97) MAX C MAX .290(7.37) MIN FULL THREAD COUPLING NUT MASTER KEY .190(4.83) .130(3.30) GROMMET EXTENSION B A MAX GROMMET 3 ACCESSORY TEETH EQUALLY SPACED D MATING THREAD E ACCESSORY THREAD 4 MINOR KEYS BLUE COLOR BAND Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O 83723 S III Shell Size +.005 -.004 A O +.13 -.10 B O Maximum C Maximum D E Mating Thread Class 2B Accessory Thread Class 2A 1/2-20UNF inch mm inch mm inch mm 8 .400 10.16 .305 7.75 .832 21.13 9/16-24UNEF 10 .521 13.23 .405 10.29 .959 24.36 11/16-24UNEF 5/8-24UNEF 12 .691 17.55 .531 13.49 1.097 27.86 7/8-20UNEF 3/4-20UNEF 14 .760 19.30 .665 16.89 1.236 31.39 15/16-20UNEF 7/8-20UNEF 16 .887 22.53 .790 20.07 1.360 34.54 1-1/16-18UNEF 1-20UNEF 18 .993 25.22 .869 22.07 1.473 37.41 1-3/16-18UNEF 1-1/16-18UNEF 20 1.118 28.40 .994 25.25 1.586 40.28 1-5/16-18UNEF 1-3/16-18UNEF 22 1.243 31.57 1.119 28.42 1.703 43.26 1-7/16-18UNEF 1-5/16-18UNEF 24 1.368 34.75 1.244 31.60 1.846 46.89 1-9/16-18UNEF 1-7/16-18UNEF 28 1.618 41.10 1.475 37.47 2.278 57.86 1-13/16-16UN 1-3/4-18UNS www.conesys.com - 139 - sales@aero-electric.com M83723/97, 98 Self-Locking, RFI Grounding Plug AE83397, 98 Threaded Coupling, Crimp Removable, Rear Release 1.280(32.51) MAX [ D MAX .290(7.37) MIN FULL THREAD COUPLING NUT MASTER KEY .160(4.06) .010(0.25) GROMMET EXTENSION [C [A MAX GROMMET RFI STRIP B NUMBER OF TEETH E MATING THREAD 4 MINOR KEYS F ACCESSORY THREAD BLUE COLOR BAND Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O A B +.13 -.10 No. of Teeth O C O Maximum D Maximum E F Mating Thread Class 2B Accessory Thread Class 2A inch mm inch mm inch mm 8 .400 10.16 12 .305 7.75 .967 24.56 9/16-24UNEF 1/2-20UNF 10 .521 13.23 15 .405 10.29 1.093 27.76 11/16-24UNEF 5/8-24UNEF 12 .691 17.55 21 .531 13.49 1.170 29.72 7/8-20UNEF 3/4-20UNEF 14 .760 19.30 24 .665 16.89 1.310 33.27 15/16-20UNEF 7/8-20UNEF 16 .887 22.53 30 .790 20.07 1.500 38.10 1-1/16-18UNEF 1-20UNEF 18 .993 25.22 33 .869 22.07 1.562 39.67 1-3/16-18UNEF 1-1/16-18UNEF 20 1.118 28.40 36 .994 25.25 1.710 43.43 1-5/16-18UNEF 1-3/16-18UNEF 22 1.243 31.57 39 1.119 28.42 1.812 46.02 1-7/16-18UNEF 1-5/16-18UNEF 24 1.368 34.75 42 1.244 31.60 1.948 49.48 1-9/16-18UNEF 1-7/16-18UNEF 28 1.618 41.10 54 1.475 37. 47 2.278 57.86 1-13/16-16UN 1-3/4-18UNS www.conesys.com - 140 - sales@aero-electric.com 83723 S III Shell Size +.005 -.004 M83723/68, 69 Lanyard Release, Quick-Disconnect Plug AE83368, 69 Quick-Disconnect, Threaded Coupling, Crimp Removable, Rear Release A 7.500(190.50) MAX MAX C ACCESSORY THREAD BLUE COLOR BAND MASTER KEY B D MAX GROMMET 4 MINOR KEYS LENGTH TO BE MEASURED WITH A .750(19.05).060(1.52) BAR TO PULL LANYARD TAUT 3 ACCESSORY TEETH EQUALLY SPACED 1.180(29.97) MAX .190(4.83) .130(3.30) GROMMET EXTENSION Page 129 Page 145 Pages 148,149 Page 128 Page 147 Page 143 Note 1: M83723/70 receptacle adapter (page 142) is required to mate the Quick-Disconnect Plug with a receptacle. Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization 83723 S III O A O Maximum Note 2: Not available in shell size 8. B C O D Accessory Thread Class 2A Maximum Shell Size inch mm inch mm inch mm 10 1.240 31.50 .405 10.29 5/8-24UNEF .526/.517 13.36/13.13 12 1.432 36.37 .531 13.49 3/4-20UNEF .696/.687 17.68/17.45 14 1.490 37.85 .665 16.89 7/8-20UNEF .765/.756 19.43/19.20 16 1.711 43.46 .790 20.07 1-20UNEF .892/.883 22.66/22.43 18 1.815 46.10 .869 22.07 1-1/16-18UNEF .998/.989 25.35/25.12 20 1.962 49.83 .994 25.25 1-3/16-18UNEF 1.123/1.114 28.52/28.30 22 2.070 52.58 1.119 28.42 1-5/16-18UNEF 1.248/1.239 31.70/31.47 24 2.195 55.75 1.244 31.60 1-7/16-18UNEF 1.373/1.364 34.87/34.65 www.conesys.com - 141 - sales@aero-electric.com M83723/70 Receptacle Adapter, Quick-Disconnect AE83370 Quick-Disconnect (Push-Pull) Receptacle Adapter .442(11.23) .005(.13) C D THREAD A B E COLOR BAND Mil Prefix Aero Prefix M83723/ AE833 70 70 W W 10 10 Specification Sheet (Shell type) 70 = Receptacle adapter, quick-disconnect Class (Material and Finish) A = Aluminum shell, black anodized finsih Note: The adapter is required to mate the Lanyard Release and Push-Pull Quick-Disconnect plugs (M83723/66 thru 69) with M83723/82, 83, 84, 85, 88, 89 and 90 threaded coupling receptacles. Use compatible thread seizing compound to permanently secure to the receptacle. G = Stainless steel shell, passivated R = Aluminum shell, elctroless nickel finish W = Aluminum shell, cadmium olive drab over nickel base Shell Size 8, 10, 12, 14, 16, 18, 20, 22 or 24 D Coupling Thread Class 2B A O B O C O E .002 .05 .002 .05 .002 .05 .005 .13 inch mm inch mm inch mm inch mm 8 9/16-24UNEF .605 15.37 .577 14.66 .687 17.45 .525 13.34 10 11/16-24UNEF .730 18.54 .712 18.08 .812 20.62 .650 16.51 12 7/8-20UNEF .917 23.29 .892 22.66 .999 25.37 .840 21.34 14 15/16-20UNEF .980 24.89 .952 24.18 1.062 26.97 .900 22.86 16 1-1/16-18UNEF 1.105 28.07 1.077 27.36 1.187 30.15 1.025 26.04 18 1-3/16-18UNEF 1.230 31.24 1.202 30.53 1.328 33.73 1.150 29.21 20 1-5/16-18UNEF 1.355 34.42 1.327 33.71 1.453 36.91 1.275 32.39 22 1-7/16-18UNEF 1.480 37.59 1.452 36.88 1.578 40.08 1.400 35.56 24 1-9/16-18UNEF 1.605 40.77 1.577 40.06 1.703 43.26 1.525 38.74 www.conesys.com - 142 - sales@aero-electric.com 83723 S III Shell Size O MIL-DTL-83723 Series III Polarization (Shell Keying, Insert Clocking) Bayonet and Threaded Shell Keying D B Insert Clocking E MASTER KEYWAY(KEY) OF SHELL MASTER KEYWAY A ENGAGING FACE VIEW FOR RECEPTACLE SHELL KEYWAYS (PLUG SHELL KEYS, OPPOSITE) C INSERT VERTICAL CENTERLINE SOCKET INSERT MATING FACE (PIN INSERT IS OPPOSITE) Notes: 1. In the normal position (N), the insert centerline coincides with the centerline of the master keyway (key) of the shell. E = 0. 2. In the alternate keying positions (6, 7, 8, 9 and Y), the minor keyways (keys) are positioned with reference to master keyway (key) as indicated in the keying position table below. Polarizing Shell Size 8*, 10 10 only 83723 S III 12 thru 24, 28** 10 thru 24 Position N 6 7 8 9 Y N 6 7 8 9 Y 1 2 3 4 5 3. In the alternate insert clocking positions (1, 2, 3, 4 and 5), the socket insert (viewing from the mating side) is rotated counter-clockwise relative to the centerline of the master keyway (key) of the shell. The pin insert is rotated clockwise. Key/Keyway Positions A 105 102 80 35 64 25 105 18 92 84 24 98 105 105 105 105 105 B 140 132 118 140 155 115 140 149 152 152 135 152 140 140 140 140 140 * Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5 are not available in shell size 8. D 265 320 312 275 304 270 265 259 342 334 240 338 265 265 265 265 265 E 0 0 0 0 0 0 0 0 0 0 0 0 10 20 30 40 50 Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. Note: Alternate positions "Z" and "10" are cancelled and superseded by Position "Y". ** Shell size 28 is not from military standard. It is only availabe in threaded family to Aero-Electric part number. www.conesys.com C 215 248 230 205 234 220 215 192 222 204 199 268 215 215 215 215 215 Insert Position - 143 - sales@aero-electric.com MIL-DTL-83723 Series III, Bayonet and Threaded Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts S LL J Z L Panel Thickness Receptacle Type Rear Mounting Wall Mount Receptacle, Bayonet Front Mounting inch mm inch mm .250 max* 6.36 max* .125 max 3.18 max Wall Mount Receptacle, Threaded .125 max 3.18 max .125 max 3.18 max Jam Nut Mount (Bayonet & Threaded) .062/.125 1.57/3.18 -- -- * Includes screw-head Flange and Jam Nut Mounting Dimensions L O J O O inch mm inch mm inch S O Z +.000 -.009 +.00 -.23 .005 .13 .005 .13 mm inch mm inch mm inch mm For Front Mounting Minimum Shell Size LL 8 .594 15.09 .620 15.75 .510 12.95 .125 3.18 .605 15.37 .635 16.13 10 .719 18.26 .748 19.00 .635 16.13 .125 3.18 .730 18.54 .760 19.30 12 .812 20.62 .918 23.32 .760 19.30 .125 3.18 .917 23.29 .947 24.05 14 .906 23.01 .988 25.10 .885 22.48 .125 3.18 .980 24.89 1.010 25.65 16 .969 24.61 1.114 28.30 1.010 25.65 .125 3.18 1.105 28.07 1.135 28.83 18 1.062 26.97 1.220 30.99 1.072 27.23 .125 3.18 1.229 31.22 1.260 32.00 20 1.156 29.36 1.346 34.19 1.197 30.40 .125 3.18 1.354 34.39 1.385 35.18 22 1.250 31.75 1.470 37.34 1.322 33.58 .125 3.18 1.479 37.57 1.510 38.35 24 1.375 34.93 1.596 40.54 1.442 36.63 .154 3.91 1.604 40.74 1.635 41.53 www.conesys.com - 144 - sales@aero-electric.com 83723 S III For Back Mounting Minimum (TP) J MIL-DTL-83723 Contacts, Tools and Seal Plugs Series III Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Plastic Contact Size Type Military No. Military No. Military No. Military No. 20 Power/Signal M39029/4-110 M39029/5-115 MS27488-20-1 M81969/14-11 16 Power/Signal M39029/4-111 M39029/5-116 MS27488-16-1 M81969/14-03 12 Power/Signal M39029/4-113 M39029/5-118 MS27488-12-1 M81969/14-04 Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. Military No. Military No. M81969/8-205 M81969/8-206 Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size Military No. M22520/1-01 M22520/1-02 M22520/1-02 M22520/2-01 M22520/2-02 M22520/2-02 16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-207 M81969/8-208 12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-209 M81969/8-210 20 Contact and Wire Data 83723 S III Test Current Voltage DC Test Max. Drop Well Dia. Amps Millivolts inch inch mm AWG mm2 inch mm inch mm 20 7.5 55 .049 .001 .155 3.94 24-20 .20-.52 .040 1.02 .083 2.11 16 13.0 49 .067 .001 .250 6.35 20-16 .52-1.31 .053 1.35 .103 2.62 12 23.0 42 .100 .002 .250 6.35 14-12 2.08-3.31 .097 2.46 .158 4.01 Contact Size Crimp Well Data Wire Range Minimum Well Dept Finished Wire O Range Minimum Maximum Note: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com - 145 - sales@aero-electric.com MIL-DTL-83723 Series III Contact Installation Instructions Bayonet and Threaded Coupling Contact Installation Instructions 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. Size Pin Contact Socket Contact 20 M39029/4-110 M39029/5-115 16 M39029/4-111 12 M39029/4-113 www.conesys.com Basic Crimp Tool Pin Positioner Socket Positioner M22520/1-01 M22520/1-02 Red M22520/1-02 Red M22520/2-01 M22520/2-02 M22520/2-02 M39029/5-116 M22520/1-01 M22520/1-02 Blue M22520/1-02 Blue M39029/5-118 M22520/1-01 M22520/1-02 Yellow M22520/1-02 Yellow - 146 - Insertion/Removal Tool M81969/14-11 M81969/14-03 M81969/14-04 sales@aero-electric.com 83723 S III 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. MIL-DTL-83723 Series III Insert Availability and Contact Information per MIL-STD-1554 Insert Availability and Contact Information Aero-Electric Total Quantity of Contacts Status No. of (by Size) Service Alternate Positions** (Insert Rotation in Degrees) Insert Arrangement QPL'd Tooled Contacts 20 Rating 1 2 3 4 5 8-2 Yes Yes 2 2 I N/A N/A N/A N/A N/A 8-3 Yes Yes 3 3 I N/A N/A N/A N/A N/A 16 12 # 8 coax 8-98 Yes Yes 3 3 I N/A N/A N/A N/A N/A 10-2 Yes Yes 2 2 I 10 20 30 40 50 10-5 Yes Yes 5 5 I 10 20 30 40 50 10-6 Yes Yes 6 6 I 10 20 30 40 50 10-20 Yes Yes 2 I 10 20 30 40 50 2 12-3 Yes Yes 3 12-12 Yes Yes 12 14-4 Yes Yes 4 14-7 Yes Yes 7 14-12 Yes Yes 12 9 15 14-15 Yes Yes 15 16-10 Yes Yes 10 16-24 Yes Yes 24 18-8 Yes Yes 8 18-14 Yes Yes 14 18-31 Yes Yes 31 20-16 Yes Yes 16 3 12 4 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 7 I 10 20 30 40 50 3 I 10 20 30 40 50 I 10 20 30 40 50 10 I 10 20 30 40 50 24 I 10 20 30 40 50 I 10 20 30 40 50 14 I 10 20 30 40 50 I 10 20 30 40 50 16 I 10 20 30 40 50 8 31 20-25 Yes Yes 25 19 6 I 10 20 30 40 50 20-28 Yes Yes 28 24 4 I 10 20 30 40 50 20-39 Yes Yes 39 37 I 10 20 30 40 50 41 20-41 Yes Yes 41 22-12 Yes Yes 12 83723 S III 22-19 Yes Yes 19 22-32 Yes Yes 32 26 22-55 Yes Yes 55 55 24-19 Yes Yes 19 24-29* N/A Yes 29 Yes 30 Yes Yes 43 23 24-57 Yes Yes 57 55 61 Yes Yes 61 Yes 42 20 30 40 50 10 20 30 40 50 I 10 20 30 40 50 6 I 10 20 30 40 50 I 10 20 30 40 50 19 N/A N/A 10 I 29 24-30* 24-61 I 12 19 24-43 28-42* 2 10 20 30 40 50 10 20 30 40 50 30 I 10 20 30 40 50 20 I 10 20 30 40 50 I 10 20 30 40 50 2 42 * Non MIL-STD-1554 layout, available to Aero-Electric part number only. Consult factory for pin insert availablility. www.conesys.com I I I 10 20 30 40 50 I 10 20 30 40 50 ** Alternate clocking positions (1, 2, 3, 4, and 5) are for interchangeability use only. Inactive for new design per MIL-STD-1554. - 147 - sales@aero-electric.com MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-83723 Series III Connectors Insert Arrangement Views 1 1 2 3 2 803 3 # 20 I 802* 2 # 20 I 2 1 2 898 3 # 20 I 1005 5 # 20 I 4 1 5 1 4 3 1002 2 # 20 I 1 2 1 6 5 1 3 1 1006 6 # 20 I 7 1 1 1 12 12 2 1020 2 # 16 I 3 1203 3 # 16 I 1212 12 # 20 I 1404 4 # 12 I 1407 7 # 16 I 1412 9 # 20, 3 # 16 I 8 10 15 1 1 1 1 24 1415 15 # 20 I 1610 10 # 16 I 1624 24 # 20 I 1808 8 # 12 I 16 14 31 25 1 1 1 1831 31 # 20 I 2016 16 # 16 I 2025 19 # 20, 6 # 12 I 41 12 28 39 1 1 2028 24 # 20, 4 # 12 I 1 1 2039 37 # 20, 2 # 16 I 2041 41 # 20 I 2212 12 # 12 I * Consult factory for pin insert availability. www.conesys.com - 148 - sales@aero-electric.com 83723 S III 1814 14 # 16 I 1 MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-83723 Series III Connectors Insert Arrangement Views 19 32 55 1 1 1 2219 19 # 16 I 2255 55 # 20 I 2232 26 # 20, 6 # 12 I 19 1 1 1 30 29 2419 19 # 12 I 2429 29 # 16 I 2430 30 # 16 I 43 61 42 57 1 83723 S III 2443 23 # 20, 20 # 16 I 1 1 2461 61 # 20 I 2457 55 # 20, 2 # 12 I 1 2842 42 # 16 I Non MIL-STD-1554 layout, available to Aero-Electric part number only. www.conesys.com - 149 - sales@aero-electric.com MIL-DTL-26500 Features and Application MS2426*/AE66* Features and Application AE66 connectors are widely used on commercial, military and aerospace systems requiring general-purpose, miniature cylindrical bayonet or threaded coupling connectors. Connector Sealing - A pressure seal at the connector interface is accomplished through the aid of a coupling device which compresses the front resilient insulators and thus offers a seal around each contact preventing the passage of moisture through the contact cavity. Rear resilient insulators are designed with a triple wire seal in each cavity to offer positive sealing and prevent wicking of moisture through the connector without the use of external clamping devices or adapters. In addition, a dynamic O'ring seal in the receptacles engages the front of the plug shell when connectors are mated and offers yet another barrier to moisture and contaminants. This family (bayonet as well as threaded) of connectors is offered in wall mount receptacles, jam nut mounted receptacles which incorporate O'ring seals, designed for rear panel "D" hole mounting, and straight plugs. Superior Contact Stability - Front release crimp contact system features a beryllium-copper retaining clip completely encased in a tough dielectric wafer, thus protecting the clip tines from damage. Twenty-one insert arrangements per MIL-STD-1554 are tooled and qualified to MIL-DTL-26500, utilizing 3 to 57 M39029 contacts. Contacts come in sizes 20, 16 and 12, terminating wire sizes from 24 to 12 gauge. Closed Entry Socket Contacts Closed-entry socket contacts facilitate positive mating. MIL-DTL-26500 family offers connectors with bayonet coupling as well as threaded coupling. These connectors are intermateable with correspondingly coupled MIL-DTL-83723 Series III connectors (except shell size 8, threaded coupling only). These connectors are only available in aluminum shells with anodic plating to the MS number. In addition, we offer connectors with passivated stainless steel shells to commercial callouts only. Insert Polarization Alternate insert positions documented in the original specification, positions 1 through 5, are still available (except in shell size 8), but are not approved for new design. These alternate insert clocking positions aid in mating of adjacent connectors having identical insert arrangement. Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having same insert arrangement. 26500 www.conesys.com - 150 - sales@aero-electric.com MIL-DTL-26500 Performance Specifications MS2426*/AE66* Performance Specifications Shock and Vibration Requirements Wired, mated connectors shall not be damaged, coupling ring shall not loosen, and there shall be no interruption of electrical continuity longer than one microsecond when subjected to the following: Operating Temperature Range Class R: -55C to +200C (-67F to +392F) Class E*: -55C to +200C (-67F to +392F) Shock Mated connectors withstand a pulse of approximate half sine wave of 100 G magnitude with duration of 6 milliseconds applied in each of the three major axes. Material and Finish Data (Class) R - aluminum shell, black anodized finish E*- stainless steel shell, passivated Corrosion Resistance Classes R and E* withstand 48-hour salt spray. Vibration Mated connectors withstand the following vibration levels: * Vibration per EIA-364, test procedure 28 conducted at a low temperature ambient of -55C (-67F) and high ambient of +200C (392F). Environmental Seal Wired, mated connectors shall meet the altitude-immersion test specified by MIL-DTL-26500. Shell-to-Shell Conductivity * Class R is non-conductive. * Maximum potential drop shall not exceed 200 millivolts for class E*. Fluid Resistance Unmated connectors resist specified immersions in MIL-PRF-5606 (hydraulic fluid), MIL-PRF-23699 (lubricating oil), MIL-PRF-7808 (lubricating oil), MIL-DTL-5624 (JP-5) and glycol. Durability Bayonet Coupling - 500 cycles Threaded Coupling - 200 cycles Voltage Rating Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) 26500 Service Rating Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft. AC (RMS) DC V RMS V RMS V RMS V RMS I 600 850 1500 450 275 200 * Class E only available to commercial callouts. Consult factory for drawings. Pages 153 thru 158 apply to class R only. ** To be used by designer only as a guide. www.conesys.com - 151 - sales@aero-electric.com MIL-DTL-26500 Part Number Development Bayonet & Threaded Coupling Part Number Development Mil. Prefix Aero Prefix MS AE 24266 666 R R 12 12 T T 12 12 P P N N -340 Shell type 24264 = Wall mount receptacle = 664 (Aero p/n) 24265 = Jam nut receptacle = 665 (Aero p/n) 24266 = Straight plug = 666 (Aero p/n) Class (Material and Finish) R = Aluminum shell, black anodized finish E* = Stainless steel shell, passivated Shell Size (SS) 8, 10, 12, 14, 16, 18, 20, 22 or 24 Coupling Mechanism B = Bayonet Coupling T = Threaded Coupling Insert Arrangement See pages 164 Contact Style P = Pin S = Socket Polarization (Keying) N = Normal 6, 7, 8, 9 or Y (Alternate keyed positions, Y is not availabe in SS 8) 1, 2, 3, 4 or 5 (Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in SS 8) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 341 = Connector kitted with MS27291-XX straight clamp Consult factory for other modifications * Class E only available to commercial callouts. Consult factory for drawings. Pages 153 thru 158 apply to class R only. www.conesys.com Note 2: Proper part number marking has no "0" in front of single digit shell size (8), and no "0" in front of single digit layouts. Example: MS24264R8B3SN and MS24264R18B8P6. Please note that in this series "N" for normal is included in part number marking. - 152 - sales@aero-electric.com 26500 Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: Two spare contacts for each size contact utilized and at least 15% of the number of contacts but no less than three sealing plugs are provided. No insertion/removal tools are provided. No spares are required for shielded contacts. MS24264R**B Wall Mounting Receptacle AE664R**B Bayonet Coupling, Crimp Removable, Front Release A 1.421(36.09) MAX B .728(18.49) .708(17.98) MASTER KEYWAY 4x C MOUNTING HOLES .072(1.83) .052(1.32) F D MAX GROMMET E ACCESSORY THREAD 3 ORANGE COLOR STRIPES EQUALLY SPACED 4 MINOR KEYWAYS Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 PANEL THICKNESS: .125(3.18)MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size .306(7.77) MIN FULL THREAD B .005 .13 inch mm O (TP) inch mm C O D E +.000 -.009 +.00 -.23 +.000 -.005 +.00 -.13 inch mm inch mm Accessory Thread Class 2A O F Maximum inch mm 8 .812 20.62 .594 15.09 .125 3.18 .536 13.61 7/16-28UNEF .328 8.33 10 .937 23.80 .719 18.26 .125 3.18 .659 16.74 9/16-24UNEF .420 10.67 12 1.031 26.19 .812 20.62 .125 3.18 .829 21.06 3/4-20UNEF .580 14.73 14 1.125 28.58 .906 23.01 .125 3.18 .898 22.81 13/16-20UNEF .664 16.87 16 1.250 31.75 .969 24.61 .125 3.18 1.025 26.04 15/16-20UNEF .769 19.53 26500 18 1.343 34.11 1.062 26.97 .125 3.18 1.131 28.73 1-1/16-18UNEF .902 22.91 20 1.437 36.50 1.156 29.36 .125 3.18 1.256 31.90 1-3/16-18UNEF 1.033 26.24 22 1.562 39.67 1.250 31.75 .125 3.18 1.381 35.08 1-5/16-18UNEF 1.152 29.26 24 1.703 43.26 1.375 34.93 .154 3.91 1.506 38.25 1-7/16-18UNEF 1.282 32.56 www.conesys.com - 153 - sales@aero-electric.com MS24265R**B Jam Nut Receptacle AE665R**B Bayonet Coupling, Crimp Removable, Front Release 1.421(36.09) MAX B .781(19.84) .761(19.33) C MASTER KEYWAY MOUNTING FLAT .306(7.77) MIN FULL THREAD D F MAX GROMMET A MAX 3 ORANGE COLOR STRIPES EQUALLY SPACED E ACCESSORY THREAD G JAM-NUT THREAD "O" RING HEX NUT WITH 3 TEFLON PLUGS EQUALLY SPACED Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 PANEL THICKNESS: .125(3.18) MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O A B inch 8 1.068 O D E .005 .13 .003 .08 +.000 -.005 +.00 -.13 mm inch mm inch mm inch mm 27.13 .979 24.87 .593 15.06 .536 13.61 Maximum Shell Size C Accessory Thread Class 2A O F G Maximum inch mm 7/16-28UNEF .328 8.33 Jam Nut Thread Class 2A 5/8-20UN 1.192 30.28 1.104 28.04 .718 18.24 .659 16.74 9/16-24UNEF .420 10.67 3/4-20UNEF 1.380 35.05 1.291 32.79 .905 22.99 .829 21.06 3/4-20UNEF .580 14.73 15/16-20UNEF 14 1.505 38.23 1.391 35.33 .968 24.59 .898 22.81 13/16-20UNEF .664 16.87 1-20UNEF 16 1.630 41.40 1.516 38.51 1.093 27.76 1.025 26.04 15/16-20UNEF .769 19.53 1-1/8-20UN 18 1.740 44.20 1.641 41.68 1.217 30.91 1.131 28.73 1-1/16-18UNEF .902 22.91 1-1/4-20UN 20 1.860 47.24 1.766 44.86 1.342 34.09 1.256 31.90 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF 22 2.040 51.82 1.954 49.63 1.467 37.26 1.381 35.08 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN 24 2.160 54.86 2.079 52.81 1.592 40.44 1.506 38.25 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF www.conesys.com - 154 - sales@aero-electric.com 26500 10 12 MS24266R**B Straight Plug AE666R**B Bayonet Coupling, Crimp Removable, Front Release A MAX COUPLING NUT 1.375(34.93) MAX MASTER KEY .306(7.77) MIN FULL THREAD B C MAX GROMMET 3 ORANGE STRIPES EQUALLY SPACED D ACCESSORY THREAD 4 MINOR KEYS Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O Shell Size A O Maximum inch mm B O +.000 -.005 +.00 -.13 inch mm C D Accessory Thread Class 2A Maximum inch mm 8 .776 19.71 .424 10.77 .328 8.33 7/16-28UNEF 10 .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF 12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF 14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF 16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF 26500 18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF 20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF 22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF 24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF www.conesys.com - 155 - sales@aero-electric.com MS24264R**T Wall Mounting Receptacle AE664R**T Threaded Coupling, Crimp Removable, Front Release A 1.421(36.09) MAX B 4x C .728(18.49) .708(17.98) MASTER KEYWAY MOUNTING HOLES .072(1.83) .052(1.32) F MAX GROMMET D MATING THREAD 4 MINOR KEYWAYS E ACCESSORY THREAD FULL MATE INDICATOR COLOR: ORANGE .306(7.77) MIN FULL THREAD PANEL THICKNESS: .125(3.18) MAX Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Shell Size .005 .13 inch mm inch O C +.000 -.009 +.00 -.23 mm inch mm (TP) D E Mating Thread Class 2A Accessory Thread Class 2A O F Maximum inch mm 8 .812 20.62 .594 15.09 .125 3.18 9/16-24UNEF 7/16-28UNEF .328 8.33 10 .937 23.80 .719 18.26 .125 3.18 11/16-24UNEF 9/16-24UNEF .420 10.67 12 1.031 26.19 .812 20.62 .125 3.18 7/8-20UNEF 3/4-20UNEF .580 14.73 14 1.125 28.58 .906 23.01 .125 3.18 15/16-20UNEF 13/16-20UNEF .664 16.87 16 1.250 31.75 .969 24.61 .125 3.18 1-1/16-18UNEF 15/16-20UNEF .769 19.53 1.343 34.11 1.062 26.97 .125 3.18 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91 1.437 36.50 1.156 29.36 .125 3.18 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24 22 1.562 39.67 1.250 31.75 .125 3.18 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26 24 1.703 43.26 1.375 34.93 .154 3.91 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56 www.conesys.com - 156 - sales@aero-electric.com 26500 18 20 MS24265R**T Jam Nut Receptacle AE665R**T Threaded Coupling, Crimp Removable, Front Release 1.421(36.09) MAX B .781(19.84) .761(19.33) C MOUNTING FLAT MASTER KEYWAY .306(7.77) MIN FULL THREAD F MAX GROMMET A D MATING THREAD MAX FULL MATE INDICATOR COLOR: ORANGE E ACCESSORY THREAD G JAM-NUT THREAD "O" RING HEX NUT WITH 3 TEFLON PLUGS EQUALLY SPACED Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O Shell Size PANEL THICKNESS: .125(3.18) MAX A B Maximum inch mm C .005 .13 .003 .08 inch mm inch mm D E Mating Thread Class 2A Accessory Thread Class 2A O F G Jam Nut Thread Class 2A Maximum inch mm 8 1.068 27.13 .979 24.87 .593 15.06 9/16-24UNEF 7/16-28UNEF .328 8.33 5/8-20UN 10 1.192 30.28 1.104 28.04 .718 18.24 11/16-24UNEF 9/16-24UNEF .420 10.67 3/4-20UNEF 12 1.380 35.05 1.291 32.79 .905 22.99 7/8-20UNEF 3/4-20UNEF .580 14.73 15/16-20UNEF 14 1.505 38.23 1.391 35.33 .968 24.59 15/16-20UNEF 13/16-20UNEF .664 16.87 1-20UNEF 16 1.630 41.40 1.516 38.51 1.093 27.76 1-1/16-18UNEF 15/16-20UNEF .769 19.53 1-1/8-20UN 26500 18 1.740 44.20 1.641 41.68 1.217 30.91 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91 1-1/4-20UN 20 1.860 47.24 1.766 44.86 1.342 34.09 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF 22 2.040 51.82 1.954 49.63 1.467 37.26 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN 24 2.160 54.86 2.079 52.81 1.592 40.44 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF www.conesys.com - 157 - sales@aero-electric.com MS24266R**T Straight Plug AE666R**T Threaded Coupling, Crimp Removable, Front Release A MAX COUPLING NUT 1.375(34.93) MAX MASTER KEY .306(7.77) MIN FULL THREAD B C MAX GROMMET E MATING THREAD D ACCESSORY THREAD 4 MINOR KEYS Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O A O inch O +.000 -.005 +.00 -.13 mm inch mm inch Maximum Shell Size B C Maximum D E Accessory Thread Class 2A Mating Thread Class 2B mm .776 19.71 .424 10.77 .328 8.33 7/16-28UNEF 9/16-24UNEF .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF 11/16-24UNEF 12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF 7/8-20UNEF 14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF 15/16-20UNEF 16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF 1-1/16-18UNEF 18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF 1-3/16-18UNEF 20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF 1-5/16-18UNEF 22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF 1-7/16-18UNEF 24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF 1-9/16-18UNEF www.conesys.com - 158 - sales@aero-electric.com 26500 8 10 MIL-DTL-26500 Polarization (Shell Keying, Insert Clocking) Bayonet and Threaded Shell Keying D B Insert Clocking A E MASTER KEYWAY(KEY) OF SHELL MASTER KEYWAY C ENGAGING FACE VIEW FOR RECEPTACLE SHELL KEYWAYS (PLUG SHELL KEYS, OPPOSITE) INSERT VERTICAL CENTERLINE SOCKET INSERT MATING FACE (PIN INSERT IS OPPOSITE) Notes: 1. In the normal position (N), the insert centerline coincides with the centerline of the master keyway (key) of the shell: E = 0. 2. In the alternate keying positions (6, 7, 8, 9 and Y), the minor keyways (keys) are positioned with reference to master key/keyway as indicated in the keying position table below. Polarizing Shell Size 8*, 10 10 only 12 thru 24 10 thru 24 3. In the alternate insert clocking positions (1, 2, 3, 4 and 5), the socket insert (viewing from the mating side) is rotated counter-clockwise relative to the centerline of the master keyway (key) of the shell. The pin insert is rotated clockwise. Key/Keyway Positions Insert Position 26500 Position A B C D E N 6 7 8 9 Y** N 6 7 8 9 Y** 1 2 3 4 5 105 102 80 35 64 25 105 18 92 84 24 98 105 105 105 105 105 140 132 118 140 155 115 140 149 152 152 135 152 140 140 140 140 140 215 248 230 205 234 220 215 192 222 204 199 268 215 215 215 215 215 265 320 312 275 304 270 265 259 342 334 240 338 265 265 265 265 265 0 0 0 0 0 0 0 0 0 0 0 0 10 20 30 40 50 * Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5 are not available in shell size 8. Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Alterate positions "Z" and "10" are cancelled and superseded by Position "Y". www.conesys.com - 159 - sales@aero-electric.com MIL-DTL-26500 Bayonet and Threaded Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts S LL J Z L Note: Maximum panel thickness of .125 inch (3.18 mm). Flange and Jam Nut Mounting Dimensions L O J O For Back Mounting Minimum (TP) J O inch mm inch mm inch S O Z +.000 -.009 +.00 -.23 .005 .13 .005 .13 mm inch mm inch mm inch mm For Front Mounting Minimum Shell Size LL 8 .594 15.09 .620 15.75 .447 11.35 .125 3.18 .605 15.37 .635 16.13 10 .719 18.26 .748 19.00 .572 14.53 .125 3.18 .730 18.54 .760 19.30 12 .812 20.62 .913 23.19 .760 19.30 .125 3.18 .917 23.29 .947 24.05 14 .906 23.01 .980 24.89 .822 20.88 .125 3.18 .980 24.89 1.010 25.65 16 .969 24.61 1.107 28.12 .948 24.08 .125 3.18 1.105 28.07 1.135 28.83 1.062 26.97 1.209 30.71 1.072 27.23 .125 3.18 1.225 31.12 1.260 32.00 1.156 29.36 1.337 33.96 1.192 30.28 .125 3.18 1.350 34.29 1.385 35.18 22 1.250 31.75 1.452 36.88 1.322 33.58 .125 3.18 1.475 37.47 1.510 38.35 24 1.375 34.93 1.577 40.06 1.442 36.63 .154 3.91 1.600 40.64 1.635 41.53 www.conesys.com - 160 - sales@aero-electric.com 26500 18 20 MIL-DTL-26500 Contacts, Tools and Seal Plugs MS2426*/AE66* Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Military No. Military No. Military No. Military No. 20 Power/Signal M39029/31-241 M39029/32-260 MS27488-20-1 N/A 16 Power/Signal M39029/31-229 M39029/32-248 MS27488-16-1 N/A 12 Power/Signal M39029/31-235 M39029/32-254 MS27488-12-1 N/A 8 Coax Coax M39029/54-343 M39029/55-345 MS27488-8-1 N/A Contact Size Plastic Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size/Type Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. M81969/17-03 M81969/19-07 Military No. Military No. Military No. M22520/1-01 M22520/1-02 M22520/1-02 M22520/2-01 M22520/2-02 M22520/2-02 16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-04 M81969/19-08 12 M22520/1- 01 M22520/1-02 M22520/1-02 M81969/17-05 M81969/19-09 M81969/17-06 M81969/19-03 20 8 Coax Inner M22520/2-01 M22520/2-24 M22520/2-24 8 Coax Outer M22520/5-01 M22520/5-10 M22520/5-10 Contact and Wire Data Contact Size Test Current Potential DC Test Drop Crimp Well Data Well Dia. Wire Range Minimum Well Dept Finished Wire O Range Minimum Maximum mm2 inch mm inch mm Amps Millivolts inch inch mm AWG 20 7.5 55 .049 .001 .267 6.78 24-20 .20-.52 .040 1.02 .090 2.29 16 13.0 49 .067 .001 .236 5.99 20-16 .52-1.31 .068 1.73 .130 3.30 12 23.0 42 .100 .002 .236 5.99 14-12 2.08-3.31 .106 2.69 .170 4.32 26500 Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com Note 2: No plastic Insertion/Removal tools are supplied as part of contact packages when ordering 26500 connectors. Metal insertion and extraction tools must be ordered separately. - 161 - sales@aero-electric.com MIL-DTL-26500 Contact Installation Instructions MS2426*/AE66* Contact Installation Instructions 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. 2. Select the appropriate tool. Place tool over the contact on mating side and insert into the cavity. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. 3. Exert nominal force axially to release retention clip. Spacer sleeve will shoulder at face of insulation when tool is inserted to proper depth. 4. Push extraction plunger to force the contact out of the rear of the insert. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. 5. Grasp contact or wire and pull the wired contact out of the rear of the insulator. 6. Remove extraction tool axially. 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Pin Contact Socket Contact 20 M39029/31-241 M39029/32-260 16 12 M39029/31-229 M39029/31-235 M39029/32-248 M39029/32-254 www.conesys.com Basic Crimp Tool M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 - 162 - Positioner M22520/1-02 Red M22520/2-02 M22520/1-02 Blue M22520/1-02 Yellow Insertion Tool Removal Tool M81969/17-03 M81969/19-07 M81969/17-04 M81969/17-05 M81969/19-08 M81969/19-09 sales@aero-electric.com 26500 Size 7. After using the extraction tool, the spacer sleeve should be set forward in the last notch to protect the end of the plunger guide. MIL-DTL-26500 Bayonet and Threaded Insert Availability and Contact Information per MIL-STD-1554 Insert Availability and Contact Information Insert Arrangement Aero-Electric Total Quantity of Contacts Status No. of (by Size) Alternate Positions (Insert Rotation in Degrees) QPL'd Tooled Contacts 20 Rating 1* 2* 3* 4* 5* 8-3 Yes Yes 3 3 I N/A N/A N/A N/A N/A 10-5 Yes Yes 5 5 I 10 20 30 40 50 12-3 Yes Yes 3 12-12 Yes Yes 12 Yes Yes 4 Yes Yes 7 14-12 Yes Yes 12 9 15 Yes Yes 15 Yes Yes 10 16-24 Yes Yes 24 18-8 Yes Yes 8 18-11+ Yes Yes 11 18-14 Yes Yes 14 18-31 Yes Yes 31 4 Yes 16 25 19 20-39 Yes Yes 39 37 41 20-41 Yes Yes 41 Yes Yes 19 22-55 Yes Yes 55 N/A Yes 30 24-43 Yes Yes 43 23 24-57 Yes Yes 57 55 50 50 20 30 40 50 20 30 40 50 3 I 10 20 30 40 50 I 10 20 30 40 50 10 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 1 16 24-30** 40 40 10 14 Yes 30 30 10 31 Yes 20 20 I 10 Yes 10 10 I 8 20-16 I I 7 24 20-25 22-19 # 8 Coax 3 14-4 14-15 12 12 14-7 16-10 16 Service I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 2 I 10 20 30 40 50 I 10 20 30 40 50 19 I 10 20 30 40 50 I 10 20 30 40 50 30 I 10 20 30 40 50 20 I 10 20 30 40 50 I 10 20 30 40 50 6 55 2 * Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Non MIL-STD-1554 layout, available to Aero-Electric part number only. + Only available less contacts (no known source for QPL Coax contact) 26500 www.conesys.com - 163 - sales@aero-electric.com MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-26500 Connectors Insert Arrangement Views 1 5 1 4 1 1 1 12 3 2 8-3 3 # 20 I 3 10-5 5 # 20 I 12-3 3 # 16 I 12-12 12 # 20 I 14-4 4 # 12 I 10 7 15 1 1 1 1 12 1 24 14-7 7 # 16 I 14-12 9 # 20, 3 # 16 14-15 15 # 20 I I 16-24 24 # 20 I 16-10 10 # 16 I 16 8 14 11 31 1 1 1 18-8 8 # 12 I 1 + 18-11 10 # 16, 1 # 8 Coax. I 1 18-14 14 # 16 I 20-16 16 # 16 I 18-31 31 # 20 I 41 19 55 39 25 1 1 1 20-25 19 # 20, 6 # 12 I 20-39 37 # 20, 2 # 16 I 1 20-41 41 # 20 I 1 22-55 55 # 20 I 22-19 19 # 16 I 43 57 1 30 1 1 26500 24-30 30 # 16 I 24-43 23 # 20, 20 # 16 I 24-57 55 # 20, 2 # 12 I Non MIL-STD-1554 layout, available to Aero-Electric part number only. + Only available less contacts (no known source for QPL Coax contact) www.conesys.com - 164 - sales@aero-electric.com Printed Circuit Board Connectors Introduction 38999 Series I, II, II & 26482 II PCB Introduction Features For many years, Aero Electric has been making mil circular connectors, and for nearly just as long, we have been supplying them with pc tail contacts. From all the applications we have supported with our pc tail connectors, and all the engineers we have worked with, we have finally taken all that we have learned and created a full product offering. 1. Clinch nut options for more secure mounting to the panel This product line is made in accordance with MIL-DTL-38999 and MIL-DTL-26482. This family of connectors offers multiple receptacle shell styles, and is available in several materials, such as aluminum, stainless steel, and for extreme corrosion environments, aluminum nickel bronze. The plating options are extensive as well, and that includes electroless nickel, olive drab cadmium, bright cadmium, hard anodized, black nickel, Zinc nickel, and Teflon nickel. 2. Stand-off with helicoils for best practice when supporting the pcb to the connector 3. Shell to PC board connection to allow for another ground path, if needed 4. Slots on the shells to allow for aqueous wash to run through and clean post wave soldering 1 2 4 3 AEP65-104 www.conesys.com - 165 - sales@aero-electric.com Printed Circuit Board Connectors Table of Contents 38999 Series I, II, II & 26482 II Table of Contents AEP65-101, AEP65-102 .............................................167-168 PCB AEP65-103, AEP65-104 .............................................169-170 AEP65-105, AEP65-106 .............................................171-172 AE65-505 .....................................................................173-174 AE65-255 .....................................................................175-176 AE6520 .........................................................................177-178 AE6524 ........................................................................ 179-180 AEP45-101, AEP45-102 .............................................181-182 AEP45-103, AEP45-104 .............................................183-184 AEP45-105, AEP45-106 .............................................185-186 AEP55-101, AEP55-102 .............................................187-188 AEP55-103, AEP55-104 .............................................189-190 AEP55-105, AEP55-106 .............................................191-192 MIL-STD 1560 Insert Arrangement List .........................193 MIL-STD 1560 Insert Arrangement Views .............194-208 AEP15-101, AEP15-102 .............................................209-210 AEP15-103, AEP15-104 .............................................211-212 AEP15-105, AEP15-106 .............................................213-214 MIL-STD 1669 Insert Arrangement List .........................215 MIL-STD 1669 Insert Arrangement Views .............216-228 PC Tail Lengths .......................................................... 229-234 www.conesys.com - 166 - sales@aero-electric.com MIL-DTL-38999 Series III Rear, Wall Mounting Receptacle AEP65-101, AEP65-102 Part Number Development Aero Prefix AEP65- 101- F E 35 P A- *** PCB Shell Type 101 = Wall Mount 102 = Wall Mount w/ Clinch Nuts Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9, B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) N = Normal (Included in part number) A, B, C, D, or E Options (Aero Modification Number) ***Consult factory for other modifications AEP65-101 and -102 Dimesional Data INCH MM INCH MM INCH MM INCH MM INCH MM .012 0.26 .010 0.26 .010 0.26 .008 0.20 .008 0.20 F THREAD TRIPLE START A .937 23.80 .719 18.26 .594 15.09 .216 5.49 .128 3.25 11 B 1.031 26.20 .812 2.062 .719 18.26 .194 4.93 .128 13 C 1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 15 D 1.220 31.00 .969 24.61 .906 23.01 .194 4.93 17 E 1.311 33.30 1.062 26.97 .969 24.61 .194 19 F 1.437 36.50 1.156 29.37 1.062 26.97 .194 21 G 1.563 39.70 1.250 31.75 1.156 29.36 .194 23 H 1.689 42.90 1.375 34.93 1.250 31.75 25 J 1.811 46.00 1.500 38.10 1.375 34.93 SHELL SIZE MS SHELL CODE 9 A B C* D* OH MAX INCH MM .6250-.1P-.3L .460 11.68 3.25 .7500-.1P-.3L .586 14.88 3.25 .8750-.1P-.3L .710 18.03 .128 3.25 1.000-.1P-.3L .834 21.18 4.93 .128 3.25 1.187-.1P-.3L .960 24.38 4.93 .128 3.25 1.250-.1P-.3L 1.070 27.18 4.93 .128 3.25 1.375-.1P-.3L 1.186 30.12 .242 6.15 .154 3.91 1.500-.1P-.3L 1.320 33.53 .242 6.15 .154 3.91 1.625-.1P-.3L 1.446 36.73 Standard PC Tail Diameters * for AEP65-101 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. www.conesys.com E* - 167 - CONTACT SIZE OJ .001 22D .019 20 .019 16 .062 sales@aero-electric.com MIL-DTL-38999 Series III Rear, Wall Mount Receptacle AEP65-101, AEP65-102 AEP65-101 Receptacle Connector, Wall Mount * PCB AEP65-102 Receptacle Connector, Wall Mount with Clinch Nuts * AEP65-101 AEP65-102 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 168 - sales@aero-electric.com MIL-DTL-38999 Series III Rear, Wall Mounting Receptacle AEP65-103, AEP65-104 Part Number Development Aero Prefix AEP65- 103- F E 35 P A- *** PCB Shell Type 103 = Wall Mount w/ Dual Flange 104 = Wall Mount w/ Dual Flange & Clinch Nut Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9, B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) N = Normal (Included in part number) A, B, C, D, or E Options (Aero Modification Number) ***Consult factory for other modifications AEP65-103 and -104 Dimesional Data SHELL SIZE 9 MS SHELL CODE A INCH MM INCH MM INCH MM INCH MM INCH MM .012 0.26 .010 0.26 .010 0.26 .008 0.20 .008 0.20 F THREAD TRIPLE START .937 23.80 .719 18.26 .594 15.09 .216 5.49 .128 3.25 .6250-.1P-.3L A B C D* E* OH MAX INCH MM .460 11.68 J* INCH MM . 005 0.13 .556 14.12 11 B 1.031 26.20 .812 2.062 .719 18.26 .194 4.93 .128 3.25 .7500-.1P-.3L .586 14.88 .686 17.42 13 C 1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 3.25 .8750-.1P-.3L .710 18.03 .802 20.37 15 D 1.220 31.00 .969 24.61 .906 23.01 .194 4.93 .128 3.25 1.000-.1P-.3L .834 21.18 .927 23.55 17 E 1.311 33.30 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 1.187-.1P-.3L .960 24.38 1.048 26.62 19 F 1.437 36.50 1.156 29.37 1.062 26.97 .194 4.93 .128 3.25 1.250-.1P-.3L 1.070 27.18 1.126 28.60 21 G 1.563 39.70 1.250 31.75 1.156 29.36 .194 4.93 .128 3.25 1.375-.1P-.3L 1.186 30.12 1.250 31.75 23 H 1.689 42.90 1.375 34.93 1.250 31.75 .242 6.15 .154 3.91 1.500-.1P-.3L 1.320 33.53 1.387 35.23 25 J 1.811 46.00 1.500 38.10 1.375 34.93 .242 6.15 .154 3.91 1.625-.1P-.3L 1.446 36.73 1.500 38.10 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. www.conesys.com - 169 - Standard PC Tail Diameters CONTACT SIZE OG .001 22D .019 20 .019 16 .062 sales@aero-electric.com MIL-DTL-38999 Series III Rear, Wall Mount Receptacle AEP65-103, AEP65-104 AEP65-103 Receptacle Connector, Wall Mount with Dual Flange * PCB AEP65-104 Receptacle Connector, Wall Mount with Dual Flange and Clinch Nuts * AEP65-103 AEP65-104 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 170 - sales@aero-electric.com MIL-DTL-38999 Series III Rear, Jam Nut Receptacle AEP65-105, AEP65-106 Part Number Development Aero Prefix AEP65- 105- F E 35 P A- *** Shell Type 105 = Jam Nut Receptacle 106 = Jam Nut Receptacle w/ Dual Flange & helicoils PCB Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9, B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) N = Normal (Included in part number) A, B, C, D, or E Options (Aero Modification Number) ***Consult factory for other modifications AEP65-105 and -106 Dimesional Data SHELL SIZE SHELL CODE B MTG. FLAT A MS INCH MM .016 0.40 INCH MM +.004 +0.10 -.006 -0.15 C HEX INCH MM D INCH MM +.024 +0.60 -.000 -0.00 E THREAD OH G (AEP65-106) F THREAD TRIPLE START INCH MM .005 0.13 MAX INCH MM 9 A 1.063 27.00 .651 16.53 .945 .859 24.00 21.82 .555 14.10 M17x1.0-6g.100R .6250-.1P-.3L .556 14.12 .460 11.68 11 B 1.252 31.80 .751 19.07 1.063 .984 27.00 24.99 .555 14.10 M20x1.0-6g.100R .7500-.1P-.3L .686 17.42 .586 14.88 13 C 1.374 34.90 .938 23.82 1.260 1.172 32.00 29.77 .555 14.10 M25x1.0-6g.100R .8750-.1P-.3L .802 20.37 .710 18.03 36.00 32.91 .555 14.10 M28x1.0-6g.100R 1.000-.1P-.3L .927 23.55 .834 21.18 15 D 1.500 38.10 1.062 26.97 1.417 1.296 17 E 1.626 41.30 1.187 30.15 1.457 1.422 37.00 36.12 .555 14.10 M32x1.0-6g.100R 1.187-.1P-.3L 1.048 26.62 .960 24.38 19 F 1.811 46.00 1.312 33.32 1.614 1.546 41.00 39.26 .555 14.10 M35x1.0-6g.100R 1.250-.1P-.3L 1.126 28.60 1.070 27.18 46.00 42.47 .555 14.10 M38x1.0-6g.100R 1.375-.1P-.3L 1.250 31.75 1.186 30.12 21 G 1.937 49.20 1.437 36.50 1.811 1.672 23 H 2.063 52.40 1.562 39.67 1.969 1.796 50.00 45.61 .555 14.10 M41x1.0-6g.100R 1.500-.1P-.3L 1.387 35.23 1.320 33.53 25 J 2.189 55.60 1.687 42.85 2.017 1.939 51.23 49.25 .555 14.10 M44x1.0-6g.100R 1.625-.1P-.3L 1.500 38.10 1.446 36.73 Standard PC Tail Diameters Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. www.conesys.com - 171 - CONTACT SIZE OJ .001 22D .019 20 .019 16 .062 sales@aero-electric.com MIL-DTL-38999 Series III Rear, Jam Nut Receptacle AEP65-105, AEP65-106 AEP65-105 Receptacle Connector, Jam Nut PCB AEP65-106 Receptacle Connector, Jam Nut with Dual Flange and Helicoils AEP65-105 AEP65-106 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 172 - sales@aero-electric.com MIL-DTL-38999 Series III Rear, Jam Nut Receptacle AE65-505 Part Number Development Aero Prefix AE65- 505- W D 19 P N- 2 4 H 1 3 5- C1 Shell Type 505 = Box Mount PCB Material Finish W = Aluminum, Olive Drab Cadmium Over Nickel F = Aluminum, Electroless Nickel E = Stainless Steel, Passivated (Non-Firewall) BN = Aluminum, Black Nickel (RoHS) BZ = Aluminum, Nickel Bronze (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9, B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, D & E (N = Normal) P.C. Tail Diameter 0=No Size 20 or 22D Contact size 20 & 22D : 1=.019, 2=.025, 3=.030 (with .033 min. stand-off dia. for contact size 22D, with .043 min. stand-off dia. o contact size 20) P.C. Tail Extension 1=.140, 2=.200, 3=.250, 4=.300, 5=.080 Plating K = 30 Microinches Gold H = 50 Microinches Gold Stand-Off 0 = No Stand-Off 1= .040 Stand-Off Minimum Solder Dip Length 0 = No Solder Dip, 1 = .100, 2 = .150, 3 = .200, 4 = .250 P.C.Tail Diameter Blank = No Size 16 Contact size 16: 5=.040, 6=.062 . (with .065 Min. Stand-Off Dia. for contact size 16) Clinch Nuts (Self-Clinching) C1 = THD size 4-40 C2 = THD size 6-32 C3 = THD size M3 Blank = No Clinch Nuts www.conesys.com - 173 - sales@aero-electric.com MIL-DTL-38999 Series III Rear, Jam Nut Receptacle AE65-505 AE65-505 A TYP D TYP E TYP F G THREAD +.000 .008 .008 TRIPLE START -.005 L OM .001 P.C TAIL EXTENSION P.C. TAIL DIAMETERS SHELL SIZE MS Shell Code 9 A .937 .719 .594 .216 .6250-.1P-.3L .475 .719 11 B 1.031 .812 .719 .194 .7500-.1P-.3L .595 .812 13 C 1.126 .906 .812 .194 .098 .710 .906 15 D 1.220 .969 .906 .173 .083 .870 17 E 1.311 1.062 .969 .194 .012 B TYP C TYP 1.000-.1P-.3L .820 OK MAX 1.187-.1P-.3L .985 22D, 20 & 16 22D & 20 N .010 16 .969 .140 .200 .250 .300 .019 .025 .030 .040 .062 1.062 19 F 1.437 1.156 1.062 .194 1.250-.1P-.3L 1.105 1.156 21 G 1.563 1.250 1.156 .194 1.375-.1P-.3L 1.225 1.250 23 H 1.689 1.375 1.250 .242 1.500-.1P-.3L 1.345 1.375 25 J 1.811 1.500 1.375 .242 1.460 1.500 .154 1.625-.1P-.3L .790 .126 .083 AE65-505 Receptacle Connector, Wall Mount with P.C. Contacts with and without Clinch Nuts www.conesys.com - 174 - sales@aero-electric.com PCB .8750-.1P-.3L .128 H MIL-DTL-38999 Series III Rear, Jam Nut Receptacle AE65-512 Part Number Development Aero Prefix AE65- 512- W B 35 P N 1 Shell Type 512 = Jam Nut PCB Material Finish W = Aluminum, Olive Drab/Cadmium F = Aluminum, Electroless Nickel E = Stainless Steel, Passivated (Non-Firewall) BN = Aluminum, Black Nickel (RoHS) BZ = Aluminum, Nickel Bronze (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9 , B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, D & E (N = Normal) Dash Number 1-"L1" Length P.C. Tail Contact 2-"L2" Length P.C. Tail Contact 3-"L3" Length P.C. Tail Contact 4-"L4" Length P.C. Tail Contact 5-"L5" Length P.C. Tail Contact AE65-512 A SHELL SIZE 9 11 MS Shell Code A B inch B Mtg. Flat MM .016 0.040 1.063 27.00 1.252 31.80 C HEX D THREAD Inch +.004 -.006 MM +0.10 -0.15 Inch MM TRIPLE START .651 16.53 .945 .859 24.00 21.82 .6250-.1P-.3L 19.07 1.063 .984 27.00 24.99 32.00 29.77 .751 F E Thread inch +.028 -.004 MM +0.71 -0.10 M17X1.0-6g.100R .087 2.21 .7500-.1P-.3L M20X1.0-6g.100R .087 2.21 .8750-.1P-.3L M25X1.0-6g.100R .087 2.21 13 C 1.374 34.90 .937 23.82 1.259 1.172 15 D 1.500 38.10 1.062 26.97 1.417 1.296 36.00 32.91 1.000-.1P-.3L M28X1.0-6g.100R .087 2.21 17 E 1.626 41.30 1.187 30.15 1.457 1.422 37.00 36.12 1.187-.1P-.3L M32X1.0-6g.100R .087 2.21 19 F 1.811 46.00 1.312 33.32 1.614 1.546 41.00 39.27 1.250-.1P-.3L M35X1.0-6g.100R .118 3.00 21 G 1.937 49.20 1.437 36.50 1.811 1.672 46.00 42.47 1.375-.1P-.3L M38X1.0-6g.100R .118 3.00 39.67 1.969 1.796 50.01 45.62 1.500-.1P-.3L M41X1.0-6g.100R .118 3.00 42.85 2.017 1.939 51.23 49.25 1.625-.1P-.3L M44X1.0-6g.100R .118 3.00 23 25 H J 2.063 2.189 www.conesys.com 52.40 55.60 1.562 1.687 - 175 - L1 L2 L3 L4 L5 P.C TAIL P.C TAIL P.C TAIL P.C TAIL P.C TAIL Dash 1 Dash 2 Dash 3 Dash 4 Dash 5 INCH MM INCH MM INCH MM INCH MM INCH MM .170 .130 4.32 3.30 .240 .200 6.10 5.08 .320 .280 8.13 7.11 .390 .350 9.91 8.89 .590 .550 14.99 13.97 sales@aero-electric.com MIL-DTL-38999 Series III Rear, Jam Nut Receptacle AE65-512 PCB AE65-512 Receptacle Connector, Jam Nut www.conesys.com - 176 - sales@aero-electric.com MIL-DTL-38999 Series III Receptacle Connector, Wall Mount AE6520 Part Number Development Aero Prefix AE65 20 W D 19 P N- 2 4 H 1 3 5- C1 Shell Type 20 = Wall Mount Receptacle PCB Material Finish W = Aluminum, Olive Drab Cadmium Over Nickel F = Aluminum, Electroless Nickel S = Stainless Steel, Electrodeposited Nickel, Firewall K = Stainless Steel, Passivated, Firewall E = Stainless Steel, Passivated (Non-Firewall) BN = Aluminum, Black Nickel (RoHS) BZ = Aluminum, Nickel Bronze (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9, B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, D & E (N = Normal) P.C. Tail Diameter 0=No Size 20 or 22D Contact size 20 & 22D : 1=.019, 2=.025, 3=.030 (with .033 min. stand-off dia. for contact size 22D, with .043 min. stand-off dia. o contact size 20) P.C. Tail Extension 1=.140, 2=.200, 3=.250, 4=.300, 5=.080 Plating K = 30 Microinches Gold H = 50 Microinches Gold Stand-Off 0 = No Stand-Off 1= .040 Stand-Off Minimum Solder Dip Length 0 = No Solder Dip, 1 = .100, 2 = .150, 3 = .200, 4 = .250 P.C.Tail Diameter Blank = No Size 16 Contact size 16: 5=.040, 6=.062 . (with .065 Min. Stand-Off Dia. for contact size 16) Clinch Nuts (Self-Clinching) C1 = THD size 4-40 C2 = THD size 6-32 C3 = THD size M3 Blank = No Clinch Nuts www.conesys.com - 177 - sales@aero-electric.com MIL-DTL-38999 Series III Receptacle Connector, Wall Mount AE6520 AE6520 SHELL SIZE MS Shell A TYP Code .012 B TYP C TYP D TYP E TYP F G THREAD +.000 .008 .008 TRIPLE START -.005 H J Max K Accessory Thread 9 A .937 .719 .594 .216 .6250-.1P-.3L 11 B 1.031 .812 .719 .194 .7500-.1P-.3L 13 C 1.126 .906 .812 .194 .8750-.1P-.3L 15 D 1.220 .969 .906 .173 17 E 1.311 1.062 .969 .194 1.187-.1P-.3L M25X1.0-6g.100R 19 F 1.437 1.156 1.062 .194 1.250-.1P-.3L M28X1.0-6g.100R 21 G 1.563 1.250 1.156 .194 1.375-.1P-.3L 23 H 1.689 1.375 1.250 .242 1.500-.1P-.3L 25 J 1.811 1.500 1.375 .242 .154 1.000-.1P-.3L 1.625-.1P-.3L OM .001 P.C. TAIL DIAMETERS 22D, 20 & 16 22D & 20 16 M12X1.0-6g.100R PCB .128 L P.C TAIL EXTENSION M15X1.0-6g.100R .820 .790 .098 .083 .126 .083 .493 M18X1.0-6g.100R M22X1.0-6g.100R .140 .200 .250 .300 .019 .025 .030 .040 .062 M31X1.0-6g.100R .523 M34X1.0-6g.100R M37X1.0-6g.100R AE6520 Receptacle Connector, Wall Mount with or without Clinch Nuts SHELL SIZE 9 N inch MM .010 0.26 .719 18.26 20.62 11 .812 13 .906 23.01 15 .969 24.61 17 1.062 26.97 19 1.156 29.36 21 1.250 31.75 23 1.375 34.93 25 1.500 38.10 www.conesys.com Connector is shown with clinch nuts and PC Contacts - 178 - sales@aero-electric.com MIL-DTL-38999 Series III Receptacle Connector, Single Hole Mount AE6524 Part Number Development Aero Prefix AE65 24 W D 19 P N- 2 4 H 1 3 5 Shell Type 24 = Single Hole Mount Receptacle PCB Material Finish W = Aluminum, Olive Drab Cadmium Over Nickel F = Aluminum, Electroless Nickel S = Stainless Steel, Electrodeposited Nickel, Firewall K = Stainless Steel, Passivated, Firewall E = Stainless Steel, Passivated (Non-Firewall) BN = Aluminum, Black Nickel (RoHS) BZ = Aluminum, Nickel Bronze (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size A=9, B=11, C=13, D=15, E=17, F=19, G=21, H=23, J=25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, D & E (N = Normal) P.C. Tail Diameter 0=No Size 20 or 22D Contact size 20 & 22D : 1=.019, 2=.025, 3=.030 4=.027 (with .040 min. stand-off dia. for contact size 22D, with .060 min. stand-off dia. o contact size 20) 5 = .019 (.019 with .046 Min stand-off diameter for contact size 22D) P.C. Tail Extension 1=.140, 2=.200, 3=.250, 4=.300, 5=.080 Plating K = 30 Microinches Gold H = 50 Microinches Gold Stand-Off 0 = No Stand-Off 1= .040 Stand-Off Minimum Solder Dip Length 0 = No Solder Dip, 1 = .100, 2 = .150, 3 = .200, 4 = .250, 5 = .080 P.C.Tail Diameter Blank = No Size 16 Contact size 16: 5=.040, 6=.062 . (with .090 Min. Stand-Off Dia. for contact size 16) www.conesys.com - 179 - sales@aero-electric.com MIL-DTL-38999 Series III Receptacle Connector, Single Hole Mount AE6524 AE6524 SHELL SIZE MS Shell A TYP Code B C .016 MTG. Flat +.004 -.008 Hex +.017 -.016 E THREAD F H THREAD +.035 TRIPLE START -.004 K Accessory Thread 9 A 1.063 .651 .875 M17X1.0-6g.100R .625-.1P-.3L 11 B 1.252 .751 1.000 M20X1.0-6g.100R .750-.1P-.3L 13 C 1.374 .937 1.188 M25X1.0-6g.100R .875-.1P-.3L 15 D 1.500 1.062 1.312 M28X1.0-6g.100R 1.000-.1P-.3L M22X1.0-6g.100R 17 E 1.626 1.187 1.438 M32X1.0-6g.100R 1.187-.1P-.3L M25X1.0-6g.100R 19 F 1.811 1.312 1.562 M35X1.0-6g.100R 1.250-.1P-.3L M28X1.0-6g.100R 21 G 1.937 1.437 1.688 M38X1.0-6g.100R 1.375-.1P-.3L 23 H 2.063 1.562 1.812 M41X1.0-6g.100R 1.500-.1P-.3L 25 J 2.189 1.687 2.000 M44X1.0-6g.100R 1.625-.1P-.3L L OM .001 P.C TAIL EXTENSION P.C. TAIL DIAMETERS 22D, 20 & 16 22D & 20 16 PCB M12X1.0-6g.100R M15X1.0-6g.100R .087 .118 M18X1.0-6g.100R .080 .140 .200 .300 .019 .025 .027 .030 .040 .062 M31X1.0-6g.100R M34X1.0-6g.100R M37X1.0-6g.100R AE6524 Receptacle Connector, Single Hole Mount www.conesys.com - 180 - sales@aero-electric.com MIL-DTL-38999 Series I Rear, Wall Mount Receptacle AEP45-101, AEP45-102 Part Number Configuration Aero Prefix AEP45- 101- F 21 35 P A- *** PCB Shell Type 101 = Rear Wall Mount 102 = Rear Wall Mount w/ Clinch Nuts Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 9, 11, 13, 15, 17, 19, 21, 23, 25 Insert Arrangement Per MIL-STD-1560. See Pages 194-208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, or D (Blank = Normal) Options (Aero Modification Number) ***Consult factory for other modifications AEP45-101 and -102 Dimesional Data SHELL SIZE www.conesys.com A .020 B OC +.010 -.005 (AEP45-101) Standard PC Tail Diameters OE +.001 -.005 OF CONTACT SIZE OG .001 MAX. 22D .019 20 .019 16 .062 09 .938 .719 .128 .572 .460 11 1.031 .812 .128 .700 .586 13 1.125 .906 .128 .850 .710 15 1.219 .969 .128 .975 .834 17 1.312 1.062 .128 1.100 .960 19 1.438 1.156 .128 1.207 1.070 21 1.562 1.250 .128 1.332 1.186 23 1.688 1.375 .147 1.457 1.320 25 1.812 1.500 .147 1.582 1.446 - 181 - Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-38999 Series I Rear, Wall Mount Receptacle AEP45-101, AEP45-102 AEP45-101 Receptacle Connector, Rear Wall Mount * PCB AEP45-102 Receptacle Connector, Rear Wall Mount with Clinch Nuts * AEP45-101 AEP45-102 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 182 - sales@aero-electric.com MIL-DTL-38999 Series I Rear, Wall Mount Receptacle, Dual Flange AEP45-103, AEP45-104 Part Number Development Aero Prefix AEP45- 103- F 21 35 P A- *** PCB Shell Type 103 = Rear Wall Mount w/ Dual Flange 104 = Rear Wall Mount w/ Dual Flange & Clinch Nuts Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 9, 11, 13, 15, 17, 19, 21, 23, 25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, or D (Blank = Normal) Options (Aero Modification Number) ***Consult factory for other modifications AEP45-103 and -104 Dimesional Data SHELL A SIZE .020 www.conesys.com B OC OE +.010 +.001 -.005 -.005 (AEP45-103) Standard PC Tail Diameters OF MAX. G 09 .938 .719 .128 .572 .460 .556 11 1.031 .812 .128 .700 .586 .686 13 1.125 .906 .128 .850 .710 .802 15 1.219 .969 .128 .975 .834 .927 17 1.312 1.062 .128 1.100 .960 1.048 19 1.438 1.156 .128 1.207 1.070 1.126 21 1.562 1.250 .128 1.332 1.186 1.250 23 1.688 1.375 .147 1.457 1.320 1.387 25 1.812 1.500 .147 1.582 1.446 1.500 - 183 - CONTACT SIZE OH .001 22D .019 20 .019 16 .062 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-38999 Series I Rear, Wall Mount Receptacle, Dual Flange AEP45-103, AEP45-104 AEP45-103 Receptacle Connector, Rear Wall Mount with Dual Flange * PCB AEP45-104 Receptacle Connector, Rear Wall Mount with Dual Flange and Clinch Nuts * AEP45-103 AEP45-104 * Standard PC tail extension length. For optional lengths, 229-234 for futher information www.conesys.com - 184 - sales@aero-electric.com MIL-DTL-38999 Series I Jam Nut Receptacle AEP45-105, AEP45-106 Part Number Development Aero Prefix AEP45- 105- F 21 35 P A- *** PCB Shell Type 105 = Jam Nut Mount 106 = Jam Nut Mount w/ Dual Flange Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 9, 11, 13, 15, 17, 19, 21, 23, 25 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, or D (Blank = Normal) Options (Aero Modification Number) ***Consult factory for other modifications AEP45-105 and -106 Dimesional Data SHELL SIZE A .016 B OC .016 D THREAD Standard PC Tail Diameters OE +.001 -.005 OF MAX G (AEP45106) 8 1.062 .650 1.188 11/16-24 UNEF .572 .460 .556 10 1.250 .750 1.375 13/16-20 UNEF .700 .586 .686 12 1.375 .937 1.500 1-20 UNEF .850 .710 .802 14 1.500 1.061 1.625 1 1/8-18 UNEF .975 .834 .927 16 1.625 1.186 1.750 1 1/4-18 UNEF 1.100 .960 1.048 18 1.812 1.311 1.938 1 3/8-18 UNEF 1.207 1.070 1.126 20 1.938 1.436 2.062 1 1/2-18 UNEF 1.332 1.186 1.250 22 2.062 1.561 2.188 1 5/8-18 UNEF 1.457 1.320 1.387 24 2.188 1.686 2.312 1 3/4-18 UNS 1.582 1.446 1.500 www.conesys.com - 185 - CONTACT SIZE OG .001 22D .019 20 .019 16 .062 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-38999 Series I Jam Nut Receptacle AEP45-105, AEP45-106 AEP45-105 Receptacle Connector, Jam Nut Mount PCB * AEP45-106 Receptacle Connector, Jam Nut Mount with Dual Flange * AEP45-105 AEP45-106 * Standard PC tail extension length. For optional lengths, 229-234 for futher information www.conesys.com - 186 - sales@aero-electric.com MIL-DTL-38999 Series II Rear, Wall Mounting Receptacle AEP55-101, AEP55-102 Part Number Development Aero Prefix AEP55- 101- F 20 35 P A- *** PCB Shell Type 101 = Rear Wall Mount 102 = Rear Wall Mount w/ Clinch Nuts Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 8, 10 , 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, or D (Blank = Normal) Options (Aero Modification Number) ***Consult factory for other modifications AEP55-101 and -102 Dimesional Data SHELL SIZE A MAX B OC +.010 -.005 (AEP55-101) Standard PC Tail Diameters OD OE CONTACT SIZE OF .001 MAX .003 22D .019 20 .019 16 .062 8 .828 .594 .120 .460 .471 10 .954 .719 .120 .586 .588 12 1.047 .812 .120 .710 .748 14 1.141 .906 .120 .834 .873 16 1.234 .969 .120 .960 .998 18 1.328 1.062 .120 1.070 1.123 20 1.453 1.156 .120 1.186 1.248 22 1.578 1.250 .120 1.320 1.373 24 1.703 1.375 .147 1.446 1.498 www.conesys.com - 187 - Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-38999 Series II Rear, Wall Mount Receptacle AEP55-101, AEP55-102 AEP55-101 Receptacle Connector, Rear Wall Mount * PCB AEP55-102 Receptacle Connector, Rear Wall Mount with Clinch Nuts * AEP55-101 AEP55-102 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 188 - sales@aero-electric.com MIL-DTL-38999 Series II Rear, Wall Mounting Receptacle AEP55-103, AEP55-104 Part Number Development Aero Prefix AEP55- 103- F 20 35 P A- *** PCB Shell Type 103 = Rear Wall Mount w/ Dual Flange 104 = Rear Wall Mount w/ Dual Flange & Clinch Nuts Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 8, 10 , 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, or D (Blank = Normal) Options (Aero Modification Number) ***Consult factory for other modifications AEP55-103 and -104 Dimesional Data SHELL SIZE A MAX B OC +.010 -.005 8 .828 .594 10 .954 12 Standard PC Tail Diameters OD OE MAX .003 .120 .460 .471 .556 .719 .120 .586 .588 .686 1.047 .812 .120 .710 .748 .802 14 1.141 .906 .120 .834 .873 .927 16 1.234 .969 .120 .960 .998 1.048 18 1.328 1.062 .120 1.070 1.123 1.126 20 1.453 1.156 .120 1.186 1.248 1.250 22 1.578 1.250 .120 1.320 1.373 1.387 24 1.703 1.375 .147 1.446 1.498 1.500 www.conesys.com F - 189 - CONTACT SIZE OG .001 22D .019 20 .019 16 .062 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-38999 Series II Rear, Wall Mount Receptacle AEP55-103, AEP55-104 AEP55-103 Receptacle Connector, Rear Wall Mount with Dual Flange * PCB AEP55-104 Receptacle Connector, Rear Wall Mount with Dual Flange and Clinch Nuts * AEP55-103 AEP55-104 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 190 - sales@aero-electric.com MIL-DTL-38999 Series II Rear, Jam Nut Receptacle AEP55-105, AEP55-106 Part Number Development Aero Prefix AEP55- 105- F 20 35 P A- *** PCB Shell Type 105 = Jam nut Mount 106 = Jam Nut Mount w/ Dual Flange Material Finish F = Aluminum, Electroless Nickel B = Aluminum, Olive Drab Cadmium Over Nickel BN = Aluminum, Black Nickel, (RoHS) T = Aluminum, Teflon Nickel (consult factory for availability) Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 8, 10 , 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL-STD-1560. See Pages 194 Thru 208 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) A, B, C, or D (Blank = Normal) Options (Aero Modification Number) ***Consult factory for other modifications AEP55-105 and -106 Dimesional Data SHELL SIZE A .016 B +.001 -.006 8 1.250 10 Standard PC Tail Diameters OC OE OF MAX G THREAD H (AEP55-106) .016 .003 .817 1.375 .471 .460 .875-20 UNEF .556 1.375 .941 1.500 .588 .586 1.000-20 UNEF .686 12 1.500 1.065 1.625 .748 .710 1.125-18 UNEF .802 14 16 1.625 1.190 1.750 .873 .834 1.250-18 UNEF .927 1.781 1.320 1.938 .998 .960 1.375-18 UNEF 1.048 18 1.890 1.440 2.016 1.123 1.070 1.500-18 UNEF 1.126 20 2.016 1.565 2.141 1.248 1.186 1.625-18 UNEF 1.250 22 2.140 1.690 2.265 1.373 1.320 1.750-18 UNS 1.387 24 2.265 1.815 2.390 1.498 1.446 1.875-16 UN 1.500 www.conesys.com - 191 - CONTACT SIZE OH .001 22D .019 20 .019 16 .062 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-38999 Series II Rear, Jam Nut Receptacle AEP55-105, AEP55-106 AEP55-105 Receptacle Connector, Jam Nut Mount * PCB AEP55-106 Receptacle Connector, Jam Nut Mount with Dual Flange * AEP55-105 AEP55-106 * Standard PC tail extension length. For optional lengths, 229-234 for further information www.conesys.com - 192 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements - Per MIL-STD-1560 The following table lists the most commonly used insert arrangements for printed circuit board applications using MIL-DTL-38999 circular connectors. Specific dimensional illustrations are included on the following pages for each of the insert arrangements in the table. For availability of other insert arrangements or for application support, please consult Conesys/Aero Electric Connector. PCB MIL-DTL-38999 Contact Size Series I Series II Series III Service Rating Total Contacts 22D 9-35 8-35 A35 M 6 9-98 8-98 A98 I 3 6 3 11-5 10-5 B5 I 5 5 11-35 10-35 B35 M 13 11-98 10-98 B98 I 6 13-4 12-4 C4 I 4 20 16 13 6 4 13-35 12-35 C35 M 22 13-98 12-98 C98 I 10 22 10 15-18 14-18 D18 I 18 18 15-19 - D19 I 19 15-35 14-35 D35 M 37 17-8 16-8 E8 II 8 17-26 16-26 E26 I 26 19 37 8 26 17-35 16-35 E35 M 55 19-11 18-11 F11 II 11 55 19-32 18-32 F32 I 32 19-35 18-35 F35 M 66 66 21-35 20-35 G35 M 79 79 21-41 20-41 G41 I 41 23-35 22-35 H35 M 100 23-55 22-55 H55 I 55 25-29 24-29 J29 I 29 25-35 24-35 J35 M 128 25-61 24-61 J61 I 61 11 32 41 100 55 29 128 61 *For information on size 12 or larger PC Tail contacts, please consult Conesys/Aero-Electric Connector. Service Rating Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft. V RMS V RMS V RMS V RMS AC (RMS) DC M 400 550 1300 550 350 200 N 300 450 1000 400 260 200 I 600 850 1800 600 400 200 II 900 1250 2300 800 500 200 ** To be used by designer only as a guide. www.conesys.com - 193 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements - Per MIL-STD-1560 Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 9-35 8-35 A35 6 22D M Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position 1 5 4 1 2 3 4 5 6 6 2 3 Connector Type Location X-Axis +.045 +.078 +.000 -.078 -.045 +.000 Y-Axis +.078 -.045 -.090 -.045 +.078 +.000 MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 9-98 8-98 A98 3 20 I Insert Designation Front face of pin insert shown Contact Locations Contact Position C A B C A B Location X-Axis +.065 +.000 -.065 Y-Axis +.038 -.075 +.038 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 194 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 11-5 10-5 B5 5 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position A B C D E A E D B C Connector Type Location X-Axis +.065 +.113 +.000 -.113 -.065 Y-Axis +.056 -.065 -.130 -.065 +.056 MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 11-35 10-35 B35 13 22D I Insert Designation Front face of pin insert shown Contact Locations Contact Position 9 10 1 11 13 8 1 2 3 4 5 6 7 8 9 10 11 12 13 2 3 12 4 7 6 5 Location X-Axis +.000 +.085 +.138 +.138 +.085 +.000 -.085 -.138 -.138 -.085 +.000 +.049 -.049 Y-Axis +.146 +.118 +.045 -.045 -.118 -.146 -.118 -.138 -.138 -.085 +.000 +.049 -.049 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 195 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 11-98 10-98 B98 6 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position A B C D E F A E F D Connector Type B C Location X-Axis +.000 +.130 +.065 -.065 -.130 +.000 Y-Axis +.130 +.000 -.113 -.113 +.000 +.000 MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 13-4 12-4 C4 4 16 I Insert Designation Front face of pin insert shown Contact Locations Contact Position A B C D A D B Location X-Axis +.000 +.146 +.000 -.146 Y-Axis +.150 +.035 -.083 +.035 C Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 196 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 13-35 12-35 C35 22 22D M Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position 1 2 3 4 5 6 7 8 9 10 11 1 21 11 Connector Type Location X-Axis +.045 +.126 +.182 +.203 +.182 +.126 +.045 -.045 -.126 -.182 -.203 Y-Axis +.197 +.158 +.088 +.000 -.088 -.158 -.197 -.197 -.158 -.088 +.000 Contact Locations Contact Position 12 13 14 15 16 17 18 19 20 21 22 X-Axis -.182 -.126 -.045 +.045 +.117 +.093 +.000 -.093 -.117 -.045 +.000 Y-Axis +.088 +.158 +.197 +.107 +.026 -.075 -.120 -.075 +.026 +.107 -.030 MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 13-98 12-98 C98 10 20 I Insert Designation Front face of pin insert shown Contact Locations Contact Position A B C D E F G H J K A B H C G KJ F Location D E Location X-Axis +.000 +.125 +.193 +.164 +.000 -.164 -.193 -.125 +.065 -.065 Y-Axis +.195 +.150 +.030 -.105 -.135 -.105 +.030 +.150 -.015 -.015 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 197 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 15-18 14-18 D18 18 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Location Contact Position L K A M T B N U J S P C R H D G F Connector Type E U J T H Y-Axis +.113 +.252 +.113 +.113 +.000 -.113 -.113 +.000 +.000 Contact Size Service Rating 15-19 N/A D19 19 20 I A B P V R D S G X-Axis -.195 -.065 -.065 +.065 +.130 +.065 -.065 -.130 +.000 Number of Contacts C K K L M N P R S T U MIL-DTL-38999 Series III Contact Locations Contact Position N Location MIL-DTL-38999 Series II Front face of pin insert shown M Y-Axis +.252 +.113 +.000 -.113 -.225 -.225 -.225 -.113 +.000 Contact Position MIL-DTL-38999 Series I Insert Designation L X-Axis +.065 +.195 +.260 +.195 +.130 +.000 -.130 -.195 -.260 A B C D E F G H J Contact Locations F E A B C D E F G H J K Location X-Axis +.000 +.130 +.195 +.260 +.195 +.130 +.000 -.130 -.195 -.260 Y-Axis +.225 +.225 +.113 +.000 -.113 -.225 -.225 -.225 -.113 +.000 Contact Locations Contact Position L M N P R S T U V Location X-Axis -.195 -.130 -.065 +.065 +.130 +.065 -.065 -.130 +.000 Y-Axis +.113 +.225 +.113 +.113 +.000 -.113 -.113 +.000 +.000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 198 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 15-35 14-35 D35 37 22D M Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 31 21 11 Connector Type a Service Rating 17-26 16-26 E26 26 20 I B U C D N Y L V c M K J W X H Y-Axis +.119 +.040 -.050 -.127 -.172 -.172 -.127 -.050 +.040 +.119 +.172 +.074 -.004 -.082 -.082 -.004 +.074 -.004 Contact Size b Z X-Axis +.123 +.170 +.170 +.123 +.045 -.045 -.123 -.170 -.170 -.123 -.045 +.045 +.090 +.045 -.045 -.090 -.045 +.000 Number of Contacts T S 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 MIL-DTL-38999 Series III Contact Locations Contact Position P Y-Axis +.262 +.217 +.160 +.080 -.010 -.098 -.175 -.232 -.262 -.262 -.232 -.175 -.098 -.010 +.080 +.160 +.217 +.262 +.172 Location MIL-DTL-38999 Series II Front face of pin insert shown A X-Axis +.045 +.123 +.211 +.254 +.266 +.247 +.200 +.130 +.045 -.045 -.130 -.200 -.247 -.266 -.254 -.211 -.123 -.045 +.045 Contact Position MIL-DTL-38999 Series I Insert Designation R Location Contact Locations E F G A B C D E F G H J K L M N Location X-Axis +.000 +.131 +.239 +.305 +.319 +.278 +.189 +.067 -.067 -.189 -.278 -.319 -.305 Y-Axis +.321 +.293 +.214 +.099 -.034 -.161 -.260 -.314 -.314 -.260 -.161 -.034 +.099 Contact Locations Contact Position P R S T U V W X Y Z a b c Location X-Axis -.239 -.131 -.070 +.070 +.175 +.178 +.119 +.000 -.119 -.178 -.175 +.000 +.000 Y-Axis +.214 +.293 +.177 +.177 +.094 -.036 -.151 -.203 -.151 -.036 +.094 +.065 -.065 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 199 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 17-35 16-35 E35 55 22D M Insert Designation Contact Locations Location Contact Position 17 10 25 32 40 4 47 53 1 55 52 3 9 16 24 31 46 39 Contact Locations Location Contact Position X-Axis -.312 -.312 -.312 -.242 -.234 -.234 -.234 1 2 3 4 5 6 7 Connector Type Y-Axis +.086 -.004 -.094 +.221 +.131 +.041 -.049 X-Axis -.234 -.234 -.172 -.156 -.156 -.156 -.156 -.156 -.156 -.089 -.078 -.078 -.078 -.078 -.078 -.078 -.078 +.000 +.000 +.000 +.000 +.000 +.000 +.000 +.089 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Y-Axis -.139 -.229 +.279 +.176 +.086 -.004 -.094 -.184 -.274 +.316 +.221 +.131 +.041 -.049 -.139 -.229 -.319 +.329 +.176 +.086 -.004 -.094 -.184 -.274 +.316 Contact Locations Contact Position 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 X-Axis +.078 +.078 +.078 +.078 +.078 +.078 +.078 +.172 +.156 +.156 +.156 +.156 +.156 +.156 +.242 +.234 +.234 +.234 +.234 +.234 +.312 +.312 +.312 Y-Axis +.221 +.131 +.041 -.049 -.139 -.229 -.319 +.279 +.176 +.086 -.004 -.094 -.184 -.274 +.221 +.131 +.041 -.049 -.139 -.229 +.086 -.004 -.094 MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 17-8 16-8 E8 8 16 II Front face of pin insert shown Contact Locations Contact Position A A B C D E F G H B H C F E Location MIL-DTL-38999 Series I Insert Designation G PCB Front face of pin insert shown D Location X-Axis +.000 +.128 +.230 +.094 -.094 -.230 -.128 +.000 Y-Axis +.236 +.086 -.078 -.216 -.216 -.078 +.086 -.052 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 200 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 19-11 18-11 F11 11 16 II Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position J A B C D E F G H J K L A B H K C G L F D E Connector Type MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 19-32 18-32 F32 32 20 I Contact Locations A U P N B V e R C f d W c X h K F Z a L J E Y b M D g j G H Y-Axis +.260 +.132 -.053 -.215 -.281 -.215 -.053 +.132 +.260 +.105 -.092 MIL-DTL-38999 Series II Front face of pin insert shown T X-Axis +.105 +.250 +.275 +.179 +.000 -.179 -.275 -.250 -.105 +.000 +.000 MIL-DTL-38999 Series I Insert Designation S Location Contact Position A B C D E F G H J K L M N P R S Location X-Axis +.066 +.189 +.286 +.345 +.357 +.321 +.242 +.130 +.000 -.130 -.242 -.321 -.357 -.345 -.286 -.189 Y-Axis +.353 +.305 +.217 +.098 -.033 -.160 -.265 -.335 -.359 -.335 -.265 -.160 -.033 +.098 +.217 +.305 Contact Locations Contact Position T U V W X Y Z a b c d e f g h j Location X-Axis -.066 +.000 +.124 +.209 +.228 +.174 +.065 -.065 -.174 -.228 -.209 -.124 +.000 +.096 +.000 -.096 Y-Axis +.353 +.230 +.193 +.095 -.033 -.151 -.221 -.221 -.151 -.033 +.095 +.193 +.096 +.000 -.096 +.000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 201 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 19-35 18-35 F35 66 22D M Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position 17 4 25 34 43 10 51 58 64 1 3 66 63 9 16 24 33 42 50 57 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Location X-Axis -.357 -.357 -.357 -.279 -.279 -.279 -.279 -.279 -.279 -.201 -.201 -.201 -.201 -.201 -.201 -.201 -.123 -.123 -.123 -.123 -.123 -.123 -.123 -.123 -.045 -.045 -.045 -.045 -.045 -.045 -.045 -.045 -.045 Y-Axis +.090 +.000 -.090 +.225 +.135 +.045 -.045 -.135 -.225 +.270 +.180 +.090 +.000 -.090 -.180 -.270 +.315 +.225 +.135 +.045 -.045 -.135 -.225 -.315 +.360 +.270 +.180 +.090 +.000 -.090 -.180 -.270 -.360 Contact Locations Contact Position 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Location X-Axis +.045 +.045 +.045 +.045 +.045 +.045 +.045 +.045 +.045 +.123 +.123 +.123 +.123 +.123 +.123 +.123 +.123 +.201 +.201 +.201 +.201 +.201 +.201 +.201 +.279 +.279 +.279 +.279 +.279 +.279 +.357 +.357 +.357 Y-Axis +.360 +.270 +.180 +.090 +.000 -.090 -.180 -.270 -.360 +.315 +.225 +.135 +.045 -.045 -.135 -.225 -.315 +.270 +.180 +.090 +.000 -.090 -.180 -.270 +.225 +.135 +.045 -.045 -.135 -.225 +.090 +.000 -.090 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 202 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 21-35 20-35 G35 79 22D M Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position 1 31 51 79 21 71 61 41 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Location X-Axis +.053 +.146 +.232 +.306 +.365 +.406 +.427 +.427 +.406 +.365 +.306 +.232 +.146 +.053 -.053 -.146 -.232 -.306 -.365 -.406 -.427 -.427 -.406 -.365 -.306 -.232 -.146 -.053 .000 +.098 +.184 +.258 +.311 +.332 +.332 +.311 +.258 +.184 +.098 .000 Y-Axis +.426 +.404 +.362 +.302 +.227 +.141 +.048 -.048 -.141 -.227 -.302 -.362 -.404 -.426 -.426 -.404 -.362 -.302 -.227 -.141 -.048 +.048 +.141 +.227 +.302 +.362 +.404 +.426 +.323 +.322 +.280 +.220 +.141 +.048 -.048 -.141 -.220 -.280 -.322 -.347 Contact Locations Contact Position 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Location X-Axis -.098 -.184 -.258 -.311 -.332 -.332 -.311 -.258 -.184 -.098 -.048 +.048 +.134 +.208 +.237 +.237 +.208 +.134 +.048 -.048 -.134 -.208 -.237 -.237 -.208 -.134 -.048 +.048 +.125 +.155 +.125 +.048 -.048 -.125 -.155 -.125 .000 +.048 -.048 Y-Axis -.322 -.280 -.220 -.141 -.048 +.048 +.141 +.220 +.280 +.322 +.241 +.241 +.199 +.139 +.048 -.048 -.139 -.199 -.241 -.241 -.199 -.139 -.048 +.048 +.139 +.199 +.146 +.146 +.090 .000 -.090 -.146 -.146 -.090 .000 +.090 +.053 -.029 -.029 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 203 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type Insert Designation MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 21-41 20-41 G41 41 20 I PCB Front face of pin insert shown W V j U C Y D k g P f n N M L G c d e F b p q E a t r R Z m s h S B X i T A H J K .300 DIA. .567 DIA. .835 DIA. Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 204 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 23-35 22-35 H35 100 22D M Insert Designation PCB Contact Locations Front face of pin insert shown Contact Positions 25 35 46 16 56 67 77 8 86 1 94 2 95 96 3 97 4 98 5 99 6 7 100 15 93 24 34 45 55 85 66 76 Contact Locations Contact Positions 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Location X-Axis -.428 -.467 -.488 -.415 -.488 -.428 -.428 -.332 -.332 -.332 -.332 -.332 -.332 -.332 -.332 -.249 -.249 -.249 -.249 -.249 -.249 -.249 -.249 -.249 -.166 -.166 Y-Axis +.241 +.154 +.061 .000 -.061 -.142 -.237 +.333 +.238 +.143 +.048 -.047 -.142 -.237 -.332 +.380 +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 +.428 +.333 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 Location X-Axis -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 .000 .000 .000 .000 .000 .000 .000 .000 .000 .000 +.083 +.083 +.083 +.083 +.083 +.083 +.083 +.083 +.083 +.083 +.083 +.166 +.166 +.166 +.166 +.166 +.166 +.166 +.166 Y-Axis +.238 +.143 +.048 -.047 -.142 -.237 -.332 -.427 +.475 +.380 +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 -.475 +.428 +.333 +.238 +.143 +.048 -.047 -.142 -.237 -.332 -.427 +.475 +.380 +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 -.475 +.428 +.333 +.238 +.143 +.048 -.047 -.142 -.237 Contact Locations Contact Positions 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Location X-Axis +.166 +.166 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.332 +.332 +.332 +.332 +.332 +.332 +.332 +.332 +.428 +.467 +.488 +.415 +.488 +.428 +.428 Y-Axis -.332 -.427 +.380 +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 +.333 +.238 +.143 +.048 -.047 -.142 -.237 -.332 +.241 +.154 +.061 .000 -.061 -.142 -.237 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 205 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 23-55 22-55 H55 55 20 I Insert Designation Contact Locations R k j P i N n AA z GG y x FF w g f L K Contact Locations Location Contact Position X-Axis +.112 +.225 +.336 +.450 +.450 +.450 +.336 A B C D E F G Connector Type Y-Axis +.455 +.390 +.325 +.130 +.000 -.130 -.325 Y-Axis -.065 +.065 +.195 +.260 +.325 +.260 +.195 +.130 +.000 -.130 -.195 -.260 -.195 -.130 +.000 +.130 +.195 +.130 +.065 -.065 -.130 -.065 +.065 +.000 Number of Contacts Contact Size Service Rating 25-29 24-29 J29 29 16 I Contact Locations S Contact Position c C U f a B T b d M D V e Z L X-Axis -.336 -.336 -.336 -.225 -.112 +.000 +.112 +.225 +.225 +.225 +.112 +.000 -.112 -.225 -.225 -.225 -.112 +.000 +.112 +.112 +.000 -.112 -.112 +.000 MIL-DTL-38999 Series III A N i j k m n p q r s t u v w x y z AA BB CC DD EE FF GG HH MIL-DTL-38999 Series II Front face of pin insert shown P Y-Axis -.390 -.455 -.455 -.390 -.325 -.130 +.000 +.130 +.325 +.390 +.455 +.390 +.325 +.260 +.195 +.065 -.065 -.195 -.260 -.325 -.390 -.325 -.260 -.195 E W Y X K F G J Location MIL-DTL-38999 Series I Insert Designation R X-Axis +.225 +.112 -.112 -.225 -.336 -.450 -.450 -.450 -.336 -.225 -.112 +.000 +.112 +.225 +.336 +.336 +.336 +.336 +.225 +.112 +.000 -.112 -.225 -.336 H J K L M N P R S T U V W X Y Z a b c d e f g h p h M C X Y q D r BB CC Z E HH s a F DD t EE b u v c G d e H J W m Contact Position H A B C D E F G H J K L M N P R Location X-Axis +.000 +.258 +.395 +.469 +.469 +.395 +.263 +.091 -.091 -.263 -.395 -.469 -.469 -.395 -.258 Y-Axis +.481 +.406 +.277 +.109 -.109 -.277 -.406 -.472 -.472 -.406 -.277 -.109 +.109 +.277 +.406 Contact Locations Contact Position S T U V W X Y Z a b c d e f Location X-Axis -.091 +.091 +.228 +.319 +.240 +.091 -.091 -.240 -.319 -.228 +.000 +.134 +.000 -.134 Y-Axis +.321 +.321 +.194 +.000 -.181 -.290 -.290 -.181 +.000 +.194 +.161 +.000 -.130 +.000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 206 - sales@aero-electric.com PCB S B V Location Contact Position A U T Contact Locations Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 25-35 24-35 J35 128 22D M Insert Designation PCB Front face of pin insert shown Contact Locations 48 59 Contact Position 71 25 36 8 82 15 94 105115 1 125 4 7 121 14 24 35 47 58 70 114 81 93 104 Contact Locations Contact Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Location X-Axis -.479 -.520 -.546 -.555 -.546 -.520 -.479 -.424 -.415 -.415 -.415 -.415 -.415 -.424 -.332 -.332 -.332 -.332 -.332 -.332 -.332 -.332 -.332 -.332 -.249 -.249 Y-Axis +.279 +.190 +.095 .000 -.095 -.190 -.279 +.357 +.190 +.095 .000 -.095 -.190 -.357 +.444 +.332 +.237 +.142 +.047 -.047 -.142 -.237 -.332 -.427 +.496 +.380 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 Location X-Axis -.249 -.249 -.249 -.249 -.249 -.249 -.249 -.249 -.249 -.160 -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.166 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 -.083 .000 .000 .000 .000 .000 .000 .000 .000 .000 .000 .000 .000 +.083 +.083 +.083 +.083 +.083 +.083 +.083 - 207 - Y-Axis +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 -.475 +.531 +.427 +.332 +.237 +.142 +.047 -.047 -.142 -.237 -.332 -.427 -.522 +.475 +.380 +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 -.475 +.522 +.427 +.332 +.237 +.142 +.047 -.047 -.142 -.237 -.332 -.427 -.555 +.475 +.380 +.285 +.190 +.095 .000 -.095 Contact Locations Contact Position 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 Location X-Axis +.083 +.083 +.083 +.083 +.160 +.166 +.166 +.166 +.166 +.166 +.166 +.166 +.166 +.166 +.166 +.166 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.249 +.332 +.332 +.332 +.332 +.332 +.332 +.332 +.332 +.332 +.332 +.424 +.415 +.415 +.415 +.415 +.415 +.424 +.479 +.520 +.546 +.555 +.546 +.520 +.479 Y-Axis -.190 -.285 -.380 -.475 +.531 +.427 +.332 +.237 +.142 +.047 -.047 -.142 -.237 -.332 -.427 -.522 +.496 +.380 +.285 +.190 +.095 .000 -.095 -.190 -.285 -.380 -.475 +.444 +.332 +.237 +.142 +.047 -.047 -.142 -.237 -.332 -.427 +.357 +.190 +.095 .000 -.095 -.190 -.357 +.279 +.190 +.095 .000 -.095 -.190 -.279 sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II and III Insert Arrangements Connector Type MIL-DTL-38999 Series I MIL-DTL-38999 Series II MIL-DTL-38999 Series III Number of Contacts Contact Size Service Rating 25-61 24-61 J61 61 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position Y X Z a u A v GG HH B b c C w D d x NN JJ V s e E PP y EE KK MM U r F f LL T G g q z DD BB CC AA h S H p J R i k j P m K N L M W t FF Contact Locations Contact Position A B C D E F G H J K L Location X-Axis +.196 +.314 +.413 +.485 +.527 +.536 +.511 +.454 +.368 +.259 +.134 Y-Axis +.500 +.435 +.343 +.230 +.101 -.030 -.164 -.287 -.391 -.470 -.519 Contact Locations Contact Position M N P R S T U V W X Y Location X-Axis +.000 -.134 -.259 -.368 -.454 -.511 -.536 -.527 -.485 -.413 -.314 Y-Axis -.537 -.519 -.470 -.391 -.287 -.164 -.030 +.101 +.230 +.343 +.435 Z a b c d e f g h i j k m n p q r s t u v w x y z AA BB CC DD EE FF GG HH JJ KK LL MM NN PP Location X-Axis -.196 -.068 +.068 +.173 +.285 +.362 +.399 +.392 +.341 +.251 +.133 +.000 -.133 -.251 -.341 -.392 -.399 -.362 -.285 -.173 +.000 +.147 +.237 +.267 +.228 +.131 +.000 -.131 -.228 -.267 -.237 -.147 +.000 +.105 +.135 +.000 -.135 -.105 +.000 Y-Axis +.500 +.454 +.454 +.363 +.283 +.175 +.046 -.088 -.213 -.314 -.379 -.402 -.379 -.314 -.213 -.088 +.046 +.175 +.283 +.363 +.338 +.223 +.122 -.010 -.139 -.233 -.267 -.233 -.139 -.010 +.122 +.223 +.200 +.094 -.041 -.132 -.041 +.094 +.000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 208 - sales@aero-electric.com MIL-DTL-26482 Series II Wall Mounting Receptacle AEP15-101, AEP15-102 Part Number Development Aero Prefix AEP15- 101- W 20 XX P W- *** PCB Shell Type 101 = Rear, wall mount 102 = Rear, wall mount Material Finish BN = Aluminum, Black Nickel, (RoHS) L = Aluminum, Electroless Nickel T = Aluminum, Teflon Nickel (consult factory for availability) W = Aluminum, Cadmium, Olive Drab Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 8, 10 , 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL-STD-1669. 216 Thru 228 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) N = Normal = Blank Alternative Polarization = W, X, Y and Z Options (Aero Modification Number) ***Consult factory for other modifications AEP15-101 and -102 Dimesional Data Standard PC Tail Diameters SHELL SIZE A MAX. B C MAX. OD (AEP15-101) OJ MAX. OU MAX. CONTACT SIZE OF .001 8 .828 .594 1.062 .120 .474 .500 20 .019 10 .964 .719 1.062 .120 .591 .627 16 .062 12 1.047 .812 1.062 .120 .751 .751 14 1.141 .906 1.062 .120 .876 .876 16 1.234 .969 1.062 .120 1.001 1.001 18 1.328 1.062 1.062 .120 1.126 1.063 20 1.453 1.156 1.124 .147 1.251 1.188 22 1.578 1.250 1.124 .147 1.376 1.313 24 1.703 1.375 1.124 .147 1.501 1.438 www.conesys.com - 209 - Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-26482 Series II Wall Mounting Receptacle AEP15-101, AEP15-102 AEP15-101 Receptacle Connector, Wall Mount MASTER KEYWAY A C MAX. B .375 .250.020 * PC TAIL EXTENSION .140 PCB F J MAX. 4 MINOR KEYWAYS 4X BLUE COLOR BAND D U MAX. 3 BAYONET PINS AEP15-102 Receptacle Connector, Wall Mount with Clinch Nuts MASTER KEYWAY A .375 C MAX. B .250.020 PC TAIL EXTENSION * 4 CLINCH NUTS (SELF-CLINCHING THREAD SIZE: #4-40 (.112-40) .140 F J MAX. 4 MINOR KEYWAYS BLUE COLOR BAND U MAX. 3 BAYONET PINS AEP15-101 AEP15-102 * Standard PC tail extension length. For optional lengths, see pages 229-234 for further information www.conesys.com - 210 - sales@aero-electric.com MIL-DTL-26482 Series II Wall Mounting Receptacle AEP15-103, AEP15-104 Part Number Development Aero Prefix AEP15- 103- W 20 XX P W- *** PCB Shell Type 103 = Rear, wall mount 104 = Rear, wall mount Material Finish BN = Aluminum, Black Nickel, (RoHS) L = Aluminum, Electroless Nickel T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) W = Aluminum, Cadmium, Olive Drab Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 8, 10 , 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL-STD-1669. See Pages 216 Thru 228 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) N = Normal = Blank Alternative Polarization = W, X, Y and Z Options (Aero Modification Number) ***Consult factory for other modifications AEP15-103 and -104 Dimesional Data Standard PC Tail Diameters SHELL SIZE A MAX. B C MAX. OD (AEP15-103) F OJ MAX. OU MAX. CONTACT SIZE OG .001 8 .828 .594 1.062 .120 .556 .474 .500 20 .019 16 .062 10 .964 .719 1.062 .120 .686 .591 .627 12 1.047 .812 1.062 .120 .802 .751 .751 14 1.141 .906 1.062 .120 .927 .876 .876 16 1.234 .969 1.062 .120 1.048 1.001 1.001 18 1.328 1.062 1.062 .120 1.126 1.126 1.063 20 1.453 1.156 1.124 .147 1.250 1.251 1.188 22 1.578 1.250 1.124 .147 1.387 1.376 1.313 24 1.703 1.375 1.124 .147 1.500 1.501 1.438 www.conesys.com - 211 - Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. sales@aero-electric.com MIL-DTL-26482 Series II Wall Mounting Receptacle AEP15-103, AEP15-104 AEP15-103 Receptacle Connector, Wall Mount with Dual Flange MASTER KEYWAY A C MAX. .375 B .250.020 PC TAIL EXTENSION * F .140 PCB G 4X .112-40 UNC-2B HELICOIL v J MAX. 4 MINOR KEYWAYS BLUE COLOR BAND 4X 3 BAYONET PINS U MAX. D AEP15-104 Receptacle Connector, Wall Mount with Dual Flange and Clinch Nuts MASTER KEYWAY A C MAX. .375 .250.020 PC TAIL EXTENSION * F B .140 4 CLINCH NUTS (SELF-CLINCHING THREAD SIZE: #4-40 (.112-40) G J MAX. 4X 4X .112-40 UNC-2B HELICOIL 4 MINOR KEYWAYS U MAX. BLUE COLOR BAND 3 BAYONET PINS AEP15-103 AEP15-104 * Standard PC tail extension length. For optional lengths, see pages 229-234 for further information www.conesys.com - 212 - sales@aero-electric.com MIL-DTL-26482 Series II Jam Nut Receptacle AEP15-105, AEP15-106 Part Number Configuration Aero Prefix AEP15- 105- W 20 XX P W- *** PCB Shell Type 105 = Jam nut mount 106 = Jam nut mount Material Finish BN = Aluminum, Black Nickel, (RoHS) L = Aluminum, Electroless Nickel T = Aluminum, Teflon Nickel, (RoHS), (consult factory for availability) W = Aluminum, Cadmium, Olive Drab Z = Aluminum, Black Zinc Nickel, (RoHS) RN = Aluminum, Electroless Nickel (RoHS) Shell Size 8, 10 , 12, 14, 16, 18, 20, 22, 24 Insert Arrangement Per MIL-STD-1669. See Pages 216 Thru 228 for Insert Selection. Contact Style P = Pin S = Socket Polarization (Keying) N = Normal = Blank Alternative Polarization = W, X, Y and Z Options (Aero Modification Number) ***Consult factory for other modifications AEP15-105 and -106 Dimesional Data SHELL SIZE A MAX. OB MAX. OC MAX. F FLAT G THREAD-UNEF-2A OJ MAX. p (AEP15-106) OU MAX. 8 .954 1.078 1.062 .525 .562-24 .474 .556 .500 10 1.078 1.230 1.062 .650 .687-24 .591 .686 .627 12 1.266 1.391 1.062 .813 .875-20 .751 .802 .751 14 1.391 1.516 1.062 .937 1.000-20 .876 .927 .876 16 1.516 1.641 1.062 1.061 1.125-18 1.001 1.048 1.001 18 1.641 1.766 1.062 1.186 1.250-18 1.126 1.126 1.063 20 1.828 1.954 1.124 1.311 1.375-18 1.251 1.250 1.188 22 1.954 2.078 1.124 1.436 1.500-18 1.376 1.387 1.313 24 2.078 2.203 1.124 1.561 1.625-18 1.501 1.500 1.438 Alternate PC Tail diameters and lengths are available. Refer to PC Tail Specification section starting on 229-234 for further information, or consult Conesys/Aero Electric Connector for application support. www.conesys.com Standard PC Tail Diameters - 213 - CONTACT SIZE OH .001 20 .019 16 .062 sales@aero-electric.com MIL-DTL-26482 Series II Jam Nut Receptacle AEP15-105, AEP15-106 AEP15-105 Receptacle Connector, Jam Nut C MAX. A MAX. MASTER KEYWAY G THREAD .375 .140 .250.020 PC TAIL EXTENSION .125 MAX. * B F FLAT PCB H J MAX. 3 BAYONET PINS 4 MINOR KEYWAYS BLUE COLOR BAND HEX NUT PER MS3186 EXCEPT THICKNESS U MAX. "O" RING AEP15-106 Receptacle Connector, Jam Nut with Dual Flange A MAX. B C MAX. .375 .140 MASTER KEYWAY .250.020 PC TAIL EXTENSION * .125 MAX. P G THREAD H F FLAT J MAX. 4 MINOR KEYWAYS 3 BAYONET PINS BLUE COLOR BAND HEX NUT PER MS3186 EXCEPT THICKNESS "O" RING AEP15-105 4X .112-40 UNC-2B HELICOIL AEP15-106 * Standard PC tail extension length. For optional lengths, see pages 229-234 for further information www.conesys.com U MAX. - 214 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Insert Arrangements - Per MIL-STD-1669 The following table lists the most commonly used insert arrangements for printed circuit board applications using MIL-DTL-26482 circular connectors. Specific dimensional illustrations are included on the following pages for each of the insert arrangements in the table. For availability of other insert arrangements or for application support, please consult Conesys/Aero Electric Connector. PCB Contact Size MIL-DTL-26482 Service Rating Total Contacts 8-2 I 2 2 20 8-3 I 3 3 8-4 I 4 4 8-33 I 3 3 8-98 I 3 3 10-6 I 6 6 12-3 II 3 12-10 I 10 16 3 10 14-5 II 5 14-18 I 18 18 5 14-19 I 19 19 16-8 II 8 16-26 I 26 8 18-11 II 11 18-32 I 32 20-16 II 16 20-24 I 24 24 20-41 I 41 41 22-21 II 21 22-55 I 55 24-31 I 31 24-61 I 61 26 11 32 16 21 55 31 61 *For information on size 12 or larger PC Tail contacts, please consult Conesys/Aero-Electric Connector. Voltage Rating Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS I 600 850 1,500 500 375 200 II 1,000 1,275 2,300 750 500 200 ** To be used by designer only as a guide. www.conesys.com - 215 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 8-2 2 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position B A B A Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 8-3 3 20 I Insert Designation Front face of pin insert shown Y-Axis .000 .000 Contact Locations Contact Position C Location X-Axis +.059 -.059 A B C A Location X-Axis +.056 -.079 -.056 Y-Axis +.018 .000 +.018 B Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 216 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 8-4 4 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position A B A B C D D Location X-Axis -.056 -.056 + .056 + .056 Y-Axis + .056 -.056 -.056 + .056 C Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 8-33 3 20 I Front face of pin insert shown Contact Locations Contact Position A B C A Location X-Axis +.000 +.065 -.065 Y-Axis +.075 -.038 -.038 C B Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 217 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 8-98 3 20 I PCB Front face of pin insert shown Contact Locations Contact Position A B C A C Location X-Axis +.065 .000 +.065 Y-Axis +.037 -.075 +.037 B Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 10-6 6 20 I Front face of pin insert shown Contact Locations Contact Position F E A D A B C D E F B C Location X-Axis .000 +.113 +.113 .000 -0.113 -0.113 Y-Axis +.130 +.065 -.065 -0.130 -.065 +.065 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 218 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 12-3 3 16 II PCB Front face of pin insert shown Contact Locations Contact Position C A B C A Location X-Axis +.094 .000 -.094 Y-Axis +.058 -.111 +.058 B Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 12-10 10 20 I Front face of pin insert shown Contact Locations Contact Position H A J G K F E A B C D E F G H J K B C D Location X-Axis .000 +.130 +.195 +.130 .000 -.130 -.195 -.130 +.065 -.065 Y-Axis +.120 +.120 .000 -.120 -.120 -.120 .000 +.120 .000 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 219 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 14-5 5 16 II Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position A E D A B C D E B Number of Contacts Contact Size Service Rating 14-18 18 20 I Front face of pin insert shown Contact Locations Contact Position J A M N T H S G B P U R F C D E Y-Axis +.100 +.024 -.148 -.148 +.024 MIL-DTL-26482 Series II Insert Designation L X-Axis .000 +.174 +.094 -.094 -.174 C Connector Type K Location A B C D E F G H J Location X-Axis +.065 +.195 +.260 +.195 +.130 .000 -.130 -.195 -.260 Y-Axis +.252 +.113 .000 -.113 -.225 -.225 -.225 -.113 .000 Contact Locations Contact Position K L M N P R S T U Location X-Axis -.195 -.065 -.065 +.065 +.130 +.065 -.065 -.130 .000 Y-Axis +.113 +.252 +.113 +.113 .000 -.113 -.113 .000 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 220 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 14-19 19 20 I PCB Front face of pin insert shown Contact Locations Contact Position M L K N H R S T J C P V U G A B C D E F G H J B A D E F Connector Type Insert Designation Contact Locations Location X-Axis .000 +.130 .195 +.260 +.195 +.130 .000 -.130 -.195 K L M N P R S T U V Number of Contacts Contact Size Service Rating 16-8 8 16 II A B C D E F G H A B H E Y-Axis .000 +.113 +.225 +.113 +.113 .000 -.113 -.113 .000 .000 Contact Locations Contact Position F X-Axis -.260 -.195 -.130 -.065 +.065 +.130 +.065 -.065 -.130 .000 MIL-DTL-26482 Series II Front face of pin insert shown G Location Contact Position Y-Axis +.225 +.225 +.113 .000 -.113 -.225 -.225 -.225 -.113 C D Location X-Axis .000 +.128 +.230 +.094 -.094 -.230 -.128 .000 Y-Axis +.236 +.086 -.078 -.216 -.216 -.078 +.086 -.052 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 221 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 16-26 26 20 I PCB Front face of pin insert shown Contact Locations Contact Position A R P N M B C T S a D U c Z L E V Y K J X A B C D E F G H J K L M N W F G H Connector Type Insert Designation Contact Locations Location X-Axis .000 +.131 +.239 +.305 +.319 +.278 +.189 +.067 -.067 -.189 -.278 -.319 -.305 Y-Axis +.321 +.293 +.214 +.099 -.034 -.161 -.260 -.314 -.314 -.260 -.161 -.034 +.099 Number of Contacts Contact Size Service Rating 18-11 8 12 I 1 2 3 4 5 6 7 8 9 10 11 A B K G C L F E Y-Axis +.214 +.293 +.177 +.177 +.094 -.036 -.151 -.203 -.151 -.036 +.094 +.065 -.065 Contact Locations Contact Position J X-Axis -.239 -.131 -.070 +.070 +.175 +.178 +.119 .000 -.119 -.178 -.175 .000 .000 P R S T U V W X Y Z a b c MIL-DTL-26482 Series II Front face of pin insert shown H Location Contact Position D Location X-Axis +.105 +.250 +.275 +.179 .000 -.179 -.275 -.250 -.105 .000 .000 Y-Axis +.260 +.132 -.053 -.215 -.281 -.215 -.053 +.132 +.260 +.105 -.092 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 222 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 18-32 32 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Location Contact Position T R B U e f d P C V W J D g N c M E h X F L b a K Y Z G H J X-Axis +.066 +.189 +.286 +.345 +.357 +.321 +.242 +.130 .000 -.130 -.242 -.321 -.357 -.345 -.286 -.189 A B C D E F G H J K L M N P R S A S Connector Type Insert Designation J A B M S N R H G D P F C X-Axis -.066 .000 +.124 +.209 +.228 +.174 +.065 -.065 -.174 -.228 -.209 -.124 .000 +.096 .000 -.096 T U V W X Y Z a b c d e f g h j Number of Contacts Contact Size Service Rating 20-16 16 16 II Contact Locations Contact Position L Y-Axis +.353 +.305 +.217 +.098 -.033 -.160 -.265 -.335 -.359 -.335 -.265 -.160 -.033 +.098 +.217 +.305 Location Contact Position MIL-DTL-26482 Series II Front face of pin insert shown K Contact Locations A B C D E F G H Location X-Axis +.118 +.271 +.341 +.308 +.182 .000 -.182 -.308 Y-Axis +.322 +.211 +.036 -.150 -.290 -.343 -.290 -.150 Y-Axis +.353 +.230 +.193 +.095 -.033 -.151 -.221 -.221 -.151 -.033 +.095 +.193 +.096 .000 -.096 .000 Contact Locations Contact Position J K L M N P R S Location X-Axis -.341 -.271 -.118 .000 +.154 +.094 -.094 -.154 Y-Axis +.036 +.211 +.322 +.175 +.062 -.122 -.122 +.062 E Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 223 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type Insert Designation MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 20-24 24 20 I Front face of pin insert shown L K J B N X a Y C P V H Z U G T A B C D E F G H J K L M A M W D R S E F Contact Position Connector Type Insert Designation Contact Locations Location X-Axis +.175 +.350 +.400 +.350 +.200 .000 -.200 -.350 -.400 -.350 -.175 .000 Contact Position Y-Axis +.375 +.200 .000 -.200 -.350 -.400 -.350 -.200 .000 +.200 +.375 +.300 N P R S T U V W X Y Z a MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 20-41 41 20 I Contact Locations Front face of pin insert shown A W B V T C X U Y j i D Z k m s E a h t S R b q p G c f P F n r g e N H d J M L K Contact Position A B C D E F G H J K L M N P R S T U V W X Location X-Axis .000 +.129 +.245 +.338 +.397 +.418 +.397 +.338 +.245 +.129 .000 -.129 -.245 -.338 -.397 -.418 -.397 -.338 -.245 -.129 .000 Y-Axis +.418 +.397 +.338 +.245 +.129 .000 -.129 -.245 -.338 -.397 -.418 -.397 -.338 -.245 -.129 .000 +.129 +.245 +.338 +.397 +.284 Location X-Axis +.150 +.250 +.200 +.075 -.075 -.200 -.250 -.150 .000 +.100 .000 -.100 Y-Axis +.200 .000 -.150 -.250 -.250 -.150 .000 +.200 +.150 +.025 -.100 +.025 Contact Locations Contact Position Y Z a b c d e f g h i j k m n p q r s t Location X-Axis +.132 +.233 +.281 +.265 +.188 +.068 -.068 -.188 -.265 -.281 -.233 -.132 .000 +.117 +.146 +.065 -.065 -.146 -.117 .000 Y-Axis +.251 +.161 +.034 -.101 -.212 -.275 -.275 -.212 -.101 +.034 +.161 +.251 +.150 +.094 -.033 -.135 -.135 -.033 +.094 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 224 - sales@aero-electric.com PCB Contact Locations Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 22-21 12 12 I Insert Designation PCB Contact Locations Front face of pin insert shown T S m k z R l P U n AA GG h CC K b u F c d e L E a t v f D Z DD w g Y s EE x C X r HH FF M B W q BB i N A B C D E F G H J K L M N P R S T U V W X A V p y Contact Position G H J Location X-Axis +.128 +.289 +.386 +.400 +.328 +.183 .000 -.183 -.328 -.400 -.386 -.289 -.128 .000 +.160 +.214 +.094 -.094 -.214 -.160 .000 Y-Axis +.385 +.285 +.123 -.065 -.239 -.362 -.406 -.362 -.239 -.065 +.123 +.285 +.385 +.245 +.146 -.035 -.194 -.194 -.035 +.146 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 225 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 22-55 55 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position A J H B M K L G F C D E A B C D E F G H J K L M N P R S T U V W X Y Z a b c d e f Location X-Axis +.112 +.225 +.336 +.450 +.450 +.450 +.336 +.225 +.112 -.112 -.225 -.336 -.450 -.450 -.450 -.336 -.225 -.112 .000 +.112 +.225 +.336 +.336 +.336 +.336 +.225 +.112 .000 -.112 Y-Axis +.455 +.390 +.325 +.130 .000 -.130 -.325 -.390 -.455 -.455 -.390 -.325 -.130 .000 +.130 +.325 +.390 +.455 +.390 +.325 +.260 +.195 +.065 -.065 -.195 -.260 -.325 -.390 -.325 Contact Locations Contact Position g h i j k m n p q r s t u v w x y z AA BB CC DD EE FF GG HH Location X-Axis -.225 -.336 -.336 -.336 -.336 -.225 -.112 .000 +.112 +.225 +.225 +.225 +.112 .000 -.112 -.225 -.225 -.225 -.112 .000 +.112 +.112 .000 -.112 -.112 .000 Y-Axis -.260 -.195 -.065 +.065 +.195 +.260 +.325 +.260 +.195 +.130 .000 -.130 -.195 -.260 -.195 -.130 .000 +.130 +.195 +.130 +.065 -.065 -.130 -.065 +.065 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 226 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 24-31 31 16 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position A M L N Z a Y X Q W C R g e J B P b f K A B C D E F G H J K L M N P Q R S T U V W X Y Z a b c d e f g c S d V D T U H E G F Location X-Axis +.158 +.316 +.474 +.474 +.316 +.158 -.158 -.316 -.474 -.474 -.316 -.158 .000 +.158 +.316 +.316 +.316 +.158 .000 -.158 -.316 -.316 -.316 -.158 .000 +.158 +.158 .000 -.158 -.158 .000 Y-Axis +.455 +.364 +.091 -.091 -.364 -.455 -.455 -.364 -.091 +.091 +.364 -.455 +.364 +.273 +.182 .000 -.182 -.273 -.364 -.273 -.182 .000 +.182 +.273 +.182 +.091 -.091 -.182 -.091 +.091 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 227 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-26482 Series II Insert Arrangements Connector Type MIL-DTL-26482 Series II Number of Contacts Contact Size Service Rating 24-61 61 20 I Insert Designation PCB Front face of pin insert shown Contact Locations Contact Position Z Y t EE U q T PP MM DD x F y g G AA z BB h i n m R E f KK LL CC p S D e JJ NN r C d w HH FF B c v GG W s V b a u X X Y Z a b c d e f g h i j k m n p q r s t u v w x y z AA BB CC DD EE FF GG HH JJ KK LL MM NN PP A k H J j K P N L M Contact Locations Contact Position A B C D E F G H J K L M N P R S T U V W Location X-Axis +.196 +.314 +.413 +.485 +.527 +.536 +.511 +.454 +.368 +.259 +.134 .000 -.134 -.259 -.368 -.454 -.511 -.536 -.527 -.485 Y-Axis +.500 +.435 +.343 +.230 +.101 -.030 -.164 -.287 -.391 -.470 -.519 -.537 -.519 -.470 -.391 -.287 -.164 -.030 +.101 +.230 Location X-Axis -.413 -.314 -.196 -.068 +.068 +.173 +.285 +.362 +.399 +.392 +.341 +.251 +.133 .000 -.133 -.251 -.341 -.392 -.399 -.362 -.285 -.173 .000 +.147 +.237 +.267 +.228 +.131 .000 -.131 -.228 -.267 -.237 -.147 .000 +.105 +.135 .000 -.135 -.105 .000 Y-Axis +.343 +.435 +.500 +.454 +.454 +.363 +.283 +.175 +.046 -.088 -.213 -.314 -.379 -.402 -.379 -.314 -.213 -.088 +.046 +.175 +.283 +.363 +.338 +.223 +.122 -.010 -.139 -.233 -.267 -.233 -.139 -.010 +.122 +.223 +.200 +.094 -.041 -.132 -.041 +.094 .000 Alternate PC Tail diameters are available. Refer to PC Tail Specification section starting on 229-234. Dimensional data for the most common insert patterns for the PCB applications are shown. For availability of other insert arrangements, please consult Conesys/Aero-Electric Connector. www.conesys.com - 228 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II, III, and MIL-DTL-26482 Series II PC Tail Lengths Standard contact length and diameter is identified on the main page for each PCB connector series/style (see pages 167 to 192 and 209 to 214. To choose an alternate contact length or diameter, locate the preferred length and diameter of contact in the tables on pages 229 Thru 234 select the modification code dash number specified for that contact configuration. Add the modifacation code to the end of the connector part number created from the part number builder. For example: A connector using size 22 pin contacts in the standard configuration (standard diameter and length) would not require any modification to the part number. However, if a size 22 pin contact with a diameter of 0.019" and pc-tail length of 0.110" is required, the connector part number needs to be specified PCB with a -1101 added to the end of the part number to specify the specific length and diameter required by the designer. Consult factory for further inofrmation or assistance. www.conesys.com Contact Modification Code Diameter Tolerance Tail Length Size 22 Pin Standard Config. 0.019 +/- .001 0.250 Tolerance +/- .020 Size 22 Pin -1101 0.019 +/- .001 0.110 +/- .020 Size 22 Pin -1102 0.019 +/- .001 0.130 +/- .020 Size 22 Pin -1103 0.019 +/- .001 0.150 +/- .020 Size 22 Pin -1104 0.019 +/- .001 0.170 +/- .020 Size 22 Pin -1105 0.019 +/- .001 0.190 +/- .020 Size 22 Pin -1106 0.019 +/- .001 0.210 +/- .020 Size 22 Pin -1107 0.019 +/- .001 0.230 +/- .020 Size 22 Pin -1108 0.019 +/- .001 0.270 +/- .020 Size 22 Pin -1109 0.019 +/- .001 0.290 +/- .020 Size 22 Pin -1110 0.019 +/- .001 0.310 +/- .020 Size 22 Pin -1111 0.019 +/- .001 0.330 +/- .020 Size 22 Pin -1112 0.019 +/- .001 0.350 +/- .020 Size 22 Pin -1113 0.019 +/- .001 0.370 +/- .020 Size 22 Pin -1114 0.019 +/- .001 0.390 +/- .020 Size 22 Pin -1115 0.019 +/- .001 0.410 +/- .020 Size 22 Pin -1116 0.019 +/- .001 0.430 +/- .020 Size 22 Pin -1117 0.019 +/- .001 0.450 +/- .020 Size 22 Pin -1118 0.019 +/- .001 0.470 +/- .020 Size 22 Pin -1119 0.019 +/- .001 0.490 +/- .020 +/- .020 Size 22 Pin -1120 0.019 +/- .001 0.510 Size 22 Pin -1121 0.025 +/- .001 0.110 +/- .020 Size 22 Pin -1122 0.025 +/- .001 0.130 +/- .020 Size 22 Pin -1123 0.025 +/- .001 0.150 +/- .020 Size 22 Pin -1124 0.025 +/- .001 0.170 +/- .020 Size 22 Pin -1125 0.025 +/- .001 0.190 +/- .020 Size 22 Pin -1126 0.025 +/- .001 0.210 +/- .020 Size 22 Pin -1127 0.025 +/- .001 0.230 +/- .020 Size 22 Pin -1128 0.025 +/- .001 0.250 +/- .020 Size 22 Pin -1129 0.025 +/- .001 0.270 +/- .020 Size 22 Pin -1130 0.025 +/- .001 0.290 +/- .020 Size 22 Pin -1131 0.025 +/- .001 0.310 +/- .020 Size 22 Pin -1132 0.025 +/- .001 0.330 +/- .020 Size 22 Pin -1133 0.025 +/- .001 0.350 +/- .020 Size 22 Pin -1134 0.025 +/- .001 0.370 +/- .020 Size 22 Pin -1135 0.025 +/- .001 0.390 +/- .020 Size 22 Pin -1136 0.025 +/- .001 0.410 +/- .020 Size 22 Pin -1137 0.025 +/- .001 0.430 +/- .020 Size 22 Pin -1138 0.025 +/- .001 0.450 +/- .020 Size 22 Pin -1139 0.025 +/- .001 0.470 +/- .020 Size 22 Pin -1140 0.025 +/- .001 0.490 +/- .020 Size 22 Pin -1141 0.025 +/- .001 0.510 +/- .020 - 229 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II, III, and MIL-DTL-26482 Series II PC Tail Lengths Standard contact length and diameter is identified on the main page for each PCB connector series/style (see pages 167 to 192 and 209 to 214. To choose an alternate contact length or diameter, locate the preferred length and diameter of contact in the tables on pages 229 Thru 234 select the modification code dash number specified for that contact configuration. Add the modifacation code to the end of the connector part number created from the part number builder. For example: A connector using size 22 pin contacts in the standard configuration (standard diameter and length) would not require any modification to the part number. However, if a size 22 pin contact with a diameter of .0019" and pc-tail length of 0.110" is required, the connector part number needs to be specified or assistance. Contact Modification Code Diameter Tolerance Tail Length Size 22 Socket Standard Config. 0.019 +/- .001 0.250 Tolerance +/- .020 Size 22 Socket -1401 0.019 +/- .001 0.110 +/- .020 Size 22 Socket -1402 0.019 +/- .001 0.130 +/- .020 Size 22 Socket -1403 0.019 +/- .001 0.150 +/- .020 Size 22 Socket -1404 0.019 +/- .001 0.170 +/- .020 Size 22 Socket -1405 0.019 +/- .001 0.190 +/- .020 Size 22 Socket -1406 0.019 +/- .001 0.210 +/- .020 Size 22 Socket -1407 0.019 +/- .001 0.230 +/- .020 Size 22 Socket -1408 0.019 +/- .001 0.270 +/- .020 Size 22 Socket -1409 0.019 +/- .001 0.290 +/- .020 Size 22 Socket -1410 0.019 +/- .001 0.310 +/- .020 Size 22 Socket -1411 0.019 +/- .001 0.330 +/- .020 Size 22 Socket -1412 0.019 +/- .001 0.350 +/- .020 Size 22 Socket -1413 0.019 +/- .001 0.370 +/- .020 Size 22 Socket -1414 0.019 +/- .001 0.390 +/- .020 Size 22 Socket -1415 0.019 +/- .001 0.410 +/- .020 Size 22 Socket -1416 0.019 +/- .001 0.430 +/- .020 Size 22 Socket -1417 0.019 +/- .001 0.450 +/- .020 Size 22 Socket -1418 0.019 +/- .001 0.470 +/- .020 Size 22 Socket -1419 0.019 +/- .001 0.490 +/- .020 +/- .020 Size 22 Socket -1420 0.019 +/- .001 0.510 Size 22 Socket -1421 0.025 +/- .001 0.110 +/- .020 Size 22 Socket -1422 0.025 +/- .001 0.130 +/- .020 Size 22 Socket -1423 0.025 +/- .001 0.150 +/- .020 Size 22 Socket -1424 0.025 +/- .001 0.170 +/- .020 Size 22 Socket -1425 0.025 +/- .001 0.190 +/- .020 Size 22 Socket -1426 0.025 +/- .001 0.210 +/- .020 Size 22 Socket -1427 0.025 +/- .001 0.230 +/- .020 Size 22 Socket -1428 0.025 +/- .001 0.250 +/- .020 Size 22 Socket -1429 0.025 +/- .001 0.270 +/- .020 Size 22 Socket -1430 0.025 +/- .001 0.290 +/- .020 Size 22 Socket -1431 0.025 +/- .001 0.310 +/- .020 Size 22 Socket -1432 0.025 +/- .001 0.330 +/- .020 Size 22 Socket -1433 0.025 +/- .001 0.350 +/- .020 Size 22 Socket -1434 0.025 +/- .001 0.370 +/- .020 Size 22 Socket -1435 0.025 +/- .001 0.390 +/- .020 Size 22 Socket -1436 0.025 +/- .001 0.410 +/- .020 Size 22 Socket -1437 0.025 +/- .001 0.430 +/- .020 Size 22 Socket -1438 0.025 +/- .001 0.450 +/- .020 Size 22 Socket -1439 0.025 +/- .001 0.470 +/- .020 Size 22 Socket -1440 0.025 +/- .001 0.490 +/- .020 Size 22 Socket -1441 0.025 +/- .001 0.510 +/- .020 www.conesys.com - 230 - sales@aero-electric.com PCB with a -1101 added to the end of the part number to specify the specific length and diameter required by the designer. Consult factory for further inofrmation Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II, III, and MIL-DTL-26482 Series II PC Tail Lengths Standard contact length and diameter is identified on the main page for each PCB connector series/style (see pages 167 to 192 and 209 to 214. To choose an alternate contact length or diameter, locate the preferred length and diameter of contact in the tables on pages 229 Thru 234 select the modification code dash number specified for that contact configuration. Add the modifacation code to the end of the connector part number created from the part number builder. For example: A connector using size 22 pin contacts in the standard configuration (standard diameter and length) would not require any modification to the part number. However, if a size 22 pin contact with a diameter of .0019" and pc-tail length of 0.110" is required, the connector part number needs to be specified PCB with a -1101 added to the end of the part number to specify the specific length and diameter required by the designer. Consult factory for further inofrmation or assistance. Contact Modification Code Diameter Tolerance Tail Length Tolerance Size 20 Pin Standard Config. 0.019 +/- .001 0.250 +/- .020 Size 20 Pin -1201 0.019 +/- .001 0.110 +/- .020 Size 20 Pin -1202 0.019 +/- .001 0.130 +/- .020 Size 20 Pin -1203 0.019 +/- .001 0.150 +/- .020 Size 20 Pin -1204 0.019 +/- .001 0.170 +/- .020 Size 20 Pin -1205 0.019 +/- .001 0.190 +/- .020 Size 20 Pin -1206 0.019 +/- .001 0.210 +/- .020 Size 20 Pin -1207 0.019 +/- .001 0.230 +/- .020 Size 20 Pin -1208 0.019 +/- .001 0.270 +/- .020 Size 20 Pin -1209 0.019 +/- .001 0.290 +/- .020 Size 20 Pin -1210 0.019 +/- .001 0.310 +/- .020 Size 20 Pin -1211 0.019 +/- .001 0.330 +/- .020 Size 20 Pin -1212 0.019 +/- .001 0.350 +/- .020 Size 20 Pin -1213 0.019 +/- .001 0.370 +/- .020 Size 20 Pin -1214 0.019 +/- .001 0.390 +/- .020 Size 20 Pin -1215 0.019 +/- .001 0.410 +/- .020 Size 20 Pin -1216 0.019 +/- .001 0.430 +/- .020 Size 20 Pin -1217 0.019 +/- .001 0.450 +/- .020 Size 20 Pin -1218 0.019 +/- .001 0.470 +/- .020 Size 20 Pin -1219 0.019 +/- .001 0.490 +/- .020 Size 20 Pin -1220 0.019 +/- .001 0.510 +/- .020 Size 20 Pin -1221 0.025 +/- .001 0.110 +/- .020 Size 20 Pin -1222 0.025 +/- .001 0.130 +/- .020 Size 20 Pin -1223 0.025 +/- .001 0.150 +/- .020 Size 20 Pin -1224 0.025 +/- .001 0.170 +/- .020 Size 20 Pin -1225 0.025 +/- .001 0.190 +/- .020 Size 20 Pin -1226 0.025 +/- .001 0.210 +/- .020 Size 20 Pin -1227 0.025 +/- .001 0.230 +/- .020 Size 20 Pin -1228 0.025 +/- .001 0.250 +/- .020 Size 20 Pin -1229 0.025 +/- .001 0.270 +/- .020 Size 20 Pin -1230 0.025 +/- .001 0.290 +/- .020 Size 20 Pin -1231 0.025 +/- .001 0.310 +/- .020 Size 20 Pin -1232 0.025 +/- .001 0.330 +/- .020 Size 20 Pin -1233 0.025 +/- .001 0.350 +/- .020 Size 20 Pin -1234 0.025 +/- .001 0.370 +/- .020 Size 20 Pin -1235 0.025 +/- .001 0.390 +/- .020 Size 20 Pin -1236 0.025 +/- .001 0.410 +/- .020 Size 20 Pin -1237 0.025 +/- .001 0.430 +/- .020 Size 20 Pin -1238 0.025 +/- .001 0.450 +/- .020 Size 20 Pin -1239 0.025 +/- .001 0.470 +/- .020 Size 20 Pin -1240 0.025 +/- .001 0.490 +/- .020 Size 20 Pin -1241 0.025 +/- .001 0.510 +/- .020 www.conesys.com - 231 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II, III, and MIL-DTL-26482 Series II PC Tail Lengths Standard contact length and diameter is identified on the main page for each PCB connector series/style (see pages 167 to 192 and 209 to 214. To choose an alternate contact length or diameter, locate the preferred length and diameter of contact in the tables on pages 229 Thru 234 select the modification code dash number specified for that contact configuration. Add the modifacation code to the end of the connector part number created from the part number builder. For example: A connector using size 22 pin contacts in the standard configuration (standard diameter and length) would not require any modification to the part number. However, if a size 22 pin contact with a diameter of .0019" and pc-tail length of 0.110" is required, the connector part number needs to be specified or assistance. Contact Modification Code Diameter Tolerance Tail Length Size 20 Socket Standard Config. 0.019 +/- .001 0.250 Tolerance +/- .020 Size 20 Socket -1501 0.019 +/- .001 0.110 +/- .020 Size 20 Socket -1502 0.019 +/- .001 0.130 +/- .020 Size 20 Socket -1503 0.019 +/- .001 0.150 +/- .020 Size 20 Socket -1504 0.019 +/- .001 0.170 +/- .020 Size 20 Socket -1505 0.019 +/- .001 0.190 +/- .020 Size 20 Socket -1506 0.019 +/- .001 0.210 +/- .020 Size 20 Socket -1507 0.019 +/- .001 0.230 +/- .020 Size 20 Socket -1508 0.019 +/- .001 0.270 +/- .020 Size 20 Socket -1509 0.019 +/- .001 0.290 +/- .020 Size 20 Socket -1510 0.019 +/- .001 0.310 +/- .020 Size 20 Socket -1511 0.019 +/- .001 0.330 +/- .020 Size 20 Socket -1512 0.019 +/- .001 0.350 +/- .020 Size 20 Socket -1513 0.019 +/- .001 0.370 +/- .020 Size 20 Socket -1514 0.019 +/- .001 0.390 +/- .020 Size 20 Socket -1515 0.019 +/- .001 0.410 +/- .020 Size 20 Socket -1516 0.019 +/- .001 0.430 +/- .020 Size 20 Socket -1517 0.019 +/- .001 0.450 +/- .020 Size 20 Socket -1518 0.019 +/- .001 0.470 +/- .020 Size 20 Socket -1519 0.019 +/- .001 0.490 +/- .020 +/- .020 Size 20 Socket -1520 0.019 +/- .001 0.510 Size 20 Socket -1521 0.025 +/- .001 0.110 +/- .020 Size 20 Socket -1522 0.025 +/- .001 0.130 +/- .020 Size 20 Socket -1523 0.025 +/- .001 0.150 +/- .020 Size 20 Socket -1524 0.025 +/- .001 0.170 +/- .020 Size 20 Socket -1525 0.025 +/- .001 0.190 +/- .020 Size 20 Socket -1526 0.025 +/- .001 0.210 +/- .020 Size 20 Socket -1527 0.025 +/- .001 0.230 +/- .020 Size 20 Socket -1528 0.025 +/- .001 0.250 +/- .020 Size 20 Socket -1529 0.025 +/- .001 0.270 +/- .020 Size 20 Socket -1530 0.025 +/- .001 0.290 +/- .020 Size 20 Socket -1531 0.025 +/- .001 0.310 +/- .020 Size 20 Socket -1532 0.025 +/- .001 0.330 +/- .020 Size 20 Socket -1533 0.025 +/- .001 0.350 +/- .020 Size 20 Socket -1534 0.025 +/- .001 0.370 +/- .020 Size 20 Socket -1535 0.025 +/- .001 0.390 +/- .020 Size 20 Socket -1536 0.025 +/- .001 0.410 +/- .020 Size 20 Socket -1537 0.025 +/- .001 0.430 +/- .020 Size 20 Socket -1538 0.025 +/- .001 0.450 +/- .020 Size 20 Socket -1539 0.025 +/- .001 0.470 +/- .020 Size 20 Socket -1540 0.025 +/- .001 0.490 +/- .020 Size 20 Socket -1541 0.025 +/- .001 0.510 +/- .020 www.conesys.com - 232 - sales@aero-electric.com PCB with a -1101 added to the end of the part number to specify the specific length and diameter required by the designer. Consult factory for further inofrmation Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II, III, and MIL-DTL-26482 Series II PC Tail Lengths Standard contact length and diameter is identified on the main page for each PCB connector series/style (see pages 167 to 192 and 209 to 214. To choose an alternate contact length or diameter, locate the preferred length and diameter of contact in the tables on pages 229 Thru 234 select the modification code dash number specified for that contact configuration. Add the modifacation code to the end of the connector part number created from the part number builder. For example: A connector using size 22 pin contacts in the standard configuration (standard diameter and length) would not require any modification to the part number. However, if a size 22 pin contact with a diameter of .0019" and pc-tail length of 0.110" is required, the connector part number needs to be specified PCB with a -1101 added to the end of the part number to specify the specific length and diameter required by the designer. Consult factory for further inofrmation or assistance. www.conesys.com Contact Modification Code Diameter Tolerance Tail Length Tolerance Size 16 Pin Standard Config. 0.062 +/- .001 0.250 +/- .020 Size 16 Pin -1301 0.062 +/- .001 0.110 +/- .020 Size 16 Pin -1302 0.062 +/- .001 0.130 +/- .020 Size 16 Pin -1303 0.062 +/- .001 0.150 +/- .020 Size 16 Pin -1304 0.062 +/- .001 0.170 +/- .020 Size 16 Pin -1305 0.062 +/- .001 0.190 +/- .020 Size 16 Pin -1306 0.062 +/- .001 0.210 +/- .020 Size 16 Pin -1307 0.062 +/- .001 0.230 +/- .020 Size 16 Pin -1308 0.062 +/- .001 0.270 +/- .020 Size 16 Pin -1309 0.062 +/- .001 0.290 +/- .020 Size 16 Pin -1310 0.062 +/- .001 0.310 +/- .020 Size 16 Pin -1311 0.062 +/- .001 0.330 +/- .020 Size 16 Pin -1312 0.062 +/- .001 0.350 +/- .020 Size 16 Pin -1313 0.062 +/- .001 0.370 +/- .020 Size 16 Pin -1314 0.062 +/- .001 0.390 +/- .020 Size 16 Pin -1315 0.062 +/- .001 0.410 +/- .020 Size 16 Pin -1316 0.062 +/- .001 0.430 +/- .020 Size 16 Pin -1317 0.062 +/- .001 0.450 +/- .020 Size 16 Pin -1318 0.062 +/- .001 0.470 +/- .020 Size 16 Pin -1319 0.062 +/- .001 0.490 +/- .020 Size 16 Pin -1320 0.062 +/- .001 0.510 +/- .020 Size 16 Pin -1321 0.040 +/- .001 0.110 +/- .020 Size 16 Pin -1322 0.040 +/- .001 0.130 +/- .020 Size 16 Pin -1323 0.040 +/- .001 0.150 +/- .020 Size 16 Pin -1324 0.040 +/- .001 0.170 +/- .020 Size 16 Pin -1325 0.040 +/- .001 0.190 +/- .020 Size 16 Pin -1326 0.040 +/- .001 0.210 +/- .020 Size 16 Pin -1327 0.040 +/- .001 0.230 +/- .020 Size 16 Pin -1328 0.040 +/- .001 0.250 +/- .020 Size 16 Pin -1329 0.040 +/- .001 0.270 +/- .020 Size 16 Pin -1330 0.040 +/- .001 0.290 +/- .020 Size 16 Pin -1331 0.040 +/- .001 0.310 +/- .020 Size 16 Pin -1332 0.040 +/- .001 0.330 +/- .020 Size 16 Pin -1333 0.040 +/- .001 0.350 +/- .020 Size 16 Pin -1334 0.040 +/- .001 0.370 +/- .020 Size 16 Pin -1335 0.040 +/- .001 0.390 +/- .020 Size 16 Pin -1336 0.040 +/- .001 0.410 +/- .020 Size 16 Pin -1337 0.040 +/- .001 0.430 +/- .020 Size 16 Pin -1338 0.040 +/- .001 0.450 +/- .020 Size 16 Pin -1339 0.040 +/- .001 0.470 +/- .020 Size 16 Pin -1340 0.040 +/- .001 0.490 +/- .020 Size 16 Pin -1341 0.040 +/- .001 0.510 +/- .020 - 233 - sales@aero-electric.com Circular Connectors - PCB Contacts MIL-DTL-38999 Series I , II, III, and MIL-DTL-26482 Series II PC Tail Lengths Standard contact length and diameter is identified on the main page for each PCB connector series/style (see pages 167 to 192 and 209 to 214. To choose an alternate contact length or diameter, locate the preferred length and diameter of contact in the tables on pages 229 Thru 234 select the modification code dash number specified for that contact configuration. Add the modifacation code to the end of the connector part number created from the part number builder. For example: A connector using size 22 pin contacts in the standard configuration (standard diameter and length) would not require any modification to the part number. However, if a size 22 pin contact with a diameter of .0019" and pc-tail length of 0.110" is required, the connector part number needs to be specified or assistance. Contact Modification Code Diameter Tolerance Tail Length Tolerance Size 16 Socket Standard Config. 0.062 +/- .001 0.250 +/- .020 Size 16 Socket -1601 0.062 +/- .001 0.110 +/- .020 Size 16 Socket -1602 0.062 +/- .001 0.130 +/- .020 Size 16 Socket -1603 0.062 +/- .001 0.150 +/- .020 Size 16 Socket -1604 0.062 +/- .001 0.170 +/- .020 Size 16 Socket -1605 0.062 +/- .001 0.190 +/- .020 Size 16 Socket -1606 0.062 +/- .001 0.210 +/- .020 Size 16 Socket -1607 0.062 +/- .001 0.230 +/- .020 Size 16 Socket -1608 0.062 +/- .001 0.270 +/- .020 Size 16 Socket -1609 0.062 +/- .001 0.290 +/- .020 Size 16 Socket -1610 0.062 +/- .001 0.310 +/- .020 Size 16 Socket -1611 0.062 +/- .001 0.330 +/- .020 Size 16 Socket -1612 0.062 +/- .001 0.350 +/- .020 Size 16 Socket -1613 0.062 +/- .001 0.370 +/- .020 Size 16 Socket -1614 0.062 +/- .001 0.390 +/- .020 Size 16 Socket -1615 0.062 +/- .001 0.410 +/- .020 Size 16 Socket -1616 0.062 +/- .001 0.430 +/- .020 Size 16 Socket -1617 0.062 +/- .001 0.450 +/- .020 Size 16 Socket -1618 0.062 +/- .001 0.470 +/- .020 Size 16 Socket -1619 0.062 +/- .001 0.490 +/- .020 Size 16 Socket -1620 0.062 +/- .001 0.510 +/- .020 Size 16 Socket -1621 0.040 +/- .001 0.110 +/- .020 Size 16 Socket -1622 0.040 +/- .001 0.130 +/- .020 Size 16 Socket -1623 0.040 +/- .001 0.150 +/- .020 Size 16 Socket -1624 0.040 +/- .001 0.170 +/- .020 Size 16 Socket -1625 0.040 +/- .001 0.190 +/- .020 Size 16 Socket -1626 0.040 +/- .001 0.210 +/- .020 Size 16 Socket -1627 0.040 +/- .001 0.230 +/- .020 Size 16 Socket -1628 0.040 +/- .001 0.250 +/- .020 Size 16 Socket -1629 0.040 +/- .001 0.270 +/- .020 Size 16 Socket -1630 0.040 +/- .001 0.290 +/- .020 Size 16 Socket -1631 0.040 +/- .001 0.310 +/- .020 Size 16 Socket -1632 0.040 +/- .001 0.330 +/- .020 Size 16 Socket -1633 0.040 +/- .001 0.350 +/- .020 Size 16 Socket -1634 0.040 +/- .001 0.370 +/- .020 Size 16 Socket -1635 0.040 +/- .001 0.390 +/- .020 Size 16 Socket -1636 0.040 +/- .001 0.410 +/- .020 Size 16 Socket -1637 0.040 +/- .001 0.430 +/- .020 Size 16 Socket -1638 0.040 +/- .001 0.450 +/- .020 Size 16 Socket -1639 0.040 +/- .001 0.470 +/- .020 Size 16 Socket -1640 0.040 +/- .001 0.490 +/- .020 Size 16 Socket -1641 0.040 +/- .001 0.510 +/- .020 www.conesys.com - 234 - sales@aero-electric.com PCB with a -1101 added to the end of the part number to specify the specific length and diameter required by the designer. Consult factory for further inofrmation Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Military Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero Document MS Number Aero D38999/20 D38999/21 D38999/22 D38999/23 D38999/24 D38999/25 D38999/26 D38999/27 D38999/28 D38999/29 D38999/30 D38999/31 D38999/32 D38999/33 M38999/1 M38999/2 M38999/3 M38999/4 M38999/5 M38999/6 M38999/7 M38999/8 M38999/9 M38999/10 M83723/1 M83723/2 M83723/3 M83723/4 M83723/5 M83723/6 M83723/7 M83723/8 M83723/9 M83723/10 M83723/11 M83723/12 M83723/13 M83723/14 M83723/15A M83723/15N M83723/15S M83723/16A M83723/16M M83723/16S Yes No Yes No Yes No Yes No No No No No Yes Yes No No No No No No No No Yes Yes No No No No No No No No No No No No No No No No No No No No Wall Mount Receptacle Box Mount Receptacle, Hermetic Dummy Receptacle Jam Nut Receptacle, Hermetic Jam Nut Receptacle Solder Mount Receptacle, Hermetic RFI Grounding Plug Weld Mount Receptacle, Hermetic Hex Mounting Nut (Jam Nut) Lanyard Release Plug, Pin Contact Lanyard Release Plug, Socket Contact Lanyard Release Plug, SS 25, Pin Metal Protective Cover, Plug Metal Protective Cover, Receptacle Grommet Nut (E-Nut) Boot Adapter EMI/RFI Crimp Ring Adapter Individual Shield Termination Backshell Straight Backshell, EMI, Environmental Straight Backshell, Non Environmental Straight Backshell, EMI/RFI 90 Split Backshell, EMI/RFI Dummy Receptacle Dummy Receptacle Narrow Flange Mount Receptacle Narrow Flange Mount Receptacle Wide Flange Mount Receptacle Wide Flange Mount Receptacle Jam Nut Receptacle Jam Nut Receptacle Cable Connecting Receptacle Cable Connecting Receptacle Narrow Flange Mt. Recept., Hermetic Wide Flange Mt. Recept., Hermetic Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Straight Plug Straight Plug 90 Strain Relief Grommet Nut (E-Nut) Straight Strain Relief 90 Heat Shrink Boot Boot Adapter Straight Heat Shrink Boot P&S C, P, X -- C, P, X P&S C, P, X P&S C, P, X -- P S P -- -- -- -- -- -- -- -- -- -- -- -- S P S P S P S P P P P P S P -- -- -- -- -- -- 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III, IV 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I 38999 Series II 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I, III 83723 Series I, III 83723 Series I, III 83723 Series I 83723 Series I 83723 Series I -- -- -- -- -- -- -- -- -- -- -- -- -- -- M85049/27 M85049/62 M85049/33-2 M85049/30 M85049/17 M85049/29 M85049/36 M85049/37 -- -- MS3470 MS3470 MS3472 MS3472 MS3474 MS3474 MS3471 MS3471 MS3440 MS3442 MS3443 MS3449 MS3476 MS3476 M85049/51 M85049/31 M85049/52 -- M85049/60-2 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- No No No No No No No No -- -- Yes Yes Yes Yes Yes Yes Yes Yes No No No No Yes Yes No No No -- No -- (MIL-DTL-) * Active - recommended for new design; Inactive - not recommended for new design; Canceled - must use superseding part. ** Equivalent part from newer Series/Spec is intermateable and intermountable; some differences in accessory threads and contact release may exist. www.conesys.com Active Active Active Active Active Active Active Active Active Active Active Active Active Active Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Active Active Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Active Active Active Superseding Available Note: Aero-Electric manufactures MIL-DTL- 26482 Series 2, MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500, MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and III. Only part numbers covered by these specifications are listed. - 235 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Military Status* Part from Shell Type Style Specification & Series of Equivalent** from Document MS Number Aero Cable Connecting Receptacle Cable Connecting Receptacle Wall Mount Receptacle Wall Mount Receptacle Box Mount Receptacle Box Mount Receptacle Straight Plug Straight Plug Wall Mount Receptacle, Hermetic Solder Mount Receptacle, Hermetic 90 Heat Shrink Boot Boot Adapter Straight Heat Shrink Boot Seal Plugs Pin Contacts (0 thru 16) Socket Contacts (0 thru 16) Insertion/Extraction Tools (20, 16, 12) Insertion/Extraction Tools (0, 4, 8) Pin Contacts (20, 16, 12) Socket Contacts (20, 16, 12) 90 Backshell with Cable Clamp Grommet Nut (E-Nut) Straight Backshell with Cable Clamp Pre-wired Plug for 8-2, 8-3, 8-4 Layouts only Pre-wired Plug for 8-2, 8-3, 8-4 Layouts only Pre-wired Narrow Flange Receptacle for 8-2, 8-3, 8-4 Layouts only Pre-wired Narrow Flange Receptacle for 8-2, 8-3, 8-4 Layouts Pre-wired Wide Flange Receptacle for 8-2, 8-3, 8-4 Layouts Pre-wired Wide Flange Receptacle for 8-2, 8-3, 8-4 Layouts RFI Grounding Plug RFI Grounding Plug Metal Protective Cover, Receptacle Dummy Receptacle Metal Protective Cover, Plug Shield Termination l, RFI Grounding Pre-wired RFI Plug for 8-2, 8-3, 8-4 Layouts only Pre-wired RFI Plug for 8-2, 8-3, 8-4 Layouts only S P S P S P S P P P -- -- -- -- P S -- -- P S -- -- -- P S 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series I, III 83723 Series II 83723 Series II 83723 Series I, III 83723 Series II 83723 Series I, III 83723 Series I, III 83723 Series II 83723 Series II 83723 Series II 83723 Series I 83723 Series I Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Canceled, Superseded by Canceled, Superseded by Inactive Inactive Inactive Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Inactive Inactive Inactive Canceled Inactive MS3451 MS3451 MS3450 MS3450 MS3452 MS3452 MS3456 MS3456 MS3142 MS3143 -- -- -- MS27488 M39029/29 M39029/30 M81969/14 M81969/14 M39029/4 M39029/5 -- -- -- -- -- Yes Yes Yes Yes Yes Yes Yes Yes No No -- -- -- Yes Yes Yes Yes Yes Yes Yes -- -- -- -- -- P 83723 Series I Canceled -- -- S 83723 Series I Canceled -- -- P 83723 Series I Canceled -- -- S 83723 Series I Canceled -- -- P S -- -- -- -- 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, MS3475 MS3475 MS3181 MS3115 MS3180 M85049/26 Yes Yes No No No No P 83723 Series I Canceled -- -- S 83723 Series I Canceled -- -- Number Aero M83723/17 M83723/18 M83723/19 M83723/20 M83723/21 M83723/22 M83723/23 M83723/24 M83723/25 M83723/26 M83723/27A M83723/27M M83723/27S M83723/28 M83723/29 M83723/30 M83723/31 M83723/32 M83723/33 M83723/34 M83723/35A M83723/35N M83723/35S M83723/36 M83723/37 No No No No No No No No No No No No No No No No No No No No No No No No Yes M83723/38 No M83723/39 No M83723/40 No M83723/41 No M83723/42 M83723/43 M83723/44 M83723/45 M83723/46 M83723/47 No No No No No No M83723/48 No M83723/49 No (MIL-DTL-) * Active - recommended for new design; Inactive - not recommended for new design; Canceled - must use superseding part. ** Equivalent part from newer Series/Spec is intermateable and intermountable; some differences in accessory threads and contact release may exist. www.conesys.com Superseding Available Note: Aero-Electric manufactures MIL-DTL- 26482 Series 2, MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500, MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and III. Only part numbers covered by these specifications are listed. - 236 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Military Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero Document MS Number Aero M83723/50A M83723/50B M83723/50R M83723/51A M83723/51B M83723/51R M83723/52 M83723/53 M83723/59 M83723/60 M83723/61 M83723/65 M83723/66 M83723/67 M83723/68 M83723/69 M83723/70 M83723/71 M83723/72 M83723/73 M83723/74 M83723/75 M83723/76 M83723/77 M83723/78 M83723/79 M83723/80 M83723/81 M83723/82 M83723/83 M83723/84 M83723/85 M83723/86 M83723/87 M83723/88 M83723/89 M83723/90 M83723/91 M83723/92 M83723/93 M83723/94 M83723/95 M83723/96 No No No No No No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No Yes Yes Yes Yes Yes Yes No No No Yes Yes No No Yes Yes 90 Cable Tie Strain Relief 45 Cable Tie Strain Relief Straight Cable Tie Strain Relief Environmental 90 Backshell Environmental 45 Backshell Environmental Straight Backshell Self Locking Plug, Firewall Self Locking Plug, Firewall Metal Protective Cover, Plug Metal Protective Cover, Receptacle Dummy Receptacle Jam Nut Receptacle, Hermetic Quick-Disconnect Plug, Less Lanyard Quick-Disconnect Plug, Less Lanyard Quick-Disconnect Plug, With Lanyard Quick-Disconnect Plug, With Lanyard Recept. Adapter for Quick-Dis. Plugs Wall Mount Receptacle Wall Mount Receptacle Jam Nut Receptacle Jam Nut Receptacle Straight Plug Straight Plug RFI Grounding Plug RFI Grounding Plug Wall Mount Receptacle, Hermetic Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Wall Mount Receptacle Wall Mount Receptacle Jam Nut Receptacle Jam Nut Receptacle Straight Plug Straight Plug Wall Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Solder Mount Receptacle, Hermetic RFI Grounding Plug RFI Grounding Plug Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Self Locking Plug Self Locking Plug -- -- -- -- -- -- P S -- -- -- P P S P S -- S P S P S P S P P P P S P S P S P P P P S P P P S P Inactive Inactive Inactive Canceled Canceled Canceled Canceled, Superseded by Canceled, Superseded by Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active -- -- -- -- -- -- MS3459 MS3459 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Yes Yes -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- (MIL-DTL-) * Active - recommended for new design; Inactive - not recommended for new design; Canceled - must use superseding part. Note 1: M83723/59, 60, 61 metal plug and receptacle covers and dummy receptacle can be used on MIL-DTL-26500 connectors. 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 SIII, Bay & Thr 83723 SIII, Bay & Thr 83723 SIII, Bay & Thr 83723 Series III, Bay 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Thr 83723 Series III, Thr Superseding Available Note 2: Aero-Electric manufactures MIL-DTL- 26482 Series 2, MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500, MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and III. Only part numbers covered by these specifications are listed. ** Equivalent part from newer Series/Spec is intermateable and intermountable; some differences in accessory threads and contact release may exist. www.conesys.com - 237 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Mil Connector Status* Superseding Available Part from Shell Type Style Specification & Series of Equivalent** from Number Aero (MIL-DTL-) Document MS Number Aero M83723/97 M83723/98 MS24264 "B" MS24264 "T" MS24265 "B" MS24265 "T" MS24266 "B" MS24266 "T" MS25042 MS25043 MS25183 MS27034 MS27291 MS27466 MS27467 MS27468 MS27469 MS27470 MS27471 MS27472 MS27473 MS27474 MS27475 MS27476 MS27477 MS27478 MS27479 MS27480 MS27481 MS27482 MS27483 MS27484 MS27485 MS27486 MS27487 MS27488 MS27489 MS27496 MS27497 MS27498 MS27499 MS27500 MS27501 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No Yes Yes Yes No No No Yes Yes Yes No No No No No No No No No Yes No No No Yes No Yes Yes No Yes Yes No RFI Grounding, Self Locking Plug RFI Grounding, Self Locking Plug Wall Mount Receptacle Wall Mount Receptacle Jam Nut Mount Receptacle Jam Nut Mount Receptacle Straight Plug Straight Plug Metal Protective Cover, Plug Metal Protective Cover, Receptacle Straight Plug, Potting Seal, Solder Solder Mount Receptacle, Hermetic Straight Clamp Front Wall Mount Receptacle RFI Grounding Plug Jam Nut Receptacle Wall Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Solder Mount Receptacle, Hermetic Front Wall Mount Receptacle Straight Plug Jam Nut Receptacle Wall Mount Receptacle, Hermetic Box Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Solder Mount Receptacle, Hermetic Wall Mount Receptacle Straight Plug Jam Nut Receptacle Wall Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic RFI Grounding Plug Potting Boot Ring Potting Boot Straight and 90 Adapter Seal Plug (22, 20, 16, 12, 8, 4, 0) Adapter Reducer Front Box Mount Receptacle Rear Wall Mount Receptacle RFI Plug with 90 Clamp Front Box Mount Receptacle Straight Plug with 90 Strain Relief Metal Protective Cover, Plug S P P&S P&S P&S P&S P&S P&S -- -- P&S C, E -- P&S P&S P&S C, P, X C, P, X C, P, X P&S P&S P&S C, P, X C, P, X C, P, X C, P, X P&S P&S P&S P P P&S -- -- -- -- -- P&S P&S P&S P&S P&S -- 83723 Series III, Thr 83723 Series III, Thr 26500 Bayonet 26500 Threaded 26500 Bayonet 26500 Threaded 26500 Bayonet 26500 Threaded 5015 Series I, II, III 5015 Series I, II, III 5015 Series I (Solder) 26500 Bay & Thr 26500 Bay & Thr 38999 Series I 38999 Series I 38999 Series I 38999 Series I 38999 Series I 38999 Series I 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series I, II 38999 Series I, II All 38999 Series I, II 38999 Series I 38999 Series II 38999 Series I 38999 Series II 38999 Series II 38999 Series I Active Active Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Can Use Active Active Inactive, Can Use Inactive, Use Inactive Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Canceled, Superseded by Canceled, Superseded by Active Canceled, Superseded by Canceled, Superseded by Active Active Active Active Active Canceled, Superseded by Active Active Active -- -- M83723/72,71 M83723/83,82 M83723/74,73 M83723/85,84 M83723/76,75 M83723/87,86 -- -- MS3456 M83723/93,90 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- MS27475 MS27477 -- M85049/58 M85049/75 -- -- -- -- -- MS27467 -- -- -- -- -- Yes Yes Yes Yes Yes Yes -- -- Yes No -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- No No -- No No -- -- -- -- -- Yes -- -- -- * Active - recommended for new design; Inactive - not recommended for new design; Canceled - must use superseding part. Note 1: MS24264 "T", MS24265 "T" and MS24266 "T" equivalents (M83723/82 thru 87) listed above do not apply for shell size 8. Note 2: Aero-Electric manufactures MIL-DTL- 26482 Series 2, MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500, MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and III. Only part numbers covered by these specifications are listed. ** Equivalent part from newer Series/Spec is intermateable and intermountable; some differences in accessory threads and contact release may exist. www.conesys.com - 238 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Mil Connector Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero (MIL-DTL-) Document MS Number Aero MS27502 MS27504 MS27505 MS27506 MS27507 MS27508 MS27510 MS27511 MS27512 MS27513 MS27515 MS27534 MS27535 MS27536 MS27558 MS27559 MS27613 MS27614 MS27615 MS27652 MS27653 MS27654 MS27656 MS27657 MS27661 MS27662 MS27663-1 MS27663-2 MS27664 MS27667 MS27668 MS27669 MS27670 MS3100 MS3101 MS3102 MS3103 MS3105 MS3106 MS3107 MS3108 MS3110 No No Yes No No Yes No No No Yes No No No No No No No No No No No No Yes No No No No No No No No No No No No No No No No No No No Metal Protective Cover, Receptacle Box Mount Receptacle Rear Box Mount Receptacle Straight Strain Relief 90 Strain Relief Rear Box Mount Receptacle Metal Protective Cover, Plug Metal Protective Cover, Receptacle Hex Mounting Nut (Jam Nut) Front Box Mt. Receptacle, Long Grommet Rear Wall Mount Receptacle Insertion/Removal Tools Size 8 Coax Contact, Socket Size 8 Coax Contact, Pin 90 Cable Support, Closed 90 Cable Clamp Wall Mount Receptacle, Firewall Jam Nut Receptacle, Firewall Ratchet Lock & Standard Plug, Firewall Wall Mount Receptacle Straight Plug Rear Wall Mount Receptacle Rear Wall Mount Receptacle Short Cable Support for Classes E, K Lanyard Release Plug Thru-Bulkhead Mounting Receptacle Straight Non-Metallic Strain Relief 90 Non-Metallic Strain Relief Rear Wall Mount Receptacle Thru-Bulkhead Mounting Receptacle Straight Cable Tie Strain Relief 45 Cable Tie Strain Relief 90 Cable Tie Strain Relief Wall Mount Receptacle Cable Connecting Receptacle Box Mount Recptacle Flange Mount Receptacle, Potting Seal Dummy Receptacle Straight Plug Quick Disconnect Plug 90 Plug Wall Mount Receptacle -- P&S P&S -- -- P&S -- -- -- P&S P&S -- S P -- -- P&S P&S P&S P&S P&S P&S P&S -- P&S C -- -- P&S C -- -- -- P&S P&S P&S P&S -- P&S P&S P&S P&S 38999 Series I 38999 Series II 38999 Series I 38999 Series I, II 38999 Series I, II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series I 38999 Series I, II 38999 Series I 38999 Series I 26500 Bay & Thr 26500 Bay & Thr 26500 Bay & Thr 26500 Bay & Thr 26500 Bay & Thr 38999 Series I 38999 Series I 38999 Series I 38999 Series I 26500 Bay & Thr 38999 Series I 38999 Series I 38999 Series I, II 38999 Series I, II 38999 Series II 38999 Series II 38999 Series I, II 38999 Series I, II 38999 Series I, II 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 26482 Series 1 Solder Active Active Active Canceled, Superseded by Canceled, Superseded by Active Active Active Inactive, Use Active Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive Inactive Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Active Inactive Active Active Canceled, Superseded by Canceled, Superseded by Canceled, Use Canceled Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive, Can Use -- -- -- M85049/49 M85049/47 -- -- -- MS3186 -- MS27656 M81969/14 M39029/59 M39029/60 -- -- M83723/83, 82 M83723/85, 84 M83723/96, 95 MS27466 MS27467 MS27656 -- -- -- -- M85049/45 M85049/46 MS27497 -- M85049/56 M85049/57 M85049/63 MS3450 MS3451 MS3452 -- -- MS3456 -- MS3456 & B/S MS3470 -- -- -- No No -- -- -- No -- Yes Yes Yes Yes -- -- Yes Yes Yes Yes Yes Yes -- -- -- -- No No Yes -- No No No Yes Yes Yes -- -- Yes -- Yes Yes * Active - recommended for new design; Inactive - not recommended for new design; Canceled - must use superseding part. ** Equivalent part from newer Series/Spec is intermateable and intermountable; some differences in accessory threads and contact release may exist. "Bayonet Coupling" equivalents do not exist. www.conesys.com Superseding Available Note 1: MS27615 standard threaded plug equivalent = M83723/87, 86 in K class. Note 2: Aero-Electric manufactures MIL-DTL- 26482 Series 2, MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500, MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and III. Only part numbers covered by these specifications are listed. - 239 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Mil Connector Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero (MIL-DTL-) Document MS Number Aero MS3111 MS3112 MS3113 MS3114 MS3115 MS3116 MS3119 MS3120 MS3121 MS3122 MS3124 MS3126 MS3127 MS3128 MS3180 MS3181 MS3400 MS3401 MS3402 MS3404 MS3406 MS3408 MS3409 MS3412 MS3436 MS3440 MS3442 MS3443 MS3449 MS3450 MS3451 MS3452 MS3454 MS3456 MS3459 MS3470 MS3471 MS3472 MS3473 MS3474 MS3475 MS3476 MS3477 MS3479 MS3507 No No No No No No No No No No No No No No No No No No No No No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes No No No Cable Connecting Receptacle Box Mount Receptacle Solder Mount Receptacle Jam Nut Receptacle Dummy Receptacle Straight Plug Thru-Bulkhead Mounting Receptacle Wall Mount Receptacle Cable Connecting Receptacle Box Mount Receptacle Jam Nut Receptacle Straight Plug Box Mount Receptacle Wall Mount Receptacle Metal Protective Cover, Plug Metal Protective Cover, Recepacle Wall Mount Receptacle Cable Connecting Receptacle Box Mount Receptacle Jam Nut Receptacle Straight Plug 90 Plug 45 Plug Wall Mount Receptacle RFI Plug, Utility (20-4 layout only) Narrow Flange Mt. Receptacle, Hermetic Wide Flange Mt. Receptacle, Hermetic Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Wall Mount Receptacle Cable Connecting Receptacle Box Mount Receptacle Jam Nut Receptacle Straight Plug Self Locking Plug Wall Mount Receptacle Cable Connecting Receptacle Wide Flange Mount Receptacle Solder Mount Receptacle, Hermetic Jam Nut Receptacle RFI Grounding Plug Straight Plug Box Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Quick Disconnect Plug (20-4 layout only) P&S P&S P P&S -- P&S S to P P&S P&S P&S P&S P&S P&S P&S -- -- P&S P&S P&S P&S P&S P&S P&S P&S P&S P P P P P&S P&S P&S P&S P&S P&S P&S P&S P&S P P&S P&S P&S P P P 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1, 2 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1, 2 26482 Series 1, 2 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 Series I (Solder) 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 5015 Series I (Solder) Inactive, Can Use Inactive, Can Use Inactive, Use Inactive, Use Inactive Inactive, Can Use Inactive Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Inactive, Use Inactive, Can Use Inactive, Can Use Inactive Inactive Active Active Active Active Active Active Active Active Inactive Inactive Inactive Inactive Inactive Active Active Active Active Active Active Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Active MS3471 MS3470 MS3443 MS3474 -- MS3476 -- MS3470 MS3471 MS3470 MS3474 MS3476 MS3470 MS3470 -- -- MS3450 MS3451 MS3452 MS3454 MS3456 MS456 & B/S MS456 & B/S MS3450 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Yes Yes No Yes -- Yes -- Yes Yes Yes Yes Yes Yes Yes -- -- Yes Yes Yes Yes Yes Yes Yes Yes -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- * Active - recommended for new design; Inactive - not recommended for new design; Canceled - must use superseding part. ** Equivalent part from newer Series/Spec is intermateable and intermountable; some differences in accessory threads and contact release may exist. www.conesys.com Superseding Available Note: Aero-Electric manufactures MIL-DTL- 26482 Series 2, MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500, MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and III. Only part numbers covered by these specifications are listed. - 240 - sales@aero-electric.com Glossary of Terms A accessories Sometimes referred to as "Rear Accessories" or "Backshells" are mechanical devices such as strain reliefs, cable clamps, adapters, potting boots, etc., which are threaded onto the rear connector accessory threads of plug or receptacle connectors to make up the total connector assembly. adapter A threaded ring device screwed onto the threads of an 83723 Series III threaded receptacle to accept a quick disconnect plug. ment panels, thru bulkheads, printed circuit boards, etc. contact Pin or socket - the conductive element of a connector which actually makes contact for the purpose of conducting electrical current. This is the heart of the connector. contact area The actual area in contact (touching) between two conductors (pin and socket) permitting the flow of electrical current. contact arrangement The number of contacts, their size and spacing in a connector. contact engagement/separation force The force necessary to engage or separate pin and socket contacts. contact resistance The electrical resistance on a mated pair of contacts (pin and socket). Resistance is measured in ohms or millivolt drop at a specified current over the engaged contacts. contact retainer Contact retention clip - a device captivated in the hard plastic of the connector body (insert) which retains the contact in the insert. contact retention The axial load in either direction (push or pull) which a contact can withstand without being dislodged from its normal position within the insert of the connector. contact size A specific number indicating the size (or gauge) of the engaging end of the contact; examples: size 20, size 16, size 8, etc. contact shoulder The flanged portion around the body of a contact which limits its forward travel into the insert and prevents it from being pushed forward out of the insert. coupling nut/ring The movable portion of a connector plug which aids in the coupling and uncoupling of a plug and a receptacle and locks the plug and receptacle together. crimp The physical compression (uniformed deformation) of a contact wire barrel around the conductor in order to captivate the conductor and make an electrical connection. crimping A pressure method using a tool to mechanically secure a contact (pin or socket) to a conductor (wire). crimp contact A contact, pin or socket, whose back portion (wire barrel) is a hollow cylinder into which a stripped wire (conductor) is inserted. The sidewalls of the wire barrel are then mechanically compressed (uniformly deformed) using a crimping tool to captivate the conductor. crimp die Portion of the crimp tool that shapes the crimp on the wire barrel. crimp tool Mechanical device that holds the crimp die and is used to perform the crimping function. B back mounted Rear mounted - a connector with its mounting flange mounted inside of a panel or box. bayonet coupling A quick coupling mechanism for mating a plug onto a receptacle utilizing three equally spaced pins protruding from the receptacle shell which engage corresponding ramps milled into the coupling nut of the mating plug. Mating and unmating is accomplished by rotating the coupling nut. BIN code Basic identification number - color bands on the wire barrel end of a contact to identify contact part number. Each BIN number corresponds to one and only one slash sheet (XX) thus identifying the complete M39029/XX-BIN part number. boot A form placed onto the boot adapter used to environmentally seal and/or strain-relieve a cable assembly. boot adapter A mechanical device with one side threaded onto the accessory thread of a connector (plug or receptacle) and the other side used to accept a boot. braid Braided wire - flexible conductor made of woven or braided assembly of wires. bussing The joining of two or more circuits. C cable clamp A mechanical device attached to the accessory threads at the rear of a plug or receptacle to support the cable or wire bundle, to provide strain relief and absorb vibration and shock which would otherwise be transmitted by the cable to the contact or wire crimp area. coaxial contact A contact with two conductive surfaces - a center contact and a surrounding coaxial sleeve. color coding A system of identification of contact insertion/extraction tools. Colors green, red, orange, blue, yellow and white indicate the proper tool to use for either insertion or extraction of appropriate contact size. connector A mechanical device, either a plug or a receptacle, used to terminate or connect electrical conductors (pin and socket contacts) of a cable and its individual wires and provide a means to continue or terminate these conductors to a mating connector which may be mounted on electrical equipwww.conesys.com D depth of crimp The distance the crimp die indenter penetrates into the wire barrel. - 241 - sales@aero-electric.com Glossary of Terms die closure The distance between the crimp die indenters when the crimp tool handle is at full closure. This is usually checked using a Go/No Go gauge. dielectric A material having electrical insulating properties. plug and receptacle. The surfaces will face each other and interface when mated. interfacial seal The sealing of mating connectors over the entire area of the interface and around each contact. This is accomplished when resilient material, with raised barriers around each cavity on the pin interface, displaces into the hard recessed (chamfered) cavities on the socket interface. This creates what is commonly called "cork and bottle seal." E environmental sealing Designed in a connector using grommets, interfacial seals, peripheral seals, gaskets or potting material to keep contaminants such as dirt and moisture out of the connector. extraction tool Removal tool - a tool used to remove contacts from a connector. J jacket Insulation - insulating material around a wire or cable. K key A rectangular projection on plug connector shell designed to slide into the rectangular slot or keyway in the mating receptacle connector to properly align and guide the two mating halves together. Generally used to obtain proper polarization. F filter contact A contact which provides filtering of EMI signals without altering its normal function. filter connector A connector using filtered contacts or filtered discs to filter EMI signals without altering its normal function. front mounting A connector mounted with its mounting flange outside of a box or panel. front release A term indicating the direction the contact removal tool must enter the connector to allow for the removal of contacts. On a front release connector, the contact removal tool must be inserted in the contact cavity from the front or face of the connector to release the contact retention clip. Whether front release or rear release, the contacts are inserted from the rear of the connector. L lanyard A sturdy wire attached to plugs of certain connectors which allows unmating and separation of plug and receptacle by a pull on the wire (lanyard). locator Positioner or Turret head - a mechanical device attached to a crimp tool with multiple locators to position different size contacts for crimping. It is indexed to a proper position by rotating. G grommet A resilient elastomeric seal bonded to the rear of a connector. It is designed with internal sealing barriers that grasp and seal on the wire's insulation to prevent contaminants from entering into the rear of the connector. grounding fingers Grounding spring - a metal band with spring fingers attached to the plug shell to ensure positive shell-to-shell grounding before the contacts engage during mating and when they disengage during unmating. They are also used to improve EMI/RFI performance. M mate The joining of two connectors. mated pair A plug and receptacle joined or to be joined together. millivolt drop Voltage loss due to resistance created by a crimp joint. O "O" ring Also referred to as peripheral seal is used around the periphery of a connector shell and is compressed internally between the plug and receptacle shells when mated to prevent contaminants from entering the connector. I insert The insulating core of the connector designed to position, retain, support and provide separation for the contacts. insertion tool A tool used to insert contacts into a connector. inspection hole A hole at the bottom of the contact wire barrel to permit visual inspection to ensure that the wire has been inserted to the proper depth in the wire barrel prior to crimping. insulation Jacket - insulating material around a wire or cable. interface The two surfaces on the contact side of a mating www.conesys.com P pin contact A "male" contact with the engagement end that enters into the socket contact. plating The overlaying of a thin coating of metal on connector shells and contacts to prevent corrosion, improve conductivity or provide for easy soldering. plug The "free to move" or "unmounted" member of a mated pair of connectors which contains the coupling ring/nut for coupling and locking the connectors together. - 242 - sales@aero-electric.com Glossary of Terms polarization Also known as clocking or keying - the mechanical arrangement of inserts or rectangular keys (projections) and keyways (slots) to ensure proper mating. It eliminates errors when mating identical connectors mounted beside each other. positioner Locator or Turret head - a device attached to a crimp tool with multiple locators to position different size contacts for crimping. It is indexed to a proper position by rotating. potting The permanent sealing of the back of a connector, after the wires have been inserted, with a material to keep out the contaminants and/or provide strain relief. potting boot a form fitted onto the potting ring , which is threaded onto the back of connector, to environmentally seal/strain relive a cable assembly. pull out force The force necessary to separate a wire from the contact crimped to it or the force necessary to pull a properly seated contact from a connector by pulling. pull test Tensile test - a controlled pull test on the contact crimp joint to determine its mechanical strength. scoop proof A term to describe a longer shell design on the pin half (plug or receptacle) of a connector. The longer shell allows the pin contacts, which protrude from the face of the connector, to be recessed sufficiently so as not to be damaged if the mating shell is "scooped" into it during mating process. This prevents pins from being bent and/or contacts from being electrically shorted during mating. This is especially important when using size 22 contacts, which because of their small size, bend easily. sealing plug A small plastic plug (MS27488-**-1, head first) inserted into the rear grommet of a connector, especially an environmental connector, to seal and prevent the entry of contaminants into any unused (unwired) cavities. selective plating The applying of plating material to a limited area of a contact, especially areas susceptible to wear. service rating The maximum amount of voltage or current a connector is designed to continuously carry. shell The outside case of a connector which holds the dielectric insert and contacts. shielded contact A contact shielded from unwanted signals (EMI/RFI) by one or more outer (protective) conductors. These contacts are not generally matched to the impedance of the cable they terminate. socket contact A contact whose engaging end is designed to accept the entry of a pin contact. solder contact A pin or socket contact that accepts a conductor (wire) which is soldered onto the "solder cup," not crimped into the wire barrel. splice Wire splice - a device used to join two or more conductors (wires). strip To remove insulation from a conductor. Generally for inserting the conductor into the wire barrel/solder cup of a contact for a crimping/soldering operation. R range Wire range - the acceptable sizes of wires accommodated by a particular contact wire barrel size. Also the acceptable diameter of wires accommodated by a sealing grommet. rear accessories Referred to as backshells, they are mechanical devices that screw onto the accessory threads on the rear of the connector. Includes strain reliefs, clamps, adapters, potting boots, etc. rear mounted Back mounted - a connector with its mounting flange mounted inside of a panel or box. rear release A term indicating the direction the contact removal tool must enter the connector to allow removal of the contacts. On a rear release connector the contact removal tool must be inserted into the contact cavity from the back or rear of the connector to release the contact retention clip. Whether rear release or front release, contacts are inserted through the rear of the connector. receptacle The fixed or mounted member of a mated pair of connectors designed to be mounted to a box, panel or bulkhead. removal tool A device used to remove contacts from a connector. T tensile test Pull test - a controlled pull test on the contact crimp joint to determine its mechanical strength. thermocouple contact A contact made of special material, used in connectors in high temperature applications as a means of measuring temperature electrically. Materials often used for these contacts are alumel, chromel, constantan, iron and copper. threaded coupling A means of coupling a mating pair of connectors by engaging threads on the exterior of a receptacle with interior threads of the plug. turret head Locator or Positioner - a device attached to a crimp tool with multiple locators to position different size contacts for crimping. It is indexed to a proper position by rotating. S safety wire A means of putting wire through holes drilled in the coupling ring/nut of a connector plug, and securing the wire to a panel of bulkhead to prevent the plug from loosening or decoupling from the receptacle during vibration. www.conesys.com - 243 - sales@aero-electric.com Conesys Specialty Products Filter and Transient Suppression Connectors Filter and transient suppression (lightning strike protected) devices are integrated into the connector to eliminate bulky exterior filtering systems and reduce weight, space and end-user testing while providing system protection from EMI and EMP. Please request Conesys/EMP Connectors publication Filter and Transient Suppression Connectors. 5015 Front Release, Reverse Bayonet, Custom Designs and Fiber Optic Products For information on MIL-DTL-5015 Front Release connectors for shipboard application, Reverse Bayonet connectors for rail/mass transit application, Fiber Optic assemblies and customized, high reliability, severe environment products for Military, Aerospace, Transportation, Telecom and Industrial applications, please request various brochures from Conesys/J-Tech. xacting quality At Conesys, quality is a state of mind that permeates our entire organization, from the newest employee to the CEO. Our philosophy is based on prevention rather than detection. We endeavor to make decisions as early as possible, based on sound statistical principles and design, building quality into our processes from the start. ISO 9001, AS9100, Six Sigma Tools - including statistical process controls (SPC), root cause and control charting - as well as training, audits and team activity are among the tools we use to validate the quality of our products and ensure our high levels of customer satisfaction. Everyone in the company is responsible for identifying and reporting quality issues and encouraged to initiate quality improvement ideas. standards Design verification Design verification, the first level of testing, is a critical component of the product development process. The Conesys Design for Quality goes through detailed checks and modeling prior to product tooling or production. After the product is tooled, we perform extensive first article inspections on the parts before they are assembled and go into the Product Verification Testing phase. Conesys products are designed and manufactured to pass the rigorous requirements for military QPL designation, UL, CSA and the specifications of our major customers. Product verification Product verification testing, performed in Conesys' well equipped environmental laboratory, ensures that the product is impervious to harsh environments, such as salt fog and humidity, thermal cycling and accelerated temperature life. Supplier re-qualification Our supplier performance index consists of quality product and on-time delivery, the same standards that our customers expect of us. Conesys continually re-qualifies suppliers, both internal and external, to ensure that they are delivering product with the integrity our customers require. Testing Testing and measurement are tools for product and performance validation, and are continuous processes at Conesys. In process testing, we perform 100% testing for dielectric withstanding voltage (DWV) and insulation resistance (IR) on the insert assemblies. Periodically, Conesys retests our products to re-certify them to the appropriate specification. Performance measurement Conesys uses measurements derived from SPC and other Six Sigma tools to monitor the quality of the product, to correct deficiencies in process or improve the existing process and reduce the cost of quality. Standard Product Families MIL-DTL-38999 Series I MIL-DTL-26482 Series 2 MIL-DTL-38999 Series II Military & Douglas (DC**) Contacts MIL-DTL-38999 Series III Douglas BAN 7025 Connectors (DC**) MIL-DTL-5015 Rear Release Specialty Connector Lines MIL-DTL-5015 Front Release MIL-DTL-83723 Series III MS27466Aero MS27467Aero MS27468Aero MS27496Aero MS27505Aero MS27656Aero MS27472Aero MS27473Aero MS27474Aero MS27484Aero MS27497Aero MS27499Aero MS27500Aero MS27508Aero MS27513Aero D38999/20Aero D38999/24Aero D38999/26Aero MS3450Aero, J-Tech MS3451Aero, J-Tech MS3452Aero, J-Tech MS3454Aero, J-Tech MS3456Aero, J-Tech MS3459Aero, J-Tech MS3400J-Tech MS3401J-Tech MS3402J-Tech MS3404J-Tech MS3406J-Tech MS3408J-Tech MS3409J-Tech JT3496J-Tech MIL-DTL-28748 Rectangular M28748/9J-Tech M28748/10J-Tech MIL-DTL-26500 (Threaded/Bayonet) MS24264Aero MS24265Aero MS24266Aero EMI and EMP Protected Products Filtered EMP Transient Suppressed EMP MS3470Aero MS3471Aero MS3472Aero MS3474Aero MS3475Aero MS3476Aero M39029/29J-Tech M39029/30J-Tech M39029/36, 37J-Tech M39029/44J-Tech M39029/45J-Tech DC38J-Tech DC39J-Tech DC64J-Tech DC65J-Tech DC30 thru DC37 DC50 thru DC57 DC60 thru DC63 Aero Aero, J-Tech Aero, J-Tech Reverse BayonetJ-Tech ESC004 (Rolls Royce) J-Tech A-TypeAIP V-TypeAIP X-TypeAIP Rapid ChangeAIP M83723/66, 67J-Tech M83723/68, 69 Aero, J-Tech M83723/70Aero M83723/71, 72 Aero, J-Tech M83723/73, 74 Aero, J-Tech M83723/75, 76 Aero, J-Tech M83723/77, 78 Aero, J-Tech M83723/82, 83 Aero, J-Tech M83723/84, 85 Aero, J-Tech M83723/86, 87 Aero, J-Tech M83723/91, 92 Aero, J-Tech M83723/95, 96 Aero, J-Tech M83723/97, 98 Aero, J-Tech Cable/Harness Assembly FiberJ-Tech CopperAIP Sales in Europe, Africa and Middle East All products made by Aero, J-Tech & EMP Conesys Europe J-Tech 548 Amapola Ave. Torrance, California 90501 Tel: 310.533.6700 Fax: 310.533.6799 j-tech@conesys.com Conesys Europe 20, avenue Jean-Monnet 31770 Colomiers. France Tel: 33.5.61.15.34.20 Fax: 33.5.61.15.48.11 sales@conesyseurope.com EMP Connector 548 Amapola Ave. Torrance, California 90501 Tel: 310.222.5780 Fax: 310.222.5781 emp@conesys.com ATI-Interco 6, Rue Jean Mermoz ZA de Saint Guenault 91080 Courcouronnes. France Tel: +33 1 69 36 64 20 Fax: +33 1 69 36 64 05 contact@ati-interco.fr Aero Industrial Products 2280 208th St. Torrance, Californa 90501 Tel: 310.618.3737 Fax: 310.618.3738 aip@conesys.com Military Aerospace Geophysical Industrial Transportation conesys.com Aero-Electric Connector 2280 208th St. Torrance, California 90501 Tel: 310.618.3737 Fax: 310.618.3738 aero-electric@conesys.com