MIL-DTL-38999 series III
and range extension
MIL-DTL-38999 series III
and range extension
2
MIL-DTL 38999 Series III
22
Connectors and interconnect systems for harsh environments
The company designs, manufactures and markets high performance interconnect solutions for severe environments from
industrial broadline and universal ranges to complex system with integrated functions:
filtering, high speed data transmission, hermetic seal, separation mechanism, remote handling, underwater mating, …
The dedicated end markets for SOURIAU’s products are aeronautical, defense-space and industrial.
Industrial
Railway
Geophysics
Manufacturing environment
Instrumentation
Automation & process
Civil & military aircraft
Helicopter
Weapon delivery system
Avionics
Military marine
Communications
Satellites
Launcher & missile
Aeronautical Equipment & system
SOURIAU was established in 1917 and has been created by successive acquisitions of the industrial, aeronautical,
defense and space activities of SOURIAU, JUPITER and BURNDY.
The Group’s products are engineered and manufactured in the USA and Dominican Republic, Europe and Morocco,
Japan and India, and sold by a worldwide sales and marketing organization, and in addition to SOURIAU’s offices,
a large network of licensed distributors and agents.
SOURIAU complies with most of national and international Quality Assurance Standards, production unit with ISO 14001.
3
Introduction
MIL-DTL 38999 Series III
This product family is in accordance with MIL-DTL-38999 K Serie III , EN 3645 and CECC standard for bronze shell
Proposed in aluminium, composite, stainless steel, titanium and bronze versions.
This family gives :
• A high contact density up to 128 contacts #22D.
• A quick screw coupling with self locking mechanism.
• 100% scoop proof offering polarising options by angular positioning of keys.
• EMI enhanced protection by shielding ring and shell to shell bottoming.
Moreover, composite connectors reach high performance in terms of:
• Resistance to salt spray (> 2000 hours)
• Endurance : (> 1500 mating / Unmating operations with specific contacts)
Its choice is recommended wherever weight is critical (typically –30% versus aluminium version) or particularly
in harsh climatic and mechanical environments.
8D Titanium version is characterized by a very high and mechanical resistance:
• Weight saving as compared to stainless steel
• Unplated and nickel plated version available
8D / D38999 family has applications in:
• Aeronautics and military
• Marine and offshore
• Industrial.
For more informations or questions, please contact us to:
Contactmilaero@souriau.com
4
MIL-DTL 38999 Series III
Summary
Companyprofile ....................................................................................................................2
Introduction ........................................................................................................................3
Overview ..........................................................................................................................5
Technicalcharacteristics .............................................................................................................6
Layouts............................................................................................................................8
8D-D38999AluminiumSeries .....................................................................................................13
8D-D38999CompositeSeries .....................................................................................................25
8D-D38999StainlessSteel ........................................................................................................33
8DTitaniumSeries ................................................................................................................39
JVSBronzeSeries .................................................................................................................47
Commonsection(contacts,orientation,panelcut-out,tools…) ...........................................................................57
8D-JVSSerieswithquadraxcontacts ...............................................................................................67
8D-JVSwithopticalEliocontacts ...................................................................................................75
8DreinforcedsealingSeries ........................................................................................................83
F38999Hermetic .................................................................................................................85
8DSerieswithRJ45USB...........................................................................................................89
CoordinatesforPCB ..............................................................................................................100
5
MIL-DTL 38999 Series III
Overview
Aluminium
A large panel of contacts and inserts available on whole product family.
Contacts: crimp : PC tails / Wire wrap / Coax / Triax / Power / Quadrax / Elièo (Optical fiber)
Titanium
Optical Elio cts Power USB
Quadrax Reinforced sealing Hermetic
Composite
QPL CECC
Stainless steel Bronze
Standard series
Range extension series
6
MIL-DTL 38999 Series III
Characteristics
• Shell:
Aluminium, composite, stainless steel, bronze
• Shells plating:
Aluminium shell:
Cadmium olive drab (W)
Nickel (F)
Black zinc nickel (Z)
Green zinc cobalt (ZC)
Composite shell:
Cadmium olive drab (J)
Nickel (M)
Without plating (X)
Stainless steel shell:
Passivated (K)
Nickel (S)
Titanium shell:
Without plating (TT)
Nickel (TF)
Boîtier bronze:
Without plating
• Insulator: Thermoplastic or thermoset.
• Grommet and interfacial seal:
Silicone elastomer
• Contacts: Copper alloy
• Contacts plating: Gold over nickel plated
• Endurance:
- 500 mating / unmating operations
whatever the material used
- 1500 mating / unmating operations
with composite connectors
+ specifics contacts
• Shock:
300g, 3 ms according EN 2591-D2 method A
• Vibration:
Sinus:
10 à 2000 Hz, 3x12 hrs
(60g, 140 – 2000 Hz)
with temperature cycling
Random:
-50 to 2000 Hz, 2x8 Hrs
(1g2/ Hz, 100 – 2000Hz) at T° max.
- 25 to 2000 Hz, 2x8 Hrs
(5g2/ Hz, 100 – 300Hz)
(at ambiant T°)
Test with accessories in acc
with EN 2591-D3
• Contacts retention:
Technical characteristics
Weight comparison
Example for a plug shell size 15
Electrical
• Test voltage rating (Vrms):
• Contact resistance:
• Insulation resistance:
≥5 000 Mh(under 500 Vdc).
• Contact rating:
• Shell continuity
Aluminium shell:
Cadmium olive drab (W): 2.5 mh
Nickel (F): 1 mh
Black zinc nickel (Z): 2.5 mh
Green zinc nickel (ZC): 2.5 mh
Composite shell:
Cadmium olive drab (J): 3 mh
Nickel (M): 3 mh
Stainless steel shell:
Passivated (K) : 10 mh
Nickel (S) : 1 mh
Titanium shell:
Without plating (TT) : 10 mh
Nickel (TF): 1 mh
Bronze shell:
Without plating: 5 mh
For Quadrax see page 70
Service At sea level At 21000 m
M 1 300 800
N 1 000 600
I 1 800 1 000
II 2 300 1 000
Materials Weight
Stainless steel 58.80 grs
Titanium 33.90 grs
Aluminium 20.35 grs
Composite 14.30 grs
40%
lighter
42%
lighter
30%
lighter
• Shielding:
Aluminium shell:
- 65 db at 10 GHz (F) – 50 db
at 10 GHz (W)
- 85 db at 1 GHz (F)
- (Z& ZC): Consult us
Composite shell:
- 90 db at 10 GHz
- 85 db at 1 GHz
Stainless steel shell:
- 45 db at 10 Ghz (K)
- 65 db at 10 Ghz (S)
Titanium shell:
- 45 db at 10 Ghz (TT)
- 65 db at 10 Ghz (TF)
Bronze shell: 85 db at 10 Ghz
Contacts size 22 20 16 12 84
Cts resistance (m
h
)14.6 7.3 3.8 3.5 32
Contacts size 22 20 16 12 84
Contact rating (A) 5 7,5 13 23 45 80
Contacts size 22 20 16 12 84
Min force in N 44 67 111 111 111 200
7
MIL-DTL 38999 Series III
Climatics
• Temperature range:
Aluminium shell:
Cadmium olive drab (W): -65°C +175°C
Nickel (F): -65°C +200°C
Black zinc nickel (Z): -65°C +200°C
Green zinc nickel (ZC): -65°C +200°C
Composite shell:
Cadmium olive drab plating (J):
-65°C +175°C
Nickel (M): -65°C +200°C
Without plating (X): -65°C +175°
Stainless steel shell:
Passivated (K): -65°C +200°C
Nickel (S): -65°C +200°C
Titanium shell:
Without plating (TT): -65°C +200°C
Nickel (TF): -65°C +200°C
Bronze shell:
No plating: -65°C +175°C
• Sealing:
Mated connectors meet altitude immersion
requirements of MIL-DTL-38999.
• Salt spray:
Aluminium shell:
Cadmium olive drab (W): 500 Hrs
Nickel (F): 48 Hrs
Black Zinc nickel (Z): 500 Hrs
Green Zinc cobalt (ZC): 250 Hrs
Composite shell:
Cadmium olive drab (J) : 2000 Hrs
Nickel (M): 2000 Hrs
Without plating (X): 2000 Hrs
Stainless steel shell:
Passivated (K): 500 Hrs
Nickel (S): 48 Hrs
Titanium shell:
Without plating (TT): 500 Hrs
Nickel (TF): 48 Hrs
Bronze shell:
No plating: 500 Hrs
Resistance to fluids
• According to MIL-DTL-38999 standard.
Gazoline: JP5 (OTAN F44)
Mineral hydrolic fluid: MIL-H-5606
(OTAN H515)
Synthetic hydraulic fluid: Skydrol 500 B4
• LD4 (SAE AS 1241).
Mineral lubrificating: MIL-L-7870A
(OTAN 0142)
Synthetic lubrificating: MIL-L-23699
(OTAN 0156), MIL-L-7808.
Cleaning fluid: MIL-DTL-25769 dilué/diluted
De-icing fluid: MIL-A-8243.
Extinguishing fluid: Chlorobrométhane
Cooling fluid: Coolanol
Technical characteristics
8
Contact layouts
MIL-DTL 38999 Series III
35
6#22D
Service M
01
1
Optical way
98
3#20
Service I
09 / A
11 / B
01
1#12
Service II
All series
excepted JVS
02
2#16
Service I
02
2
Optical ways
04
4#20
Service I
12
1#12
Service II
only for JVS
22
4#22D
Service M
35
13#22D
Service M
81
1#8 Quadrax
98
6#20
Service I
99
7#20
Service I
80
1#8 triax
Service I
13 / C
04
4#16
Service I
04
4
Optical ways
08
8#20
Service I
26
2#12
6#22D
Service M
35
22#22D
Service M
98
10#20
Service I
01
1#8
Service I
only for JVS
05
5#20
Service I
Elio fiber optics Ethernet Quadrax
9
Contact layouts
MIL-DTL 38999 Series III
15 / D
05
5#16
Service II
15
1#16
14#20
Service I
18
18#20
Service I
19
19#20
Service I
35
37#22D
Service M
97
4#16
8#20
Service I
17 / E
02
38#22D
1#8 triax
Service M
06
6#12
Service I
08
8#16
Service II
20
4#12
16#22D
Service M
26
26#20
Service I
35
55#22D
Service M
75
2#8 triax
Service M
82
2 Quadrax
99
2#16
21#20
Service I
19 / F
11
11#16
Service II
08
8
Optical ways
28
26#20
2#16
Service I
32
32#20
Service I
35
66#22D
Service M
81
38#22D
1#8 Quadrax
Elio fiber optics Ethernet Quadrax
10
MIL-DTL 38999 Series III
21 / G
11
11#12
Service I
16
16#16
Service II
35
79#22D
Service M
39
2#16
37#20
Service I
41
41#20
Service I
48
4#8 power
Service I
75
4#8 triax
Service M
84
4 Quadrax
23 / H
21
21#16
Service II
35
100#22D
Service M
53
53#20
Service I
54
4#12
9#16
40#22D
Service M
55
55#20
Service I
Elio fiber optics Ethernet Quadrax
25 / J
04
8#16
48#20
Service I
07
2#8 triax
97#22D
Service M
08
8#8 triax
Service M
19
19#12
Service I
20(1)
10#20
4#12 coax
13#16
3#8 triax
Service N
24
12#16
12#12
Service II
29
29#16
Service I
35
128#22D
Service M
37
37#16
Service I
41
22#22D
3#20
11#16
2#12
3#8 triax
Service M
44
4#4 power
4#16
Service I
46
40#20
4#16
2#8 coax
Service I
61
61#20
Service I
82
97#22D
2#8 Quadrax
24
24
Optical Ways
81
22#22D - 3#20
11#16 - 2#12
3#8 Quadrax
86
40#20
4#16
2#8 Quadrax
80
10#20 - 4#12
13#16
3#8 Quadrax
88
8 Quadrax
11
2#20
9#10
Service N
43
23#20
20#16
Service I
Contact layouts
(1) For classes F, W, K, S only.
11
MIL-DTL 38999 Series III
(1) For classes F, W, S, K only
(2) For CECC, Layout 25 - 08 only delivery without contact
Souriau’s layout Layout according to MIL-DTL-38999
X = Layout according to CECC 75.201.00
MIL - DTL - 38999 (QPL) JVS
Shell Layout Service Alu Stainless Composite 8D (CECC) Hermetics Number of #22D #20 #16 #12 #10 #8 #4 Optical
Size steel Titanium Bronze contacts Power Way
09 - 01 -11
09 / A 09 - 35 Mx66
09 - 98 Ix33
11 - 01 II 11
11 - 01 II x1 1 Coax
11 - 02 Ix22
11 - 02 -22
11 - 04 I44
11 - 05 Ix55
11 / B 11 - 12 Ix11
11 - 22 M44
11 - 35 Mx13 13
11 - 80 I11 Triax
11 - 81 -11 Quadrax
11 - 98 Ix66
11 - 99 Ix77
13 - 04 Ix44
13 - 04 -44
13 - 08 Ix88
13 / C 13 - 26 Mx862
13 - 35 Mx22 22
13 - 98 Ix10 10
15 - 05 II x55
15 - 15 Ix15 14 1
15 / D 15 - 18 Ix18 18
15 - 19 Ix19 19
15 - 35 Mx37 37
15 - 97 Ix12 84
17 - 02 M 39 38 1 Triax
17 - 06 Ix66
17 - 08 II x88
17 - 20 M 20 16 4
17 / E 17 - 26 Ix26 26
17 - 35 Mx55 55
17 - 75 Mx22 Triax
17 - 81 - 39 38 1 Quadrax
17 - 82 -22 Quadrax
17 - 99 Ix23 21 2
19 - 08 -88
19 - 11 II x 11 11
19 / F 19 - 28 Ix28 26 2
19 - 32 Ix32 32
19 - 35 Mx66 66
21 - 11 Ix11 11
21 - 16 II x 16 16
21 - 35 Mx79 79
21 / G 21 - 39 Ix39 37 2
21 - 41 Ix41 41
21 - 48 Ix44 Power
21 - 59 M 59 55 4
21 - 75 -x44 Triax
21 - 84 -44 Quadrax
23 - 21 II x 21 21
23 - 35 Mx100 100
23 / H 23 - 53 Ix53 53
23 - 54 M 53 40 94
23 - 55 Ix55 55
25 - 04 I 56 48 8
25 - 07 M 99 97 2 Triax
25 - 08 -x
(2) 8 8 Triax
25 - 11 N 11 29
25 - 19 Ix19 19
25 - 20(1) Nx30 10 13
4
3 Triax
25 - 24 II x 24 12 12
25 - 24 - 24 24
25 - 29 Ix29 29
25 - 35 Mx128 128
25 / J 25 - 37 I 37 37
25 - 41 N 41 22 3 11 2 3 Triax
25 - 43 Ix43 23 20
25 - 44 I844
25 - 46 Ix46 40 4 2 Coax
25 - 61 Ix61 61
25 - 80 N 30 10 13 4 3 Quadrax
25 - 81 N 41 22 3 11 2 3 Quadrax
25 - 82 M 99 97 2 Quadrax
25 - 86 I 46 40 4 2 Quadrax
25 - 88 -88 Quadrax
Contact layouts
12
MIL-DTL 38999 Series III
Notes
MIL-DTL 38999 Series III
Aluminium Series
13
8D - D38999 Aluminium Series
MIL-DTL 38999 Serie III
Aluminium Series
18
8D - D38999 Aluminum Serie
Connector part numbers
MIL-DTL-38999 part numbers*
* Note: To place an order of MIL connectors delivered without MIL removable crimp contacts and keep P or S plus orientation marking,
it must be specify clearly on the order (by adding a suffix L at the end of the P/N or specified in comment).
Basic Series 8D 0 - 11 W 35 P N **
Shell style:
0: Square flange receptacle
1: In line receptacle
7: Jam nut receptacle
5: Plug with RFI shielding.
Type:
-: Connectors with standard crimp contacts.
L: Receptacle with long spill (male and female size #22D, #20).
C: Receptacle with short spill (male and female #22D, #20, #16).
S: Receptacle with specific spill (male et female #22D)
W: Receptacle with male contacts #22D for wire wrap (3 wraps)
T: Receptacle with male contacts #20 for wire wrap (2 wraps)
Shell size: 09 - 11 - 13 - 15 - 17 - 19 - 21 - 23 - 25
Plating:
W: Olive drab cadmium
F: Nickel
ZC: Green zinc cobalt
Z: Black zinc nickel
Contact layout: See page 8 to 11
Contact type:
P: Pin. A: Connector supplied less pin contact or with specific contacts (connector marking: A + orientation).
S: Socket. B: Connector supplied less socket contact or with specific contacts (connector marking: B + orientation).
Orientation: N, A, B, C, D & E (see page 58)
Specification:
046: Tinned straight spills
251: Connector provided with power contacts (layouts with contact #8)
022: Fuel tank
L: For P or S contact type only, connectors delivered without contacts, connectors marking P or S plus orientation.
Basic Series D38999 20 W B 35 P N L
Shell style:
20: Square flange receptacle
24: Jam nut receptacle
26: Plug with RFI shielding.
Plating:
W: Olive drab cadmium
F: Nickel
Shell size: A - B - C - D - E - F - G - H - J
Contact layout: See page 11 for layout according to MIL-DTL-38999
Contact type:
P: Pin. A: Connector supplied less pin contact or with specific contacts (connector marking: A + orientation).
S: Socket. B: Connector supplied less socket contact or with specific contacts (connector marking: B + orientation).
Orientation: N, A, B, C, D & E (see page 58)
L: For P or S contact type only, connector delevired without contacts, connector marking P or S (without L)
15
Dimensions
8D - D38999 Aluminium Series
Receptacle type 0
Receptacle type 7
Shell ABCDE FGHJ
size Max. Max. Max. thread ± 0,30 ± 0,20 ± 0,20
09 (A) 20.90 10.60 2.50 M12 x 1-6g 23.80 18.26 15.09 3.25 5.49
11 (B) 20.90 10.60 2.50 M15 x 1-6g 26.20 20.62 18.26 3.25 4.93
13 (C) 20.90 10.60 2.50 M18 x 1-6g 28.60 23.01 20.62 3.25 4.93
15 (D) 20.90 10.60 2.50 M22 x 1-6g 31.00 24.61 23.01 3.25 4.93
17 (E) 20.90 10.60 2.50 M25 x 1-6g 33.30 26.97 24.61 3.25 4.93
19 (F) 20.90 10.60 2.50 M28 x 1-6g 36.50 29.36 26.97 3.25 4.93
21 (G) 20.10 11.40 3.20 M31 x 1-6g 39.70 31.75 29.36 3.25 4.93
23 (H) 20.10 11.40 3.20 M34 x 1-6g 42.90 34.93 31.75 3.91 6.15
25 (J) 20.10 11.40 3.20 M37 x 1-6g 46.00 38.10 34.93 3.91 6.15
Shell A + 0,10 BCDE FG
size - 0,15 Max. Max. Max. Max. ± 0,40 thread
09 (A) 16.53 9.90 3.20 30.50 23.00 27.00 M12 x 1-6g
11 (B) 19.07 9.90 3.20 35.20 26.00 31.80 M15 x 1-6g
13 (C) 23.82 9.90 3.20 38.40 31.00 34.90 M18 x 1-6g
15 (D) 26.97 9.90 3.20 41.60 34.00 38.10 M22 x 1-6g
17 (E) 30.15 9.90 3.20 44.80 37.00 41.30 M25 x 1-6g
19 (F) 33.32 9.90 3.50 49.50 41.00 46.00 M28 x 1-6g
21 (G) 36.50 9.90 3.50 52.70 46.00 49.20 M31 x 1-6g
23 (H) 39.67 9.90 3.50 55.90 47.00 52.40 M34 x 1-6g
25 (J) 42.85 9.90 3.50 59.00 52.00 55.60 M37 x 1-6g
8D - D38999 Aluminium Series
Maximum coupling torque on panel for jam nut receptacle (type 7)
Plug type 5
Mated connectors dimensions
Type 0 with plug Type 7 with plug
Dimensions in millimeters
Shell ABC
size Max. thread Max.
09 (A) 31.00 M12 x 1-6g 21.80
11 (B) 31.00 M15 x 1-6g 25.00
13 (C) 31.00 M18 x 1-6g 29.40
15 (D) 31.00 M22 x 1-6g 32.50
17 (E) 31.00 M25 x 1-6g 35.70
19 (F) 31.00 M28 x 1-6g 38.50
21 (G) 31.00 M31 x 1-6g 41.70
23 (H) 31.00 M34 x 1-6g 44.90
25 (J) 31.00 M37 x 1-6g 48.00
In line receptacle type 1
Shell D
Ø F
size thread
09 (A) M12 x 1-6g 15.90
11 (B) M15 x 1-6g 19.05
13 (C) M18 x 1-6g 22.25
15 (D) M22 x 1-6g 25.40
17 (E) M25 x 1-6g 30.15
19 (F) M28 x 1-6g 31.75
21 (G) M31 x 1-6g 34.75
23 (H) M34 x 1-6g 37.10
25 (J) M37 x 1-6g 41.30
Shell A BCD
size Max. Max. Max. Max.
09 (A) 37.00 52.30 38.30 53.60
11 (B) 37.00 52.30 38.30 53.60
13 (C) 37.00 52.30 38.50 53.80
15 (D) 37.00 52.30 38.50 53.80
17 (E) 37.00 52.30 38.50 53.80
19 (F) 37.00 52.30 38.50 53.80
21 (G) 36.00 51.30 38.50 53.80
23 (H) 36.00 51.30 38.50 53.80
25 (J) 36.00 51.30 38.50 53.80
Shell 09 11 13 15 17 19 21 23 25
(A) (B) (C) (D) (E) (F) (G) (H) (J)
Coupling 6810 13 20 23 25 26 28
torque (N.m)
16