High Power Conectors High Power Connectors Hyperboloid(R) Technology Sabritec's High Power connectors utilize the superior performing Hyperboloid(R) contact technology, ideal for harsh and demanding environments with low contact resistance. These connectors provide high current ratings with smaller contacts for the same power thus saving overall weight and space. Contact Mechanical & Environmental Specifications Key Features: * Low coupling force * Improved low rate of wear and high coupling durability * Shock and vibration resistance Contact Endurance Contact Mating Cycles >1000 Operating Temperature -65C to +150C Connector Materials and Finishes * Operate in harsh environments * Reduced contact resistance Shell Aluminum Alloy, Stainless Steel, Composite * Contact elements can be insulated, to enable multi-pole use (coaxial) Contacts Copper Alloy, Gold Over Nickel * Contact mating sequence can be used to gain benefits such as power switching Inserts Glass Filled Thermoplastic or Epoxy Seals & O Ring Fluorosilicone Rubber * Mating of shorter contact can energize main power for system or safety requirements * Increased power handling capability by 25% as compared to standard contacts Hyperboloid(R) Performance vs MIL-C-39029 Pin Size Pin Diameter, mm (in) Socket OD maximum, mm (in) MIL Spec Current Rating Continuous, A Hyperboloid(R) Contact Current Rating Continuous, A Hyperboloid(R) Contact Resistance Typical, m Hyperboloid(R) Contact Resistance Maximum, m 8 3.61 (0.142) 6.50 (0.256) 46 60 0.20 .50 4 5.72 (0.225) 9.53 (0.375) 80 100 0.10 .50 0 9.07 (0.357) 13.35 (0.526) 150 300 0.10 .20 00 10.31 (0.406) 18.55 (0.730) 185 300 0.07 .20 0000 12.70 (0.500) 21.02 (0.828) 225 500 0.05 .10 High Power 2010 High Power Connector Housing MIL-DTL-38999 and MIL-DTL-5015 Connector Styles MIL-DTL-38999/26 Plug (Series III Shown) L Max A Thread Q Shell Size B Dia 21 25 Dimensions B L + .008 Max - .000 1.235 1.500 1.235 1.744 A Thread .1 Pitch .3 Lead 1.375 1.625 Q Dia. Max 1.642 1.890 V Thread Metric M31X1 M37X1 V Thread MIL-DTL-38999/20 or 24 Receptacle (Series III Shown) R1 R2 Z Dimensions A Thread PP Shell Size A Thread .1 Pitch .3 Lead P .008 21 1.375 0.154 25 1.625 0.154 PP .008 0.242 R1 R2 S V Max W Max Z + .005 - .010 B Thread Metric 1.250 1.156 1.563 0.790 0.126 1.235 M31X1 1.500 1.375 1.811 0.790 0.126 1.235 M37X1 B Thread P W V S MIL-DTL-5015 Plug Dimensions L Shell Size E Thread Class 2A Q Dia Max 14 16 18 20 22 24 28 32 36 40 44 48 7/8-20 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 2 3/4-16 UN 3-16 UN 1.156 1.25 1.344 1.469 1.594 1.719 1.969 2.219 2.469 2.719 2.969 3.219 Q V Thread E Thread L Max 2.100 2.250 V Thread Class 2A 7/8-20 UNEF 1-20 UNEF 1 1/16-18 UNEF 1 3/16-18 UNEF 1 5/16-18 UNEF 1 7/16-18 UNEF 1 3/4-18 UNS 2-18 UNS 2 1/4-16 UN 2 1/2-16 UN 2 3/4-16 UN 3-16 UN MIL-DTL-5015 Receptacle Dimensions R A M K T S L B Shell Size A Thread Class 2A 14 16 18 20 22 24 28 32 36 40 44 48 7/8-20 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 2 3/4-16 UN 3-16 UN K .015 0.083 L Max M + .031 - .000 2.100 0.75 0.812 0.125 2.250 0.875 R S 0.906 0.969 1.062 1.156 1.250 1.375 1.562 1.750 1.938 2.188 2.375 2.625 1.188 1.281 1.375 1.500 1.625 1.750 2.000 2.250 2.500 2.750 3.000 3.250 T Dia + .005 - .000 0.115 0.142 0.168 B Thread Class 2A 7/8-20 UNEF 1-20 UNEF 1 1/16-18 UNEF 1 3/16-18 UNEF 1 5/16-18 UNEF 1 7/16-18 UNEF 1 3/4-18 UNS 2-18 UNS 2 1/4-16 UN 2 1/2-16 UN 2 3/4-16 UN 3-16 UN High Power Connectors and Contacts High Power Socket Contact Termination Styles High Power Contact Terminations Hyperboloid Contact with Wire Crimp Termination E C Thread A Hyperboloid Contact with Male C Threaded Post Termination Thread B Contact Dimensions Contact Size A Thread B Thread C Max E Max 8 1/4-20 UNC-2A 1/4-20 UNC-2B .256 .182 4 3/8-16 UNC-2A 3/8-16 UNC-2B .375 .283 0 9/16-12 NC-2A 9/16-12 UNC-2B .526 .455 00 5/8-11 UNC-2A 5/8-11 UNC-2B .730 .500 0000 3/4-10 UNC-2A 3/4-10 UNC-2B .828 .641 22-2 3X Size 8 22-7 1 Size 0 Hyperboloid Contact with C Female Threaded Termination Hyperboloid Contact with R/A C Thread Post (Male, Female or Thread A Crimp Termination) MIL-DTL-38999 Connector Insert Arrangements ? 21-75 POSITION 4 Size 8 Contacts SPECIAL 25-21 2 Size 0 Contacts CUSTOM ARRANGEMENT MIL-DTL-5015 Connector Insert Arrangements 14-3 1 Size 8 22-22 4 Size 8 16-12 1 Size 4 18-6 1 Size 4 24-9 2X Size 4 20-2 1 Size 0 18-7 1 Size 8 24-10 7X Size 8 24-22 4X Size 8 20-19 3X Size 8 28-3 3X Size 8 20-23 2X Size 8 28-6 3X Size 4 22-1 2X Size 8 32-5 2X Size 0 32-17 4X Size 4 ? 32-63 5X Size 4 36-4 3X Size 0 36-5 4X Size 0 36-6 4X Size 4 2X Size 0 Special size 32 4X Size 0 Special size 40 2X Size 0000 CUSTOM ARRANGEMENT High Power Rack and Panel Solutions Ordering Information Sabritec also provides rack and panel power and combo layout solutions. A hybrid configuration consisting of 3 phase power that can be combined with integrated signal, fiber optic, coax, triax and high speed quadrax inserts within a single panel solution. Accessory hardware is available with custom backshells and power modules exceeding 500 A current ratings. Buss bars are attached to the threaded end of the connector pin or socket contact or standard cable crimp terminations for power cable AWG ratings with current ratings up to 500 Amps in a single contact. Blindmate or screw lock accessory hardware configurations are offered for any rack and panel solutions in a variety of sizes and configurations. Complete 360 Degree RF connector shielding with EMI ground spring fingers integrated into each connector shell arrangement and cavity is also available. Modularity is key to the design with interchangeable insert assemblies available for an array of signal, power and hybrid contact reverse gender configurations. Power Connector Part Number Description Code HPC - 4 - 38999 - S - T Contact Prefix Contact Size 8 - 60 Amp 4 - 100 Amp 0 - 300 Amp 00 - 300 Amp 0000 - 500 Amp Termination Style T - Threaded Post H - Internal Thread C - Crimp RC- Right Angle Crimp Threaded Post RM- Right Angle Male Threaded Post RH- Right Angle Female Threaded Post Connector MIL-DTL-5015 MIL-DTL-38999 * Contact Gender P - Pin S - Socket * Contacts are only available for Series I, III and IV Power Contact Ordering Information HP - 38999/III - P - 21-75 - C - S - T - N Polarization N, A, B, C, D, E ** N, W, X, Y, Z *** Prefix Connector Shell 5015 38999/Series I 38999/Series III 38999/Series IV Termination Style T - Threaded Post H - Internal Thread C - Wire Crimp RC- Right Angle Wire Crimp RM- Right Angle Male Threaded Post RH- Right Angle Female Threaded Post Shell Style P - Plug J - Jam Nut Receptacle F - Square Flange Receptacle Contact Gender P - Pin S - Socket Arrangement ** Polarization keys available for MIL-DTL-38999 connectors *** Polarization keys available for MIL-DTL-5015 connectors Sabritec 17550 Gillette Ave, Irvine CA 92614, USA t: +1 (949) 250-1244 f: +1 (949) 250-1009 e: customerservice@sabritec.com FOR FURTHER INFORMATION VISIT >> www.sabritec.com Plating C - Cadmium over Nickel N - Electroless Nickel