Features Application MIL-DTL-38999 Series newest cylindrical conn
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MIL-DTL-38999 Features Application Series
Features Application
MIL-DTL-38999 Series newest cylindrical connector designed highest performance capabilities used both general purpose severe environment applications. These connectors feature improved "one-turn" coupling system, utilizing self-locking acme thread. Acme threads provide coupling durability, while thicker wall sections greater coupling surface area improve strength shock resistance. Blunting threads both receptacle plug coupling eliminates cross threading. Elongated mounting holes permit Series Connector intermount with various existing Mil-spec flange mounted receptacles, giving design replacement advantage. Wall mount receptacle, receptacle straight self-locking plug offered shell sizes insert arrangements utilizing M39029 contacts sizes 22D, power twinax. These connectors available wide range shell materials finishes. Aluminum shells offered electroless nickel olive drab cadmium. Other finishes such anodic zinc cobalt available upon request commercial callouts only. addition, offer stainless steel shells (both passivated electro-deposited nickel plated) with firewall inserts, highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). MIL-STD-1560 Insert Arrangements Series connectors insert patterns contacts common Series making easy transition from bayonet triple-lead, acme-thread, self-locking coupling. Metal-to-Metal Bottoming This feature precludes relative shell-to-shell motion, which result ordinary connector wear moisture entrapment. Lockwiring Eliminated Self-locking quick coupling plug eliminates need lockwiring. Firewall Capability Stainless steel shells both firewall classes offered.
Universal Tool single, expendable plastic tool used both insertion removal contacts. Scoop-Proof Design Recessed pins elongated shells minimize possibility contact damage. blind mating application, mating shells cannot "scoop" pins, cause shorting bending contacts. Closed-Entry Socket Insert Hard dielectric socket face lead-in chamfers positive alignment pins (even partially bent within pre-established limits) with sockets. Interfacial Insert Seal Raised moisture barriers around each pin, which mate into lead-in chamfers hard face socket insert, provide individual contact sealing. Interfacial seal never touched service tools. Elastomer Wire Sealing Grommet Sealing over wide range wire diameters assured triple wire seal each cavity rear connector. Superior Contact Stability Rear release crimp contact system features stamped beryllium-copper retaining clip captivated molded-in shoulders each contact cavity insulator. rear-inserted M81969 plastic tool expands tines beyond shoulder, releasing contact. Metric Accessory Thread Metric thread results additional wall thickness giving greater strength shock resistance.
MIL-DTL- 38999
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MIL-DTL-38999 Performance Specifications Series
Performance Specifications
Operating Temperature Range Classes BZ*: -65°C +200°C (-85°F +392°F) Classes ZC*: -65°C +175°C (-85°F +347°F) Material Finish Data (Class) aluminum shell, electroless nickel finish stainless steel shell, passivated, firewall stainless steel shell, electrodeposited nickel, firewall aluminum shell, olive drab cadmium over nickel base aluminum nickel bronze shell, insert ZC*- aluminum shell, zinc cobalt finish Corrosion Resistance Classes withstand 500-hour salt spray. Classes withstand 48-hour salt spray. Durability Minimum mating cycles. Fluid Resistance Connectors resist specified immersions MIL-PRF-7808, MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5), SAE-AMS1424 Type other solvents cleaning agents. Shielding Effectiveness attenuation specified frequencies meet requirements MIL-DTL-38999. shielding effectiveness mated connectors with backshells measured triaxial radio frequency leakage fixture. shielding effectiveness measured interface mated connectors tested mode-stirred technique specified method 3008 MIL-STD-1344. Voltage Rating
Suggested Operating Voltage Service Rating (Sea Level) (RMS) 1250 Level 1300 1000 1800 2300
Environmental Seal Wired, mated connectors with specified accessories attached, shall meet altitude-immersion test specified MIL-DTL-38999. Shell-to-Shell Conductivity Maximum potential drop shall exceed: Classes millivolt. Class millivolts, Class 10.0 millivolts MIL-DTL- 38999 Shock Vibration Requirements Wired, mated connectors shall damaged, shall there current interruption longer than microsecond when subjected following: Shock Pulse approximate half sine wave percent magnitude with duration milliseconds applied three axes. High Impact Shock When mounted specified MIL-S-901, grade drop Hammer from foot, feet feet applied connector three axes, totaling nine impacts. Vibration Wired mated connectors withstand following vibration levels: Sine vibration where connector samples with simulated accessory load subjected simple harmonic motion from 2,000 three mutually perpendicular axes, minute sweeps, hours each axis velocity mm/sec from 10-50 displacement from 50-140Hz acceleration from 140-2,000Hz. Random Vibration MIL-STD-1344, method 205, test condition ambient temperature test condition Letter elevated temperature.
QPL, supplied Aero-Electric part number only. Test Voltage Test Voltage 50,000 Test Voltage 70,000 Test Voltage 100,000
Note: establishment electrical safety factors left entirely designer, best position know
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exactly what peak voltages, switching currents, transients, etc., expected particular circuit.
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MIL-DTL-38999 Part Number Development Series
Military Aero-Electric Part Number Development
Mil. Prefix Aero Prefix
Shell Type (Specification Sheet Number) Wall mount receptacle receptacle Self-locking, grounding plug Class (Material Finish) Aluminum shell, electroless nickel finish Aluminum shell, olive drab cadmium over electroless nickel base Stainless steel shell, passivated, with firewall insert Stainless steel shell, electrodeposited nickel, with firewall insert Aluminum nickel bronze shell with standard insert (Aero only) Aluminum shell, zinc cobalt plating (Aero only) Shell Size Insert Arrangement pages thru Contact Style Socket connector less pins (with intent non-std contacts) Socket connector less sockets (with intent non-std socket contacts) Polarization (Keying) Normal (Included part number) Modification (applies Aero part numbers only) Less contacts marked part) Connector kitted with M85049/15-XXX Connector kitted with M85049/38-XXX straight clamp Connector kitted with M85049/39-XXX right angle clamp Consult factory other modifications QPL, supplied Aero-Electric part number only.
D38999/
-340
MIL-DTL- 38999
Note Each connector furnished with contacts unless ordered less contacts (L/C) follows: spare contact inserts requiring through each contact spares inserts with more contacts, minimum sealing plug number contacts. Spare Coax Twinax contacts supplied. insertion/extraction tool each contact size also included.
Note Proper part number marking front single digit layout. Example: D38999/20WB5SN. normal included. addition, must marked immediately front part number.
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D38999/20 Wall Mounting Receptacle AE320
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
MASTER KEYWAY 31.50(1.240)
7.11(.280) FULL THREAD 2.16(.085) GROMMET EXTENSION
GROMMET
MIL-DTL- 38999
NUMBER TEETH
MINOR KEYWAYS
MATING THREAD
LOCKING INDICATOR BAND COLOR:
BLUE COLOR BAND (REAR RELEASE)
ACCESSORY THREAD
Page Page Pages 17-19 Page Pages Page
Completed Part Number Contacts, Sealing Plugs Tools Insert Arrangements Performance Specifications Insert Availability Contact Information Polarization
Note Accessory Thread AE320 same AE326 ("D" Accessory Thread) page Note Mating Thread AE320 same AE326 ("E" Mating Thread) page except Class Note Maximum Grommet Extension insert layouts incorporating size contacts 5.95(.234).
Shell Size ±.012 inch .937 1.031 1.126 1.220 1.311 1.437 1.563 1.689 1.811 ±.30 23.80 26.20 28.60 31.00 33.30 36.50 39.70 42.90 46.00 inch .719 .812 .906 .969 1.062 1.156 1.250 1.375 1.500
(TP) 18.26 20.62 23.01 24.61 26.97 29.36 31.75 34.93 38.10 inch .594 .719 .812 .906 .969 1.062 1.156 1.250 1.375
(TP) 15.09 18.26 20.62 23.01 24.61 26.97 29.36 31.75 34.93 ±.008 inch .216 .194 .194 .173 .194 .194 .194 .242 .242
±.20 5.49 4.93 4.93 4.39 4.93 4.93 4.93 6.15 6.15 ±.008 inch .128 .128 .128 .128 .128 .128 .128 .154 .154
±.20 3.25 3.25 3.25 3.25 3.25 3.25 3.25 3.91 3.91
Maximum inch .820 .820 .820 .820 .820 .820 .790 .790 .790 20.83 20.83 20.83 20.83 20.83 20.83 20.07 20.07 20.07
Maximum inch .098 .098 .098 .098 .098 .098 .126 .126 .126 2.50 2.50 2.50 2.50 2.50 2.50 3.20 3.20 3.20
Teeth
Maximum inch .299 .427 .541 .666 .791 .897 1.022 1.147 1.272 7.59 10.85 13.74 16.92 20.09 22.78 25.96 29.13 32.31
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D38999/24 Receptacle AE324
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
32.50 (1.280)
MASTER KEYWAY LOCKING INDICATOR BAND COLOR:
BLUE COLOR BAND (REAR RELEASE)
2.16(.085) GROMMET EXTENSION
FLAT
GROMMET
MIL-DTL- 38999
Shell Size
MINOR KEYWAYS
MATING THREAD THREAD
D38999/28
NUMBER TEETH ACCESSORY THREAD
RING SEAL
PANEL THICKNESS 3.20(.126) 1.58(.062)
Page Page Pages 17-19 Page Pages Page
Completed Part Number Contacts, Sealing Plugs Tools Insert Arrangements Performance Specifications Insert Availability Contact Information Polarization
Note Accessory Thread AE324 same AE326 ("D" Accessory Thread) page Note Mating Thread AE324 same AE326 ("E" Mating Thread) page except Class Note Maximum Grommet Extension insert layouts incorporating size contacts 5.95(.234).
±.016 inch 1.063 1.252 1.374 1.500 1.626 1.811 1.937 2.063 2.189 ±.40 27.00 31.80 34.90 38.10 41.30 46.00 49.20 52.40 55.60 +.004 -.006 inch .651 .751 .938 1.062 1.187 1.312 1.437 1.562 1.687
+.10 -.15 16.53 19.07 23.82 26.97 30.15 33.32 36.50 39.67 42.85 inch .945/.859 1.063/.984 1.260/1.172 1.417/1.296 1.457/1.422 1.614/1.546 1.811/1.672 1.969/1.796 2.017/1.939
+.024 -.000 24.00/21.82 27.00/24.99 32.00/29.77 36.00/32.91 37.00/36.12 41.00/39.26 46.00/42.47 50.00/45.61 51.23/49.25 inch .555 .555 .555 .555 .555 .555 .555 .555 .555
+.60 -.00 14.10 14.10 14.10 14.10 14.10 14.10 14.10 14.10 14.10
Teeth +.035 -.004 inch .087 .087 .087 .087 .087 .118 .118 .118 .118
+.90 -.10 2.20 2.20 2.20 2.20 2.20 3.00 3.00 3.00 3.00
Maximum inch .299 .427 .541 .666 .791 .897 1.022 1.147 1.272 7.59 10.85 13.74 16.92 20.09 22.78 25.96 29.13 32.31
Thread 0.100R M17x1-6g M20x1-6g M25x1-6g M28x1-6g M32x1-6g M35x1-6g M38x1-6g M41x1-6g M44x1-6g
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D38999/26 Self-Locking, Grounding Plug AE326
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
31.00(1.220) BLUE COLOR BAND LOCATION OPTIONAL (REAR RELEASE)
MASTER
COUPLING
2.16(.085) GROMMET EXTENSION 7.11(.280) FULL THREAD
GROMMET
MIL-DTL- 38999
STRIP
NUMBER TEETH ACCESSORY THREAD
MINOR KEYS MATING THREAD
Page Page Pages 17-19 Page Pages Page
Completed Part Number Contacts, Sealing Plugs Tools Insert Arrangements Performance Specifications Insert Availability Contact Information Polarization
Note Maximum Grommet Extension insert layouts incorporating size contacts 5.95(.234).
Shell Size Maximum inch .858 .984 1.157 1.280 1.406 1.516 1.642 1.768 1.890 21.80 25.00 29.40 32.50 35.70 38.50 41.70 44.90 48.00 inch .299 .427 .541 .666 .791 .897 1.022 1.147 1.272
Maximum 7.59 10.85 13.74 16.92 20.09 22.78 25.96 29.13 32.31
Accessory Thread Metric M12x1.0-6g 0.100R M15x1.0-6g 0.100R M18x1.0-6g 0.100R M22x1.0-6g 0.100R M25x1.0-6g 0.100R M28x1.0-6g 0.100R M31x1.0-6g 0.100R M34x1.0-6g 0.100R M37x1.0-6g 0.100R
Mating Thread Class .6250-0.1P-0.3L .7500-0.1P-0.3L .8750-0.1P-0.3L 1.0000-0.1P-0.3L 1.1875-0.1P-0.3L 1.2500-0.1P-0.3L 1.3750-0.1P-0.3L 1.5000-0.1P-0.3L 1.6250-0.1P-0.3L
Teeth
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MIL-DTL-38999 Polarization Series
Keying Positions
NORMAL
MASTER KEYWAY
MIL-DTL- 38999 Notes: Mating face receptacle shown (plug opposite). minor keyways (keys) rotated provide shell polarization while master keyway (key) remains fixed shown. Key/Keyway
Shell Size Identification Letter
angles given connector same whether contains socket inserts. Insert arrangement does rotate relative master keyway (key). Key/Keyway Positions
(11) (13) (15)
(17) (19) (21) (23) (25)
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MIL-DTL-38999 Series Flange Receptacles Panel Cutouts
Panel Cutouts
FLANGE MOUNT
3.20(.126) 1.58(.062) PANEL THICKNESS
MIL-DTL- 38999
Note: Diameter cutout dimensions listed separately back front panel mounting.
Shell Size (11) (13) (15) (17) (19) (21) (23) (25) (TP) inch .719 .812 .906 .969 1.062 1.156 1.250 1.375 1.500 18.26 20.62 23.01 24.61 26.97 29.36 31.75 34.93 38.10
Back Mounting Minimum inch .656 .796 .922 1.047 1.219 1.297 1.422 1.547 1.672 16.66 20.22 23.42 26.59 30.96 32.94 36.12 39.29 42.47
Front Mounting Minimum inch .516 .625 .750 .906 1.016 1.141 1.266 1.375 1.484 13.11 15.88 19.05 23.01 25.81 28.98 32.16 34.93 37.69 ±.005 inch .128 .128 .128 .128 .128 .128 .128 .154 .154
±.13 3.25 3.25 3.25 3.25 3.25 3.25 3.25 3.91 3.91 +.000 -.010 inch .670 .771 .955 1.085 1.210 1.335 1.460 1.585 1.710
+.00 -.25 17.02 19.59 24.26 27.56 30.73 33.91 37.08 40.26 43.43 +.010 -.000 inch .700 .825 1.010 1.135 1.260 1.385 1.510 1.635 1.760
+.25 -.00 17.78 20.96 25.65 28.83 32.01 35.18 38.35 41.53 44.70
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MIL-DTL-38999 Contacts, Tools Seal Plugs Series
Contacts, Plastic Insertion/Removal Tools Seal Plugs Application
Contact Size Coax Coax (Power) Coax Twinax Type Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Power Coax Twinax
Contacts
Military 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
Socket Contacts
Military 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
Seal Plugs
Military MS27488-22-1 MS27488-20 MS27488-16 MS27488-12-1 M85049/81-10*** MS27488-8-1 MS27488-8-1
Insertion/Removal Tools
Plastic Military M81969/14-01 M81969/14-10 M81969/14-03 M81969/14-04 M81969/14-05 M81969/14- M81969/14-12
MIL-DTL- 38999
Crimping Metal Insertion/Extraction Tools Crimp Tool
Contact Size/Type Coax Inner Coax Outer Power) Coax Inner Coax Outer Twinax Center Twinax Outer Intermediate Military M22520/2- M22520/1- M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 M22520/2-01 M22520/5-01 M22520/2-01 M22520/5-01
Positioner
Contacts Military 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 Closure M22520/2-37 M22520/5-200
Positioner
Socket Contacts Military 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 Closure M22520/2-37 M22520/5-200
Insertion Tool
Metal Military M81969/8-01 M81969/8-05 M81969/8-07 M81969/8-09 M81969/8-11 M81969/8-13**
Extraction Tool
Metal Military M81969/8-02 M81969/8-06 M81969/8-08 M81969/8-10 M81969/8-12 M81969/8-14
Contact Wire Data
Test Current* Contact Size Test Amps 13.0 23.0 33.0 Voltage* Max. Drop Millivolts Crimp Well Data Well Dia. inch .0345 ±.0010 .047 ±.001 .067 ±.001 .100 ±.002 .137 ±.003 Minimum Well Dept inch .141 3.58 .209 5.31 .209 5.31 .209 5.31 .355 9.02 Wire Range 28-22 24-20 20-16 14-12 12-10 .08-.33 .20-.52 .52-1.31 2.08-3.31 3.31-5.26 Finished Wire Minimum inch .030 .040 1.02 .065 1.65 .097 2.46 .135 3.42 Range Maximum inch .054 1.37 .083 2.11 .109 2.77 .142 3.61 .162 4.12
MS3348 bushing required with gauge wire. When tested with silver-plated wire. Insertion tool required. Dummy contact, used lieu unwired contact seal plug.
Note: Size coax contacts used with M17/095-RG180 cable, while size Twinax contacts used with M17/176-00002 cable.
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MIL-DTL-38999 Contact Installation Instructions Series
Contact Installation Instructions
Crimping Contacts Select appropriate crimp tool ensure that proper crimp head positioner used. Cycle tool sure indentors open. Determine correct selector setting wire size from data plate positioner (turret head assembly) selector knob crimp tool match. Place contact, mating first, into tool. Insert stripped wire into hollow contact. sure wire inserted will Close tool completely crimp. Unless tool closed completely, tool will release contact. Remove crimped contact from tool. Check inspection hole verify that wire fully inserted. Insertion Contacts Before inserting contacts, unscrew accessories (clamps, backshells adapters) from rear plug receptacle. Slide hardware over wire bundle proper order reassembly after contacts inserted. assist insertion contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate will leave conductive film. Caution: Never lubricant other than isopropyl alcohol.
Size Contact M39029/58-360 M39029/58-363 M39029/58-364 M39029/58-365 M39029/58-528 Socket Contact M39029/56-348 M39029/56-351 M39029/56-352 M39029/56-353 M39029/56-527 Basic Crimp Tool M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01
Place correct insertion tool contact that wire runs along groove tool. (Tool will butt against shoulder.) Hold plug receptacle body firmly. Beginning with center cavity, insert contact into insulator with slow, even pressure until contact snaps into position. Make sure contact tool held perpendicular face insert during contact installation grommet could damaged. MIL-DTL- 38999 contacts inserted prior removing insertion tool, reinsert insertion tool. Instead, remove contact again; otherwise reinserting insertion tool damage inside contact cavity. Remove tool check face connector proper contact installation. Proper installation also checked pulling back lightly wire make sure contact properly seated. Completion After cavities have been filled, slide hardware back into position connector tighten. Extraction Contacts (Rework) Slide hardware back over wire bundle. Select appropriate tool. Place wire into extraction tool socket. Slowly slide extraction tool down wire into contact cavities until tool bottoms against contact shoulder, expanding clip retaining tines. Hold wire firmly tool pull wired contact tool straight rear insulator.
Positioner M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 Blue M22520/1-04 Yellow Socket Positioner M22520/07 M22520/1-04 M22520/2-10 M22520/1-04 Blue M22520/1-04 Yellow Insertion/Removal Tool M81969/14-01 M81969/14-10 M81969/14-03 M81969/14-04 M81969/14-05
Coax Twinax contacts refer instructions that supplied with contacts.
Contact Daniels Manufacturing crimp tool/positioner.
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