Bridging The Gap - Glenair
Introduction toMilitary Standard Cylindrical ConnectorsBridging the Gapthe corresponding wires joined together, the circuitwould not be affected.”When connectors are used to connect oneset of wires to another, they are called wire-to-wireconnectors. Wire-to-board connectors connect awire to a Printed Circuit Board (PCB). And boardto-board connectors directly interconnect PCB’s.The purpose of a connector is easy todescribe: connectors bridge gaps betweenindividual pieces of electronic equipmentto make assembly, repair and upgrades easierto accomplish. Instead of struggling with agordian knot of soldered circuits and splicedwiring, connectors enable technicians to makeinterconnections with ease and convenience.Connectors bridge the gap betweenindividual wires to provide contact between twoconductive elements of an electronic system.The connection they make enables electricalcurrent (or light waves in the case of fiber optics)to flow from one conductor to the next. Edward’sPublishing’s indispensable Encyclopedia ofConnectors defines the connector thus: “Anelectromechanical device which permits twoor more circuit elements to be electrically andmechanically separated and reconnected atwill without disturbing any other elements of thecircuit. A connector performs no circuit functionand should have no effect on the electricalperformance of the device to which it is attached.If the connectors of a device were eliminated andConnectors facilitate the manufactureand assembly of electronic products by enablingdesigners to treat each subassembly as a unique,modular unit. Interconnection can then beaccomplished at the most convenient time andplace in the production process. Connectors alsofacilitate the equipment repair process by allowingtechnicians to quickly and easily replace suspectcomponents. Without opening black box cabinetsand without introducing contaminants like solderand flux into the system, technicians can swap outsuspect equipment and have a system back online in a matter of minutes. Connectors also permitupgrades to electronic equipment without majordisruptions to the overall system. Connectors giveengineers the flexibility to integrate new productsand components into existing systems simply bymaintaining a consistent connector specification.While there is great variety in the makeupand design of each type of connector, as a familythey generally share a common set of designelements and component parts. In fact, in orderto function as a separable interconnect device, aconnector must house the following elements: Contact Interface: a mechanical means ofjoining the conductive contacts together undernormal force Contact Spring Members: a means ofgenerating the normal force required tomaintain the electrical path betweenconductive contact elements Contact Finish: a means of protecting thecontacts from corrosion, and for optimizing thelubricity and durability of the contact interface Contact Housing: a means of holding thecontacts and spring members in place andmaintaining their exact position and alignment.Connector testing is designed to simulate a lifetime of useover a short period of time. Environmental, mechanical andelectrical tests are conducted to measure both the reliabilityof the connector and the system. The number-one criterion ofreliability is a change in contact resistance. 2004 Glenair, Inc.CAGE CODE 06324Printed in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-2E-Mail: sales@glenair.com
Introduction toMilitary Standard Cylindrical ConnectorsThe contact housing also shields the contactsfrom the operating environment.of its components. Connectors can fail due toplug dependent mechanisms, wear mechanismsor corrosion mechanisms. Total system life,power on-hours (POH) and system on/off cycles(number of times that a product powers on andoff) are important factors determining systemreliability. Military standard connectors (andtheir commercial equivalents) are chosen fortheir performance and reliability even in the mostsevere interconnect applications.Connectors are selected with considerationto electrical, mechanical and environmentalrequirements. Electrical requirements includewire type and size, contact resistance, transferimpedance and current rating. Mechanicalspecifications, such as thermal shock, vibrationand durability indicate how well a connectorwill perform under critical stress factors.Environmental requirements include moistureabsorption, temperature resistance, corrosionand resistance to electromagnetic interference.Environmentally resistant connectors are requiredfor interconnect systems which are subjectedto fluids in combination with vibration, shock,thermal extremes and corrosion.“Power” connectors carry contactsfrom size 4/0 to 16“Miniature” connectors from size 12 to 20“High-density” connectors from size 20 to 22“Microminiature” size 24.The military standard connector is madeup of two separate component assembliesknown as the “plug and receptacle” whichintermate to connect wires with pin and socketcontacts. Connector families are definedin this high-reliability world by the militarydetail specifications which spell out the exactrequirements for every aspect of the connector’sdesign and performance. Connector familiesare distinguished by their coupling mechanisms,physical shape, contact types, environmentalclasses and termination methodologies.Plug and receptacle connector pairs areavailable in various mounting configurations toaccommodate different levels of interconnectionand different application requirements. Themost common configurations are for in-line (wireto-wire) applications, or for various bulkhead,chassis and enclosure mountings. In general,connectors are available to accommodate anyfixed mounting or in-line requirement.Circular connectors are selected because oftheir compact, rugged design and their ability toeffectively seal the connector from environmentalhazards. Circular connectors may incorporatebayonet couplings, threaded couplings, balldetent couplings (push/pull), and/or breech lockcouplings as their mechanism for locking themated pairs together.While the same basic connector designmay be used for both signal and/or powerdistribution, power connectors use contactsdesigned specifically for the unique requirementsof power distribution. This is due to the relativelyhigher current/voltage requirements of powerapplications and the temperature rise experiencedby power connectors. A disk drive in a personalcomputer, for example, uses both signal andpower connectors. The power connector bridgesthe circuit that drives the unit. The signalconnector carries the digital data. While thesignal and power contacts may be combined intoa single connector housing, each contact type isuniquely suited for its role in transmitting eithersignal or power electrical energy.The Military Standard ConnectorThe multi-contact electrical connector usedin Air Force, Navy and other high-reliabilityapplications is a critical subassembly withinthe wiring system. Military connectors findmany diversified applications due to severeenvironments, mobility, and field repairability.The key attribute of such connectors is betterreliability when compared to less expensivecommercial connectors. The reliability of asystem is essentially a measure of the failure rate 2004 Glenair, Inc.CAGE CODE 06324Printed in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-3E-Mail: sales@glenair.com
Introduction toMilitary Standard Cylindrical ConnectorsRectangular connectors are selected tomaximize the number of contacts possible in arestricted space. However, rectangulars are notas easily sealed against fluid damage and otherenvironmental hazards. Spring style rack/panelcouplings as well as standard jackscrew fastenersare both common coupling styles in rectangularconnectors.Both circulars and rectangulars canaccommodate multiple contact types includingpower or high-voltage contacts, signal contacts,coaxial and triaxial contacts, or fiber-optic termini.High reliability contacts are usually made from goldplated, copper alloy material. Large diameter powercontacts and solder type contacts may be eithergold or silver plated copper alloy.Crimp style contacts are preferred for allaerospace and other high-reliability applications(except those requiring a hermetic seal) due to theirrelative ease of assembly and maintenance. Soldertype contacts are usually selected when cost is theprimary consideration and repairability secondary.Solder type contacts are also used in hermeticconnectors.Installation of both crimp and solder typecontact connectors requires unobstructed workingroom behind the connector. Rear release crimpcontacts require additional working room to installthe extraction tool to remove the contact. Anotherimportant design feature of crimp type contactconnectors is the connector insert wire sealinggrommet. The grommet provides moisture sealingaround each individual wire.The shell of a circular connector is a cylinderavailable in incremental sizes starting as small as.375” diameter up to 3.25” diameter and larger. Themost common shell sizes are available in .0625”increments starting at shell size 8 (.50”) to shellsize 36 (2.25”). Shell size may be determined bymultiplying the shell size number by .0625. Shellsize 24, for example, has a 1.50” outside diameter(24 x .0625” 1.50”). This nomenclature becomessignificant, as backshells (accessories which attachonto the connector shell) must inter mate with theconnector shell rear-end geometry. Connectorand accessory manufacturers both use the term 2004 Glenair, Inc.“shell size” to designate the size of their respectiveproducts.Making Sense of Connector Part NumbersMilitary standard connectors are organizedunder specification series numbers: MIL-C-5015,MIL-C-38999 and so on. The specification seriesnumber identifies the master document whichexplains everything about the particular connectorfamily. The actual part numbers of connectorcomponents are designed to call out the physicalconnector type and its dimensional attributes. Forexample, a MIL-C-5015 receptacle connectordesigned to be mounted on a box would have a partnumber such as MS3402DS28-21PY. The numbercan be dissected as follows:The first 4 digits after the MS (Military Standard)designate the physical connector type, like so:3400 - Wall mounted receptacle3401 - In line receptacle3402 - Box mount receptacle3404 - Jam nut receptacle3406 - Straight plug3408 - 90 plug3409 - 45 plug3412 - Box mount receptacle with rear threadsThe single character which follows indicates theconnector service class:D - High ShockK - FirewallL - High TemperatureW - General PurposeThe next character, S in our example, indicatesthe shell material; in this case stainless steel. Thenext two characters, 28 in our example, identify theshell size. The following pair of numbers, 21 in ourexample, identifies the contact arrangement. If thispair of characters is followed by an “S”, it indicatesfemale-style (socket) contacts. If they are followedby a “P”, it indicates male contacts (Pin). The finalcharacter, Y in our example, indicates the choice ofpolarization keying.That’s all there is to it. While there are manypart number complexities and nuances throughoutthe various MS connector families, they all follow thesame basic approach to part number development.CAGE CODE 06324Printed in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-4E-Mail: sales@glenair.com
Introduction toMilitary Standard Cylindrical ConnectorsDesign Elements of CommonMilitary Standard ConnectorsMIL-C-5015 Connectors, CircularMS3400 (Front Release Contact) andMS3450 (Rear Release Contact) SeriesCrimp Type Contacts;Glenair Designator Code AThe following pages recap standard circularmilitary connector design features includingillustrations of the individual design characteristicsimportant to the accessory manufacturer whenselecting or designing backshells.Safety Wire HolesAccessory Interlock3 Teeth @ 120 ApartGrommet Dia.Controlled to MaximumMIL-C-5015 Connectors, Circular,MS3100 Series, Solder Types;Glenair Designator Code BMay or may nothave AccessoryInterlockingTeeth(See Note 2)See Note 1CaptiveCoupling NutSee Note 2Controlled Thread Size& Length, Per MS 3155StandardDesign Features:See Note 1Single KeywayPlug/ReceptaclePolarizing KeywayThreadedCoupling Nut(Not Captive) Uncontrolled ThreadLength and Size(See Note 3) Design Features: Threaded coupling design.Fifteen shell sizes—Range 8 thru 48(.500” to 3.000” diameter).Wide variety of contact sizes, standarddensity; 1 to 100 contacts.Conductive finish—Cadmium/Olive drab,96-hour corrosion protection.Notes:1. Same interface features as MS3100 andMS3106; intermateable.2. Single keying may not always ensure shellpolarizing.MIL-C-26482 Connectors, CircularMS3110 and MS3116 Series 1,Solder ContactsGlenair Designator Code DNotes:1. Contacts may mate prior to connectorshell mating.2. Single keying may not always ensure shellpolarizing.3. Uncontrolled accessory interface.4. Plug or receptacle may have pin or socketcontacts.5. Connector shell may strike pin contacts,thus power should always be on socketcontacts. 2004 Glenair, Inc.Threaded coupling design, captive.Fifteen shell sizes—Range 8 thru 48(.500” to 3.000” diameter).Wide variety of contact sizes, standarddensity; 1 to 100 contacts.Cadmium/Olive drab conductive finish,500 hour salt spray; electroless-nickeloptions.Bayonet Coupling NutNot CaptiveFive Keyways Plug/ReceptaclePolarizing KeywaySee Note 1CAGE CODE 06324UncontrolledThread Sizeand Lengthmay extendunder theCoupling Nut(See Note 2)NoAccessoryInterlock,SmoothPrinted in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-5E-Mail: sales@glenair.com
Introduction toMilitary Standard Cylindrical ConnectorsMIL-C-26482 Connectors, Circular, MS3470Series 2, Crimp Contacts, Rear Release;Glenair Designator Code ADesign Features: Bayonet coupling design, quickdisconnect. Ten shell sizes—Range 6 through 24(.3750” to 1.500” diameter). 12, 16, and 20 gauge contacts, standarddensity, 3 to 61 contacts. Conductive and non-conductive finishes;Cadmium/Olive drab and anodic.Notes:1. Contacts may mate prior to connectorshell mating.2. Plug may have less than three threads.Captive Coupling Nut(See Note 3)Five KeywaysPlug/ReceptaclePolarizing KeyingMS3120and MS3126IntermatableUncontrolled ThreadLength (See Note 2)MIL-C-28840 Connectors, Circular, FrontRelease, Crimp ContactsGlenair Designator Code GNo AccessoryInterlock, SmoothOptional GroundingFingers available onNon-MS-ConnectorsRapidAdvance CouplingSafety Wire Holes5 Keyways toPlug/ReceptacleMateDesign Features: Bayonet coupling design, quickdisconnect. Eight shell sizes—Range 8 thru 24 (.500”to 1.500” diameter). 12, 16, 20, and 22 gauge contacts, standard density, 3 to 61 contacts.Notes:1. Contacts may mate prior to connectorshell mating when grounding fingers notsupplied.2. Same limitations as MS3110 and MS3116solder type connectors.3. Uncontrolled wire seal grommet geometry;accessories properly mate. 2004 Glenair, Inc.Accessory Interlock3 Teeth @ 120 apartOptional ShellGrounding FingersDesign Features: Bayonet coupling design, quickdisconnect. Nine shell sizes—8 through 24(.500” to 1.500” dia) 12, 16, 20, and 22 gauge contacts,standard density, 3 to 61 contacts.Uncontrolled GrommetDia. (See Note 3)See Note 1ControlledGrommet LengthControlledDiameterControlled toMaximumMIL-C-26482 Connectors, Circular,MS3120 and MS3126 Series 1,Crimp Contacts, Front Release;Glenair Designator Code DCoupling NutNot CaptiveFive KeywaysPlug/ReceptaclePolarizing KeywayControlled ThreadSize & Length, PerMS 3155 StandardStandard UniformThread Sizes,Ruggedized BarrelControlledGrommetDiameterScoop sDesign Features: Threaded coupling design, rapid advance,captive, scoop proof. Nine shell sizes—Range 11 through 33(.500 to 2.000 diameter). 20 gauge high density contacts, 7 to 155.CAGE CODE 06324Printed in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-6E-Mail: sales@glenair.com
Introduction toMilitary Standard Cylindrical ConnectorsMIL-DTL-38999 Connectors, Series ICrimp Contacts, Rear Release;Glenair Designator Code FCaptiveCoupling Nut(See Note 3)MIL-DTL-38999 Connectors, Series IICrimp Type Contacts, Rear Release;Glenair Designator Code FControlledThreadSize andLength5 Keyways toPlug/ReceptacleMateGrommetLengthControlledto Max.ThreadmayextendunderFlangeCaptiveCoupling Nut(See Note 3)5 Keyways toPlug/ReceptacleMateSee Note 1See Note 1Design Features: Design Features:ShellGroundingFingersBayonet coupling design, quickdisconnect.Nine shell sizes—Range 8 through 24(.500” to 1.500” diameter).12, 16, 20, and 22 gauge contacts, standard density and 22 gauge high densityarrangements; 3 to 128 contacts.Scoop-proof shell design to prevent shellto contact problem.Controlled accessory interface per MILDTL-38999, figure 11.Cork and bottle primary insert interfaceseal and shell environmental seal, fuelresistant silicone elastomers.Conductive and non-conductive finishes;electroless nickel, Cadmium/Olive drab500 hour salt spray, and anodic. Bayonet coupling design, quickdisconnect, captive. Nine shell sizes—Range 8 through 24(.500” to 1.500” diameter). 16, 20, and 22 gauge contacts, standarddensity and 22 gauge high densityarrangements; 3 to 128 contacts. Shell ground available on MS andcommercial part numbers. Controlled accessory interface per MILDTL-38999 figure II. Cork and bottle primary interface andshell environmental seals, fluid resistantsilicone elastomers. Conductive and non-conductive finishes;electroless nickel, Cadmium/Olive drab,500-hour salt spray, and anodic. Short barrel construction for minimumenvelope.Notes:1.2.3.Long barrel design to prevent shell strikingcontacts.Serrated accessory interlocking toothdesign may prevent reliable moisture sealor EMI bond to accessories.Bayonet coupling may not perform undersevere conditions with large diametercable and backshell. 2004 Glenair, Inc.ShellGroundingFingersControlled ThreadLength extends underCoupling Nut.May have modifiedThread formUncontrolledGrommet Dia.and Length toMaximum(See Note 2)AccessoryInterlock Teeth,Circumferential(See Note 3)Notes:1.Very short barrel, shell may strike pincontacts.2.Wire seal grommet controlled to maximumcondition only, over compression willcause contact splaying.3.Same limitations as D38999 Series I.CAGE CODE 06324Printed in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-7E-Mail: sales@glenair.com
Introduction toMilitary Standard Cylindrical ConnectorsMIL-DTL-38999 Connectors, Series IIICircular, Crimp ContactsRear Release; Glenair Code HVibration ProofThreaded Coupling5 Keyways forPlug/ReceptaclePolarizingMIL-DTL-38999 Connectors, Series IVCircular, Crimp ContactsRear Release; Glenair Code H5 Keyways forVibration ProofPlug/Receptacle 1/4 Turn, BlindPolarizingBreech CouplingControlled ThreadSize and Length,Metric (See Note 2)ControlledGrommet LengthControlledGrommetLengthAccessoryInterlock100 Teeth,CircumferentialSee Note 1Shell GroundingFingersSee Note 1O-RingSealingSurfaceShell GroundingFingersAccessoryInterlock100 TeethCircumferentialO-RingSealing SurfaceDesign Features: Breech lock coupling design, rapid advance, self-locking. Eight shell sizes—Range 11 through 25(.500” to 1.500” diameter). 12, 16, 20, and 22 gauge contacts, standard density and 22 gauge high densityarrangements; 3 to 128 contacts. 16 gauge fiber-optic insert arrangements. Scoop proof shell design to prevent shellto contact problems. Controlled accessory interface with metricthreads. Ruggedized construction for shipboardservice. Cork and bottle primary interface and shellenvironmental seals, fluid resistantfluorosilicone elastomers. Conductive and non-conductive finishes;Cadmium/Olive drab 500 hour salt spray,electroless nickel, anodic, and stainlesssteel.Notes:1. 100 percent scoop proof, positive shellmating.2. Same accessory interlock teeth as MIL-DTL38999, Series III.3. Same O-ring seal features asMIL-DTL-38999, Series III.Design Features: Threaded coupling design, rapid advance,self-locking. Nine shell sizes—Range 9 through 25(.500” to 1.500” diameter). 12, 16, 20, and 22 gauge contacts, standard density and 22 gauge high densityarrangements; 3 to 128 contacts. 16 gauge fiber-optic insert arrangement. Scoop-proof shell design to prevent shellto contact problem. Controlled accessory interface with metricthreads. Diaphragm contact seal interface and shellenvironmental seal, fluid resistantfluorosilicone elastomers. Conductive and non-conductive finishes;Cadmium/Olive drab 500 hour salt spray,electroless nickel, anodic and stainlesssteel. Conductive composite shell, cadmium/olive drab over electroless nickel, andelectroless nickel, 2000 hour salt spray.Notes:1. Same barrel features as MIL-DTL-38999Series I, except metric threads.2. 100 percent scoop proof, positive shellmating. 2004 Glenair, Inc.AccessoryInterlock Teeth(See Note 2)CAGE CODE 06324Printed in U.S.A.GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 818-247-6000 FAX 818-500-9912www.glenair.comA-8E-Mail: sales@glenair.com
Crimp style contacts are preferred for all aerospace and other high-reliability applications (except those requiring a hermetic seal) due to their relative ease of assembly and maintenance. Solder type contacts are usually selected when cost is the primary consideration and repairability secondary. Solder type contacts are also used in hermetic
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Bridging the Gap Across the Sister Islands FEATURES OF THIS EDITION H O U S E O F A S E M B L Y V I R G IN S L A N D S 1st Quarter 2022 BRIDGING THE GAP Message: Bridging the Gap Across the Sister Islands (Hon. Shereen Flax-Charles) Special Feature: BVI NPO Collaboration Service Day on ANEGADA Sister Islander of the Quarter: Guess Who?
