Download - What’s in this Product Guide€¦ · A = Cadmium plated nickel base • B= Olive drab cadmium plated nickel base • F= Electroless nickel • C= Anodic coating (Alumite) • E=

Working closely with suppliers and manufacturers worldwide we offer a

comprehensive range of connectors and associated products for the

Defence, Aerospace, Marine and Industrial markets. Our customer

service team includes specialists by sector and by product, to provide

the best customer support that we can.

We offer a wide selection of MIL specification electrical, opticaland high speed connectors, plus hermetic feedthroughs andcustom designed products. Our experience and knowledgeis able to provide you with advice and support on the bestproduct available for the application, whether it is an off theshelf or a bespoke designed connector/feedthrough.

Military Vehicles • Naval Ships & Submarines •Military Aircraft & Helicoptors • Weapons Systems •Industrial Applications • C4ISTAR

What’s in th is Product Guide

Introduction

Defence, Aerospace, Marine & Industr ia l Markets

Contents

WIRE..it SWITCH..it PROTECT..it MANAGE..it IDENTIFY..it BOOT..it RELAY..it CONNECT..it

SIMPLIFYING PROCUREMENT

Not only can we ‘SOURCE..it’ but also ‘CONSOLIDATE..it’ with IS-Rayfast. Ouraim is to solve all your requirements in one easy package. Wire, switches, heat-shrink tubing, protective sleeving, cable management, identification methods andsystems, plus relays, are just a small selection of high performance products wesupply alongside our flexible inventory management and value added services.

IS-Rayfast will solve your design challenges. We will save you time and money byallowing your engineering team to focus solely on critical elements. We will engagewith you early in the engineering cycle, give you access to engineers around theworld, provide the design tools, methodology and bring world-class expertise toyour application requirements in order to accelerate your project cycle and off loada significant portion of the design effort.

SOURCE..it

CONSOLIDATE..it

NOTE: This publication is issued to provide outline information only and unless specifically agreed to the contrary by IS-Rayfast Ltd in

writing, is not to form part of any order or contract or be regarded as a representation relating to the products or services concerned.

IS-Rayfast reserve the right to alter without notice the product design, price or conditions of supply of any product or service. Whilst

every effort has been made to ensure that the information in this guide is accurate, no responsibility can be accepted for any errors or

ommissions nor for the effects of such errors or ommissions. 2

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MIL-38999

MIL-5015

Specials

Hermetic

Industrial

Accessories

MIL-DTL-38999 Series I, II, III, Derivatives & PowerOffers high density contact arrangements in a circular shell in various styles. Range offered includes

all series and variants such as NATO standard VG96912 qualified to JAN1003, on pages 3 and 4.

With series III and composite versions which can be found on pages 5 and 6. In addition micro

derivatives and power are included on page 7

Shell Finish OptionsThere are a number of options available on selected product types including the latest RoHS

compliant Black Zinc Nickel, plus the latest Nickel Aluminium Bronze and Composite materials.

This section briefly outlines the various material performance characteristics. Whilst not

comprehensive it is intended as a guide and should you have further queries please contact us.

MIL-DTL-5015Includes the threaded MS3100 Series and upgraded bayonet VG95234 version as designed for

NATO combat vehicles, aircraft and airbourne equipment. We also offer the threaded MS3450 Series

version which fills the gap between the older series and higher technology needs.

Bespoke and Special ApplicationssWhether you need batch prototype samples to large production orders, we can help design the

solution, these will be deliverable in terms of timescale and final cost for connectors and

feedthroughs. Plus pages 15 and 16 focus on ruggedised high speed connectors.

Bespoke Connectors • Explosion Proof • Filter • Fibre Optic • EMI Filtered Comms

Hermetic Connectors and FeedthroughsWe offer a wide range of hermetic connectors and feedthroughs for all the popular military

specifications in use today, including those mentioned in this product guide but not limited to, as

our sales team will be happy to help design and source a solution for you.

D38999 • D26482 • D5015 • D26500 • M12 • M23 • M40 • EN2997

Industrial ConnectorsThe range included in this product guide is just a selection of the key industrial connectors that we

can supply, with focus on circular connectors for high performance applications and harsh

environments.

C16 Series • C91 Series • Snap-in Connectors • Watertight Miniature • Circular

Push-Pull • Powerlock

Comprehensive Solutions - AccessoriesFor all your connection needs, we have a solution, offering an extensive range of connector

accessories, backshells, adaptors and protective caps and associated components from world

leading manufacturers to assemble a wiring harness. Plus a listing of military and industrial

connector specifications for the key products supplied.

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MIL-DTL-26482 Series I, II & 62GBOffers high density contact arrangements in a circular shell in various contact formats. These

circular connectors provide quick disconnect bayonet coupling for rapid mating and unmating. in

several mounting styles and shell sizes.

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MIL-26482

Shell Finishes

INCLUDES

MIL-DTL-38999 Series I, (1.5) & II MIL-DTL-38999 Series I & II

Description and Technical Specifications

Feature by Model Series I VG96912

Wire Gauge Range (AWG) 24 to 12

Number of Circuits 3 to 128

Sealed Against Water Jets Yes

EMI/RFI-Shielding Yes

Style Circular

Operating Voltage/DWV 2300 Vac max

Current Rating (Amps) 1.5 to 23 max

Power & Signal on Same Layout Yes

Operating Temperature oF -67oF to +392oF max

Submersible Yes

Individual Wire Sealing Yes

Cable Jacket Sealing Yes

Life in Mating Cycles (min) 500

Shock Test (g’s) 300

Vibration Test (grms) 49.5

Shell Material Aluminium Alloy

Shell PlatingCadmium, Electroless Nickel or

Anodised

Positive Shell Polarization Yes

Insert Polarization Options Yes

User Polarization No

Standards/Associated Specs. MIL-DTL-38999 Series I

Contact Plating Gold

Contact StyleCrimp, PCB Solder, Thermocouple

& Coax

Fibre Optic - Option •

Operating Temperature oC -55oC to +200oC max

28 to 12

3 to 128

Yes

Yes

Circular

2300 Vac max

1.5 to 23 max

Yes

-67oF to +392oF max

Yes

Yes

Yes

500

300

49.5

Aluminium Alloy

Yes

Yes

No

n/a

Gold

Crimp, PCB Solder, Thermocouple

& Coax

•

-55oC to +200oC max

Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com

First-Mate Last Break n/a n/a

Series II

28 to 12

3 to 128

Yes

Yes

Circular

2300 Vac max

1.5 to 23 max

Yes

-67oF to +392oF max

Yes

Yes

Yes

500

300

43.7

Aluminium Alloy

Cadmium, Electroless Nickel,

Anodised or Zinc Cobalt

Yes

Yes

No

MIL-DTL-38999 Series II

Gold


& Coax

•

-65oC to +200oC max

n/a

Building Your MIL-DTL-38999 Series I & II Part Number

Cadmium, Electroless Nickel or

Anodised

MIL-DTL-38999 - SERIES I100% Scoop-Proof Design with Quick, Positive Bayonet Coupling

Offers high density contact arrangements and are suitable for extremely high reliability connections,

including use in military and commercial aviation. These connectors are environmentally sealed, have a

wide operating temperature range and meet the requirements of HE308, plus they are intermateable with

all MIL-DTL-38999 series 1 connectors, formerly called MIL-C-38999.

Scoop Proof Design • Quick mating with three point bayonet coupling system • Shielded

interconnect, 360º EMI/RFI shielding protection • Many contact layouts and styles • Utilises

high quality military contacts • Corrosion resistant

MIL-DTL-38999 - SERIES IILightweight Space Saving Design

Offers high density contact arrangements in a smaller size than series I. They were designed for high

performance requirements, including military and commercial aviation applications. These connectors are

enviromentally sealed and have a wide operating range, plus all they are intermateable with all the common

MIL-DTL-38999 connectors and were formerly called MIL-C-38999.

High-reliability, performing flawlessly under wide temperature ranges, high vibrations and

resistant to a vast array of contaminents • Low profile connector design, for use in areas

that would otherwise be impossible for other mating systems • Light weight, for today’s

aircraft designs • High density connectors offering up to 128 contacts • Operates at extreme

temperatures • Quick mating coupling system, three point bayonet

MIL-D38999 Style (1.5) - VG96912Miniature Connector Qualified to JAN1003

Offers high density contact arrangements, which are environmentallly sealed and have a wide operating

temperature range.These connectors meet the requirements of VG96912, are qualified to JAN1003 and

are NATO standard. Commonly referred to as D38999 Series 1.5 offering the same features as series I.

For HE308

series

connectors,

military part

numbering

please

contact us.

Connector Style - Series I

27466 = Front mount with rear accessory threads • 27467 = Plug, also available with PC pins •

27468 = Jam nut with rear accessory threads • 27496 = Front mount without rear accessory threads •

27505 = Rear mount without rear accessory threads • 27656 = Rear mount with rear accessory threads.

Class

E = Grommet & Compression nut (not applicable for box mount receptacles) • P = Potting ring & cup •

T = No rear accessories, NOT used on MS27505E & MS27496E • Y = Hermetically sealed

Other commercial options available please contact.

Shell Size - Insert Arrangements

Contact us for seperate MIL arrangement charts.

MS27466 MS27467 MS27468 MS27496 MS27505 MS27656

Contact Type

P = Pin contacts • S = Socket contacts • H = 1500 mating cycles pin (not Series II) • J = 1500 mating

cycles socket (not Series II) • A = Supplied less pins • B = Supplied less sockets

Plating

A = Cadmium plated nickel base • B = Olive drab cadmium plated nickel base • F = Electroless nickel

• C = Anodic coating (Alumite) • E = Passivated steel (Hermetic only) • NOTE - Electroless nickel

space compatible & Stainless steel also available.

Connector Style - Series II

27472 = Front mount. With accessory threads • 27473 = Plug. Standard • 27474 = Rear mount. Jam

nut with accessory threads • 27484 = Plug. With grounding spring • 27497 = Rear mount. With

accessory threads • 27499E = Front mount. No accessory threads • 27508E = Rear mount. No

accessory threads. • 27513E = Front mount. No accessory threads.

Modifier (OMIT for standard contacts)

LC = Less contacts, wire hole fillers and plastic insertion/extraction tool

Part number exampleMS27468 T 25-35 F P A-LC

Keyway Rotation

N = North (omit for normal) • A = North North West • B = North West • C = North

East • D = North North East.

NOTE; ‘B’ Has limited availability - ‘C’ & ‘D’ Check availability.

Composite

Aluminium

Firewall

Hermetic

Bronze

38999 Series II

38999 Series I.5

Power

Fibre Optic

Quadrax

Please note that actual product appearance may vary

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43

Commercial

grade

connectors in

this series

are also

available

please call us

for details.

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MS27472 MS27473 MS27474 MS27484 MS27497* MS27499E MS27508E MS27513E*

Commercial

grade

connectors in

this series are

also available

please call us

for details.Feature by Model Series III Series III Composite





Style Circular


Current Rating (Amps) 1.5 to 46 max



Submersible Yes



Life in Mating Cycles (min) 500/1500


Vibration Test (grms) 60

Shell MaterialAluminium Alloy, Stainless steel, Marine nickel

Aluminium or Bronze.

Shell PlatingCadmium, Electroless Nickel, Anodised or

Aluminium Bronze




Standards/Associated Specs. MIL-DTL-38999 Series III


Contact Style Crimp, PCB Solder, Thermocouple & Coax



28 to 12

to 128

Yes

Yes

Circular

2300 Vac max

1.5 to 46 max

Yes

-67oF to +248oF max

Yes

Yes

Yes

500

n/a

n/a

Composite

Yes

Yes

No

MIL-DTL-38999 Series III

Gold

Crimp, PCB Solder, Thermocouple & Coax

•

-55oC to +125oC max



Cadmium or Electroless Nickel

MIL-DTL-38999 Series IIIstandard and composite

MIL-DTL-38999 Series IIIstandard and composite

MIL-DTL-38999 - SERIES IIICombines High Coupling Durability with EMI-Shielding, Moisture and Corrosion Resistance

Series III connectors have high density contact arrangements in a Tristart threaded coupling circular shell.

Originally designed for high-performance requirements of military and commercial aircraft, these circular

connectors are perfect for applications requiring extremely reliable inter connections.

With space and weight becoming a critical element in the design of cabling infrastructure, the double

density range has been specifically designed to address this issue and take into consideration the growing

demand for more data lines in a compact harsh environment. The increased density allows design engineers

much more scope in design flexibility when considering equipment requirements and cable infrastructure.

Visual confirmation of mating • Outstanding EMI-Shielding protection integrity due to the

shielded mating system that utilises 360º shell grounding fingers, providing protection of up

to 65 dB at 10 GHz. • Operates at extreme temperatures from -85ºF to +392ºF (-65ºC to

+200ºC) • Contact protection, designed to be scoop proof.

MIL-DTL-38999 - SERIES III CompositeLight-Weight Commercial 38999 Perfect for Communications Equipment in Harsh Environments.

These new composite connectors are on average 30% lighter than the equivalent standard aluminium

interconnects, having been designed specifically for the aerospace market. Both military and commercial

manufacturers are under continual pressure to reduce operational aircraft weight. Lightweight components

can play a key role in achieving this goal.

Composite 38999 series III connectors offer the highest performance capabilities for harsh environments,

including military and commercial aircraft, avionics systems and unmanned aircraft.

Quick mating with three point bayonet coupling system • Shielded interconnect, 360º of

EMI/RFI shielding protection • Many contact layouts and styles up to 128 contacts • Utilises

high quality military contacts • Corrosion resistant, passed 500 hour military salt spray tests.

Class

C = Anodized (Aluminium) • F = Electroless nickel (Aluminium) • J = Composite (Olive drab chromate

over Cadmium) • K = Stainless steel shell, passivated firewall insert, 45db • M = Composite

(electroless nickel) • S = Stainless steel, electroless nickel • T = Nickel - PTFE (Aluminium) •

W = Olive drab chromate over cadmium (Aluminium).

Please contact us for details on G = Space -Grade • L = Corrosion resistant steel/Electrodeposited

nickel • Y = Hermetic stainless steel • N = Hermetic stainless steel/Electrodeposited nickel.



D38999/20 D38999/24 D38999/26

Contact Type

P = Pin contacts • S = Socket contacts • H = 1500 mating cycles pin (Composite type only) •

J = 1500 mating cycles socket (Composite type ony) • A = Supplied less pins • B = Supplied less

sockets • X = Eyelet contacts, hermetics only.

Modifier (OMIT for standard contacts)

LC = For use with standard contacts supplied with contacts, seal plugs or tools

U = Universal endbell for heatshrink tube or boots • US = Universal endbell with shielding spring •

UT = Universal endbell with shielding tap • UW = Universal endbell with shielding tape and spring •

SB or HSB = Heavy-duty heat shrink boot • CG = Cord grip adapter • CA = Flexible conduit adapter.

Part number exampleD38999/20 F A35 P N-LC

Connector Style - Series III Composite

D38999/20 = Wall mount receptacle • D38999/24 = Jam nut receptacle • D38999/26 = Straight plug

Building Your MIL-DTL-38999 Series III Part NumberDescription and Technical Specifications

Insert Rotation

For full details refer to seperate MIL arrangement charts:

N = Normal standard • A = Highly popular • B = Limited availability • C = Check for availability •

D = Check for availability.

Connector Style - Series III

D38999/20 = Wall mount receptacle • D38999/21 = Box mount receptacle • D38999/23 = Jam nut

receptacle, hermetic • D38999/24 = Jam nut receptacle • D38999/25 = Solder mount receptacle,

hermetic • D38999/26 = Straight cable plug • D38999/27 = Weld mount receptacle, hermetic •

D38999/31 = Lanyard plug.

Specifications are subject to change

Composite

Aluminium

Firewall

Hermetic

Bronze

Power

Fibre Optic

QuadraxPlease note that actual product appearance may vary

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SIII

38999 Series III

65

38999 (III) Composite

CALL US+44(0)1793 616700

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D38999/20 D38999/24 D38999/26

Smaller Higher Density MIL-DTL-38999 derivativesThere are numerous derivatives of MIL-DTL3899 Series III available going by numerous names, but

essentially they offer a 38999 style connector in a much smaller package, some with the advantage

of offering a Break-Away functionality. Other derivatives such as Power, Fibre Optic and Quadrax

are covered elsewhere in this product guide.

Micro 38999 derivatives are smaller and more compact than the standard D38999 connector, but retain all

the technical features and excellance required by the Military and Aerospace markets.

Miniature solutions are often available in different shell materials, for example Aluminium and Composite

materials are used for strength: weight ratio, Brass for its

ruggedness and Aluminium Bronze for its corrosion

resistance in marine applications. A variety of different

contact designs and termination methods are available

dependant on the product application and environment.

Connectors can be fully populated with pre-tinned

contacts ready for loading straight onto

PCB boards for increased reliability.

Typical shell sizes range from ‘03’ to ‘15’

depending on contact arrangement and

particular manufacturer, the most popular

versions are often referred to as follows.

micrø38999 • HD38999 • 2M Micro-

Miniature • Wildcat Micro •

Wildcat Series III • Mighty Mouse

Colour Olive Drab Black (non reflective) Black (non reflective)Shiny Silver

Cadmium Black Zinc Nickel Black Zinc CobaltElectroless Nickel

Shell Continuity 2.5 mΩ 2.5 mΩ 2.5 mΩ1 mΩ

Salt Spray 500 hours

>90dB @ 100 MHz>

>50dB @ 10GHz

>80dB @ 100 MHz>

>45dB @ 10GHz

>90dB @ 100 MHz>

>65dB @ 10GHz

RoHS Compliant NO YES YESYES

MIL-DTL-38999 DerivativesPower and Miniature

Material FinishesOptions

Overview of the Common Variations Description and Overview

For more information: www.is-rayfast.com7 Tel: +44(0) 1793 616700 . [email protected] 8

Fin

ish

es

Durability 500 cycles

2.5mV max 5.0mV max1.0mV max

Temperature Range -65ºC to +175ºC max

500 cycles 500 cycles500 cycles

EMI Shielding>90dB @ 100 MHz>

>50dB @ 10GHz

Shell Conductivity 2.5mV max

500 hours 48 hours48 hours

-65ºC to +175ºC max -55ºC to +125ºC max-65ºC to +200ºC max

Dark Green

Green Zinc Cobalt

2.5 mΩ

>80dB @ 100 MHz>

>45dB @ 10GHz

NO

5.0mV max

500 cycles

96 hours

-55ºC to +125ºC max

Plating Finish

Nickel Alu Bronze CompositeStainless Steel

Salt Spray 500 hours 2000 hours2000 hours

Finish OptionsSingle Pole High Power ConnectorOne of the key products available in this range includes the RHINO 38999, with hyperbolic contacts

that extend the boundaries of high power connector technology.

There is a broad range of high power connector products available, that combine the benefits of field

proven MIL-DTL-38999 Series III circular connectors designed to meet the latest military and industrial

specifications. Manufacturers have recognised the trend towards increased power and voltage within such

applications as military and electric drive vehicles, aircraft, intelligence bases and stations.

An effective solution to achieving an electrical interface that exceeds typical interconnect systems is a

hyperboloid contact which distributes normal forces over a high percentage of the mating surface to ensure

smooth and even engagement with exceptionally high performance under vibration. The large surface area

of the socket contact also results in a very low contact resistance, enabling much higher current ratings

compared to non hyperboloid designs. High reliability applications including vehicular, aerospace,

industrial, automation, mining, offshore and other harsh environments can all be addressed.

Also Available:

D38999 Power, multi-pin 60-125A • D38999 Power Safe - first to mate 7.5-60A, 250-500V

Same number of contacts ina smaller connector!

33% Smaller Diameter

50% Shorter Length

3 TIMES Lighter

1.7mm Pitch

2.28mm Pitch

Electrical compatiility of Zinc Nickel

with Cadmium

Electrical potential of Zinc Nickel and

Cadmium are very similar which

removes the risk of galvanic corrosion

and defects after 500 hours salt spray.

Power Connectors

Key Features

Technology

Benefits

Current Rating 100-750A max

Operating Voltage 630V max

Termination

Crimp or screw or flathead contact termination

available. Straight or right angled backshells

available for strain relief and 360º EMC/RFI

screening.

Mechanical

38999 Series III or special breakaway connector

interface, jam-nut, flange mount and in line

connections, 500 mating cycle durability

Safety IP2X, plastic cap on pin contact to prevent shock.

Environmental

Aluminium, Stainless Steel or Aluminium Bronze

shells. Temperature range -45ºC to +125ºC max,

IP68 sealing, plating dependant, 500Hrs Salt Spray.

Micro-38999

Break-Away

Threaded

Bayonet

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Environment Friendly, limitation for

Nickel PTFE

A number of manufacturers also offer

PTFE based RoHS compliant

products. However, the average bath

lifetime of the chemical nickel PTFE is

half that of electroless nickel and ten

times less than nickel alloy (Zinc

nickel). Furthermore, the waste toxicity

of electroless nickel or nickel alloys is

higher than the electrolytic process:

Cadmium•

Nickel electroless•

Nickel PTFE•

Electrolytic zinc nickel•

In addition, the PTFE material is toxic

and indestructable.

Toxicity

level

CALL US+44(0)1793 616700

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SPOKE DESIGN

High Amperage

Low Insertion Force

Hyperbolic contacts are usually stamped and formed flat

grids, uniquely twisted into a hyperbolic geometry to

provide robust, high density contact to mating

pin contact. Most pin and socket

technologies rely upon spring (beam

element) properties to the contact

elements, which can weaken over time.

Unlike most other pin and socket

solutions, these contacts utilise the tensile

strength properties of the flat, high

conductivity alloy grid. This provides the forces required

for conductivity, while also providing a large flexible and

conductive surface area.

Black is the Latest GreenMilitary connectors are getting a ‘green’ make-over with an eco-friendly, cadmium-free black plating. Having

eliminated lead from virtually all electronic components, the directive on the Restriction of Hazardous

Substances (RoHS) focusses attention on cadmium. Unlike lead, however, where defence, aeronautical

and other critical equipment was exempt, the Ministry of Defence is set to phase out cadmium plating on

military connectors. It will be replaced with a new, and more environmentally-friendly, black zinc nickel

plating.

Up to recently, Cadmium was the most widely used surface coating and industry preference for connectors

and accessories complying with standard MIL-DTL-38999 in defence and aeronautical applications. To

replace it with more environmentally friendly solutions a number of manufacturers have now industrialised

and qualified their Electrolytic Zinc Nickel plating process to reduce or eliminate the use of Cadmium.

IS-Rayfast are pleased to offer a range of products with RoHS compliant plating alternative to Cadmium.

Black Zinc Nickel plating is now available on a wide range of connectors and accessories including

proprietary MIL-DTL-38999 and MIL-DTL-26482. This conductive and non reflective black finish is approved

for 500hrs salt spray endurance and is fast becoming the defence industry standard.

Black Zinc Nickel plating is compatible with other platings, without corrosion or electrochemical erosion

with Cadmium, Zinc Cobalt or Electroless Nickel plated parts.

The latest ecological and sustainability regulations now seek EU Directive

Requirement 2011/65/EU - The Directive requires that the homogeneous materials

within new electrical and electronic equipment must contain less than 0.1% by

weight of lead, mercury, hexavalent chromium, polybrominated iphenyls (PBB) or

polybrominated diphenyl ethers (PBDE) and less than 0.01 Cadmium. Although

most Defence and Aerospace applications can be exempted.

For buyers, this means looking at the plating on common military connectors, such

as the MIL-DTL-38999 & MIL-DTL-26482, to ensure a planned change-over.

In some ways, the transition from traditional olive-green cadmium to black zinc will

be easier for buyers than the move from lead-inclusive to lead-free. For

manufacturers the type of coating will be specified using a different identifier within

the part number. At goods-in, all it will take is a simple visual inspection to confirm

whether the connector is olive-green or black.

The main driver for the change is the reduced environmental impact, but black zinc

nickel-plated connectors are also capable of providing rugged performance in harsh

environmental conditions. This is crucial because, typically, connectors such as

MIL-DTL-26482, MIL-DTL-38999 and the Rhino 38999 series, are used in military

as well as other harsh applications including next-generation electric and mass

transit vehicles, or vehicles used in difficult environments, as well as in

communication, power generation and metering equipment.

The conductive, non-reflective finish of the new black zinc nickel plating allows

connectors to operate between -65 and 175°C, in accordance with MIL-DTL-38999,

and the finish is approved to withstand 500 hours of exposure to salt spray.

Further tests by manufacturers have demonstrated that black zinc nickel has a high

level of compatibility with other plating materials and there are no significant

galvanic reactions with cadmium, zinc cobalt or electro-less nickel-plated parts.

While not recommended, this means black zinc nickel-plated connectors could still

be mated with legacy connectors during the transition period.

MIL-DTL-26482 Series I & II

Feature by Model Series I 62GB






MIL-DTL-26482 - SERIES IOffers high density contact arrangements in a circular shell. Available with solder contacts, crimp contacts

and a commercial crimp option. These circular connectors provide quick disconnect bayonet coupling for

rapid mating and unmating and several mounting styles and shell sizes. Ideally suitable for general military

applications and is the connector interface of choice for many Military Communications equipment.

Rugged shell • Environmentally sealed • Resistant to military environments • Wide range

of wire gauges and current carrying capability • Resilient Insulator & Grommet • Removable

crimp contacts • Crimp or Solder contacts.

Style Circular

Operating Voltage/DWV 1000 Vac/5kv max

Current Rating (Amps) 23 max


Operating Temperature oF -67oF to +257oF

Submersible Yes







Shell PlatingCadmium, Anodised, Electroless

Nickel & Zinc Alloy




Standards/Associated Specs. MIL-DTL-2648


Contact StyleCrimp, Solder, PCB Solder,

Thermocouple & Coax

Fibre Optic n/a

Operating Temperature oC -55oC to +125oC

24 to 8

2 to 61

Yes

Yes

Circular

1500 Vac max

22 max

Yes

-67oF to +257oF

Yes

Yes

Yes

500

100

10

Aluminium Alloy

Yes

Yes

No

BS9522 F00 17

Gold

Crimp, Solder & PCB Solder

n/a

-55oC to +125oC


First-Mate Last Break • n/a

Series II

24 to 12

3 to 61

Yes

Yes

Circular

2300 Vac max

23 max

Yes

-67oF to +392oF

Yes

Yes

Yes

500

150

20

Aluminium Alloy

Cadmium & Electroless Nickel

Yes

Yes

No

MIL-DTL-2648 II

Gold


& Coax

•

-55oC to +200oC

n/a

MIL-DTL-26482 Series I & II

MS Number

311 = MIL -DTL-26482 Series I Solder Type • 312 = MIL-DTL-26482 Series I Crimp Type

Endbell

A = General-duty threaded • E = Environmental no clamp • F = Environmental with clamp •

J = Environmental with clamp and cable jacket gland seal • P = Potted type with potting boot.

Insert Rotation

W = East North East • X = East South East • Y = West South West • Z = West North West

No letter required for normal (no rotation position.

Contact Type

P = Pin contacts • S = Socket contacts • A = Supplied less pins • B = Supplied less sockets

Building Your MIL-DTL-26482 Series I/II Part Number

Cadmium, Anodised, Electroless

Nickel & Zinc Alloy

Finish

L (‘R’ commercial) = Electroless nickel (RoHS) • A = Black anodised • W = Olive drab chromate over

cadmium over nickel 500 salt spray • G = Stainless steel 303 grade • B = Conductive black alloy (RoHS

with A15 mod code): • NOTE - Green zinc & Durmalon platings are also available.

Shell Size Insert Arrangements

See insert MIL arrangement charts.

MS3470 L 8-33 P W

Contact Type (crimp)

P = Pin contacts • S = Socket contacts • A = Supplied less pins • B = Supplied less sockets

Building Your MIL-DTL-26482 Series II Part Number

Part number example

Insert Rotation

W = East North East • X = East South East • Y = West South West • Z = West North West

No letter required for normal (no rotation position).

Shell Size Layout/Insert Arrangement


Part number example

Plating Default plating: Olive drab cadmium

02 = Black anodised • 23 = Electroless nickel (RoHS) • 24 = Olive drab zinc alloy

Composite

26482 Series I

26482 Series II

Aluminium

Firewall

Hermetic

Bronze

Power

Fibre Optic

Quadrax

MS311 0 E 8-2 P W

Commercial

grade

connectors in

this series are

also available

please call us

for details.



26

48

2 S

I/II

26482 style 62GB

9 10

MIL-DTL-26482 - SERIES IIMiniature cylindrical connectors have a quick-mating, three point bayonet coupling system. Given their

small size and high-quality contact retention and seal, they are an excellent choice for harsh environments

where high-reliability is required, including the aerospace industry.

Total enviromental sealing • Wide operating temperature range • Quick mating, three point

bayonet coupling • 100% scoop proof shell design • EMI-RFI shielding • Available in rugged

500 hour salt spray plating • Crimp contacts, with solder contacts available.

62GB SERIES Pattern 105The 62GB Series connectors are similar to MIL-DTL-26482 but with the advantage of keyway orientation

to reduce mis-mating among multiple connectors. They feature aluminium shells with brass or stainless

steel options available plus optional EMC 360o screen termination.

Rugged, machined connector shell • Environmentally sealed • Resistant to harsh

environments • Wide variety of endbell styles • Meets BS 9522 F00 17 & Pattern 105.

CALL US+44(0)1793 616700

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SPOKE DESIGN

26

48

2 S

I/II

Connector Style

0 = Wall mount receptacle • 1 = Cable connecting receptacle • 2 = Box mounting receptacle •

3 = Solder mount receptacle (hermetic only) • 4 = Jam nut receptacle • 6 = Straight plug •

7 = Box mount receptacle with dual mounting holes • 8 = Wall mount receptacle with mounting holes.

0. Wall 1. Cable 2. Box 4. Jam nut 6. Cable Bulkhead Right anglemount mount mount plug receptacle plug

Connector Style

3470 = Wall mount receptacle with narrow flange • 3472 = Wall mount receptacle with wide flange •

3471 = Cable connecting receptacle • 3474 = Jam nut receptacle • 3476 = Straight plug • 3475 =

Straight plug with RFI grounding fingers.

MS3476 MS3475 MS3470 MS3471 MS3472 MS3474


MIL-DTL-5015MIL-DTL-5015standard and special

MIL-DTL-5015 - Threaded MS3100 SeriesEnvironmentally Sealed for Challenging Environments

The MS3100 Series are a threaded circular MIL-DTL-5015 connector for use in harsh environments, sealed

to withstand moisture, condensation, vibration and flash-over. Over 86 contact layouts are available, in

variations that allow for just power, just signal, or a mix of both contact types. Available in five mounting

styles, nineteen shell sizes, solder or crimp termination

Operates at temperatures between -67ºF to +257ºF (-55ºC to +125ºC) • A resilient neoprene

insulator and rear seal grommet provide a liquid tight assembly • Up to 150 amps for

standard military contacts and up to 255 amps commercially.

Feature by Model MS3100 Series VG95234 Series





Style Circular


Current Rating (Amps) 150 to 245 max



Submersible Yes







Shell PlatingCadmium, Electroless Nickel, Zinc

Alloy or Anodised




Standards/Associated Specs. MIL-DTL-5015

Contact Plating Silver or Gold

Contact Style Crimp, Solder, PCB Solder,



26 to 0

1 to 85

Yes

Yes

Circular

3000 Vac max

150 to 245 max

Yes

-67oF to +257oF max

Yes

Yes

Yes

500/2000

50

15

Aluminium Alloy

Yes

Yes

No

MIL-DTL-5015, VG95234

Silver or Gold

Crimp, Solder, PCB Solder,

•

-55oC to +125oC max


M3450 Series

20 to 0

1 to 85

Yes

Yes

Circular

3000 Vac max

150 to 245 max

Yes

-75oF to +392oF max

Yes

Yes

No

100

50

15

Aluminium Alloy

Cadmium, Anodised, Electroless

Nickel or Zinc Alloy

Yes

Yes

No

MIL-DTL-5015

SIlver or Gold

Crimp, PCB Solder,

•

-55oC to +200oC max

n/a

Black Anodised, Electroless Nickel,

Cadmium or passivated Cadmium

Connector Style - MS3100 Series

MS3100 = Wall mount receptacle • MS3101 = Cable connecting plug • MS3102 = Box mount receptacle

• MS3106 = Straight plg • MS3108 = 90o plug

Service Class

A = Solid shell for general, non-environmental applications • C = Solid shell for pressurised applications,

limits air leakage regardless of type and class of plug mated with • E = Environmental resisting •

F = Environmetl resisiting with strain relief • R = Lightweight environmental resisting.

Other commercial options available please contact.



Contact Type

P = Pin contacts • S = Socket contacts

Part number example

Insert Rotation

W = East North East (80o) • X = East South East (110o) • Y = West South West (250o) •

Z = West North West (280o) No letter required for normal (no rotation position).

MS3100 A 24-21 S W


Finish

L = Electroless Nickel • W = Olive drab Chromate over Cadmium • LS = Stainless Steel shell, Passivated

• KT* = Steel shell, Olive drab Chromate over Cadmium, Firewall •

KS* = Stainless Steel shell, Passivated, Firewall

*KT and KS finishes are not QPLD for styles MS3451, MS3452 and MS3454

Other commercial options available please contact us



MS3450 MS3451 MS3452 MS3454 MS3456 MS3459

Contact Type

P = Pin contacts • S = Socket contacts • A = Less pin contacts • B = Less socket contact

The ‘A’ and ‘B’ designators are used only for non-power contacts

Part number example

Insert Rotation

W = East North East (80o) • X = East South East (110o) • Y = West South West (250o) •

Z = West North West (280o)

No letter required for normal (no rotation position).

MS3450 L 18-11 P W

MS3100A MS3101A MS3102A MS3106A MS3108A

Specifications are subject to change Please note that actual product appearance may vary


Composite

Aluminium

Firewall

Hermetic

Bronze

Power

Fibre Optic

Quadrax

MS3100 Series

VG95234 Series

Commercial

grade

connectors in

this series are

also available

please call us

for details.

Commercial

grade

connectors in

this series are

also available

please call us

for details.

Building Your MIL-DTL-5015 Part Number

50

155

01

5

MS3450 Series

11 12

MIL-DTL-5015 - Bayonet VG95234 SeriesImproved coupling over threaded MIL-DTL-5015

Replaces the threaded coupling of the MS 3100 series, with a positive, quick mating, three point reverse

bayonet lock for improved performance. Offers the same shell dimensions, contact layouts, contacts and

performance characteristics as the threaded versions; however, the two series do not intermate.

Made in accordance with German miitary specification VG95234 and MIL-DTL-5015. Originally

designed for NATO combat vehicles, aircraft and airborne equipment • Quick and simple

120º rotation mating and un-mating.

MIL-DTL-5015 - MS3450 SeriesHigh performance alternative to older MIL-DTL-5015 solder types

Rear release threaded connectors with a retention clip. These connectors fill the gap between the older

MIL-DTL-5015’s and higher performance needs of new technoligies.

Broad operating temperatures between -75ºF to +392ºF (-55ºC to +200ºC) • The rugged

aluminium alloy or steel shells are highy resistent to damage and corrosion with firewall

capabilities.

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Connector Style - MS3450 Series

MS3450 = Wall mount receptacle • MS3451 = Cable connecting receptacle • MS3452 = Box mount

receptacle • MS3454 = Jam nut receptacle • MS3456 = Standard plug+ • MS3459 = Plug with self-

locking coupling nut+


Bespoke Design and Explosion Proof

SPECIALS & BESPOKE DESIGNSconnectors and feedthroughs

SPECIALS & BESPOKE DESIGNSconnectors and feedthroughs

FILTER

Filter and Fibre Optic Connectors

BESPOKE SOLUTIONS

Sp

ec

ials

ATEX - Explosion Proof

13 14

START to FINISH

SIGNAL RJ45 USBPOWER

Sp

ec

ials

Fibre Optic Fibre Optic ConnectorsSingleway and multiway connectors for single mode and multimode applications

Connectors are available in a number of different types; circular, rectangular, modular; and come in a variety

of materials and finishes, including Aluminium, Composite and Aluminium Bronze. Often including features

such as rear insertable/removable optical contacts and a removable alignment sleeve, enabling simple,

effective cleaning and maintenance.

Industrial

JN1055

MIL-DTL-83526/20

MIL-T-29504 Style

MIL-DTL-38999

MIL-DTL-38999

Popular Products

Ruggedised Singleway

Key Features

Ceramic PC ferrule and alignment sleeve providing optimum performance for Multimode

and Singlemode

JN1055 (J62.710)A high performance singleway connector suitable for aerospace environments. This

connector series complies with the Eurofighter JN standard.

38999 Series IIIUtilising MIL-T-29504 style termini. Rugged design offers maximum performance for

shock and vibration, environmental, moisture, corrosion resistance and EMI shielding.

MultiwayA high performance singleway connector suitable for aerospace environments. This

connector series complies with the Eurofighter JN standard.

for bespokesolutions pleas

e

contact ourcustomer servic

e

team for moreinformation+44(0)1793 6167

00

Whether you need batch prototype samples to large production

orders, we can help design the solution. In a crisis we can also make

viable suggestions for alternative products. If you need additional

support for your engineering department, we can help design a

solution that will be deliverable in terms of timescale and final cost.

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Explosion Proof ConnectorsATEX and IECex-approved for Zone 1-rated (Europe) and Class I, Division II (USA) hazardous

applications (IECex 60079)

We can supply a range of compatable products machined from high tensile strength aluminium and plated

with a hard anodic coating to 40 points on rockwell C scale, or stainless steel to withstand the most extreme

environments. These are compatible with standard copper contacts, as well as coax and fibre optic

contacts to allow power and signal to pass through Hazardous rated areas.

A key criteria of our selected ranges is their smaller package size than most hazardous area connectors

and offers a complete line of inserts and arrangements.

The mating system has a double lead ACME threaded coupling system to ensure positive mating which

allows for self cleaning mating action and does not clog with ice, mud, snow or sand. Inserts are compatible

with the D38999 series III layouts up to shell size 21.

The cable gland terminations allow for use of various types of cable in the construction such as

unarmoured, armoured and sheathed cable. Flexible cables such as SOOW-A,W, G-GC and DLO can also

be used. Rated IP68-8Communication systems•

Sensor systems (in camera’s etc)•

Structural health monitoring (in strain gauges and systems that•

monitor for vital changes in temperature and pressure)

Defensive-aid sub systems (detecting and deploying missiles )•

Databuses and missions systems.•

Advantages of Fibre Optic over Copper are:

Higher bandwidth over longer distances • Transmission

security • Low loss • Immmunity to Electromagnetic

Interference • Lightweight and miniature • Non-

Conductive • Future proof

A multiway

planar array

filter device,

assembled

with its ferrite

elements and connector

contacts, ready for insertion into the

connector shell. The flexible design allows

for different capacitive values on individual

pins as well as the integration of hybrid

contacts such as optical termini.

EMI/EMP Filter ConnectorsCustom and standard filter connectors, compliant with the key MIL-DTL standards including those

in this product guide overview

IS-Rayfast is able to provide an extensive range of standard and customised connectors including EMC

and EMP protection for sensitive circuits for a wide range of applications within Military and Civil Aerospace,

C4i systems, Vetronics, Industrial and Power Distribution Systems.

Filter connector designs may be optimised for use in a wide range of application environments including

avionic systems, down hole drilling and logging devices, network centric ground warfare systems, plus

missile and satellite/space applications. Common electrical customisations include

unique capacitance values on individual lines, electrostatic discharge designs,

transient voltage suppression diodes, grounded holes and feed-throughs, as

well as the incorporation of customer-specified filter

architectures including Pi, C, L-C and T configurations.

Certain electrical criteria are useful to know when

discussing your initial requirements with us, including the;

• Capacitance Value

• Working & Surge Voltage

• Dielectric Withstand Voltage

• Insulation Resistance

• Transient Protection

Non standard packaging options in EMI/EMP filter

connectors include the following:

Hybrid Fibre Optic & Electrical contacts • Dual-Flange PCB Mount Designs • Composite

Thermoplastic Shell Materials • Variable Length PCB Tails • Piggy-Back Crimp Contacts •

EMI Grounding Fingers and gaskets • In-Line, Feed-Through, Plug and Other Shell Styles.

Design Services & Special Interconnect ProductsIS-Rayfast specialise in providing solutions. We can help improve or cost reduce an existing design,

or we can come up with a complete design based on your application. Our standard platforms make

it easy to come up with a proven design that is both cost effective and reliable.

We are seeing a greater demand for improved performance and quality levels from customers which has

resulted in a greater need for glass to metal sealing (GMS) technology, particuarly within the analysing and

sensing markets.

IS-Rayfast can help to source a “Total Service” by offering value added services including machining,

sealing and plating to military quality standards at competitive prices, either Stainless Steel, Titanium or

Inconel.

Our proven product development process ensures a smooth transition from concept to production. Initially

our team of technical specialists and field sales engineers will liaise with you to define the projects

requirements and specifications. We discuss ALL the options with our various supply partners to obtain

the optimum solution for your particular situation and jointly draw up a design verification, to ensure that

the proper procedures, fixtures, training and test equipment are in place to build your product. We can

then with the input of the quality control departments ramp-up to full production.

Quadrax Power ConnectorsHundreds of unique Quadrax high-speed connector options.

We can offer our customers through our partners probably the largest

range of Quadrax connectors available, with very attractive minimum

order quantities and lead times.

High speed Quadrax contacts consist of an outer contact with four

contacts spaced in two 100 or 150 Ohm impedance differential pairs.

Both contacts when used in MIL-DTL-38999 Seriess III, MIL-DTL-5015

and ARINC type connectors, provide an excelllent alternative for harsh

environment applications such as:

Ethernet 100 Base-T-100 Ohm • Gigabit Ethernet 1000 Base-T-100 Ohm, 1000 Base-CX, 150

Ohm • Fibre Channel-150 Ohm, 1G/2G • IEEE 1394B FireWire-110 Ohm • Serial FPDP

Applications, 2.5Gbps • SCSI-2,3.2Gbps

Differential Twinax and Quadrax contact options include:

Quadrax Power Contacts • Crimp or printed circuit board termination • Established designs to

accomodate a variety of cable types and gauges • Incorporation of Quadrax contacts into

ground plane connectors.

Ground Plane connectors have conductive inserts that ground the outer conductor of the contact to the

shell of the connector. Accomodate size 8 and 12 shielded contacts, of which size 8 can be a Quadrax

type.

Data Interconnect for Defence and Industrial ApplicationsThere is an extensive selection of high performance Ethernet connectors and cable assemblies

capable of supporting up to 10 Gigabit, that are suitable for Military and industrial applications.

Developed in response to demand, the MIL spec high speed RJ45 (and USB) connector systems

incorporate ABAC (MIL-DTL-38999 series III) or ABO5 (MIL-DTL-26482) derived metal shells with full 360º

EMC, IP68 sealing and mechanical protection. Across the range, all-metal housings ensure the toughest

thermal resiliance, enabling operation from -40ºC to +120ºC. Additionally, the ultra-high speed connector,

ABAC R6A, enables data rates up to 10Gbit/s for CAT6e mil-spec networks.


for Soldier Communication Equipment

SPECIAL APPLICATIONSruggedised data connectors

SPECIAL APPLICATIONSruggedised data connectors

Ethernet RJ45

High Speed RJ45 and Quadrax

Da

ta

Ruggedised USB

15 16

EMI Filtered Comms

Features

Quick release breakaway

Multiple keying options

Brass base metal

Integral backshell

Benefits

Fast, safe, connect and disconnect.

Release in snagging situations.

Reduced interconnection damage.

Five keying options to prevent mis-mating.

Robust.

Wear resistant.

Crush resistant.

360º screening.

No special tooling or training required.

Quick termination.

Common plug connectorSuitable for mating with both snatch and latch style

receptacles.

Latched version Allowing connectors to be locked together.

2000 plus matings

Mating durability four times greater than MIL-DTL

standard bayonet and thread coupling connectors.

Increased connector life before repalcement.

Gigabit ethernet and USB 2.0 compatible Suitable for computers, LAN switches and routers.

Shell Sizes

06, 07 and 08

Technology Conformance to High Speed USB 2.0 specification.

Mating Options Two versions available; push-pull snatch style, or latch with coupling ring.

Mechanical Backshell for strain reief and screen termination, 2000 mating cycles, 5 keyring options,

miniature footprint.<16mm Ø.

Compatability Intermateable with standard COTS Micro-USB plug connectors.

Environmental Temperature range -55ºC to +85ºC, IP68 sealing 1 hr @ 2m immersion, 1000hrs salt spray,

vibration 10g sine, 30hrs, 5Khz.

QUADRAX

Da

ta

Data Interconnect for Industrial ApplicationsIP67 Sealed, Metal or Plastic Shell ODVA-Compliant Industrial Ethernet Connectors. For use in harsh

environments, features a quick-connect bayonet coupling system to IEC 61076-3-106 Variant 1.

The 8 position plug and receptacle connectors are available either shielded or unshielded, with end caps

additionally available to protect unmated connectors. The

quick-turn bayonet coupling and positive locking ring help

provide reliable connections under the harshest conditions. The

HBT sealing gaskets are UV resistant. The connectors have an

operating temperature range from -40ºC to +85ºC.

Suitable for EtherNet/IP, DeviceNet and ControlNet applications.

Choose between thermoplastic and metal shells to suit your

application.

D38999 Series III

D5015 & VG95234

IndustrialVersatile shell materials: available in Aluminium, Composite,•

Stainless Steel, Bronze and Titanium

Different finishes are available including RoHS Compliant•

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SPOKE DESIGN

Ruggedised Micro-USB ConnectorNew generation Micro-USB interface designed especially for harsh environment communication

systems. Combines the benefits of a rugged and IP68 sealed connector with the recognised

technology of Micro-USB

The specification of the Micro-USB supports the current USB ON-The-Go (OTG) supplement and provides

total mobile interconnectivity by enabling portable devices to communicate directly with each other without

the need for a host computer.

The shell design ensures blind-mating of receptacle to plug and IP68 sealing in both mated and unmated

condirions, which eliminates ingress of moisture and dust through the interface. Available in various RoHS

compliant finishes the Micro-USB connector series are suitable for both defence and industrial applications.

AlternativesRuggedised standard USB and Mini-USB connectors are also available, within

MIL standard shells and rugged industrial shells.

Please contact us for more information and requirements, because if it doesn’t

exist today we can advise as to wether it would be possible to create a bespoke

design to suit your requirements.

Soldier Communications ConnectorsIntended for harsh environment applications and used extensively in soldier communications, the

Terrapin is a miniature series of circular push-pull connectors. With a rugged shells , offering superior

EMC performance and high environmental sealing to IP68. Resilient in severe battlefield situations

the RoHS compliant black-silver plating is both low lustre and corrosion resistant. Featuring an

optional locking mechaism, multiple shell sizes with up to 37 contact and suitability for overmoulding.

The miniature size and footprint of battlefield connectors mean it is widely used for applications where

space is at a premium i.e. hand-held devices and highly connectorised equipment. Embedding the filtering

within the connector eliminates the need for ‘dirty’ areas or additional filter boards and circuitry within the

box, resulting in weight and space savingsIn-Field terminable connectors also available

Also available is a wide range of field terminable connectors that allow you to transform a standard infocom

cordset into a rugged waterproof connector for harsh environments.

A full range of versions depending on the application•

No cabling operation nor measurement required after installation.•

*Sealing: IP67 (1m immersion, up to 30 minutes).•

Shock, vibration and traction resistant.•

Mechanical coding/polarisation•

No cabling or tool required•

EMI protection•MIL-DTL-26482

MIL-DTL-38999

Industrial


Overview of Hermetics

HERMETIC

HERMETIC INTER-CONNECTSconnectors and feedthroughs

WELD MOUNT FLANGE MOUNT O-RING SEALING

FEED THROUGH STYLES

Feed throughs are available in standard and bespoke shell styles designed for flange and weld mounting as well as ‘O’ ring

sealing. Other styles or specials are available dependent on customer requirements, this extends to pressure variants which

require individual glass beads. For normal applications feed throughs would be supplied with a continuous glass preform.

Contact layouts between 1 and 155 ways are commonly available, however, specials are designed and manufactured to

specific customer requirements.

SQUARE FLANGE RECEPTACLE WELD MOUNT RECEPTACLE JAM NUT RECEPTACLE

Outlined below are some general guidelines for selecting the product and information that would be useful for us to source

the right product for your particular application.

Interface Variations

MIL-DTL-5015

MIL-DTL-26482

MIL-DTL-38999

M12

Bespoke

Connector.

Feedthrough.

Special.

Electroless Nickel.

Nickel.

Passivated.

Cadmium Olive Drab.

Black Zinc.

Please refer to applicable

MIL insert layout tables,

or Bespoke

Solder Bucket.

Keyways.

Contact Termination

Styles & Material.

Interface Standard Type Shell Finish Insert Arrangements Special Features

HERMETIC INTER-CONNECTSconnectors and feedthroughs

In Matched Seal hermetics, thermal

expansion of the glass and metal materials are

similar. The stress in the glass is therfore relatively

small - an important factor with the design of

rectangular connectors, due to the varying degrees of

stress on the glass caused by the shape.

With Mismatched (compression) Seals,

the thermal expansion and or contraction

of the metal exceeds that of the glass.

During cooling, the metal

contracts into the already

solidifying glass to form an

extremely robust

compression bond. Seal

produced can be reliable to

pressures as high as

14,000 psi (1000 bar), the

MIL-DTL-38999 for

example.

Glass Insulator

Metal Shell

Typical shellmaterials includeInconel, StainlessSteel, Carbon Steel,Titanium, Aluminiumand NickelAluminium Bronze.

These connectors are miniature

threaded and hermitcally

sealed, designed to meet and

exceed the mechanical and

environmental requirements

IEC-61076-2-101 with fixed pin

contacts, fused into a glass

dielectric insert. Shell is

manufactured from Stainless

Steel and are designed to exceed IP68 in an unmated state.

These connectors have a wide variety of applications and can

be found in most industry sectors, such as transport and

instrumentation, for use with proximity switches, sensors and

interconnection in harsh enviromental conditions.

M12

CONNECTOR FEEDTHROUGH

JAM NUT RECEPTACLE (Rear thread)

We a

lso

do

He

rme

ticH

erm

etic

17 18

MIL 38999

MIL 26482

MIL 5015

MIL 26500

M12 • M23 • M40

Pseudo Hermetic

EN2997

CALL US+44(0)1793 616700

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SPOKE DESIGN

Hermetic Connectors & FeedthroughsWe offer a wide range of hermetic connectors for all the popular miltary specifications in use today

including those mentioned in this catalogue but not limited to, as our sales team will be happy to

source a solution for you.

Hermetic inter-connects are used in a wide variety of applications across sectors as diverse as industrial,

military, marine, medical and aerospace. IS-Rayfast will work in close partnership with our clients to design

and develop bespoke connectors where required, or select from our standard range. Many of the

connectors supplied by the company are ‘mission critical’; therefore absolute precision, total quality and

attention to detail are in every part.

Hermetic connectors are custom designed to match existing or specialist mounting requirements and meet

the most stringent demands, including military standards. Where space is at a premium, alternative

solutions to conventional connectors can often be developed. Glass-to-metal seals are typically designed

as ‘compression’ or ‘matched’ seals and subject to the application requirements, can be supplied as single

glass inserts, or as individual glass beads for high pressure applications.

Ceramic feedthroughs, with housing and pin contacts available in a variety of materials, have been

developed to operate in environments as diverse as cryogenics processes, or at temperatures of up to

1100°C.

Hermetic connectors are designed for use in pressurised or severe environmental applications, with typical

environments including geophysical, medical and military aerospace. The requirement for an hermetic

connectors was orginally driven by military electronic applications, such as in the Tactical Unmanned Aerial

Vehicle for example . Hermeticity is generally defined as the state or condition of being air or gas tight. In

interconnect applications, “hermetic” refers to packaging technology designed to prevent gasses from

passing through pressure barriers via the connector, as it is important to prevent any moisture in the leaked

gas from condensing on inside the pressurised enclosure. The point at which moisture will condense is

called the “dew point’ or the precise moment when humidity, pressure, and temperature allows

condensation to form.

Depending on the style of the connector being produced (rectangular versus circular, for example) two

distinct categories of glass-seal hermetics may be specified. These are known as Matched and Mismatched

(or Compression) Seals

CONNECTOR STYLES

Hermetic interconnects are available in the standard popular shell styles as illustrated below, other variations may be available,

for more details on these and additional options please give us a call.

Feature

Protection degree IEC 60529

Temperature range

Contact resistance

Typical

IP67


≤15 mΩ

Cable outlet 2.5mm to 8mm

Wire gauge 0.25mm2 (max. AWG 24)

Mechanical operation >5000 mating cycles

Circular Miniature Connectors C16sThe C16 series are designed to meet the high requirements of industrial applications under harsh

environments. Ruggedised, screw coupling, plastic bodied housing.

The C16-1/16-3 Series connectors are used in a wide variety of industries and equipment. Some of these

include industrial machines and controls, data processing, instrumentation and test equipment, medical

devices, telecommunications network and equipment, plus outdoor and marine applications.

The range includes versions with screw, solder and crimp terminations.


Circular Push-Pull ConnectorsPrecision modular connectors to suit your application

High quality push-pull connectors are found in a variety of challenging application environments including

military, medical, industrial control, test and measurement, audio-video and telecommunications. The

modular design provides multiple combinations of connectors from miniature Ø 2mm to 50mm.

The attractive high tech design of these connectors enhances any front panel display contributing to the

design aesthetic and premium quality feel. Whilst the outer metallic shell offers screen efficiency superior

to that of standard screened cables and most other industrial connectors. Standard examples include;

Miniature Circular

INDUSTRIALconnectors

INDUSTRIALconnectors

C16-1 / C16-3 Series

Feature by Model C16-1

Protection degree IEC 60529 IP67

C16-3

IP65

Contact arrangements 3 + PE and 6 + PEShell size 1: 8+PE, 14+PE, 17+PE

Shell size 2: 5+PE, 12+PE, 14+PE, 19+PE

Colour coding Yes Yes

Connection method Threaded coupling Bayonet coupling with lock

Miniature Circular

C91 A/B/D Series Circular Miniature Connectors C91sThese connectors are designed and produced in conformity with the low voltage directive

(73/23/EWG) and DIN EN 61984 (VDE 0627); IEC 60664-1 (VDE 0110-1) and IEC 60529.

The C91 Series connectors are used in a wide variety of industries and equipment. Some of these include

industrial machines and controls, data processing, instrumentation and test equipment, medical devices,

telecommunications network and equipment, plus outdoor and marine applications.

Male and female cable connectors - Straight or right angled, with solder and crimp connections

Male and female receptacles - Panel or PCB mount, with dip solder contacts and crimp connections

Feature by Model C 091 B

Protection degree IEC 60529 IP40

C 091 D

IP65 & IP67

Number of contacts 3 to 8, 12 and 14 3 to 8, 12 and 14

Coloured back shells optional Yes No

Connection method Plastic bayonet coupling

Metal screw coupling

DIN EN 60130-9

IEC 60130-9

C 091 A

IP40

2 to 8, 12 and 14

Yes

Metal screw coupling

DIN EN 60130-9

IEC 60130-9

Back Shell material Plastic MetalPlastic

Sealing material - Neoprene-

Housing material Die cast, nickel plated Die cast, nickel platedCoupling ring brass, strain

relief, die cast, nickel-plated

Snap-in Connectors Circular Snap-in ConnectorsA wide range of snap-in connectors, available in various configerations, offering up to IP67

protection, internal strain relief, easy assembly and choice of optional colours

A comprehensive range is available of these snap in sub-miniature connectors are available, from IP40

rated products up to metal bodied versions. If this method could be a solution to your needs please give

us a call so we can advise on the best and most cost effective solution for you.

Feature by Model

Protection degree IEC 60529

Number of contacts

Temperature range

Contact resistance

Typical

IP67

3, 5, 8, 12


≤3 mΩ

Cable outlet 2.5mm to 8mm

Connections Solder

Mechanical operation >500 mating cycles

Watertight Miniature IP67 Rated Plastic Bodied Waterproof ConnectorsAlways watertight even in an unmated condition, with no need for a protective cap. Ideal for all types

of portable or hand held equipment. The efficiency of the design achieves a product life in excess of

5,000 mating cycles.

The connector is a panel-mount receptacle in which the electrical contacts are protected from water, dust

and foreign particles by a spring mounted lid when unmated. When the cable plug is mated, the contact

cover is pushed inside the receptacle body, the

contacts engage and the connector is locked with

a quarter turn of a bayonet-locking collar.

Connectors have eight gold-plated contacts, rated

to 2.0A and 175V in solder and dip-solder versions

catering for cable sizes from 2.5mm to 8.0mm in

diameter.

Watertight even when un-mated

Circular Push-Pull

Type B

Standard self-latching

multipole connectors with

alignment key.

Type S

Self-latching connectors with

stepped inserts for alignment

(of multupole version).

For cable Ø 1 to 25mm For cable Ø 1 to 30mm

Type K

Watertight self-latching

multipole, with alignment key

and rugged housing.

For cable Ø 1 to 23mm

Type E

As type K but with stepped

inserts for multipole version.

For cable Ø 1 to 30mm

IP50 IP50 IP66 / IP68 IP66 / IP68

Shielding:

> 75dB @ 10Mhz

> 40dB @ 1 Ghz

Shielding:

> 75dB @ 10Mhz

> 40dB @ 1 Ghz

Shielding:

> 95dB @ 10Mhz

> 80dB @ 1 Ghz

Shielding:

> 95dB @ 10Mhz

> 80dB @ 1 Ghz

19 20

Ind

ustr

ial

PowerLock High Current Single Pole ConnectorsThe PowerLock series for field installable power distributon systems.

PowerLock is available in four standard formats which allow complete hook up through the standard daisy

chain principle. There are two Source connectors, one for panel mounting and one for cable attachment.

These are identified as panel source and Line Source. The other two types are Drain connectors, which

are identified as Panel Drain and Line Drain

Typical applications for PowerLock include three phase motors, generators, load banks, lighting distribution

panels and in -house supplies.

400 Amp and 660 Amp - Continuous

current ratings

Colour coded and keyed to ensure

correct coupling

Sealed to IP67 when mated ratings

IP2X Finger protected contacts for safer

handlingCALL US+

44(0)1793 616700

BE

SPOKE DESIGN

Ind

ustria

l

Aerospace & Spin-Lok

Backshell Adaptors

Standard fixed and Spin-Lok

variable angle backshell that

enables 45º & 90º cable

terminations.

Cable Bonding Adhesives

Protective Sleeving Relays Switches

Heatshrink Tube

Identification

Micro MouldedWire

Protective Edging

Backshells and Assemblies

Accessoriescomplete solution

Comprehensive Solutionsto simplify your life

Catalogue and Specifications


SPECIFICATIONS

ACCESSORIES

MIL-DTL-27599

MIL-DTL-38999

MIL-DTL-5015

MIL-DTL-55116

MIL-DTL-55181

MIL-DTL-83513

MIL-DTL-83723

MIL-DTL-83733

MIL-I-23053

MIL-I-81969

MIL-T-29504

MIL-T-81714

MS18235

MS18236

MS18237

MS18238

MS24256

MS25010

MS25041

MS25042

MS25043

MS25183

MS25251

MS25256

MS25257

162GB

164GB

62IP

62GB Series

602GB

AEX

ARINC600

ATEX

BACC10

BACC45

BACC47

BACC63

BACC65

BACC66

BKA

BS 9522 F00 17

C091

C146

C16-3

CECC 75.201.001

CECC 75.201.002

CECC 75.201.003

CIR

DIN 72585

DIN EN 61984

ECO MATE

ECTA

EN60079-0

EN0079-1

EN60601-1

IEC0664-1

IEC60529

IECex

JN1003

Mighty Mouse

MIL-A-55339

MIL-C-10544

MIL-C-25520

MIL-C-28840

MIL-C-39012

MIL-C-39029

MIL-C-81511

MIL-C-81659

MIL-C-85049

MIL-C-85528

MIL-DTL-22992

MIL-DTL-24308

MIL-DTL-25955

MIL-DTL-26482

MIL-DTL-26500

MS25331

MS25446

MS27291

MS27466

MS27467

MS27468

MS27485

MS27486

MS27488

MS27505

MS27656

MS3057

MS3100 Series

MS3109 Series

MS3110 Series

MS3117 Series

MS3120 Series

MS3180 Series

MS3191

MS3410 Series

MS3420

MS3440 Series

MS3450

MS3470

MS90376

MS90455

NAS1744

NAS1745

NAS1746

NF F 61030

PPM

PT (Pattern 105)

SCE/TERRAPIN

SS-*P or SS-*S

UG

VDE 0110-1

VDE0627

VG 95 234

VG95 324

VG 95 328

VG 95 343

VG 96 912

VG 96 929

WILD CAT

WK,GK,SK,NK,

FK, or LK

Comprehensive Product PortfolioCATALOGUEConnector Adaptors & Backshell Assemblies

Backshell Adaptors

A range of popular styles in

straight or 90º form, to

accomodate heat shrink

boots, EMC screen

termination.

Tinel-Lock® Adaptors

Memory metal securing ring

that shrinks uniformly when

heated, with spin-coupling.

For totally secure retention

of screening braid.

FlexiScreen & Hexashield

360º high performance EMC

shielding adaptors for each

individual cable. Field

repairable using heat shrink

rollback boot.

TCFS Assembly

Part pre-installed cable

feedthrough, for screened

and unscreened cable. Easy

to install in one piece.

KTKK Assembly

One part assemblies for

screened and unscreened

cables. Simply fasten and

shrink the rear moulded

part.

Moulded Parts

Based on heat-shrink

technology, moulded parts &

shapes are available in a

vast range of configerations.

Heatshrink Feedthroughs

A range of cable entry seals

available in Polyolefin and

modified Elastomer. Offers

strain relief and pressure

seal.

IS-Rayfast

distribute a

wide variety of

accessories to

customise your

connection

products and

meet specific

requirements.

Our

accessories

include cable

ties, insulation

products, heat

shrink

adaptors,

extender

backshells,

self-locking

endbellls, dust

caps,

screening braid

and much

more.

If you need

help, contact

our engineering

team.

Bandstrap Adaptors

Features corrosion resistant

steel band to terminate the

cable screen, by means of

specified hand tool.

Dust Caps

Wide range of dust caps

and blanking plugs to suit all

types of circular MIL

connectors.

Protective Tubing

Extensive range of heat

shrinkable tubing, sleeving

and solid conduit for

protecting cables and joints.

Tools

A wide range and variety of

stripping, crimping and

application tools, is available

please contact.

The current

IS-Rayfast

product

portfolio has

been carefully

selected to

meet the wide

diversity of

customer

requirements,

as well as

meeting

international

standards and

specifications.

This product

guide is just an

overview for

some of what

we can offer,

Listed here are

the various

connector

specifications

that we can

supply against.

21 22

Military and Industrial Connector Specifications

Key Supplier Partners

Amphenol • AB Connectors • Axon • Binder • Brand-Rex • Breyden •

Cotronics • Device Technologies • Federal-Mogul SPG • Fischer •

Glenair • Harting • Ideal Industries • ITT Cannon • Kemtron • Lapp

Muller • Lemo • Martec • ODU • OTTO Switches • Panduit • Polamco

• Souriau • Sunbank • TE Connectivity • TE DeutschCALL US+

44(0)1793 616700

BE

SPOKE DESIGN

Download - What’s in this Product Guide€¦ · A = Cadmium plated nickel base • B= Olive drab cadmium plated nickel base • F= Electroless nickel • C= Anodic coating (Alumite) • E=

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