Features and Application

MIL-DTL-38999 Series III is the newest cylindrical connector designed for highest performance capabilities used in both general purpose and severe environment applications.

These connectors feature an improved “one-turn” coupling system, utilizing self-locking acme thread. Acme threads provide coupling durability, while thicker wall sections and greater coupling surface area improve strength and shock resistance. Blunting of the threads on both receptacle and plug coupling nut eliminates cross threading.

Elongated mounting holes permit the Series III Connector to intermount with various existing Mil-spec flange mounted receptacles, giving it a design replacement advantage.

Wall mount receptacle, jam nut receptacle and straight self-locking RFI plug are offered in 9 shell sizes and 54 insert arrangements utilizing M39029 contacts in sizes 22D, 20, 16, 12, 10 power and 8 twinax.

These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel and olive drab cadmium. Other finishes such as anodic and zinc cobalt are available upon request to commercial callouts only. In addition, we offer stainless steel shells (both passivated and electro-deposited nickel plated) with firewall inserts, and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only).

MIL-STD-1560 Insert Arrangements – Series III connectors use insert patterns and contacts common to Series I, making for an easy transition from bayonet to triple-lead, acme-thread, self-locking coupling.

Metal-to-Metal Bottoming – This feature precludes relative shell-to-shell motion, which may result in ordinary connector wear and moisture entrapment.

Lockwiring Eliminated – Self-locking quick coupling plug eliminates the need for lockwiring.

Firewall Capability - Stainless steel shells in both K and S firewall classes are offered.

Universal I/R Tool – A single, expendable plastic tool is used for both insertion and removal of contacts.

Scoop-Proof Design – Recessed pins in elongated shells minimize the possibility for contact damage. In a blind mating application, mating shells cannot “scoop” the pins, and cause a shorting or bending of contacts.

Closed-Entry Socket Insert – Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets.

Interfacial Pin Insert Seal – Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools.

Elastomer Wire Sealing Grommet – Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector.

Superior Contact Stability – Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact.

Metric Accessory Thread – Metric thread results in additional wall thickness giving greater strength and shock resistance.

Operating Temperature Range
Classes F, K, S and BZ*: -65°C to +200°C (-85°F to +392°F)
Classes W and ZC*: -65°C to +175°C (-85°F to +347°F)

Material and Finish Data (Class)
F – aluminum shell, electroless nickel finish
K – stainless steel shell, passivated, firewall
S – stainless steel shell, electrodeposited nickel, firewall
W– aluminum shell, olive drab cadmium over nickel base

Corrosion Resistance
Classes K,W, BZ* and ZC* withstand 500-hour salt spray.
Classes F and S withstand 48-hour salt spray.

Durability
Minimum of 500 mating cycles.

Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808,
MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol
25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5),
SAE-AMS1424 Type I, and other solvents and cleaning agents.

Shielding Effectiveness
RFI and EMI attenuation at the specified frequencies meet
the requirements of MIL-DTL-38999.
• RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture.

• EMI shielding effectiveness is measured at the interface of mated connectors and tested by the mode-stirred technique specified in method 3008 of MIL-STD-1344.

Environmental Seal
Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-38999.

Shell-to-Shell Conductivity
Maximum potential drop shall not exceed:
• Classes F and S = 1.0 millivolt.
• Class W = 2.5 millivolts, Class K = 10.0 millivolts

Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, nor shall there be a current interruption longer than one microsecond when subjected to the following:

Shock
Pulse of approximate half sine wave of 300 G ±15 percent magnitude with duration of 3±1 milliseconds applied in three axes.

High Impact Shock
When mounted as specified in MIL-S-901, grade A, a drop of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to connector in three axes, totaling nine impacts.

Vibration
Wired and mated connectors withstand the following vibration levels:
• Sine vibration where connector samples with simulated accessory load are subjected to simple harmonic motion from 10 to 2,000 Hz in three mutually perpendicular axes, in 20 minute sweeps, for 12 hours in each axis at velocity of 254 mm/sec from 10-50 Hz, displacement of 1.5 mm from 50-140Hz and acceleration of 60G from 140-2,000Hz.
• Random Vibration per MIL-STD-1344, method 205, test condition V at ambient temperature and test condition VI, Letter “J” at elevated temperature.