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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.
DESIGN..it
1
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
Crimp, PCB Solder, Thermocouple
& 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
38
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I/II38999 Series I
43
Commercial
grade
connectors in
this series
are also
available
please call us
for details.
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I/II
CALL US+44(0)1793 616700
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SPOKE DESIGN
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
Wire Gauge Range (AWG) 28 to 12
Number of Circuits 3 to 128
Sealed Against Water Jets Yes
EMI/RFI-Shielding Yes
Style Circular
Operating Voltage/DWV 23000 Vac max
Current Rating (Amps) 1.5 to 46 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) 500/1500
Shock Test (g’s) 300
Vibration Test (grms) 60
Shell MaterialAluminium Alloy, Stainless steel, Marine nickel
Aluminium or Bronze.
Shell PlatingCadmium, Electroless Nickel, Anodised or
Aluminium Bronze
Positive Shell Polarization Yes
Insert Polarization Options Yes
User Polarization No
Standards/Associated Specs. MIL-DTL-38999 Series III
Contact Plating Gold
Contact Style Crimp, PCB Solder, Thermocouple & Coax
Fibre Optic - Option •
Operating Temperature oC -55oC to +200oC max
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
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
First-Mate Last Break n/a n/a
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.
Shell Size - Insert Arrangements
Contact us for seperate MIL arrangement charts.
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
38
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III3
89
99
SIII
38999 Series III
65
38999 (III) Composite
CALL US+44(0)1793 616700
BE
SPOKE DESIGN
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
38
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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
BE
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
Wire Gauge Range (AWG) 24 to 12
Number of Circuits 1 to 61
Sealed Against Water Jets Yes
EMI/RFI-Shielding Yes
Description and Technical Specifications
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
Power & Signal on Same Layout Yes
Operating Temperature oF -67oF to +257oF
Submersible Yes
Individual Wire Sealing Yes
Cable Jacket Sealing Yes
Life in Mating Cycles (min) 500
Shock Test (g’s) 50
Vibration Test (grms) 15
Shell Material Aluminium Alloy
Shell PlatingCadmium, Anodised, Electroless
Nickel & Zinc Alloy
Positive Shell Polarization Yes
Insert Polarization Options Yes
User Polarization No
Standards/Associated Specs. MIL-DTL-2648
Contact Plating Gold
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
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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
Crimp, PCB Solder, Thermocouple
& 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
Contact us for seperate MIL arrangement charts.
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.
Please note that actual product appearance may vary
Please note that actual product appearance may vary
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
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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
Wire Gauge Range (AWG) 26 to 0
Number of Circuits 1 to 85
Sealed Against Water Jets Yes
EMI/RFI-Shielding Yes
Style Circular
Operating Voltage/DWV 3000 Vac max
Current Rating (Amps) 150 to 245 max
Power & Signal on Same Layout Yes
Operating Temperature oF -67oF to +257oF max
Submersible Yes
Individual Wire Sealing Yes
Cable Jacket Sealing Yes
Life in Mating Cycles (min) 100
Shock Test (g’s) 50
Vibration Test (grms) 15
Shell Material Aluminium Alloy
Shell PlatingCadmium, Electroless Nickel, Zinc
Alloy or Anodised
Positive Shell Polarization Yes
Insert Polarization Options Yes
User Polarization No
Standards/Associated Specs. MIL-DTL-5015
Contact Plating Silver or Gold
Contact Style Crimp, Solder, PCB Solder,
Fibre Optic - Option •
Operating Temperature oC -55oC to +125oC max
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
First-Mate Last Break n/a n/a
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.
Shell Size - Insert Arrangements
Contact us for seperate MIL arrangement charts.
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
Description and Technical Specifications
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
Shell Size - Insert Arrangements
Contact us for seperate MIL arrangement charts.
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
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+
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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.
CALL US+44(0)1793 616700
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SPOKE DESIGN
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.
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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•
CALL US+44(0)1793 616700
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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
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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
-25ºC to +85ºC max
≤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.
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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
-40ºC to +85ºC max
≤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
Tel: +44(0) 1793 616700 . [email protected] more information: www.is-rayfast.com
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
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SPOKE DESIGN