Connection Te chnologies
8D Series
MIL-DTL-38999 Series III
8D Series
MIL-DTL-38999 Series III
3
© 2012 - SOURIAU
Contents
• A universal product platform ...............................................
• 8D Series - Presentation .......................................................
• Product overview ......................................................................
• A superior concept ..................................................................
• A performing MIL standard connector design ............
• Technical features & benets .............................................
• Contact layouts .........................................................................
• Contact layouts (matrix) .........................................................
• Aluminum Series
Part numbers ................................................................
Dimensions ...................................................................
Backshells ......................................................................
Dummy receptacle .....................................................
Caps ................................................................................
Connectors weight ......................................................
• Composite Series
Part numbers ................................................................
Dimensions ...................................................................
Backshells ......................................................................
Connectors weight ......................................................
• Stainless Steel Series
Part numbers ................................................................
Dimensions ...................................................................
Connectors weight ......................................................
• Titanium Series
Part numbers ................................................................
Dimensions ...................................................................
Connectors weight ......................................................
• Bronze Series
Part numbers ................................................................
Dimensions ...................................................................
Backshells ......................................................................
Dummy receptacle .....................................................
Caps ................................................................................
• Crimp contacts ..........................................................................
• Straight PC tail contacts ........................................................
• Coaxial contacts #12 ..............................................................
• Solder cup ...................................................................................
06
07
08
09
10
11
13
18
22
24
27
33
33
35
36
38
40
41
42
44
47
48
49
52
54
55
58
62
63
66
68
69
69
• Crimp contacts: 1500 mating ...............................................
• Wire wrap contacts ...................................................................
• Quadrax #8 contacts ................................................................
• Thermocouple contacts ...........................................................
• Dummy contacts ........................................................................
• Filler plugs .....................................................................................
• Wiring instruction .......................................................................
• Crimping tools .............................................................................
• Insertion and extraction tools ..............................................
• Gaskets ..........................................................................................
• Plastic protective caps .............................................................
• Orientations .................................................................................
• Panel cut-out ................................................................................
• Coordinates for straight PC tail terminations .................
• Reinforced sealing Series .......................................................
• Hermetic Series ..........................................................................
• Integrated clinch nuts ..............................................................
• Double ange ..............................................................................
• PCB contacts without shoulder ............................................
• High density .................................................................................
• Quadrax contacts .......................................................................
• Power contacts ............................................................................
• High power contacts .................................................................
• Optical ELIO® Contacts ............................................................
• Coaxial BMA contacts ..............................................................
• RJ45/USB Series .......................................................................
• micro38999 .................................................................................
• 8D hermetic ELIO® feedthrough ..........................................
• Rack & panel ................................................................................
• 230V connector .......................................................................
• 8D8 / 8D9 Series .......................................................................
• 8DB bulkhead feedthrough ...................................................
• 8PS Series .....................................................................................
• 8D hermetic aluminum power & signal ............................
• 8D36 lanyard release ..............................................................
• 8TFD lter connector ..............................................................
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98
102
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12 3
13 0
13 4
14 2
14 2
14 3
14 3
14 4
14 4
14 5
14 5
14 6
14 6
Overview
Common Section
Standard Series
Derived Series
Range Extension
8D Series
Overview
8D Series
A universal product platform .......................................................................................................
8D Series - Presentation ...............................................................................................................
Product overview .............................................................................................................................
A superior concept .........................................................................................................................
A performing MIL standard connector design ......................................................................
Technical features & benefits .......................................................................................................
Contact layouts ................................................................................................................................
Contact layouts (matrix) .................................................................................................................
06
07
08
09
10
11
13
18
8D Series
MIL-DTL-38999 Series III
6© 2012 - SOURIAU
A universal product platform: VG96912 & JN1003
8ST Series
High density - same layouts as 38999 Series I
Lightweight version of Series I
Scoop proof, bayonet coupling
Method of mounting: screws or jam nut
Shell: Aluminum alloy
Plating: olive green cadmium or nickel
VG 96912 German specification
JN 1003 Typhoon specification
A universal product platform: MIL-DTL-38999
38999 Series II: 8T Series
Short version of MIL-DTL-38999 Series I
Low profile = lightweight
High density MIL-spec circular (1980’s)
Non-scoop proof, bayonet coupling
Method of mounting: screws or jam nut
Shell: Aluminum alloy
Plating: cadmium, nickel, hard anodized
QPL approved
Numerous layouts
38999 Series I: 8LT Series
High density (#22D) MIL-spec circular (1980’s)
Scoop proof
Coupling system: Bayonet
Method of mounting: screws or jam nut
Shell: Aluminum alloy
Plating: olive green cadmium or nickel
QPL approved
Numerous layouts
8D Series
MIL-DTL-38999 Series III
7
© 2012 - SOURIAU
8D Series - Presentation
Since the early 80’s, Souriau is a major supplier of 38999 Series III, the screw-coupled
version of MIL-C-38999. Present on the main international programs, Souriau has
developed a range of products that meet the performance required in extreme
environments:
•Civilandmilitaryaeronautics
•Groundmilitary
•Industrial
•Marineandoffshore
This evolution of MIL-C-38999 allows:
•Ahighcontactdensityupto128contacts#22D
•Aquickscrewcouplingwithselflockingmechanism
•Highresistancetoharshenvironments(vibration,200°C)
Always at the cutting edge of innovation, Souriau’s teams have continuously improved
this range of connectors:
•Compositeversioninthe90’s(Itschoiceisrecommendedwhereverweightiscritical)
•Titaniumversionforweightsavingandveryhighandmechanicalresistance
•TodaySouriauremainsinnovativewithcadmiumfreeandRoHSsolutions.
In2009SouriauwasthersttobeQPLqualiedforZincNickelplating.
This product family is in accordance with MIL-DTL-38999 Series III, EN 3645, CECC
(standard for bronze shell), ... and also meets many customers’ standards (Rolls Royce,
ABS, BACC, ...)
38999 Series III: 8D Series
8D Series
MIL-DTL-38999 Series III
8© 2012 - SOURIAU
8D Series - Product overview
Standard Series
Derived Series
5 different materials
A full platform that matches any environment
Different platings (includingRoHS&Cadmiumfreeplatings)
Various possibilities of range extension
& shell variant from Standard Series
The only limit is your imagination: Consult us !
Quadrax
Power / High Power
Reinforced Sealing
Hermetic
RJ45/USB
Clinch Nut
Double Flange
Fuel Tank
ELIO
®
Fiber Optic
Coax BMA
8D Aluminum
8D Composite
8D Stainless Steel
8D Bronze
8D Titanium
8D Series
MIL-DTL-38999 Series III
9
© 2012 - SOURIAU
8D Series - A superior concept
A full range of contacts
Multi-contact technology provides versatile connectors
Various contact styles
Crimp Solder cup PC tails Wire wrap PCB contacts without shoulder
Common cavity for all #8 contacts
Signal transmission
High power transmission
Up to 850A
High speed data transmission
Quadrax
Twinax
Coax
ELIO
®
ber optic
Metallic clips
Unique clip retention technology
High performance contact retention system:
Insure high temperature withstanding
Provides superior strength in vibrations
Better retention characteristics than plastic clips
High performance sealing (IP67)
Each contact cavity is individually
sealed
Accessories available
Protective caps, backshells, tools, ...
8D Series
MIL-DTL-38999 Series III
10 © 2012 - SOURIAU
A performing MIL standard connector design
EMI Ring
360°teethforoptimumshield
continuity with accessories
Quick screw coupling
Fully shielded connector
Scoop proof connector
Noriskofdamagingthecontact
during the coupling operation
Visual mating indication
Red band visible = not correctly mated
Red band hidden = correctly mated
1 1/4 turn to mate
360°shielding
Shell to shell bottoming
= perfect shield continuity
Patented by Souriau
Connector will never unscrew
even under high vibration (44g)
Unique self locking mechanism
8D Series
MIL-DTL-38999 Series III
11
© 2012 - SOURIAU
Description
•Highcontactdensitylayoutsavailable
•Screwcoupling,Shellsizefrom9to25
•Contactprotection:100%Scoopproof
•Protectedbycadmium,nickel,green
zinccobaltorblackzincnickelplating
•RFI-EMIshieldingandshelltoshell
continuity
•Accessoriesavailable(protectivecaps,
backshells,etc…)
•Hermeticversions
•Highpowerupto850A
•Opticallayouts
•230Vlayoutsavailable(ABS22-19,ABS22-
20,ABS22-21&ABS22-22qualied)
Applications
•CivilandMilitaryAerospace
•MarineandOffshoreEquipment
•DefenseandGroundMilitary
•Industrial
Standards
•MIL-DTL-38999SeriesIII
•EN3645
•BACC63CT/CU;BACC63DB/DC
Technical features
Mechanical
• Shell:
Aluminum,composite,stainlesssteel,bronze
• Shell plating:
.Aluminumshell:
Cadmium olive drab (W)
Nickel(F)
Blackzincnickel(Z)
Greenzinccobalt(ZC)
.Compositeshell:
Cadmium olive drab (J)
Nickel(M)
Without plating (X)
.Stainlesssteelshell:
Passivated (K)
Nickel(S)
.Titaniumshell:
Without plating (TT)
Nickel(TF)
.Bronzeshell:
Without plating
• Insulator: Thermoplastic
• Grommet and interfacial seal:
Silicone elastomer
• Contacts: Copper alloy
• Contacts plating: Goldovernickelplated
• Endurance:
. 500 mating cycles all materials
. 1500 mating cycles with composite
connectors with specifics contacts
• Shock:
300g,3msaccordingEN2591-D2
method A
• Vibration:
.Sinus:
.10à2000Hz,3x12hrs
(60g,140-2000Hz)withT°cycling
.Random:
.50to2000Hz,2x8Hrs
(1g2/Hz,100-2000Hz)atT°max.
.25to2000Hz,2x8Hrs
(5g2/Hz,100-300Hz)atambiantT°
Test with accessories in acc with
EN2591-D3
• Contact retention:
Weight comparison
Exampleforaplugshellsize15
Materials Weight
Stainless
steel 58.80 g
Titanium 33.90 g
Aluminum 20.35 g
Composite 14.30 g
42%
lighter
40%
lighter
30%
lighter
HD
Contacts size 22 20 16 12 8 4
Min force in N 44 67 111 111 111 200
8D Series
MIL-DTL-38999 Series III
12 © 2012 - SOURIAU
Electrical
• Test voltage rating (Vrms)
• Contact resistance
• Insulation resistance:
5 000 MΩ(under500Vdc)
• Contact rating:
• Shell continuity
.Aluminumshell:
Cadmiumolivedrab(W):2.5mΩ
Nickel(F):1mΩ
Blackzincnickel(Z):2.5mΩ
Greenzinccobalt(ZC):2.5mΩ
.Compositeshell:
Cadmiumolivedrab(J):3mΩ
Nickel(M):3mΩ
.Stainlesssteelshell:
Passivated(K):10mΩ
Nickel(S):1mΩ
.Titaniumshell:
Withoutplating(TT):10mΩ
Nickel(TF):1mΩ
.Bronzeshell:
Withoutplating:5mΩ
• Shielding:
.Aluminumshell:
F:65dbat10GHz
Z,F&W:85dbat1GHz
Z&W:50dbat10GHz
ZC:Consultus
.Compositeshell:
J&M:85dbat1GHz
.Stainlesssteelshell:
K:45dbat10GHz
S:65dbat10GHz
.Titaniumshell:
TT:45dbat10GHz
TF:65dbat10GHz
.Bronzeshell:
85dbat10GHz
Climatics
• Temperature range:
.Aluminumshell:
W:-65°C+175°C
F:-65°C+200°C
Z:-65°C+200°C
ZC:-65°C+175°C
.Compositeshell:
J:-65°C+175°C
M:-65°C+200°C
Withoutplating(X):-65°C+17
.Stainlesssteelshell:
K:-65°C+200°C
S:-65°C+200°C
.Titaniumshell:
TT:-65°C+200°C
TF:-65°C+200°C
.Bronzeshell:
Withoutplating:-65°C+175°C
• Sealing:
Mated connectors meet altitude immersion
requirementsofMIL-DTL-38999.
• Salt spray:
.Aluminumshell:
W:500Hrs
F:48Hrs
Z:500Hrs
ZC:250Hrs
.Compositeshell:
J:2000Hrs
M:2000Hrs
Withoutplating(X):2000Hrs
.Stainlesssteelshell:
K:500Hrs
S:500Hrs
.Titaniumshell:
TT:500Hrs
TF:48Hrs
.Bronzeshell:
Withoutplating:500Hrs
Resistance to uids
• According to MIL-DTL-38999 standard
.Gasoline:JP5(OTANF44)
.Mineralhydraulicfluid:MIL-H-5606
(OTANH515)
.Synthetichydraulicfluid:Skydrol500B4
• LD4 (SAE AS 1241)
.Minerallubricating:MIL-L-7870A
(OTAN0142)
.Syntheticlubricating:MIL-L-23699
(OTAN0156),MIL-L-7808
.Cleaningfluid:MIL-DTL-25769diluted
.De-icingfluid:MIL-A-8243
.Extinguishingfluid:Chlorobrométhane
.Coolingfluid:Coolanol
Service sea level at 21000 m
R 400 N/A
M 1 300 800
N1 000 600
I 1 800 1 000
II 2 300 1 000
Contacts size 26 22 20 16 12 8 4
Resistance mΩ16 14.6 7. 3 3.8 3.5 3 2
Contacts size 26 22 20 16 12 8 4
Rating (A) 357. 5 13 23 45 80
8D Series
MIL-DTL-38999 Series III
13
© 2012 - SOURIAU
Contact layouts
Contact#26&#22D
Contact#20
Contact#16
Contact#12
Contact#10
Contact#8TwinaxorCoax - consult us
Contact#8Power
Contact#8Quadrax
Contact ELIO® (fiber optic)
Contact#4Power
ELIO® fiber optic Ethernet Quadrax HighDensitylayout
HD
35
6#22D
Service M
09 / A
1 Optical
position
01
1#8Quadrax
12
12#26
Service R
05 98
3#20
Service I
HD
01
1#12
Service II
all series
exceptedJVS
26
26#26
Service R
01 02 04 05 12 2202
1#8Coax
Service I
onlyforJVS
2#16
Service I
2 Optical
positions
4#20
Service I
5#20
Service I
1#12
Service II
onlyforJVS
4#22D
Service M
11 / B
35 80 98 9981
13#22D
Service M
1#8Twinax
Service I
1#8Quadrax 6#20
Service I
7#20
Service I
80
Spec 251
1#8Power
HD
8D Series
MIL-DTL-38999 Series III
14 © 2012 - SOURIAU
Contact layouts
ELIO® fiber optic Ethernet Quadrax HighDensitylayout
HD
13 / C
03 04 08 26 35 4304
3#16
Service I
4#16
Service I
4 Optical
positions
8#20
Service I
2#12
6#22D
Service M
22#22D
Service M
43#26
Service R
98
10#20
Service I
HD
15 / D
5#16
Service II
05
6 Optical
positions
1#16
14#20
Service I
18
18#20
Service I
19
19#20
Service I
35 97
37#22D
Service M
4#16
8#20
Service I
15
06
8D Series
MIL-DTL-38999 Series III
15
© 2012 - SOURIAU
Contact layouts
ELIO® fiber optic Ethernet Quadrax
19 / F
181108
8 Optical
positions
11#16
Service II
14#22D
4#8Twinax
Service M
18
Spec 251 28 32 35
14#22D
4#8Power
26#20
2#16
Service I
32#20
Service I
66#22D
Service M
14#22D
4#8Quadrax
84
H1
1#00
Highpower
17 / E
02 22
35 75
38#22D
1#8Twinax
Service M
2#12
2#8Twinax
Service M
55#22D
Service M
2#8Twinax
Service M
9982
2#12
2#8Quadrax
38#22D
1#8Quadrax
2#8Quadrax 2#16
21#20
Service I
818075
Spec 251
2#8Power
22
Spec 251 26
2#12
2#8Power
26#20
Service I
02
Spec 251 06 08
38#22D
1#8Power
6#12
Service I
8#16
Service II
4#12
16#22D
Service M
20
8D Series
MIL-DTL-38999 Series III
16 © 2012 - SOURIAU
86
23 / H
6#8Twinax
06
21#16
Service II
32#20
Service I
35
100#22D
Service M
53
53#20
Service I
54 55
4#12,9#16
40#22D
Service M
55#20
Service I
21 32
6#8Power
06
Spec 251
6#8Quadrax
H1
1#000
Highpower
Contact layouts
ELIO® fiber optic Ethernet Quadrax
17#22D
2#8Quadrax
78
21 / G
11#12
Service I
12 Optical
positions
11
42
2#4Power
Service I
4#8Quadrax
84
18#20
2#8Quadrax
80
48
4#8Power
Service I
55#22D
4#12
Service M
6#16
2#4Power
Service I
75
4#8Twinax
Service M
59 72 75
Spec 251
4#8Power
77
17#22D
2#8Twinax
Service M
77
Spec 251
17#22D
2#8Power
16#16
Service II
20
18#20
2#8Twinax
Service M
16 20
Spec 251
18#20
2#8Power
35
79#22D
Service M
39 41
2#16
37#20
Service I
41#20
Service I
12
8D Series
MIL-DTL-38999 Series III
17
© 2012 - SOURIAU
Contact layouts
ELIO® fiber optic Ethernet Quadrax *ForclassesF,W,K,Sonly
25 / J
48#20
8#16
Service I
97#22D
2#8Twinax
Service M
19
19#12
Service I
04 07
20*
10#20,13#16
4#12Coax
3#8Twinax
ServiceN
24 Optical
positions
29#16
Service I
37
37#16
Service I
41
22#22D,3#20
11#16,2#12
3#8Twinax
Service M
43 44
23#20
20#16
Service I
4#16
4#4Power
Service I
29
46
40#20,4#16
2#8Coax
Service I
10#20
13#16
4#12Coax
3#8Quadrax
22#22D
3#20,11#16
2#12
3#8Quadrax
97#22D
2#8Quadrax
40#20
4#16
2#8Quadrax
36#22D
6#8Quadrax
8#8Quadrax
90
40#20,4#16
2#8Twinax
Service I
80
81 82 86 87 88
128#22D
Service M
35
61#20
Service I
61
24
46
Spec 251
40#20,4#16
2#8Power
Service I
41
Spec 251
22#22D,3#20
11#16,2#12
3#8Power
20*
Spec 251 24
10#20
13#16,4#12
3#8Power
12#16
12 # 12
Service I
97#22D
2#8Power
08
8#8Twinax
Service M
07
Spec 251 08
Spec 251
8#8Power
11
2#20
9#10
ServiceN
17
36#22D
6#8Twinax
17
Spec 251
36#22D
6#8Power
H1
1#0000
Highpower
8D Series
MIL-DTL-38999 Series III
18 © 2012 - SOURIAU
Contact layouts (matrix)
3Souriau’slayout
QSouriau’slayout&Layoutaccordingtocorrespondingnorm
(1) Groundedinsertonly-Pleaseconsultus
#8 Pow: Power;Qdx: Quadrax;Twx: Twinax
Shell
size Layout
MIL-DTL-38999
(QPL)
Aluminum,
Stainless steel
& Composite
8D
Titanium
JVS-CECC
Bronze
connector
Hermetics EN3645
BACC63
CT/CU
DB/DC
Number
of
contacts
#26 #22D #20 # 16 # 12 # 10 #8 #4
Fiber
optic
or
High
power
09 / A
09-01 3 3 3 1 1 Optic.
09-05 (1) 3 3 3 1 1 Qdx
09-12 312 12
09-35 Q3Q3Q Q 6 6
09-98 Q3Q3Q Q 3 3
11 / B
11-01 3 3 1 1
11-01 3 3 3 1 1 Coax
11-02 Q3Q Q Q 2 2
11-02 3 3 3 2 2 Optic.
11-04 Q3 3 Q4 4
11-05 Q3Q Q Q 5 5
11-12 31 1
11-22 3 3 3 4 4
11-26 326 26
11-35 Q3Q3Q Q 13 13
11-80 3 3 3 1 1 Twx
11-80 sp 251 3 3 3 1 1 Pow
11-81 3 3 3 1 1 Qdx
11-98 Q3Q3Q Q 6 6
11-99 Q3Q Q Q 7 7
13 / C
13-03 3 3 3 3
13-04 Q3Q3Q Q 4 4
13-04 3 3 3 4 4 Optic.
13-08 Q3Q3Q Q 8 8
13-26 3 3 Q Q 8 6 2
13-35 Q3Q3Q Q 22 22
13-43 343 43
13-98 Q3Q3Q Q 10 10
15 / D
15-05 Q3Q Q Q 5 5
15-06 3 3 3 6 6 Optic
15 - 15 Q3Q Q Q 15 14 1
15-18 Q3Q3Q Q 18 18
15-19 Q3Q Q Q 19 19
15-35 Q3Q3Q Q 37 37
15-97 Q3Q3Q Q 12 8 4
17 / E
17-02 3 3 3 Q Q 39 38 1 Twx
17-02 sp 251 3 3 3 39 38 1 Pow
17 - 0 6 Q3Q Q Q 6 6
17-08 Q3Q3Q Q 8 8
17-20 3 3 3 20 16 4
17-22 3 3 3 4 2 2 Twx
17-22 sp 251 3 3 3 4 2 2 Pow
17-26 Q3Q3Q Q 26 26
17-35 Q3Q3Q Q 55 55
17 - 7 5 3 3 3 2 2 Twx
17-75 sp 251 3 3 3 2 2 Pow
17-80 3 3 3 4 2 2 Qdx
17 - 8 1 3 3 3 39 38 1 Qdx
17-82 3 3 3 Q2 2 Qdx
17-99 Q3Q Q Q 23 21 2
19 / F
19-08 3 3 3 8 8 Optic.
19-11 Q3Q Q Q 11 11
19-18 Q3 3 Q18 14 4 Twx
19-18 sp 251 3 3 3
19-28 Q3Q Q 28 26 2
19-32 Q3Q Q Q 32 32
19-35 Q3Q3Q Q 66 66
19-84 3 3 3 18 14 4 Qdx
19-H1 311#00