MIL-DTL-38999 Features and Application Series I Features and Application 38999 S I 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. MIL-DTL-38999 Series I is a bayonet coupling subminiture configuration with high contact density, ideal for smaller wire gauge, general-purpose applications. These environmentresisting connectors are 100% "scoop-proof." Pins are recessed in elongated shells to prevent the possibility of bending contacts when plugs are scooped into the mating receptacles. 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. This family of connectors is offered in 5 receptacle-mounting styles. They include square flange receptacles, for both front and rear panel (wall) mounting; square flange receptacles, for both front and rear box mounting; and jam nut receptacles which incorporate "O" ring seals, designed for rear panel "D" hole mounting. 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. Standard plugs provide RFI protection by incorporating a continuous strip of attached grounding fingers attenuating interference up to 1 GHz. Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having identical insert arrangement. Fifty-seven insert arrangements per MIL-STD-1560 are tooled and qualified to MIL-DTL-38999 Series I, utilizing 2 to 128 contacts. Contacts come in sizes 22M, 22D, 20, 16, 12, and 8 (coax and twinax), terminating wire sizes from 28 gauge to 12 gauge including coaxial cable. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel, olive drab cadmium and bright cadmium. Other finishes such as anodic and zinc cobalt are available upon request to commercial callouts only. In addition, we offer passivated stainless steel shells with standard environment-resisting inserts (commercial callouts only), and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). 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. www.conesys.com - 3 - sales@aero-electric.com MIL-DTL-38999 Performance Specifications Series I Performance Specifications Operating Temperature Range Finish B: -65C to +175C (-85F to +347F) Finish F: -65C to +200C (-85F to +392F Finish A: -65C to +150C (-85F to +302F) Material and Plating Data (Finish) B - aluminum shell, olive drab cadmium over nickel base F - aluminum shell, electroless nickel finish A - aluminum shell, silver to light iridescent yellow color (bright) cadmium over electroless nickel 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: Corrosion Resistance Finishes A and B withstand 500-hour salt spray. Finish F withstands 48-hour salt spray. Standard Shock Mated connectors withstand a pulse of approximate half sine wave of 300 G 15 percent magnitude with duration of 3 1 milliseconds applied in three axes per MIL-STD-1344, method 2004. Durability Minimum of 500 mating cycles Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-38999. 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. 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. Vibration Mated connectors, with proper accessories, withstand the following vibration levels: * Sine Vibration per MIL-STD-202, method 204, test condition G. * Random Vibration per MIL-STD-1344, method 2005, test condition V and test condition VI, Letter "J" at ambient temperature. Shell-to-Shell Conductivity * Finish F = 1.0 millivolt maximum potential drop * Finishes A and B = 2.5 millivolts maximum potential drop Voltage Rating Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS M 400 550 1300 550 350 200 N 300 450 1000 400 260 200 I 600 850 1800 600 400 200 II 900 1250 2300 800 500 200 exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. Note: The establishment of electrical safety factors is left entirely to the designer, as he is in the best position to know www.conesys.com - 4 - sales@aero-electric.com 38999 S I 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. MIL-DTL-38999 Part Number Development Series I Military and Aero-Electric Part Number Development 38999 S I Mil. Prefix Aero Prefix MS AE 27467 167 T T 13 13 B B 35 35 P P A A -340 Shell Type 27466 = Front, wall mount receptacle = 166 (Aero p/n) 27467 = RFI grounding plug = 167 (Aero p/n) 27468 = Jam nut receptacle = 168 (Aero p/n) 27496 = Front, box mount receptacle = 196 (Aero p/n) 27505 = Rear, box mount receptacle = 105 (Aero p/n) 27656 = Rear, wall mount receptacle = 156 (Aero p/n) Class T = With acc. thread (MS27466, MS27467, MS27468 & MS27656) E = Same as T in line above but is not approved for new design (E-nut is not included) = No acc. thread, box mount (MS27496 & MS27505) Shell Size 9, 11, 13, 15, 17, 19, 21, 23 or 25 Finish (Material & Plating) A = Aluminum shell, silver to light iridescent yellow color (bright) cadmium over nickel base B = Aluminum shell, olive drab cadmium over electroless nickel base F = Aluminum shell, electroless nickel finish S = Stainless steel shell, passivated (Aero p/n only) Insert Arrangement See page 19 thru 21 Contact Style P = Pin S = Socket A = Pin connector less pins (with intent to use non-standard pin contacts) B = Socket connector less sockets (with intent to use non-standard socket contacts) Polarization (Keying) N = Normal (Omitted in part number) A, B, C, or D (B & C keyways are not available in shell size 9) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/27-XXX E-nut 341 = Connector kitted with M85049/49-2-XXX straight clamp 342 = Connector kitted with M85049/47XXX right angle clamp Consult factory for other modifications Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 1 through 26 of each contact and two spares for inserts with more than 26 contacts and a minimum of one sealing plug up to 10% of the number of contacts. Spare Coax and Twinax contacts are not supplied. One insertion/ removal tool for each contact size is also included. www.conesys.com Note 2: Proper part number marking has no "0" in front of single digit shell size (9) and no "0" in front of single digit layout. Example of each: J MS27466T9B35S and J MS27466T11B5S. In both, "N" for normal is omitted. In addition, J or JAN must now be marked in front of the MS part number. - 5 - sales@aero-electric.com MS27466 Front, Wall Mounting Receptacle AE166 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.323(33.60) MAX D 38999 S I A MASTER KEYWAY F B .219(5.56) MIN. FULL THREAD .060(1.52) MAX GROMMET EXTENSION H E MAX GROMMET J ACCESSORY TEETH G ACCESSORY THREAD 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size B .020 .51 inch mm OC (TP) inch mm D OE F G OH J Maximum No. of Teeth +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 Accessory Thread inch mm inch mm inch mm inch mm UNEF-2A inch mm 9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 7/16-28 .299 7.59 12 11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 9/16-24 .427 10.85 16 13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 11/16-24 .541 13.74 20 15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 13/16-20 .666 16.92 24 17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28 19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32 21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36 23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40 25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44 www.conesys.com - 6 - sales@aero-electric.com MS27656 Rear, Wall Mounting Receptacle AE156 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.350 (34.29) MAX 38999 S I A MASTER KEYWAY D B F .219 (5.56) MIN FULL THREAD .060 (1.52) MAX GROMMET EXTENSION H E MAX GROMMET J ACCESSORY TEETH G ACCESSORY THREAD 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size B .020 .51 inch mm OC (TP) inch mm Note: See page 14 for panel thickness. D OE F G OH J Maximum No. of Teeth +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 Accessory Thread inch mm inch mm inch mm inch mm UNEF-2A inch mm 9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 7/16-28 .299 7.59 12 11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 9/16-24 .427 10.85 16 13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 11/16-24 .541 13.74 20 15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 13/16-20 .666 16.92 24 17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28 19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32 21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36 23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40 25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44 www.conesys.com - 7 - sales@aero-electric.com MS27496 Front, Box Mounting Receptacle AE196 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.104(28.04) MAX D B 38999 S I A MASTER KEYWAY F .060(1.52) MAX GROMMET EXTENSION H G MAX GROMMET MAX E .312(7.93) MAX 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B OC D OE F OG +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 OH Shell Size .020 .51 inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm 9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 .469 11.91 .299 7.59 11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 .594 15.09 .427 10.85 13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 .719 18.26 .541 13.74 15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 .844 21.44 .666 16.92 (TP) Maximum Maximum 17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 .969 24.61 .791 20.09 19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1.078 27.38 .897 22.78 21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1.203 30.56 1.022 25.96 23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1.328 33.73 1.147 29.13 25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1.453 36.91 1.272 32.31 www.conesys.com - 8 - sales@aero-electric.com MS27505 Rear, Box Mounting Receptacle AE105 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.100(27.94) MAX 38999 S I A MASTER KEYWAY D B F .060(1.52) MAX GROMMET EXTENSION H E G MAX MAX GROMMET 4X MINOR KEYWAYS 4x C BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size B .020 .51 inch mm inch OC Note: See page 14 for panel thickness. D OE F OG OH +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 mm inch mm inch mm inch mm inch mm inch mm inch (TP) Maximum Maximum mm 9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 .547 13.89 .299 7.59 11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 .656 16.66 .427 10.85 13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 .828 21.03 .541 13.74 15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 .953 24.21 .666 16.92 17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 1.078 27.38 .791 20.09 19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1.203 30.56 .897 22.78 21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1.328 33.73 1.022 25.96 23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1.453 36.91 1.147 29.13 25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1.578 40.08 1.272 32.31 www.conesys.com - 9 - sales@aero-electric.com MS27468 Jam Nut Receptacle AE168 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof E 1.308 (33.22) MAX 38999 S I B .920 (23.37) .910 (23.11) .615 (15.62) .598 (15.19) MASTER KEYWAY .060 (1.52) MAX GROMMET EXTENSION K OC OA FLAT MAX GROMMET G No. OF TEETH OD 4X MINOR KEYWAYS 3X BAYONET PINS EQUALLY SPACED Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 "O"-RING J THREAD BLUE COLOR BAND HEX NUT PER MS3186 PANEL THICKNESS .125(3.18) .062(1.57) Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA Shell Size F ACCESSORY THREAD BLUE COLOR BAND B OC +.001 -.005 +.03 -.13 +.011 -.010 +.28 -.25 inch mm inch mm inch OD E F .016 .41 .016 .41 Accessory Thread mm inch mm inch mm UNEF- 2A Maximum G J K No. of Jam Nut Thread Flat Teeth Class 2A .005 .13 inch mm 9 .572 14.53 .109 2.77 .299 7.59 1.188 30.18 1.062 26.97 7/16-28 12 11/16-24UNEF .650 16.51 11 .700 17.78 .109 2.77 .427 10.85 1.375 34.93 1.250 31.75 9/16-24 16 13/16-20UNEF .750 19.05 13 .850 21.59 .109 2.77 .541 13.74 1.500 38.10 1.375 34.93 11/16-24 20 1-20UNEF .937 23.80 15 .975 24.77 .109 2.77 .666 16.92 1.625 41.28 1.500 38.10 13/16-20 24 1-1/8-18UNEF 1.061 26.95 17 1.100 27.94 .109 2.77 .791 20.09 1.750 44.45 1.625 41.28 15/16-20 28 1-1/4-18UNEF 1.186 30.12 19 1.207 30.66 .140 3.56 .897 22.78 1.938 49.23 1.812 46.02 1-1/16-18 32 1-3/8-18UNEF 1.311 33.30 21 1.332 33.83 .140 3.56 1.022 25.96 2.062 52.37 1.938 49.23 1-3/16-18 36 1-1/2-18UNEF 1.436 36.47 23 1.457 37.01 .140 3.56 1.147 29.13 2.188 55.58 2.062 52.37 1-5/16-18 40 1-5/8-18UNEF 1.561 39.65 25 1.582 40.18 .140 3.56 1.272 32.31 2.312 58.72 2.188 55.58 1-7/16-18 44 1-3/4-18UNS 1.686 42.82 www.conesys.com - 10 - sales@aero-electric.com MS27467 RFI Grounding Plug AE167 Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.294 (32.87) MAX F MAX. COUPLING NUT 38999 S I MASTER KEY E ACCESSORY THREAD RFI STRIP .060(1.52) GROMMET MAX EXTENSION A C MIN MAX GROMMET D No. OF TEETH .219(5.56) MIN FULL THREAD 4 MINOR KEYS BLUE COLOR BAND Page 5 Page 15 Pages 19-21 Page 4 Pages 16-18 Page 13 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization OA OC D E Minimum Maximum No. of Teeth Accessory Thread Class 2A Shell Size inch mm inch mm OF Maximum inch mm 9 .417 10.59 .299 7.59 12 7/16-28UNEF .859 21.82 11 .545 13.84 .427 10.85 16 9/16-24UNEF .984 24.99 13 .657 16.69 .541 13.74 20 11/16-24UNEF 1.156 29.36 15 .782 19.86 .666 16.92 24 13/16-20UNEF 1.281 32.54 17 .907 23.04 .791 20.09 28 15/16-20UNEF 1.406 35.71 19 1.012 25.70 .897 22.78 32 1-1/16-18UNEF 1.516 38.51 21 1.137 28.88 1.022 25.96 36 1-3/16-18UNEF 1.641 41.68 23 1.262 32.05 1.147 29.13 40 1-5/16-18UNEF 1.766 44.86 25 1.387 35.23 1.272 32.31 44 1-7/16-18UNEF 1.891 48.03 www.conesys.com - 11 - sales@aero-electric.com M38999/9 Dummy Stowage Receptacle AE109 Dummy Stowage Receptacle, Bayonet Coupling 38999 S I Part Number Configuration MIL. Prefix Aero Prefix M38999 AE10 9/ 9- XX XX B B Shell Type 9 = receptacle, dummy stowage, bayonet coupling Shell Size 9 THRU 25 (Note: single digit for shell size 9) Material Finish B = Aluminum, Cadmium Olive Drab A = Aluminum, Bright Cadmium over Nickel base (Aero p/n only) F = Aluminum shell, Electroless Nickel finish (Aero p/n only) S = Stainless steel shell, passivated (Aero p/n only) BN = Aluminum, Black Nickel (Aero p/n only) BZ = Bronze (Aero p/n only) SHELL SIZE OA +.001 -.005 K +.015 -.000 M .010 OT +.010 -.005 S .020 J +.010 -.015 9 .572 .085 .727 .128 .938 .567 11 .700 .085 .727 .128 1.031 .567 13 .850 .085 .727 .128 1.125 .567 15 .975 .085 .727 .128 1.219 .567 17 1.100 .085 .727 .128 1.312 .567 19 1.207 .085 .727 .128 1.438 .567 21 1.332 .115 .697 .128 1.562 .567 23 1.457 .115 .697 .147 1.688 .567 25 1.582 .115 .697 .147 1.812 .567 www.conesys.com - 12 - sales@aero-electric.com MIL-DTL-38999 Polarization Series I Keying Positions 38999 S I NORMAL C N MASTER KEYWAY A B D 5 DATUM F Notes: 1. Mating face of receptacle shown (plug is opposite). 2. The master keyway (key) has various positions relative to DATUM F; the minor keyways (keys) remain fixed as shown. In the Normal position, the master keyway (key) is at 95 from DATUM F. 3. The angles for a given connector are the same whether it contains pin or socket inserts. 4. The insert arrangement does not rotate relative to master keyway (key). Keying Positions BSC Shell Size N A B C D 9 95 77 - - 113 11 95 81 67 123 109 13 95 75 63 127 115 15 95 74 61 129 116 17 95 77 65 125 113 19 95 77 65 125 113 21 95 77 65 125 113 23 95 80 69 121 110 25 95 80 69 121 110 www.conesys.com - 13 - sales@aero-electric.com MIL-DTL-38999 Series I Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts D MAX PANEL THICKNESS 4x C 38999 S I JAM NUT MOUNT FLANGE MOUNT .125(3.18) .062(1.57) PANEL THICKNESS B MIN b =F A Note 1: Flange Mounting Dimensions (O B cutout and D MAX) listed only for back of panel mounting (MS27505 and MS27656). Note 2: D MAX includes mounting hardware. Flange and Jam Nut Mounting Dimensions A OB (TP) Minimum Shell Size inch mm inch OC D .005 .13 mm inch mm inch E OF +.000* -.010 +.00* -.25 +.010 -.000 +.25 -.00 mm inch mm inch mm Maximum 9 .719 18.26 .656 16.66 .128 3.25 .234 5.94 .657* 16.70* .693 17.60 11 .812 20.62 .796 20.22 .128 3.25 .234 5.94 .771 19.59 .825 20.96 13 .906 23.01 .922 23.42 .128 3.25 .234 5.94 .955 24.26 1.010 25.65 15 .969 24.61 1.047 26.59 .128 3.25 .234 5.94 1.085 27.56 1.135 28.83 17 1.062 26.97 1.219 30.96 .128 3.25 .234 5.94 1.210 30.73 1.260 32.01 19 1.156 29.36 1.297 32.94 .128 3.25 .234 5.94 1.335 33.91 1.385 35.18 21 1.250 31.75 1.422 36.12 .128 3.25 .204 5.18 1.460 37.08 1.510 38.35 23 1.375 34.93 1.547 39.29 .154 3.91 .204 5.18 1.585 40.26 1.635 41.53 25 1.500 38.10 1.672 42.47 .154 3.91 .193 4.90 1.710 43.43 1.760 44.70 * Tolerance .10mm (.004") www.conesys.com - 14 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series I Contacts, Plastic Insertion/Removal Tools and Seal Plugs 38999 S I Contact Size 22D 22M* 22* 20 16 12 12 Coax 12 Coax 8 Coax 8 Twinax Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Power/Signal Power/Signal Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Coax Twinax Military No. M39029/58-360 M39029/58-361 M39029/58-362 M39029/58-363 M39029/58-364 M39029/58-365 M39029/28-211 M39029/102-558 M39029/60-367 M39029/90-529 Military No. M39029/56-348 M39029/56-349 M39029/56-350 M39029/56-351 M39029/56-352 M39029/56-353 M39029/75-416 M39029/103-559 M39029/59-366 M39029/91-530 Military No. Plastic Military No. Positioner Positioner Insertion Tool Extraction Tool For Socket Contacts Military No. M22520/2-07 M22520/2-07 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 Metal Military No. M81969/8-01 M81969/8-03 Metal Military No. M81969/8-02 M81969/8-04 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M81969/8-13** M81969/8-14 M81969/14-01 MS27488-22-1 MS27488-20-1 MS27488-16-1 -- M81969/14-10 M81969/14-03 MS27488-12-1 M81969/14-04 MS27488-8-1 MS27488-8-1 M81969/14-06 M81969/14-12 Crimping and Metal Insertion/Extraction Tools Contact Size/ Type Crimp Tool 16 12 12 Coax Inner 12 Coax Outer 8 Coax Inner Military No. M22520/2-01 M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 M22520/2-01 8 Coax Outer M22520/5-01 8 Twinax Center 8 Twinax Outer & Intermediate M22520/2-01 For Pin Contacts Military No. M22520/2-09 M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 M22520/5-01 M22520/5-200 22D, 22M* 22* 20 -- M22520/5-200 -- Contact and Wire Data Test Current Voltage Contact Size 22D 22M* 22* 20 16 12 DC Test Amps 5.0 3.0 5.0 7.5 13.0 23.0 Max. Drop Millivolts 73 45 73 55 49 42 Crimp Well Data AWG 28-22 28-24 26-22 24-20 20-16 14-12 mm2 .08-.33 .08-.20 .13-.33 .20-.52 .52-1.31 2.08-3.31 Finished Wire O Range Minimum inch mm .030 .76 .030 .76 .034 .86 .040 1.02 .065 1.65 .097 2.46 Maximum inch mm .054 1.37 .050 1.27 .060 1.52 .083 2.11 .109 2.77 .142 3.61 Note 2: Size 12 coax contacts purchased in bulk. * Inactive for new design ** Insertion tool is not required. Note 3: Size 8 coax contacts are used with M17/095-RG180 cable, while size 8 Twinax contacts are used with M17/176-00002 cable. Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com Wire Range Well Dia. Minimum Well Dept inch inch mm .0345 .0010 .141 3.58 .028 .001 .141 3.58 .0365 .0010 .141 3.58 .047 .001 .209 5.31 .067 .001 .209 5.31 .100 .002 .209 5.31 - 15 - sales@aero-electric.com MIL-DTL-38999 Contact Installation Instructions Series I Contact Installation Instructions Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 4. Place the contact, mating end first, into the tool. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner 22D 22M 22 M39029/58-360 M39029/58-361 M39029/58-362 M39029/56-348 M39029/56-349 M39029/56-350 20 M39029/58-363 M39029/56-351 20 12 M39029/58-364 M39029/58-365 M39029/56-352 M39029/56-353 M22520/2-01 M22520/2-01 M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-09 M22520/2-09 M22520/2-09 M22520/1-04 Red M22520/2-10 M22520/1-04 Blue M22520/1-04 Yellow M22520/2-07 M22520/2-07 M22520/2-07 M22520/1-04 Red M22520/2-10 M22520/1-04 Blue M22520/1-04 Yellow Insertion/Removal Tool M81969/14-01 M81969/14-01 M81969/14-01 M81969/14-10 M81969/14-03 M81969/14-04 For coax and twinax contacts refer to instructions that are supplied with contacts. www.conesys.com - 16 - sales@aero-electric.com 38999 S I 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. MIL-DTL-38999 Series I Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information Insert Arrangement Aero-Electric Service Status Total Quantity of Contacts No. of (by Size) 38999 S I Series I QPL'd Tooled Rating Contacts 9-6* 9-35 9-98 11-2 11-4 11-5 11-13* 11-35 11-98 11-99 13-4 13-8 13-22* 13-35 13-98 15-5 15-15 15-18 15-19 15-35 15-37* 15-97 17-6 17-8 17-26 17-35 17-55* 17-99 19-11 19-28 19-30 19-32 19-35 19-66* Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M M I I I I M M I I I I M M I II I I I M M I I II I M M I II I I I M M 6 6 3 2 4 5 13 13 6 7 4 8 22 22 10 5 15 18 19 37 37 12 6 8 26 55 55 23 11 28 30 32 66 66 See next page for Shell Sizes 21 thru 25 layouts. www.conesys.com 22D 22M 22 20 16 12 10 8 6 6 3 2 4 5 13 13 6 7 4 8 22 22 10 14 18 19 5 1 37 37 8 4 6 8 26 55 55 21 26 29 32 2 11 2 1 66 66 * Not approved for new design. Tooled and qualified but their separate pictorials are not shown on pages 19 thru 21, as they are the same as corresponding (-35) layouts that take the same quantity of 22D contacts, but are supplied with 22M contacts instead. - 17 - sales@aero-electric.com MIL-DTL-38999 Series I Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information (continued) Insert Arrangement Aero-Electric Service Total Status Quantity of Contacts No. of QPL'd Tooled Rating Contacts 21-1* 21-11 21-16 21-35 21-39 21-41 21-48** 21-75 23-1* 23-2*** 23-21 23-32 23-35 23-53 23-55 25-1* 25-4 25-19 25-24 25-29 25-35 25-43 25-46 25-61 Yes Yes Yes Yes Yes Yes N/A Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M I II M I I I Twinax M M II I M I I M I I I I M I I, Coax I 79 11 16 79 39 41 4 4 100 85 21 32 100 53 55 128 56 19 24 29 128 43 46 61 (by Size) 22D 22M 22 20 16 12 10 8 79 11 16 79 37 41 2 4 (Power) 4 (Twinax) 100 85 21 32 100 53 55 128 48 8 12 29 19 12 128 23 40 61 20 4 2 (Coax) * Not approved for new design. Tooled and qualified but their separate pictorials are not shown on pages 19 thru 21, as they are same as corresponding (-35) layouts that take the same quantity of 22D contacts, but are supplied with 22M contacts instead. ** 21-48 layout is not to MIL-STD-1560. It is tooled and intended for commercial use only. *** Not approved for new design. Pictorial is shown on page 20. www.conesys.com - 18 - sales@aero-electric.com 38999 S I Series I MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I Connectors Insert Arrangements Views 38999 S I 5 C 1 6 4 3 A B D A A E 1 A 10 B 2 B C D C 3 8 B 13 12 7 6 4 5 9-35 9-98 11-2 11-4 11-5 11-35 6 # 22D, M 3 # 20, I 2 # 16, I 4 # 20, I 5 # 20, I 13 # 22D, M A A E F D F B E C G A B D A G H F 1 15 C C E 11-99 13-4 13-8 13-35 4 # 16, I 8 # 20, I 22 # 22D, M E J B N H D L B M R C J D P A T U S G K C P R F L B N M H E G C K M A B N P U J D T H E S G 13-98 10 # 20, I 1 C 31 D R V D C D 7 # 20, I L A C F 11-98 K B J K 6 # 20, I A G B E A H 14 21 22 B D K 21 A L J B H E C M G F F F D E 15-5 15-15 15-18 15-19 15-35 15-97 5 # 16, II 1 # 16, 14 # 20, I 18 # 20, I 19 # 20, I 37 # 22D, M 4 # 16, 8 # 20, I G F 17-6 6 # 12, I www.conesys.com B S T E 17-8 8 # 16, II C D M L V c Y J G H 17-26 26 # 20, I - 19 - E F W X K 32 A 40 R 47 D U Z 25 P 1 b a 17 4 C N H 10 B R P B F C A A A E D 2 11 9 53 55 3 52 9 16 24 31 39 17-35 55 # 22D, M 46 Y B T S C Z U D N V X M E W L K J H F G 17-99 2 # 16, 21 # 20, I sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I Connectors Insert Arrangements Views A T S A J B G C Y g L G K E J Y K J L F G H 19-30 19-32 32 # 20, I 34 J 43 51 L A 63 24 33 42 j h Z m r p F R H f P M 21-39 2 # 16, 37 # 20, I 29 20 39 48 58 b c G 5 75 J N A M B W R V K C Z 11 81 28 38 47 57 66 74 U J D K T G 23-2* 23-21 85 # 22, M 21 # 16, II Y J E H h g 21-75 4 # 8 Twinax, Twinax S c 16 25 35 46 56 67 77 86 1 94 2 C 95 3 T d i 8 B R 96 4 97 98 S 85 B A P b a L X 4 C C 21-48** 4 # 8 Power, I P L 82 1 19 B D K L N M A H 21-41 41 # 20, I 67 D F d e N K 12 p q E a n r g J L m t S G 21-35 79 # 22D, M A D Z s h E c d e M T a n f F C Y k i 11 E B X j U D b q P D G 21-16 16 # 16, II A W V C Y 61 41 B k i R 21-11 11 # 12, I X 71 79 P D E A W 31 C F 50 19-35 66 #22D, M V N H C 57 16 J L 66 9 S 21 G 3 B 51 B M H K 1 A K 58 64 N Z 1 # 16, 29 # 20, I 4 g a 19-28 25 E b M G H X 2 # 16, 26 # 20, I 1 S R E D g h 19-11 17 T c C W f j 11 # 16, II 10 U N F Y J d X Z K V e P f W F Z D B U R C V a L a U e M E A T S B T b D X M A d c N W e D F C b N L V c P P 38999 S I K H d R S R B U D f e X U V H G 99 6 10 0 7 W F E 5 F 15 24 34 45 55 66 76 85 23-32 23-35 32 # 20, I 100 # 22D, M 93 * Inactive for new design. ** Not MIL-STD-1560 layout (not QPL'd.). www.conesys.com - 20 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I Connectors Insert Arrangements Views S T R 38999 S I GG EE f t w e K v d J a b c i G g L C Y X D P n m N M 15 25 36 48 59 K 94 105 X 115 122 125 4 E m F 7 G 24 H J 35 47 5870 81 93 104 11 4 Z A p w k v h u R 121 14 G Y U S W X F G n W V K E 25-19 19 # 12, I 1 V D R S H L 8 d Y V T J J k 71 82 C H h U e L g B b x r c t s d f e P N M 25-35 25-43 20 # 16, 23 # 20, I AA X X C Y v W Z D V E z w c m h M g L K F G e f H J u t GG s FF r HH q T KK CC P N M L 25-46 25-61 40 # 20, 4 # 16, 2 # 8 Coax, I / Coax 61 # 20, I www.conesys.com H i j k F G h AA BB m E g z LL D f y MM n C e x JJ DD P R d PP EE J B c w NN G H A b v U S d x y k Z a Y B F L 128 # 22D, M A E K 25-29 u D q 29# 16, I W t C a 25-24 a N p P G D F q P AA BB CC U B 12 # 12, 12 # 16, I s n KK K f g DD q R B f Z b R G LL N 25-4 8 # 16, 48 # 20, I c M p S S C E U r T r T H T N T V U F EE L F z JJ s E e y A M D T a V c e S a H U J b Z J E C d HH FF A P S W Z b u K R R K V 23-55 55 # 20, I B N D B c x GG t Y a d f H u t v A P L DD EE w 23-53 55 # 20, I M CC s FF x N H M Z u HH y P F C r A b w v W X q BB GG j R W p AA z E Y x m S k D X s DD g L CC HH W r X B V n C V q FF y M p BB A T B U AA z h N n m P k A a Z Y U J K - 21 - sales@aero-electric.com