MIL-DTL-26482H.pdf

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DETAIL SPECIFICATION

CONNECTORS, ELECTRICAL, CIRCULAR, MINIATURE, QUICK DISCONNECT,

ENVIRONMENT RESISTING, RECEPTACLES AND PLUGS, GENERAL SPECIFICATION FOR

This specification is approved for use by all Departments and

Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This specification covers the general requirements for two series of environment resisting, quick disconnect, miniature, circular electrical connectors (and accessories). Each series includes hermetic receptacles. The two series of connectors are intermateable when using power contacts and are not intermateable when using shielded contacts. When intermated, the minimum performance requirement for series 1 type connectors will be met.

1.1.1 Part or Identifying Number (PIN). The following are examples of PINs:

a. PIN example (series 1):

MS3114 E 12 A 10 A P Y T

MS number (see supplement) Class (see 1.2.1) Shell size (see 1.2.2) Termination type & shell material (see 1.2.3, for hermetic receptacles only) Insert arrangement (see 1.2.4) Insert arrangement for shielded contacts (see 3.1, omit if not applicable) Contact style (see 1.2.5) Polarization position (see 1.2.6) Finish (see 3.3.9.4) (Note: Finish W is the default finish. No finish designator is included in the PIN when finish W is required. A finish designator is required for all other Series 1 finishes.)

INCH - POUND

Reactivated after 5 October 2006, and may be used for new and existing designs and acquisitions.

MIL-DTL-26482H

w/AMENDMENT 5 24 June 2020

SUPERSEDING

MIL-DTL-26482H

w/AMENDMENT 4 26 September 2019

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MIL-DTL-26482H

w/AMENDMENT 5

b. PIN example (series 2):

MS3470 L 12 A 10 A P Y

MS number (see supplement) Class (see 1.2.1) Shell size (see 1.2.2) Termination type & shell material (see 1.2.3, for hermetic receptacles only) Insert arrangement (see 1.2.4) Insert arrangement for shielded contacts (see 3.1, omit if not applicable) Contact style (see 1.2.5) Polarization position (see 1.2.6)

c. Environmental classes only, series 1, classes E, P, J and F, and series 2, classes A, L, W, K and

T: In the PIN, a dash symbol ( - ) is required to be included before the insert arrangement (see 3.1).

1.1.2 Series description. The connectors are identified as series 1 or series 2 and are designed to provide contact protection during mating.

a. Series 1 – Connector, bayonet coupling, solder or front release crimp removable contacts (125ºC). Series 1, hermetic are also available. Alternative conductive finishes, including W, T and K, are available (See 3.3.9.4) (See 6.1 for intended use.).

b. Series 2 – Connector, bayonet coupling, rear release crimp removable contacts (classes A and L (200ºC) and classes H, N, T, W and K (175°C)). Series 2, hermetic connectors are available with nonremovable solder type contacts or crimp removable terminations (see 6.2).

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1.2 Classification.

1.2.1 Class. The class and series of connectors are identified as shown in table I.

TABLE I. Connector class and series.

Class

Series 1 (125°C) Series 2 (200°C) Series 2 (175°C)

Solder

Front release crimp removable contacts

Rear release crimp removable contacts

Solder

Rear release crimp removable contacts

A - Grommet seal, nonconductive

X

E - Grommet seal, conductive (finish options W, T and K)

X X 1/

P - Potted seal, conductive (finish options W, T and K)

X X

H - Hermetic seal, conductive X X J - Insert seal with gland seal for jacketed cable, conductive (finish options W, T and K)

X

L - Fluid resistant, conductive electroless nickel 1/ 2/

N - Hermetic seal, crimp termination conductive

F - Grommet seal with strain relief clamp, conductive (finish options W, T and K)

W - Cadmium plate, corrosive and fluid resistant, conductive

K - Zinc-nickel, corrosive and fluid resistant, conductive

X

T - Nickel fluorocarbon polymer, corrosive and fluid resistant, conductive

X

1/ Class L is upgraded to 200°C and replaces class E, series 2, rear release, crimp removable contacts.

2/ Class L was created for space application. It is considered to be unsuitable for Navy and most Air Force applications due to the relatively low corrosion resistance of the electroless nickel surface finish.

1.2.2 Shell size. Shell sizes are as specified on the applicable MS standard.

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1.2.3 Termination type and shell material (hermetic receptacles only). The type of termination and shell material are designated as follows:

Type A – Solder cup termination – stainless steel shell (series 1 and 2).

Type B – Eyelet termination – stainless steel shell (series 1 and 2).

Type C – Solder cup termination – ferrous alloy shell (series 1 and 2), in accordance with

ASTM A108.

Type D – Crimp termination – ferrous alloy shell (series 2), in accordance with ASTM A108.

Type Y – Eyelet termination – ferrous alloy shell (series 1), in accordance with ASTM A108.

1.2.4 Insert arrangement. The insert arrangements showing quantity, size, service rating, and positional location of contacts are as specified in MIL-STD-1669.

1.2.5 Contact style:

a. The following contact designators are for use with connectors that utilize standardized contact arrangements as specified in MIL-STD-1669:

C – Feedthrough contacts.

P – Pin contacts.

S – Socket contacts.

The C, P, and S designators are used to indicate that connectors will be used with full compliments of the applicable standard contacts in accordance with MIL-STD-1669. These designators are part of the connector PIN and are marked on the connectors (see 1.1.1).

Standard crimp removable contacts are required to be qualified to SAE- AS39029.

Connectors that accommodate crimp removable contacts (P and S) may be ordered without standard contacts by adding an appropriate note on the purchase order. However, the connector PIN and the marking requirements remain unchanged (see 6.3).

b. The following contact designators are for use with connectors utilizing non-standard contact complements (i.e., contacts complements which are other than those specified in

MIL-STD-1669):

A - Less pin contacts.

B - Less socket contacts.

When A or B designators are used, standard contacts should not be supplied with the connectors. The contacts that will be used with the connectors should be ordered separately (see 3.7.1 and 6.3). The A and B designators are part of the connector PIN and should be marked on the connectors.

A and B contact designators should be specified when connectors are intended for use with contact complements that are not in accordance with the insert arrangements specified in MIL-STD-1669. As an example, the standard connector insert arrangement may require standard power contacts, but the user intends to populate the connector insert with types of contacts (such as thermocouple contacts or coaxial contacts) or fiber optic termini that are not specified in MIL-STD-1669 for that insert arrangement.

NOTE: If inserts are populated with contacts other than the standard complements of contacts specified in MIL-STD-1669 for that insert arrangement, the connectors may not meet the requirements stated herein.

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1.2.6 Insert position. The insert position is the angular position of the insert relative to the master key or keyway of the shell. Insert positions other than normal are indicated by letter designators in accordance with the alternate insert positions specified in MIL-STD-1669.

1.2.7 Military PIN. The military PIN for qualified connectors in accordance with MIL-DTL-26482, and which are provided in accordance with this specification, should conform to the latest issue in effect of MIL-DTL-26482 and 1.1.1 herein.

1.3 Temperature.

1.3.1 Temperature (series 1). Series 1 connectors are rated for specified operation within a temperature range of -55ºC (-67ºF) to 125ºC (257ºF). The upper temperature is the maximum internal hot spot temperature resulting from any combination of electrical load and ambient temperature.

1.3.1.1 Insulation resistance (series 1). Insulation resistance varies with temperature as follows

(see figure 1):

Hot spot temperature Minimum insulation resistance 25ºC (77ºF) 5,000 megohms 105ºC (221ºF) 12 megohms 125ºC (257ºF) 3 megohms

1.3.1.2 Service life (series 1). Service life varies with temperature as follows (see figure 2):

Hot spot temperature Service life 25ºC (77ºF) continuous 105ºC (221ºF) 1,000 hours 125ºC (257ºF) 250 hours

1.3.2 Temperature (series 2). Series 2 connectors are capable of specified operation within a temperature range of -55ºC (-67ºF) to 200ºC (392ºF) under any combination of electrical load and ambient temperature. These connectors are rated for specified operation for 1,000 hours, at 200ºC (392ºF) maximum internal hot spot temperature.

1.3.2.1 Insulation resistance (series 2). Insulation resistance limits vary with temperature as follows

(see figure 3):

Hot spot temperature Minimum insulation resistance 25ºC (77ºF) 5,000 megohms 200ºC (392ºF) 500 megohms

1.3.2.2 Service life (series 2). Service life varies with temperature as follows (see figure 4):

Hot spot temperature Service life 25ºC (77ºF) continuous 200ºC (392ºF) 1,000 hours

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1.4 Wire range accommodations. The wire range given in table II is to be accommodated by series 1 and series 2 connectors as indicated.

TABLE II. Wire range accommodations. 1/

Wire barrel size

Wire size

OD of finished wire, inch (mm) 2/

Series 1 Series 2

Min Max Min Max

.047 (1.19)

3/

.083 (2.11)

.040 (1.02)

.083 (2.11)

.066 (1.68)

.109 (2.77)

.053 (1.35)

.103 (2.62)

.097 (2.46)

.142 (3.61)

.097 (2.46)

.158 (4.01)

1/ Dimensions are in inches. Metric equivalents are given for information only.

2/ Wire reference: SAE-AS22759.

3/ Minimum outside diameter (OD) for solder contact connectors is .060 inch (1.52 mm).

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification.

This section does not include documents cited in other sections of this specification or recommended for addition information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

DEPARTMENT OF DEFENSE SPECIFICATIONS

MS3112 - Connectors, Electrical, (Circular, Miniature, Quick Disconnect, Environment Resisting), Receptacle, (Box Mounting Flange, Bayonet Coupling, Solder Contact), (Series 1).

MS3119 - Connectors, Electrical, (Circular, Miniature, Quick Disconnect, Environment Resisting), Receptacle, (Thru-Bulkhead Mounting Flange, Bayonet Coupling), (Series 1).

MS3122 - Connectors, Receptacle, Electric, Crimp-Type, Box Mounting, Flange, No. 4 Holes, Bayonet Coupling.

MS3127 - Connectors, Receptacle, Electric, Crimp-Type, Box Mounting, Flange, No. 4/6 Holes, Bayonet Coupling.

MS3187 - Plug, Sealing, for MIL-DTL-26482 and MIL-C-81703 (Navy) Electrical Connectors.

MS3460 - Test Gage, MIL-DTL-26482 Series 1 or MIL-C-81703 Series 2 Contact

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Retention Feature.

MS3461 - Test Gage, MIL-DTL-26482 Series 2 or MIL-C-81703 Series 3 Contact Retention Feature.

MS3462 - Test Gage, MIL-DTL-26482, Series 2 (Class N) or MIL-C-81703 Series 3 (Class N) Contact Retention Feature.

MIL-PRF-5606 - Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance.

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5.

MIL-PRF-7808 - Lubricating Oil, Aircraft Turbine Engine, Synthetic Base.

MIL-PRF-8516 - Sealing Compound, Polysulfide Rubber, Electric Connectors and Electric Systems, Chemically Cured.

MIL-A-8625 - Anodic Coatings for Aluminum and Aluminum Alloys.

MIL-PRF-23699 - Lubricating Oil, Aircraft Turbine Engines, Synthetic Base.

MS27488 - Plug, End Seal, Electric Connector.

MIL-DTL-45204 - Gold Plating, Electrodeposited.

MIL-PRF-87937 - Cleaning Compound, Aerospace Equipment.

(See supplement 1 for list of MIL-DTL-26482 specification sheets.)

(Copies of these documents are available online at https://quicksearch.dla.mil.)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-202-208 - Method 208, Solderability MIL-STD-202-215 - Method 215, Resistance to Solvents MIL-STD-790 - Standard Practice for Established Reliability and High Reliability

Qualified Products List (QPL) Systems for Electrical, Electronic, and Fiber Optic Parts.

MIL-STD-810 - Test Method Standard for Environmental Engineering Considerations and Laboratory Tests.

MIL-STD-889 - Dissimilar Metals.

MIL-STD-1285 - Marking of Electrical and Electronic Parts.

MIL-STD-1669 - Insert Arrangements for MIL-DTL-26482 Environment Resisting, Circular Electrical Connectors.

(Copies of these documents are available online at https://quicksearch.dla.mil.)

2.3 Non-Government publications. The following documents form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

ASME INTERNATIONAL

ASME-B46.1 - Surface Texture (Surface Roughness, Waviness, and Lay).

(Copies of these documents are available online at http://www.asme.org.)

ASTM INTERNATIONAL

ASTM B85/B85M - Standard Specification for Aluminum-Alloy Die Castings.

ASTM B339 - Standard Specification for Pig Tin.

ASTM A342/A342M - Standard Test Methods for Permeability of Feebly Magnetic Materials.

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ASTM B545 - Standard Specification for Electrodeposited Coatings of Tin.

ASTM B733 - Metal, Autocatalytic Electroless Nickel – Phosphorus Coatings on.

ASTM B841 - Standard Specification for Electrodeposited Coatings of Zinc Nickel Alloy

Deposits.

ASTM A967/A967M - Chemical Passivation Treatments for Stainless Steel Parts.

ASTM D4814 - Standard Specification for Automotive Spark-Ignition Engine Fuel.

(Copies of these documents are available at http://www.astm.org.)

ELECTRONIC COMPONENTS INDUSTRY ASSOCIATION (ECIA)

EIA-359 - Standard Colors for Color Identification and Coding.

EIA-364 - Electrical Connector/Socket Test Procedures including Environment Classifications.

EIA-364-02 - Air Leakage Test Procedure for Electrical Connectors.

EIA-364-03 - Altitude Immersion Test Procedure for Electrical Connectors.

EIA-364-05 - Contact Insertion, Release and Removal Force Test Procedure for Electrical Connectors.

EIA-364-06 - Contact Resistance Test Procedure for Electrical Connectors.

EIA/ECA-364-13 - Mating and Unmating Forces Test Procedure for Electrical Connectors and

Sockets.

EIA-364-14 - Ozone Exposure Test Procedure for Electrical Connectors.

EIA-364-17 - Temperature Life With or Without Electrical Load Test Procedure for

Electrical Connectors and Sockets.

EIA-364-20 - Withstanding Voltage Test Procedures for Electrical Connectors, Sockets and Coaxial Contacts.

EIA/ECA-364-21 - Insulation Resistance Test Procedure for Electrical Connectors, Sockets, and Coaxial Contacts.

EIA-364-24 - Maintenance Aging Test Procedure for Electrical Connectors.

EIA-364-25 - Probe Damage Test Procedure for Electrical Connectors.

EIA/ECA-364-26 - Salt Spray Test Procedure for Electrical Connectors, Contacts and

Sockets.

EIA-364-27 - Mechanical Shock (Specified Pulse) Test Procedure for Electrical

Connectors.

EIA-364-28 - Vibration Test Procedure for Electrical Connectors and Sockets.

EIA/ECA-364-29 - Contact Retention Test Procedure for Electrical Connectors.

EIA-364-31 - Humidity Test Procedure for Electrical Connectors and Sockets.

EIA-364-32 - Thermal Shock (Temperature Cycling) Test Procedure for Electrical

Connectors and Sockets.

EIA/ECA-364-35 - Insert Retention Test Procedure for Electrical Connectors.

EIA-364-42 - Impact Test Procedure for Electrical Connectors.

(Copies of these documents are available online at http://eciaonline.org.)

INSTITUTE FOR INTERCONNECTING AND PACKAGING ELECTRONIC CIRCUITS

J-STD-006 - Electronic Grade Solder Alloys and Fluxed and Non-Fluxed Solid Solders for Electronic Soldering Applications, Requirements for.

(Copies of these documents are available online from http://www.ipc.org.)

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NCSL INTERNATIONAL

NCSL Z540.3 - Requirements for the Calibration of Measuring and Test Equipment.

(Copies of these documents are available online at http://www.ncsli.org.)

SAE INTERNATIONAL

SAE-AMS-QQ-N-290 - Nickel Plating (Electrodeposited).

SAE-AMS-QQ-P-416 - Plating, Cadmium (Electrodeposited).

SAE-AMS-QQ-S-763 - Steel Bars, Wire, Shapes, and Forgings; Corrosion Resistant.

SAE AMS1424/1 - Deicing/Anti-Icing Fluid, Aircraft SAE Type I Glycol (Conventional and Non-Conventional) Based SAE-AIR1351 - Aerospace Electrical and Electronic Wiring Devices and

Accessories, Manufacturers’ Identification of.

SAE-AS22520 - Crimping Tools, Wire Termination, General

Specification for.

SAE-AS22759 - Wire, Electric, Fluoropolymer-Insulated, Copper or Copper

Alloy.

SAE-AS39029 - Contact, Electrical Connector, General Specification for.

SAE-AS39029/4 - Contacts, Electric, Pin, Crimp Removable, Composition A.

SAE-AS39029/5 - Contacts, Electric, Socket, Crimp Removable, Composition A.

SAE-AS39029/7 - Contacts, Electric, Connector, Pin, Crimp Removable, Composition

D, Type 3 (200ºC), Shielded Cable Applications, Size 12.

SAE-AS39029/8 - Contacts, Electric, Connector, Socket, Crimp Removable, Composition D, Type 3 (200ºC), Shielded Cable Applications, Size 12.

SAE-AS39029/9 - Contacts, Electric, Pin, Crimp Removable, Composition C, Thermocouple.

SAE-AS39029/10 - Contacts, Electrical Connector, Socket, Crimp Removeable, Thermocouple, (for MIL-C-26482 Series 2, MIL-C-81703 Series 3, MIL-C-83723 Series 3, and MIL-C-83733 Connectors).

SAE-AS39029/23 - Contacts, Electric, Pin, Shielded, Crimp, Removable (Size 8).

SAE-AS39029/24 - Contacts, Electric, Socket, Shielded, Crimp, Removable (Size 8).

SAE-AS39029/25 - Contacts, Electric, Pin, Shielded, Crimp, Removable, Composition

A, 200ºC (Size 12).

SAE-AS39029/26 - Contacts, Electric, Socket, Shielded, Crimp, Removable (Size 12).

SAE-AS39029/31 - Contact, Electrical Connector, Pin, Crimp Removable, (for

MIL-C-26482 Series 1, MIL-C-26500 and MIL-C-26518 Connectors).

SAE-AS39029/32 - Contacts, Electrical Connector, Socket, Crimp Removable, (for MIL-C-26482 Series 1, and MIL-C-26500 Connectors).

SAE-AS31971 - Pin, Gage, for Socket Contact Engagement Test.

SAE-AS81969/14 - Installing And Removal Tools, Connector Electrical Contact, Type

III, Class 2, Composition B SAE-AS81969/17 - Installing And Removal Tools, Connector Electrical Contact, Type I, Class 1, Composition C SAE-AS81969/19 - Installing And Removal Tools, Connector Electrical Contact, Type II, Class 1, Composition C SAE-AS81969/30 - Installing And Removal Tools, Connector Electrical Contact, Type II, Class 2, Composition C, For Unwired Contacts

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SAE-AS85049 - Connector Accessories, Electrical, General Specification for.

SAE-EIA-557 - Statistical Process Control Systems.

(Copies of these documents are available at http://www.sae.org.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Specification sheet. The individual item requirements shall be as specified herein and in accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern.

3.2 Qualification. The connectors and accessories furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 4.3 and 6.5).

Upon application for qualification testing, the qualifying activity shall verify that the manufacturer has established written procedures to assure actual connector performance to the requirements of this specification. Emphasis shall be on the molded plastic retention system piece parts prior to assembly into the connector. These procedures shall include:

a. Analysis of minimum/maximum dimensions of contacts and molded plastic retention discs.

b. Acceptable levels for:

(1) Plastic mixtures and chemical tests.

(2) Pureness of materials.

(3) Flash control in plastic parts.

(4) Method for flash removal.

c. Contact retention tests on molded plastic retention disc based on analysis of (a).

d. Insertion and removal forces for pin and socket contacts in plastic disc.

When approved by the qualifying activity, these shall become the minimum requirements for molded plastic contact retention systems prior to assembly into connectors for that manufacturer.

3.2.1 Quality.

3.2.1.1 Statistical process control (SPC). The contractor shall implement and use SPC techniques in the manufacturing process for parts covered by this specification. The SPC program shall be developed and maintained in accordance with SAE-EIA-557. The SPC program shall be documented and maintained as part of the overall reliability assurance program as specified in MIL-STD-790.

3.3 Materials. Materials which are not specified (see 3.1), or which are not specifically described herein shall be of the lightest practical weight and shall be suitable for the purpose intended.

3.3.1 Fungus resistance. Materials used in the construction of these connectors shall be fungus inert

(see 4.2).

3.3.2 Dissimilar metals. When dissimilar metals are used in intimate contact with each other, protection against galvanic corrosion shall be provided. The use of dissimilar metals in contact, which tend toward active galvanic corrosion (particularly brass, copper, or steel used in contact with aluminum or aluminum alloy) is not acceptable. However, metal plating of dissimilar base metals to provide similar or suitable abutting surfaces is permitted. The use of dissimilar metals separated by a suitable insulating

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MIL-STD-889.

3.3.3 Nonmagnetic materials (except classes H and N). The relative permeability of the connector assembly shall be less than 2.0µ when measured with an indicator in accordance with

ASTM A342/A342M.

3.3.4 Contact material.

3.3.4.1 Series I (except class H). Nonremovable contacts shall be made of suitably conductive materials. Hoods shall be made of passivated stainless steel. Springs shall be suitably protected or made from noncorrosive materials.

3.3.4.2 Classes H and N. Contacts shall be made of ferrous alloy or as specified. The materials used shall be compatible with the requirements of this specification.

3.3.5 Contact finish. When tested as specified in 4.6.53, contact finish shall meet the requirements as specified herein.

3.3.5.1 Series 1 solder contact finish (except class H). Nonremovable contacts shall have a finish as specified in 3.3.5.1.1 or 3.3.5.1.2. Each desired finish shall be qualified.

3.3.5.1.1 Overall finish. Contact body shall be gold plated in accordance with MIL-DTL-45204 type II, grade C, class 1, .00005 inches (50 microinches) (0.00127 mm) minimum, over a suitable underplate, except silver shall not be used. Accessory members of the socket contacts need not be plated, but shall comply with the requirements for dissimilar metals specified in 3.3.2.

3.3.5.1.2 Localized finish. Contact body shall be gold plated in accordance with MIL-DTL-45204 type II, grade C, class 1 applied to areas X and Y (see figure 7), as applicable. All other body surfaces shall be finished with gold in accordance with MIL-DTL-45204, any type and grade (no thickness specified).

The entire surface of the contact body shall be nickel underplated in accordance with SAE-AMS-QQ-N- 290, class 2, .00003 to .000150 inches (30 to 150 microinches) (0.000762 to 0.00381 mm) minimum.

Gold discoloration in areas other than areas X and Y is acceptable.

3.3.5.2 Series 1 and 2, class H.

3.3.5.2.1 Types A and B, and type C (series 2). Nonremovable contacts shall be gold plated in accordance with MIL-DTL-45204, .000050 inches (50 microinches) (0.00127 mm) minimum, over a suitable underplate, except silver shall not be used. Wire marks on the back of the contact around the “nonfunctional” outside diameter (OD) of the wire well caused by electrical contact for plating are permissible.

3.3.5.2.2 Types C and Y (series 1). Contact plating for class H, types C and Y, shall be gold plated to a minimum of .000050 inches (50 microinches) (0.00127 mm) in accordance with MIL-DTL-45204, over a suitable underplate, except silver shall not be used. Wire marks caused by electrical contact during plating around the “nonfunctional” outside diameter of the nonmating end of the contact are permissible.

3.3.6 RFI finger spring. RFI finger springs shall be made of a spring temper copper alloy suitably protected to prevent corrosion.

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3.3.7 Dielectric materials.

3.3.7.1 Insert and grommet. Insert and grommet materials shall be high grade dielectric having hardness, electrical, and mechanical characteristic suitable for the purpose intended.

3.3.7.1.1 Rigid (except classes H and N). Rigid dielectric materials shall be high grade having electrical and mechanical characteristics suitable for the purpose intended. The impact strength shall be such that the material shall not chip, crack, or break during assembly or normal service.

3.3.7.1.2 Rigid (classes H and N). The rigid dielectric materials in hermetic connectors shall be of a single piece of vitreous material.

3.3.7.1.3 Resilient. Resilient dielectric materials shall conform to the requirements specified herein.

The resilient faces of series 1 and 2 connectors shall be designed so that the performance requirements are met when mated to counterpart connectors of either series 1 or 2.

3.3.7.1.4 Insert faces (series 1). Insert faces or blankets to a minimum depth of 0.080 inch (2.03 mm) .033 inch (0.84 mm) on class H shall be resilient within a Shore A range of 35-85 for crimp contact connectors and class H connectors and 65-85 for solder contact connectors.

3.3.7.1.5 Pin insert faces (series 2). Pin insert faces shall be resilient within a Shore A range of 30 to 55.

3.3.8 Potting form (series 1). Potting forms shall be made of translucent nylon. The form shall incorporate a means for attachment to the connector.

3.3.9 Material and finish for shells, coupling rings and metallic accessories.

3.3.9.1 Series 1 (except class H). Shells, coupling rings, and protective covers shall be made of high grade aluminum alloys. Die castings, if used, shall be in accordance with ASTM B85/B85M.

Accessories (backshells) shall be in accordance with SAE-AS85049.

3.3.9.2 Shells, coupling rings, and accessories (backshells) (series 2).

a. Shells, coupling rings, and accessories shall be made of impact extruded, machined or die cast aluminum alloy.

b. Accessories (backshells) shall be in accordance with SAE-AS85049.

3.3.9.3 Shells (classes H and N). Shell materials shall be as specified (see 3.1).

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3.3.9.4 Finish (series 1, except class H). Aluminum parts and accessory hardware, unless otherwise specified, shall be in accordance with the following designations:

Finish T (125°C) - Nickel fluorocarbon polymer. Nickel with fluorocarbon polymer additives over a suitable underplate to withstand 500 hours dynamic salt spray. Color shall be nonreflective, conductive, and shall meet the requirements as specified herein.

Finish W (125°C) - Cadmium plate in accordance with SAE-AMS-QQ-P-416 over a suitable underplate to withstand 48 hours salt spray. Color shall be olive drab, conductive.

Finish K (125°C) - Zinc-nickel alloy in accordance with ASTM B841, Type D (black) over a suitable underplate to withstand 500 hours dynamic salt spray. Color shall be nonreflective, conductive, and shall meet the requirements as specified herein.

3.3.9.4.1 Finish (series 1, class H). Unless otherwise specified (see 3.1), stainless steel shells

(shell types A and B) shall be passivated in accordance with ASTM A967/A967M. Tin plated ferrous alloy shells (shell type C) shall be in accordance with ASTM B339 and ASTM B545 over nickel in accordance with SAE-AMS-QQ-N-290. The resultant finish shall be suitable for soft soldering to a mounting surface.

3.3.9.5 Finish (series 2). Metal parts shall be of a corrosion resistant material or be protected to meet the performance requirements of this specification. The type of finish and class designation shall be as follows:

Class A - Hard, anodic, nonconductive in accordance with MIL-A-8625, type III, .0008 inch (0.02032 mm) minimum.

Class L - Electrically conductive, electroless nickel plating in accordance with

ASTM B733, Service Category SC2, .0005 inches (0.013 mm) minimum thickness. Use of a suitable underplate is permissible.

Finish shall withstand 48 hours salt spray in accordance with EIA/ECA-364-26 test condition B.

Classes H and N - Finish shall be tin plated in accordance with ASTM B545 over nickel underplate in accordance with SAE-AMS-QQ-N-290. Minimum plating thickness shall be in accordance with applicable MS sheets.

Class W (175°C) - Cadmium plate in accordance with SAE-AMS-QQ-P-416 over a suitable underplate to withstand 500 hours dynamic salt spray.

Resultant color to be olive drab, conductive.

Class K (175°C) - Zinc-nickel alloy in accordance with ASTM B841, type D (black) over a suitable underplate to withstand 500 hour dynamic salt spray.

Finish shall be conductive and nonreflective and shall meet the requirements as specified herein.

Class T (175°C) - Nickel fluorocarbon polymer. Nickel with fluorocarbon polymer additives over a suitable underplate to withstand 500 hour dynamic salt spray. Finish shall be conductive and nonreflective and shall meet the requirements as specified herein.

3.3.10 Bayonet pins. Bayonet pins shall be made of corrosion resistant steel in accordance with SAE-AMS-QQ-S-763. To indicate that the connectors are fully mated when the bayonet pins are fully visible, the top of the bayonet pins shall be colored blue, orange or yellow and shall be a contrasting

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Not for Resale, 07/31/2020 07:04:11 MDTNo reproduction or networking permitted without license from IHS color as compared to the color of the connector body. Bayonet pins with bright nickel or natural stainless steel finish used with connector shells with olive drab or black finishes are also acceptable (see 3.4.4.1).

3.3.11 Recycled, recovered, environmentally preferable, or biobased materials. Recycled, recovered, environmentally preferable, or biobased materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.4 Design and construction. Connectors and accessories shall be designed and constructed to withstand normal handling incident to installation and maintenance in service. Connector interchangeability control dimensions shall be as specified on figure 5. Rear accessory interchangeability control dimensions of series 2 connectors shall be as specified on figure 6.

3.4.1 Contacts. Contacts shall be so designed that neither the pins nor the sockets will be damaged during mating of counterpart connectors. A quantity of crimp contacts consisting of the normal complement, plus one spare contact for connector arrangements having 26 contacts or less and two spares for arrangements over 26 contacts shall be included in the unit package. Unless otherwise specified, connectors shall be supplied with contacts (see 1.2.5 and 6.3).

3.4.1.1 Solder contacts (series 1). Solder contacts shall conform to the dimensions on figure 7 and shall be nonremovable from the insert. Solder cups shall be so designed that during soldering no components will be damaged. A vent hole or equivalent may be provided to prevent air entrapment during soldering.

3.4.1.2 Crimp contacts (series 1).

3.4.1.2.1 Crimp power contacts. Crimp power contacts shall be qualified to and in accordance with

SAE-AS39029/31 or SAE-AS39029/32.

3.4.1.2.2 Crimp shielded contacts. Size 8 shielded contacts shall be qualified to and in accordance with SAE-AS39029/23 or SAE-AS39029/24. Size 12 shielded contacts shall be qualified to and in accordance with SAE-AS39029/25 or SAE-AS39029/26. Unless otherwise specified, shielded contacts shall not be supplied with the connector (see 6.3).

3.4.1.2.3 Insertion and removal tools (series 1). The individual contacts shall be positively retained in the connector when installed with the applicable contact insertion tools in accordance with SAE-AS81969/17 and SAE-AS81969/19. The individual contacts shall be capable of being removed from the connector when using the applicable contact removal tools in accordance with SAE-AS81969/17 and SAE-AS81969/19.

3.4.1.3 Through-bulkhead contacts (series 1). The engaging ends of contacts in through-bulkhead connectors shall conform dimensionally to corresponding details on figure 7 (classes E, P and J).

Contacts shall be nonremovable.

3.4.1.4 Crimp contacts (series 2).

3.4.1.4.1 Crimp power contacts. Crimp power contacts shall be in qualified to and in accordance with

SAE-AS39029/4, /5, /9, or /10. Neither the pin nor socket shall be damaged by twisting or forcing during mating and unmating of the connectors, or by insertion of contacts into or removal of contacts from the connector with the tools specified for insertion or removal.

3.4.1.4.2 Crimp shielded contacts. Size 12 shielded contacts shall be qualified to and in accordance with SAE-AS39029/7 or SAE-AS39029/8. Contacts shall be inserted and removed with the same tools

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3.4.1.4.3 Insertion and removal tools (series 2). Tools required for assembly or disassembly of pin and socket contacts into their connector inserts, shall be in accordance with SAE-AS8196930 or SAE-AS81969/14. Unless otherwise specified, connectors shall be supplied with insertion and removal tools (see 6.3).

3.4.2 Insert design and construction.

3.4.2.1 Insert design and construction (series 1). Inserts shall be of voidless construction and shall be secured to prevent rotation within the shell. The inserts shall be nonremovable from the shell and shall be installed in the position in accordance with MIL-STD-1669.

3.4.2.1.1 Inserts for crimp contact connectors (series 1). In crimp contact connectors, the insert and wire sealing grommet or insulating spacer shall be one integral part. The design shall permit the removal and reinsertion of individual contacts without any damage detrimental to connector performance to any part of the insert, including contact retention mechanisms or the sealing members, in accordance with SAE-AS81969/17 and SAE-AS81969/19 tools.

3.4.2.1.2 Contact arrangement (series 1). All solder cup openings shall be oriented with openings facing the master key or keyway. All eyelet terminations shall be oriented with eyelet holes facing the master key or keyway.

3.4.2.1.3 Contact spacing. Minimum nominal center-to-center spacing and minimum dielectric thickness, contact to shell, or contact to contact shall be in accordance with the values shown in table III.

3.4.2.1.4 Contact alignment (series 1). Inserts for socket contacts shall provide an overall side-play of the socket contacts of .0025 to .0075 inch (0.063 to 0.190 mm) from the required position to facilitate alignment with mating pin contacts.

3.4.2.1.5 Class H (series 1). Contacts shall be fused into the vitreous inserts of class H connectors. A resilient face shall be permanently bonded to the insert to ensure an interfacial seal in mating.

TABLE III. Minimum nominal contact spacing and minimum dielectric thickness. 1/ 2/

Classes and finishes

Contact size

Service rating I Service rating II

Center to center

Dielectric Center to center

Dielectric rigid resilient rigid resilient

A, E, F, J, L, P, N, T, W and Z

.130 (3.30)

.168 (4.27)

.205 (5.21)

.006 (0.15)

.008 (0.20)

.162 (4.11)

.190 (4.82)

.230 (5.84)

.008 (0.20)

.012 (0.30)

H 20

.130 (3.30) .168 (4.27) .205 (5.21)

.030 (0.76)

.162 (4.11)

.190 (4.82)

.230 (5.84)

.030 (0.76)

1/ Dimensions are in inches.

2/ Metric equivalents are given for information only.

3.4.2.2 Insert design and construction (series 2). The inserts shall be rigid plastic and so designed and constructed with proper-sections and radii that they will not chip, crack or break during normal assembly or service. Hollow-type inserts shall not be used. The inserts shall be nonremovable, mechanically

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Not for Resale, 07/31/2020 07:04:11 MDTNo reproduction or networking permitted without license from IHS retained, and bonded to the shell with the design and construction such that all air paths between cavities are eliminated. The insert engaging faces shall be designed and constructed such that all air paths between cavities at the connector interfaces shall be eliminated when the connectors are mated. The inserts shall be so designed that positive locking of the contacts in the inserts is provided. Socket insert face shall be of a rigid plastic material. The design shall permit the removal and reinsertion of individual contacts without any damage detrimental to connector performance to any part of the insert, including contact retention mechanisms and the sealing members, using the applicable tool in accordance with SAE-AS81969/14 or SAE-AS81969/30.

3.4.2.2.1 Inserts (series 2, class H). Class H receptacle inserts shall be so designed and constructed with proper sections and radii that they will not readily chip, crack or break during normal assembly or service. The inserts shall be nonremovable from the shell and shall meet the requirements of this specification.

3.4.2.2.2 Inserts (series 2, class N). The inserts shall be bonded assembly forming a single unit; the front shall be of a vitreous material with a resilient face and the back shall be rigid plastic. The inserts shall be so designed and constructed with proper-sections and radii that they will not chip, crack or break during normal assembly or service. Hollow-type inserts shall not be used. The insert assembly shall be nonremovable such that all air paths between cavities are eliminated. The insert engaging connector interfaces shall be designed and constructed such that all air paths between cavities at the connector interfaces shall be eliminated when the connectors are mated. The inserts shall be so designed that positive locking of the crimp terminals in the rigid plastic is provided.

3.4.2.2.3 Contact insertion and extraction (series 2, except class H). The connector design shall permit individual insertion and extraction of contacts without removing the insert or sealing numbers.

Insertion of the contacts into and extraction of the contacts from the insert shall be accomplished from the wire side of the connector and with the aid of tools specified in 3.4.1.4.3. Insertion/extraction shall be possible with a full complement of maximum outside diameter (OD) wire (see table IV).

TABLE IV. Maximum wire diameter. 1/ 2/

Contact size Maximum OD

.083 (2.11)

.103 (2.62)

.158 (4.01)

3.4.2.2.4 Contact arrangement identification. The contact positions shall be permanently designated in contrasting color on the front face of the insert and on the rear face of the wire sealing grommet as noted on the insert arrangement in accordance with MIL-STD-1669, and on figure 8.

3.4.2.2.5 Insert position (series 2). The inserts shall be positioned with respect to the shell within the tolerance specified on figure 5.

3.4.2.2.6 Alternate insert position (series 2). Alternate insert position shall be in accordance with

MIL-STD-1669.

3.4.2.2.7 Contact alignment (series 2). The alignment of pin contacts assembled into either plug or receptacle shall be in accordance with MIL-STD-1669 when measured at the engaging end of the contacts.

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3.4.2.2.8 Contact float (series 2). Socket contacts assembled in either plug or receptacle shall allow for contact float of .0025 to .0075 inch (0.063 to 0.190 mm) from true alignment position.

3.4.3 Shell design (except classes H and N). The connector shells shall be seamless and shall retain their inserts in a positive manner. The shells for the connectors shall be designed to accept and retain a cable support or other accessory as shown in the applicable MS standard. Connectors shall be designed in such a manner as to incorporate a static peripheral seal located within the receptacles.

3.4.3.1 Jam nut receptacle shells. Jam nut mounting connectors shall be provided with a mounting nut and an O-ring seal.

3.4.3.2 Connector shell (series 2). The connector shell shall have a blue color band in accordance with EIA-359 indicating a rear release connector. The location of the color band shall be as specified (see 3.1).

3.4.3.3 Backshell accessories (series 2). Backshells shall conform to requirements specified (see 3.1).

The backshells shall have provision for safety wiring. In addition, they shall have wire sealing grommet compression capability. Backshells shall be free of any sharp edges or other configurations that could cause damage to wire extending through them. In addition, the RFI backshell shall provide metal-to-metal bottoming of the follower to the rear face of the connector shell. Interchangeability dimensions shall be as specified in SAE-AS85049.

3.4.3.4 RFI finger spring (series 2) (RFI plugs). Grounding springs shall have a minimum of six fingers per inch. Spring fingers shall be designed to make electrical contact with the mating shell without interfering with proper engagement. The grounding springs shall be permanently fixed to the shell periphery.

3.4.4 Engagement of connectors. Counterpart connectors of any arrangement and accessories shall be capable of being fully engaged and disengaged without the use of tools. Engagement of connectors shall be defined as full insertion of pins into sockets and proper sealing of the mating insert faces. Full engagement shall be indicated by an audible sound at the completion of the coupling cycle, and a positive detent shall be included in the coupling mechanism to lock connectors in the engaged position.

3.4.4.1 Coupling. Connectors shall be coupled to counterpart connectors by means of bayonet coupling rings. Coupling shall be accomplished by clockwise rotation of the coupling ring; uncoupling by counterclockwise rotation. The bayonet coupling rings shall be knurled to provide a gripping surface.

Coupling pins on the receptacle shall have end surfaces of contrasting color to the coupling ring (see 3.3.10). The ends of the pins shall be visible through suitable holes in the coupling ring when the connectors are fully engaged and the coupling ring is in the locked position.

3.4.4.2 Shell polarization. Polarization of connectors shall be accomplished by matched integral key(s) and keyway(s) of counterpart connectors. The polarization of counterpart connectors shall take place before coupling rings are engaged, and before any pin contacts can touch the opposing insert face or socket of the counterpart connector.

3.4.4.3 Lubrication. Bayonet coupling slots shall be coated with a suitable lubricant. Features which are intended to provide potting compound anchorage shall be free of lubricant. Accessory threads of series 1 shall be coated with a suitable lubricant.

3.4.4.4 Engagement seal. Connectors shall contain sealing means so that engaged connectors comply with the requirements specified herein. The design of the seal shall be such that in mated connectors all paths between adjacent contacts and between contacts and shells are eliminated. There

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Not for Resale, 07/31/2020 07:04:11 MDTNo reproduction or networking permitted without license from IHS shall be interfacial mating of the engaged connector insert to provide dielectric under compression of .005 inch (0.13 mm) minimum.

3.4.4.5 Protective covers and storage receptacles (series 1). When mated to counterpart connectors, the protective covers and storage receptacles shall maintain the connector free of moisture, shall prevent air leakage, and shall comply with the applicable requirements of this specification.

3.4.5 Wire sealing.

3.4.5.1 Classes E and F connectors (series 1). Class E and F connectors, except MS3112, MS3119, MS3122 and MS3127 shall be provided with a wire-sealing resilient grommet and gland nut capable of sealing on wires of the sizes specified in table II.

3.4.5.1.1 Solder contact connectors (series 1). Class E solder contact connectors shall be provided with a removable resilient grommet and retaining feature. The grommet shall be designed to fit firmly against the rear face of the insert and around each contact and wire termination so that any air path from each…