Glenair QwikConnect Magazine • January 2022 • Volume 26 • Number 1
G L E N A I R • J A N U A R Y 2 0 2 2 • V O L U M E 2 6 • N U M B E R 1
M I S S I O N - D R I V E N D E S I G N : MIL-DTL-38999 TYPE Micro Miniature Conne c t o r s a nd Ca b l e s
Electronic and digital embedded systems technology—such as deployed in fly-by-wire computer systems or in other electronics gear—enables military and commercial aircraft to process the massive loads of data generated by critical navigation, communication, and flight-control systems.
Embedded RF transmit/receive systems on communication satellites require interconnects that save size and weight and can operate successfully under the extreme environmental conditions of space
Interconnects and the Evolution of Modern Flight Systems Mission-critical electronics extend through every zone of a modern aircraft, ship, or spacecraft, and require complex interconnection of critical power supplies, remote sensors, and control computers. Radio frequency (RF) and higher-frequency microwave systems, for example, are ubiquitous in avionic platforms. RF transmission-and-receive modules are backbone technologies in AESA radar systems. Other RF LRUs are found in satellite communications and instrument flight procedure (IFP) platforms. High-speed digital datalinks, such as deployed in short-distance copper connections for 10 Gigabit Ethernet, are critical in a wide range of sensor, video downlink, and data storage applications.
Power connections are equally essential, as every avionic and flight technology system depends on the safe provision of electrical power for operation. From low-power sensor requirements (say 3–5 amps) to higher power requirements for actuators and other electromechanical devices, the delivery of reliable power is a key requirement in EWIS wiring. In all these cases—RF, high-speed digital, and power, as well as in more conventional signal (databus) applications—industry requirements have evolved far beyond the capabilities of conventional interconnect devices. Gone are the days when a standard-density power or signal connector would be of any interest to EWIS designers facing extreme data-rate, mechanical, environmental, and electrical requirements of operation. Likewise gone is any interest in interconnect technologies that fail to contribute to size and weight reduction efforts in modern aerospace systems. Mighty Mouse: The Original Small Form-Factor Circular From fixed wing and rotary aircraft to space launch and satellite systems, the evolution in connector and cable miniaturization has reached full maturity in high- density, ruggedized connectors like the Glenair Mighty Mouse. These reduced form-factor circulars have been optimized for harsh environmental performance in aerospace and defense platforms. The Mighty Mouse Series 805, for example—a double-start rapid mate circular connector—has been designed into more commercial and military aircraft platforms than any other mil-grade micro miniature connector.
Evaluation flight of the first-ever formation of F-16 Fighting Falcons equipped with Active Electronically Scanned Array (AESA) radars
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GLENAIR
But even the Series 805, as ideally suited as it has been for aircraft applications these many years, has been historically unable to meet several of the most stringent performance benchmarks of the MIL-DTL-38999 spec.— the “gold-standard” in the qualification of interconnects for aerospace use. In key areas such as vibration and shock resistance, high-altitude environmental performance, and high-altitude DWV, the double- start Series 805 has been limited to use in less-harsh, pressurized aircraft zones. Series 806: Mission-Driven Design For this reason, Glenair embarked several years ago on a new miniaturized connector development project to create the ultimate harsh-environment, reduced form- factor circular connector—one that could truly meet, if not exceed, MIL-DTL-38999 Series III specifications. Our goal was to create a triple-start ACME-thread mating connector, suitable for use in every aircraft zone, both pressurized and non-pressurized.
The result of this work, the Series 806 Mil-Aero, is today the only available micro-miniature circular connector with independent lab-verified performance in accordance with every MIL-DTL-38999 Series III qualification requirement. The Series 806 is a mature interconnect solution with environmental crimp-contact offerings as well as hermetics, filters, high-speed, RF, fiber optic, and power solutions. The Series 806 is fully tooled, 100% made in America, and available with lead-times from one day to five weeks. Connector optimization and miniaturization is a complex matter, calling for deep fluency in material dielectrics, frequency modulation, partial discharge, optical back- reflection and dozens of other disciplines. As LRU proliferation and packaging continues to evolve, so must connector and cable technologies. The differing equipment sets used in manned and unmanned applications, as well as in evolving systems such as eVTOL air taxis, all share the same challenges and opportunities: compliance to harsh application safety requirements and the reduction of size and weight so critical to mission performance.
Connector optimization and miniaturization is a complex matter, calling for deep fluency in countless disciplines, from material dielectrics, to frequency modulation, partial discharge, optical back-reflection, and dozens of other requirements.
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M I S S I O N - D R I V E N D E S I G N : MIL-DTL-38999 TYPE Micro Miniature Conne c t o r s a nd Ca b l e s
The Series 806 Mil-Aero is a high-density, high- performance micro miniature circular connector ideally suited for harsh military/ aerospace applications.
Band-Master ATS® Nano banding tool
SHOCK + VIBE The Series 806 Mil-Aero is an aerospace-grade micro miniature circular connector with triple-start threaded coupling. The 806 connector is smaller and lighter than conventional aerospace connectors. Featuring size 22HD and 20HD contacts, plus size 8 power and high-speed El Ochito®, quadrax, and fiber optic options, the Series 806 offers up to twice the number of contacts—with no reduction in performance—compared to MIL-DTL-38999 Series III. In fact, independent laboratory testing has demonstrated that the Series 806 meets, and in many cases exceeds, the requirements of MIL-DTL-38999. Glenair pioneered integral shield banding platforms to allow direct attachment of cable shields, boots, and overmolds. This innovation continues with the 806— Glenair’s first connector to exclusively use the ultra lightweight Nano shield Band-Master ATS band for maximum size and weight reduction.
Integral shield banding platform
O-ring peripheral seal
But there is more to the 806 than just size and weight reduction. This flight-proven high-performance connector has many innovative features that meet the most aggressive requirements of the military/aerospace industry, including better resistance to vibration-induced decoupling. This is accomplished by re-engineering the ratchet mechanism and introducing a shallower mating thread ramp angle than is available in D38999. When it comes to sealing, the Series 806 Mil-Aero connector features an O-ring radial interface sealing design instead of a flat gasket. This allows for easier metal-to-metal coupling for improved sealing, as well as better EMI performance. The MIL-DTL-38999 Series III and other legacy aerospace circular connectors have a flat gasket inside the receptacle shell. This peripheral seal must be compressed sufficiently to allow full metal- to-metal connector bottoming. In certain tolerance conditions this seal can make it difficult to fully mate the connectors “without the use of tools” as is required by MIL-DTL-38999.
Reduced Ramp Angle Modified triple-start stub ACME thread for improved de-coupling performance, especially in small shell sizes
High-Vibe Coupler Materials and design for
improved overall performance in high-vibe and shock applications
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Commercial Aircraft
CrownWiring SATCOM / Ku Band Antennas, IFE, Lighting, Cabin Audio System, Oxygen System, Redundant Electrical Systems
Side-of-Body Electrical Feedthrus and Pressure Seals Wing and Engine Control Wiring / Sensors
Aft Pressure Bulkhead Feedthru Connectors, Pressure Seal Bulkhead Feedthrus
Flight Control Surfaces Electrical Interface Wiring
Electrical Feedthrus and Pressure Seals Wing and Engine Control Wiring / Sensors
Electronic Engine Control Unit
Forward Bulkhead Pressure Seal Bulkhead Connectors and Feedthrus
Rigorous Qualification Testing Glenair has completed numerous rounds of qualification testing on the Series 806 and has all necessary test reports on file. A comprehensive summary report on Series 806 performance, including operating temperature range, moisture resistance, vibration and shock, and dielectric withstanding voltage is offered here in this issue. But for overview purposes, let’s take a look now at four of the most important qualification benchmarks. High-temperature tolerance in the range of +200°C is a rare capability in micro miniature connectors. High temperature tolerance is critical for the Series 806 Mil- Aero as high-altitude DWV and the placement of the connector in FADEC controls and other areas in close proximity to engines was a primary design requirement. Dielectric insulators are fabricated from high-temperature tolerant, glass-filled rigid dielectric. And unlike many current and legacy military/aerospace connectors, insert retention in the Series 806 is guaranteed through the incorporation of a mechanical retention ring.
For applications requiring even higher temperature tolerance, special ThermaRex and ThermaRex Cryo designs are currently in testing, with expanded temperature tolerance from -200°C to +300°C.
Glass-filled rigid dielectric insulator
Insert retention ring
Both the dielectric glass material and the insert retention ring contribute to the improved strength and reliability of Series 806 Mil- Aero connectors in high-temperature environments like aircraft FADECs.
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ENVIRONMENTAL SEALING passed all MIL-DTL-38999 Series III vibration tests including sine and random vibration testing at 200°C. The anti-decoupling mechanism, engineered around a special 7075 Aluminum alloy shell, delivers excellent ductility, strength, and proven performance in highly- stressed structural applications such as the knurled ratchet mechanism on the Series 806. High-durability performance in the anti-decoupling mechanism is further ensured with the use of a stainless-steel ratchet spring. We mentioned earlier that the shallower ramps on the triple-start thread mating interface, combined with an extremely robust self-locking coupling nut, results in a connector series that excels in vibration testing. In fact, Series 806 Mil-Aero is the only high-density micro miniature connector of its kind that has successfully “Triple ripple”wire grommet seal
SERIES 806 VIBRATION
TEST
REQUIREMENT
MIL-DTL-38999M SPEC Para. 4.5.23.2.3 with Figure 24 accessory load EIA-364-28 +200°C
Random vibration, elevated temp., 43g rms Random vibration, ambient temp., 49g rms Sine vibration, 60g
No discontinuities of 1 ms or longer. No resonance at frequencies less than 300 Hz
No discontinuities of 1 microsecond or longer
Para. 4.5.23.2.4 EIA-364-28 Test Condition V
No discontinuities of 1 microsecond or longer
Para. 4.5.23.2.1 with Figure 24 accessory load. 12 hours in each of 3 axes. 4 hours at ambient, 4 hours at -55° C, 4 hours at +200° C
SST ratchet spring for reliable anti-decoupling performance
Turning to environmental performance, the Series 806 Mil- Aero utilizes a “triple ripple”wire grommet seal, cork-and- bottle interfacial seal, and internal O-ring peripheral seal to ensure robust environmental sealing, even during 75,000 ft. altitude immersion testing. Ensuring high-altitude voltage ratings is a critical concern for microminiature circulars, given the minimal center-to-center distance between contacts. Nevertheless, it was considered critical for this connector to meet the same sea level and 70,000 ft. unpressurized zone DWV benchmarks as the MIL- DTL-38999 for both size #22HD and #20HD contacts utilized in high-density Series 806 insert arrangements.Glenair engineers were able to achieve this higher voltage rating through the use of an innovative Top Hat insulator, which lengthens the discharge creep path in shorting and flashover testing. This unique capability and design is only available in the Series 806 Mil-Aero—the only micro miniature circular with proven real-world performance meeting this 70,000 ft. DWV rating.
Cork-and-bottle interfacial seal
HIGH- ALTITUDE DWV
“Top Hat” insulator lengthens creep path
Maximize Contact Density with Series 806 The promise of the Series 806 Mil-Aero is not only that it meets or exceeds MIL-DTL-38999 performance— and that it does so in a significantly smaller size and weight package—but that it enables much higher contact density compared to standard subminiature connectors. This figure compares a D38999 Series III size 9 (lower left) with a Series 806 size 11 (upper right). Although relatively similar in size, the Series 806 size 11 can carry over three times the number of size #22HD contacts. Even when the 38999 is equipped with ultra-small size 23 contacts, the 806 can still carry more than double that number of larger size #22s, with better electrical performance and larger gauge wire support.
Series 806 Mil-Aero Size 11 19 #22HD contacts
MIL-DTL-38999 Size 9 6 #22 contacts or 9 #23 contacts
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GLENAIR
Communications Satellites
Satellite Command and Control Guidance, Telemetry, Navigation, Connectors and Wire-Harness Applications
Communications System
Antenna and Transponder RF Interconnects / Cables, High-Speed Video Downlink
Databus I/O Data Acquisition, Sensors, Actuator Control Harnessing
Propulsion System Rocket Sensors and Control Systems, Thermal Controls
IMPROVED CONTACT DENSITY
Series 806 20HD Arrangements Compared to MIL-DTL-38999 Series III Size 20 Arrangements No. of Contacts vs. Coupling Nut Diameter
Series 806 #22HD Arrangements Compared to MIL-DTL-38999 Series III #22D and #23 Arrangements No. of Contacts vs. Coupling Nut Diameter
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Series 806 #22HD D38999 #22 D38999 #23
Series 806 #20HD
D38999 #20
Number of Contacts 0 10 20 30 40 50 60
Number of Contacts 0 20 40 60 80 100 120 140 160 180 200
70
90
80
100
The table on the left demonstrates overall improved density compared to D38999 across all shell sizes for size 20HD in the Series 806 (the blue line) and size 20 in the 38999 (the orange line). The table on the right compares 38999 with size 22 contacts (the red line), 38999 with size 23 contacts (the green line), and series 806 with size 22HD contacts (the blue line). Again, the Series 806 Mil-Aero delivers significantly improved contact density and package miniaturization.
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CONTACT SELECTION GUIDE
Crimp Contacts #22HD and #20HD
Fiber Termini Size #20HD
El Ochito Contacts High-Speed Octax
Twinax / Quadrax Size #8 RF
Power Contacts Size #8
RF Coax Contacts Matched-Impedance
Glenair’s new product development model—for all our signature connector series—features constant, relentless expansion of supported contacts, wire sizes, and tooled insert arrangements. The Series 806 Mil-Aero is no different, and has now become the interconnect industry’s most comprehensive high-density circular connector solutions with tooled support for over 60 hybrid and non-hybrid contact arrangements. As you can see from the graphic above, the series now offers support for five contact sizes, giving the Series 806 the ability to support everything from standard signal, to power, high-speed datalink, high-frequency RF and microwave, fiber optics, and more.
RF / Microwave The Series 806 Mil-Aero is designed for rugged, harsh- environment land, air, and space applications, such as AESA and SAR radar, RF/microwave signal processing, GPS navigation, signal intelligence, altitude and orbit control systems, tracking telemetry and control, and other radio frequency- controlled systems. Drop-in multi-channel RF coaxial contacts in sizes 16, 12, and 8 are readily incorporated into the Series 806, and offered as turnkey assemblies with tested cable and commercial RF interfaces. Catalog solutions support frequencies DC to 6 GHz. Higher-frequency offerings up to 40 GHz may also be supported, depending on application requirements. The system supports both singlemode and multimode applications in all common wavelengths, and delivers outstanding environmental , electrical, and optical performance, with typical insertion loss of only 0.5 dB. As mentioned, Series 806 Mil-Aero is available in standard environmental, high-speed, high-temperature, hermetic, EMI filtered, and other special-purpose designs. Datasheets on these solutions are provided later in the issue—but for now, let’s do a brief overview of these many high-performance offerings. Fiber Optic Glenair Signature #20HD fiber optic termini, available in hybrid and non- hybrid insert arrangements, offer the same high data rate performance as larger size #16 D38999 series connectors with more fiber lines and reduced form factor in every shell size. 806 plug with #20HD F/O termini
High Temperature Sensor devices in aerospace engine applications are increasingly exposed to higher temperature operating environments, well beyond the capabilities of conventional interconnect devices. As mentioned, the Series 806 Mil-Aero is available in a special high- temperature solution. ThermaRex 806 includes connectors, cables, and accessory wire protection conduit systems for high-temperature applications up to 300°C. The series utilizes high-temperature ceramic insulators, and silicone seals. The key technology, however, is the Glenair Signature Crown Ring contacts that ensure continuous low-resistance performance in high continuous operating temperatures. Available in all standard Series 806 power and signal insert arrangements, Glenair Crown Ring Series 806 Mil-Aero: a complete range of connector classes and functionality
contacts deliver far superior high- temperature performance than any other available contact series.
High-temperature ThermaRex connector and Crown Ring contacts
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GLENAIR
Fuel Management
Fighter Jets
Pressure Sensor and Switch Interconnects, In-Tank Harnesses
Radar LRUs Radar Rack Cables,
Antenna Power Converter, Receiver Exciter Processor Interconnects
AESA Radar Antenna, T/R Modules, RF Signal Processor, Radar Controller Interconnects
Electronic Engine Controller (FADEC) High-Temperature I/O Connectors and Cables
Flight Deck Avionics / Equipment Bay Flight Management Systems, Flight controls, Autopilot, Cockpit Displays, and Computing Platform I/O Connectors and Harnesses
Flight Control Actuators and Sensors SWAMP Zone Transducers / Sensors, Primary and Secondary Surface Controls, Lift Control InterfaceWiring
High Speed High-speed datalink El Ochito octaxial solutions for Series 806 include environmental connectors with customer- terminateable drop-in contacts, PCB solutions for high- speed board applications, and turnkey double- and single-ended jumper cables. Series 806 El Ochito jumper solutions are available for single-ended flying leads, back-to-back assemblies, and even point-to-point solutions with El Ochito terminated to a COTS Ethernet, USB, or HDMI interconnect. These latter solutions are typically used for testing in a lab environment.
The need to launch impedance-controlled signals from a circuit board may be accomplished with El Ochito transition adapters supplied as an unassembled kit. The kit accepts 90 ohm USB 3.0 cable or 100 ohm Category 6A Ethernet cable. Series 806 Mil-Aero: Advanced Electrical, Mechanical, and Environmental Performance, With Reduced Size andWeight Summarizing the key attributes of this innovative micro miniature circular, the Series 806 offers users significant size and weight savings while delivering true MIL-DTL-38999 performance. The series is equipped with a robust coupling mechanism and reduced-pitch triple-start mating thread for superior anti-decoupling performance, particularly in small shell sizes, and is available in additional mil-aero classes including hermetics and EMI filter designs. Here now is a complete briefing book on this fully-tooled, high-availability micro miniature connector series.
Series 806 high- speed solutions include El Ochito drop-in contacts and turnkey jumper cable assemblies
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MICRO MINIATURE CIRCULAR Series 806 Mil-Aero Connectors
Product Features
Plug Connector
KEY FEATURES
Next-generation high- performance micro miniature aerospace connector Reduced-pitch triple-start modified anti-decoupling stub ACME thread Higher density 20HD and 22HD contact arrangements +200° C operating temperature High-strength aluminum alloy plug barrel “Triple ripple”wire sealing grommet (75,000 ft. rated) Snap-in, rear-release crimp contacts Metal contact retention clips Integral Nano-Band shield termination platform EMI shielding effectiveness IAWMIL-DTL-38999M para. 4.5.28 (65 dB min. leakage attenuation @ 10GHz) 10,000 amp indirect lightning strike 300g. shock MIL-S-901 Grade A high-impact shock Aluminum and stainless steel versions Environmental crimp contact, glass-to-metal seal PC tail and solder cup hermetics, RF, fiber, and EMI filter versions RoHS compliant nickel, nickel- PTFE, black zinc and stainless steel plus mil-grade cadmium finish options Printed circuit board versions with threaded mounting holes
Coupling Nut Retainer Ring Stainless steel
Coupling Nut Aluminum alloy
Insert Retention Ring Stainless steel
Wire Seal fluorosilicone rubber
Insulators Glass-filled rigid dielectric Contacts Gold-plated copper
Anti-Decoupling Spring Stainless steel
Plug Barrel High-strength aluminum alloy
Interfacial Seal fluorosilicone rubber
EMI Ground Spring Nickel-plated BeCu
Receptacle Connector
Insert Retention Ring Stainless steel
Wire Seal Fluorosilicone rubber
Insulators Glass-filled rigid dielectric
Jam-nut Aluminum alloy
Shell / Mating Interface Aluminum, modified triple-start
Panel O-ring Fluorosilicone
Shell Body Aluminum alloy
AVAILABLE LIGHTWEIGHT ALUMINUM“CODE RED”HERMETICS CODE RED is a lightweight encapsulant sealing and application process with 50% package-weight savings compared to glass-to-metal seal Kovar/stainless steel solutions. Non- outgassing CODE RED (IAW NASA/ESA) provides durable hermetic sealing with better than 1X10 -7 leak-rate performance. Gold-plated copper PCB contacts deliver outstanding low-resistance current carrying capacity. See 806-028.
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Exploded View
SERIES 806 MIL-AERO DESIGN FEATURES IAWMIL-DTL-38999 SERIES III
Interface Seal
Radial Peripheral Seal Better sealing, easier met- al-to-metal bottoming
Metal-to-Metal Mating
“Triple Ripple” Wire Seal meets 75,000 ft. altitude immersion test
Five Keys Positive alignment
High-Density Crimp Pins Gold plated copper alloy
“Top Hat” Insulator Higher voltage rating, foolproof alignment
Retention Ring Fail-safe mechanical retention of insert assembly
High-Density Crimp Sockets Gold plated copper alloy
EMI Spring Low shell-to-shell resistance, excellent EMI protection
SST Ratchet Spring and ShallowMating Thread Ramp Angle Foolproof anti-decoupling
Rear-Release Contact Retention Clip BeCu alloy
Series 806 Mil-Aero , with its high-density size #8, #20HD and #22HD contact arrangements, is designed for universal mil-aero use. The many special design features shown above allow this micro miniature circular connector to meet and even exceed MIL-DTL-38999 performance even in high-altitude, unpressurized zones. In addition to high-density signal contacts, Series 806 also supports a broad range of high-speed shielded contacts including Glenair Signature El Ochito®, as well as Size #8 Coax, and fiber optic termini.
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MICRO MINIATURE CIRCULAR Series 806 Mil-Aero Connectors Contact Arrangements (Mating face of pin connector shown. Socket numbering is reversed.)
Contact Arranagements
Number of Contacts
Number of Contacts
Number of Contacts
Number of Contacts
14-3 16-4 16-7 18-8
7-3 8-4 8-7 9-11
18-59 11-14 12-14 14-22 12-14 16-42 18-62
14-20 16-31 18-41 20-55 22-69 24-92
3 4
3 4
55 13 12 20
4
20 31 41 55 69 92
1
7
7
2 2 2 2 2
8
11
20-11 22-13 24-19 10-1 16-2 18-3 20-4 22-5 24-8 10-8A 11-13 12-27 14-21 16-41
10-15 11-19 12-26 14-39
11 13 19
15 19 26 39 60 85
12
40 60 19 20 18 24 40 93
8-1
1
14-20A
10-2 11-4 12-5 14-7
1
1
2 4 5 7
16-60 18-85 20-110 22-140 24-186
16-22 18-21 20-28 22-44 24-97
2 3 4 5 8
2 3 4 4 4
110 140 186
16-12 18-15 20-22 22-24 24-35
12
15 22 24 35
8-3 9-5
6
2 2
3 5 8
Note: Size 8 contact cavities are key-wayed for use with keyed size #8 El Ochito octaxial, quadrax, and differential twinax contacts
11
10-8 11-10 12-15
26 17 37
1
9-1
4 4
10 15
1
12-2
2
Series 806 Size 22HD Contact Arrangements (1300 VAC, 5 A)
Mating face of pin connector. Socket numbering is reversed.
1
19
1 2
20
3
3 1
11
1
4
6
1 2
10
9
1
33
4
7
30
1 2
12
1 2
2
10 11
8
11
9
12
3
6
7
2
9
39
8
13
15
12
3
7
3
18
16 21
16
15
13
8
5
4
3
14
6
4
4 3
4
23
Symbol indicates master key location.
17
19
7
5
25
24
6 5
26
10
7-3
8-4
8-7
9-11
10-15
11-19
12-26
14-39
Arrangement No. No. of Contacts
3
4
7
11
15
19
26
39
72
101
58
116
45
130
Mating face of pin connector. Socket numbering is reversed.
65
33
52
87
77
143
40
50
90
22
62
39
102
29
73
29
39
155
48
29
19
113
12
83
20
58
20
27
166
35
10
12
20
92
67
12
123
42
12
5
75
100
5
50
5
5
176
4
132
82
183
107
57
1
1
1
1
138
1
140
4
3
4
4
4
60
85
110
186
Symbol indicates master key location.
137
56
11
9
11
81
11
182
106
11
49
19
19
19
74
41
99
26
18
66
131
34
175
28
28
91
57
38
21
122
47
28
165
38
82
49
112
32
72
39
61
51
154
101
64
44
89
142
76
57
129
71
115
86
100
16-60
18-85
20-110
22-140
24-186
Arrangement No. No. of Contacts
60
85
110
140
186
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Contact Arrangements (Mating face of pin connector shown. Socket numbering is reversed.)
Series 806 Size 20HD Contacts Arrangements (1800 VAC, 7.5 A)
Mating face of pin connector. Socket numbering is reversed.
1
17
1
13
11
1
18
1 2
10
27
1 2
14
1 2
2
8
3
1 2
3
7
9
15
31
9 10
20
8
3
5
10
3
7
4
6
4
8
3
4
Symbol
4
5
7
6 5
6 5
indicates master key location.
10
8-3
9-5
10-8
11-10
12-15
14-20
16-31
Arrangement No. No. of Contacts
3
5
8
10
15
20
31
1
31
Mating face of pin connector. Socket numbering is reversed.
1
32
1
23
27
1
20
24
56
40
47
74
20
61
34
70
30
50
50
40
86
55
20
41
92
60
69
50
30
Symbol
10
30
40
40
indicates master key location.
10
20
10
10
18-41
20-55
22-69
24-92
Arrangement No. No. of Contacts
41
55
69
92
Series 806 Size 16 Contact Arrangements
Mating face of pin connector. Socket numbering is reversed.
9
1
6
1
E
A
10
1
2
2
8
5
7
2
A
A B
3
7
B
D
11
12
4
3
4 3
Symbol indicates master key location.
6
4
C
5
8-1
10-2
11-4
12-5
14-7
16-12
Arrangement No. No. of Contacts
1
2
4
5
7
12
Mating face of pin connector. Socket numbering is reversed.
18
1
17
2
1
15
1
14
2
16
14
3
30
19
2
10
1
20
29
13
16
13
3
15
15
4
3
23
31
17
9
2
16
21
28
12
35
12
32
21
15
11
14
4
5
22
4
22
24
18
22
8
3
27
11
14
12
17
33
34
11
5
20
13
6
5
21
19
Symbol indicates master key location.
13
23
26
10
18
6
19
10
7
4
6
20
24
12
25
7
9
6 5
8
11
7
7
9
8
8
10
9
18-15
20-22
22-24
24-35
Arrangement No. No. of Contacts
15
22
24
35
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MICRO MINIATURE CIRCULAR Series 806 Mil-Aero Connectors
Contact Arrangements (Mating face of pin connector shown. Socket numbering is reversed.)
Series 806 Size 12 Contact Arrangements
Mating face of pin connector. Socket numbering is reversed.
1
6
1
1
2
A
2
7
5
2
3
Symbol
3
4
indicates master key location.
9-1
12-2
14-3
16-7
Arrangement No. No. of Contacts
1
2
3
7
Mating face of pin connector. Socket numbering is reversed.
1
12
1
10
11
2
1
9
1
7
13
2
9
8
2
10
11
3
18
14
2
6
8
19
3
8
11
10
7
3
12
13
4
9
17
15
3
5
Symbol
7
16
4
4
indicates master key location.
5
8
6
4
5
6
5
6
7
18-8
20-11
22-13
24-19
Arrangement No. No. of Contacts
8
11
13
19
Series 806 Size 8 Contact Arrangements
Mating face of pin connector. Socket lettering is reversed. Symbol indicatesmaster key location.
A
B
B
A
B
A
A
B
G
C
B
A
H
A
E
C
D
C
C
D
F
D
E
10-1 1 - #8
16-2
18-3 3x #8
20-4 4x #8
22-5 5x #8
24-8 8x #8
Arrangement No. No. of Contacts
2 - #8
Series 806 Size 22HD and 16 Combo Contact Arrangements
Mating face of pin connector. Socket numbering is reversed. Symbol indicatesmaster key location.
1
28
1 2
3
22 23 24
29
1 2
50
4
1
25
21
16
36
15 16
2
A
A
15
1 2
26
35
20
5
3
17
A
14
8
1
54
51
9 10 11
3
18
7
2
27
26
34
14
19
6 7
4
13
5
4
25
37
A
B
19
A
A
B
55
17 B
D
B
D
18
13
8
24
34
B
45 D
5
20
C
5
23
28
33
6
12
8
17
21
12
21
22
6
3
6
29
32
6
9
16
11
53
52
5
4
11
4 3
8 C
7
31
30
C
7
10
15
10
10
8
9
9
14 13 12 11
40
15
10-8A
11-13
12-27
14-21
16-41
18-59
Arrangement No.
11
6 2
26
17
37
55
No. of #22HD Contacts No. of #16 Contacts
2
1
4
4
4
QwikConnect • January 2022
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Contact Arrangements (Mating face of pin connector shown. Socket numbering is reversed.)
Series 806 Size 22HD and 12 Combo Contact Arrangements
Mating face of pin connector. Socket numbering is reversed. Symbol indicatesmaster key location. Arrangement No. No. of #22HD Contacts No. of #12 Contacts
1
28
1 2
29
23 36
50
3
24 25
22
1
14
21
4
A
58
51
1
10 A
52
57
35
26
5
20
1 2
15
20
59
12 13
37
2
40
9
34
27
7
34
6
18 19
A
3
11
B
A
B
A
8
11 3
12
45
21
7
9 10
4
B
7
B
4
5
8
17
39 38
33
28
18
60
5
17
8 7
6
6
56
53
9
29
16
32
31 30
10
15
40
14 13 12 11
7
8
15 14
11-14
12-14
14-22
16-42
18-62
12
13
20
40
60
2
1
2
2
2
Series 806 Size 22HD and 8 Combo Contact Arrangements
1
44
Mating face of pin connector. Socket numbering is reversed. Symbol indicatesmaster key location.
40
1
1
6
4
51
45
26
25
74
76
A
B
B
17
A
1
4
B
A
73
52
A
14 B
13
33
18 19 1 2
86
7
24
6
15
1
13
17
3
5
16
B
A
16
21
85
77
37
19
90
4
32
27
10
18
15
5
22
24
40
34
36
38
A
87
89
93
91
C
D
12
C
20
6
C
D
18
15 5
D
14
C
28
31
39
23
20
92
83
79
7
13
8
13
18
16
12
7
17
16
8
12 11
19
12
35
67
58
88
10 9
19
30
8
9
29
30
59
12
9
82
66
80
18
13
20
14-20A
16-22
18-21
20-28
22-44
24-97
Arrangement No.
19
20
18
24
40
93
No. of #22HD Contacts
1
2
3
4
4
4
No. of #8 Contacts
Series 806 Mil-Aero combo insert arrangements support applications with both standard data signal requirements, plus high-speed datalink (multi-gigabit Ethernet, HDMI, etc.), as well as RF / microwave, and power. Keyed El Ochito® octaxial contacts support 10GbE in a single shielded contact. Keyed size #8 differential Twinax and industry-standard Quadrax are also supported. A broad range of non-keyed RF Coax contacts—available in different frequency ranges—as well as non- keyed size #8 power contacts are also supported in these combo insert arrangements.
LIGHTWEIGHT DUMMY CONTACT SEALING PLUGS Glenair recommends the use of dummy contact sealing plugs for use in unwired contact cavities. Sealing plugs are available for use in any of the above insert arrangements with size #22HD and #20HD contacts. Dummy Contact Sealing Plugs (DCSP) are a weight-saving alternative to populating unused cavities with electrical contacts and conventional sealing plugs, as they do not require the use of unwired contacts in the effective sealing of the contact cavity from the interfacial seal to the rear-end grommet seal. Insertion and removal of DCSP follows the same procedures and uses the same tools as with standard contacts.
QwikConnect • January 2022
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MICRO MINIATURE CIRCULAR Series 806 Mil-Aero Connectors
Materials and Finishes, Performance Specification
Standard Materials and Finishes
DESCRIPTION
MATERIAL
FINISH
Pin Contact
Copper alloy
50 microinches gold over nickel 50 microinches gold over nickel Contact hood: passivate
Socket Contact
Copper alloy, with stainless steel hood
Insulators
High-grade rigid dielectric
None None Nickel
Seals
Fluorosilicone/silicone blend, blue
EMI Spring
Beryllium copper
Shell, Coupling Nut, Jam-nut
Aluminum alloy or stainless steel
See how-to-order tables for finish options
Contact Retention Clip
Beryllium copper
None
Anti-Decoupling Ratchet Spring
Stainless steel
Passivate
Performance Specification
TEST DESCRIPTION
REQUIREMENT
PROCEDURE
Dielectric withstanding voltage at sea level
MIL-DTL-38999M para. 4.5.11.1 EIA-364-20 Method A 2 mA maximum leakage current Unmated pairs MIL-DTL-38999M para. 4.5.11.2 EIA-364-20 Method A 2 mA maximum leakage current Mated pairs
Contact Size
Altitude Sea level Sea level
Voltage
20HD 22HD
1800 1300
Dielectric withstanding voltage at altitude
Contact Size
Altitude 50,000 ft 70,000 ft 100,000 ft 50,000 ft 70,000 ft 100,000 ft
Voltage
1000 1000 1000
20HD
800 800 800
22HD
Insulation resistance at ambient temperature Insulation resistance at elevated temperature
5000 megohms minimum
MIL-DTL-38999M Para. 4.5.10.1 EIA-364-21 MIL-DTL-38999M Para. 4.5.10.2 EIA-364-21
1000 megohms minimum
Contact resistance at 25°C, crimp contacts
AS39029C Para. 4.7.5 EIA-364-06 Silver-plated wire
Maximum Voltage Drop (millivolts)
Test Current Amperes
After Conditioning
Wire Size
Initial
20 22 24 26 28 30
7.5
55 73 45 52 54 60
66 88 54 63 65 73
5 3 2
1.5
1
Contact resistance at 200° C, crimp contacts
AS39029C Para. 4.7.5 EIA-364-06 Silver-plated wire
Test Current Amperes
Maximum Voltage Drop (millivolts)
Wire Size
20 22 24 26 28 30
7.5
94
5 3 2
125
77 89 92
1.5
1
103
Low level contact resistance, crimp contacts
AS39029C Para. 4.7.4 EIA-364-23 Silver plated wire
Maximum Contact Resistance (milliohms) Initial Values After Conditioning
Wire Size
20 22 24 26 28 30
9
11 17 23 38 60 88
15 20 31 50 75
QwikConnect • January 2022
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Performance Specification
Performance Specification
TEST DESCRIPTION
REQUIREMENT
PROCEDURE
Contact resistance, glass-sealed hermetic connectors
MIL-DTL-38999M Para. 3.18.2 EIA-364-06
Contact Size, Wire Size
Test Current Amperes
Maximum Millivolt Drop Initial
After Conditioning
20 22
5 3
60 85
75 95
Shell-to-shell conductivity
MIL-DTL-38999M Para. 4.5.25 EIA-364-83
Finish Code
Shell Matl/Fin Al/OD Cad Al/Ni-PTFE
Millivolt Drop (mV)
NF MT ME ZR Z1 ZL NF MT ME ZR Z1 ZL
2.5 2.5 1.0 2.5
Al/EN
Al/Zn-Ni SST/pass. SST/Ni
10.0 1.0
Backshell shield braid to shell conductivity
MIL-DTL-38999M Para. 4.5.25.1 EIA-364-83
Finish Code
Shell Matl/Fin Al/OD Cad Al/Ni-PTFE
Millivolt Drop (mV)
5.0 5.0 3.5 5.0
Al/EN
Al/Zn-Ni SST/pass. SST/Ni
15.0 3.5
Indirect lightning strike
No evidence of damage which could impair proper functioning. Connectors shall meet shell-to-shell conductivity, DWV and coupling torque.
MIL-DTL-38999M Para. 4.5.47 EIA-364-75 10,000 Amps peak current MIL-DTL-38999M Para. 4.5.28
EMI shielding
Leakage Attenuation, (dB) minimum
Freq. MHz 100 200 300 400 800
Electroless Nickel Finish
Cadmium, Nickel-PTFE, Zinc-Nickel Finish
90 88 88 87 85 85 76 70 69 68 66 65
90 88 88 87 85 85 69 65 61 58 55 50
1,000 1,500 2,000 3,000 4,000 6,000 10,000
Durability
No evidence of damage which could impair proper function- ing following 500 cycles of mating and unmating.
MIL-DTL-38999M Para. 4.5.8 EIA-364-09 MIL-DTL-38999M Para. 4.5.7 EIA-364-114
Coupling and uncoupling torque
Maximum Engagement lbs-inch.
Minimum Disengagement lbs.-inch.
Shell size
8 9
8 8
2 2 2 2 2 2 3 3 3 5 5
10 11 12 14 16 18 20 22 24
12 12 12 16 20 24 28 32 36
Insert retention
100 pounds per square inch, 25 pound minimum force
MIL-DTL-38999M Para. 4.5.12 EIA-364-35
External bend moment
MIL-DTL-38999M Para. 4.5.16 EIA-364-43
Shell size
Pound inches
8 9
100 100 100 200 300 400 500 600 700 800 900
10 11 12 14 16 18 20 22 24
QwikConnect • January 2022
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Performance Specification MICRO MINIATURE CIRCULAR Series 806 Mil-Aero Connectors
Performance Specification
TEST DESCRIPTION
REQUIREMENT
PROCEDURE
Contact retention
MIL-DTL-38999M Para. 4.5.20.1 EIA-364-29
Contact size
Pounds ± 10 percent
22HD 20HD
10 10
Magnetic permeability
2 µ maximum
MIL-DTL-38999M Para. 4.5.48 EIA-364-54
Contact engaging /separation force Contact forces shall meet AS39029 Table 9 requirements
AS39029C Para. 4.7.6 EIA-364-37
No evidence of damage detrimental to the function of the connector
MIL-DTL-38999M Para. 4.5.4 EIA-364-32 Mated connectors, -65° C to +200° C
Temperature cycling (thermal shock) Random vibration, elevated temperature, 43g rms Random vibration, ambient temperature, 49g rms
No discontinuities of 1 microsecond or longer No resonance at frequencies less than 300 Hz No discontinuities of 1 microsecond or longer
MIL-DTL-38999M Para. 4.5.23.2.3 with Figure 24 accessory load EIA-364-28 +200°C MIL-DTL-38999M Para. 4.5.23.2.4 EIA-364-28 Test Condition V MIL-DTL-38999M Para. 4.5.23.2.1 with Figure 24 accessory load 12 hours in each of 3 axes 4 hours at ambient, 4 hours at -55° C, 4 hours at +200° C
Sine vibration, 60g
No discontinuities of 1 microsecond or longer
Mechanical shock, 300g
No discontinuities of 1 microsecond or longer
MIL-DTL-38999M Para. 4.5.24.1 EIA-364-27 MIL-DTL-38999M Para. 4.5.24.2 MIL-S-901 Grade A MIL-DTL-38999M Para. 4.5.26 EIA-364-31 Method 4 10 cycles, 10 days, 25 – 65°C 80 – 100% RH
High impact shock (901)
No discontinuities of 1 microsecond or longer No evidence of damage which could impair proper functioning.
Humidity (cyclic)
Meet DWV and IR test
Ozone exposure
No evidence of damage detrimental to the function of the connector No damage to plastic, elastomeric and bonding materials detrimental to the function of the connector. Connector shall meet coupling torque and DWV requirements when tested within 3 hours of immersion. No evidence of moisture on connector interface or contacts. At the end of the third cycle, while still submersed, connec- tors shall meet dielectric withstanding voltage and 1,000 megohms insulation resistance. Connectors shall meet insulation resistance requirement while at -65°C and 100,000 ft. Connectors shall meet DWV requirement when returned to ambient conditions. All nonmetallic materials shall not exceed 1.0% Total Mass Loss and 0.1% Total Volatile Condensible Materials. Applica- ble only to connectors that have been subjected to optional thermal vacuum outgassing.
MIL-DTL-38999M Para. 4.5.29 EIA-364-14
Fluid immersion
MIL-DTL-38999M Para. 4.5.30 EIA-364-10
Altitude immersion
MIL-DTL-38999M Para. 4.5.9 EIA-364-03 75,000 feet
Altitude (low temperature)
MIL-DTL-38999M Para. 4.5.21 EIA-364-105 -65°C 100,000 ft. MIL-DTL-38999M Para. 4.5.42 ASTM E595
Thermal vacuum outgassing
Salt Spray (dynamic)
MIL-DTL-38999M Para. 4.5.13.2 EIA-364-26 500 mating cycles
Finish Code
Matl/Fin
Hours
NF MT ME ZR Z1 ZL
Al/OD Cad Al/Ni-PTFE
500 500
Al/EN
96
Al/Zn-Ni
500
SST/passivate
1000 1000
SST/Ni
QwikConnect • January 2022
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MADE IN AMERICA: From Design Engineering to Component Part Manufacture, Assembly, and Test Connector shells, plating, inserts, contacts, environmental seals, filter arrays, cable assembly, and qualification testing all performed in-house
Largest small form-factor connector engineering team in the industry Largest U.S. CNC metal turning operation in the high-rel interconnect industry Largest U.S. interconnect component part fabrication and assembly facility Fully certified in-house (third party) qualification test facility Massive same-day inventory of Series 806 Mil-Aero connectors and cables—bagged, tagged, and ready for immediate shipment
QwikConnect • January 2022
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AR MA ALLOYS
THAT’S WHAT
Key to Elements
Titanium Alloy
Beryllium
Al
Mg
Cu Pb
Sn Zn
98%
1%
85%
5
Al Au N V O S Nb Ta Mo Co Mn K Ag
Aluminum Gold Nitrogen Vanadium Oxygen Sulfur Niobium Tantalum Molybdenum Cobalt Manganese Potassium Silver
Al
Aluminum
Developed in 1935. Originally called “Alloy 61S”
Si Cu Cr
5%
5
Mg Si Cu Cr Sn Pb Zn Fe C P Ni Ti Be
Magnesium Silicon Copper Chromium Tin Lead Zinc Iron Carbon Phosphorus Nickel Titanium Beryllium
<1%
Excellent corrosion resistance, workability, and joining characteristics
Corrosion resistant, th produces litt
Inconel (X-750)
Marine B
Cu Be Co Ni Fe 98%
Used in high-st Fe C Mn Si Cu 98%
Used in springs, cryogenic equipment, and percussion instruments
2%
<1%
High-strength, non-magnetic, non-sparking. Ductile, weldable, and machinable.
Hard, high-strength
FR4
Sold
K (CN) 2 Ag
Primary material has high is workable, and cor A barrier material, usually N copper substrate before pla C 2 Au K N
In high-humidity environments, “red plague” galvanic corrosion can occur
Primary material has the highest known electrical and thermal conductivity of all metals
Chromoly Steel
Silver P
Metals
Nonmetals Other
24%– 26%
6%– 8%
Fe Mo Mn Cr 60% 3%– 5%
Ni
Ni Ti
Nb & Ta Cr
_>70%
Metalloids
1.2% max
2.25%– 2.75%
First developed for use in the paper industry
Puzzle answers published at: www.glenair.com/qwikconnect
High corrosion resistance and mechanical strength
Oxidation corrosion r extreme pressure and
QwikConnect • January 2022
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