New Interconnect Technology for Modern Soldier Systems

Future Soldier Systems. Glenair QwikConnect • January 2015 • Volume 19 • Number 1

JANUARY 2015 NUMBER 1 Qwik Connect n n n VOLUME 19

GLENAIR

IN THIS ISSUE: NEW INTERCONNECT TECHNOLOGY FOR MODERN SOLDIER SYSTEMS

NEW INTERCONNECT TECHNOLOGY FOR MODERN SOLDIER SYSTEMS

Mighty Mouse jumper cable for NATO power module

FUTURE SOLDIER SYSTEMS When infantry soldiers went to war during the 20th century they typically carried a rifle, helmet, ammunition, food and some spare clothes. While their 21st century counterparts might look back and appreciate the simplicity of such an outfit, few of them would be happy to lose the equipment innovations that have so measurably advanced 21st century ground soldier effectiveness. Soldier equipment modernization efforts—such as have been implemented in the US, UK, France, Singapore, Germany and elsewhere—have gone by a variety of names: Future Soldier, Future Force Warrior, Land Warrior, NETT Warrior and so on. A common theme among these modernization programs has been their “systems of systems” approach, which emphasises the blending of individual components into a complete integrated system. More recently, other models have emphasized a versatile power and networking backbone with the flexibility to accommodate a wide range of available device types—particularly as soldier operational requirements vary so significantly from one battle geography to the next.

With serious conflicts continuing to simmer throughout the world, governments and industry remain actively engaged in research and development in soldier systems and discrete technologies. In this special issue of QwikConnect , we review the equipment that currently supports the 21st century warrior as well as some innovations still in the development phase— signs of what is to come in the ongoing effort to advance soldier effectiveness, lethality, mobility and survival. POWER MANAGEMENT AND WEIGHT SAVING To anyone who hasn’t carried a soldier’s load of equipment, power management might not sound like the most important military technology topic. In fact, it is one of the most critical technology issues for future soldiers. Without efficient and sustainable electrical power, none of the electronic innovations detailed here would be possible. Simply put, soldiers do not have the luxury of mains power and are totally dependent on a mobile power sub-system to keep night vision goggles, thermal-imaging sights, electronic counter-measures, personal radios, GPS and other technologies working in the field. For many years this requirement has been served with high- performance batteries. But size and weight reduction efforts

have led to new power management systems and rechargeable cell technologies. Throughout the history of modern soldier programs, and as the number of electronic soldier devices increased, battery power—a heavy and cumbersome resource—has had to expand. A soldier going out on a week-long patrol, for example, needs sustainable power for every device he uses. Command and control (situational awareness) capabilities are a major element of future soldier programs. But such technologies are power hungry and add significantly to pack weight and transportability. The lack of ready power can and will adversely impact soldier effectiveness across the broad range of their work: from disaster relief to counter-terrorism. Possibly one of the biggest changes to soldier battery/power management technology has been the switch from primary batteries (non-rechargeable) to rechargeable. During the early stages of the Iraq War, most batteries in theater were still primary, which placed significant strains on military supply chains. To say soldiers have been burdened with batteries presents the problem too mildly. The Iraq and Afghanistan wars tested soldiers to their physical limits—with some carrying nearly 60% (around 50-60kg) of their body in gear and equipment. It should come as no surprise that musculoskeletal

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medical conditions—caused by excessive loads—have become more common throughout the military services. Now in the aftermath of Afghanistan and Iraq, there is a renewed effort to reduce loads—particularly in the development and use of centralized battery packs, integrated, multiport power hubs and interconnect cabling that allow soldiers to run devices off one rechargeable lithium-ion cell. In addition, researchers have increasingly focused on improving lithium-ion technology itself. Organizations like the US Army Research Laboratory have made significant gains in lithium-ion technology. One

and networking capabilities. The aim is not only to revolutionize how troops speak to each other but also how voice, location and data is transmitted through integrated warfighter information networks.

Iraq and Afghanistan have demonstrated soldiers must remain networked at all times to maintain tactical effectiveness and agility. The US military, for instance, is completely overhauling its information sharing capabilities for dismounted troops under a program called Nett Warrior. The aim is to mimic the simplicity and capacity of commercial networks, but retain the encryption needed for modern military operations. This “network centric” approach emphasizes the need to connect, or network, different technologies to enable greater data sharing and battlefield awareness. It is the “digital backbone” for any 21st century soldier. Nett Warrior will allow soldiers to securely share pictures, text messages and transmit location data across the network using an off-the-shelf (OTS) smartphone and software-defined radio. The core of this is the single channel AN/PRC-154 Rifleman Radio - made by General Dynamics C4 Systems and Thales - that transmits voice and data simultaneously using the Soldier Radio Waveform. Information from each device is also sent higher up the chain of command so commanders have a real-time picture of the battlefield. Along with OTS smartphone hardware, military and industry are also focusing on developing soldier-focused software applications (or apps). It’s not so much the future, but

of the most important developments has been the improvement in power output. Current lithium-ion batteries operate around the 3.6V-4.2V range but an improved

understanding of the interface between a battery’s cathode and electrolyte means 5V may soon be possible. Ultimately, that means batteries will last much longer and fewer spares will be necessary. Glenair has also been at the forefront of soldier power

management and weight saving work. Small form factor connectors, such as Mighty Mouse and now SuperFly have enabled integrated power system manufacturers to reduce the footprint of power equipment below what would otherwise have been possible. Glenair innovations in wire and cabling—such as

conductive materials woven directly into webbing—has also contributed to reductions in power management system size and weight.

keeping up with the rapid pace of technological change in the commercial sector. Soldiers are often frustrated their military communications gear doesn’t reflect the capabilities of their personal cellphones or tablets. US agency DARPA is working to revolutionize acquisition and

TACTICAL COMMUNICATIONS AND NETWORKING It is a universal motto among soldiers: “no comms, no bombs.” Those four words sum up the vital contribution communication systems play on the modern battlefield. After a decade of conflict in Iraq and Afghanistan, many Western armies are now focusing on upgrading their communication

soldier capabilities through its Transformative Apps (TransApp) program. The idea is to create a military-style “App Store” where applications of all varieties

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The backbone for future US soldier communications is the Warfighter Information Network-Tactical (WIN-T), which delivers voice and

are available. These apps can evolve to reflect a changing operational environment. Apps already in use include: blue force tracking, training manuals, mission planning, ballistics calculator for snipers and IED detection and geo-tagging. Although there are still concerns over security and robustness, expect to see more commercial devices in the hands of soldiers in the future. In our technology-driven world—where a new phone is released every few months—it is no longer viable for armies to spend thousands of dollars on a military-grade smartphone that will be obsolete as soon as it is operational. Communication capabilities and situational awareness on the battlefield is also being improved through enhanced networking capabilities. This means soldiers are no longer limited to traditional line of sight communications, which can have limited range in built-up areas or under cover. Take for example the Exelis SpearNet radio, it is a mobile ad-hoc networking (MANET) device, which means the signal “hops” from one radio user to the next and therefore extends the range of the network. Radio such as SpearNet can provide voice, integrated GPS with SA reporting, and data transfer (100-1500 Kbps) across dismounted networks spanning 6 km. The Spanish Army has chosen the SpearNet for its Combatiente de Futuro (COMFUT) modernization efforts.

data services to soldiers without the need for fixed infrastructure.

WIN-T utilizes satellite communications (SATCOM) to extend the network in maneuver Brigade Combat Teams (BCTs). WIN-T is also self-healing, which means devices can re-route bandwidth if a node breaks down.

 Army Signal Corps patch and HiPer 55116 radio connectors

The latest WIN-T, Increment 2, allows soldiers to use voice and data communications on the move using mobile, self-forming networks - meaning it creates its own transmission paths based on terrain and environment - a first for the US military. WIN-T systems were deployed to West Africa in 2014 as US troops tackled the Ebola outbreak in the region. The equipment improved communications between US Africa Command, troops on the ground and NGOs. The US Army is also upgrading its battle-proven Force XXI Battle Command Brigade and Below/Blue Force Tracking (FBCB2/BFT) system to prepare for the new network. FBCB2/BFT, a system which resembles a large ruggedized tablet, is fitted to most infantry vehicles like MRAPs or Stryker vehicles. The software upgrade means any changes inputted on a vehicle’s FBCB2/BFT will be seen by a dismounted soldier on his Nett Warrior device. The French Army is also placing a significant emphasis on networked communications and data sharing as part of its FELIN (Fantassin à Équipements et Liaisons Intégrés) soldier modernisation. French vehicles are fitted with Sagem’s Spider terminal, a touch-screen display system that resembles the US Army’s FBCB2/BFT. Dismounted squad leaders also have a portable terminal information system designated the SIT COMDE (Offboard Soldier Terminal Information System), which will improve blue force tracking and overall situational awareness.

 Air Force Capt. Bryony Veater, Space Liaison Officer and Space Weapons Officer with the 807th Expeditionary Air Support Operations Squadron, using a Defense Advanced GPS Receiver. Captain Veater trains U.S. and coalition forces how to utilize space weapons into ground warfare. (U.S. Air Force photo by Staff Sgt. David Carbajal)

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War, could amplify light several thousand times but were almost useless without some form of ambient light. This “Generation 1” equipment was also bulky and had a voracious appetite for batteries. Today’s “Generation 3” I2 devices— like the US Army’s helmet-mounted AN/ PVS-14 monocular night vision device— amplifies a wider spectrum of available light and even some infrared energy, thanks to advances

Unit location, video and images are currently shared over the network. In the future, soldiers could be fitted with physiological sensors that can detect dehydration, elevated blood pressure or cognitive delays from lack of sleep. That information would then be shared over the battlefield network where commanders could assess unit effectiveness and readiness in real time. Smart weapons will also be able to transmit information such as shots fired and remaining ammunition. NIGHT VISION EQUIPMENT The ability to see at night or in degraded visual conditions, such as fog or haze, is a huge tactical advantage on today’s battlefield, and at times can mean the difference between life and death. Soldiers equipped with night vision capabilities are able to see, and engage, the enemy far quicker than if they were relying on their naked eye. In addition, they can navigate obstacles and identify possible booby traps which are obscured under normal conditions. Night vision equipment is becoming cheaper and more available, potentially finding its way into the hands of terrorist groups like Islamic State or the Taliban. So, militaries are keen to procure newer and more capable night vision equipment to retain their technological edge. The US Army in particular - which Militaries currently use two types of night vision technology; the first is known as image intensification (I2), which amplifies existing light. The second is thermal vision, also known as infrared, which forms an image using infrared radiation. saw the massive benefits gained from using night vision gear in Iraq and Afghanistan - is investing in new technologies which will achieve this end.

in photocathode technology. Importantly, newer I2 devices can keep functioning for more than 20 hours on a single AA battery which has benefits for both logistics and soldier loads. The lightweight AN/PVS-14 - manufactured by ITT Exelis and L-3 Warrior Systems - remains one

of the most popular NVG devices in the world. In 2012, the UK placed a $33m contract with ITT Exelis to provide AN/PVS-14 equipment as part of British Army modernisation efforts. Elsewhere, Israeli company Elbit Systems introduced the ZACT-NV32 micro monocular I2 sight in 2012, which is thought to be the lightest product on the market at just 180 grams. I2 technology has several drawbacks, however, including its reliance on ambient light and being limited only to night operations. Thermal imaging - which creates a picture based on infrared radiation - offers a step up in capability and While the technology has been fitted to aircraft and vehicles for several decades, IR systems for the dismounted soldier were rare up until the late ‘90s. They were often too cumbersome and costly to be viable for every frontline soldier, and so were often reserved for reconnaissance or special forces units. That has changed over recent years with thermal sights now becoming a regular addition to the soldier’s loadout.

can “see through” adverse weather or battlefield obscurants like smoke, even during the day. Because thermal sights are digital, it also opens up the possibility for video output across the network.

Traditional night vision goggles (NVGs) and night weapon sights use image intensification (I2). Early I2 devices, such as the US Army’s revolutionary AN/PVS-2 introduced during the Vietnam

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SuperJack™ the new industry standard interconnect for thermal weapons sights

ISTAR - TARGETING EQUIPMENT AND OPTICS

It is one of the great constants in warfare, you must know more about your enemy than they know about you. Gaining the upper hand will keep you alive. That’s why advanced intelligence, surveillance, target acquisition and reconnaissance equipment is some of the most valued equipment for militaries. These are the technologies used by fire support teams or dismounted reconnaissance troops to locate, and then eliminate, enemy forces in a warzone.

The US Army is currently fielding the latest generation of thermal sights, designated the AN/PAS-13 Thermal Weapon Sight (TWS). The latest TWS uses uncooled, forward-looking infrared technology with 17 micron sensors that offer significant weight and power savings over previous models using 25 micron sensors. Many thermal sights, like the AN/PAS-13, also feature standard video output

for training, image transfer or remote viewing. Modernization programs, like the French Army’s FELIN system, want to integrate the TWS with a head-mounted display (HMD) to allow observation, and firing, around

Today’s surveillance and reconnaissance devices are also connected to the battlefield network, meaning they can send video and data across the 21st century digital battlespace, giving greater situational awareness for commanders at all levels.

corners or obstacles. The US Army’s current effort is called the Family of Weapon Sights which will wirelessly link weapon-mounted thermal sights to NVGs, allowing soldiers to rapidly engage targets without switching between devices. Yet like I2

Several militaries are currently in the process of upgrading or replacing their legacy

dismounted ISTAR equipment. The US Army is fielding the latest version of the Northrop Grumman- built Lightweight Laser Designator Rangefinder (LLDR-2H) system. Nicknamed the “Eye of God,” LLDR-2H offers extremely accurate target designation for GPS-

guided munitions like the JDAM or Excalibur. The LLDR incorporates a thermal imager, day camera, laser designator and digital magnetic compass. A built-in GPS calculates coordinates and a Laser Designator Module (LDM) emits coded laser pulses, which are compatible with US and NATO guided munitions.

technology, thermal sights can also have several downsides especially when it comes to seeing detail. Developers are trying to bring together both worlds with fused systems, blending I2 and thermal images into one. One of the best examples of fused technology is the AN/PSQ-20 Enhanced Night

Vision Goggle - made by ITT Exelis and L-3 Warrior Systems - which is currently being fielded with the US military.

Equipped with the LLDR, soldiers are able to designate stationary targets from over 5km and identify vehicle-sized targets at more than 7km during the day. At 31.5 pounds (14.2kg) it

In Europe, Thales has introduced the Minie-Dir fused system, an adaptation of the Minie-D which has already been selected for modernization programs in France, Germany and Spain. The 490g Minie-D can also work as

is lighter than previous models, though certainly not lightweight. Lighter systems with embedded GPS receivers are also available including BAE Systems’ TRIGR and Northrop’s Mark VIIE which both weigh just over 5 pounds.

a HMD receiving video from unmanned systems, or send video to command posts.

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Thales also has a successful family of lightweight surveillance and target acquisition systems

Civilian Applications

SuperFly night- vision goggle I/O to board jumper 

The clarion call has been, “reduce weight” when it comes to advanced soldier systems, but

named Sophie. The Sophie range, used extensively by French armed forces, features a high-resolution thermal imager, color daylight camera or optics, laser pointer and integrated GPS. In 2012, the Australian Army selected the Sophie MF system for its LAND 17 1B program in a full-scale

an alternative approach might be to develop technology that helps soldiers manage larger and heavier loads. Lockheed Martin has developed a hydraulic-

powered anthropomorphic exoskeleton called the Human Universal Load Carrier (HULC) designed to help users carry up to 200 pounds of equipment for extended periods. DARPA, in collaboration with Boston Dynamics,

effort to modernize indirect fire support. With its latest product, the Sophie Lite, Thales has shaved 2kg off the Sophie range with a product that weighs just 1.6kg, yet delivers comparable performance to earlier models. For Joint Terminal Attack Controllers (JTAC) - whose job it is to direct air strikes against the enemy - accurate target acquisition is particularly important. Being a JTAC is an incredibly skilled job and one wrong move could lead to ineffective fire or, much worse, a friendly fire incident. Pilots and JTACs must work closely to locate the enemy, choose the type of munition and then engage - often only using paper maps and a radio. L-3 Communications has developed the Remote Operations Video Enhanced Receiver (Rover) to improve coordination and target acquisition between air and ground units. The early Rover system included a receiver, antenna and rugged laptop that displayed sensor data from airborne platforms. The latest version is a pocket-sized edition called the Tactical Rover (e), which is interoperable with laptops or tablets, and is a fraction of the weight of original Rover devices. Similar technology is being developed under DARPA’s Persistent Close Air Support programme, which digitally links pilots and JTACs. Contractor Raytheon is currently flight testing the technology, with live fire tests expected in 2015 using an A-10 attack aircraft. DARPA claims the system could potentially reduce the time for calling in airstrikes from one hour to just six minutes. SOLDIER HEAD-UP DISPLAYS For years aircrews have been able to use the head-up display (HUD), a transparent screen which projects data and allows a pilot to fly without looking down at the instruments - hence the “head-up” moniker. A further enhancement of this technology has been the HMD, used by AH-64 Apache pilots among others, which projects information directly onto the pilot’s eye from a reticule attached to the helmet. Dismounted soldiers can also benefit from the greater situational awareness and information superiority afforded by HMD systems. The US, Spain, Malaysia, Singapore and Germany have all experimented with soldier HMD systems as part of

has also developed a four-legged robot called the LS3 which helps US Marines carry ordnance and equipment over rough terrain. But the applications for load carrying

technology is not strictly limited to the military. Firefighters for example, are actively pursuing civilian applications for exoskeleton technology. A wearable robot exoskeleton of this type would enable users to travel further, reduce fatigue and risk of injury. Heads up display technology, such as has been developed by the Osterhout

Design Group may be used to assist police, TSA and other security services implement facial recognition software crucial to protecting civilian populations from terrorist attacks. Perhaps the most familiar and immediately useful military technology already used on a daily basis by civilian populations, the Global Positioning System (GPS), is a US Department of Defense network of satellites, ground stations, and software interfaces. In addition to its role enhancing soldier

situational awareness,

the GPS has become a ubiquitous navigation tool now used by lost and confused husbands on a worldwide basis.

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camera can also enable augmented reality features such as facial recognition or, like Q-Warrior, battlefield data. Most importantly, ODG’s smart glasses do not require a separate battery pack or any specialist equipment. CONCLUSION Soldiers at the squad level now enjoy more real-time data and situational awareness than staff officers did just one generation ago. They can communicate in the most inhospitable regions on earth utilizing communications gear super-charged with audio, visual and data networking. Enhanced vision technology enables new clarity—even in the fog of war— and new targeting technology delivers pin-point accuracy even in the dead of night. Better power management and battery technology enables multiple devices to be powered simultaneously—in ever smaller and lighter packages. These advances have made modern militaries extremely agile, flexible and potent. “System of Systems” development models as well as R and D approaches that leverage the speed and innovation of commercial solutions, such as network-based software distribution, have both yielded important technology successes. The ongoing application of these technologies is of vital concern to the world’s democracies as we pursue our shared military goals, manage civil unrest, counter terrorism, protect vulnerable populations, and deliver disaster relief— noble goals indeed for the future soldier. The remaining pages of this special edition of QwikConnect outline the world’s most comprehensive and innovative line of interconnect solutions for soldier applications—from small form-factor connectors to lightweight EMI cable shielding—all designed and manufactured by Glenair.

 The snap-lock, trigger-release MouseBud connector is ideally suited for HUD-equipped helmet technology

their modernization programs. A soldier HMD works in a similar way to a pilot’s HUD, displaying vital information without the soldier having to look down at maps or devices. In 2009, Rockwell Collins was awarded a contract to provide 1,500 of its ProView S035A HMD systems—originally developed for tank crews—to the US military under its Land Warrior program. The S035A features a high-resolution display module with a 35-degree diagonal field of view, allowing soldiers to view C2 data and video feeds. The display is connected to a control module which is powered by three AA batteries lasting around eight hours. In 2014, BAE Systems unveiled its own version of HMD technology for soldiers called Q-Warrior. The system has been designed and developed at its Electronic Systems business in Kent, England. Q-Warrior uses a holographic waveguide display so it resembles traditional HUD systems both in form and function. The display module clips on a standard helmet rail and doesn’t require modification to existing kit. Unlike previous HMD technology for soldiers, BAE Systems’ technology allows data to blend intuitively with the soldier’s view of the real world. This is popularly known as augmented reality in the commercial world and offers several advantages over previous HMD systems. Q-Warrior overlays full-color graphical iconography—including friendly/hostile positions, navigation waypoints and close air support data—directly onto the real world. Soldiers can access live video feed from unmanned aircraft and other surveillance assets, improving situational awareness. BAE Systems says the technology will be best suited for JTACs or with Special Forces. Much of the technology found in Q-Warrior has been developed as part of DARPA’s Urban Leader Tactical Response, Awareness and Visualization (ULTRA-Vis) programme. One of the key challenges that remains for the soldier HMD is size, weight and price. Today’s systems can be unwieldy and cost thousands of dollars which ultimately means widespread adoption is unlikely, but as technology advances we can expect to see much wider use. And you don’t have to look far to see what the future might look like. In 2014, San Francisco-based company Osterhout Design Group unveiled its smart glasses concept which has the potential to revolutionize wearable tech for soldiers. The innovative X-6 glasses feature a dual-core processor, 64GB storage and two see-through HD displays. A tiny 5 megapixel

 Q-Warrior lightweight, full-color see-thru display for day and night applications. Photo: BAE Systems

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SMALL, LIGHTWEIGHT CONNECTORS AND CABLES

Field and factory tested, Glenair’s range of ultraminiature connectors and cables have become the gold standard for warfighter applications. Today’s combat environment demands total reliability from every electronic component—from soldier-wearable devices to eye-in-the- sky UAV payloads. Interconnect technologies—contacts, connectors, shields, jackets, cables and more—are no exception. Our warfighters deserve highly-engineered, reliable systems that contribute to mission success without adding burdensome size and weight. Mission-critical interconnect technologies with proven defense industry pedigree and performance

Don’t see it in our catalog? Just ask. Unusual small-quantity requests are our specialty. Plus, popular part numbers are available for immediate, same- day shipment with no dollar or quantity minimums.

Mighty Mouse The industry standard ultraminiature push-pull soldier interconnect

SuperFly™ The ultimate nanominiature tactical connector for high-speed applications

MouseBud™ The low-profile, snap-lock, trigger-release connector for wearable soldier systems

SuperSeal™ RJ45 and USB connectors for harsh environmental applications

Mighty Mouse 824 The high-performance locking push-pull connector for tactical soldier applications

SuperJack™ The ultra harsh-environment unipole connector for audio, data, and power

HiPer 55116 Advanced-performance audio frequency JTRS radio connectors and cables

Mighty Mouse Cobra The compact EMI/RFI plug assembly for low-profile, reduced space applications

Turnkey Cable Assemblies All Glenair connector technologies are available wired, tested and ready for immediate use

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U.S. Army photo by Staff Sgt. Adam Mancini • 9

SuperFly® is ideally suited for the interconnection of wearable soldier equipment such as communications, situational awareness and other C4ISR technologies that depend on small size and high- speed performance.

SuperFly ® : the ultimate nanominiature tactical connector SERIES 88 Rear-panel mount push-pull and threaded PCB receptacles, and AlphaLink flex jumpers now available

Ready for the toughest, smallest, and highest-speed applications you’ve got

SUPPORTED CONTACTS

G lenair Series 88 SuperFly ® represents a perfect storm of high-performance contacts, shells, wires, termination and mating technologies. SuperFly ® is the only connector series in existence that combines the weight-saving and performance advantages of nanominiature, microminiature and AS39029 type (size #23) contacts in a precision package for battlefield communications, computing, and other high-performance applications. Available in factory-terminated cordsets, single-ended pigtails, and discrete PCB termination receptacles for complete flexibility in cable and box configurations. QDC and threaded SuperFly cordsets can ship with a variety of cabling options, including ultra- flexible GhostWire or impedance-controlled twisted pairs for high-speed applications.

#23 AS39029 Type 5 Amp Crimp Contact

#24 Micro 3 Amp TwistPin Contact

#30 Nano 1 Amp TwistPin Contact

PRINTED CIRCUIT BOARD PLUG AND RECEPTACLES

Quick-Disconnect

Threaded

Right Angle, Rear Panel Mount, PCB Mounting Holes

Vertical, Rear Panel Mount, PCB Mounting Holes

Right Angle, Rear Panel Mount

Vertical, Rear Panel Mount, Ground Pins

Vertical Plug, Rear Panel Mount

Right Angle, Rear Panel Mount

Vertical, Rear Panel Mount

SERIES 88 SuperFly ® Ultraminiature Soldier System Connectors and Cordsets

ULTRAMINIATURE SUPERFLY® CORDSETS AND PIGTAILS

Overmolded threaded plug and receptacle

Threaded pigtail plug and receptacle

Quick-disconnect overmolded cordset

Quick-disconnect pigtail plug and jam nut receptacle

IP67 immersion rated High-reliability contacts: 5 Amp, 3 Amp, and 1 Amp High shock and vibration Robust EMI shielding

Designed for high speed data applications Pre-wired, epoxy-sealed cordsets Straight and 90° PC tail receptacles

27 Contact arrangements Front or rear panel mounting Aluminum or stainless steel Accepts #22 to #32 AWG wire

1 Amp

CONTACT ARRANGEMENTS Series 88 SuperFly connectors are available in 27 contact arrangements with 1 Amp, 3 Amp, 5 Amp contacts, and mixed-contact hybrid arrangements

1 2

8 14 19

10 7

3 6

22 28

6 7

9 7 10

30 31

B7N (7) 1A

C10N (10) 1A

E19N (19) 1A

F22N (22) 1A

G31N (31) 1A

H37N (37) 1A

J44N (44) 1A

3 Amp

Combo 1 Amp & 5 Amp

1 4 2

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

7 8 9 10 11 12 13 14 15 16 17 18 19 20

6 1

3 4

9 7 10

D2W2N (2) 1A, (2) 5A

F4W4N (4) 1A, (4) 5A

H6W14N (14) 1A, (6) 5A

J7W19N (19) 1A, (7) 5A

D3M (3) 3A

E4M (4) 3A

F7M (7) 3A

G10M (10) 3A

K19M (19) 3A

L22M (22) 3A

5 Amp Contacts

Combo 1 Amp & 3 Amp

1 4 2

1 2

14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29

1 6

7 9 10 11 12 13 14 15 16 8

11 16

10 7

8 13 18

10 15

30 31 32

12 17

9 14

9 7 10

E3W (3) 5A

F4W (4) 5A

G7W (7) 5A

H10W (10) 5A

C2M2N (2) 1A, (2) 3A

E4M4N (4) 1A, (4) 3A

F4M8N (8) 1A, (4) 3A

G6M10N (10) 1A, (6) 3A

G6M12N (12) 1A, (6) 3A

K13M19N (19) 1A, (13) 3A

The Series 860 MouseBud™ is designed for vest-wearable and helmet-mounted cable- to-tactical equipment interconnections. The ultra low- profile spring contact equipped MouseBud™ mated connector stack is less than 1/2 inch, making it the lowest-profile right-angle solution available today.

MouseBud ™ The snap-lock, trigger-release connector SERIES 860 U ltra low-profile MouseBud™ connectors are lightweight, shielded and designed for use in hostile environments. Mating is a snap—simply push to mate and lock. To release, actuate the thumb trigger on the coupling ring (small and large triggers available). Plugs feature spring-loaded gold plated contacts, stainless steel shells and self-actuating bayonet coupling rings. Cable mount versions are fully assembled, shielded, overmolded and 100% tested. MouseBud is fully protected from sand and dust, moisture ingress, electromagnetic interference and a multitude of other environmental stresses. The spring-loaded contact system is rated for 2000 mating cycles. Series 860 connectors are suitable for high-speed data, power, video and audio.

Self-locking auto- coupling, trigger-release mechanism Spring-loaded pins for extended durability and easy cleaning One meter, one hour water immersion 2000 cycles mechanical life High-speed data, power, video, and audio applications Meets MIL-STD-810G shock, vibration, immersion EMI protected with integral backshell and ground spring Ultra low-profile and lightweight

Panel mount MouseBud receptacles with “hot shoe” type contacts are suitable for hostile environments including soldier wearable electronics and tactical gear. Contacts are easy to clean and damage-resistant. These receptacle connectors meet MIL- STD-810G requirements for reliable performance in hostile environments—both mated and unmated. Connector attaches to panel with a stainless steel jam nut. A fluorosilicone O-ring provides panel sealing. Terminate to flex circuits with pc tail terminals, or choose solder cup terminals for wire attachment.

The MouseBud right angle plug features a single piece “cobra style”connector shell and a tightly fitting lid. A rubber gasket is sandwiched between the shell and lid to prevent moisture intrusion. The total height when mated to a rear panel mounted receptacle is well under 1/2 inch. Overmolded MouseBud cordsets are

.425"

PANEL

available in two standard versions. Style 1 cordsets feature thermoplastic polyurethane cable jackets and polyamide overmolding. Style 2 cordsets with thermoplastic rubber (TPV) cable jackets and overmolding offer excellent cold bend performance down to -55° C.

SERIES 860 MouseBud ™ The snap-lock, trigger-release connector for helmets, vests, and other low-profile applications

MouseBud™ Plugs

Plug Connector Construction • Shell: stainless steel • Bayonet pins, retainer ring and torsion spring: stainless steel • Coupling ring: aluminum, 2 trigger sizes • Lid: aluminum • Contacts: copper alloy, gold plated • Insert: glass-filled thermoplastic • Ground spring: gold-plated stainless steel • Gasket: fluorosilicone • Potting compound: RTV silicone

860-001P Overmolded Plug Cordset 860-002P Plug Cordset for USB+BAT (IAW US Army Personal Area Network, PAN protocol)

Plug Cordsets Overmolded cordsets with rugged tactical-grade shielded cable.

MouseBud™ Receptacles

Panel Receptacle Construction • Shell: stainless steel • Jam nut: stainless steel

860-004R Panel Receptacle with PC Tails 860-005R Panel Receptacle,Solder Cups

• Contacts: copper alloy, gold plated • Insert: glass-filled thermoplastic • O-ring: fluorosilicone • Peripheral seal: fluorosilicone • Potting compound: RTV silicone

Panel Mount Receptacles Jam nut mounting. Solder cup or printed circuit tails.

Overmold

Rubber Gasket

Thermoplastic Insulator

Lid

Flex Jumper

Peripheral Seal

Plug Shell

Jam Nut

O-ring

Coupling Nut

Stainless Steel Shell

Band-Master Shield Termination

Ground Spring

Encapsulant

Spring Pin

Bayonet Pin

Thermoplastic Insulator

Contact

Overmolded Plug Cordset

Panel Receptacle

MouseBud Specifications

Voltage rating Current rating

500 VAC 5 amps

Glenair MouseBud snap-lock, trigger-release connectors feature a spring-loaded contact system for excellent resistance to damage and debris entrapment. The biased plunger is machined from solid copper alloy for improved strength, durability, and electrical performance compared to plungers drawn from sheet metal.

Contact resistance

20 milliohms maximum

Plug-to-receptacle ground resistance <5 milliohm Maximum wire size #24 AWG Insulation resistance

5000 megohms min.

Water immersion

MIL-STD-810 Method 512, one meter for one hour

Durability

2000 mating cycles

Corrosion resistance

1000 hours

Sine vibration

EIA-364-28 condition IV, 20g peak EIA-364-28 condition V letter H, 29g rms EIA-364-27 condition D, 300g peak

Random vibration

Shock

EMI shielding effectiveness

40 dB minimum to 10 GHz

Wearable soldier electronics— from power supplies to PDAs— depend on environmentally sealed connectors and cables that meet soldier requirements for durability, handling, and reduced size. The Series 80 Mighty Mouse has become the de facto worldwide interconnect standard for future soldier systems. 6 coupling styles and 67 contact arrangements from 1 – 130 contacts MIL-DTL-38999 caliber environmental, mechanical, and electrical performance Ultraminiature #23 contacts set on .076" centers Size #20, #20HD, #16, #12, #8 signal, power, fiber optic and shielded contacts Discrete connectors and turnkey cable assemblies

Mighty Mouse Connectors and Cables SERIES 80 The industry standard—used on virtually every future soldier platform T he Series 80 Mighty Mouse Connector is designed for use in high-reliability, mission- critical applications—from commercial aerospace to soldier systems—that require robust environmental and EMC performance as well as reduced size and weight. The Series 80 Mighty Mouse connector offers comparable performance to MIL-DTL-38999 interconnects with up to 71% weight and 52% size savings for similar contact layouts. The industry-standard Mighty Mouse is a mature connector series with a proven range of catalog and custom configurations.

Series 80 Mighty Mouse Connectors: Available in Environmental, Filtered, and Hermetic Versions

Series 800

Series 801

Series 802

Series 803

Series 804

Series 805

Light-Duty UNF Thread

Rugged Double-Start ACME Thread

Fast-Mate Bayonet Coupling

Quick-Disconnect Push-Pull

Ratcheted Triple-Start

3500 PSI AquaMouse

SERIES 80 Ultraminiature Mighty Mouse Connectors and Cables

Series 80 Mighty Mouse Contact Arrangements

Contact Quantity Contact Arrangement* #23 #20 #20HD #16 #12 #8 Series 800 Series 801 Series 802 Series 803 Series 804 Series 805

Contact Size and Current Rating

3 4 6

5-3 6-4 6-6 6-7

N/A 8-4 8-6

8-7

Size #23 Contacts 5 Amp Max. Current #22-#28 AWG

10 13 19 26 31 37 55 85

7-10 8-13 9-19 N/A 12-37 N/A N/A 10-26

7-10 8-13 9-19

9-10 10-13 11-19 12-26 13-31 15-37 18-55 19-85 21-100 23-130 10-28 11-210 15-220 18-235 19-241 21-255 23-269 8-23 9-25

10-26 11-31 13-37 16-55 17-85 19-100 21-130 6-23 7-25 8-28 9-210 13-220 16-235 17-241 19-255 21-269

10-26 N/A 12-37 14-55 15-85 21-130 6-23 7-25 8-28 9-210 N/A 12-220 14-235 15-241

10-26 N/A 12-37 14-55

10-26 11-31 12-37 14-55

750 VAC DWV

N/A N/A N/A 6-23

100 130

N/A N/A 6-23 7-25

3 5 8

7-25 8-28 9-210 12-220 14-235

Size #20HD Contacts 7.5 Amp Max.Current #20-#24 AWG

8-28 9-210 12-220

10 20 35 41 55 69

N/A N/A N/A N/A 6-1 8-2 9-4 10-5 12-7 N/A N/A N/A N/A 10-2 12-2 12-3 N/A 7-1 N/A N/A N/A N/A N/A N/A N/A

N/A N/A N/A 6-1 8-2 9-4 10-5 12-7 14-12 N/A N/A N/A 10-2 12-2 12-3 14-5 7-1 N/A N/A N/A N/A N/A N/A N/A

1000 VAC DWV

N/A

21-269

6-1 8-2 9-4 10-5 13-7

6-1 8-2 9-4 10-5 12-7

8-1

2 4 5 7

10-2 11-4 12-5 15-7

Size #16 Contacts 13 Amp Max. Current #16-#20 AWG

12 14 19 22

16-12 17-14 19-19 21-22 10-2 13-2 13-3 16-5 17-7 21-12 7-1

14-12 15-14 N/A 21-22 10-2 12-2 12-3 14-5 15-7 21-12 N/A N/A N/A 7-1

18-12 19-14 21-19 23-22 12-2 15-2 15-3 18-5 19-7 10-1 18-2 19-3 21-4 23-12 23-5 9-1

1800 VAC DWV

Size #12 Contacts 23 Amp Max. Current #12-#14 AWG

2 2 3 5 7

1800 VAC DWV

8-1

Size #8 Contacts 46 Amp Max. Current #8 AWG 1800 VAC DWV

2 3 4 5

16-2 17-3 19-4 21-5

N/A N/A

10-200 10-201 12-200 12-201 9-200 10-202 8-200 9-201 12-202 12-203

10-200 10-201 13-200 13-201 9-200 10-202 8-200 9-201 13-202 13-203 16-204 16-205 17-203 13-204 13-205 16-206 16-207 17-204 16-208 17-205 19-201 19-202 21-200

10-200 10-201 12-200 12-201 9-200 10-202 8-200 9-201 12-202 12-203 14-204 14-205 15-203 12-204 12-205 14-206 14-207 15-204

10-200 10-201 12-200 12-201 9-200 10-202 8-200 9-201 12-202 12-203 14-204 14-205 12-204 12-205 14-206 14-207 N/A 15-204

12-200 12-201 15-200 15-201 11-200 12-202 10-200 11-201 15-202 15-203 18-204 18-205 19-203 15-204 15-205 18-206 18-207 19-204 18-208 19-205 21-201 21-202 23-200

4 6 4 8

2 2 2

Size #23 and #12 Contacts

2 2

Size #23 and #16 Contacts Size #23 and #20 Contacts

4 2 8 2

2 4 2 4 4

Size #23 and #16 Contacts

40 32 40

N/A N/A N/A

2 4 2 4 4

12-204 12-205

Size #23 and #12 Contacts

34 20 28 32 40 44

N/A N/A N/A N/A N/A N/A N/A N/A

1 1

N/A N/A N/A N/A N/A

Size #23 and #8 Contacts

2 4 4

* DWV rating is applicable to contact arrangements shown.

SuperJack™ is designed for small-footprint, multi-circuit blind-mate applications such as picatinny rail mounted weapons sights, night vision scopes, and laser targeting

T he SuperJack connector is a rugged, lightweight, miniaturized connector featuring watertight sealing, 3 to 7 poles, EMI protection and heavy gold plating. The jack (receptacle) has spring-loaded contacts for low resistance and high durability. Plugs are available in two styles. Overmolded cordsets feature high strength lightweight jacketed cable. Blind mate chassis-mounted plugs feature solder cup or printed circuit board contacts. Jacks feature gold-plated canted springs for electrical grounding and mechanical retention of plug. SuperJack is ideally suited for ultra harsh-environment interconnect applications such as are found on soldier communications gear, electronic weapons sights, noise-cancelling SERIES 153 SuperJack ™ Connectors The ultra harsh-environment unipole connector system for audio, data, and power

5 Amp current rating 5000 mating cycles 500 VDC EMI Shielded IP67 ingress protection Optional spring-loaded sealing flap in jack 3 – 7 circuit configurations Suitable for blind-mate applications Hardened for temperature extremes from -45° to +125° C

headsets, and vision systems. Panel-mounted SuperJack plugs are ideal for module-to-module connection. Chassis jacks are available with solder terminals or PC tails for easy termination to wire or flex circuits.

SERIES 153 SuperJack ™ Connectors The ultra harsh-environment unipole connector for audio, data, and power

TECHNICAL OVERVIEW

Canted Spring

Jam Nut

Aluminum Housing

Panel O-ring

Optional Spring-Loaded Flap For enhanced ingress protection when unmated. Rubber gasket prevents moisture and debris from entering jack.

Thermoplastic Housing

SPECIFICATIONS • Operating temperature: -55°C. to +125°C.

• Voltage rating: 500 Vac • Current rating: 3 amps

Spring Pins

• Contact resistance: 20 milliohms max. • Plug-to-jack ground resistance: <5 milliohm • Maximum wire size: #24 AWG • Insulation resistance: 200 megohms min. • Water immersion: MIL-STD-810 Method 512, 1 meter water immersion for 1 hour • Durability: 5000 mating cycles • Corrosion resistance: 500 hours • Sine vibration: EIA-364-28 condition IV, 20g peak • Random vibration: EIA-364-28 condition V letter H, 29g rms • Shock: EIA-364-27 condition D, 300g peak • EMI shielding eff ectiveness: 40 dB min.

AVAILABLE STYLES

Plug and Jack Cordsets

Right-Angle Plug Cordset

For more information contact Glenair at 818-247-6000 or visit our website at www.glenair.com U.S. CAGE code 06324

Chassis Plug

Chassis Jack

SOLVE THE EQUATIONS Example: “A the W in 80 D” Equals “Around the World in 80 Days.” The pictures might be clues!

1. 26 L of the A 2. 12 S of the Z 3. 8 S on a S S 4. 9 P in the SS

5. 88 K on the P K 6. 13 S on the A F 7. W F at 32 D F 8. 200 D for P G in M 9. 54 C in a D (with the J) 10. 90 D in a R A

11. 4 Q in a G 12. 1 W on a U 13. 5 D in a Z C 14. 29 D in F in a L Y 15. 11 P on a F T

16. 64 S on a C 17. It T 2 to T 18. 101 D 19. 57 H V 20. 24 H in a D

Answers posted February 15th www.glenair.com/qwikconnect

Qwik Connect n January 2015

Field data communications and networking rely on commercial standard RJ45 Ethernet and Universal Serial Bus (USB) technologies. SuperSeal™ ruggedized field connectors ensure these networks deliver

reliable environmental and electromechanical performance

SuperSeal ™ RJ45 and USB field connectors RJ45/USB Smallest form-factor high-performance solution for integration of the commercial USB interface, plus environmentally-sealed RJ45 and USB connectors in industry-standard MIL-DTL-38999 Series III packaging

Superior sealing, IP67 in unmated condition compared to other available environmental circulars with RJ45 or USB Superior grounding for electrostatic discharge and EMC Superior cable shield termination with integrated banding platform Optional spring-loaded protective covers for environmental protection of junction boxes and switches speed Ethernet/network protocols supported, including USB 2.0 Wide range of high Series 801 Mighty Mouse Plug and Receptacle with SuperSeal® Micro-B USB

SUPERSEAL™ INNOVATIONS

Crimp contact termination MIL-DTL-38999 Series III RJ45

PC tail and solder cup termination

IP67 sealed and EMC grounded RJ45 and USB inserts

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