D38999/20WH35SB - Aero Conesys

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MIL–DTL– 38999 S III

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MIL-DTL-38999

Features and Application

Series III

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Features and Application

MIL-DTL-38999 Series III is the newest cylindrical connector

designed for highest performance capabilities used in both

general purpose and severe environment applications.

These connectors feature an improved “one-turn” coupling

system, utilizing self-locking acme thread. Acme threads

provide coupling durability, while thicker wall sections and

greater coupling surface area improve strength and shock

resistance. Blunting of the threads on both receptacle and

plug coupling nut eliminates cross threading.

Elongated mounting holes permit the Series III Connector to

intermount with various existing Mil-spec ﬂange mounted

receptacles, giving it a design replacement advantage.

Wall mount receptacle, jam nut receptacle and straight

self-locking RFI plug are offered in 9 shell sizes and 54 insert

arrangements utilizing M39029 contacts in sizes 22D, 20, 16,

12, 10 power and 8 twinax.

These connectors are available in wide range of shell materials

and ﬁnishes. Aluminum shells are offered in electroless nickel

and olive drab cadmium. Other ﬁnishes such as anodic and

zinc nickel are available upon request to commercial callouts

only. In addition, we offer stainless steel shells (both passivated

and electro-deposited nickel plated) with ﬁrewall inserts, and

for highly corrosive environments, nickel-aluminum-bronze

shells with standard environment-resisting inserts (commer-

cial callouts only).

MIL-STD-1560 Insert Arrangements – Series III connectors

use insert patterns and contacts common to Series I,

making for an easy transition from bayonet to triple-lead,

acme-thread, self-locking coupling.

Metal-to-Metal Bottoming – This feature precludes relative

shell-to-shell motion, which may result in ordinary connector

wear and moisture entrapment.

Lockwiring Eliminated – Self-locking quick coupling plug

eliminates the need for lockwiring.

Firewall Capability - Stainless steel shells in both K and S

ﬁrewall classes are offered.

Universal I/R Tool – A single, expendable plastic tool is used

for both insertion and removal of contacts.

Scoop-Proof Design – Recessed pins in elongated shells

minimize the possibility for contact damage. In a blind

mating application, mating shells cannot “scoop” the pins,

and cause a shorting or bending of contacts.

Closed-Entry Socket Insert – Hard dielectric socket face

has lead-in chamfers for positive alignment of pins (even

partially bent within pre-established limits) with sockets.

Interfacial Pin Insert Seal – Raised moisture barriers

around each pin, which mate into lead-in chamfers of

hard face socket insert, provide individual contact sealing.

Interfacial seal is never touched by service tools.

Elastomer Wire Sealing Grommet – Sealing over a wide

range of wire diameters is assured by a triple wire seal in

each cavity at the rear of the connector.

Superior Contact Stability – Rear release crimp contact

system features a stamped beryllium-copper retaining clip

captivated by molded-in shoulders of each contact cavity in

the insulator. A rear-inserted M81969 plastic tool expands

the tines beyond the shoulder, releasing the contact.

Metric Accessory Thread – Metric thread results in

additional wall thickness giving greater strength and shock

resistance.

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MIL–DTL– 38999 S III

MIL-DTL-38999

Performance Speciﬁcations

Series III

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Performance Speciﬁcations

Operating Temperature Range

Classes F, K, S and BZ*: -65°C to +200°C (-85°F to +392°F)

Classes W and ZC*: -65°C to +175°C (-85°F to +347°F)

Material and Finish Data (Class)

F – aluminum shell, electroless nickel ﬁnish

K – stainless steel shell, passivated, ﬁrewall

S – stainless steel shell, electrodeposited nickel, ﬁrewall

W– aluminum shell, olive drab cadmium over nickel base

BZ* – aluminum nickel bronze shell, std insert

Z*– aluminum shell, zinc nickel ﬁnish

Corrosion Resistance

Classes K, W, BZ* and Z* withstand 500-hour salt spray.

Classes F and S withstand 48-hour salt spray.

Durability

Minimum of 500 mating cycles.

Fluid Resistance

Connectors resist speciﬁed immersions in MIL-PRF-7808,

MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol

25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5),

SAE-AMS1424 Type I, and other solvents and cleaning agents.

Shielding Effectiveness

RFI and EMI attenuation at the speciﬁed frequencies meet

the requirements of MIL-DTL-38999.

●RFI shielding effectiveness of mated connectors with RFI

backshells is measured in a triaxial radio frequency leakage

ﬁxture.

●EMI shielding effectiveness is measured at the interface

of mated connectors and tested by the mode-stirred

technique speciﬁed in method 3008 of MIL-STD-1344.

Voltage Rating

Environmental Seal

Wired, mated connectors with speciﬁed accessories

attached, shall meet the altitude-immersion test speciﬁed in

MIL-DTL-38999.

Shell-to-Shell Conductivity

Maximum potential drop shall not exceed:

●Classes F and S = 1.0 millivolt.

●Class W = 2.5 millivolts, Class K = 10.0 millivolts

Shock and Vibration Requirements

Wired, mated connectors shall not be damaged, nor shall

there be a current interruption longer than one microsecond

when subjected to the following:

Shock

Pulse of approximate half sine wave of 300 G ±15 percent mag-

nitude with duration of 3 ±1 milliseconds applied in three axes.

High Impact Shock

When mounted as speciﬁed in MIL-S-901, grade A, a drop

of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to

connector in three axes, totaling nine impacts.

Vibration

Wired and mated connectors withstand the following

vibration levels:

●Sine vibration where connector samples with simulated

accessory load are subjected to simple harmonic motion

from 10 to 2,000 Hz in three mutually perpendicular axes,

in 20 minute sweeps, for 12 hours in each axis at velocity of

254 mm/sec from 10-50 Hz, displacement of 1.5 mm from

50-140Hz and acceleration of 60G from 140-2,000Hz.

●Random Vibration per MIL-STD-1344, method 205,

test condition V at ambient temperature and test

condition VI, Letter “J” at elevated temperature.

* Not on QPL, can be supplied to Aero-Electric part number only.

Service

Rating

Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage

(Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft.

AC (RMS) DC V RMS V RMS V RMS V RMS

M 400 550 1300 550 350 200

N 300 450 1000 400 260 200

I 600 850 1800 600 400 200

II 900 1250 2300 800 500 200

Note: The establishment of electrical safety factors is left

entirely to the designer, as he is in the best position to know

exactly what peak voltages, switching currents, transients, etc.,

can be expected in a particular circuit.

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MIL–DTL– 38999 S III

MIL-DTL-38999

Part Number Development

Series III

Military and Aero-Electric Part Number Development

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* Not on QPL, can be supplied to Aero-Electric part number only.

Note 1: Each connector is furnished with contacts unless

ordered less contacts (L/C) as follows: One spare contact for

inserts requiring 2 through 26 of each contact and two

spares for inserts with 27 or more contacts, and a minimum

of one sealing plug up to 10% of the number contacts.

Spare Coax and Twinax contacts are not supplied. One

insertion/extraction tool for each contact size is also included.

Note 2: Proper part number marking has no “0” in front

of single digit layout. Example: JD38999/20WB5SN. “N” for

normal is included. In addition, J or JAN must be marked

immediately in front of MIL part number.

Mil. Preﬁx D38999/ 20 W C 35 P N

Aero Preﬁx AE3 20 W C 35 P N -340

Shell Type (Speciﬁcation Sheet Number)

20 = Wall mount receptacle

24 = Jam nut receptacle

26 = Self-locking, RFI grounding plug

Class (Material & Finish)

F= Aluminum shell, electroless nickel ﬁnish

W= Aluminum shell, olive drab cadmium over electroless nickel base

K= Stainless steel shell, passivated, with ﬁrewall insert

S= Stainless steel shell, electrodeposited nickel, with ﬁrewall insert

BZ* = Aluminum nickel bronze shell with standard insert (Aero p/n only)

Z* = Aluminum shell, zinc nickel plating (Aero p/n only)

Shell Size

A, B, C, D, E, F, G, H or J

Insert Arrangement

See pages 15 thru 19

Contact Style

P= Pin

S= Socket

A= Pin connector less pins (with intent to use non-std pin contacts)

B= Socket connector less sockets (with intent to use non-std socket contacts)

Polarization (Keying)

N= Normal (Included in part number)

A, B, C, D, or E

Modiﬁcation (applies to Aero part numbers only)

01 = Less contacts (is not marked on the part)

340 = Connector kitted with M85049/14-XXX

341 = Connector kitted with M85049/38-XXX straight clamp

342 = Connector kitted with M85049/39-XXX right angle clamp

Consult factory for other modiﬁcations

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MIL–DTL– 38999 S III

D38999/20

Wall Mounting Receptacle

AE320

Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof

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BLUE COLOR BAND

(REAR RELEASE)

4 MINOR KEYWAYS

LOCKING INDICATOR BAND

COLOR: RED

MATING THREAD

MASTER KEYWAY G

MAX

31.50(1.240)

MAX

2.16(.085) MAX

GROMMET EXTENSION

J NUMBER OF TEETH

K ACCESSORY THREAD

7.11(.280)

MIN FULL THREAD

H MAX

[ L

MAX

GROMMET

Page 38 Completed Part Number

Page 44 Contacts, Sealing Plugs and Tools

Pages 17–19 Insert Arrangements

Page 37 Performance Speciﬁcations

Pages 15, 16 Insert Availability and Contact Information

Page 42 Polarization

Note 1: “K” Accessory Thread for AE320 is same as AE326

(“D” Accessory Thread) on page 41.

Note 2: “F” Mating Thread for AE320 is same as AE326

(“E” Mating Thread) on page 41 except it is Class 2A.

Note 3: Maximum Grommet Extension for insert layouts

incorporating size 8 and 10 contacts = 5.95(.234).

Shell

Size

A B C D E G H J  L

No. of

±.012 ±.30 (TP) (TP) ±.008 ±.20 ±.008 ±.20 Maximum Maximum Teeth Maximum

inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm

A .937 23.80 .719 18.26 .594 15.09 .216 5.49 .128 3.25 .820 20.83 .098 2.50 12 .299 7.59

B 1.031 26.20 .812 20.62 .719 18.26 .194 4.93 .128 3.25 .820 20.83 .098 2.50 16 .427 10.85

C 1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 3.25 .820 20.83 .098 2.50 20 .541 13.74

D 1.220 31.00 .969 24.61 .906 23.01 .173 4.39 .128 3.25 .820 20.83 .098 2.50 24 .666 16.92

E 1.311 33.30 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 .820 20.83 .098 2.50 28 .791 20.09

F 1.437 36.50 1.156 29.36 1.062 26.97 .194 4.93 .128 3.25 .820 20.83 .098 2.50 32 .897 22.78

G 1.563 39.70 1.250 31.75 1.156 29.36 .194 4.93 .128 3.25 .790 20.07 .126 3.20 36 1.022 25.96

H 1.689 42.90 1.375 34.93 1.250 31.75 .242 6.15 .154 3.91 .790 20.07 .126 3.20 40 1.147 29.13

J 1.811 46.00 1.500 38.10 1.375 34.93 .242 6.15 .154 3.91 .790 20.07 .126 3.20 44 1.272 32.31