series 806 mighty mouse mil-aero connectors

89 Pages·2017·10.28 MB·English

ULTRAMINIATURE CIRCULAR
SERIES 806 MIGHTY MOUSE
MIL-AERO CONNECTORS
Next-Generation High-Density Connector Series for Demanding
Aerospace, Defense and other Harsh-Application Environments
FIRST EDITION · APRIL 2017
Series 806
Mighty Mouse
Mil-Aero Connectors
Advanced electrical, mechanical and
environmental performance plus reduced „„Next-generation small
form factor aerospace-
size and weight compared to D38999
grade circular connector
„„Designed for general
Series 806 offers significant size and weight savings while meeting key performance
use in harsh application
benchmarks for a broad range of applications such as commercial and military
environments such
aerospace, industrial robotics, transportation systems and more. Designed for general
as aircraft, industrial
use in harsh vibration, shock and environmental settings—as well as high-altitude,
robotics and more
unpressurized aircraft zones with aggressive voltage ratings and altitude immersion
„„Upgraded environmental,
standards—the Series 806 Mil-Aero features numerous mechanical design innovations
electrical and mechanical
including durable mechanical insert retention, radial seals and triple-ripple grommet
performance
seals. Its reduced thread pitch and re-engineered ratchet prevent decoupling
problems, particularly in small shell sizes, solving one of the major problems of shell „„Integrated anti-
size 9 and 11 MIL-DTL-38999 Series III connectors. decoupling technology
„„Higher density 20HD
SAVE SIZE AND WEIGHT WITH SERIES 806 CONNECTORS and 22HD contact
arrangements
„„Glass hermetic,
Series 806 Mil-Aero MIL-DTL-38999 lightweight aluminum
Smallest Size Smallest Size hermetic, and filtered
.500 In. Mating Threads .625 In. Mating Threads
versions
3 #20 Contacts or 7 #22 3 #20 Contacts or 6 #22
contacts contacts „„+200° C temperature
rating
© 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Table of Contents
MIGHTY MOUSE MIL-AERO GENERAL INFORMATION AND REFERENCE
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Introduction and Contact Performance Space-Grade Printed Circuit Board
Product Features Arrangements Specifications Information Layouts
Page 2 Page 5 Page 6 Page 9 Page 70
SERIES 806 MIGHTY MOUSE MIL-AERO CONNECTORS
Plugs Square Flange Line Receptacles Jam Nut Receptacles Jam Nut PCB
806-012 Receptacles 806-019 806-020 Receptacles
Page 10 806-013 Page 14 Page 16 806-021
Page 12 Page 18
Square Flange Glass Hermetic Glass Hermetic Lightweight Hermetic Filtered Filtered PCB
PCB Receptacles Receptacles PCB Receptacles PCB Receptacles Receptacles Receptacles
806-022 806-025 806-026 806-028 240-806 240-806-21
Page 20 Page 22 Page 25 Page 28 Page 30 Page 32
SERIES 806 MIGHTY MOUSE MIL-AERO ACCESSORIES
Contacts Crimp Tools, Filler Plugs Band-Master ATS® Panel O-rings Panel Gaskets
Page 34 Ins/Ext Tools Page 38 Page 38 Page 38 Page 39
Page 37
Connector Nut Plates Protective Covers Stowage Shrink Backshell
Holding Tools Page 40 Page 41 Receptacles Boots Selection Guide
Page 39 Page 44 Page 45 Page 48
© 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero 1
Dimensions in Inches (millimeters) are subject to change without notice.
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Introduction
About The Series 806
Save Size and Weight with Series 806 Connectors
The Mighty Mouse Series 806
Mil-Aero is an aerospace-grade
Mighty Mouse Mil-Aero Is The Next Generation Higher Density
ultraminiature circular connector with
Connector for Demanding Aerospace and Defense Applications
triple-start threaded coupling. The
806 connector is smaller and lighter
than traditional aerospace connectors.
Featuring size 20HD and 22HD contacts,
the Series 806 offers up to twice the
Series 806 plug with 19 #22 contacts
number of contacts with no reduction
compared to MIL-DTL-38999 Series
in performance. Independent laboratory
III with 6 #22 contacts. More than 3X
testing has demonstrated that the Series
the number of contacts, yet only .020
806 meets the requirements of MIL-
DTL-38999 Series III. inches larger diameter.
But there is more to the 806 than
size and weight reduction. This new MIL-DTL-38999 Series 806
high-performance connector has many
innovative features that meet the most Series 806 20HD Arrangements Compared to
MIL-DTL-38999 Series III Size 20 Arrangements
aggressive requirements of the military/
No. of Contacts vs. Coupling Nut Diameter
aerospace industry. One such feature is
better resistance to vibration-induced es)2.0
h
decoupling. This is accomplished by re- nc1.8
engineering the ratchet mechanism and r (I
introducing a shallower mating thread te1.6
e
ramp angle. m
a1.4
Glenair pioneered integral banding Di
platforms to allow direct attachment Nut 1.2 Series 806 #20HD
of cable shields, boots and overmolds. g 1.0
n D38999 #20
TGhleisn ianinr’so vfairtsito nco cnonneticntuoer st ow iethxc tlhues i8v0e6ly, upli0.8
o
use the ultralightweight Nano-Band for C0.6
maximum size and weight reduction. 0 10 20 30 40 50 60 70 80 90 100
Another enhancement is a “top hat” Number of Contacts
insulator with raised bosses for foolproof
alignment of insulator cavities and
Series 806 #22HD Arrangements Compared to
retention clips as well as higher voltage
MIL-DTL-38999 Series III #22D and #23 Arrangements
ratings.
No. of Contacts vs. Coupling Nut Diameter
The 806 series connector features an es)2.0
O-ring radial interface sealing design h
c
ifnosr teeaasdi eorf ma eftlaatl- tgoa-smkeett.a Tl hcios uapllloinwgs, er (In1.8
t1.6
improved sealing, and better EMI e
m
performance. The MIL-DTL-38999 Series a1.4
Di
III and other legacy aerospace circular ut 1.2 Series 806 #22HD
connectors have a flat gasket inside the N
D38999 #22D
receptacle shell. This peripheral seal must ng 1.0 D38999 #23
be compressed sufficiently to allow full pli
metal-to-metal connector bottoming. ou0.8
C
In certain tolerance conditions this seal
0.6
can make it difficult to fully mate the 0 20 40 60 80 100 120 140 160 180 200
connectors “without the use of tools” as Number of Contacts
is required by MIL-DTL-38999.
2 © 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero
Dimensions in Inches (millimeters) are subject to change without notice.
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Product Features
KEY FEATURES Plug Connector
„„Next-generation high
Coupling Nut Retainer Ring
performance ultraminiature Stainless steel
aerospace connector Coupling Nut
Aluminum alloy
„„Reduced pitch triple-start
Insert Retention Ring
modified anti-decoupling stub Stainless steel
ACME thread Wire Seal
fluorosilicone rubber
„„Higher density 20HD and Insulators
22HD contact arrangements Glass-filled rigid dielectric
Contacts
„„+200° C operating temperature
Gold-plated copper
Anti-Decoupling
„„High strength aluminum alloy Spring Plug Barrel
plug barrel Stainless steel High strength
7alloy
„„“Triple ripple” wire sealing Interfacial Seal
fluorosilicone rubber
grommet (75,000 ft. rated)
EMI Ground Spring
„„Snap in, rear release crimp Nickel-plated BeCu
contacts
„„Metal contact retention clips Receptacle Connector
„„Integral Nano-Band shield
Insert Retention Ring
termination platform Stainless steel
Wire Seal
„„EMI shielding effectiveness per Fluorosilicone rubber
MIL-DTL-38999M para. 4.5.28
Insulators
(65 dB min. leakage Glass-filled rigid dielectric
attenuation @ 10GHz)
Jam Nut
Aluminum alloy
„„10,000 amp indirect lightning
strike Shell / Mating
Interface
„„300g. shock Aluminum, modified
Panel O-ring
triple-start
Fluorosilicone
„„MIL-S-901 Grade A high impact
Shell Body
shock
Aluminum alloy
„„Aluminum and stainless steel
versions
„„Environmental crimp contact,
glass-to-metal seal PC tail and
solder cup hermetics, and EMI AVAILABLE LIGHTWEIGHT ALUMINUM “CODE RED” HERMETICS
filter versions
CODE RED is a lightweight
„„RoHS compliant nickel, nickel- encapsulant sealing and
application process with
PTFE, black zinc and stainless
50% package-weight
steel plus mil-grade cadmium
savings compared to glass-to-metal seal Kovar/stainless steel solutions. Non-
finish options
outgassing CODE RED (IAW NASA/ESA) provides durable hermetic sealing with
„„Printed circuit board versions better than 1X10-7 leak rate performance. Gold-plated copper contacts deliver
outstanding low-resistance current carrying capacity. See 806-028 page 27.
with threaded flange
© 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero 3
Dimensions in Inches (millimeters) are subject to change without notice.
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Product Features
SERIES 806 MIGHTY MOUSE MIL-AERO FEATURES
Interface Seal Radial Peripheral Seal
Metal-to-Metal
Mating Better sealing, easier metal-to-
metal bottoming
“Triple Ripple” Wire Seal
meets 75,000 ft. altitude Five Keys
immersion test 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
High Density Crimp Sockets
insert assembly
Gold plated copper alloy
EMI Spring
Low shell-to-shell resistance,
SST Ratchet Spring Rear Release Contact excellent EMI protection
and Shallow Mating Thread Retention Clip
Ramp Angle BeCu alloy
Foolproof anti-decoupling
Series 806 Mighty Mouse, with its high-density size #20HD and #22HD contact
arrangements, is designed for universal mil-aero use. The many special design features
shown above allow this ultraminiature connector to meet and even exceed MIL-DTL-38999
performance even in high-altitude, unpressurized zones. Other Mighty Mouse Series
connectors, such as the 801 and 805 with their size #23 contact layouts, are optimized for
size and weight reduction in land, sea and pressurized-zone aircraft applications.
4 © 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero
Dimensions in Inches (millimeters) are subject to change without notice.
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Contact Arrangements
Series 806 Arrangements with #20HD Contacts (1800 Vac, 7.5 A)
Mating face of pin 17 1 18
connector. Socket 1 2 1 2 11121 13 1 27
numbering is 1 2 1 2 8 8 3 10 2 20 14
reversed. 3 7 3 9 10 195 133 10
indkSeicyyam ltoebcsoa mtl ioans t.er 3 5 4 6 5 4 7 6 5 4 8 7 146 5 4 31 10
Arrangement No. 8-3 9-5 10-8 11-10 12-15 14-20 16-31
No. of Contacts 3 5 8 10 15 20 31
31 1 32
40 23 1 24 1 27
Mating face of pin 20 1 21
40
connector. Socket 20
numbering is 47 56
reversed. 34 61 30 70 74
30 41 50 55 20 69 50 50 92 86 60
Symbol
indicates master
key location. 30 10
40
10 10 10 20 40
Arrangement No. 18-41 20-55 22-69 24-92
No. of Contacts 41 55 69 92
Series 806 Arrangements with #22HD Contacts (1300 Vac, 5 A)
Mcoanntuninmegcb tfoaecrr.ie nS ogofc i spk eint 1 2 1 2 8 9 1 2 10 11 1 2 7 3 2 1 4 116 3 1 2 49 19 1 20 33 1 512202735425057
reversed. 6 7 3 7 1110 3 9 11521143 3 12 815 1230
indkSeicyyam ltoebcsoa mtl ioans t.er 4 3 5 4 6 5 4 87 6 5 4 161918 1713 1823 25 26 242116 10 39 41119 263441495660
Arrangement No. 8-4 8-7 9-11 10-15 11-19 12-26 14-39 16-60
No. of Contacts 4 7 11 15 19 26 39 60
Mcoanntuninmegcb tfoaecrr.ie nS ogofc i spk eint 15122029394858677582 1 5122029395062738392101007 141019294052657790102111321331238 1512223345587287101116130141351516176863
reversed.
4 186
Symbol 4 85 4 110 3 140 182
indkeicya ltoecsa mtioanst.er 1119283847 57667481 1119283849 61 72829199106 9182839516476 89101112122113317 11213244577186100115129141251461575
Arrangement No. 18-85 20-110 22-140 24-186
No. of Contacts 85 110 140 186
© 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero 5
Dimensions in Inches (millimeters) are subject to change without notice. Rev. 07.14.17
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Materials and Finishes, Performance Specification
Standard Materials and Finishes
DESCRIPTION MATERIAL FINISH
Pin Contact Copper alloy 50 microinches gold over nickel
Socket Contact Copper alloy, with stainless steel hood 50 microinches gold over nickel
Contact hood: passivate
Insulators High grade rigid dielectric None
Seals Fluorosilicone/silicone blend, blue None
EMI Spring Beryllium copper Nickel
Shell, Coupling Nut, Jam Nut Aluminum alloy or stainless steel See sales drawing or catalog 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 Contact Size Altitude Voltage MIL-DTL-38999M para. 4.5.11.1
sea level 20HD Sea level 1800 EIA-364-20 Method A
22HD Sea level 1300 2 mA maximum leakage current
Unmated pairs
Dielectric withstanding voltage Contact Size Altitude Voltage MIL-DTL-38999M para. 4.5.11.2
at altitude 20HD 50,000 ft 1000 EIA-364-20 Method A
70,000 ft 1000 2 mA maximum leakage current
100,000 ft 1000 Mated pairs
22HD 50,000 ft 800
70,000 ft 800
100,000 ft 800
Insulation resistance at ambient 5000 megohms minimum MIL-DTL-38999M Para. 4.5.10.1
temperature EIA-364-21
Insulation resistance at elevated 1000 megohms minimum MIL-DTL-38999M Para. 4.5.10.2
temperature EIA-364-21
Contact resistance at 25°C, Maximum Voltage Drop AS39029C Para. 4.7.5
crimp contacts (millivolts) EIA-364-06
Test Current After Silver-plated wire
Wire Size Amperes Initial Conditioning
20 7.5 55 66
22 5 73 88
24 3 45 54
26 2 52 63
28 1.5 54 65
30 1 60 73
Contact resistance at 200° C, AS39029C Para. 4.7.5
Test Current Maximum Voltage
crimp contacts EIA-364-06
Wire Size Amperes Drop (millivolts)
Silver-plated wire
20 7.5 94
22 5 125
24 3 77
26 2 89
28 1.5 92
30 1 103
Low level contact resistance, Maximum Contact Resistance (milliohms) AS39029C Para. 4.7.4
crimp contacts Wire Size Initial Values After Conditioning EIA-364-23
20 9 11 Silver plated wire
22 15 17
24 20 23
26 31 38
28 50 60
30 75 88
6 © 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero
Dimensions in Inches (millimeters) are subject to change without notice.
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Performance Specification
Performance Specification
TEST DESCRIPTION REQUIREMENT PROCEDURE
Contact resistance, glass-sealed Contact Size, Test Current Maximum Millivolt Drop MIL-DTL-38999M Para. 3.18.2
hermetic connectors Wire Size Amperes Initial After Conditioning EIA-364-06
20 5 60 75
22 3 85 95
Shell-to-shell conductivity Finish Code Shell Matl/Fin Millivolt Drop (mV) MIL-DTL-38999M Para. 4.5.25
NF Al/OD Cad 2.5 EIA-364-83
MT Al/Ni-PTFE 2.5
ME Al/EN 1.0
ZR Al/Zn-Ni 2.5
Z1 SST/pass. 10.0
ZL SST/Ni 1.0
Backshell shield braid to shell Finish Code Shell Matl/Fin Millivolt Drop (mV) MIL-DTL-38999M Para. 4.5.25.1
conductivity NF Al/OD Cad 5.0 EIA-364-83
MT Al/Ni-PTFE 5.0
ME Al/EN 3.5
ZR Al/Zn-Ni 5.0
Z1 SST/pass. 15.0
ZL SST/Ni 3.5
Indirect lightning strike No evidence of damage which could impair proper functioning. MIL-DTL-38999M Para. 4.5.47
Connectors shall meet shell-to-shell conductivity, DWV and EIA-364-75
coupling torque. 10,000 Amps peak current
EMI shielding Leakage Attenuation, (dB) minimum MIL-DTL-38999M Para. 4.5.28
Freq.
Electroless Nickel Cadmium, Nickel-PTFE, Zinc-
MHz
Finish Nickel Finish
100 90 90
200 88 88
300 88 88
400 87 87
800 85 85
1,000 85 85
1,500 76 69
2,000 70 65
3,000 69 61
4,000 68 58
6,000 66 55
10,000 65 50
Durability No evidence of damage which could impair proper function- MIL-DTL-38999M Para. 4.5.8
ing following 500 cycles of mating and unmating. EIA-364-09
Coupling and uncoupling torque MIL-DTL-38999M Para. 4.5.7
Maximum Minimum
EIA-364-114
Shell size Engagement Disengagement
lbs-inch. lbs.-inch.
8 8 2
9 8 2
10 12 2
11 12 2
12 12 2
14 16 2
16 20 3
18 24 3
20 28 3
22 32 5
24 36 5
Insert retention 100 pounds per square inch, 25 pound minimum force MIL-DTL-38999M Para. 4.5.12 EIA-364-35
External bend moment Shell size Pound inches MIL-DTL-38999M Para. 4.5.16
8 100 EIA-364-43
9 100
10 100
11 200
12 300
14 400
16 500
18 600
20 700
22 800
24 900
© 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero 7
Dimensions in Inches (millimeters) are subject to change without notice.
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Performance Specification
Performance Specification
TEST DESCRIPTION REQUIREMENT PROCEDURE
Contact retention Contact size Pounds ± 10 percent MIL-DTL-38999M Para. 4.5.20.1
22HD 10 EIA-364-29
20HD 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
Temperature cycling (thermal No evidence of damage detrimental to the function of the MIL-DTL-38999M Para. 4.5.4 EIA-364-32
shock) connector Mated connectors, -65° C to +200° C
Random vibration, elevated tem- No discontinuities of 1 microsecond or longer MIL-DTL-38999M Para. 4.5.23.2.3 with Figure 24
perature, 43g rms No resonance at frequencies less than 300 Hz accessory load EIA-364-28 +200°C
Random vibration, ambient tem- No discontinuities of 1 microsecond or longer MIL-DTL-38999M Para. 4.5.23.2.4 EIA-364-28 Test
perature, 49g rms Condition V
Sine vibration, 60g No discontinuities of 1 microsecond or longer 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
Mechanical shock, 300g No discontinuities of 1 microsecond or longer MIL-DTL-38999M Para. 4.5.24.1
EIA-364-27
High impact shock (901) No discontinuities of 1 microsecond or longer MIL-DTL-38999M Para. 4.5.24.2
No evidence of damage which could impair proper functioning. MIL-S-901 Grade A
Humidity, cyclic Meet DWV and IR test MIL-DTL-38999M Para. 4.5.26
EIA-364-31 Method 4
10 cycles, 10 days, 25 – 65°C
80 – 100% RH
Ozone exposure No evidence of damage detrimental to the function of the MIL-DTL-38999M Para. 4.5.29 EIA-364-14
connector
Fluid immersion No damage to plastic, elastomeric and bonding materials MIL-DTL-38999M Para. 4.5.30
detrimental to the function of the connector. Connector EIA-364-10
shall meet coupling torque and DWV requirements when
tested within 3 hours of immersion.
Altitude immersion No evidence of moisture on connector interface or contacts. MIL-DTL-38999M Para. 4.5.9
At the end of the third cycle, while still submersed, connec- EIA-364-03
tors shall meet dielectric withstanding voltage and 1,000 75,000 feet
megohms insulation resistance.
Altitude- low temperature Connectors shall meet insulation resistance requirement MIL-DTL-38999M Para. 4.5.21
while at -65°C and 100,000 ft. Connectors shall meet DWV EIA-364-105
requirement when returned to ambient conditions. -65°C
100,000 ft.
Thermal vacuum outgassing All nonmetallic materials shall not exceed 1.0% Total Mass MIL-DTL-38999M Para. 4.5.42
Loss and 0.1% Total Volatile Condensible Materials. Ap- ASTM E595
plicable only to connectors that have been subjected to
optional thermal vacuum outgassing.
Salt Spray (dynamic) MIL-DTL-38999M Para. 4.5.13.2
Finish Code Matl/Fin Hours
EIA-364-26
NF Al/OD Cad 500
500 mating cycles
MT Al/Ni-PTFE 500
ME Al/EN 96
ZR Al/Zn-Ni 500
Z1 SST/passivate 1000
ZL SST/Ni 1000
8 © 2017 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324 • Series 806 Mighty Mouse Mil-Aero
Dimensions in Inches (millimeters) are subject to change without notice.