Cooper Interconnect MIL-DTL-38999 Series IV

1 MIL-DTL- 38999 Series IVBreech-Lok and Power-Breech Connectors and Cable Assemblies 2 The industry s largest installed base of MIL-DTL- 38999 Series IV connectorsGeneral purpose connectors Overview 10 Technical specifications 11 Ordering information 12 Shell/insert configurations 13 Insert/contact ratings 14 Insert drawings 15 Polarization tables 18 Installation instructions 55 Wall-mount receptacles (D38999/40)Mechanical drawings 20In-line receptacles (D38999/49)Mechanical drawings 22 Box mount receptacles (D38999/42) Mechanical drawings 21 Straight plugs(D38999/46 & 47) Mechanical drawings 19 Jam-nut receptacles (D38999/44)Mechanical drawings 23 Feed-through receptaclesMechanical drawings 24 Cooper Interconnect offers an extensive range of QPL and modified solutions.

2 Please refer to the ordering-information pages for listings of QPL-certified and quick-turn-custom connector and cable solutionsSpecialized Interconnect solutionsWing-Lok plugs Overview 31 Technical specifications 32 Ordering information 33 Shell/insert configurations - 34 Mechanical drawings 35 Accessories(D38999/50, 51, & 52)Overview 25 Receptacle & plug covers 26 Dummy stowage receptacles - 29 Connector Savers 30 Hermetic receptacles (D38999/41,43,45, & 48) Overview 45 Technical specifications 46 Ordering information 47 Shell/insert configurations 48 Mechanical drawings 49 Filtered receptacles Overview 37 Technical specifications 38 Ordering information 41 Shell/insert configurations 42 Mechanical drawings 43PC tail connectorconfigurations Overview 53 Ordering information 54 Power-Breech customsUp to 900 ampsOverview 8 Custom connectors Overview 5 Cable assemblies Overview 74 Engineered for uncompromised performance in military and aerospace applicationsBreech-Lok connectors feature a coupling mechanism that only requires 90 of rotation to engage and disengage.

3 This rugged design distributes the coupling load over solid-metal lands while internal-drive threads provide the mechanical advantage needed to ensure positive engagement of the contacts and interfacial harsh - environment design depicted below is representative of all of Cooper Interconnect s standard and custom Breech-Lok features and options include: Operating temperatures from -65 C to 200 C. Finish Class K configurations provide 2000 F firewall protection for 20 minutes minimum. High speed data including MIL-STD-1553. 500 hour salt-spray-rated design advantagesContact retainer clip Metal clip designed for high shock, vibration, and cover retaing ringRear cover Coupling nutHigh-strength couplingring and plug housingEMI ringDetent spring Provides positive mating hole-to-hole surpasses Mil spec for extremely precise pin/socket retaining ring Press fit, self-centering design ensures proper spring Increases resistance to vibration damageO-ring environmental sealDesigned and manufactured in the custom connectors and cable assembliesCooper Interconnect combines the industry s most advanced engineering tools with an extensive array of vertically-integrated-manufacturing resources to quickly deliver custom- Interconnect solutions.

4 This tightly integrated, design-through-deployment methodology improves performance and reliability, reduces cost, and accelerates time to market across a wide range of production volumes. Please refer to page seven for descriptions of application specific, Breech-Lok integration accelerates design-to-delivery cycle timesA comprehensive range of mission-critical-engineering resourcesSix Week Cycle TimeCustomer Engagement and Technical ExchangeDesign SolidWorks ModelGenerate Plastic Model with SLA PrinterProduce Working PrototypePerform Validation TestingDeliver Functional ConnectorExtensive experience Cooper Interconnect has an in-depth understanding of the materials, mechanisms, and electronic design required for harsh environment , mission-critical applicationsThe DMEDI process New product development is controlled through a defined toll-gate process to ensure consistent, predictable.

5 And successful portfolio An extensive portfolio of field-proven products and technologies satisfies a significant number of customer requirements with only minor and simulation Our design teams utilize SolidWorks to simulate a complete array of harsh - environment mechanical and thermal stresses, as well as simulation of custom capabilities Straight pull releases with as low as 90 pounds of force. 15 off-angle separations with as low as 100 pounds of force. Designed to withstand 500 harsh - environment mating cycles and 100 snatch releases. Additional lanyard-plug modifications include redundant releases and custom and adjustable lanyard lengths. Breech-Lok lanyard release, flight heritage includes the Bell Helicopter V22 Osprey and the Eurocopter custom lanyard solutions require significantly lowerseparation forces than D38999/31-compliant connectors High-speed data including: fiber optic, MIL-DTL-1553, USB, and 10/100/1000/10 GBASE-T Ethernet.

6 Contact configurations include split-pair quadrax, standard quadrax, differential twinax, and controlled impedance. A readily-available library of custom inserts such as four #8 power and eight #16 contacts in a size 23 shell. Power-Breech custom solutions providing up to 900 amps are described on page 8. Additional customer-defined features: custom shell materials, platings, mounting flanges, backshells, strain reliefs, and extended coupling inserts, shells, and accessories deliverhigh contact densities and application-optimized performance Custom solutions available with Class G finish, space-rated materials. Space-rated materials provide a total-mass loss of < 1% and contain < volatile materials. Breech-Lok products have been space-flight approved by the NASA Goddard Space Flight Center.

7 Flight heritage includes the Space Shuttle, EUVE, UARS, and the Hubble Space Telescope. Custom configurations available with the ergonomic Wing-Lok design are ideal for EVA and IVA rated, Breech-Lok technologies accelerate EVA and IVA custom-solution technologies facilitate mission-critical successesCooper Interconnect provides a broad range of cable assemblies and wiring harnesses including: overmolded; RF coaxial; flat ribbon; fiber optic; and voice, data, and hybrid communications. Our engineers are experts at providing protection against harsh -environmental conditions including: Extreme high and low temperatures Shock and vibration Radiation Corrosive contaminants EMI and RFI Vacuum and pressures to 20,000 PSI In addition to turnkey design and manufacturing for new projects, Cooper Interconnect offers build-to-print services for production-ready Cable Assemblies and Wiring HarnessesCooper Interconnect has delivered one of the industry s broadest ranges of mission critical, custom solutions.

8 Actuator-released interconnects Cryogenic connectors Deadfaced in-flight disconnects EVA quick disconnects High voltage quick disconnects Integrated gas and fluid fittings Interstage-raceway connectors Low-imparted-impulse connectors Umbilical connectors and cable assemblies Vertical launch disconnects Zero-separation-force connectorsThis extensive program heritage has provided a comprehensive array of Interconnect technologies that have been field proven to deliver uncompromised performance in challenging one-stop shop for custom connectivityin QPL and customer-defined form factorsCooper Interconnect s cables provide exacting performance and an exact custom solutions up to 900 ampsMeets MIL-DTL- 38999 Series IV performance requirementsThe Power-Breech Series offer MIL-DTL- 38999 Series IV performance in configurations with large contacts and shell sizes that are not available in QPL solutions.

9 A Series IV derived, breech-lock-coupling mechanism provides quick, positive engagements. These heritage-proven design platforms can be customized to meet a wide range of mission-specific requirements: Current ratings up to 900 amps. Extreme shock, vibration, temperature, humidity, and EMI/RFI environments. harsh - environment cable assemblies. Heritage includes Peacekeeper ICBM qualifications; Boeing specifications 280-36501, 280-36503, 280-36505, and 280-36507. High-current capabilities include solutions configured with four, #4/0 contacts. Available with 2024 Al-alloy shells and CAD/OD (per QQ-P-416) finishes that withstand 500 hours salt spray. MIL-DTL- 38999 Series IV derived, breech-mating designs survive 500 engagement cycles. Vibration and shock capabilities include MIL-STD-202, Method 204, Condition D and MIL-STD-38999H, Series IV.

10 Positive-detent mechanism utilizes 270 of engagement rotation and provides visual, audible, and tactile mating indications. Shell designs are 100% scoop proof and are available in ten polarization configurations. Please contact Cooper Interconnect at to discuss your high-current shell-size 41 connectors mate with 14 #8 contacts to provide a 640-amp current Power-Breech solution utilizes four #4/0 contacts in a size 57 shell to provide 900 technical specificationsMaterials, finish, and mechanicalShell and coupling ring material2024 AluminumShell and coupling ring platingCAD/OD per QQ-P-416 Contact material & platingCopper alloy with gold plating, 50 micro-inches minimumInsulatorHard dielectric waferGrommet and sealFluorosiliconeGrounding springsBeryllium copperMating life500 cycles minimumContact retentionUp to 25 poundsPolarization270 engagement rotation available with ten different polarizationsElectrical and environmentalCurrent ratingsUp to 900 ampsService ratingsUp to 2800 VRMS at sea levelEMI leakage attenuation> 85dB from to 1,000 MHz 10dB per octave from 1,000 to 10,000 MHzShell-to-shell millivolt maximum dropOperating temperature-65 C to 200 C (-85 F to 392 F)