High Power Planforms - Amphenol Ltd

1 high PowerPlanforms23 Key FeaturesTypical Power ApplicationsP Intelligent Power distribution unitsP Power conversion and transformersP Slip ringsP Turret systemsP MotorsP Engine marriage panelsP Bulkhead feedthroughsP Integrated starter generatorsP Actuation systemsP Hybrid vehiclesHigh Power 38999 Part NumberingInsert Arrangements11-0117-5221-7521-42 Service ratingMMIINo. of contacts1242 Contact size8884 AHGFEBCDABCDEFGHABCDABCDEFGHJKLAFDEBCABC DEFGHABADCBAB21-7221-4823-06 Service ratingIMMNo. of contacts2646 Contact size41688 Front face of pin inserts illustrated25-0825-1125-1 AService ratingMNMNo. of contacts89244 Contact size81020416 Contact legend48101620 Series DesignatorTV MIL-DTL-38999 Series IIITVS 200 RatedStyleSee page 5 Shell ClassRW = Olive Drab CadmiumZN = Black Zinc NickelRB = Nickel-Aluminium BronzeRF = Electroless NickelY = Hermetic SealShell SizeOdd numbers 11 to 25 Insert Arrangement (see below)Contact StyleP = Pin ContactS = Socket ContactAlternate KeywayN, A, B, C, D, EPowerTV P00 RW 21 75 P N WP 000 Contact Termination000 = Pintail: #16 + #20001 = Crimp002 = Threaded post: #4003 = Flat tail with cross hole: #4004 = Short busbar: #4 + #8005 = Long busbar: #4 + #8 For mixed planform contact termination consult Power 38999 Planforms Amphenol is the world leader in the design, manufacture and supply of high -performance interconnect systems for military, commercial and industrial applications.

2 Amphenol offers a complete portfolio of Power solutions for demanding and harsh has extended its series of 38999 circular connectors to include a new range of Power inserts to respond to market demands for increased Power in a proven high reliability 38999 circular connector format. The demand for more Power is consistent across all of Amphenol s core markets military, commercial air and industrial and typical applications are intelligent Power distribution units, Power conversion and transformers, slip rings, turret systems, motors, integrated starter generators, actuation systems and hybrid s extended series of 38999 Power inserts offers customers a range of contact sizes from size #20 ( ) to size #4 (100A). Terminations are available to suit different applications such as busbar, tapped hole, crimp, solder bucket and pintails. Inserts are available in standard connector styles such as; jam-nut, box mount, plug, and bulkhead can be manufactured in Aluminium, Aluminium-Bronze, Stainless Steel, Composite and Titanium.

3 Additionally hermetic sealing is available if customers require a glass-metal seal. Amphenol can incorporate EMI and EMP filters to protect against EMI interference and transient energy surges, such as lightning 38999 Power inserts are available in either proprietary or QPL qualified plating finishes including Cadmium, Nickel, Zinc Cobalt and the latest qualified QPL Black Zinc Nickel RoHS compliant plating. Amphenol s new range of 38999 Power inserts coupled with its new high Power Single Pole 38999 Rhino connector, which carries up to 1000A, means Amphenol can offer a complete solution for all customers Power challenges. P Electrical Performance to 100A, operating voltage up to 600vP Range single and multi-pole mixed insert arrangementsP Termination busbar, tapped hole, crimp, pintail and solder bucketP Shell Materials Aluminium, Aluminium-Bronze, Stainless Steel, Titanium and CompositeP Rugged 38999 qualified performanceP RoHS Black Zinc Nickel PlatingP Added-value services harness and cable assembly capability45 StylesTV06 (D38999/26) Straight MAXV +.

4 003 . +.08 . MAXVIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TOVIEW DFOR SIZE 8 COAXIAL ONLY,RELATIVE TO A A V +.003 . +.08 . MAXV +.003 . +.08 . MAXVIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TOVIEW DFOR SIZE 8 COAXIAL ONLY,RELATIVE TO A A V +.003 . +.08 .00 QShell SizeMS Shell Size CodeQ Thread dimensions in mm, for reference (D38999/24) Jam Nut ReceptacleCHS2 PLACESPANEL MIN .125 MIN MAXK REFSHELL SIZES 9/11 .871 SIZES 13/25 .878 MAXV MAX .940 MAXVIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TOVIEW DFOR SIZE 8 COAXIAL ONLY,RELATIVE TO A A CHS2 PLACESPANEL MIN .125 MIN MAXK REFSHELL SIZES 9/11 .871 SIZES 13/25 .878 MAXV MAX .940 MAXVIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TOVIEW DFOR SIZE 8 COAXIAL ONLY,RELATIVE TO A A Shell SizeMS Shell Size CodeC Hex+.

5 43 .41S .25V Thread : Deep reach receptacles are available for panel thicknesses up to .750 max. All dimensions in mm, for reference (D38999/20) Wall Mounting ReceptacleAll dimensions in mm, for reference PLACESTT4 PLACESS2 PLACES2 PLACES2 PLACESR1R2V MAX(TV) .909 MAX(CTV) MAX(TV) MAX(CTV)VIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TOVIEW DFOR SIZE 8 COAXIAL ONLY,RELATIVE TO A A Shell SizeMS Shell Size CodeL Max. M +.00 .13R1R2S .20V Thread MetricLL +.15 .00TT . true position dimensioningHigh Power 38999 Performance InformationTest/parameterDescriptionElec tricalCurrent Ratingsize #20 contacts: #16 contacts: 13A #10 contacts: 33A # 8 contacts: 60A # 4 contacts: 100A to Shell Continuity10m maximum for finishes ZN, RW, RF, SS & RBContact Resistancesize #20 contacts: size #16 contacts: size #10 contacts: size # 8 contacts: size # 4 contacts: Insulation Resistance5000M at ambient, 1000M at max Voltage M: 400V Service AC (RMS)N: 300V Service AC (RMS) I: 600V Service AC (RMS)Dielectric Withstanding VoltageM: 1300 VRS Test Voltage (sea level)N: 1000 VRS Test Voltage (sea level)I.

6 1800 VRS Test Voltage (sea level)TechnicalMating Durabiity500 cyclesTorque Settings ( )Shell SizeBackshellPanel Nut#1171/8140/46#17111/12180/85#21131/14 1100/110#23131/141110/120#25131/141120/1 30 EnvironmentalOperating Temperature Range 65 C to +175 C for finishes ZN, RW, RB 65 C to +200 C for finishes RF, SSSealingAs per Mil-DTL-38999 Salt SprayUp to 500hrs dependant on plating finishRoHS CompliantYes, dependant on plating finish67 Accessories and ToolingBackshellsFamily codeAngle/profile:S = Straight A = 90 B = 45 Connector group (default)BK4 X X K 99 99 9 X X-B1 Entry size:0102 Contact style:B = With band for braid fixingX = Without bandCoupling:S = Self-lock R = Spin couplingShell size Designator: 10-24 Suitable boot, omit for non:B1 = Straight boot B2 = 90 bootMaterial/finish: ZN = Black Zinc NickelN = Electroless NickelZ = Black Zinc CobaltY = Olive Drab Zinc CobaltW = CadmiumLength:9 = Standard sizeLanyard length (all +/- inches) inches (90mm)-02 Electroless Nickel plate0404 inches (100mm)-03 Olive Drab Cadmium0505 inches (125mm)-04 Olive Drab Zinc Cobalt0606 inches (150mm)-08 Stainless Steel0909 inches (230mm)-09 Nickel Aluminium Bronze12012 inches (300mm)-10 Black Zinc NickelCapUse for MIL-DTL-38999 Series III TVEyelet:0 = No eyelet, no lanyard 1 = Lanyard + crimp ferrule2 = Lanyard + large eyelet3 = Lanyard + small eyelet3 1 - 13 R 030 1 - 04 Shell size:Series III (11 to 25)Finish See table below418-60 Style:P = Plug R = ReceptacleF = Heavy Duty PlugG = Heavy Duty ReceptacleLanyard lengthSee table belowLanyard type.

7 0 = No lanyard 1 = Black terylene cord2 = Stainless steel chain3 = Plastic covered wire ropeFamily codeContact Size/TypeCrimping ToolTurret Die or Positioner#4 Pin and Socket809947809948#8 Pin and Socket809872809873#10 Pin and SocketTP-201423 Not applicable#12 Pin and SocketM22520/1-01M22520/1-04#16 Pin and SocketM22520/1-01M22520/7-01M22520/1-04M 22520/7-04#20 Pin and SocketM22520/1-01M22520/2-01M22520/7-01M 22520/1-04M22520/2-10M22520/7-08 Crimping ToolsStandard ContactsInsertion and Removal ToolsContact SizePinSocketSeal Plug#4900007418-3031N/A#8900197900217MS2 7488-8-3#10M39029/58-528M39029/56-527M85 049/81-10#12M39029/58-365M39029/56-353MS 27488-12-2#16M39029/58-364M39029/56-352M S27488-16-2#20M39029/58-363M39029/56-351 MS27488-20-2 Contact Size Plastic ToolsMetal ToolsInsertion ToolRemoval ToolInsertion ToolRemoval Tool#4N/AM81969/14-07N/A809943#8N/AM8196 9/14-12N/AM81969/8-14#10M81969/14-05M819 69/14-05M81969/8-11M81969/8-12#12M81969/ 14-04M81969/14-04M81969/8-09M81969/8-10# 16M81969/14-03M81969/14-03M81969/8-07M81 969/8-08#20M81969/14-10M81969/14-10M8196 9/8-05M81969/8-06 Where 2 or 3 tools are listed for a contact size, only one tool and its die or positioner, adjacent within the table, are required to crimp the contact.

8 The above crimping tools and positioners are available from a QPL approved tool consult factory for advice on backshell specification to suit cable Ltd, UKThanet Way, WhitstableKent, CT5 3 JFUnited KingdomT: +44 1227 773 200 Amphenol Socapex, France948, promenade de l Arve BP29 74311 Thyez CedexFranceT: +33 4 50 89 28 00 Amphenol Air LB, France10 rue champ Raymond08110 CarignanFranceT: +33 3 24 22 32 70 Amphenol AIR LB GmbH, GermanyAm Kleinbahnhof 466740 SaarlouisGermanyT: +49 6831 981 00 Amphenol NordicT: +46 702 129 200 Amphenol Switzerland and South CentreSwitzerland, Slovenia, Serbia, Montenegro, Yugoslavia, Greece, Bulgaria948, promenade de l Arve BP2974311 Thyez CedexFranceT: +33 4 50 89 28 00 Amphenol ItalyVia Barbaiana Lainate, MilanoItalyT: +39 293 254 214 Amphenol BeneluxZadelmaker 121 NL2401 PD Alphen aan den RijnThe NetherlandsT: +31 172 444 903 Amphenol IbericaEdificio Burgosol, Oficina nr 55 Comunidad de Madrid, 35 bis Las Rozas (Madrid)SpainT: +34 91 640 73 06 Amphenol Poland and Central East EuropeAustria, Poland, Czech Republic, Slovakia, RomaniaWiener gasse 682380 Perchtoldsdorf AustriaT: +43 699 10396 071 EuropeAmphenol Daeshin, Korea558 SongNae-2 Dong, SoSa-Gu, Bucheon City, Gyeonggi-do422-040, KoreaT: +82 32 610 3800 Amphenol Interconnect India Private Limited105 Bhosari Industrial AreaPune 411 026 IndiaT: +91 203 068 8304 Amphenol Japan471-1 Deba, Ritto-CityShiga 520-3041 JapanT: +81 77 553 8501 Amphenol PCD CO Ltd, ChinaBuilding 21, 1st Liao Keng Industrial Zone, Shi Yan Street Bao An District, Shenzhen 518108 ChinaT: +86 755 8173 8000 AsiaAmphenol PCD USA72 Cherry Hill DriveBeverly, MA.

9 01915-1065 USAT: +1 978 624 3400 Amphenol Canada Corporation605 Milner AvenueToronto, OntarioCanadaM1B 5X6T: +1 416 291 4401 North AmericaAmphenol ArgentinaAv. Callao 930 2do piso Oficina B Plaza C1023 AAP, Buenos AiresArgentinaT: +54 11 4815 6886 Amphenol Australia Pty Limited2 Fiveways Blvd, Keysborough, Melbourne, Victoria 3173 AustraliaT: +61 3 8796 8888 Amphenol Do BrazilRua Diogo Moreira132, 20 andar, rooms 2001-2-3 CEP: 05423 010 Sao Paulo SPBrazilT: +55 11 3815 1003 Bar-Tec Ltd, Israel3 Hagavish Street, K fir-Barkan BldgEast Industrial ZoneKfar-Sava, 44102 IsraelT: +972 9 764 4100 Amphenol MexicoProlongacion Reforma 61-6 B2 Col Passo de las Lomas : +52 55 5258 9984 Amphenol RussiaYaroslavskaja Street 8129164 MoscowRussiaT: +7 495 937 6341 Amphenol South Africa30 Impala Road2196 ChislehurstonSandtonSouth AfricaT: +27 11 783 9517 Amphenol TurkeySun Plaza 15 Kat:15 Maslak Hah. BilimSok. , 34398 TurkeyT: +90 212 367 92 19 Other areasWorldwide sales contactsFor more information call +44 (0)1227 773200 Amphenol Ltd Thanet Way Whitstable Kent CT5 3JF | Email: | images Ministry of Defence, licensed under the Open Government Licence Cover image of Toyota Prius Teddy Leung | June 2014