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Technical Questions
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8D Power Series
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The High Power Connectors are presented in the 8D catalogue, in “Derived Series” section.
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D38999 Series III connectors
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D38999 qualified connectors are intermateable and interchangeable.
Only connectors of the same series are intermateable, D38999 series I, II and III are not intermateable.
Most of the manufacturers of the D38999 series offer QPL listed layouts and non-qualified layouts:
QPL layouts, qualified to the MIL standard MIL-STD-1560, of different manufacturers are interchangeable Non-QPL layouts could be manufacturer specific, i.e. when manufacturer specific contacts are used. In the case of SOURIAU D38999 Series I ( Souriau 8LT series ) and Series III ( Souriau 8D series ) these are layouts that can include small size #26 contacts, size #8 power contacts, Ethernet Quadrax contacts, ELIO fiber optic contacts -
We can cross the D38999 references to MS27 references, via the SOURIAU 8D references to SOURIAU 8LT references, in order to have the bayonet design. However this would not necessarily lead to a price advantage, because the 8LT range is not so frequently in demand as the 8D range. Furthermore the 8LT range does not cover all the contact layouts of the 8D range.
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MIL-DTL-5015 are reverse bayonet connectors that have existed on the market for very long time. They are offered by quite a lot of suppliers.
MIL-DTL-5015 is not a reference when looking at shielding, weight and handling. It is not recommend for layouts with small signal contacts, or mixed power and signal layouts.
The signal integrity and the mating characteristics are poor, MIL-C-5015 is not scoop-proof and it only has one polaristion key.We recommend you stay with the state of the art D38999 series III Souriau 8D connectors !
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Aluminium nickel plated shells could be a RoHS compliant alternative, nickel plating is electrically conductive, however it is shiny and reflective. Moreover nickel plating's resistance to salt spray is only 48 hours.
If you are looking for a light weight Aluminium shell then consider Aluminium black zinc nickel class Z. Black zinc nickel plating, non reflective and electrically conductive resists 500 hours to salt spray and has the same properties as Cadmium (Nickel and Stainless Steel do not!).
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Power Layouts, meaning layouts that contain power contacts #8 and #4 are not QPL because the contacts are not contained in the MIL standard.
For example the layouts 17-22 with 2 #8 power and the layout 21-48 with 4#8 Power contacts are only available with the 8D SOURIAU reference.
It is important to note in these layouts that the suffix 251 is included, because the two layouts 17-22 and 21-48 also exist with #8 Triax contacts. Only when the suffix -251 is included in the SOURIAU reference will these layouts be delivered with power contacts.
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8D - Is the 8D series suitable for power supply applications using nominal voltages above 150 Volts?
The 8D series is specified by the MIL standard MIL-DTL-38999 and for this reason is not qualified to IEC standards. In some military or some custom specific applications this might not be important, however we have to decline any responsibilities for such a use.
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Normally an electrical conductive O-Ring is not needed because the flange area of the Jam Nut receptacle ensures the bonding to the front panel. In some specific cases the bonding resistance might not be sufficient. In such cases we can offer custom specific solutions.
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The clinch nut square flange receptacles have got a wider flange in order to accommodate the clinch nut and to support the press force of the clinch nut.
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This is possible however a custom specific part number must be created then.
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It is possible to insert and to remove spill contacts in the same way as crimp contacts as the contact cavities are equipped with retention clips. Spill versions with standard lengths for the 8D receptacles are listed in the 8D catalogue.
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One can only equip the cavities needed, however non used cavities must be equipped with a non-crimped contact and additionally sealed with a filler plug. For certain power contacts, dummy contacts, a combination of a filler plug and a non-crimped contact are available.
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Although crimp contacts are defined for AWG wire sizes, it is possible to convert AWG wire sizes into metric wire sizes. In some cases the use of a reducing sleeve might be required. In this case the extraction force of the wire needs to be checked carefully.
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It is possible to equip 8D receptacles with spill contacts of different lengths, this can be done by the customer, however it is not possible to order such a combination as a standard part. If needed, a custom specific partnumber can be created.
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It is possible to couple different classes of 8D connectors, however it has to be obeyed if the galvanic potential of the classes are not too far from each other. An application note including guidelines is available at Souriau.
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The MIL standard MIL-DTL-38999 specifies the crimp versions only because the connector suppliers have no impact on the soldering process of the spill contacts. 8D receptacles with spill contacts can be used in combination with any MIL-DTL-38999 specified plugs. The qualification of the spill receptacle is done with the qualification of the system equipment.
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It is possible to use Souriau 8D spill versions instead of competitors spill versions but it needs to be checked if the dimensions, the length and the diameter of the spill, are corresponding. The reason for this is that the spills are not specified by any standard.
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No the 8D Quadrax versions are not qualified to the MIL standard MIL-DTL-38999 because the MIL standard does not include Quadrax contacts.
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Quadrax contacts are not concentric as Coax or Triax contacts and they have got a keying to avoid turning in the cavity. On the other hand side it is possible to insert other size #8 non keyed contacts like Coax, Triax or Power contacts into a Quadrax cavity.
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The insulators of the 8D series are fixed in the 8D shells in order to guarantee the correct position and the retention force of the insulator which are specified in the MIL standard M-DTL-38999. For this reason the insulators can’t be purchased separately.
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No it is not possible, the insulator for male contacts is different to the insulator for female contacts.
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Yes, it is possible to use MIL contacts M39029 type. The MIL contacts are colour coded with rings, in some cases the extraction force of the wire can differ slightly to Souriau 8D contacts. This does not have any significant impact on the performance of the connector, but in cases where the extraction force of the wire is defined in the customer specification it needs to be checked.
1.27μm gold plated = MIL-DTL-38999 qualified crimp contacts
0.8μm gold plated = SOURIAU crimp contacts
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The standard 8D series is not provided with a backshell. We have got an extensive offer of Sunbank backshells which can be combined with the 8D series. Also, we propose 8DA derived Series, available for plug, with integrated backshell (please consult our 8D catalogue, in “Derived Series” section). For 8D High Power connectors, part numbers including backshell can be built.
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8LT & 8T Series
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Yes, Sunbank offers accessories suitable for MIL-DTL-28999 Series II.
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8T series uses contacts of size #22D, #20, #16 and #12.
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The 8T series uses the same pin contacts as the 8LT and 8D series. The socket contacts are shorter than the 8LT and the 8D socket contacts and are available with their own partnumbers.
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The shell size of 8T is expressed in even numbers. There are 9 different shell sizes available starting with shell size 08 and ending with shell size 24.
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Souriau 8T Series is qualified to the MIL-DTL-38999 Series II and HE 309, QPL listed with appropriate product identification MS or HE309.
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Yes the 8LT series comprises a Rack and Panel Version to support easy and fast connection without any coupling / uncoupling of a float mounting and a fixed unit. For the 8LT Rack and Panel version a separate catalogue is available.
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Yes, Sunbank offers accessories suitable for MIL-DTL-28999 Series I.
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8LT series uses all the major contacts sizes from size #22D, #20, #16 and #12 to size #8 and size #4. Quadrax-Layouts are also available.
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The pin contacts are the same but the socket contacts of 8T series are shorter.
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In terms of coupling and uncoupling force the shell size 9 of 8LT series is equal to shell size 8 of 8T series and so forth.
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The shell size of 8LT is expressed in uneven numbers, there are 9 different shell sizes available starting with shell size 09 and ending with shell size 25.
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As the dimensions of both connector series are different both series can’t be interchanged 1:1. The front panel cut outs must be observed for each shell size and foe each shell type.
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No, thus both series have got a bayonet locking mechanism, 8LT series is scoop proof whereas 8T series is non-scoop proof with a low profile design. Both series are not intermateable.
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Souriau 8LT Series is qualified to the MIL-DTL-38999 Series I and HE 308, QPL listed with appropriate product identification MS or HE308.
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851 Series
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The 8525 and 8526 connectors provide a higher coupling torque and can be used instead. This is only a qualitative statement, individual differences in coupling torques must be investigated for each individual combination.
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The series 851, 8525 and 8526 are intermateable as defined in the MIL-DTL-26482 standard. The 8525 is a light version of the MIL-DTL-26482 SII standard. The sealing level of such a combination is determined by the less performing half of the connection.
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The endshells are included in the series 851. Our catalogue includes a complete range of connectors with military backshells. For the industrial market we have got connector versions including backshells suitable for the industrial market.
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Solder contacts are gold plated as standard, but they are also available with pre-tinned solder area. As the solder contacts bonded in the connectors, the connector partnumber changes. The partnumbers are listed in the series 851 catalogue.
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Solder contacts with solder bucket and straight spill both are bonded into the insulator and can’t be removed. It is possible to purchase wire wrap contacts with quadratic termination area and to use them instead of crimp contacts. For solder receptacle snot accepting backshell it is possible to have either versions with bonded wire-wrap contacts that can’t be removed or versions with non-bonded wire-wrap contacts that can be removed.
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Series 851 crimp contacts are front release, the extraction tool must be used from the mating side. Please be aware that only the tools shown in the 851 catalogues can be used.
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Series 851 is fully interchangeable and intermateable with VG95328, when connecting series 851 with VG95328; please consier the connection properties are the minimum performance requirements.
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Series 851 is fully intermateable with MIL-DTL-26482 series I connectors and also with MIL-DTL-26482 Series II connectors. However when mating with series II, please consider the properties of the connection to be the minimum performance requirements.
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851 can’t be used in rolling stock applications because of the Neoprene insulator which is flammability rating UL94HB ( slowly burning, not self extinguishing ). For rolling stock equipment we have specially designed ranges such as the VGE-1 or the UTS series.
In signaling equipment outside, where the flammability rating does not play a decisive role, it might be possible to use 851 series, but this has to be checked. -
The insulator material is Neoprene Rubber and therefore it is not allowed to use 851 series in aeronautical applications. For aeronautical applications the series 8526 fully compliant with MIL-DTL-26482 Series II or the series 8525 derived from MIL-DTL-26482 Series II and fully compliant with EN3646 are designed.
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EN3646 & 26482 Serie 2
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Series 8526 is fully interchangeable and intermateable with series 851, when connecting with 851 series the minimum performance of requirements determine the properties of the connection.
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Series 8525 uses specific backshells qualified to EN3646, NSA and ASN_E standards. The performance of the connector can’t be guaranteed when other backshells are used.
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The Series 8525 is a lightweight version of the MIL-DTL-26482 II Series especially designed for aircraft applications. The differences are the lower weight, the platings, the fluid resistance and the wider temperature range. Apart from that, the insulators are made from different materials and are equipped with a grommet and with an interfacial seal.
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Series 8525 is fully intermateable with MIL-DTL-26482 series connectors – both series I and II. However when mating with series I and II the minimum performance of requirements are determining the properties of the connection. Attention must also be paid to the different platings and to the galvanic potentials.
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853 Series
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Each version must be equipped with contacts designed for the relevant temperature range. In the 8533 catalogue the contacts for 175°C, 200°C and 260°C are listed. The contacts can be ordered separately or together with the connector.
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Yes, as follows: The rear thread version 8533 is intermateable with the 8535 version with integrated backshell. The rear thread version 8534 is intermateable with the 8536 integrated backshell version.
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No, the two versions are not intermateable.
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A special long term fuel immersion version tested with 3 cycles of 96h immersion is available within the standard offering.
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ARINC 600 Series
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By inserting the cavity #8 extraction tool from the front / mating side the contact spring will release. The front release adapter can be withdrawn then from the front side. Obviously the ELIO contact must be removed before the withdrawal.
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We provide solutions that use the ELIO Arinc600 adapter to mount ELIO contacts into coded #8 Quadrax cavities. The ELIO adapters are available in rear release and in front release. The front release ELIO adapter is for the Arinc600 receptacle.
At a certain time we have been looking at Arinc600 insulators that could take the ELIO contacts without ELIO adapter, the 22 ELIO insert for the big Arinc600 cavities, but this solution turned out to be susceptible to the high retention forces of the ELIO contact springs, so this has not pursued any further. -
At the moment in time we do not provide any solutions for Arinc801 contacts in Arinc600 connectors. Such solutions must be investigated from our side.
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Sealed versions of the Arinc 600 connectors are availalble within the Souriau standard Arinc 600 range. The sealing is done by compound and / or grommet for the receptacle and by compound and / or grommet and an O-ring for the rack plug. The front release inserts can’t be equipped with a grommet, receptacles with front release PCB contacts are only available in unsealed.
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Standard Arinc 600 inserts are equipped with metal clips so that the contacts can be inserted and removed during the service time of the Arinc 600 connector. Harpooned contacts use special inserts without clips and the contacts can’t be removed once installed in the factory. This technology is used for pcb signal contacts #22 as a cost effective solution. Souriau harpooned inserts are fully qualified by the aircraft and equipment manufacturers.
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Standard grounding is done thanks to a EMI Ring on plug (nickel plated version only)
As as option :
Additional grounding can be realized by a ground blade or alternatively by one or two ground fingers. As the additional grounding is installed in the polarization field, one or two polarization keys have to be taken out.
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Arinc 600 contains the rack plug that is installed on the rack (avionic trays) or in the cabinet and the equipment receptacle which is installed on the LRU equipment unit.
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ARINC 600 Backshell Series
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Sunbank offers a range of backshells specially designed for Arinc 600 connectors. The backshells are listed in the Souriau Arinc 600 catalogue which you can find by clicking on the link below.
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MQuick Series EN4165
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The shells are made of composite material, either unplated or nickel plated. The composite shell offers extremely high stability and weight reduction.
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Unmated sealed versions use modules with an O-Ring. Sealed modules are in the standard offering of MQuick.
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MQuick modules use the proven design with metallic retention clips. The clips ensure that the contacts can be inserted into a module without the danger of damaging the clips. The metallic clips also ensure enhanced vibration and shock resistance.
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At the moment the mono module version as described in the EN4165 is available. Multi modules shells in under market analysis.
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MQuick is designed to be EN4165 Compliant. The certification process is ongoing.
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MQuick modules are available in packages with contacts but also in bulk pack without contacts. The contacts can be purchased separately.
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MQuick modules can be inserted into shells of other manufacturers qualified to EN4165.
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MQuick is fully mateable with manufacturers qualified to EN4165.
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MQuick uses standard MIL-39029 series II contacts.
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A universal coded insulator can be placed in any coded shell. The coding then is determined by the shell.
As components can be sold separately, this range includes 2 levels of coding :
- Coding to avoid mistakes when mounting modules in shells
- Coding to avoid mistakes when mounting plug on receptacle
For modules keying, please refer to :
For shells Keying, N as universal key in compliant for a use on all others keys. Please make sure to avoid this solution if 2 connectors need to be used on the same equipment.
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The receptacle is coded by a colour band and a colour coding plate can be purchased for better visibility
The plug is coded by the coloured coupling ring, which is determined by the reference of the plug shell.
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We offer customers the following accessories for receptacles only:
- Colored Coding Plate for visual help for mating sequence
- Panel Gasket for better sealing performances
- Nut Plate for avoiding loosing part in system (EWISE)
These accessories can be ordered separately or with receptacles.
For extended receptacles also a backshell is needed. -
Three types of shells are available, plug, short receptacle and extended receptacle.
- The extended receptacle has got the possibility to mount a backshell and is designed for harness cabling.
- Short receptacle is designed for box mounting and is to be used with PCB contacts.
- Plug is compliant for the use on both receptacles.
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MQuick is sold in components, insulators, contacts, shells, backshells and accessories.
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UTL Series
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The mixed layouts allow power supply and signal transmission in only one connector. This reduces the system complexity and minimizes the installation costs. One twisted pair allows simplex data transmission, two twisted pairs allows duplex data transmission.
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The UTL series covers four different layouts:
- 4 positions for power delivery (layout 3G1)
- 6 positions for power and signal delivery (layout 2G1W3) compliant with RS485 / DMX protocol
- 8 positions for power and delivery (layout 2G1W5) compliant with RS485 / Full DMX protocol
- 5 positions with backshell for field installation thanks to screw termination contact.
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The protective earth is of opposite gender to the power and the signal contacts to achieve an improved security in the assembly process and in the operation. The different gender of the protective earth contact allows to protect the contact particularly against damage and mismating.
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UTL can be self-assembled with a heatshrink or a backshell. A detailed instruction manual is available, and it can be purchased in readily overmolded harnesses in standard lengths.
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UTL series has got Current Break Capacity. The voltage and the current values for the CBC operation are listed in the UTL catalogue.
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8D Series
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The 8D #8 power contacts are for AWG#8 wire size. With the reducer that is offered in the catalogue in the contacts section, the contacts can also be suitable for AWG#10 wire size.
In any case a boot must be inserted into the grommet, the boots for the AWG#8 and AWG#10 wire sizes are different in seize and have different partnumbers. The boots are also offered in the contacts section of the 8D catalogue.
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EN2997 Series
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The EN standard EN2997 requires that connectors delivered with A,M or C in the partnumber block are always marked with M on the connector. The label, the CoC and the note of delivery however stay with the A,M or C.
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SWIM Series
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Unfortunately we are unable to send out detailed material specifications of our connectors. The material is generally specified in our catalogue.
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09 Series
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The choice of an integrated backshell or a separate backshell depends on the application and on individual preferences:
- Integrated backshell enables optimized space and weight-savings, and of course less components
- On integrated backshells it is only possible to fix the shield braid with a band adapter.
- However this might be a problem when more complex contact arrangements are used i.e. layouts with shielded contacts, when more individual shields must be connected to the outer shield.
Band adapter means direct contact of three different materials: the connector shell, the braid and the band. The material combination, which includes the surface treatment of the connector shell must be carefully chosen in order to minimize the galvanic potential.
- In some military applications, the fixing of the shield braid with a fixing cone ( backshell with fixing cone ) is preferred. The shield braid is firstly fixed with a fixing wire, and secondly clamped by the fixing cone.
- Fixing cones provide an enhanced sturdiness and robustness, however the braid thickness and the braid construction must not exceed the space limitations given by the construction of the fixing cone. Problematic could be double braids, braids with an increased thickness or combinations of shield braids and shield foils.
- The major disadvantages of endshells with fixing cones are their space consumption and their weight.
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UTG Series
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There is a chamfer in front of the internal thread of the UTS backshell. The reason for this is that the seal between the UTS series connector and backshell is located in front of the fastening thread.
The housing of the UTG series does not have this chamfer. The seal between the UTG series connector and backshell is located at the rear of the fastening thread.
Therefore you can’t screw an UTG series endshell onto an UTS series connector, the connection would not be sealed and the coupling ring would have no hold.
UTG backshells do not fit on UTS connectors, however they do fit on 851 series connectors.
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Others
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PFH is not applicable to components like connectors but to a system. The PFH is calculated from the reliability of each component of the system, but the PFH mainly depends on the architecture design strategy of the system, how it is designed to monitor, sense signals and detect error, and how redundant it is.
The reliability of components is usually defined by the MTBF (Mean Time Between Failures). The MTBF depends on the mission profile of the application. For example for a connector, it will depend on the number of mating cycles, the environmental temperature range, the vibration, the pressure, the current, and all the other parameters defining the mission profile.
If we receive a detailed mission profile of the application, we could quote a specific study to calculate the MTBF.