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
Advanced electrical, mechanical and
environmental performance
plus reduced
size and weight
compared to D38999
Series 806
Mighty Mouse
Mil-Aero Connectors
S
Next-generation small
form factor aerospace-
grade circular connector
Designed for general
use in harsh application
environments such
as aircraft, industrial
robotics and more
Upgraded environmental,
electrical and mechanical
performance
Integrated anti-
decoupling technology
Higher density 20HD
and 22HD contact
arrangements
Glass hermetic,
lightweight aluminum
hermetic, and filtered
versions
+200° C temperature
rating
eries 806 offers significant size and weight savings while meeting key performance
benchmarks for a broad range of applications such as commercial and military
aerospace, industrial robotics, transportation systems and more. Designed for general
use in harsh vibration, shock and environmental settings—as well as high-altitude,
unpressurized aircraft zones with aggressive voltage ratings and altitude immersion
standards—the Series 806 Mil-Aero features numerous mechanical design innovations
including durable mechanical insert retention, radial seals and triple-ripple grommet
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
size 9 and 11 MIL-DTL-38999 Series III connectors.
SAVE SIZE AND WEIGHT WITH SERIES 806 CONNECTORS
Series 806 Mil-Aero
Smallest Size
.500 In. Mating Threads
3 #20 Contacts or 7 #22
contacts
MIL-DTL-38999
Smallest Size
.625 In. Mating Threads
3 #20 Contacts or 6 #22
contacts
© 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
17
27
1 18
MIGHTY MOUSE MIL-AERO
.120
.067
O
Series 806
Ultraminia
ture Circu
lar Connector
s
Product Specificatio
n
Millivolt Drop
2.5
2.5
1.0
2.5
10.0
1.0
(mV)
2X .351
.053
Series 806
Connectors
Ultraminiature Circular
Materials and Finishes,
DESCRIPTION
Pin Contact
Socket Contact
Insulators
Seals
EMI Spring
Jam Nut
Shell, Coupling Nut,
Contact Retention Clip
Anti-Decoupling Ratchet
Product Specification
Standard Materials
MATERIAL
Copper alloy
Copper alloy, with stainless
steel hood
MIGHTY MOUSE
MIL-AER
and Finishes
FINISH
over nickel
50 microinches gold
over nickel
50 microinches gold
Contact hood: passivate
None
None
Nickel
See sales drawing or
None
Passivate
catalog for finish options
Product Specifi
cation
TEST DESCRIPTION
Shell-to-shell
conductivity
High grade rigid dielectric
blend, blue
Fluorosilicone/silicone
Beryllium copper
steel
Aluminum alloy or stainless
Beryllium copper
Stainless steel
Spring
Product Specification
REQUIREMENT
Contact Size
20HD
22HD
Contact Size
20HD
22HD
Altitude
Sea level
Sea level
Altitude
50,000 ft
Voltage
1800
1300
Voltage
1000
1000
1000
800
800
800
PROCEDURE
4.5.11.1
MIL-DTL-38999M para.
A
EIA-364-20 Method
current
2 mA maximum leakage
Unmated pairs
4.5.11.2
MIL-DTL-38999M para.
A
EIA-364-20 Method
current
2 mA maximum leakage
Mated pairs
Backshell shield
braid to shell
conductivity
Finish Code
NF
MT
ME
ZR
Z1
ZL
Finish Code
NF
MT
ME
ZR
Z1
ZL
REQUIREMENT
Shell Matl/Fin
Al/OD Cad
Al/Ni-PTFE
Al/EN
Al/Zn-Ni
SST/pass.
SST/Ni
Shell Matl/Fin
Al/OD Cad
Al/Ni-PTFE
Al/EN
Al/Zn-Ni
SST/pass.
SST/Ni
PROCEDURE
MIL-DTL-38999
M Para. 4.5.25
EIA-364-83
Dielectric withstanding
sea level
TEST DESCRIPTION
voltage at
.411
(mV)
10X HOLE TO ACCEPT .032 MAX
DIA CONTACT
1
2
Millivolt Drop
5.0
5.0
3.5
5.0
15.0
MIL-DTL-38999
M Para. 4.5.25.1
EIA-364-83
Dielectric withstanding
at altitude
voltage
Indirect lightning
EMI shielding
70,000 ft
100,000 ft
50,000 ft
70,000 ft
100,000 ft
strike
at ambient
Insulation resistance
temperature
at elevated
Insulation resistance
temperature
25 °C
Contact resistance at
5000 megohms minimum
1000 megohms minimum
Maximum Voltage Drop
(millivolts)
After
Conditioning
Initial
55
73
45
52
54
60
66
88
54
63
65
73
4.5.10.1
MIL-DTL-38999M Para.
EIA-364-21
4.5.10.2
MIL-DTL-38999M Para.
EIA-364-21
AS39029C Para. 4.7.5
EIA-364-06
Silver-plated wire
Wire Size
20
22
24
26
28
30
Test Current
Amperes
7.5
5
3
2
1.5
1
Durability
Coupling and
uncoupling
Contact resistance at
200 °C
Wire Size
20
22
24
26
28
30
Test Current
Amperes
7.5
5
3
2
1.5
1
Maximum Voltage
Drop (millivolts)
94
125
77
89
92
103
AS39029C Para. 4.7.5
EIA-364-06
Silver-plated wire
torque
No evidence
3.5
of damage
which could
Connectors
impair proper
shall
coupling torque. meet shell-to-shell
functioning.
conductivity,
MIL-DTL-38999
DWV and
M Para. 4.5.47
EIA-364-75
Freq.
Leakage Attenuation,
10,000 Amps
MHz
Electroless
(dB) minimum
peak current
Nickel
Cadmium,
Finish
MIL-DTL-38999
Nickel-PTFE,
100
M Para. 4.5.28
Nickel Finish Zinc-
90
200
88
300
90
88
400
88
87
800
88
85
1,000
87
85
1,500
85
76
2,000
85
70
3,000
69
69
4,000
65
68
6,000
61
66
10,000
58
65
55
No evidence
50
of damage
ing following
which could
impair proper
500 cycles
of mating
and unmating. function- MIL-DTL-38999
M Para. 4.5.8
Maximum
EIA-364-09
Shell size
Minimum
Engagement
MIL-DTL-38999
Disengagemen
lbs-inch.
M Para. 4.5.7
t
EIA-364-114
8
lbs.-inch.
8
9
10
11
12
14
16
18
20
22
24
8
12
12
12
16
20
24
28
32
36
2
2
2
2
2
2
3
3
3
5
5
4X
.140
3
8
9
10
4
6
5
.125
.058
7
2X .351
31
10
Low level contact resistance
Wire Size
20
22
24
26
28
30
(milliohms)
Maximum Contact Resistance
After Conditioning
Initial Values
9
15
20
31
50
75
11
17
23
38
60
88
AS39029C Para. 4.7.4
EIA-364-23
Silver plated wire
Insert retention
External bend
moment
100 pounds
per square
Shell size
8
9
10
11
12
14
16
18
20
22
24
inch, 25 pound
minimum
force
Pound inches
100
100
100
200
300
400
500
600
700
800
900
6
© 2016 Glenair,
to change without notice.
(mm). Information subject
U.S. CAGE code 06324
• www.glenair.com •
Dimensions are in inches
CA 91201 • 818-247-6000
Inc • 1211 Air Way, Glendale,
MIL-DTL-38999
M Para. 4.5.12
EIA-364-35
MIL-DTL-38999
M Para. 4.5.16
EIA-364-43
7
© 2016 Glenair, Dimensions are in inches
Inc • 1211 Air
(mm). Information
Way, Glendale,
subject
CA 91201 •
818-247-6000 to change without notice.
• www.glenair.co
m • U.S. CAGE
code
06324
.058
.140
Introduction and
Product Features
Page 2
Contact
Arrangements
Page 5
Performance
Specifications
Page 6
Space-Grade
Information
Page 9
Printed Circuit Board
Layouts
Page 70
SERIES 806 MIGHTY MOUSE MIL-AERO CONNECTORS
Plugs
806-012
Page 10
Square Flange
Receptacles
806-013
Page 12
Line Receptacles
806-019
Page 14
Jam Nut Receptacles
806-020
Page 16
Jam Nut PCB
Receptacles
806-021
Page 18
Square Flange Glass Hermetic Glass Hermetic
Lightweight Hermetic
Filtered
PCB Receptacles Receptacles PCB Receptacles
PCB Receptacles
Receptacles
806-022
Page 20
806-025
Page 22
806-026
Page 25
806-028
Page 28
240-806
Page 30
Filtered PCB
Receptacles
240-806-21
Page 32
SERIES 806 MIGHTY MOUSE MIL-AERO ACCESSORIES
Contacts
Page 34
Crimp Tools,
Ins/Ext Tools
Page 37
Filler Plugs
Page 38
Band-Master ATS® Panel O-rings
Page 38
Page 38
Panel Gaskets
Page 39
Connector
Holding Tools
Page 39
Nut Plates
Page 40
Protective Covers
Page 41
Stowage
Receptacles
Page 44
Shrink
Boots
Page 45
Backshell
Selection Guide
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
Dimensions in Inches (millimeters) are subject to change without notice.
1
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Introduction
About The Series 806
he Mighty Mouse Series 806
Mil-Aero is an aerospace-grade
ultraminiature circular connector with
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
number of contacts with no reduction
in performance. Independent laboratory
testing has demonstrated that the Series
806 meets the requirements of MIL-
DTL-38999 Series III.
But there is more to the 806 than
size and weight reduction. This new
high-performance connector has many
innovative features that meet the most
aggressive requirements of the military/
aerospace industry. One such feature is
better resistance to vibration-induced
decoupling. This is accomplished by re-
engineering the ratchet mechanism and
introducing a shallower mating thread
ramp angle.
Glenair pioneered integral banding
platforms to allow direct attachment
of cable shields, boots and overmolds.
This innovation continues with the 806,
Glenair’s first connector to exclusively
use the ultralightweight Nano-Band for
maximum size and weight reduction.
Another enhancement is a “top hat”
insulator with raised bosses for foolproof
alignment of insulator cavities and
retention clips as well as higher voltage
ratings.
The 806 series connector features an
O-ring radial interface sealing design
instead of a flat gasket. This allows
for easier metal-to-metal coupling,
improved sealing, and better EMI
performance. The MIL-DTL-38999 Series
III and other legacy aerospace circular
connectors have a flat gasket inside the
receptacle shell. This peripheral seal must
be compressed sufficiently to allow full
metal-to-metal connector bottoming.
In certain tolerance conditions this seal
can make it difficult to fully mate the
connectors “without the use of tools” as
is required by MIL-DTL-38999.
2
T
Save Size and Weight with Series 806 Connectors
Mighty Mouse Mil-Aero Is The Next Generation Higher Density
Connector for Demanding Aerospace and Defense Applications
Series 806 plug with 19 #22 contacts
compared to MIL-DTL-38999 Series
III with 6 #22 contacts. More than 3X
the number of contacts, yet only .020
inches larger diameter.
MIL-DTL-38999
Series 806
Coupling Nut Diameter (Inches)
Series 806 20HD Arrangements Compared to
MIL-DTL-38999 Series III Size 20 Arrangements
No. of Contacts vs. Coupling Nut Diameter
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0
10
20
30
40
50
60
70
80
90
100
Series 806 #20HD
D38999 #20
Number of Contacts
Series 806 #22HD Arrangements Compared to
MIL-DTL-38999 Series III #22D and #23 Arrangements
No. of Contacts vs. Coupling Nut Diameter
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0
20
40
60
120
80
100
Number of Contacts
140
160
180
200
Series 806 #22HD
D38999 #22D
D38999 #23
© 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.
Coupling Nut Diameter (Inches)
2.0
ULTRAMINIATURE CIRCULAR
Series 806
Mighty Mouse Mil-Aero Connectors
Product Features
KEY FEATURES
Next-generation high
performance ultraminiature
aerospace connector
Reduced pitch triple-start
modified anti-decoupling stub
ACME thread
Higher density 20HD and
22HD contact arrangements
+200° C operating temperature
High strength aluminum alloy
plug barrel
“Triple ripple” wire sealing
grommet (75,000 ft. rated)
Snap in, rear release crimp
contacts
Metal contact retention clips
Integral Nano-Band shield
termination platform
shielding effectiveness per
EMI
MIL-DTL-38999M para. 4.5.28
(65 dB min. leakage
attenuation @ 10GHz)
10,000 amp indirect lightning
strike
300g. shock
MIL-S-901 Grade A high impact
shock
Aluminum and stainless steel
versions
Environmental crimp contact,
glass-to-metal seal PC tail and
solder cup hermetics, and EMI
filter versions
RoHS compliant nickel, nickel-
PTFE, black zinc and stainless
steel plus mil-grade cadmium
finish options
Printed circuit board versions
with threaded flange
AVAILABLE LIGHTWEIGHT ALUMINUM “CODE RED” HERMETICS
CODE RED is a lightweight
encapsulant sealing and
application process with
50% package-weight
savings compared to glass-to-metal seal Kovar/stainless steel solutions. Non-
outgassing CODE RED (IAW NASA/ESA) provides durable hermetic sealing with
better than 1X10
-7
leak rate performance. Gold-plated copper contacts deliver
outstanding low-resistance current carrying capacity. See 806-028 page 27.
Panel O-ring
Fluorosilicone
Aluminum alloy
Plug Connector
Coupling Nut Retainer Ring
Stainless steel
Coupling Nut
Aluminum alloy
Insert Retention Ring
Stainless steel
Wire Seal
fluorosilicone rubber
Insulators
Contacts
Glass-filled rigid dielectric
Anti-Decoupling
Spring
Stainless steel
Gold-plated copper
Plug Barrel
High strength
7alloy
fluorosilicone rubber
Interfacial Seal
EMI Ground Spring
Nickel-plated BeCu
Receptacle Connector
Insert Retention Ring
Stainless steel
Wire Seal
Fluorosilicone rubber
Insulators
Glass-filled rigid dielectric
Jam Nut
Aluminum alloy
Shell / Mating
Interface
Aluminum, modified
triple-start
Shell Body
© 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.
3
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