17550 Gillette Avenue, Irvine, CA 92614 • www.sabritec.com • Tel: (949) 250-1244 • Fax (949) 250-1009
Pg. 159
High Power Connectors
Overview and Contact Performance
Sabritec’s High Power connectors utilize the superior performing Hyperboloid® contact technology, ideal for harsh
and demanding environments with low contact resistance. These connectors provide high current ratings with smaller
contacts for the same power thus saving overall weight and space.
Contact Mechanical & Environmental
Key Features:
• Low coupling force
• Improved low rate of wear and high coupling durability
• Shock and vibration resistance
• Operate in harsh environments
• Increased power handling capability by 25% as compared to standard
contacts
• Reduced contact resistance
• Contact elements can be insulated, to enable multi-pole use (coaxial)
Shell
Contacts
Inserts
Seals & O Ring
Specifications
Contact
Endurance
Operating
Temperature
Contact Mating Cycles >1000
-65˚C to +150˚C
Connector Materials and Finishes
Aluminum Alloy, Stainless Steel,
Composite
Copper Alloy, Gold Over Nickel
Glass Filled Thermoplastic or Epoxy
Fluorosilicone Rubber
• Contact mating sequence can be used to gain benefits such as power switching
• Mating of shorter contact can energize main power for system or safety requirements
Hyperboloid
®
Performance vs MIL-C-39029
Pin Size
8
4
0
00
0000
Pin Diameter,
mm (in)
3.61 (0.142)
5.72 (0.225)
9.07 (0.357)
10.31 (0.406)
12.70 (0.500)
Socket OD
maximum, mm
(in)
6.50 (0.256)
9.53 (0.375)
13.35 (0.526)
18.55 (0.730)
21.02 (0.828)
MIL Spec
Current Rating
Continuous, A
46
80
150
185
225
Hyperboloid
®
Contact
Current Rating
Continuous, A
60
100
300
300
500
Hyperboloid
®
Contact
Resistance
Typical, mΩ
0.20
0.10
0.10
0.07
0.05
Hyperboloid
®
Contact
Resistance
Maximum, mΩ
.50
.50
.20
.20
.10
Mating Cycles (Durability):
MIL-Spec = 500
Hyperboloid® Equivalent = 5,000
Current Derating Curve
Contact Resistance vs. Load
De-rating guide for power connectors used at elevated temperatures.
Cable and / or busbar type and installation arrangements
need to be considered in applying this data.
Pg. 160
17550 Gillette Avenue, Irvine, CA 92614 • www.sabritec.com • Tel: (949) 250-1244 • Fax (949) 250-1009
High Power Connectors and Contacts
High Power Socket Contact Termination Styles
High Power Contact Terminations
C
E
Hyperboloid Contact with Wire
Crimp Termination
Thread A
C
Hyperboloid Contact with Male
Threaded Post Termination
Thread B
Contact Dimensions
Contact
Size
8
4
0
00
0000
A
Thread
1/4-20 UNC-2A
3/8-16 UNC-2A
9/16-12 NC-2A
5/8-11 UNC-2A
3/4-10 UNC-2A
B
Thread
1/4-20 UNC-2B
3/8-16 UNC-2B
9/16-12 UNC-2B
5/8-11 UNC-2B
3/4-10 UNC-2B
C
Max
.256
.375
.526
.730
.828
E
Max
.182
.283
.455
.500
.641
C
Hyperboloid Contact with
Female Threaded Termination
C
Thread A
Hyperboloid Contact with R/A
Thread Post (Male, Female or
Crimp Termination)
MIL-DTL-38999 Connector Insert Arrangements
?
21-75 POSITION
4 Size 8 Contacts
SPECIAL 25-21
2 Size 0 Contacts
CUSTOM
ARRANGEMENT
MIL-DTL-5015 Connector Insert Arrangements
14-3
1 Size 8
16-12
1 Size 4
18-6
1 Size 4
18-7
1 Size 8
20-2
1 Size 0
20-19
3X Size 8
20-23
2X Size 8
22-1
2X Size 8
22-2
3X Size 8
22-7
1 Size 0
22-22
4 Size 8
24-9
2X Size 4
24-10
7X Size 8
24-22
4X Size 8
28-3
3X Size 8
28-6
3X Size 4
32-5
2X Size 0
32-17
4X Size 4
?
32-63
5X Size 4
36-4
3X Size 0
36-5
4X Size 0
36-6
4X Size 4
2X Size 0
Special size
32 4X Size 0
CUSTOM
Special size
40 2X Size 0000
ARRANGEMENT
17550 Gillette Avenue, Irvine, CA 92614 • www.sabritec.com • Tel: (949) 250-1244 • Fax (949) 250-1009
Pg. 161
High Power Connector Housing
MIL-DTL-38999 and MIL-DTL-5015 Connector Styles
MIL-DTL-38999/26 Plug (Series III Shown)
A Thread
Q
L Max
Shell
Size
B Dia
21
25
V Thread
A Thread
.1 Pitch
.3 Lead
1.375
1.625
Dimensions
B
L
+ .008
Max
- .000
1.235
1.500
1.235
1.744
Q
Dia.
Max
1.642
1.890
V
Thread
Metric
M31X1
M37X1
MIL-DTL-38999/20 or 24 Receptacle (Series III Shown)
R1
R2
Z
A Thread
Shell
Size
21
25
A Thread
.1 Pitch
.3 Lead
1.375
1.625
P
± .008
0.154
0.154
PP
± .008
0.242
Dimensions
R1
1.250
1.500
R2
1.156
1.375
S
1.563
1.811
V
Max
0.790
0.790
W
Max
0.126
0.126
Z
+ .005
- .010
1.235
1.235
B
Thread
Metric
M31X1
M37X1
PP
P
S
V
W
B Thread
MIL-DTL-5015 Plug
Dimensions
L
Shell
Size
14
16
18
20
22
24
28
32
36
40
44
48
E Thread
Class 2A
7/8-20 UNEF
1-20 UNEF
1 1/8-18 UNEF
1 1/4-18 UNEF
1 3/8-18 UNEF
1 1/2-18 UNEF
1 3/4-18 UNS
2-18 UNS
2 1/4-16 UN
2 1/2-16 UN
2 3/4-16 UN
3-16 UN
Q Dia
Max
1.156
1.25
1.344
1.469
1.594
1.719
1.969
2.219
2.469
2.719
2.969
3.219
L
Max
2.100
V Thread
Class 2A
7/8-20 UNEF
1-20 UNEF
1 1/16-18 UNEF
1 3/16-18 UNEF
1 5/16-18 UNEF
1 7/16-18 UNEF
1 3/4-18 UNS
2-18 UNS
2 1/4-16 UN
2 1/2-16 UN
2 3/4-16 UN
3-16 UN
Q
V Thread
E Thread
2.250
MIL-DTL-5015 Receptacle
Dimensions
R
A
M
K
B
Shell
Size
14
16
18
20
22
24
28
32
36
40
44
48
A Thread
Class 2A
7/8-20 UNEF
1-20 UNEF
1 1/8-18 UNEF
1 1/4-18 UNEF
1 3/8-18 UNEF
1 1/2-18 UNEF
1 3/4-18 UNS
2-18 UNS
2 1/4-16 UN
2 1/2-16 UN
2 3/4-16 UN
3-16 UN
K
± .015
0.083
L
Max
2.100
M
+ .031
- .000
R
0.906
0.969
1.062
1.156
1.250
1.375
1.562
1.750
1.938
2.188
2.375
2.625
S
1.188
1.281
1.375
1.500
1.625
1.750
2.000
2.250
2.500
2.750
3.000
3.250
T Dia
+ .005
- .000
B Thread
Class 2A
7/8-20 UNEF
1-20 UNEF
1 1/16-18 UNEF
1 3/16-18 UNEF
1 5/16-18 UNEF
1 7/16-18 UNEF
1 3/4-18 UNS
2-18 UNS
2 1/4-16 UN
2 1/2-16 UN
2 3/4-16 UN
3-16 UN
T
0.75
0.115
0.812
0.125
2.250
0.875
0.142
S
0.168
L
Pg. 162
17550 Gillette Avenue, Irvine, CA 92614 • www.sabritec.com • Tel: (949) 250-1244 • Fax (949) 250-1009
High Power Connector Ordering Information
Part Description Code for High Power Connectors/Contacts
Connector Part Number Description Code
HP - 38999/III - P - 21-75 - C - S - T - N
Prefix
Connector Shell
5015
38999/Series I
38999/Series III
38999/Series IV
Shell Style
P - Plug
J - Jam Nut Receptacle
F - Square Flange Receptacle
Arrangement
Polarization
N, A, B, C, D, E **
N, W, X, Y, Z ***
Termination Style
T - Threaded Post
H - Internal Thread
C - Wire Crimp
RC- Right Angle Wire Crimp
RM- Right Angle Male Threaded Post
RH- Right Angle Female Threaded Post
Contact Gender
P - Pin
S - Socket
Plating
C - Cadmium over Nickel
N - Electroless Nickel
** Polarization keys available for MIL-DTL-38999 connectors
*** Polarization keys available for MIL-DTL-5015 connectors
Contact Ordering Information
HPC - 4 - 38999 - S - T
Contact Prefix
Contact Size
8 - 60 Amp
4 - 100 Amp
0 - 300 Amp
00 - 300 Amp
0000 - 500 Amp
Connector
MIL-DTL-5015
MIL-DTL-38999 *
*
Termination Style
T - Threaded Post
H - Internal Thread
C - Crimp
RC- Right Angle Crimp Threaded Post
RM- Right Angle Male Threaded Post
RH- Right Angle Female Threaded Post
Contact Gender
P - Pin
S - Socket
Contacts are only available for Series I, III and
IV
17550 Gillette Avenue, Irvine, CA 92614 • www.sabritec.com • Tel: (949) 250-1244 • Fax (949) 250-1009
Pg. 163