What is MIL-DTL-5015?
MIL-DTL-5015 is a United States military specification that defines the requirements for heavy-duty circular threaded electrical connectors with soldered or crimped contacts. They are used for both digital and analog signals, as well as power distribution, and are common in various fields including defense, aerospace, industrial machinery, and telecommunications. These connectors are renowned for their ruggedness, versatility, reliability, and relatively low cost, making them a popular choice for harsh environmental conditions.
Connector Series and Types
MIL-DTL-5015 connectors are categorized into different series and classes to meet various application requirements:
Connector Series
MIL-DTL-5015 specifies four discrete product categories known as series. Connectors from each of the first three series are compatible; however, their individual components differ:
| Series | Category | Standard Military PIN | Corresponding SAE Standard |
|---|---|---|---|
| I | Solder contact connectors | MS3100 | SAE-AS31001B |
| II | Front release, crimp contact connectors | MS3400 | SAE-AS39029/44D |
| III | Rear release, crimp contact connectors | MS3450 | SAE-AS39029/29C |
| IV | Connector accessories | (Various) | SAE-AS85049/31B |
Environmental Classes
MIL-DTL-5015 connectors also refer to classes, which specify products in more detail:
| Class | Crimp Contacts | Solder Contacts | Features |
|---|---|---|---|
| A | No | Yes | Solid shell |
| B | No | Yes | Split shell |
| C | No | Yes | For pressurized equipment |
| D | Yes | Yes | For high-impact conditions |
| DJ | Yes | Yes | High-impact; with backshell |
| E | No | Yes | Environment resistant |
| F | No | Yes | Environment resistant; with clamp |
| H | No | Yes | Hermetically sealed |
| K | Yes | Yes | For firewalls |
| L | Yes | No | Fluid resistant |
| P | Yes | No | Environment resistant; potted solder contacts |
| R | Yes | Yes | Grommet-sealed without clamp |
| U | Yes | No | Fluid resistant |
| W | Yes | No | General purpose |
Coupling Types
- Threaded Coupling: Secure connection with a screw-threaded coupling mechanism.
- Bayonet Coupling: Quick-connect design for fast mating and unmating with a bayonet locking mechanism.
- Reverse Bayonet: Combines bayonet coupling with enhanced environmental sealing.
Technical Specifications
The MIL-DTL-5015 connectors are designed to meet rigorous military and industrial standards. Below are the detailed technical specifications:
| Parameter | Specifications |
|---|---|
| Contact Sizes |
|
| Voltage Rating | Up to 3,000 VAC RMS at sea level (depending on contact arrangement) |
| Current Rating | Up to 225A for size 0 contacts in Series I connectors |
| Insulation Resistance | Minimum of 1,000 Megaohms at 25°C |
| Dielectric Withstanding Voltage | Up to 2,500 VAC RMS at sea level (varies by arrangement) |
| Operating Temperature Range | -55°C to +200°C, depending upon the class of the connector |
| Durability | Minimum of 500 mating cycles |
| Vibration Resistance | Resistance to vibration and mechanical shock (anti-decoupling springs) |
| Shock Resistance | Meets MIL-STD-202 Method 213 |
| Sealing | Environmental and hermetic sealing options available; up to IP67 rating |
| Polarization | Single key/keyway; limited polarization options |
| Shell Sizes | 19 shell sizes ranging from size 8 to size 40, accommodating 1 to 85 contacts |
| Materials |
|
| Plating Options |
|
| EMI/RFI Shielding | Available with conductive finishes and accessories for enhanced shielding |
| Compliance Standards |
|
| Insert Arrangements | Over 160 approved insert arrangements incorporating 1 to 85 contacts |
| Contact Termination |
|
| Contact Retention | High retention force with resilient inserts for secure contact positioning |
| Moisture Resistance | Designed to resist moisture, humidity, and corrosion in harsh environments |
| Altitude Immersion | Effective sealing up to 70,000 feet altitude |
| Shell Styles | Available in straight, right angle, wall receptacle, box receptacle, cable plug, and jam-nut receptacle configurations |
Refer to manufacturer datasheets and the official MIL-DTL-5015 or SAE-AS50151 specifications for detailed engineering information and additional parameters.
Advantages and Disadvantages
Advantages
- Ease of engagement and disengagement
- Compatibility with different types and numbers of contacts, allowing power and signal lines in one connector
- Wide range of allowable contact voltages and currents (up to 225A for Series I)
- Rugged mechanical performance under harsh environmental conditions
- Variety of materials and finishes (stainless steel, aluminum, zinc)
- Wide temperature range of -55°C up to +200°C, depending upon the class of the connector
- Resistance to vibration and mechanical shock (anti-decoupling springs)
- Relatively low price
- Interlock and captive nut to prevent inadvertent disassembly
- Several shell styles (straight, right angle, wall receptacle, box receptacle, cable plug)
Disadvantages
- Inefficient use of panel surface area when used in arrays, compared to rectangular connector housings
- Fine threads are prone to mechanical damage and can be time-consuming to tighten
- Only one keyway, limiting the ability to prevent mismating in areas with multiple connectors
Insert Arrangements
MIL-DTL-5015 connectors offer a comprehensive range of insert arrangements to accommodate various electrical requirements. Inserts are designed to hold contacts in specific configurations within the connector shell. These arrangements define the number of contacts, their sizes, and their positions within the connector.
Understanding Insert Arrangement Numbers
Each insert arrangement is identified by a number that represents the shell size and the specific contact layout. For example, an insert arrangement numbered "22-14" indicates a shell size 22 with a specific pin configuration identified by the number 14.
These connectors are available in 19 different shell sizes (from size 8 to size 40) with over 160 approved insert arrangements, accommodating from 1 to 85 contacts.
Common Insert Arrangements
| Shell Size | Insert Arrangement | Total Contacts | Contact Sizes | Application |
|---|---|---|---|---|
| 10SL | 10SL-3 | 3 | 16 | Signal Applications |
| 12 | 12-3 | 3 | 12 | Power Transmission |
| 14S | 14S-2 | 2 | 12 | Higher Current Needs |
| 14S | 14S-7 | 7 | 16 | Control Circuits |
| 16S | 16S-1 | 5 | 16 | Signal Applications |
| 18 | 18-1 | 10 | 16 | Signal and Low Power |
| 20 | 20-7 | 7 | 12 | Power Applications |
| 22 | 22-2 | 19 | 16 | High-Density Signal |
| 24 | 24-28 | 28 | 20, 16 | Mixed Signal |
| 28 | 28-21 | 21 | 12, 16 | Mixed Power/Signal |
| 32 | 32-17 | 55 | 20, 16 | High-Density Signal |
| 36 | 36-10 | 52 | 20 | Data and Communications |
Special Contact Types
In addition to standard power and signal contacts, MIL-DTL-5015 connectors can be configured with special contact types:
- Coaxial Contacts: For high-frequency signal transmission.
- Twinaxial Contacts: For differential signal pairs.
- Thermocouple Contacts: For temperature measurement applications.
- Fiber Optic Contacts: For optical signal transmission.
Selecting an Insert Arrangement
When choosing an insert arrangement, consider the following factors:
- Number of Contacts: Total number required for your application.
- Contact Size: Based on current-carrying capacity and wire size.
- Contact Type: Power, signal, or special contacts like coaxial or fiber optic.
- Shell Size Compatibility: Ensure the chosen insert fits within the required shell size.
- Environmental Requirements: Sealing and material compatibility for the operating environment.
Keying and Polarization
Insert arrangements are designed to prevent mismating. However, MIL-DTL-5015 connectors have only one keyway, which provides limited polarization options compared to connectors with multiple keyways (like MIL-DTL-38999). This limitation can make it challenging to prevent mis-mating of same-shell-size connectors in areas where multiple connectors are used. Care must be taken in such environments to ensure correct mating.
Insert Arrangement Charts
For detailed insert arrangement diagrams, including pin numbering and contact positions, refer to the following resources:
- Amphenol Insert Arrangement Catalog
- ITT Cannon Insert Arrangement Guide
- Glenair Insert Arrangement Charts
Custom Insert Arrangements
For applications requiring unique configurations, custom insert arrangements can be developed. Contact connector manufacturers to discuss custom solutions tailored to your specific needs.
Part Number Decoder
The MIL-DTL-5015 part numbering system follows a standardized format that provides information about the connector's type, shell size, insert arrangement, contact type, class, and other features. Understanding the part number is crucial for selecting the correct connector for your application.
Example Part Number Structure:
MS3106 A 18 - 10 P
│ │ │ │ └─ Contact Type: P - Pin, S - Socket
│ │ │ └───── Insert Arrangement (Contact Layout)
│ │ └───────── Shell Size
│ └─────────── Class (A, B, C, E, F)
└─────────────── Connector Type
Use our upcoming interactive part number builder to easily create and decode part numbers.
Accessories and Backshells
Enhance the performance and usability of your connectors with a range of accessories:
- Backshells: Provide strain relief, EMI/RFI shielding, and environmental sealing.
- Cable Clamps: Secure cables to prevent movement and mechanical stress.
- Gaskets and Seals: Improve environmental protection and sealing effectiveness.
- Protective Caps: Safeguard connectors when not in use.
- Heat Shrink Boots: Offer additional sealing and protection for cable terminations.
Cross-Reference Guides
Find equivalent parts across different manufacturers:
| Military Part Number | Amphenol | ITT Cannon | Glenair | TE Connectivity |
|---|---|---|---|---|
| MS3106A18-1S | 97-3106A18-1S | KPT06A18-1S | 3106-18-1S | Y3106A18-1S |
| MS3102A16-10P | 97-3102A16-10P | KPT02A16-10P | 3102-16-10P | Y3102A16-10P |
| MS3101F20-27P | 97-3101F20-27P | KPT01F20-27P | 3101-20-27P | Y3101F20-27P |
Technical Resources
Access detailed technical documents and datasheets:
Applications
MIL-DTL-5015 connectors are used for many situations where mechanical and electrical reliability is important. This includes both civil and military applications:
- Aerospace Systems: Aircraft avionics, control systems, and communication equipment.
- Military Ground Vehicles: Tanks, armored vehicles, and support equipment.
- Shipboard Equipment: Naval communication and control systems.
- Industrial Machinery: Factory automation, robotics, machining tools, and process control.
- Heavy Equipment: Construction, mining, earthmoving, and agricultural machinery.
- Oil & Gas: Exploration equipment requiring reliability under harsh conditions.
- Telecommunications: Robust connections for outdoor installations.
- Rail and Transportation: Signaling and control systems.
- Generators: Power generation equipment.
- Petrochemical Industry: Equipment operating in corrosive environments.
- Saltwater Applications: Marine equipment requiring corrosion resistance.
FAQs
Common questions about MIL-DTL-5015 connectors:
What are the different classes (A, C, E, F)?
The class designation indicates the environmental sealing and construction features:
- Class A: General-purpose connectors without grommets or seals (unsealed).
- Class C: Pressurized connectors for high-altitude or vacuum applications.
- Class E: Environmental-resistant connectors with grommets and seals.
- Class F: Environmental-resistant with potting to enhance sealing.
How do I select the right connector for my application?
Consider the following factors:
- Environmental conditions (temperature extremes, moisture, dust, chemicals)
- Electrical requirements (current capacity, voltage levels, signal integrity)
- Mechanical considerations (vibration levels, physical shock, mating cycles)
- Space and weight constraints (available space, overall connector size, weight limitations)
- Compliance with industry standards and regulations
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