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
  • Size 0: Up to 200A
  • Size 4: 4 AWG, up to 80A
  • Size 8: 8 AWG, up to 46A
  • Size 12: 12 AWG, up to 23A
  • Size 16: 16 AWG, up to 13A
  • Size 20: 20 AWG, up to 7.5A
  • Size 24: 24 AWG, up to 3A
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
  • Shells: Aluminum alloy, stainless steel, or zinc
  • Contacts: Copper alloy with silver or gold plating
  • Insulators: Neoprene or high-grade elastomers for sealing
Plating Options
  • Olive Drab Cadmium over Nickel
  • Zinc Cobalt (RoHS Compliant)
  • Electroless Nickel
  • Black Anodize
  • Stainless Steel Passivation
EMI/RFI Shielding Available with conductive finishes and accessories for enhanced shielding
Compliance Standards
  • MIL-DTL-5015
  • SAE-AS50151
  • RoHS Compliance options available
  • MIL-STD-1344 (Test Methods for Electrical Connectors)
  • MIL-STD-202 (Test Methods for Electronic Components)
Insert Arrangements Over 160 approved insert arrangements incorporating 1 to 85 contacts
Contact Termination
  • Crimp Termination
  • Solder Termination
  • PCB Tail (Printed Circuit Board) 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:

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

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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