High Power
Connectors
High Power Connectors
Hyperboloid
®
Technology
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.
Key Features:
• Low coupling force
• Improved low rate of wear and high coupling durability
• Shock and vibration resistance
• Operate in harsh environments
• Reduced contact resistance
• Contact elements can be insulated, to enable multi-pole use (coaxial)
• Contact mating sequence can be used to gain benefits such as power
switching
Shell
Contacts
Inserts
Seals & O Ring
Contact Mechanical & Environmental
Specifications
Contact Mating Cycles >1000
-65˚C to +150˚C
Contact
Endurance
Operating
Temperature
Connector Materials and Finishes
Aluminum Alloy, Stainless Steel,
Composite
Copper Alloy, Gold Over Nickel
Glass Filled Thermoplastic or Epoxy
Fluorosilicone Rubber
• Mating of shorter contact can energize main power for system or safety requirements
• Increased power handling capability by 25% as compared to standard contacts
Hyperboloid
®
Performance vs MIL-C-39029
MIL Spec
Current Rating
Continuous, A
46
80
150
185
225
Hyperboloid
®
Contact Current
Rating Continuous, A
60
100
300
300
500
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)
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
High Power
2010
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
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
Contact Dimensions
Contact
Size
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
8
4
0
00
0000
C
Hyperboloid Contact with Male
Threaded Post Termination
Thread B
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
Special size
40 2X Size 0000
CUSTOM
ARRANGEMENT
High Power Rack and Panel Solutions
Ordering Information
Sabritec also provides rack and panel power and combo layout solutions. A hybrid configuration
consisting of 3 phase power that can be combined with integrated signal, fiber optic, coax, triax
and high speed quadrax inserts within a single panel solution. Accessory hardware is available
with custom backshells and power modules exceeding 500 A current ratings.
Buss bars are attached to the threaded end of the connector pin or socket contact or
standard cable crimp terminations for power cable AWG ratings with current ratings up to
500 Amps in a single contact. Blindmate or screw lock accessory hardware configurations are
offered for any rack and panel solutions in a variety of sizes and configurations.
Complete 360 Degree RF connector shielding with EMI ground spring fingers integrated into
each connector shell arrangement and cavity is also available. Modularity is key to the design
with interchangeable insert assemblies available for an array of signal, power and hybrid contact
reverse gender configurations.
Power Connector Part Number Description Code
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
Power Contact Ordering Information
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
Sabritec
17550 Gillette Ave, Irvine
CA 92614, USA
t: +1 (949) 250-1244 f: +1 (949) 250-1009
e: customerservice@sabritec.com
FOR FURTHER INFORMATION VISIT
>>
www.sabritec.com
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