HyperRel Series
HyperRel Series
Ruggedized Connectors Intermateable
with MIL-DTL-38999 Series III
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Available with metal (HRM) and composite (HRC) shells
Ruggedized socket interconnects
High shock and vibration resistance
Metal and composite shell styles
Hypertac
®
style 39029 contacts
Intermateable with industry standard Mil 38999
Series III connectors
• Cable-to-cable and panel mount styles available
• Available with high temperature hyperboloid
contact technology
HRC (HyperRel Composite): Highlights
The HyperRel HRC is a high performance composite
connector intermateable with MIL-DTL-38999 Series III
connectors. The combination of the legendary Hypertac
contact with the superior design of the composite
shell/insert, along with the respective strain reliefs, favorably
influence intra-system life-cycle performance and costs.
Shells:
The total performance of the HRC connector is
matched by the individual components within the system.
For example, the use of composite materials increases
the durability of the connector housing and coupling
mechanism to 1500 cycles.
Specifications:
EMI shielding effectiveness
Meets and exceeds the requirements of MIL-DTL-38999,
paragraph 3.3.1
Fluid immersion
Meets and exceeds the requirements of MIL-DTL-38999,
paragraph 3.33
Temperature
The metal surface will not delaminate from the composite
material even after extreme temperature excursions.
The HRC meets all requirements of MIL-DTL-38999,
paragraph 3.8
Magnetic permeability
The magnetic permeability of the fully assembled HRC
connector is less than 2.0 µ, meeting all the requirements
of MIL-DTL-38999, paragraph 3.3.4
Materials
All the materials used in the shell and inserts in the HRC
are in accordance with MIL-DTL-38999, paragraph 3.3.
The contacts are in accordance with MIL-C-39029,
paragraph 3.3
Finish
Shells: Meet the requirements of MIL-DTL-38999
Contacts: Meets the requirements of MIL-C-39029
Insulation resistance
Meets all the requirements of MIL-DTL-38999,
paragraph 3.13
Dielectric withstanding voltage
Meets all the requirements of MIL-DTL-38999,
paragraph 3.14
Contacts:
Up to 80% less mating force
50% reduction in resistance
300% increase in mating cycles
Vibration/shock proven at 2 nano seconds
Five times more contact elements than the
MIL-C-39029 (e.g. Size number 22)
• Hypertac contact life expectancy (fretting) is
100 times longer than the MIL-C-39029 contact
The HRC eliminates the largest contributing factor in
advanced systems malfunction: corrosion – the main cause
of mechanical, electrical, and electromagnetic connector
degradation. Electromotive force differentials between many
dissimilar metals found in connectors and accessories
produce galvanic action. The HRC eliminates these dissimilar
metals resulting in an interconnect system that withstands
over 2000 hours of salt spray.
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Dimensions are in inches [mm]
www.hypertronics.com
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HyperRel Series
HRM (HyperRel Metal): Highlights
The HyperRel HRM is a high performance metal connector
with triple start, self-locking, threaded coupling and crimp-
type terminations, intermateable with MIL-DTL-38999
Series III.
HyperRel connectors are built upon the legendary Hypertac
contact technology that outperforms other interconnect
options in terms of performance reliability, number of mating
cycles, contact forces, contact resistance and value.
The HyperRel HRM has a rugged design that offers
the maximum in vibration, shock and EMI resistance.
A general duty threaded connector, the HRM series offers
thicker wall sections and greater coupling surface with
100% metal-to-metal bottoming, a superior anti-coupling
system, and proven dielectric contact retention. The positive
metal-to-metal coupling design, superior interfacial seals,
and cadmium over nickel plating provide excellent EMI,
moisture and corrosion resistance. In a 360 degrees turn
of the coupling nut, the HRM quickly mates and self-locks.
Blunting of the thread makes cross-threading virtually
impossible. Elongated mounting holes permit the HRM
connector to intermount with existing standard MS/38999
box or wall mount receptacles, providing a design
replacement advantage.
Contact Resistance (Size 22D)
50% reduction in contact resistance compared to
MIL-C-39029
Vibration / Shock (Size 22D)
Proven at 2 nano seconds compared to MIL-C-39029
(which is proven at 1 micro second)
Fluid Immersion
Fluid resistant to many fuels, coolants and solvents
per MIL-DTL-38999
Mating Force
Up to 80% less mating force compared to
MIL-C-39029 requirements
Mating Cycles
300% increase in mating cycles compared to
MIL-C-39029 requirements
Contact Elements (Size 22D)
10 off springs compared to 2 off springs on a
MIL-C-39029 contact; five times more contact elements
means higher reliability
Contact Points (Size 22D)
10 off lines compared to 4 off points on a MIL-C-39029
contact; infinitely more points (reliability)
Fretting (Size 22D)
Hypertac hyperboloid contact has a life expectancy
100 times greater than MIL-C-39029 requires
Materials
Shell: Aluminum alloy
Contacts: Copper alloy
Inserts: Plastic; silicone
Finish
Shell: Olive drab cadmium over nickel (class W)
Nickel plated (class F)
Contacts: Gold over nickel
Specifications
Shock
High impact per MIL-S-901
EMI Shielding
Effective over a range of 100 MHz to 10 GHz
With a minimum 50 dB effectiveness at 10 GHz
Insulation Resistance
5000 megaohms min at 25° C (77° F)
Corrosion (Class W)
500 hours salt spray per MIL-DTL-38999
Crimp Contact Rating and Wire AWG
Size 22D: 5.0 Amps (accepts 22 thru 28 AWG)
Size 20: 7.5 Amps (accepts 20 thru 24 AWG)
Size 16: 13.0 Amps (accepts 16 thru 20 AWG)
Size 12: 23.0 Amps (accepts 12 thru 14 AWG)
Dimensions are in inches [mm]
2 / 38
www.hypertronics.com
HyperRel Series
A full complement of HRC and HRM inserts
6 Size 22D Contacts
A35 (HRC)
9-35 (HRM)
3 Size 20 Contacts
A98 (HRC)
9-98 (HRM)
5 Size 20 Contacts
B05 (HRC)
11-5 (HRM)
13 Size 22D Contacts
B35 (HRC)
11-35 (HRM)
6 Size 20 Contacts
B98 (HRC)
7 Size 20 Contacts
B99 (HRC)
11-99 (HRM)
4 Size 16 Contacts
C04 (HRC)
13-4 (HRM)
8 Size 20 Contacts
C08 (HRC)
22 Size 22D Contacts
C35 (HRC)
13-35 (HRM)
10 Size 20 Contacts
C98 (HRC)
13-98 (HRM)
5 Size 16 Contacts
D05 (HRC)
15-5 (HRM)
18 Size 20 Contacts
D18 (HRC)
15-18 (HRM)
19 Size 20 Contacts
D19 (HRC)
3 Size 16 Contacts
2 Size 20 Contacts
18 Size 22 Contacts
D23 (HRC)
37 Size 22D Contacts
D35 (HRC)
15-35 (HRM)
4 Size 16 Contacts
8 Size 20 Contacts
D97 (HRC)
15-97 (HRM)
6 Size 12 Contacts
E06 (HRC)
17-6 (HRM)
8 Size 16 Contacts
E08 (HRC)
17-8 (HRM)
4 Size 16 Contacts
11 Size 20 Contacts
4 Size 22 Contacts
E19 (HRC)
26 Size 20 Contacts
E26 (HRC)
17-26 (HRM)
NOTE
Insert drawings are not to scale.
Dimensions are in inches [mm]
www.hypertronics.com
2 / 39
HyperRel Series
A full complement of HRC and HRM inserts
55 Size 22D Contacts
E35 (HRC)
17-35 (HRM)
21 Size 20 Contacts
2 Size 16 Contacts
E99 (HRC)
11 Size 16 Contacts
F11 (HRC)
19-11 (HRM)
32 Size 20 Contacts
F32 (HRC)
19-32 (HRM)
66 Size 22D Contacts
F35 (HRC)
19-35 (HRM)
11 Size 12 Contacts
G11 (HRC)
21-11 (HRM)
16 Size 16 Contacts
G16 (HRC)
21-16 (HRM)
79 Size 22D Contacts
G35 (HRC)
21-35 (HRM)
37 Size 20 Contacts
G39 (HRC)
41 Size 20 Contacts
G41 (HRC)
21-41 (HRM)
NOTE
Insert drawings are not to scale.
Dimensions are in inches [mm]
2 / 40
www.hypertronics.com
HyperRel Series
A full complement of HRC and HRM inserts
21 Size 16 Contacts
H21 (HRC)
23-21 (HRM)
100 Size 22D Contacts
H35 (HRC)
23-35 (HRM)
53 Size 20 Contacts
H53 (HRC)
23-53 (HRM)
55 Size 20 Contacts
H55 (HRC)
23-55 (HRM)
8 Size 16 Contacts
48 Size 20 Contacts
J04(HRC)
25-4 (HRM)
19 Size 12 Contacts
J19 (HRC)
25-19 (HRM)
12 Size 12 Contacts
12 Size 16 Contacts
J24 (HRC)
25-24 (HRM)
29 Size 16 Contacts
J29 (HRC)
25-29 (HRM)
128 Size 22D Contacts
J35 (HRC)
25-35 (HRM)
NOTE
Insert drawings are not to scale.
Dimensions are in inches [mm]
www.hypertronics.com
2 / 41
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