The Devil's in the Details
Dotting the I's and Crossing the T's of Our Microminiature Product LineMicro-D connectors are miniaturized, .050" spacing rectangular connectors. These connectors are defined in the United States under military specification MIL-DTL-83513, and in The United Kingdom under BS9523F0002 and BS9524F0013. The connectors are used widely in missiles, avionics and space applications and are selected due to their rugged performance and track-record for high reliability. The Micro-D offers excellent mechanical, environmental, and electrical performance in a miniaturized connector, and has become the interconnect solution of choice for a broad range of applications which cannot tolerate poor connector performance or failure.Glenair designs and manufactures its Micro-D connector components and assemblies in its Microway Systems Division in Chicago, Illinois, in its Glenair UK Ltd Division in Mansfield, England, and at the company's corporate headquarters in Glendale, California. All three facilities are qualified to produce products to their controlling military specification. And all three utilize Glenair's unique TwistPin contact technology across the entire range of Micro-D interconnects. As we said, Micro-D TwistPin connectors offer superior mechanical and electrical performance. But the performance of the connector is meaningless if it's not available when and where you need it. In fact, the same can be said of all critical components in a high-reliability interconnect system. For this reason, Glenair is aggressively adding every MIL-DTL-83513, BS and Glenair commercial Micro-D part number to stock. In this issue of QwikConnect, we'll introduce you to all tools and information you'll need to take advantage of Glenair's growing inventory of "Same-Day" Micro-Ds.
Day-O, Same Day-OGlenair's Same Day Inventory Program has traditionally focused on the military standard and commercial connector accessory part numbers which constitute Glenair's core business: EMI/RFI and environmental backshells, strain-reliefs, banding adapters, dust caps and so on. It's a service model we've relied on for over 15 years to provide our backshell customers with complete convenience in ordering for a wide range of circular and rectangular connector accessories. The complete inventory of accessory part numbers is now well over 25,000 part numbers, and is recognized as one of the best values in the interconnect industry. Customer benefits include significant cost savings from reduced inventory control costs and the ability to enjoy direct out-of-pocket savings by ordering only the exact quantity needed of any line-item. But perhaps most importantly, Same Day availability means immediate access to critical components when and where they are needed to service mission-critical commercial and defense industry equipment. The impact of Glenair's Same-Day Inventory on both product availability and customer satisfaction is unparalleled. And Glenair is committed to providing the same levels of service for all our customers -- from fiber optics and conduit systems to marine hardware, and of course Micro-D's. With this goal in mind, the company embarked on a Same-Day Micro-D production project beginning in May of 1999. Over the past year, Glenair has built up its stock on hundreds of M83513 Micro-D part numbers at our interconnect hardware division in Glendale, California. Similar production is also well underway at Glenair UK Ltd to create a "Same-Day" inventory of British Standard Micro-D part numbers to service the needs of our European customers. The following pages present the Micro-D interconnects and accessories which are now in stock in Glendale and ready for immediate shipment. For those part numbers which do not appear in the stock list, such as vertical mount PCB connectors, Glenair has committed to accelerated lead times to ensure industry-leading availability for these components. Please see www.glenair.com for ongoing updates on stocking levels.
Same Day Availability Not Enough? Here are Five More Reasons to Select a High Reliability Glenair Micro-D Connector:First and foremost, you need recognized performance standards. Every element of the MIL-DTL-83513 Micro-D is exactly controlled, from terminal spacing to approved wire termination methods. The military standard defines contact resistance, dielectric withstanding voltage, corrosion resistance, shock and vibration tolerances and a wide range of other electrical, mechanical and environmental performance standards. Standardized measurement and test methodologies ensure consistent, predictable performance throughout this broad family of ruggedized connectors. Standards are fine, but you also need proven reliability under tough operating conditions. For applications where interconnect failure is simply not an option, the Glenair high-reliability Micro-D offers a wealth of performance benefits which far outweigh any potential cost savings realized by specifying a lesser caliber connector. While standard SCSI-2 connectors with stamped shells and "tuning fork" contacts may be adequate for use in systems where downtime is not a critical concern, they cannot match the long-term durability and performance advantages of the MIL-DTL-83513 Micro-D, which include:
Third, you need the flexibility of easy customization. Manufacturers of satellite communications systems, geophysical exploration devices, medical diagnostics and industrial equipment face many of the same packaging requirements for reduced size, weight and shape as do their military counterparts. And the ability to design-in a wide range of custom modifications which fit the unique packaging requirements of these specialized applications is a distinct advantage of the Glenair Micro-D -- making it the connector of choice for many unique or small quantity applications.
Finally, you need trouble-free mating and unmating. Glenair has perfected a nickel underplating combined with a proprietary duplex gold overplating which provides optimal contact lubricity (anti-galling) and effectively eliminates the oxidation common to copper flash underplating. Glenair's advanced plating process contributes to the overall durability of the connector by reducing contact engaging and separating forces. Glenair 100 contact Micro-D connectors have been successfully tested to 25,550 mating cycles (test report ER1010) proving the durability of the Glenair plating process.
We're Havin' a Heat WaveThe mil-spec temperature rating of 125°C is more than adequate for typical Micro-D aerospace applications. So why worry about higher temperatures? The answer is simple: for use in high-heat geophysical application environments. The Micro-D's small size, ruggedness and range of configurations have led to its widespread use in well logging instruments for the petroleum industry. Deep-hole drilling requires instrumentation capable of withstanding much higher temperatures than normally found in the aerospace industry. Well logging tools are typically rated at +400°F (204°C) with some instruments now rated at +500oF (255°C) for short durations.Unfortunately, the M83513 Micro-D's standard materials and finishes cannot safely withstand a temperature of 260°C or above. Not only is the LCP insulator material almost at its melting point, but the contacts and shells are also approaching their upper limits. Meeting this temperature requires re-engineering the connector -- especially the choice of epoxy potting compound. Each application must be individually analyzed to optimize the design. Glenair's TwistPin contact system has the inherent ability to withstand continuously high temp- eratures. The spring properties of the TwistPin create a multi-point contact system while under compression in the mating socket. The contact socket is precision machined to ensure mating and unmating forces stay well within acceptable values. Heat can soften mated contacts over time, reducing contact retention forces. This is the case for all types of contacts -- machined, drawn, stamped or twisted. But careful materials selection coupled with advanced fabrication and heat treating techniques enable Glenair's TwistPin contact to resist high temperature stress relaxation. Two major petroleum industry instrument manufacturers have tested and approved the Glenair TwistPin Micro-D for use at 200°C. But in both cases the parts tested were built with a special high temperature epoxy potting compound. For applications over 150°C continuous operating temperature, Glenair now recommends connectors be specified with this material, a proprietary blend of Cotronics® high temperature epoxies which can withstand up to 500°F. The remaining standard materials and finishes used in the Glenair Micro-D are well suited to high temperature. The T6061 aluminum shells, LCP Vectra® insulators, flourosilicone seals, and beryllium copper contacts are generally known to be appropriate materials for 200°C exposure. Glenair does however recommend electroless nickel plating for the connector shells, as cadmium plating is not recommended for use in high-temperature applications over 150°C. How to Order a 200°C Micro-D
Micro-D Connector Weights
Weights shown are for solder cup connectors.
For pigtail cable assemblies, add the weight of the wire per the following factors:
Example: P/N MWDM1L-25P-6K1-18B (18" of M22759/11-26 wire x .86 grams/ft. x 25 conductors = 32.3 grams) (32.3 grams + 3.4 grams from above table = 35.7 grams total)
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Fourth, you need high temperature tolerance. Heat from electrical or environmental sources can soften mated contacts over time and reduce contact retention force. Under extreme conditions of shock and vibration, this loss of normal retention can result in unstable resistance across the interconnect. This is the case for all types of contacts -- machined, drawn, stamped and twisted. But materials selection and advanced fabrication and heat treating techniques enable Glenair's TwistPin contact to resist high temperature stress relaxation for up to 1000 hours at 125° C and thus perform at levels unmatched by other contact designs.