Series 806 Mil-Aero Micro Miniature D38999 Connectors and Cable Assemblies

Advanced Electrical, Mechanical and Environmental Performance plus Reduced Size and Weight Compared to D38999

Meets every MIL-DTL-38999 Performance Specification

Series 806

Series 806 offers significant size and weight savings while meeting key performance benchmarks for a broad range of applications such as commercial and military aerospace, industrial robotics, transportation systems and more. Designed for general use in harsh vibration, shock and environmental settings — as well as high-altitude, unpressurized aircraft zones with aggressive voltage ratings and altitude immersion standards — the Series 806 Mil-Aero features numerous mechanical design innovations including durable mechanical insert retention, radial seals and triple-ripple grommet seals. Its reduced thread pitch and re-engineered ratchet prevent decoupling problems, particularly in small shell sizes, solving one of the major problems of shell size 9 and 11 MIL-DTL-38999 Series III connectors.

• Integrated anti-decoupling technology
• Higher density 20HD and 22HD contact arrangements
• Glass hermetic, lightweight aluminum hermetic, high-temperature, fiber optic, and filtered versions
• High-Speed configurations with El Ochito octaxial contacts. Available turnkey factory terminated pigtail and jumper assemblies

The Series 806 Mil-Aero is an aerospace-grade micro miniature circular connector with triple-start threaded coupling. The 806 connector is smaller and lighter than conventional aerospace connectors. Featuring size 22HD, 20HD contacts plus size 8 power and high speed El Ochito®, quadrax, and fiber optic options. The Series 806 offers up to twice the number of contacts with no reduction in performance than MIL-DTL-38999 Series III. In fact, independent laboratory testing has demonstrated that the Series 806 meets, and in many cases exceeds, the requirements of MIL-DTL-38999. Another enhancement is a "top hat" insulator with raised bosses for foolproof alignment of insulator cavities and retention clips as well as higher voltage ratings.

General Reference

• Introduction: Mil-Aero Connectors
• Table of Contents
• Product Features
• Materials and Finishes, Performance Specification
• NASA and D38999, Class G Space-Grade Guidelines, Screening/Outgassing for Space Applications
• Torque Values: Series 806 Recommended Torque Values for High Vibration Environments

Contact Arrangements and PCB Footprints

• Contact Arrangements
• PCB Layouts and Footprints

Series 806 Mil-Aero Micro Miniature Connectors, Environmental

Series 806 Mil-Aero High-Speed PCB Receptacles and Turnkey El Ochito Contact Jumper Assemblies, Single- and Double-Ended, Environmental

ThermaRex HT Series 806 Micro Miniature Connectors and Accessories

High-Temperature Micro Miniature Connectors, Cables, and Wire Protection Accessories

Sensor devices in aerospace engine applications are increasingly exposed to higher temperature operating environments. Environmental sensors in nuclear power reactors—an extremely high temperature and radiation-rich environment — are also exposed to temperature extremes well beyond the capabilities of conventional interconnect devices. Series 806 micro miniature connectors with Glenair Signature ThermaRex high-temperature inserts are designed to survive and excel in high continuous operating temperature application environments up to 300°C. The Series 806 Mil-Aero ThermaRex product family includes connectors, cables, and accessory wire protection conduit systems.

• HT Service rating up to 300°C
• Vibration-resistant threaded coupling
• High-temperature ceramic insulators and silicone seals
• Durable stainless steel construction
• Utilizes Glenair Signature Crown Ring contacts
• Contact and wire support in sizes #20HD, #16, #12, and #8

Series 806 Mil-Aero Connectors and Accessories, ThermaRex Cryo

Series 806 Mil-Aero Micro Miniature Connectors and Accessories, Fiber Optic

High Data Rate, Reduced Size and Weight Micro Miniature F/O Connector Series

Glenair's innovative fiber optic / electrical connector design meets key performance benchmarks for harsh vibration, shock, and environmental settings in rigid conformance with MIL-DTL-38999 Series III — but at nearly half the size and weight. The rugged fiber optic connection system delivers typical insertion loss 0.5 dB and supports 50/125, 62.5/125, and 9/125 size fiber in singlemode (1310 and 1550 nm) and multimode (850 and 1300 nm) wavelengths. Glenair Signature #20HD fiber optic termini offer the same high data rate performance as larger size #16 D38999 series connectors with more fiber lines and reduced shell size in every insert arrangement.

Reference

• Introduction: Series 806 Mil-Aero Fiber Optics
• Fiber Optic Connectors, Termini, and Backshells

Series 806 Mil-Aero Micro Miniature Connectors, Hermetic Glass-to-Metal Seal

Resolve Gas, Moisture and Particle Ingress Problems with Advanced-Performance Glass-Sealed Hermetic Connectors

Helium Leak Testing

All Series 806 hermetic connectors are 100% tested prior to shipment. A helium leak test is performed to certify the hermetic seal. This test is conducted by inducing 1 ATM of vacuum on one side of the connector. Helium gas is released on the other side, and a mass spectrometer "counts" the number of helium molecules that penetrate the connector seal. Helium leak testing takes advantage of the small size of a helium molecule compared to air or water vapor. Helium is inert, rare in our atmosphere, and is easy to detect with a mass spectrometer. Series 806 hermetic connectors are designed specifically for commercial and military aircraft zones such as engine compartments. These areas are typically exposed to fuel, oil and changes in elevation. Such conditions present the need to protect sensitive electronic equipment from the effects of caustic chemicals and moisture ingress through standard environmental connectors where high pressure leads to sealing failure. Other aircraft locations such as the fuselage require hermetic connectors to maintain passenger cabin pressure while allowing for data transmission through separated compartments of the aircraft.

Reference

• Introduction: Glass-Sealed Hermetic Connectors

Series 806 Mil-Aero Glass-to-Metal Seal Hermetic Connectors

Series 806 Mil-Aero Lightweight Encapsulant-Sealed Hermetic CODE RED Micro Miniature Circular Connectors

"Mission-Critical" Hermetic Encapsulant Sealing with 1x10^-7 Leak-Rate Performance and Low Contact Resistance

Hermetically-sealed interconnects used in vacuum or high-altitude applications prevent moisture and other contaminants from damaging sensitive electronic equipment. Glass-to-metal hermetic sealing has been the gold standard in the aerospace and petrochemical industries for decades due to the strength and long-term durability of the materials used. But glass-to-metal seal hermetics come with a big price tag in both weight and electrical resistance.

CODE RED is an innovative sealing encapsulant and application process — invented by Glenair — that provides durable hermetic sealing in a lightweight aluminum package. CODE RED allows for the use of conventional gold-plated copper alloy contacts, significantly improving electrical performance. CODE RED hermetic connectors are available now in Glenair SuperNine® (D38999 Series III type metal and composite), Series 80 Mighty Mouse, and M24308 D-Sub; and deliver reliable, life-of-system 1x10^-7 max leak-rate hermetic sealing. Special non-magnetic (zero residual magnetism) versions are also available, consult factory.

• Series 806 Mil-Aero Lightweight Hermetic CODE RED Micro Miniature Circular Connectors

Series 806 Mil-Aero Micro Miniature Connectors, EMI / RFI Filtered

Series 240-806

Glenair Series 806 filter connectors for use in EMC/EMP management of electronic systems and interconnect cabling. 806 filter connectors are designed in accordance with applicable connector specifications, and are designed to mate with plugs with the same insert configuration and opposite contact gender. Planar filter arrays and TVS diodes may be integrated into both standard catalog as well as build-to-order configurations. Glenair’s state-of-the-art diode burn-in process tests leaded and surface mount diodes with leakage current monitored throughout the entire test procedure ensuring field reliability.

• Introduction: Filtered Series 806 Mil-Aero Micro Miniature Connectors

Series 806B Mil-Aero Bayonet-Coupling Micro Miniature Circular Connectors, Environmental

• Contact Arrangements

Glenair supplies a complete family of low-resistance, high-durability rear-release crimp contacts for snap-in use in environmental versions of our Signature micro miniature Series 806 Mil-Aero. We supply and stock for immediate shipment all supported sizes of crimp signal contacts, power contacts, RF/Coaxial, differential Twinax, and Quadrax contacts.

Size 22HD

Size 20HD

Size 16

Size 12

Size 8

Series 806 Mil-Aero Tools, Accessories, and Backshells

• Series 806 Tools and Accessories Selection Guide

Series 806 Mil-Aero Backshell, Adapter, and Strain Relief

• Series 806 Backshell, Adapter and Strain Relief Selection Guide