Connectors for Military Electronics

© Brooke Clarke 2001 - 2023


Background
Audio
Antenna
Battery
Contact Pins
Circular Multi-Pin
Rectangular Multi-Pin
Coaxial
Telegraph era
USB
    Connectors: A, B, Mini-B, Micro-B, C, USB3 Micro-B
    USB-A to Multi Phone Charging Cables
    Power Delivery
HDMI
0.1" Headers
Unknown - Wanted
Links

Background

The first thing that you need after acquiring a military electronics treasure is the power cord or some other cable.  These are almost never available so the next thing is to make up one, but that requires the manual (see an example of reverse engineering) and the mating connector.

Audio

Separate web page for Audio connectors.
My main source for the U-183 (6 pin version of the U-229) has been surplus cables sold on eBay. But they are available from Newark.

Antenna

Many field radios use what amounts to a threaded hole to mount the antenna.  In order to connect a coaxial cable you will need some type of adapter.
PRC-68 series radio antenna adapter.

Battery

Contact Pins

The contact pins have a size number that may be related to the American Wire Gauge (Wiki: AWG) of a solid copper wire.  Connector makers have tables saying what size wire can be used with a certain contact size, but those are for solid wire.  As the number of strands increases (for the same total AWG) the bundle diameter increases.  Also if the wire is twisted the size gets bigger.  So if you are having trouble getting the wire to fit into a solder cup, first be sure the wires are straight and second use a pin vise and drill bit to slightly enlarge the hole.  Note that it's common for a bur to be pointing into the solder cup and just cleaning the bur can make the difference.
Contact #
Wires
AWG
Solid Cu
Wire dia mils
Wire Max
Amps
contact Max
Amps1
22D
22 - 28
25.3 5.0
5
22M
24 - 28
25.3 5.0
3
22
22 - 26
25.3
5.0
5
20
20 - 24
32.0
7.5
7.5
16
16 - 20
50.8
13
13
12
12 - 14
80.8
23
23
8
8 - 10
128.5
46
46
4
4 - 6
204.3
80
80
0
0 - 2
324.9
150
150
0000
0000 - 00
460
225

Note1: applies when all contacts are carrying current.  Slightly more current if only one contact is carrying current.

The Amp brochure for their MIL-C-22992 Heavy Duty Cylindrical connectors has this relationship between shell size and current:
Shell Size
Amps Max
Contact Size
28
40
6
32
60
4
44
100
1/0
52
200
4/0

Circular Multi-Pin

In almost all cases the part number is printed on the connector or a partial p/n on the insulating body.  You may need a magnifying glass or need to look at the front or back side, but in 99.9% of the cases it will be there.
Although there are as many of these as there are stars in the sky, most come from a few families and do not use many of the options.
Most of these are very modular.  For example there is a shell that comes in a number of standard sizes and for use on cables or panels.  Some shells use a screw on coupling and others use a lug and twist lock connection.  There are what would be called wards (Wiki) in the locksmith trade, ridges on one shell and groves on the mating shell to both get the correct rotation and to be sure that two connectors with the same insert but different applications will not be cross connected.  It is not often that the optional warding is used, only on large boxes were there are many of these connectors.  Into the shell you can put either pins/plugs or sockets into an insert.  There are a limited number of inserts for each shell.  Then for cable applications there is the cable clamp/strain relief.

There are a number of families of similar connectors.  One of the most common is the MS series (Mil Spec).  There are many manufacturers that make these.

Another common type is the Bendix series.

The connector can be made with the pins and sockets captured or the pins and sockets may be separate parts so that they can be crimped or soldered to the wire, then pressed into the insert. This is almost mandatory for an insert with a large number of contacts because of the difficulty in soldering with nearby contacts.  It's pretty easy to attach a contact to a loose wire using the proper crimping tool. A crimp type connection is superior to a soldered connection in a number of ways and for many high reliability programs are mandatory.

In all of these cases you need to be careful when ordering that you get all the bits and pieces that are needed.
The type of connector shell is determined by the 4 digits that follow the "MS" and control if you get a receptacle or plug and other factors.

Receptacle

This connector shell has no moving parts and is typically found mounted to a panel

Plug

This connector shell has a sleeve that moves to join to a receptacle.

DIY

It is possible to make your own connector using the loose pins/sockets and epoxy or hot melt glue.  The idea is to connect the pins/sockets to the wires, spray a very light coat of WD-40 as a mold release agent, and apply the epoxy or hot melt glue.  I have not yet tried this method, but there are a number of web references to doing this.  In some cases I have just used the pins/sockets from connectors sold at my local Radio Shack and connected to the connector without any molding.  This works well for indoor bench type work, but would not be good for outdoor use.

Amphenol Catalogs and Series

Catalog
Title
Style
Coupling
shells
Shell
Sizes
12-022
97 Series Std Cyl
MIL-C-5015
Threaded
MS3100A
MS3101A
MS3102A
MS3106A
MS3106B
MS3107A
MS31-7B
MS3108A
MS3108B
8S-1
to
36-403
12-023
67 &











 165 Series Miniaturized
"Mini E"
MIL-C-5015

Bayonet








all about size 16
-00E
-00P
-00C
-01E
-01P
-01C
-02E
-03E
-06E
-06P
-06C
-06J
?
12-7
to
22-69









16-5
to
16-24
12-026
MIL-C-5015 MIL-C-5015
Threaded
MS3450
MS3454
MS3456
MS3459
8S-1
to
40-62
12-053
QWL Cyl
Heavy Duty Industrial
MS type shells
Threaded plugs & receptacles
0
1
2
3
4
6
7
9
10S-2
to
48-62
12-070
Miniature Cyl
MIL-C-26482 Series 1
MIL-C-26482 Series 1
Bayonet or
Threaded
solder cup
PT00 (MS3110)
PT01 (MS3111)
PT02 (MS3112)
PT06 (MS3116)
PT07 (MS3114)
PT08E SP08E
PTB, SPB
PT1H (MS3113H)
PT02H
PT07H (MS3114H)
crimp (add E suffix)
6-1
to
24-79
12-071
MIL-C-26482 Series 2
MIL-C-26482 Series 2
Bayonet
Crimp
MS3470
MS3472
MS3471
MS3474
MS3476
MS3475
8-33
to
24-61
12-073
MIL-C-83723 Series III
MIL-C-83723 Series III
Bayonet,
Threaded or
 Quick Disconnect
Crimp
/71 & /72
/73 & /74
/75  /76 /77 /78
/82 & /83
/84 & /85
/86 /87 /91 /92
/95 & /96
/66 & /67 /68 /69
0803
to
2842
12-091
SJT Miniature
MIL-DTL-38999 Ser 1 Lengths
MIL-DTL-38999 Ser 3 dims
Bayonet
Crimp
SJT00RT
SJTP00RT
SJTP02RE
SJT06RT/SJTG06RT
SJT07RT
Hermetic
SJTIY
SJT07Y

8-6
to
24-61
12-092
Tri-Start Subminiature MIL-DTL-38999 Ser 3
Metal or Composite
Threaded
TVP00R (38999/20)
CTVP00R (38999/20)
TVP02R
CTVP02R
TV06R (38999/26)
CTV06R (38999/26)
TV26/MTV26
TV07R (38999/24)
CTV07R (38999/24)
TV01R
CTV01R
TV09R
TVPS02Y (38999/21)
TVS07Y (38999/23)
TVSIY (38999/25)
TVSHIY (38999/27)
C prefix = Composite
9-5
to
25-97

non Mil
25-16
to
37-5
MS-102
Amp /Pyle Hi Temp

M83723
Pyle BT
Boeing BACC
Pyle BSK
Pyle ESC11
AECMA EN 2997
SOBAC/RR ESC10
Aerospatiale ASN-EO
MIL-C-83723 Series 3
Threaded
71
72
73
74
75
76
82
83
84
85
86
87
95
96
08-98
to
28-42
62GB Plugs
62GB Recp
62 GB- Series Plugs CE-2Pa
62 GB- Series Recp CE-2Ra
MIL-C-26482
Bayonet
Solder
0
1
2
3
4
5
6
7

8-2
to
24-61
GB for Great Britain

For more on the cables and connectors used with the VINSON series (KY-57) of voice security equipment see the USM-481 Cable Tester web page.

Amphenol - Aerospace -
Bluefeather - Special Connectors for Military Surplus and Aerospace Hardware -
Digi-Key - has some mil type connectors
Encyclopedia of Connectors by Edward's Publishing Co - 10 volumes, very pricey
ITT (Cannon) -
Newark - has many mil type connectors
Spacecraft Components Corp. -
William Perry Co in Louisville, KY - Connectors:Amphenol, Bendix, Cannon, Burndy, Cinch and Winchester
Plug List by Ray Robinson - some have drawings

Rectangular Multi-Pin

Cinch - Jones

D-Sub (Wiki)

These are the popular connectors used on computers for RS-232 serial and many other applications.  They can be built with coax connectors intermixed with the normal pins and sockets.
Conec - D-Sub Combination Connectors -

Micro Miniature D Connectors

This is the connector used on the PRC-68 Family of Squad Radios for the Secure Voice Module.
It is made by Microdot Connectors who is part of Tyco Electronics - Micro Minature D .
MCK series has a metal shell and MCD has a plastic shell.

Coaxial

Pasternak Coax Connector ID Chart.pdf - handy way to ID coax connectors.

N (Wiki), BNC (Wiki), TNC (Wiki)

Note: you can mate a male from any of these to a female of any of these, but it may require removing the male nut.  I say this not for some practical reason but to make the point that they have identical electrical interfaces.

2540012 Electrical Connector, Salati Octavio M, Jan 30, 1951, 333/260, 174/89, 333/33, 439/314 - developed to allow constant impedance connectors for coax cables 1/4" or less diameter.  Done by stepping up and down the impedance is such a way as to maintain the line impedance when two connectors are mated.  Patent is for the BNC connector.

Connectors: N,
                BNC, TNC
The N, BNC & TNC connectors all have the same 50 Ohm interface.
Adapters: Nf-HNm,  BNCf-Nm,  TNCf-Mini_UHFm
Connectors: N
                & HN
The Nm on left and the HN (High Voltage N) on the right.
The N O.D.of the ground sleeve is close to 0.325".  For the HN the ground sleeve O.D. is about 0.555".

2540012 Electrical connector, Octavio M Salati, Hazeltine Res, App: 1945-05-19, W.W.II, Pub: 1951-01-30, - connector for 1/4" coax, stepped Z rather than taper.
6609925B1 Precision BNC connector, James Edward Cannon, Agilent, 2003-08-26, - makes it suitable for use up to 18 GHz in precision applications.

SMA (Wiki)

In the 1960s when I was working with these connectors the male connector was made by starting with some 0.141" OD simi-rigid coax cable which was similar to a copper pipe with Teflon insulation and a copper center conductor.  50 Ohm impedance.  The shield and insulation were cut without nicking the center conductor and a nut assembly slipped over the coax outer conductor and soldered in place.  The center conductor acted as the male pin.  Pasternack Enterprises PE4007 is an example.

The female center pin has springy fingers that grab the male pin.

I learned a number of ways of making microwave male and female SMA connectors to be part of a number of products like detectors (Shrike missile) or the ALR-54 front end limiter-detectors and many other products that used SMA(m) microwave input connectors and SMA(f) output connectors.  The key things were to get the spring into the female center contacts by choosing the metal alloy and heat treatment and capturing the male and female center contacts so that they did not move.

RG-174 Coax Connectors

Note that this cable comes in many flavors.  Some are for use in applications where low Triboelectric noise (Wiki)  is important, like vibration sensors on shake tables.

Here is some quick ID info for common coax connectors used with small diameter coax like RG-174:
50 Ohm SMA uses a 1/4-36 thread
50 Ohm SMB these are the push on type where the diameter of the part with the male pin is 0.144"
75 Ohm SMB these are the push on type where the diameter of the part with the male pin is 0.243"
50 Ohm SMC uses a 10-32 male thread on the part with the male pin and also has a body diameter of 0.144"
75 Ohm SMC uses a 0.3125-32 thread
              SSMB looks like SMB but has a body diameter of 0.104"
The antenna connectors for the AS-2108 DF antenna are not there, anyone know what these are (one has 2 lugs, the other 3 lugs)?
Most of these are standards, except for the antenna connector on field radios, which are much more rugged than normal connectors.
Amphenol coax web page with drawings for most types
Kings Electronics - aerospace & RF -
Pasternack Enterprises - Good Connector ID info - Minimum PO is $100 and $10 per line.
Pomona Electronics -
S. M. Electronics - On line, photos and 1 each pricing
The R.F. Connection - RF and other connector types + adapters
Tower Electronics - carries the 3.5mm to SO-239 needed for the BK radios RF jack.
Trompeter -
Also see my distributors web page for more sources.

Telegraph era

Also See the Telegraph web page for Binding Posts, phone tip, Fahnestock Clip, etc.

USB

    Connectors

Wiki-USB  - Hardware  -




Width

USB 1

USB 2

USB 3

Wiki: USB-C
USB 3.2


Type-A: 12 x 4.46mm
Type-B: 8.45 x 7.26 mm



USB 2.0
Mini-B
6.8 wide x 3 mm



Micro-B
6.85 wide x 1.8mm




USB connectors from Wiki

USB 1.x/2.0 Miniplug/Microplug
Pin Name Color Description
1 VCC Red +5 V




2 D− White Data −
3 D+ Green Data +
4 ID none permits distinction of

Micro-A- and Micro-B-Plug

Type A: connected to Ground

Type B: not connected

5 GND Black Signal Ground

USB-C
                end drawing (from wiki)

USB A & B connectors
USB A, Mini-B, Micro-B USB-A to USB-C cable

A = 12 mm wide  
       4.46 mm thick                             B = 8.45 mm wide
Micro-B= 5.2 mm wide                             Mini-B = 6.8 mm wide
C:  8.25 x 2.4 mm
LG-998T G6 phone
USB Data Cable, DC1709

The USB 3 Micro-B is like two connectors side-by-side
and is used on external USB hard drives.


There are (July 2009) three connectors:

USB-A to Multi Phone Charging Cables

This would be a good match with a Solar Phone Panel.

USB-A to Multi-phone cable
Left to Right:
USB-A input
USB Micro-B phone connector
USB-C phone connector
Apple Lightening? (Wiki) phone connector marked "down" the other side marked "up".

USB Power Delivery (Wiki)

The maximum current for a USB device (Wiki: Allowable Current Draw) varies between 0.1 and 5 Amps at 5 Volts.  But Power Delivery devices for USB-C 1, 2 or 3 it is up to 20 Volts & 5 Amps (100Watts).  For the newest USB-C 3.1 Power Delivery devices it's 48 Volts & 5 Amps (240Watts).  Note Starlink uses PoE (Wiki) with 56 Volts @ 1.6 Amps (89 Watts).

While the Wiki page says Power Delivery was made part of the USB spec in 2012, it's only in 2023 that I learned about the "ZYPDS ZY12PDN USB-C Type-C PD2.0 3.0 to DC USB Fast Charge Trigger Poll Detector".  This device can be used to test a USB power source to see what voltages it can deliver and also be used to make up power cables from USB-C to 9, 12, 15 or 20 Volts. 

2023 June 23 (Wiki): Voltages: 5, 9, 15, 20, 281, 361 & 481 Volts with up to 3 or 5 Amps. (240 Watts max).  This applies to Power Delivery certified USB-A, USB-B (and USB-C?) cables.
Note 1: Requires electronically marked EPR 5 AMp. cables.

NOTES ON USB PD TRIGGERS (AND ZY12PDN INSTRUCTIONS) -
ZY12PDN The colors indicate:
  1. Red; Selectable mode, 5V present
  2. Yellow: 9V
  3. Green: 12V
  4. Ice/Teal: 15V
  5. Blue: 20V
Git Hub: manuelbl / zy12pdn-oss -

HDMI

High-Definition Multimedia Interface (Wiki) replaced the old analog video cabling.  It's required in order to get high-definition images since it includes High-bandwidth Digital Content Protection (Wiki).  If you use prior art analog cable to connect a DVD player to a monitor the HDCP will limit the output quality to that of a VHS tape.  The people that use Yellow, White & Black RCA cables, or other analog cables on their DVD players are degrading the image quality.

My Nikon D800E camera has a mini HDMI jack so I'm learning about the three sizes of HDMI connectors: full size, mini and micro.  Not all eBay sellers properly label their products.
Fig 1 HDMI (standard) male to HDMI mini male cable
The correct one to connect my D800E to the monitor
HDMI (standard) male to HDMI mini male cable
Fig 2 Showing mislabeled adapter.
It is an HDMI mini female to HDMI micro male
HDMI mini
                  female to HDMI micro male

0.1" Headers

First generation printed circuit boards used DIP (Wiki) packaged parts where the pitch was 0.1" and the separation between rows of pins was an integer multiple of 0.1".  This means that the board would be laid out on a gird that's 0.1" x 0.1".  Most through hole components (Wiki) fit nicely on this grid.  One of those components is the Pin Header (Wiki).  The first generation have a pitch of 0.1" and have many uses.

Metric

Note that 2.54mm is exactly the same as 0.1"  So you will see Molex KK 254 and Molex KK 0.1" which are identical parts.  It's very common to see this sort of exact conversion of an inch unit to a metric unit where both parts are interchangeable.

But what is NOT identical are parts that have a pitch of 2.5mm.  Note these parts are not interchangeable with inch parts!

LCD modules typically have the interface connector laid out for a header or ribbon cable, for example see: PIC 16F88 LCD Interface.
The hole pattern for an 8-pin header is on the 6 digit 7-segment display board of 22 Feb '03.
Sometimes jumpers are used in combination to select options.  Either the jumper is installed or not installed to choose.

On YouTube: BigCliveCom: Crimping tool test that I screwed up. (Read description.) - uses 2-contact versions for wiring up low voltage battery and solar circuits that typically involve LEDs.
 Example of using these: salvaged lithium cells to power LEDs directly. (with protection test) -

Parts on order (2020 March 9):
22-01-3027 Housings
08-50-0114 plain Terminals
11-01-0185 CR2262C crimp tool
08-50-0032 cat's ears terminal
22-23-2021 2-pin locking header

Hints

  • The Molex tooling is dependent on the actual terminal part number.  So you will NOT find crimp tooling information on their web pages associated with the housings. Not only is there tooling information on the terminal web page and there is also information on previous tooling that's very handy when searching eBay for used crimp tools.
  • The black resin parts seem to be stocked mostly in the EU, probably because of ROHS (Wiki) requires higher soldering temperatures.

Wire Termination, 2-circuit housing Molex 22013027 (eBay: 22-01-3027)

Headers that mate with 2222-01-3027 Housing-01-3027 Housing

Header
Polarized
Material
Pins
42375 no
Black resin
Straight
42376 no
Black resin Right Angle
42377 no
Black resin Right Angle
4030 no
Nylon
Straight
6373 yes
Nylon Straight
6410 yes
Nylon Straight
171856 yes
Black resin Straight
171857 yes Black resin Right Angle

Terminals

KK 254 (0.1") Crimp Terminal

Series
Terminal p/n
Note 1
Pin
Metal/plating
Crimp
Tool
Previous Tools
Cat's Ears Wire
U
Width
Insulation
U
Width
2759 08-50-0114 Brass/Tim
638118200 11-01-0185
69008-0955
no
1.8
2.1
6459 08-52-0123
Phosphor Bronze/Tin 638118200 "
no


41572 08-65-0805
Phosphor Bronze/Tin 638118200 "
no


4809 08-50-0032
Brass/Tin 638118200 "
Yes


8088 97-00-0225
Phosphor Bronze/none 638118200 "
Yes

Note 1: there are other terminals in each Series, I'm just showing one of them.  See the Series page for a list of terminals.
Note: Phosphor Bronze has more springiness than Brass so may offer a better mechanical & electrical contact.  Need to check the spec sheets to see.
Note: There are versions of the terminals that have gold plating on either the wire crimp or both the wire and insulation crimp.
Note: Have an open question to Molex about "Cat's Ears".

Mating 2-circuit Headers

Note these are designed to be soldered on a PCB, not terminated on a wire.  But Big Clive is just soldering wires to them to end up with a wire-wire connection.

p/n
Polarized
Angle
Lock
Body
Material
42375 no
straight none
Black
Resin
42377 no
straight none Black
Resin
42376 no
Right none Black
Resin
4030 no
straight none Nylon
6373 Yes
straight Friction
Nylon
6410 Yes straight Friction Nylon
171856 Yes straight Friction Black
Resin
171857 Yes Right
Friction
Black
Resin

Crimp Tool

While (as of March 2020) the current tool is the 638118200 older tools still work and can be used such as the 11-01-0185 and the 69008-0955.  I found this 11-01-0185 on eBay for a fraction of the cost of a new tool.
Markings: Molex, 11-01-0185, ENG# CR2262C,
A 22-24 AWG
B 26-30 AWG
Made in Sweden
J455255
999129
This tool includes both wire crimp and insulation crimp on each cycle.  The optional Locator Blade that helps position the terminal did not come with it.
The maximum insulation diameter is 1.57mm (0.0615" or about 1/16").

Photos
Fig 1
Molex,
                    11-01-0185, ENG# CR2262C

Wire

For the "A" notch in the crimp tool the range includes 22 & 24 AWG.  The "B" notch includes 26, 28 & 30 AWG, so I have some 28 AWG wire on order that complies with Mil-W-16878/1.  The specs are:


The nominal OD of 0.035 is about half the allowed the maximum diameter.

Unknown - Wanted

They all are coax connectors with a male pin for the center conductor and have 2 or 3 lugs for the mating connector.
Looking for the mating connectors to make up cables.  Manufacturer might be Dage.
 
Where Used
AS2108/ARN-89
C-7392/ARN-89
AN/URC-68
O.D.(inch)
0.285
0.285
0.264
Photo 
2-lug & 3-lug
2-lug
ID
inside the white dielectric is about 0.143"
DAGL 1-531-1
5935-783-7232 SM-B-597016-1

Links

RS Components - Connectors and Cable -
William Perry Co in Louisville, KY - Connectors:Amphenol, Bendix, Cannon, Burndy, Cinch and Winchester
PEI-Genesis -
Brian, at Prime Connectors Inc. recommended on the Army Radios list-server (no web presence)
Voice line is 1-215-658-0700,    FAX is 1-215-658-1495
Nexus - Audio Plugs & Jacks
Spacecraft Components Corp - circular and Coax - ARC-114A
Cooper Interconnect - Mil Connectors
Pasternack Enterprises - many coax connectors including a connector ID helper
Brooke's Home, Military Information, Electronics Page
[an error occurred while processing this directive] page created Jan 30, 2001.