High PowerPlanforms

High Power 38999 Planforms
Amphenol is the world leader in the design, manufacture and supply of high-performanceinterconnect systems for military, commercial and industrial applications. Amphenol
offers a complete portfolio of power solutions for demanding and harsh environments.
Amphenol has extended its series of 38999 circularconnectors to include a new range of power inserts to
respond to market demands for increased power in a
proven high reliability 38999 circular connector format.
The demand for more power is consistent across all of
Amphenol’s core markets – military, commercial air andindustrial – and typical applications are intelligent power
distribution units, power conversion and transformers,
slip rings, turret systems, motors, integrated starter
generators, actuation systems and hybrid vehicles.
Amphenol’s extended series of 38999 Power inserts
offers customers a range of contact sizes from size #20(7.5A) to size #4 (100A). Terminations are available tosuit different applications such as busbar, tapped hole,crimp, solder bucket and pintails. Inserts are available
in standard connector styles such as; jam-nut, box
mount, plug, and bulkhead feed-through.

Key Features

Typical PowerApplications

2Shells can be manufactured in Aluminium, AluminiumBronze, Stainless Steel, Composite and Titanium.
Additionally hermetic sealing is available if customers
require a glass-metal seal. Amphenol can incorporate
EMI and EMP filters to protect against EMI interference
and transient energy surges, such as lightning strike.
The 38999 Power inserts are available in either
proprietary or QPL qualified plating finishes including
Cadmium, Nickel, Zinc Cobalt and the latest qualified
QPL Black Zinc Nickel RoHS compliant plating.
Amphenol’s new range of 38999 Power inserts
coupled with its new High Power Single Pole 38999
Rhino connector, which carries up to 1000A, means
Amphenol can offer a complete solution for all
customers’ power challenges.

P Electrical Performance – 7.5A to 100A, operating voltage up to 600v
P Range – single and multi-pole mixed insert arrangements
P Termination – busbar, tapped hole, crimp, pintail and solder bucket
P Shell Materials – Aluminium, Aluminium-Bronze, Stainless Steel,Titanium and Composite
P Rugged – 38999 qualified performance
P RoHS – Black Zinc Nickel Plating
P Added-value services – harness and cable
assembly capability

P Intelligent power distribution units
P Power conversion and transformers
P Slip rings
P Turret systems
P Motors
P Engine marriage panels
P Bulkhead feedthroughs
P Integrated starter generators
P Actuation systems
P Hybrid vehicles

High Power 38999 Part Numbering
Style
See page 5

Contact Style
P = Pin Contact
S = Socket Contact

Shell Size
Odd numbers 11 to 25

Series Designator
TV MIL-DTL-38999 Series III
TVS 200° Rated

Alternate Keyway
N, A, B, C, D, ETV P00 RW – 21 – 75 P N WP 000Shell Class
RW = Olive Drab Cadmium
ZN = Black Zinc Nickel
RB = Nickel-Aluminium Bronze
RF = Electroless Nickel
Y = Hermetic Seal

Insert Arrangement(see below)

PowerContact Termination
000 = Pintail: #16 + #20
001 = Crimp
002 = Threaded post: #4003 = Flat tail with cross hole: #4004 = Short busbar: #4 + #8005 = Long busbar: #4 + #8

For mixed planform contact termination consult factory.

Insert Arrangements
Front face of pin inserts illustrated
DAAACB
B

B

11-01

17-52

21-75

21-42

Service rating

M

M

I

I

No. of contacts

1242Contact size

8884A

A

H

A

E

B
G

C

F

DB
F

B

DDE

C

C

21-72

21-48

23-06

IM

M

Service rating
No. of contacts

2646Contact size

41688

A

A

A

G

H

B

H

B

B

J
H

G

F

CC

L

E

GCK

F

DF

DDE
E

25-08

25-1125-1A

Service ratingM

No. of contacts

89244

Contact size

81020

416N

M

Contactlegend
481016203

High Power 38999 Performance Information
Test/parameterDescription

Electrical
Current Rating

size #20 contacts: 7.5A d.c.
size #16 contacts: 13A d.c.
size #10 contacts: 33A d.c.
size # 8 contacts: 60A d.c.
size # 4 contacts: 100A d.c.

Shell to Shell Continuity

10mΩ maximum for finishes ZN, RW, RF, SS & RB

Contact Resistancesize #20 contacts: 4.70mΩ
size #16 contacts: 2.00mΩ
size #10 contacts: 0.85mΩ
size # 8 contacts: 0.60mΩ
size # 4 contacts: 0.26mΩ

Insulation Resistance

5000MΩ at ambient, 1000MΩ at max temp.

Working Voltage

M: 400V Service AC (RMS)
N: 300V Service AC (RMS)
I: 600V Service AC (RMS)

Dielectric Withstanding Voltage

M: 1300 VRS Test Voltage (sea level)
N: 1000 VRS Test Voltage (sea level)
I: 1800 VRS Test Voltage (sea level)

TechnicalMating Durabiity

500 cycles

Torque Settings (lb.f.in.)

Shell Size

Backshell

Panel Nut

#11

71/81

40/46

#17

111/121

80/85

#21

131/141

100/110#23

131/141

110/120#25

131/141

120/130

Environmental
Operating Temperature Range–65°C to +175°C for finishes ZN, RW, RB–65°C to +200°C for finishes RF, SSSealing

As per Mil-DTL-38999

Salt Spray

Up to 500hrs dependant on plating finish

RoHS Compliant

Yes, dependant on plating finish

4Styles
TV06 (D38999/26) – Straight Plug
1.234 MAX
31.34 MAXShellSize

1.220 MAX
VIEW D
31.00 MAXFOR SIZE 8 COAXIAL ONLY,RELATIVE TO –A–Q

MS Shell Size
CodeQ

111.656 MAX
42.06 MAX

V Thread Metric
VIEWQ
D Max.
FOR SIZE 8 COAXIAL ONLY,
25.0
M15X1-6g
RELATIVE TO –A–B

17E
G

35.7
1.656
MAX
42.06 MAX

M25X1-6g

2141.7

M31X1-6g

23H

44.9

M34X1-6g

25J

48.0

M37X1-6g

V THREAD

All dimensions in mm, for reference only.

.359 MAX9.12 MAX

3080.591 +.003–.000
15.01 +.08–.00

VIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TO –A–VIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TO –A–

1.797 MAX
45.64 MAX1.797 MAX
45.64 MAX

TV07 (D38999/24) – Jam Nut Receptacle
1.234 MAX
31.34 MAXQ

Q

C

PANEL THICKNESS.062 MIN .125 MAX
1.57 MIN 3.18 MAX

C.378 MAX
9.60 MAXPANEL THICKNESS.062 MIN .125 MAX
1.57 MIN 3.18 MAX.378 MAX
9.60 MAX

V THREAD.359 MAX9.12 MAX

3080REF
KKREF
SHELL
SIZES
9/11
SHELL SIZES
9/11– –.871
22.12.871
22.12
SHELL SIZES– –SHELL
SIZES13/25
13/25
.878
22.30
.878
22.30
1.280 MAX
1.280 MAX
32.51 MAX
32.51 MAXSS
2 PLACES
2 PLACES

H Hex
+.43
–.41

S
±.25

V Thread
Metric

B

35.20

25.40

31.75

M15X1-6g

E

44.73

36.53

41.28

M25X1-6g

G

52.65

42.80

49.23

M31X1-6g

23H

55.85

46.02

52.37

M34X1-6g

25J

59.00

50.80

55.58

M37X1-6g

Note: Deep reach receptacles are available for panel thicknesses

VIEW D

VIEW DFOR SIZE 8 TWINAXONLY,up to.750 max. All dimensions in mm, for reference only.
FOR SIZE 8 TWINAX ONLY,–A–RELATIVERELATIVE
TO –A– TO.091
2.31MAXMAX
2.31 MAXHRELATIVE TO –A–VIEW D
11MAX ONLY,FOR SIZE 8.794
COAXIAL
20.17
RELATIVE TO–A–MAX
17.794 MAX
20.17 MAX 21.591 +.003–.000
V THREAD
15.01 +.08V THREAD–.00.091 MAX

H

MS ShellSize
VIEWShell
D
FOR SIZEONLY, C Max.
Size8 COAXIAL
Code.940 MAX.940 MAX
23.88 MAX
23.88 MAX

TVP00 (D38999/20) – Wall Mounting Receptacle
S
2 PLACESMSShell
M
Shell Size+.00
Size Code L Max. –.13

VIEW DFOR SIZE 8 COAXIAL ONLY,RELATIVE TO –A–.861 MAX
21.87 MAX(TV)

LL

R12 PLACESM

R22 PLACESLV THREADTT
4 PLACES.005 M

S
T
Max. ±.20

V ThreadMetric

LL+.15 TT–.00 ±.20

B

11.91

20.83

20.62

18.26

26.5

3.25

M15X1-6g

22.99

4.93

17E

11.91

20.83

26.97

24.61

33.7

3.25

M25X1-6g

22.99

4.93

21G

12.70

20.07

31.75

29.36

40.1

3.25

M31X1-6g22.99

4.93

23H

12.70

20.07

34.93

31.75

43.3

3.91

M34X1-6g

22.99

6.15

25J

12.70

20.07

38.10

34.93

46.4

3.91

M37X1-6g

22.99

6.15

VIEW DFOR SIZE 8 TWINAX ONLY,RELATIVE TO –A–
1.037 MAX
26.34 MAX
(TV)

.13 M

R211.909 MAX
23.09 MAX(CTV)T
4 PLACES

R11.240 MAX
31.50 MAX

Designates true position dimensioning

All dimensions in mm, for reference only.

1.084 MAX
27.53 MAX
(CTV)

5

Accessories and Tooling
Backshells
Family code

Suitable boot, omit for non:B1 = Straight bootB2 = 90° bootConnector
group (default)

BK4 X X K 99 99 9 X X-B1
Material/finish:
ZN = Black Zinc		Nickel
N =	Electroless
NickelZ = Black Zinc		Cobalt
Y = Olive Drab		 Zinc Cobalt
W = Cadmium

Angle/profile:
S = StraightA = 90°B = 45°Coupling:
S = Self-lock
R = Spin coupling
Shell size
Designator: 10-24
Please consult factory for advice on backshell specification to suit
cable requirements.

Contact style:
B = With band for		braid fixing
X = Without band

Entry size:
01
02

Length:9 = Standard size

CapFamily code

418-60

Use for MIL-DTL-38999
Series III TV

3 1 - 13 R 030 1 - 04

Eyelet:0 = No eyelet, no lanyard
1 = Lanyard + crimp ferrule
2 = Lanyard + large eyelet
3 = Lanyard + small eyelet

Shell size:
Series III (11 to 25)

Style:
P = Plug
R = Receptacle
F = Heavy Duty PlugG = Heavy Duty Receptacle

Lanyard length (all +/- 0.25 inches)

6FinishSee table below

Lanyard type:
0 = No lanyard
1 = Black terylene cord
2 = Stainless steel chain
3 = Plastic covered wire rope

Lanyard length
See table below

Finish035

3.5 inches (90mm)-02

Electroless Nickel plate040

4 inches (100mm)-03

Olive Drab Cadmium050

5 inches (125mm)-04

Olive Drab Zinc Cobalt

060

6 inches (150mm)-08

Stainless Steel090

9 inches (230mm)-09

Nickel Aluminium Bronze

120

12 inches (300mm)-10Black Zinc Nickel

Crimping Tools
Contact Size/Type

Crimping Tool

Turret Die or Positioner#4 Pin and Socket

809947809948#8 Pin and Socket

809872809873#10 Pin and Socket

TP-201423

Not applicable#12 Pin and Socket

M22520/1-01

M22520/1-04#16 Pin and Socket

M22520/1-01
M22520/7-01

M22520/1-04
M22520/7-04#20 Pin and Socket

M22520/1-01
M22520/2-01
M22520/7-01

M22520/1-04
M22520/2-10
M22520/7-08

Where 2 or 3 tools are listed for a contact size, only one tool and its die or positioner, adjacent within the table, are required to crimp the contact.
The above crimping tools and positioners are available from a QPL approved tool manufacturer.

Standard Contacts
Contact Size

PinSocket

Seal Plug#4900007

418-3031

N/A#8900197

900217MS27488-8-3#10M39029/58-528M39029/56-527

M85049/81-10#12

M39029/58-365

M39029/56-353

MS27488-12-2#16

M39029/58-364

M39029/56-352

MS27488-16-2#20

M39029/58-363

M39029/56-351

MS27488-20-2

Insertion and Removal Tools
Contact Size

Plastic Tools

Metal Tools

Insertion Tool

Removal Tool

Insertion Tool

Removal Tool

#4

N/A

M81969/14-07

N/A809943#8N/A

M81969/14-12

N/A

M81969/8-14#10

M81969/14-05

M81969/14-05

M81969/8-11

M81969/8-12#12

M81969/14-04

M81969/14-04

M81969/8-09M81969/8-10#16

M81969/14-03

M81969/14-03

M81969/8-07

M81969/8-08#20

M81969/14-10

M81969/14-10

M81969/8-05

M81969/8-06

7

Worldwide sales contacts
EuropeAmphenol Ltd, UK
Thanet Way, Whitstable
Kent, CT5 3JF
United Kingdom
T: +44 1227 773 200

Amphenol Nordic
T: +46 702 129 200

Amphenol Socapex, France
948, promenade de l’Arve BP2974311 Thyez Cedex
FranceT: +33 4 50 89 28 00
Amphenol Air LB, France
10 rue champ Raymond
08110 Carignan
FranceT: +33 3 24 22 32 70
Amphenol AIR LB GmbH, Germany
Am Kleinbahnhof 466740 Saarlouis
Germany
T: +49 6831 981 00

Amphenol Switzerland
and South Centre
Switzerland, Slovenia,Serbia, Montenegro,
Yugoslavia, Greece,
Bulgaria
948, promenade de l’Arve BP2974311 Thyez Cedex
FranceT: +33 4 50 89 28 00
Amphenol Italy
Via Barbaiana n.5
20020 Lainate, MilanoItaly
T: +39 293 254 214

Amphenol Benelux
Zadelmaker 121 NL
2401 PD Alphen aan den Rijn
The Netherlands
T: +31 172 444 903
Amphenol Iberica
Edificio Burgosol, Oficina nr 55
Comunidad de Madrid, 35 bis Las
Rozas (Madrid)Spain
T: +34 91 640 73 06
Amphenol Poland andCentral East Europe
Austria, Poland,
Czech Republic,
Slovakia, Romania
Wiener gasse 68
2380 Perchtoldsdorf
Austria
T: +43 699 10396 071

North America

Asia

Amphenol PCD USA
72 Cherry Hill Drive
Beverly, MA. 01915-1065
USA
T: +1 978 624 3400

Amphenol Daeshin, Korea
558 SongNae-2 Dong, SoSa-Gu,
Bucheon City, Gyeonggi-do
422-040, Korea
T: +82 32 610 3800

Amphenol Japan
471-1 Deba, Ritto-City
Shiga 520-3041
Japan
T: +81 77 553 8501

Amphenol Canada Corporation605 Milner Avenue
Toronto, Ontario
CanadaM1B 5X6
T: +1 416 291 4401

Amphenol Interconnect India
Private Limited
105 Bhosari Industrial Area
Pune 411 026
India
T: +91 203 068 8304

Amphenol PCD CO Ltd, China
Building 21, 1st Liao Keng Industrial
Zone, Shi Yan Street
Bao An District, Shenzhen 518108
China
T: +86 755 8173 8000

Bar-Tec Ltd, Israel
3 Hagavish Street, K fir-Barkan Bldg
East Industrial Zone
Kfar-Sava, 44102
Israel
T: +972 9 764 4100

Amphenol South Africa
30 Impala Road2196 Chislehurston
SandtonSouth Africa
T: +27 11 783 9517

Amphenol Mexico
Prolongacion Reforma 61-6 B2
Col Passo de las Lomas CP.013130
MexicoT: +52 55 5258 9984

Amphenol Turkey
Sun Plaza 15 Kat:
15 Maslak Hah. Bilim
Sok. No.5
Sisli/Istanbul, 34398
TurkeyT: +90 212 367 92 19

Other areas
Amphenol Argentina
Av. Callao 930 2do piso Oficina B“Plaza” C1023 – AAP, Buenos Aires
Argentina
T: +54 11 4815 6886
Amphenol Australia Pty Limited
2 Fiveways Blvd, Keysborough,Melbourne, Victoria 3173
Australia
T: +61 3 8796 8888
Amphenol Do Brazil
Rua Diogo Moreira132, 20 andar, rooms 2001-2-3
CEP: 05423 010 Sao Paulo SPBrazil
T: +55 11 3815 1003

Amphenol Russia
Yaroslavskaja Street 8129164 MoscowRussia
T: +7 495 937 6341

For more information call +44 (0)1227 773200
Amphenol Ltd Thanet Way Whitstable Kent CT5 3JF | Email: info@amphenol.co.uk | www.amphenol.co.uk
Military images ©Ministry of Defence, licensed under the Open Government Licence v2.0. Cover image of Toyota Prius ©Teddy Leung | June 2014