Military, security and aerospace COTS connector solutions

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Samuel Ramsey
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1 Military, security and aerospace COTS connector solutions

LEMO M Series M Series micro-connectors LEMO M Series range of triple-start micro-connectors provide significant space savings in comparison to MIL 8999 Series III connectors, and are LEMO s smallest

Soldier and vehiclemounted equipment Communications UAV s/umv s Avionics and Aerospace LEMO M-Series SAVE UP TO 5% ON ENCLOSURE FLANGE TO PCB DEPTH MIL 8999 LEMO M-Series high-strength aluminium

2 LEMO M Series M Series micro-connectors LEMO M Series range of triple-start micro-connectors provide significant space savings in comparison to MIL 8999 Series III connectors, and are LEMO s smallest multi-pin, fully shielded, vibration-secure and sealed connectors available, offering a lightweight connection with high pin-count density, 60º EMC shielding protection, and LEMO rugged quality. Soldier and vehiclemounted equipment Communications UAV s/umv s Avionics and Aerospace LEMO M-Series SAVE UP TO 5% ON ENCLOSURE FLANGE TO PCB DEPTH MIL 8999 LEMO M-Series high-strength aluminium connectors incorporate a triple-start fast-locking ratchet mechanism for use in high vibration and harsh environments, providing significant size and weight advantages over MIL-8999 connectors and other micro circular connectors. Already selected for use on the FECU and a number of military and avionics applications, the M Series is continuing the excellent reputation of LEMO connectors for high quality and reliable interconnection solutions that meet customers requirements. Main features and benefits include: Triple-start thread ratchet coupling mechanism for fast (/ turn) & secure connection Small size with high contact density for significant space savings Multiple keys and keyways for ease of mating and security Short flange to pcb depth for greatly reduced enclosure sizes and cost savings Integral backshell, but with MIL backshell options if preferred Unique LEMO precision gold-plated contact system for exceptional performance and longterm reliability With power pin and reduced crimp barrel contacts, accommodates wire from 6 to AWG Designed for use in harsh environments, M Series connectors have been tested to the full range of MIL tests including vibration, gunfire, altitude, lightning, temperature, immersion,chemical and flammability, clearly demonstrating capability of the range to handle many aerospace, military and security applications. This catalogue provides a summary of the M Series range and accessories with comparisons to some popular MIL 8999 shell sizes to demonstrate the potential equipment savings that can be made by adopting the M Series. Note that this catalogue does not cover the whole M Series range and other housings are available some examples below. The full catalogue giving full details of the complete M Series range is available via our website The M Series has a wide range of shell design options to suit customer requirements. Variants include: In-line plugs (FM* & FG*) and sockets (PM* & PH*) Fixed sockets -front panel, back panel and bulkhead fixing Watertight pcb sockets when unmated Two coupling nut styles knurled and arctic grip Three cable fixing options metal tie-wrap or constant force spring clip, MIL backshell and overmoulding

LEMO M Series Examples of COTS alternatives Possible COTS alternatives to popular MIL 8999 shell configurations selected from the M Series range below give an idea of the scope for significant space

3 LEMO M Series Examples of COTS alternatives Possible COTS alternatives to popular MIL 8999 shell configurations selected from the M Series range below give an idea of the scope for significant space reductions whilst still meeting rating requirements for your application. These are some examples only and many other housings and contact configurations are available see our full LEMO M Series catalogue for further information. LEMO M Series a few examples with part numbers of COTS equivalent options MIL 8999 Shell size No of contacts 6 6 Contact size 0 0 Nominal dia mm LEMO COTS alternative Description 0M.0 M.08 M.08 M.9 No of contacts No Wire sizes AWG * * Contact rating Amps 8A 5A 0A A Plug nominal dia mm Straight plug with integral backshell, FGN.0M.0.XLC FGN.M.08.XLC FGN.M.08.XLC FGN.M.9.XLC Bulkhead socket with integral backshell, PEN.0M.0.XT PEN.M.08.XT PEN.M.08.XT PEN.M.9.XT Fixed socket, watertight when unmated, pcb contacts HEN.0M.0.XLNP HEN.M.08.XLNP HEN.M.08.XLNP HEN.M.9.XLNP In-line socket with integral backshell, PHN.0M.0.X PHN.M.08.X PHN.M.08.X PHN.M.9.X Heatshrink boot Straight boot UKT.0007 UKT.0007 UKT.0007 UKT.0007 Right angled boot UKT UKT UKT UKT LEMO CABLE Cable to DEF STAN 6-, braided screen, or DIN, VDE, UL or proprietary cable as requested 7--C 7--8C 6--8C 7--0C For cable end to take overmoulding add "T" to end of part number Optional back end for overmoulding e.g. e.g. e.g. e.g. FGN.0M.0.XLCT FGN.M.08.XLCT FGN.M.08.XLCT FGN.M.9.XLCT PHN.0M.0.XT PHN.M.08.XT PHN.M.08.XT PHN.M.9.XT To add an optional MIL backshell fitting, add 'M' to the end of the part number **Optional back end for fitting backshell e.g. e.g. e.g. e.g. FGN.0M.0.XLCM FGN.M.08.XLCM FGN.M.08.XLCM FGN.M.9.XLCM PHN.0M.0.XM PHN.M.08.XM PHN.M.08.XM PHN.M.9.XM Backshell Thread size Mx N/A M5x M5x **Straight backshell option N/A UKT.B.M.0.ZN UKT.B.M5.06.ZN UKT.B.M5.08.ZN shell too small **90º backshell option N/A UKT.B.M.0.ZN UKT.B.M5.06.ZN UKT.B.M5.08.ZN * Reduced barrel contacts available for smaller wire gauges down to AWG. ** Note standard M Series has integral backshell. For reduced barrel contacts change the th character of the LEMO part number from L to B for contacts and from M to P for contacts. Standard contacts Reduced barrel contacts

4 LEMO M Series Examples of COTS alternatives A few more possible COTS alternatives to popular MIL 8999 configurations are given below. LEMO M Series a few examples with part numbers of COTS equivalent options MIL 8999 Shell size No of contacts 7 55 Contact size 6 Nominal dia mm LEMO COTS alternative Description M.0 M No of contacts No Wire sizes AWG * --6* --6* Contact rating Amps Plug nominal dia mm Straight plug with integral backshell, FGN.M.0.XLC FGN.M.0.XLC FGN..0.XLC FGN..68.XLC Bulkhead socket with integral backshell, PEN.M.0.XT PEN.M.0.XLCT PEN..0.XT PEN..68.XT Fixed socket, watertight when unmated, pcb contacts HEN.M.0.XLNP HEN.M.0.XLNP HEN..0.XLNP HEN..68.XLNP In-line socket with integral backshell, PHN.M.0.X PHN.M.0.X PHN..0.X PHN..68.X Heatshrink boot Straight boot UKT.0007 UKT.0007 UKT.0007 UKT Right angled boot UKT UKT UKT UKT LEMO CABLE Cable to DEF STAN 6-, braided screen, or DIN, VDE, UL or proprietary cable as requested 6--C 7--6C On request On request For cable end to take overmoulding add "T" to end of part number Optional back end for overmoulding e.g. e.g. e.g. e.g. FGN.M.0.XLCT FGN.M.0.XLCT FGN..0.XLCT FGN..68.XLCT PHN.M.0.XT PHN.M.0.XT PHN..0.XT PHN..68.XT To add an optional MIL backshell fitting, add 'M' to the end of the part number **Optional back end for fitting backshell e.g. e.g. e.g. e.g. FGN.M.0.XLCM FGN.M.0.XLCM FGN..0.XLCM FGN..68.XLCM PHN.M.0.XM PHN.M.0.XM PHN..0.XM PHN..68.XM Backshell Thread size M5x M8x M8x M5x **Straight backshell option UKT.B.M5.0.ZN UKT.B.M8.07.ZN UKT.B.M8.08.ZN UKT.B.M8.0.ZN **90º backshell option UKT.B.M5.0.ZN UKT.B.M8.07.ZN UKT.B.M8.08.ZN UKT.B.M8.0.ZN * Reduced barrel contacts available for smaller wire gauges down to AWG. ** Note standard M Series has integral backshell. For reduced barrel contacts change the th character of the LEMO part number from L to B for contacts and from M to P for contacts. Standard contacts Reduced barrel contacts

LEMO M Series Code for positioner Rated current 0M M M Fe for sockets 0 0.9 0-- 0.0 0 0.9 0-- 8.0 0 0.7 --6 7.0 05 5 0.7 --6 6.5 05 5 0.9 0-- 9.0 07 7 0.7 --6 7.00 08 8 0.7 --6 5.00 0. 6-8-0.

mm øa Number of contacts Contact configurations The previous pages contain a selection of insert types to give an idea of how the M Series compares with MIL 8999 Series III configurations.

5 LEMO M Series Code for positioner Rated current 0M M M Fe for sockets Reference Male for plug AWG Contact dia. mm øa Number of contacts Contact configurations The previous pages contain a selection of insert types to give an idea of how the M Series compares with MIL 8999 Series III configurations. However a much wider range of contact configurations is offered which is growing all the time. If you do not see what you are looking for please contact LEMO to see if the configuration you require is available. All contacts other than for pcb are for which you will need a standard style 70 crimp tool and LEMO positioner. Use the positioner code in the table opposite to select the relevant positioner below. DCE Positioners for Positioners part number M Code For contacts DCE VC DCE VC DCE VC DCE VC DCE.9.0.VG For contacts DCE MVM DCE MVM DCE.9.09T.VM DCE.9.07T.VM DCE.9.0.VU DPC Manual crimping tool M tbd Crimping tool to MIL-C-50/7-0 for use with positioners above. DPC.9.70.V tbd Contact extraction tools Contact diameter (mm) tbd DCF LT DCF LT DCF.9..LT 5

β Accessories Keying options Up to 5 keying options are available, some with reverse gender contacts. N key is the standard for sizes 0M to M, and W key is the standard for the remaining sizes.

0M to M to Front view of a socket γ Front view of a socket γ α β δ Model Model N P U S T W R X V Nb of keys Nb of keys 5 Angles β γ 65 0 50 60 0 00 55 50 5 90 Angles α β γ δ 95 5 5 5 05 5 0 0 00 5 0

with the same size/series as the connector. For chrome- Blanking caps for plugs Blanking caps for fixed sockets plated brass caps for marine applications change the X to C.

6 β Accessories Keying options Up to 5 keying options are available, some with reverse gender contacts. N key is the standard for sizes 0M to M, and W key is the standard for the remaining sizes. Change the rd character of the LEMO part number to select your required key as per the table below. 0M to M to Front view of a socket γ Front view of a socket γ α β δ Model Model N P U S T W R X V Nb of keys Nb of keys 5 Angles β γ Angles α β γ δ Colour code blue yellow green red orange Colour code blue yellow red orange Contact type Plug Socket Contact type Plug Socket Blanking caps To select the correct cap choose a part number with the same size/series as the connector. For chrome- Blanking caps for plugs Blanking caps for fixed sockets plated brass caps for marine applications change the X to C. Blanking caps for in-line sockets BGF BGE BGF BGF.0M.00.XAV BGE.0M.00.XAZ BGF.0M.00.XAZ BGF.M.00.XAV BGE.M.00.XAZ BGF.M.00.XAZ BGF.M.00.XAV BGE.M.00.XAZ BGF.M.00.XAZ BGF.M.00.XAV BGE.M.00.XAZ BGF.M.00.XAZ BGF..00.XAV BGE..00.XAZ BGF..00.XAZ BGF.M.00.XAV BGE.M.00.XAZ BGF.M.00.XAZ BGF..00.XAV BGE..00.XAZ BGF..00.XAZ BGF..00.XAV BGE..00.XAZ BGF..00.XAZ Cable A range of high quality cables is stocked at LEMO UK, including to DIN, VDE and UL specifications, with the DEF STAN 6- range being offered as standard for use with the M Series. Some examples are shown in the tables on pages &, and options are available to match the full range of inserts shown on page 5. A full cable assembly service is also available from LEMO UK see page 8. Cable can be made up to suit customer requirements. Heatshrink boots 6 Straight and right-angled boots suitable for a range of connectors. They are manufactured from high quality elastomer suitable for a wide range of temperatures (-75ºC to +50ºC) and environments with excellent resistance to fuels in particular. Adhesive-lined with a high-temperature (-75ºC to +00ºC) capability epoxy adhesive also with excellent resistance to fuels and oils, this range of heat-shrink boots complements the excellent performance of M Series connectors in demanding applications. Series 0M M M M M Straight no lip, epoxy adhesive UKT.0007 UKT.0007 UKT.0007 UKT.0007 UKT.0007 UKT UKT UKT Min cable OD no lip, epoxy adhesive UKT UKT UKT UKT UKT UKT UKT UKT.0008 Min cable OD

Accessories Backshells A range of backshells have been specially designed to be fitted to the LEMO M Series connectors where customers require the additional benefits of a separate backshell note

LEMO backshells are available in primary models straight, 5º and 90º and are manufactured as standard from the same lightweight high strength aluminium as the M Series.

A slotted option is available for termination of additional drain wires. The connector interface is to the MIL 8999 Series III and IV shell sizes and a range of cable entry diameters are offered.

ZN M Series Thread size Cable entry nominal size Max entry (mm) UKT.

7 Accessories Backshells A range of backshells have been specially designed to be fitted to the LEMO M Series connectors where customers require the additional benefits of a separate backshell note that the M Series has an integral backshell. The design is shorter than standard MIL spec adaptors in order to complement the space savings offered by the M Series. LEMO backshells are available in primary models straight, 5º and 90º and are manufactured as standard from the same lightweight high strength aluminium as the M Series. Other materials are available on request.the rear fixing channel is designed to take metal tie-wraps or spring clips, depending upon the customer s preference. A slotted option is available for termination of additional drain wires. The connector interface is to the MIL 8999 Series III and IV shell sizes and a range of cable entry diameters are offered. Part number structure is shown below (add M to the end of M Series part number for the correct interface). Part number structure Interface thread sizes Cable entry sizes Part number example UKT.B.M.0.ZN M Series Thread size Cable entry nominal size Max entry (mm) UKT.B M 0 ZN S = straight, = 5º, = 90º Interface thread size - see table Cable entry size - see table Material (aluminium as standard) Plating (eg. zinc nickel black) Add S if slots required for additional drain wire termination, else leave blank Plating options include electroless nickel (C), electroless nickel + high phosphor for space applications (CHP), zinc cobalt black (ZK) and zinc nickel black (ZN). M M M M Mx.0 M5x.0 M8x.0 M8x.0 Mx.0 M5x.0 Mx Microbands and Constant Force Spring clips for screen termination Termination of the cable screen to M Series connectors can be achieved through the use of either metal microbands or constant force spring clips. The closing of microbands requires the use of a special tool to ensure sufficient tightening of the band, whereas the spring clips are manually applied and are contained by a the heatshrink boot. Microband tool A099 M Series Constant Force Spring Clips A range of constant force spring clips are available for use with M Series connectors, which permits repair of cable terminations without having to discard any of the existing braid shield system. When used in conjunction with LEMO heatshrink boots, a fully sealed termination is achieved. An additional benefit of the constant force spring isthat it provides excellent resistance to shock or vibration due to its self-tensioning properties. Metal microband A89 Series 0M M M M M Braid grounding location diameter (mm) UKT UKT UKT UKT UKT UKT.0007 UKT.0007 UKT.0007 Front conical nut tightening tools M Series size LEMO socket drive Torque Nm LEMO wrench A range of tightening tools consisting of / socket drives and calibrated wrenches has been developed for the conical front nuts to ensure correct torque is applied, as well as avoiding damage to the appearance of the nuts during assembly. 0M M M M M UKT.0008 UKT.0008 UKT.0008 UKT UKT UKT UKT UKT UKT UKT

Cable assembly LEMO UK offers a full cable assembly service from its modern facilities with fully trained technicians, and we pride ourselves on the quality of the terminations provided.

8 Cable assembly LEMO UK offers a full cable assembly service from its modern facilities with fully trained technicians, and we pride ourselves on the quality of the terminations provided. CAD drawings are created for new assemblies and are fully structured on our system to provide appropriate controls & full traceability. Whilst our emphasis is naturally on the termination of LEMO connectors, we have extensive experience of connectors from other manufacturers. LEMO UK has the capability for termination of both copper and fibre optic cable assemblies. At LEMO every cable assembly is fully inspected to ensure it meets the required standard. In many instances the technical requirements for an assembly are the same for many different customers. For this reason a part numbering system for M Series standard cable assemblies has been created, where the specification is a text description based on DEF STAN 6- standard cables and standard pin-outs to match the connector. Variants according to customer requirements can be accommodated, though the part numbering will be different and will be generated at the time of an order. Short run cables can be made up to suit customer requirements. Part number structure description and example for standard M Series cable assemblies Type Size/series Contact Primary model Second model Lengths in metres. configuration connector connector Decimals of a ("XXX" if none metre preceded by "-" UKS. 0M 0 FGN PHN 00 Examples Part number example Description UKS.M08FGNPHN00 UKS.M0FGNPHN00 UKS.M9EGNXXX-05 FGN.M.08.XLC terminated to PHN.M.08.X on a 0m length of cable to DEF STAN 6- construction (7--8C) and pin-out FGN.M.08.XLC terminated to PHN.M.08.X on a 0m length of cable to DEF STAN 6- construction (6--8C) and pin-out EGN.M.9.X terminated to a 50mm length of cable to DEF STAN 6- construction (7--0C) and pin-out Please contact uksales@lemo.com or phone for further information. LEMO UK Ltd 0 North Street, Worthing, West Sussex, BN DU. Tel: (+ 90) 5 Fax: (+ 90) 0 6 uksales@lemo.com LEMO S.A. Chemin de Champs-Courbes 8 P.O. Box 9, CH-0 Ecublens, Switzerland Tel (+ ) Fax (+ ) info@lemo.com LEMO Worldwide AUSTRIA LEMO Elektronik GesmbH Tel: (+ ) CHINA LEMO Trading (Shanghai) Co., Ltd. Tel: (+86 ) DENMARK LEMO DENMARK A/S Tel: (+5) FRANCE LEMO FRANCE Sàrl Tel: (+ ) GERMANY LEMO Elektronik GmbH Tel: (+9 89) 77 0 HONG KONG LEMO Hong Kong Ltd. Tel: (+85) HUNGARY REDEL Elektronika Kft Tel: (+6 ) 7 0 ITALY LEMO ITALIA srl Tel: (+9 0) JAPAN LEMO JAPAN Ltd Tel: (+8 ) 5 9 NETHERLANDS/BELGIUM/ LUXEMBURG LEMO Connectors Benelux Tel: (+) NORWAY/ICELAND LEMO NORWAY A/S Tel: (+7) SPAIN/PORTUGAL IBERLEMO S.A. Tel: (+ 9) SINGAPORE LEMO Asia Pte Ltd Tel: (+65) SWEDEN/FINLAND LEMO Nordic AB Tel: (+6 8) SWITZERLAND LEMO VERKAUF AG Tel: (+ ) USA LEMO USA Inc. Tel: (+ 707) (+ 800) 5 66 LEMO Distributors AUSTRALIA BRAZIL CANADA CZECH REPUBLIC GREECE INDIA ISRAEL NEW ZEALAND PHILIPPINES? POLAND RUSSIA? SINGAPORE? SOUTH AFRICA SOUTH KOREA TAIWAN THAILAND TURKEY UKRAINE April 0

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