MIL-DTL-55116 Audio Connectors

Comprehensive Technical Specification, Classifications, Mechanical/Environmental Characteristics & Specification Sheets Directory

1.  Scope & Electrical Ratings

This engineering guide summarizes the technical requirements of the MIL-DTL-55116 (formerly MIL-C-55116) specification. MIL-DTL-55116 covers waterproof, polarized, five-pin and six-pin electrical audio connectors (plugs and receptacles) designed for audio frequency circuits. Operating parameters specify a maximum potential of 60 volts RMS, a maximum current of 0.5 amperes, and an operating temperature range from -65°C to +125°C. Connectors feature keyway polarization and quick-connect J-slot or bayonet lock coupling.

2.  Connector Configurations & Mating Matrix

SlashSheetTypePinsTerminalsStrain Relief /MountingLegacyDesignatorMating Slash Sheets
MIL-DTL-55116/1Plug5Crimp SleeveWire Strain ReliefU-229 Type/9, /11, /13
MIL-DTL-55116/2Plug6Crimp SleeveWire Strain ReliefU-229 Type/10, /12, /14
MIL-DTL-55116/3Plug5Solder CupWire Strain ReliefU-229 Type/9, /11, /13
MIL-DTL-55116/4Plug6Solder CupWire Strain ReliefU-229 Type/10, /12, /14
MIL-DTL-55116/5Plug5Crimp SleeveMolded Strain ReliefU-182 Type/9, /11, /13
MIL-DTL-55116/6Plug6Crimp SleeveMolded Strain ReliefU-182 Type/10, /12, /14
MIL-DTL-55116/7Plug5Solder CupMolded Strain ReliefU-182 Type/9, /11, /13
MIL-DTL-55116/8Plug6Solder CupMolded Strain ReliefU-182 Type/10, /12, /14
MIL-DTL-55116/9Receptacle 5Solder Cup SpringPanel MountU-183 Type/1, /3, /5, /7
MIL-DTL-55116/10Receptacle6Solder Cup SpringPanel MountU-183 Type/2, /4, /6, /8
MIL-DTL-55116/11Receptacle5Crimp SleeveSpringWire Strain ReliefU-228 Type/1, /3, /5, /7
MIL-DTL-55116/12Receptacle6Crimp SleeveSpringWire Strain ReliefU-228 Type/2, /4, /6, /8
MIL-DTL-55116/13Receptacle5Solder Cup SpringWire Strain ReliefU-228 Type/1, /3, /5, /7
MIL-DTL-55116/14Receptacle6Solder Cup SpringWire Strain ReliefU-228 Type/2, /4, /6, /8
MIL-DTL-55116/15Receptacle6Solder Cup SpringWire Strain Relief (ON)ON Series(U-228)/2, /4, /6, /8
MIL-DTL-55116/16CapLanyard MountProtective CapAll M55116 Plugs/Receptacles

3.  Material Composition & Surface Coating Specifications

Component PartBase Material SpecificationSurface Coating / Plating Finish
Connector Shell (Metal)Stainless Steel (304 / 303 / SAE AMS 5639)Light abrasive blast finish type E300(MIL-DTL-14072)

MIL-DTL-55116 Reference Guide — For Engineering & Procurement Use

MIL-DTL-55116 AUDIO CONNECTORS — TECHNICAL SPECIFICATION                                                                                                                           

Component PartBase Material SpecificationSurface Coating / Plating Finish
Connector Shell (Aluminum)Aluminum / Aluminum AlloyDyed black finish type E-511 (MIL-DTL-14072)
Outer Shell CoveringGlass-filled Nylon 6, 6/10, or 6/12 (ASTM D6779)Molded Black Plastic
Insulator InsertDiallyl Phthalate Resin (SDG-F, GDI-30F, MDG perASTM D5948)Molded Resin (Unplated)
Electrical ContactsBrass UNS C36000, Temper H02 (ASTMB16/B16M)Gold plate (.000030 in. min) over Nickel (.0001 in.min)
Contact SpringsBeryllium Copper C17200 / C17300 (ASTMB197/B196)Silver plate (M351) or Gold over Silver (ASTMB488)
Locking PinsStainless Steel (Type 304 Condition B / Type 416)Hardened Stainless Steel
Bend Relief SpringStainless Steel Wire Composition 302 (ASTMA313)Chemical blackening, Class 3 or 4(MIL-DTL-13924)
Seals & O-RingsSynthetic Rubber (ASTM D2000)Molded Synthetic Elastomer

4.  Environmental Resistance & Engineering Parameters

Engineering RequirementSpecified Value / Operating RangeTest Standard / Condition
Operating Temperature-65°C to +125°CMIL-DTL-55116 General Requirement
Maximum Operating Voltage60 V rms maximum potentialMIL-DTL-55116D Section 1.1
Maximum Operating Current0.5 A maximum current per contactMIL-DTL-55116D Section 1.1
Contact Resistance≤ 0.050 Ω (terminal-to-terminal mated)MIL-DTL-55116D Section 3.5.3 / 4.7.3
Dielectric Withstanding (Sea Level)500 V rms (1 minute test)MIL-DTL-55116D Section 4.7.1.1
Dielectric Withstanding (High Alt)300 V rms at 3.4 in. Hg (50,000 ft altitude)MIL-DTL-55116D Section 4.7.1.2
Contact Spring Depression Force1.25 lbs. to 1.75 lbs. per non-rigid contactMIL-DTL-55116D Section 3.6.1
Total Spring Force (5 Pins)6.25 lbs. to 8.75 lbs. total depression forceMIL-DTL-55116D Section 3.6.1
Total Spring Force (6 Pins)7.50 lbs. to 10.50 lbs. total depression forceMIL-DTL-55116D Section 3.6.1
Thermal Shock / TemperatureCyclingMating & unmating capable during 5th cycleMIL-STD-202 Method 107 Condition A
Salt Spray Corrosion ResistanceNo base metal corrosion exposed (50 hrs test)MIL-STD-202 Method 101 Condition B
Humidity ResistanceMeets post-test dielectric & air leakage limitsECA/EIA-364-31 Method IV
Mechanical Drop Impact6 random drops from 6 ft. height onto fir/concreteMIL-DTL-55116D Section 4.9.3
Shell Compression / Crush Load500 lbs. load without structural deformationMIL-DTL-55116D Figure 3
Air Leakage / WaterproofImmersion2.5 psi internal pressure under waterMIL-DTL-55116D Section 3.6.2
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