Comprehensive Technical Specification, Classifications, Mechanical/Environmental Characteristics & Specification Sheets Directory
1. Document Scope and Series Overview
This report establishes the technical requirements and engineering standards for environment-resisting and hermetically sealed circular electrical connectors, contacts, and accessories as defined by MIL-DTL-83723H (including Amendment 4). These components are engineered for high-performance military and aerospace applications, supporting both crimp and solder terminations.
The specification categorizes connectors into three distinct series:
- Series I: Utilizing Type B (bayonet) coupling. These specification sheets have been officially cancelled and are superseded by MIL-DTL-26482 Series II.
- Series II: Utilizing Type T (threaded) coupling. These units are designed for intermateability with SAE-AS50151 (specifically SAE-AS34501, 34511, 34521, 34561, and 34591).
- Series III: Utilizing both Type T (threaded) and Type B (bayonet) coupling. These are intermateable with applicable MIL-DTL-26500 connectors. This series includes provisions for hermetic receptacles with nonremovable contacts.
2. Connector Classes and Physical Features
The following matrix details the mechanical and environmental classifications for MIL-DTL-83723 connectors. Per Table I, the self-locking feature for Type T plugs is subject to specific specification sheet availability.
| Class | Base Material / Shell Finish | Coupling | Contact Type | Special Features | Max Temp (°C) |
|---|---|---|---|---|---|
| A | Aluminum / Anodize (Nonconductive) | B / T | Crimp | Fluid Resistant Insert | 200 |
| G | Stainless Steel / Passivated | B / T | Crimp | Grounding Fingers | 200 |
| H | Cold Rolled Steel / Tin | B / T | Solder | Hermetic, Interfacial Seal | 150 |
| J | Cold Rolled Steel / Tin | B / T | Eyelet | Hermetic, Interfacial Seal | 150 |
| K | Stainless Steel / Passivated | T | Crimp | Firewall | 200 |
| L | Stainless Steel / Electrodeposited Nickel | T | Eyelet | Hermetic | 200 |
| M | Aluminum / Electrodeposited Aluminum | B / T | Crimp | Grounding, 500hr Salt Spray | 175 |
| N | Stainless Steel / Electrodeposited Nickel | T | Crimp/Solder/Eyelet | Firewall, Hermetic, Self-locking* | 200 |
| P | Stainless Steel / Passivated | B / T | Eyelet | Hermetic, Interfacial Seal | 200 |
| R | Aluminum / Electroless Nickel | B / T | Crimp | Grounding | 200 |
| S | Stainless Steel / Passivated | T | Crimp | Firewall, Grounding, Self-locking* | 200 |
| T | Aluminum / Nickel Fluorocarbon | B / T | Crimp | Grounding, 500hr Salt Spray | 175 |
| W | Aluminum / Cadmium (Olive Drab) | B / T | Crimp | Grounding, 500hr Salt Spray | 175 |
| Y | Stainless Steel / Passivated | B / T | Solder | Hermetic, Interfacial Seal | 200 |
| Z | Aluminum / Zinc Nickel Alloy (Black) | B / T | Crimp | Grounding, 500hr Salt Spray | 175 |
*Note: Refer to applicable specification sheets for self-locking feature availability.
3. Material and Finish Specifications
3.1 Shell Materials
- Aluminum Alloy: Utilized for Classes A, M, R, T, W, and Z. Standard fabrication involves impact extrusion or machining.
- Corrosion-Resistant Steel (Stainless): Utilized for Classes G, K, N, S, Y, L, and P. These materials are selected for high-temperature and firewall applications.
- Cold Rolled Steel: Specifically restricted to Hermetic Classes H and J.
3.2 Finish and Corrosion Protection
The specification mandates 500-hour salt spray resistance for Classes M, T, W, and Z. Classes M, T, and Z are further required to be nonreflective. Finish thicknesses are strictly controlled, notably Class N and L nickel plating at 0.0001-inch minimum.
3.3 Contact Metallurgy and Plating
- Hermetic Contacts: Constructed from ferrous alloy and gold-plated per MIL-DTL-45204.
- Plating Thickness: A minimum gold thickness of 0.000050 inch (0.00127 mm) is required for hermetic contacts.
- Pure Tin Prohibition: To prevent “tin whiskers,” the use of pure tin as a final finish or underplate is prohibited. Tin content must not exceed 97% by mass and must be alloyed with a minimum of 3% lead.
4. Design and Coupling Mechanics
4.1 Mechanical Operation
Type B (Bayonet) connectors utilize a grooved coupling ring achieving full engagement within 120 degrees of rotation. Type T (Threaded) connectors utilize threaded rings; Series III Type T plugs often feature anti-rotation self-locking mechanisms to eliminate safety wire requirements.
4.2 Engagement and Disengagement Torque
Table IV: Type B (Bayonet) Torque Limits
| Shell Size | Max Engagement/Disengagement (lb-in) | Min Disengagement (lb-in) |
|---|---|---|
| 08 | 8 | 2 |
| 10 | 12 | 2 |
| 12 | 14 | 2 |
| 14 | 20 | 4 |
| 16 | 24 | 4 |
| 18 | 28 | 4 |
| 20 | 32 | 6 |
| 22 | 36 | 7 |
| 24 | 44 | 7 |
Table V: Type T (Threaded) Torque Limits
| Series | Shell Size | Max Coupling (lb-in) | Min Uncoupling (lb-in) | Max Uncoupling (lb-in) |
|---|---|---|---|---|
| II | 08 / 8S | 12 | 8 | 20 |
| II | 10 / 10S / 10SL | 14 | 8 | 25 |
| II | 12 / 12S / 13 | 16 | 10 | 28 |
| II | 14 / 14S / 15 | 20 | 12 | 35 |
| II | 16 / 16S / 17 | 24 | 16 | 40 |
| II | 18 | 30 | 22 | 45 |
| II | 20 | 40 | 28 | 52 |
| II | 22 | 46 | 35 | 65 |
| II | 24 | 55 | 40 | 75 |
| II | 28 | 66 | 50 | 90 |
| II | 32 | 78 | 60 | 105 |
| II | 36 | 93 | 65 | 115 |
| II | 40 | 106 | 70 | 125 |
| III | 08 | 11 | 5 | 18 |
| III | 10 | 13 | 6 | 23 |
| III | 12 | 14 | 6 | 25 |
| III | 14 | 18 | 8 | 32 |
| III | 16 | 21 | 9 | 36 |
| III | 18 | 27 | 11 | 40 |
| III | 20 | 31 | 13 | 45 |
| III | 22 | 32 | 13 | 59 |
| III | 24 | 46 | 19 | 63 |
4.3 Coupling Assurance and Visual Indicators
- Bayonet Assurance: Receptacle bayonet pins feature contrasting colors (blue, yellow, or orange) visible through ring slots when locked.
- Threaded Assurance: Series III receptacles utilize a red band that is fully obscured only when the connector is completely mated.
- Rear Release Identification: Crimp contact shells must feature a blue color band to signify a rear-release retention system.
5. Contact and Wiring Configurations
5.1 Wire Accommodation (Table III)
| Contact Size | Min Outer Diameter (in) | Max Outer Diameter (in) |
|---|---|---|
| 20 | .040 (1.02 mm) | .083 (2.11 mm) |
| 16 | .053 (1.35 mm)* | .103 (2.62 mm) |
| 12 | .097 (2.46 mm) | .158 (4.01 mm) |
| 8 | .164 (4.17 mm) | .255 (6.48 mm) |
| 4 | .288 (7.32 mm) | .370 (9.40 mm) |
| 0 | .415 (10.54 mm) | .550 (13.97 mm) |
*Note: Series II size 16 minimum OD is .068 (1.73 mm).
5.2 Mechanical Performance and Tooling
- Contact Stability (Table XI): Max displacement for size 20 is .038 in; sizes 16 and 12 are .062 in.
- Axial Load: Under retention testing, axial displacement shall not exceed .012 inch (0.30 mm).
- Insertion/Removal Forces: Size 20/16 max force is 20 lbs; size 12 is 30 lbs.
- Tooling: SAE-AS81969/14 (sizes 20-8) and SAE-AS81969/29 (sizes 4-0) are required. One tool must be enclosed in every unit package.
6. Environmental and Performance Parameters
6.1 Dielectric Withstanding Voltage (Table VII)
| Altitude | Series II (Inst) | Series II (A) | Series II (D) | Series II (E) | Series II (B) | Series II (C) | Series III (I) | Series III (II) |
|---|---|---|---|---|---|---|---|---|
| Sea Level | 1000 | 2000 | 2800 | 3500 | 4500 | 7000 | 1500 | 2300 |
| 50,000 ft | 400 | 600 | 675 | 750 | 825 | 975 | 500 | 750 |
| 70,000 ft | 260 | 360 | 400 | 440 | 480 | 560 | 375 | 500 |
| 110,000 ft | 200 | 200 | 200 | 200 | 200 | 200 | 200 | 200 |
6.2 Contact Resistance and Shielding
- Millivolt Drop (Table VI): Initial max drop for size 20 is 105mV; sizes 16 and 12 are 95mV.
- RFI Shielding (Table IX):
- 100 MHz: 65 dB
- 200 MHz: 60 dB
- 300 MHz: 55 dB
- 400 MHz: 55 dB
- 600 MHz: 50 dB
- 800 MHz: 45 dB
- 1000 MHz: 45 dB
- 1000 MHz: 45 dB
6.3 Firewall and Hermetic Integrity
- Firewall Test: 20-minute flame resistance. Continuity must be maintained for the first 5 minutes at currents ranging from 7.5A (size 20) to 245A (size 0).
- Hermetic Leakage: Shall not exceed 0.01 micron ft³/h (1 x 10⁻⁷ cm³/s).
- Coupling Pin Strength: Receptacle bayonet pins must withstand 50 ± 5 lbs axial load.
7. Part or Identifying Number (PIN) Structure
The PIN identifies the specific configuration of the assembly.
Example: M83723/72 W 08 08 N
- M83723/72: Specification Sheet Number.
- W: Class Designator (e.g., Aluminum/Cadmium).
- 08: Shell Size (2 digits, zero-padded; may include additional letters).
- 08: Insert Arrangement (2 digits, zero-padded).
- N: Polarizing Position (e.g., N, 1, 2, 3, 4, 5, 6, 7, 8, 9, Y).
8. Engineering Standards References
- MIL-STD-1554 / MIL-STD-1651: Insert Arrangements.
- MIL-HDBK-454: General Guidelines for Electronic Equipment.
- SAE-AS39029: General Specification for Contacts.
- SAE-AS81969: Installing and Removal Tools.
- EIA-364: Electrical Connector Test Procedures.
- ASTM-B841: Zinc Nickel Alloy Plating Requirements.