What are MIL-DTL-5015 Connectors? Part Numbers, Specs, and Everything You Need to Know

In the demanding world of industrial and military applications, reliable connectivity is important. When systems operate in harsh environments, facing vibration, shock, and extreme temperatures, normal connectors simply will not work. This is where the robust and time-tested MIL-DTL-5015 connector comes in. In this comprehensive guide, we'll delve deep into the world of MIL-DTL-5015 connectors. We’ll explore their fundamental concepts, key specifications, applications, contact arrangements, part numbers, and so on.

In this section, I will introduce you to the MIL-DTL-5015 connector, covering its fundamental concepts, standards, historical development, and common applications.

The MIL-DTL-5015 connector (also known as the MS5015 connector) is a circular electrical connector designed for high-reliability applications. Its rugged construction and durable design make it an ideal choice for environments where less robust connectors would fail.

Click here to view Metabee’s MIL-DTL-5015 connectors

The MIL-DTL-5015 standard (formerly known as MIL-C-5015) is a United States military specification. It outlines the design, performance, and testing requirements for these connectors. Since its inception, this standard has become a benchmark for durable and reliable connectivity, extending its influence far beyond military applications into various industrial sectors. Over the years, the standard has seen revisions and updates to adapt to evolving technological needs while maintaining its core principles of robustness and dependability.

The history of MIL-DTL-5015 connectors:

l  Early 1930s: Cannon (now ITT Cannon) was contracted by Douglas Aircraft Company to develop electrical circular connectors for their DC-1, DC-2, and DC-3 aircraft platforms. This marked the initial development of connectors that would later form the basis of the MIL-DTL-5015 standard.

l  1939: The original AN9534 standard was released. This is considered the direct precursor to the MIL-C-5015 specification. Cannon's Type AN (Army-Navy) series became the industry benchmark, setting the standard for modern circular connectors.

l  1949: The MIL-C-5015 standard was officially released. The standard was subsequently updated three times, in 1958, 1971, and 1976.

l  March 1994: The final revision of MIL-C-5015, designated MIL-C-5015G, was published.

l  May 2000: Six years after its publication, MIL-C-5015G was officially superseded by MIL-DTL-5015H. This marked a shift in designation from "MIL-C" (Military Specification - Connector) to "MIL-DTL" (Military Detail Specification).

l  December 2009: According to the U.S. Department of Defense's initiative to favor industry technical standards, MIL-DTL-5015 was superseded by SAE-AS50151.

Please note that while the U.S. Department of Defense has officially renamed the MIL-DTL-5015 standard to SAE-AS50151, most users and manufacturers still refer to these connectors as "MIL-DTL-5015 connectors." Additionally, some manufacturers and users continue to use the older designation "MIL-C-5015 connectors," while others may call them "MS5015 connectors."

For consistency, Metabee uniformly refers to this product line as "MIL-DTL-5015 connectors."

The MIL-DTL-5015 connector has 5 key features, including

l  Ruggedness and Durability: MS5015 connectors are designed to endure significant mechanical stress, including high levels of vibration and shock encountered in heavy machinery and military vehicles. Their robust shells, typically made from durable aluminum alloys, provide a protective barrier for the internal contacts and insulators.

l  Threaded Coupling: The threaded coupling mechanism of MS5015 connectors provides a secure and positive locking action. This ensures a reliable electrical connection that resists accidental disconnection caused by vibration, movement, or accidental bumps.

l  Solder or Crimp Contacts: These connectors support both solder and crimp contacts for varied wiring needs. Solder connections provide a strong and reliable electrical and mechanical bond. Crimp connections offer faster and more consistent termination, especially in high-volume production environments or for field repairs.

l  Environmental Resistance: Many MIL-DTL-5015 connectors are designed to withstand harsh environmental conditions. Features like robust shell interfaces provide significant resistance to moisture ingress, dust, and temperature extremes. Some variations offer even higher levels of environmental protection, making them suitable for fully exposed outdoor or marine applications.

l  Versatility: These connectors are available in 19 shell sizes (specified as size 08 through 40) with about 160 approved insert arrangements to accommodate diverse application needs. The number of contacts ranges from 1 to 85. Whether the application requires a simple power connection or a complex array of signal and power lines, there's likely a MIL-DTL-5015 configuration to meet the need. This versatility has contributed significantly to its widespread adoption across different industries.

The application scenarios for MIL-DTL-5015 connectors are vast and varied. In the military sector, they are crucial in:

l  Aerospace: Connecting critical systems in aircraft and helicopters.

l  Ground Vehicles: Ensuring reliable power and signal transmission in tanks and other military vehicles.

l  Communication Systems: Providing robust connections for radios, radar, and other communication equipment.

Beyond the military, these connectors are indispensable in numerous industrial applications, including

l  Heavy Machinery: Connecting sensors, actuators, and control systems in construction and agricultural equipment.

l  Transportation: Used in railway systems, marine vessels, and other forms of heavy transport.

l  Oil and Gas: Providing reliable connections in demanding offshore and onshore environments.

MIL-DTL-5015 defines 4 distinct product categories, referred to as series. While connectors from the first three series are mutually compatible, their individual components vary.

The following table outlines these four series:

You can buy MIL-DTL-5015 Series I connectors on our website. For connectors or accessories in other series, please contact us.

The MIL-DTL-5015 Series I connectors offer versatility through 5 standard shell styles. Each style is designed for specific mounting and interconnection needs:

l  MS3100A wall mounting receptacles: These receptacles are suitable for secure attachment to a panel or the wall of an enclosure. They typically feature a flange with mounting holes. MS3100A receptacles mate with MS3106A and MS3108A plugs.

l  MS3101A cable connecting receptacles: This receptacle is designed to mate with a plug, creating a robust and environmentally sealed cable-to-cable connection. They often feature a threaded coupling nut to secure the connection with the plug. These are essential for extending cable runs or creating detachable cable assemblies in harsh environments. MS3101A plugs mate with MS3106A and MS3108A receptacles.

l  MS3102A box mounting receptacles: Similar in function to wall mounting receptacles, box mounting receptacles often feature a square or rectangular flange with mounting holes. This flange design can provide a larger surface area for mounting and may be preferred in applications where a more substantial mounting interface is required for added stability. MS3102A receptacles mate with MS3106A and MS3108A plugs.

l  MS3106A straight plug: These plugs feature a cylindrical body with a threaded coupling nut. They are typically used for creating cable-to-cable connections when mated with an MS3101A receptacle or for connecting directly to a receptacle mounted on equipment. MS3106A plugs mate with MS3100, MS3101, and MS3102 receptacles.

l  MS3108A right-angle plugs: These plugs are used where space is limited and wires must be brought at abrupt angles. MS3108A plugs mate with MS3100, MS3101, and MS3102 receptacles.

Choosing the correct MIL-DTL-5015 connector hinges on a careful evaluation of its performance characteristics across electrical, mechanical, environmental, and material aspects.

The electrical performance of a connector dictates its ability to conduct electrical current and signals efficiently and safely. Key electrical parameters for MIL-DTL-5015 connectors include:

This specifies the maximum continuous voltage that the connector can safely withstand without the risk of dielectric breakdown or arcing between contacts or between contacts and the shell. Under normal ambient temperatures, the rated voltage of MS5015 connectors is 500V. At high temperatures, their rated voltage is 250V.

l  Normal temperatures: 500V

l  High temperatures: 250V

Each contact within a MIL-DTL-5015 connector is designed to carry a specific maximum continuous current. This rating is primarily determined by the contact's material, size, and the resulting heat dissipation. MS5015 connector current ratings:

l  16 AWG: 13A

l  12 AWG: 23A

l  8 AWG: 46A

l  4 AWG: 80A

l  0 AWG: 150A

This parameter measures the opposition to the flow of electrical current through the mated contact interface. Low contact resistance is desirable as it minimizes voltage drop and power loss across the connection, leading to more efficient system operation and reduced heat generation. The maximum contact resistance of the MS5015 connector is 10 milliohms.

This indicates the ability of the insulating materials to prevent the leakage of electrical current between adjacent contacts or between a contact and the conductive shell. High insulation resistance, usually measured in megohms, is essential for maintaining electrical isolation and preventing short circuits, especially in high-voltage applications. The MS5015 connector has an insulation resistance of 5000 megohms or higher.

MIL-DTL-5015 connectors are built to endure physical stresses encountered in demanding applications. Key mechanical performance parameters include:

Metabee offers two series of MIL-DTL-5015 connectors: the MS Series, which features a threaded coupling mechanism, and the CA Series, which utilizes a bayonet coupling mechanism.

l  MS Series: threaded coupling mechanism

l  CA series: bayonet coupling mechanism

This refers to the number of times a connector can be mated and unmated without significant degradation in its electrical or mechanical performance. MIL-DTL-5015 connectors are typically designed for 500 mating cycles.

While the MS3108 series connectors utilize a 90-degree elbow, the remaining types – MS3100, MS3101, MS3102, and MS3106 – all feature a straight configuration.

l  MS3100, MS3101, MS3102, and MS3106: Straight

l  MS3108: Right Angle

MS5015 connectors frequently utilize wire gauges within the range of 0 to 16 AWG, including sizes 0, 4, 8, 12, and 16 AWG.

A hallmark of MIL-DTL-5015 connectors is their ability to perform reliably in diverse and often challenging environmental conditions. Key environmental performance parameters include:

This specifies the range of ambient temperatures within which the connector is designed to operate without significant degradation in performance or material properties. MIL-DTL-5015 connectors are often designed for wide temperature ranges, from -55°C to 125°C.

The IP rating indicates the level of protection the connector offers against the intrusion of solid objects (like dust) and liquids (like water). Typically, MS5015 connectors have an IP67 rating.

The materials used in the construction of MIL-DTL-5015 connectors directly impact their performance and durability.

MIL-DTL-5015 connectors typically feature aluminum alloy shells. They offer an excellent combination of strength and lightweight properties. Cadmium plating, finished with an olive drab chromate conversion coating, provides superior corrosion resistance.

Contacts are typically made from high-conductivity copper alloys to ensure efficient current flow. To prevent corrosion and improve conductivity, the contacts are often plated with gold or silver. Gold plating offers excellent resistance to corrosion and low contact resistance, making it ideal for critical signal applications. The solder ends of the contacts are tin-plated to enhance conductivity and solderability.

The insulator, typically made from durable synthetic rubber, provides electrical insulation between the contacts and the shell, as well as mechanical support for the contacts. The choice of insulator material influences the connector's dielectric properties, temperature range, and resistance to chemicals and moisture.

METABEE utilizes high-quality materials in the production of their MIL-DTL-5015 connectors to ensure optimal performance.

The table below lists the key specifications and materials for MIL-DTL-5015 connectors.

The key positions on a MIL-DTL-5015 connector refer to a system of polarization designed to ensure correct mating between the plug and receptacle. It prevents accidental cross-mating of connectors with the same insert arrangement. This is achieved through a keyway on the receptacle shell and a corresponding key on the plug shell. These mechanical features must align for the connectors to fully mate.

Beyond the standard key position (often referred to as "normal"), MIL-DTL-5015 connectors offer alternate keying positions. These are achieved by rotating the insert within the shell to different angular orientations. These alternate positions are typically designated by letters, including W, X, Y, and Z.

The contact arrangement of a MIL-DTL-5015 connector is a critical factor in determining its functionality and suitability for a specific application. It essentially defines the internal architecture of the connector. It specifies the number, size, and spatial organization of the conductive contacts within the insulator body. Think of the contact arrangement as the connector's internal wiring blueprint, dictating how many individual electrical pathways it can accommodate and their respective capabilities.

The primary purpose of contact arrangements is to provide a standardized and organized way to interface with multiple circuits through a single, robust connector. Instead of having numerous individual connections, an insert arrangement consolidates these into a manageable and reliable interface. This simplifies wiring, reduces the potential for errors during assembly and maintenance, and contributes to the overall ruggedness of the system.

The image below illustrates the contact arrangement for some MS5015 connector models.

Click here to download the METABEE MIL-DTL-5015 Connectors Catalog to view all Contact Arrangement diagrams.

At Metabee, we understand the critical need for reliable connectivity solutions. Our comprehensive MIL-DTL-5015 connector catalog offers a wide range of series, shell styles, and insert arrangements to meet your diverse application requirements. We are committed to providing high-quality connectors that adhere to the MIL-DTL-5015 standard, ensuring rugged performance and long-term reliability.

Download our catalog today to explore our extensive selection and find the perfect MIL-DTL-5015 connector for your project!

The MIL-DTL-5015 part numbering system provides a structured way to identify the specific characteristics of a connector. Understanding this system is key to accurately specifying and ordering the exact connector you need. While specific formats can vary slightly between manufacturers, the underlying logic remains consistent:

A typical MIL-DTL-5015 part number breaks down into several key components, each providing crucial information about the connector's features. Let's dissect a representative example:

Example Part Number: MS3106A20-29S

MS: This prefix generally indicates that the connector conforms to a Military Standard specification. In this case, it signifies adherence to the MIL-DTL-5015 standard (or its predecessor, MIL-C-5015).

l  MS: designates Military Standard

l  CA: Bayonet Type

3106: This series designator identifies the shell style. 3106 commonly refers to a straight plug with a standard coupling thread. Different numbers in this position indicate other shell styles.

l  3100: wall mounting receptacle

l  3101: cable connecting plug

l  3102: box mounting receptacle

l  3106: straight plug

l  3108: 90° Right angle plug

A: This letter often denotes the service class. For instance, "A" means “General purpose, Solid Endbell”. The exact meaning of this letter can vary between manufacturers and specific series.

l  A: General purpose, Solid Endbell

l  E: Environmental resisting, with grommet seal & strain relief back shell

l  F: Environmental resistance with grommet seal & strain relief back shell, 3106F, and 3108E style include a front ‘O’ ring seal

l  R: Environmental resisting with grommet seal, lightweight and shorter, overall length 310R style includes a front ‘O’ ring seal

20-29: This is the insert arrangement designator. The first number ("20") typically indicates the **shell size** (the nominal diameter of the connector shell), and the second number ("29") specifies the **arrangement of contacts** within that shell size (number of contacts and their sizes). You'll need to refer to insert arrangement diagrams to see the specific contact layout for "20-29."

S: This suffix indicates the contact gender. "S" commonly stands for socket (female) contacts. A "P" in this position would indicate pin (male) contacts.

l  P: designates pin contact, (+) Male

l  S: designates socket contact, (-) Female

The diagram below shows the breakdown of the MIL-DTL-5015 connector part number.

To better understand MS5015 connector part numbers, you need to download the METABEE MIL-DTL-5015 Connectors Catalog.

A range of accessories enhances the functionality and durability of MIL-DTL-5015 connectors:

Dust caps are simple yet indispensable accessories designed to protect the mating interfaces of MIL-DTL-5015 connectors when they are not connected. They come in two main types:

l  Dust Caps for Plugs (MS25042): These caps are designed to protect the MS3106 and MS3108 plugs.

l  Dust Caps for Receptacles (MS25043): These caps are designed to protect MS3100, MS3101, and MS3102 receptacles.

l  Cable Clamps (MS3057): MS3057-style cable clamps were designed for use with jacketed cable or wire protected by tubing.

l  Telescoping Bushing (MS3420): Telescoping grand bushings (used with 3057 clamps) keep dirt, oil, and moisture out of the endbell.

l  Sealing Gasket (BMA31): The flat gasket of synthetic rubber material is provided to take complete advantage of waterproof and pressure-sealing features. It is used with the flange-mounted receptacle.

While the MIL-DTL-5015 connector stands as a robust and widely utilized solution, the landscape of military standard connectors encompasses a diverse array of designs tailored to specific performance requirements and application niches. Here's a brief introduction to two other prominent military connector standards: MIL-DTL-38999 and MIL-DTL-26482.

MIL-DTL-38999 connectors represent a significant step up in performance and sophistication compared to MIL-DTL-5015 connectors. These connectors are designed for the most demanding aerospace, military, and high-reliability industrial applications where size, weight, and extreme environmental performance are paramount.

Click here to view METABEE MIL-DTL-38999 connectors.

MIL-DTL-26482 connectors offer a more compact and lightweight alternative for applications that require reliable performance but may not face the extreme demands of MIL-DTL-38999 environments. They are widely used in both military and industrial applications where size and weight savings are important.

Click here to view METABEE MIL-DTL-26482 connectors.

The enduring legacy and widespread use of MIL-DTL-5015 connectors have led to several prominent manufacturers establishing themselves as key players in their production. These companies have a long history of supplying high-quality, reliable connectors that adhere to the stringent requirements of the MIL-DTL-5015 standard. When sourcing MIL-DTL-5015 connectors, these manufacturers are often the go-to choices due to their reputation, extensive product offerings, and commitment to quality.

Amphenol is a global leader in interconnect solutions, and their Amphenol 97 series is a widely recognized and respected line of MIL-DTL-5015 connectors. Amphenol offers a vast array of shell styles, insert arrangements, and material options within this series, catering to a broad spectrum of military and industrial applications.

Another historical powerhouse in the connector industry, ITT Cannon's CA/MS series is synonymous with the MIL-DTL-5015 standard. Their connectors are known for their robust construction and versatility, serving a wide range of demanding applications.

Metabee, a chinese manufacturer with a significant global presence, also offers a comprehensive range of MIL-DTL-5015 compliant connectors. Our products are known for their reliability and performance in harsh environments, serving both military and industrial sectors. Our products not only deliver reliable performance but also boast a strong price advantage because we sell directly from the factory, thereby avoiding multiple intermediaries.

MIL-DTL-5015 connectors stand as a testament to robust and reliable connectivity in demanding environments. Their rugged design, versatile configurations, and adherence to stringent military standards have made them a cornerstone in numerous military and industrial applications worldwide. By understanding their key features, specifications, and their part numbers, you can ensure that your systems are equipped with connectors that deliver unwavering performance and longevity. Explore Metabee's MIL-DTL-5015 catalog today and discover the ideal MIL-DTL-5015 connector to unlock the full potential of your applications.

l  MIL-DTL-5015 Connectors

l  MIL-DTL-38999 Connectors

l  MIL-DTL-26482 Connectors

If you have any questions or would like to learn more about our products, please contact us or email us at info@metabee.com.