Connectors & Disconnects

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Applications

Typical applications include:

  • Satellite, spacecraft and payloads
  • Stage separation
  • Umbilical disconnects
  • Panel disconnect assemblies
  • Harsh environments

Key Features

  • Zero, positive, or negative separation force
  • Mounts from rear of panel or bracket
  • Tolerates wide range of linear and angular misalignment permitting blind engagement
  • Standard MIL-DTL-38999 inserts
  • Full range of keying configurations
  • Service Class H
  • Utilizes MIL-C-39029 pin and socket contacts
  • AS85049 compatible backshell
  • Backshell hardware available
  • Complete harness and disconnect assemblies available
  • ZSF100 series mates with our Model DF200 and 201 dead face connectors
  • Absolute electrical isolation prior to separation at the separation plane
 

Overview

NEA provides a highly customizable line of electrical In-Flight Disconnects (IFDs) for satellites, spacecraft, rocket stage and umbilical separation.  The connectors are highly customizable and can be provided with MIL standard inserts.  The connectors can be provided with Zero Separation Force (ZSF) features that can be tuned to specific positive, zero or negative separation forces.  Dead Face (DF) connectors are also available that provide electrical isolation prior to separation.  The DF connectors are designed to work with NEA’s ZSF connectors.

Principle of Operation

NEA’s electrical In-Flight Disconnects utilize industry standard MIL-DTL-38999 inserts and MIL-C-39029 pin and socket contacts that are housed in a custom shell that provides the zero separation force and dead face functionality.

NEA ZSF connectors feature a set of stainless steel kickoff springs that are custom configured to meet the specific force profile required.  Each mated connector pair is factory calibrated to compensate for connector pin engagement and other retention forces, assuring precise and smooth separation.

NEA DF connectors have an internal shuttle that disconnects and isolates electrical signals prior to physical separation at the separation plane, assuring upstream integrity of electrical interfaces, even during harsh environmental conditions after separation. DF connectors are designed to work in conjunction with NEA’s ZSF connectors at the separation interface to provide a complete solution to stage separation.

IFD connectors feature a floating shell, eliminating jamming during mating and separation. Blind engagement of the plug and receptacle pairs is possible, since the connectors allow for linear and angular misalignment. Connectors can be mounted from the rear of the panel or bracket, allowing for ease of installation. All of the in-flight disconnects are backshell ready, and if required, backshells can be provided with the overall system.

Technical Advantages

NEA In-Flight Disconnect technology provides significant advantages.

Customization

NEA IFDs are built around industry standard connector inserts that allow NEA to offer a large range of possible configurations.  Since NEA designs and manufactures the connector shell we can tailor the features, separation forces and interface to specific requirements.  The ability to interface ZSF connectors with DF connectors provides additional possibilities to satisfy critical application requirements.

Low Risk

NEA’s flight heritage of In-Flight-Disconnect technology assures customers are taking the lowest risk approach.

Short Lead Time

NEA In-Flight Disconnects are a highly customizable flight proven solution that can be provided in a relatively short lead time.

Performance

NEA Zero Separation Force connectors can be precisely tuned to minimize their influence on payload trajectory.  NEA Dead Face connectors are designed to disconnect their conduction paths prior to complete separation assuring critical electronics are protected from harsh environments that might be encountered in application such as ocean splashdown and recovery.

Mechanical Interface

The mechanical interface of NEA's Connectors and Disconnects are compliant with MIL-DTL-38999.

Model ZSF and IFD Configurations

Connector Model
Style
MIL-DTL-38999
Mates With
Shell Size1
Insert Arrangement1
ZSF100P
Plug
17
25
8
7, 19, 24, 61, 62
DF200SS2
DF201SS2 & ZF202S
ZSF100
Plug
21
11, 16, 35, 41
ZSF200
IFD100
Plug
19
25
35
4, 20
IFD200
IFD200
ZSF200
Receptacle
21
11, 16, 35, 41
ZSF100
ZSF202S
Receptacle
25
62
ZSF100P
IFD200
Receptacle
19
25
35
4, 20
IFD100
IFD100
Notes:
1Existing shell sizes and insert arrangements shown.  Other MIL-DTL-38999 shell size and insert arrangements available.
2See data sheet for NEA Model DF200 and 201 dead face connectors

Model ZSF and IFD Technical Specifications

Parameter
Capability
Separation Force
0 N (0 lbf) (or adjustable to customer spec)
Engagement Force
90 N (20 lbf)
Linear Misalignment
0.76mm (0.03 in) min
Maximum Angular Misalignment
20° cone
Qualification Temperature Range1
-55°C to +200°C
Mass2
117 g (0.29 lb)
Notes:
1The values presented for qualification temperature range are not a measure of the limits of the device.
2Representative of ZSF100 and ZSF200 mated pair, 21-35 insert arrangement with electrical contacts. Contact NEA Electronics for other configurations.

Model DF Dead Face Connector Configurations

Connector Model
Style
MIL-DTL-38999
Mates With
Shell Size1
Insert Arrangement1
DF200SS
Receptacle
17
8
ZSF100P2
DF200SS, 201SS
Receptacle
25
7, 29, 24, 61, 90
ZSF100P2
Notes:
1Existing shell sizes and insert arrangements shown.  Other MIL-DTL-38999 shell size and insert arrangements available.
2See data sheet for NEA Model ZSF100 connectors

Model DF Technical Specifications

Parameter
Capability
Separation Force
0 N (0 lbf) (or adjustable to customer spec)
Engagement Force
90 N (20 lbf)
Linear Misalignment
0.76mm (0.03 in) min
Maximum Angular Misalignment
5° cone (half cone)
Qualification Temperature Range1
-55°C to +200°C at 10-4 Torr
Short Duration Firewall
1,343°C
Shock2
14,200 G peak
Random Vibration2
17 Grms, 180 sec per axis
Insulation Resistance
100MΩ min at 1500 VDC
Dielectric Withstanding Voltage
2mA max leakage at 1000 VAC
Shell to Shell Conductivity
10mV drop at 1A
Mass3
380 g (0.84 lb)
Notes:
1The values presented for qualification temperature range are not a measure of the limits of the device.
2Shock and random vibration testing performed in the mated and unmated configurations.
3Representative of DF200SS, 25-24 insert arrangement with electrical contacts. Contact NEA Electronics for other configurations.