YF8-36ZK or TJ Separation (Breakaway) Electrical Connector

YF8-36ZK/TJ Separation (Breakaway) Electrical Connector | Handwheel Coupling with High-Current Contacts & Fire Resistance

The YF8‑36ZK/TJ Separation Connector series delivers unmatched power density and fire safety in a single, handwheel‑operated breakaway interface. With four Φ10 contacts capable of 200 A each and thirty‑two Φ1.5 signal contacts (10 A), this connector handles both primary power and multiple control circuits in one compact package. The handwheel coupling ensures secure mating even in tight spaces, while the 850 °C / 80 s fire resistance guarantees survival in post‑crash or engine fire scenarios. Solder termination, rigorous vibration/shock qualification, and a calibrated 100–150 N separation force make the YF8‑36 the preferred choice for launch vehicles, aircraft pylons, and naval systems where high power and fire safety are paramount.

Product Descriptions from the Supplier

The YF8‑36ZK/TJ Separation (Breakaway) Electrical Connector is a high‑performance interconnect solution engineered for applications demanding both high‑current power transmission and multi‑circuit signal capacity within a single, fire‑resistant separation interface. Fully compliant with enterprise standard Q/21EJ2079, this connector features 36 solder‑terminated contacts: thirty‑two Φ1.5 contacts rated at 10 A each (≤4 mΩ) for signal and low‑power circuits, and four Φ10 power contacts rated at 200 A each (≤5 mΩ) for primary power distribution.

A standout feature is the handwheel coupling mechanism, which allows positive mating and demating without requiring axial space for a traditional coupling ring—ideal for confined installations such as launch vehicle umbilical panels or aircraft weapons pylons. The connector is also certified to withstand 850 °C for 80 seconds while maintaining insulation resistance ≥20 MΩ, meeting stringent fire safety requirements for aerospace and defense applications.

All contacts are terminated via solder cups, a dependable, field‑serviceable method suitable for prototyping, maintenance, and production. The mechanical separation mechanism is calibrated to release with a force of 100–150 N, ensuring a secure hold during operation while guaranteeing positive separation when commanded.

Engineered for extreme environments, the YF8‑36 operates from -55 °C to +125 °C and survives severe dynamic conditions: random vibration of 0.4 G²/Hz (26.4 Grms), sinusoidal vibration of 200 m/s², shock of 1200 m/s², and constant acceleration of 500 m/s². With a mechanical life of 500 mating cycles, these connectors are suitable for ground testing and operational reuse.

Dielectric withstanding voltage is 1500 V AC rms at sea level, derated to 500 V under low temperature and humidity, and 200 V at low pressure. Insulation resistance exceeds 1000 MΩ at room temperature, remains ≥500 MΩ at temperature extremes, and stays ≥20 MΩ after humidity and rain testing, ensuring long‑term reliability.

Available in two configurations:

• YF8‑36TJ: Plug (cable‑attached half) with pin contacts
• YF8‑36ZK: Receptacle (panel‑mount half) with socket contacts

Typical applications include launch vehicle umbilicals, aircraft external store separation, naval deck interfaces, and any system requiring high power, fire resistance, and handwheel operation.

Specifications

Applications

• Launch Vehicles: High‑power umbilical disconnects with handwheel operation.
• Aircraft: External store separation, wing pylon interfaces requiring fire safety.
• Naval Systems: Deck-mounted separation connectors with high current capacity.
• Missile Systems: Canister launch interfaces with combined power/signal needs.
• Industrial: High‑power emergency disconnect systems in fire‑hazard areas.
• Energy: Battery and power distribution separation in harsh environments.

Functionality

• Handwheel Coupling: Enables secure mating in confined spaces without axial pull‑up.
• High‑Current Power Contacts: Four Φ10 contacts handle 200 A each for main power.
• Multi‑Signal Capacity: Thirty‑two Φ1.5 contacts (10 A) for control and monitoring.
• Fire Resistance: Withstands 850 °C for 80 s, maintaining insulation ≥20 MΩ.
• Controlled Separation Force: Calibrated 100–150 N breakaway ensures positive release.
• Solder Termination: Reliable, field‑serviceable connections for all contacts.
• Environmental Robustness: Withstands extreme vibration, shock, and acceleration.

Key Features

• Hybrid High‑Current & Signal Design: 200 A power plus 10 A signal circuits in one connector.
• Handwheel Operation: Ideal for tight spaces where traditional coupling rings cannot be used.
• 850°C Fire Resistance: Certified for post‑crash fire safety (aerospace/defense requirement).
• High Contact Density: 36 total contacts in a rugged package.
• Aerospace‑Grade Qualification: Tested to rigorous vibration, shock, and acceleration standards.
• Solder Termination: Simple, reliable, and field‑serviceable without special tooling.
• 500‑Cycle Life: Suitable for ground testing and multiple mission uses.
• Wide Temperature Range: -55 °C to +125 °C suits harsh environments.

Custom Design

The YF8‑36 platform can be adapted to meet unique mission requirements:

• Custom Contact Mix: Adjust the quantity of Φ1.5 and Φ10 contacts, or add other sizes.
• Separation Force Adjustment: Modify breakaway force for specific release requirements.
• Enhanced Fire Rating: Higher temperature or longer duration available on request.
• Special Materials: Select shell finishes for enhanced corrosion resistance.
• Cable Assembly Integration: Complete harness solutions with soldered contacts and overmolding.
• Non‑Standard Testing: Additional screening for high‑reliability programs.

Why Choose MXTD​​​​​​​

At MXTD, we specialize in separation connectors that push the limits of power, density, and safety. The YF8‑36 series exemplifies our engineering excellence—combining 200 A power contacts, 36‑circuit density, handwheel operation, and 850 °C fire resistance in a single, field‑proven package. Manufactured under strict enterprise standard Q/21EJ2079, each YF8‑36 undergoes comprehensive testing including contact resistance verification, separation force calibration, and fire certification. Our team brings decades of experience in aerospace and naval separation systems, working closely with customers to ensure that every interface meets the unique demands of the mission. When you choose MXTD, you're partnering with a dedicated team focused on the success of your program, from prototype to production.

FAQ

Q: What makes the YF8‑36 unique among separation connectors?
A: It combines 200 A high‑current contacts, handwheel coupling, and 850 °C fire resistance in a single 36‑contact package—unmatched in power density and safety.

Q: What is the handwheel coupling advantage?
A: Handwheel operation allows secure mating in confined spaces where a traditional coupling ring cannot be turned, making it ideal for umbilical panels and weapon pylons.

Q: What is the fire resistance rating?
A: The connector withstands 850 °C for 80 seconds while maintaining insulation resistance ≥20 MΩ, meeting stringent aerospace fire safety requirements.

Q: How many contacts are there, and what are their ratings?
A: There are 36 contacts total: thirty‑two Φ1.5 contacts rated at 10 A each (≤4 mΩ) and four Φ10 contacts rated at 200 A each (≤5 mΩ).

Q: What termination method does this series use?
A: Termination is via solder cups for all contacts, providing reliable, field‑serviceable connections.

Q: What is the separation force range?
A: The mechanical separation force is calibrated between 100 N and 150 N.

Q: What vibration and shock levels can it withstand?
A: It withstands random vibration of 0.4 G²/Hz (26.4 Grms), sinusoidal vibration of 200 m/s², shock of 1200 m/s², and constant acceleration of 500 m/s².

Q: What is the difference between YF8‑36TJ and YF8‑36ZK?
A: YF8‑36TJ is the plug (cable‑attached half) with pin contacts; YF8‑36ZK is the receptacle (panel‑mount half) with socket contacts.

Q: What is the insulation resistance after environmental testing?
A: After humidity and rain testing, insulation resistance remains ≥20 MΩ.

Q: Do you provide mating connectors?
A: Yes, both plug and receptacle versions are available. Please specify your configuration when ordering.

Contact Us

eady to integrate a high‑power, fire‑resistant separation connector with handwheel operation into your mission‑critical system? Our technical experts are standing by to discuss your specific application requirements and recommend the optimal YF8‑36 configuration—from contact mix to separation force and custom testing.

Whether you need standard units for immediate deployment or custom‑engineered solutions for next‑generation systems, we're here to help you achieve your mission objectives.

Reach out to our team today: manager04@mxtdinfo.com

Let us show you how our YF8‑36 series separation connectors can deliver reliable power and signal performance with unmatched fire safety.