ACT90WJ35SN Equivalent & Substitute Parts

Part Overview

The ACT90WJ35SN is a 128-position circular connector receptacle manufactured by TE Connectivity Deutsch Connectors, designed for MIL-DTL-38999 Series III applications. This connector features female sockets with crimp termination, composite shell construction, and gold-plated mating contacts rated for 5A continuous current. The part is currently discontinued at DiGi Electronics, necessitating identification of functionally equivalent alternatives that maintain electrical and mechanical compatibility for aerospace and military applications.

Key Parameters

Parameter	ACT90WJ35SN Value
Connector Type	Receptacle, Female Sockets
Number of Positions	128
Shell Size - Insert	25-35
Mounting Type	Panel Mount
Mounting Feature	Flange
Termination	Crimp
Fastening Type	Threaded
Orientation	N (Normal)
Contact Finish - Mating	Gold
Shielding	Shielded
Current Rating	5A
Operating Temperature	-65°C ~ 175°C
Contact Material	Copper Alloy
Ingress Protection	Environment Resistant

Substitute Part Grouping Explanation

Substitution of the ACT90WJ35SN is determined by strict equivalence across the following critical parameters:

Primary Compatibility Criteria:

Connector type: Receptacle, Female Sockets
Position count: 128
Shell size insert: 25-35
Mounting configuration: Panel Mount with Flange
Termination method: Crimp
Fastening: Threaded
Contact finish: Gold-plated mating surfaces
Shielding: Shielded construction

Secondary Compatibility Criteria:

Orientation: Normal (N)
Contact material: Copper Alloy
Ingress protection: Environment Resistant or equivalent
Operating temperature range: Minimum -65°C to 175°C

Substitute parts are grouped into two categories based on shell material composition and regulatory compliance status. Group 1 comprises Amphenol Aerospace Operations Tri-Start™ TV series connectors with composite shells. Group 2 comprises TE Connectivity Deutsch Connectors and Souriau-Sunbank by Eaton connectors with metal (aluminum) shells. All listed substitutes maintain the 128-position, 25-35 shell size configuration with crimp termination and gold contact finish required for direct functional replacement.

Parameter Comparison

Parameter	ACT90WJ35SN	CTVP00RW-25-35JN	CTVPS00RF-25-35JN	D38999/20WJ35SN	D38999/20FJ35SN
Manufacturer	TE Connectivity Deutsch	Amphenol Aerospace	Amphenol Aerospace	TE Connectivity Deutsch	Souriau-Sunbank by Eaton
Connector Type	Receptacle, Female Sockets	Receptacle, Female Sockets	Receptacle, Female Sockets	Receptacle, Female Sockets	Receptacle, Female Sockets
Number of Positions	128	128	128	128	128
Shell Size - Insert	25-35	25-35	25-35	25-35	25-35
Mounting Type	Panel Mount	Panel Mount	Panel Mount	Panel Mount	Panel Mount
Mounting Feature	Flange	Flange	Flange	Flange	Flange
Termination	Crimp	Crimp	Crimp	Crimp	Crimp
Fastening Type	Threaded	Threaded	Threaded	Threaded	Threaded
Orientation	N (Normal)	N (Normal)	N (Normal)	N (Normal)	N (Normal)
Contact Finish - Mating	Gold	Gold	Gold	Gold	Gold
Shielding	Shielded	Shielded	Shielded	Shielded	Shielded
Current Rating (Amps)	5A	Not specified	Not specified	5A	5A
Operating Temperature	-65°C ~ 175°C	-65°C ~ 175°C	-65°C ~ 200°C	-65°C ~ 175°C	-65°C ~ 200°C
Contact Material	Copper Alloy	Copper Alloy	Copper Alloy	Copper Alloy	Copper Alloy
Ingress Protection	Environment Resistant	Environment Resistant	Environment Resistant	Environment Resistant	IP67 - Dust Tight, Waterproof
Product Status	Discontinued	Active	Active	Active	Active
RoHS Status	RoHS non-compliant	RoHS non-compliant	ROHS3 Compliant	RoHS non-compliant	RoHS non-compliant

Engineering Selection Recommendations

Primary Recommendation: D38999/20WJ35SN

The D38999/20WJ35SN from TE Connectivity Deutsch Connectors is the direct functional equivalent to the discontinued ACT90WJ35SN. Both connectors share identical electrical and mechanical specifications, including 128-position configuration, 25-35 shell size, 5A current rating, and -65°C to 175°C operating temperature range. The D38999/20WJ35SN maintains active product status with 15,800 units in stock, ensuring supply continuity. Both parts are RoHS non-compliant and carry identical ECCN and HTSUS classifications. The D38999/20WJ35SN features self-locking capability and aluminum shell construction with olive drab cadmium finish, providing enhanced mechanical durability compared to the composite shell of the original part.

Secondary Recommendation: D38999/20FJ35SN

The D38999/20FJ35SN from Souriau-Sunbank by Eaton provides functional equivalence with extended operating temperature capability to 200°C and enhanced ingress protection rated to IP67. This connector maintains the 128-position, 25-35 shell size configuration with 5A current rating and crimp termination. The aluminum shell with nickel finish and silver color differentiate this part cosmetically from the original. This option is suitable for applications requiring superior environmental sealing or elevated temperature operation within the -65°C to 200°C range.

Tertiary Recommendation: CTVPS00RF-25-35JN

The CTVPS00RF-25-35JN from Amphenol Aerospace Operations offers ROHS3 compliance, distinguishing it from the original non-compliant part. This connector maintains 128-position configuration, 25-35 shell size, and crimp termination with extended operating temperature to 200°C. The electroless nickel shell finish and silver color provide alternative surface treatment. ROHS3 compliance makes this option suitable for applications subject to updated environmental regulations, though the composite shell construction differs from the aluminum shells of other alternatives.

Alternative Option: CTVP00RW-25-35JN

The CTVP00RW-25-35JN from Amphenol Aerospace Operations maintains the 128-position, 25-35 shell size configuration with composite shell construction and olive drab cadmium finish matching the original part's appearance. This connector operates across the -65°C to 175°C temperature range identical to the ACT90WJ35SN. The Tri-Start™ TV series designation indicates compatibility with MIL-DTL-38999 Series III specifications.

Frequently Asked Questions (FAQ)

Q: Can the D38999/20WJ35SN directly replace the discontinued ACT90WJ35SN in existing applications?

A: Yes. The D38999/20WJ35SN maintains identical electrical and mechanical specifications across all critical parameters: 128-position configuration, 25-35 shell size, crimp termination, 5A current rating, gold contact finish, and -65°C to 175°C operating temperature range. Both connectors are shielded, threaded-fastening receptacles with female sockets designed for panel mount flange installation. The primary difference is enhanced mechanical durability through aluminum shell construction and self-locking features in the D38999/20WJ35SN.

Q: What is the difference between composite and aluminum shell construction in these connectors?

A: The ACT90WJ35SN features composite shell material, while D38999/20WJ35SN and D38999/20FJ35SN feature aluminum shells. Aluminum shells provide superior mechanical strength, thermal conductivity, and electromagnetic shielding effectiveness. Composite shells offer lighter weight and reduced cost. Both construction types meet MIL-DTL-38999 Series III specifications and maintain equivalent electrical performance for the 128-position, 25-35 configuration.

Q: Are there RoHS-compliant alternatives available?

A: Yes. The CTVPS00RF-25-35JN and CTVPS00RF-25-35J from Amphenol Aerospace Operations are ROHS3 compliant. These connectors maintain the 128-position, 25-35 shell size configuration with crimp termination and gold contact finish. The ROHS3-compliant options operate across -65°C to 200°C, providing extended temperature capability compared to the original -65°C to 175°C range.

Q: What is the significance of the contact finish thickness difference between 50.0µin and 100.0µin?

A: Contact finish thickness is specified in microinches (µin) or micrometers (µm). The ACT90WJ35SN and D38999/20WJ35SN specify 50.0µin (1.27µm) gold plating thickness, while Amphenol Aerospace and some Souriau-Sunbank alternatives specify 100.0µin (2.54µm). Thicker gold plating provides enhanced wear resistance and extended contact life under repeated mating cycles. Both thicknesses meet MIL-DTL-38999 Series III requirements and are functionally equivalent for standard applications.

Q: Can CTVP00RW-25-35JN and CTVPS00RF-25-35JN be used interchangeably?

A: Both connectors maintain the 128-position, 25-35 shell size configuration with crimp termination and gold contact finish. However, they differ in shell finish (olive drab cadmium versus electroless nickel), color (olive drab versus silver), operating temperature range (175°C versus 200°C maximum), and RoHS compliance status (non-compliant versus ROHS3 compliant). Selection between these options depends on specific application requirements for temperature range, environmental regulations, and cosmetic specifications.

Q: What is the inventory availability for substitute parts?

A: D38999/20WJ35SN maintains the highest inventory with 15,800 units in stock. CTVPS00RF-25-35J provides 1,140 units, D38999/20FJ35SN provides 1,157 units, CTVP00RW-25-35JN provides 868 units, and CTVPS00RF-25-35JN provides 793 units. The original ACT90WJ35SN has 681 units remaining in stock but is discontinued at DiGi Electronics.

Q: Are all substitute parts rated for 5A continuous current?

A: The ACT90WJ35SN, D38999/20WJ35SN, and D38999/20FJ35SN are explicitly rated for 5A continuous current. The Amphenol Aerospace Operations connectors (CTVP00RW-25-35JN, CTVPS00RF-25-35JN, CTVPS00RF-25-35J, and CTVP00RW-25-35S) do not specify current rating in the provided data. For applications requiring confirmed 5A rating, D38999/20WJ35SN or D38999/20FJ35SN are recommended.

Q: What packaging options are available?

A: The ACT90WJ35SN is supplied without specified packaging. D38999/20WJ35SN is supplied in bulk packaging. D38999/20FJ35SN is supplied in bag packaging. CTVP00RW-25-35S and CTVPS00RF-25-35S are supplied in bulk packaging. CTVP00RW-25-35JN, CTVPS00RF-25-35JN, and CTVPS00RF-25-35J are supplied without specified packaging designation.

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