SAE AS 39029 121-2015 CONTACTS ELECTRICAL CONNECTOR SOCKET CRIMP REMOVABLE EXPANDED PERFORMANCE SIZES 10 12 16 20 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS).pdf

1、 AEROSPACE STANDARD CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) AS39029/121Copyright 2015 SAE International All rights reserved. No part of this publication may be reproduced, stored in a ret

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5、s.RATIONALE THIS DETAIL SPECIFICATION SHEET IS REQUIRED TO ALIGN/HARMONIZE THE CONTACT PERFORMANCE REQUIREMENTS WITH THE APPLICABLE CONNECTOR PERFORMANCE REQUIREMENTS AND INCLUDE ADDITIONAL VERIFICATION TESTING FOR THE VIBRATION AND SHOCK REQUIREMENTS INCLUDING PERIODIC TESTING, TO ADD SIZE 23 CONTA

6、CT DETAILS/PART NUMBERS, TO ADD METAL TOOLING, TO CHANGE THE APPLICABLE CONNECTORS TO 38999 SERIES III ONLY, TO CHANGE SIZE 23-28 TO 23-26, TO DELETE SIZES 22 AND 22M, TO ADD WIRE RANGE ACCOMMODATION FOR SIZE 26 WIRE BARREL, TO DELETE THE .445-.425 DIMENSION FROM FIGURE 2, TO CLARIFY VISUAL/VIBRATIO

7、N TESTING DETAILS AND TO ADD THE BLENDED RADIUS OPTION TO THE H DIMENSION. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS39029. FIGURE 1 - CONNECTOR CONTACT (EXCEPT SIZE 23) AS39029/121 SHEET 1 OF 9 PROCUREMENT SP

8、ECIFICATION: AS39029 SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS39029_121 FIGURE 1 - CONNECTOR CONTACT (EXCEPT SIZE 23) (CONTINUED) AEROSPACE STANDARD AS39029/121 SHEET 2 OF 9 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP

9、 REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) DETAIL X FIGURE 1 - CONNECTOR CONTACT (EXCEPT SIZE 23) (CONTINUED) AEROSPACE STANDARD AS39029/121 SHEET 3 OF 9 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SI

10、ZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) DETAIL Z SIZE 23-22 AND 23-26 WIRE BARRELS FIGURE 2 - CONNECTOR CONTACT (SIZE 23 ONLY) AEROSPACE STANDARD AS39029/121 SHEET 4 OF 9 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16,

11、20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) TABLE 1 - FIGURE 1 AND 2 DIMENSIONS BIN CODE MATING END SIZE WIRE BARREL SIZE A REFERENCE B MINIMUM C D E F MAXIMUM G H 662 23 26 .934 (23.72) .028 (0.711) .0555 (1.41) .0540 (1.37) .022 (0.56) .018 (0.46) .0235 (0.60) .0215 (0.55) .055 (1.40)

12、0480 (1.22) .0465 (1.18) .006 (0.15) .003 (0.08) 663 23 22 .934 (23.72) .028 (0.711) .0555 (1.41) .0540 (1.37) .0355 (0.90) .0335 (0.85) .055 (1.40) .0480 (1.22) .0465 (1.18) .006 (0.15) .003 (0.08) 664 22 22D .855 (21.72) .031 (0.79) .062 (1.57) .060 (1.52) .0355 (0.90) .0335 (0.85) .062 (1.57) .0

13、48 (1.22) .046 (1.17) .005 (0.13) .003 (0.08) 665 20 20 .0415 (1.05) .094 (2.39) .091 (2.31) .032 (0.81) .026 (0.66) .048 (1.22) .046 (1.17) .078 (1.98) .070 (1.78) .068 (1.73) .010 (0.25) .005 (0.13) 666 16 16 .064 (1.63) .130 (3.30) .127 (3.23) .042 (1.07) .036 (0.914) .068 (1.73) .066 (1.68) .113

14、 (2.87) .103 (2.62) .101 (2.57) 667 12 12 .0955 (2.43) .182 (4.62) .179 (4.55) .042 (1.07) .036 (0.914) .102 (2.59) .098 (2.49) .161 (4.09) .151 (3.84) .148 (3.76) .016 (0.41) .005 (0.13) 668 10 10 1.021 (25.93) .1265 (3.21) .242 (6.15) .238 (6.05) .052 (1.32) .046 (1.17) .140 (3.56) .134 (3.40) .21

15、5 (5.46) .213 (5.41) .207 (5.26) TABLE 1 - FIGURE 1 AND 2 DIMENSIONS (CONTINUED) BIN CODE MATING END SIZE WIRE BARREL SIZE J K MINIMUM L MINIMUM M N P MINIMUM S U MAXIMUM 662 23 26 .726 (18.44) .716 (18.19) .155 (3.94) .145 (3.68) N/A N/A N/A N/A .218 (5.54) .208 (5.28) .038 (0.965) 663 23 22 .726 (

16、18.44) .716 (18.19) .155 (3.94) .145 (3.68) N/A N/A N/A N/A .218 (5.54) .208 (5.28) .038 (0.965) 664 22 22D .626 (15.90) .616 (15.65) .141 (3.58) .585 (14.86) - 50 44 .047 (1.19) .237 (6.02) .231 (5.87) N/A 665 20 20 .209 (5.31) .078 (1.98) .072 (1.83) 47 40 .053 (1.35) N/A 666 16 16 .209 (5.31) .08

17、8 (2.24) .082 (2.08) 47 40 .084 (2.13) N/A 667 12 12 .209 (5.31) .088 (2.24) .082 (2.08) 47 40 .118 (3.00) N/A 668 10 10 .385 (9.98) .355 (9.02) .115 (2.92) .108 (2.74) N/A .146 (3.71) 1/ .405 (10.29) .395 (10.03) N/A 1/ FULL RADIUS PERMISSIBLE. AEROSPACE STANDARD AS39029/121 SHEET 5 OF 9 CONTACTS,

18、ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) TABLE 2 - DESIGN CHARACTERISTICS BIN CODE COLOR BANDS MATING END SIZE WIRE BARREL SIZE TYPE CLASS 1ST2ND3RD662 BLUE BLUE RED 23 26 A B 663 BLUE BLUE ORANGE 2

19、3 22 664 BLUE BLUE YELLOW 22 22D 665 BLUE BLUE GREEN 20 20 666 BLUE BLUE BLUE 16 16 667 BLUE BLUE VIOLET 12 12 668 BLUE BLUE GRAY 10 10 TABLE 3 - TOOLS BIN CODE BASIC CRIMPING TOOL POSITIONER INSTALLING TOOL 1/ REMOVAL TOOL WIRED CONTACT UNWIRED CONTACT 662 M22520/2-01 M22520/2-16 M81969/1-05 (METAL

20、 FOR BIN CODES 665, 666, 667 AND 668, DIAMETERS E AND G TO BE CONCENTRIC WITHIN .001 (TIR) AT MAXIMUM MATERIAL CONDITION (MMC). THE .029-.033 SHOULDER DIMENSION DOES NOT APPLY TO BIN CODES -662, 663, AND -664. FOR DETAIL “S”, THE MECHANICAL PRESSURE MEMBER SHALL BE SHROUDED. IN HOOD ATTACHMENT AREA,

21、 THE CONTACT BODY “C” DIAMETER SHALL EXCEED THE HOOD “F” DIAMETER BY .001 INCH MINIMUM (RFS). OPTIONAL DESIGNS MAY HAVE A FULL LENGTH CORROSION RESISTANT STEEL HOOD. THE .036-.041 DIAMETER IN DETAIL “T” SHALL BE CONCENTRIC TO G DIAMETER WITHIN .003 (TIR) (RFS). FOR DIMENSION H, THE FOLLOWING BLEND R

22、ADIUS DIMENSIONS ARE OPTIONAL: SIZE 23 - BLEND RADIUS .010 INCH .005 INCH. SIZE 22 - BLEND RADIUS .010 INCH .005 INCH. SIZE 20 - BLEND RADIUS .015 INCH .005 INCH. SIZE 16 - BLEND RADIUS .020 INCH .005 INCH. SIZE 12 - BLEND RADIUS .020 INCH .010 INCH. SIZE 10 - BLEND RADIUS .020 INCH .010 INCH. FIGUR

23、E 2 ADDITIONAL DETAILS: DIMENSION “U” IS THE POINT OF INITIAL ENGAGEMENT. THERE SHALL BE A MAXIMUM GAP OF .008 INCH BETWEEN THE HOOD AND BODY OF THE CONTACT. A .002 INCH MAXIMUM BURR IS PERMITTED ON THE PERIPHERY OF SHOULDER NOTED (SEE SECTION OF DETAIL Z). 2. TOOLS: TOOLS REQUIRED FOR CRIMPING CONT

24、ACTS TO THE WIRE/CABLE AND THE INSTALLING/REMOVAL FROM THE CONNECTOR SHALL BE IN ACCORDANCE WITH TABLE 3. 3. PART NUMBERS: CONTACT PART NUMBERS SHALL BE IN ACCORDANCE WITH TABLE 5. SUPERSEDED PART NUMBERS ARE AS SPECIFIED. 4. MATERIALS: MATERIALS SHALL BE IN ACCORDANCE WITH AS39029. 5. MECHANICAL: M

25、ECHANICAL PROPERTIES SHALL BE IN ACCORDANCE WITH AS39029. RESISTANCE TO PROBE DAMAGE - SEE TABLE 4. AEROSPACE STANDARD AS39029/121 SHEET 7 OF 9 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) 6.

26、ELECTRICAL: ELECTRICAL PROPERTIES SHALL BE IN ACCORDANCE WITH AS39029. 7. ENVIRONMENTAL: ENVIRONMENTAL PROPERTIES SHALL BE IN ACCORDANCE WITH AS39029 AND AS LISTED BELOW: VIBRATION: THE FOLLOWING VIBRATION TESTS SHALL BE PERFORMED ON SEPARATE SAMPLES FOR EACH TEST. EACH TEST SAMPLE MUCH COMPLY WITH

27、THE AS39029 BASIC SPECIFICATION SAMPLE REQUIREMENTS. SAMPLE PREPARATION: THE SAMPLE SIZE OF CONTACTS FOR GROUP 2 SHALL BE TRIPLED TO ALLOW FOR 3 GROUPS OF CONTACTS TO BE SUBJECTED TO THE VIBRATION TEST. THE CONTACTS SHALL BE DIVIDED INTO 3 SUB-GROUPS AND MOUNTED IN MIL-DTL-38999 CONNECTORS (MATING F

28、REE PLUG AND RECEPTACLE) RATED AT 200 C. HIGH STRENGTH WIRE MAY BE USED FOR VIBRATION TESTING. VIBRATION TESTS: a. THE FIRST SUB-GROUP SHALL BE TESTED TO THE VIBRATION REQUIREMENTS OF MIL-DTL-38999 SINE VIBRATION PARAGRAPH APPLICABLE TO SERIES III ONLY. THE HIGH TEMPERATURE PART OF THE TEST SHALL BE

29、 PERFORMED AT A TEMPERATURE OF 200 C. b. THE SECOND SUB-GROUP SHALL BE TESTED TO THE VIBRATION REQUIREMENTS OF MIL-DTL-38999 RANDOM VIBRATION PARAGRAPH APPLICABLE TO SERIES 1, III AND IV ONLY AT A TEMPERATURE OF 200 C. c. THE THIRD SUB-GROUP SHALL BE TESTED TO THE VIBRATION REQUIREMENTS OF MIL-DTL-3

30、8999 RANDOM VIBRATION PARAGRAPH APPLICABLE TO SERIES 1, III AND IV ONLY, TEST CONDITION 5 USING THE VIBRATION ENVELOPE SHOWN IN THE APPLICABLE FIGURE, AT AMBIENT TEMPERATURE. d. DURING EACH OF THE ABOVE VIBRATION TESTS THE CONTACTS SHALL BE MONITORED FOR ELECTRICAL DISCONTINUITY TO THE REQUIREMENTS

31、OF EIA364-46. THERE SHALL BE NO DISCONTINUITIES IN EXCESS OF 1 MICROSECOND. e. FOLLOWING THE VIBRATION TESTS ABOVE, THE CONTACTS SHALL BE INDIVIDUALLY MEASURED FOR CONTACT RESISTANCE IN ACCORDANCE WITH EIA364-06. THE CONTACTS SHALL BE MEASURED AT AMBIENT TEMPERATURE AND UNDISTURBED WHILE STILL WITHI

32、N THE CONNECTOR. THE MEASURING POINTS SHALL BE AT A TOTAL DISTANCE OF 6 INCHES APART. THE CONTACT RESISTANCE SHALL MEET THE REQUIREMENTS OF AS39029 TABLES 5 OR 6 (WHERE APPROPRIATE) AT THE CURRENTS SHOWN IN THE TABLES. SHOCK: CONNECTORS/CONTACTS SHALL BE TESTED IN ACCORDANCE WITH EIA-364-27, TEST CO

33、NDITION D. THE FOLLOWING DETAILS SHALL APPLY: a. THE PULSE SHALL BE AN APPROXIMATE HALF SINE WAVE OF 300 G 15% MAGNITUDE WITH A DURATION OF 3 MILLISECONDS 1 MILLISECONDS. b. THE WIRE BUNDLE SHALL BE CLAMPED TO FIXED POINTS AT LEAST 8 INCHES FROM THE REAR OF THE CONNECTOR. HIGH-IMPACT SHOCK: WIRED AN

34、D MATED CONNECTORS SHALL BE SUBJECTED TO THE TEST SPECIFIED IN MIL-S-901, GRADE A WITH THE FOLLOWING MODIFICATIONS AND ADDITIONS. CONNECTORS SHALL BE COUPLED TOGETHER BY NORMAL COUPLING MEANS. DURING THE HIGH IMPACT SHOCK TESTING, THE CONTACTS SHALL BE MONITORED FOR ELECTRICAL DISCONTINUITY AS REQUI

35、RED B Y EIA364-46. THERE SHALL BE NO DISCONTINUITIES IN EXCESS OF 1 MICROSECOND. MOUNTING FIXTURES SHALL BE IN ACCORDANCE WITH MIL-S-901, LIGHTWEIGHT. THE CABLE OR WIRE BUNDLE SHALL BE SUPPORTED ON A STATIONARY FRAME IN SUCH A MANNER TO PROVIDE A FREE FLEXING CABLE LENGTH BETWEEN THE FRAME AND FIXTU

36、RE OF NOT LESS THAN 36 INCHES (914.4 MILLIMETERS). THE PLUG SHALL BE TERMINATED WITH AT LEAST 80% OF WIRED CONTACTS. THE WIRE BUNDLE SHALL BE PROVIDED WITH STRAIGHT, OPEN FRAME, STRAIN RELIEF ACCESSORY HARDWARE. FOLLOWING THE SHOCK TEST THE CONTACTS SHALL BE INDIVIDUALLY MEASURED FOR CONTACT RESISTA

37、NCE IN ACCORDANCE WITH EIA364-06. THE CONTACTS SHALL BE MEASURED UNDISTURBED WHILE STILL WITHIN THE CONNECTOR. THE MEASURING POINTS SHALL BE AT A TOTAL DISTANCE OF 6 INCHES APART. THE LOW LEVEL CONTACT RESISTANCE SHALL MEET THE REQUIREMENTS OF AS39029 TABLES 5 OR 6 (WHERE APPROPRIATE) AT THE CURRENT

38、S SHOWN IN THE TABLES. AEROSPACE STANDARD AS39029/121 SHEET 8 OF 9 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS) VISUAL EXAMINATION: FOLLOWING THE COMPLETION OF THE VIBRATION AND SHOCK TESTS TH

39、E INDIVIDUAL CONTACTS SHALL BE REMOVED FROM THE CONNECTORS AND VISUALLY EXAMINED FOR EVIDENCE OF CORROSION FRETTING USING A MINIMUM OF X10 MAGNIFICATION. THERE SHALL BE NO EXPOSURE OF BASE MATERIAL AT X10. BASE MATERIAL EXPOSURE DETECTED AT MAGNIFICATION LEVELS HIGHER THAT X10 SHALL NOT BE CONSIDERE

40、D FAILURES. 8. QUALIFICATION: QUALIFICATION SHALL BE IN ACCORDANCE WITH AS39029. PERIODIC/RETENTION TESTING: IN ADDITION TO THE PERIODIC TESTS REQUIRED BY AS39029, THE ABOVE LISTED VIBRATION AND SHOCK TESTS SHALL BE REPEATED AT AN INTERVAL OF 72 MONTHS FROM THE DATE OF INITIAL APPROVAL, AND AT 72 MO

41、NTH INTERVALS THEREAFTER. THE MANUFACTURERS RELIABILITY ASSURANCE PROGRAM SHALL COMPLY WITH THE AS9100 AEROSPACE STANDARD FOR QUALITY MANAGEMENT SYSTEM REQUIREMENTS. OTHER ESTABLISHED AND INDUSTRY RECOGNIZED QUALITY ASSURANCE STANDARDS THAT ASSURE ALL PRODUCTS PRODUCED CONFORM TO THE CONTRACT REQUIR

42、EMENTS ARE ACCEPTABLE. HOWEVER, IF USED, IT IS THE RESPONSIBILITY OF THE MANUFACTURER TO PROVIDE EVIDENCE OF COMPLIANCE TO AS9100. THE QUALIFYING ACTIVITY (QA) AUTHORITY RESERVES THE RIGHT TO MONITOR, MEASURE, AND VALIDATE COMPLIANCE AT THEIR DISCRETION. APPLICATION NOTES: 1. CONTACT MATES DIRECTLY

43、WITH AN AS39029/122 PIN AS SHOWN IN TABLE 6. TABLE 6 - CONTACT MATING PART NUMBERS AS39029/121 BIN CODE MATING AS39029 SLASH SHEET/BIN CODE -662 M39029/122-669 -663 M39029/122-670 -664 M39029/122-671 -665 M39029/122-672 -666 M39029/122-673 -667 M39029/122-674 -668 M39029/122-675 2. THIS CONTACT IS F

44、UNCTIONALLY INTERCHANGEABLE WITH THE AS39029/56 CONTACT; HOWEVER, IT INCLUDES ADDITIONAL PERFORMANCE REQUIREMENTS. ADDITIONAL PERFORMANCE REQUIREMENTS INCLUDE THE VIBRATION/SHOCK REQUIREMENTS OF THE APPLICABLE MIL-DTL-38999 CONNECTOR SPECIFICATION. THIS CONTACT ALSO INCLUDES THE ADDITIONAL VIBRATION

45、/SHOCK VERIFICATION TESTING AND REQUIRED PERIODIC TESTING INTERVALS FOR THE VIBATION AND SHOCK TESTING. THIS SPECIFICATION ALSO INCLUDES REQUIREMENTS FOR SIZE 23 CONTACTS. 3. CONTACT USAGE IS LIMITED TO MIL-DTL-38999 SERIES III CONNECTORS. SPECIFICATION NOTES: 1. A CHANGE BAR (l) LOCATED IN THE LEFT

46、 MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE B

47、ARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS NOR IN DOCUMENTS THAT CONTAIN EDITORIAL CHANGES ONLY. AEROSPACE STANDARD AS39029/121 SHEET 9 OF 9 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, EXPANDED PERFORMANCE, SIZES 10, 12, 16, 20, 22 AND 23 (FOR MIL-DTL-38999 SERIES III CONNECTORS)