1、BRITISH STANDARD BS9522 N0001:1982 Incorporating Amendment No.1 Detail specification for Multi-contact circular electrical connectors for d.c. and low frequency applications Bayonetcoupling with front release, rear removable crimp contacts Fullassessment level UDC 621.315.683BS9522N0001:1982 BSI05-2
2、000 Committee reference ECL/21 ISBN 0 580 12603 X A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obli
3、gations. Summary of pages This document comprises a front cover, an inside front cover, pagesi andii, pages1 to45 and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. A
4、mendments issued since publication Amd. No. Date of issue Comments 6821 September 1991 Indicated by a sideline in the marginBS9522N0001:1982 BSI 05-2000 i Contents Page 1 Pattern number 1 2 Related documents 1 3 Description of connector and intended application 1 4 Marking of the component and packa
5、ge 2 5 Ordering information 3 6 Outline drawings 3 7 Ratings 3 8 Characteristics 4 9 Certified test records (CTRs) 6 10 Quality assessment procedure 6 11 Inspection requirements 6 Appendix A Outline drawings 16 Appendix B Arrangement of preferred specimens in minimum quantitiesforgroup D tests 43 Ap
6、pendix C Preferred compatibility gauging plan 45ii blankBS9522N0001:1982 BSI 05-2000 1 1 Pattern number The specification number without the letters BS is used as the pattern number. This range of connectors is known as Pattern9522 N0001. 2 Related documents BS6001, Sampling procedures and tables fo
7、r inspection by attributes. BS9000, General requirements for electronic components of assessed quality. BS9520:1982, Electrical connectors of assessed quality for frequencies below3MHz: generic data and methods of test. PD9002, BS9000 component selection guide. BS G210, PTFE insulated equipment wire
8、s C with silver plated copper conductors. 3 Description of connector and intended application Multi-contact circular connectors with bayonet coupling and front release rear removable crimp contacts, for d.c. or a.c. applications. Environment resistant (non-barrier sealed) for general purpose applica
9、tions. The connectors employ contacts that are rear insertable, front release and rear removable using the appropriate insertion and removal tools. To ensure compliance with this specification, connectors shall always have a full complement of contacts fitted, with filler plugs behind unwired contac
10、ts. Specification obtainable from: BRITISH STANDARDS INSTITUTION 101PENTONVILLEROADLONDON N19ND TELEPHONE01-837-8801: TELEX 23218 45 pages ELECTRONIC COMPONENTS OF ASSESSED QUALITY DETAILSPECIFICATION IN ACCORDANCE WITH BS9520. MANUFACTURERS TYPE NUMBER PD9002 For ordering information seeclause5 TYP
11、ICAL CONNECTORS MULTI-CONTACT CIRCULAR ELECTRICAL CONNECTORS. Bayonet coupling with front release rear removable crimp contacts. ENVIRONMENTAL CATEGORY55/125/56 FULL ASSESSMENT For marking information seeclause4 For outline drawings seeA.2 Refer to Qualified Products List PD9002 for details of manuf
12、acturers approved to this specification.BS9522N0001:1982 2 BSI 05-2000 Polarization is effected by housing (shell) keys and keyways, or by angular disposition of the insert. The preferred method is housing (shell) keys and keyways, which provides up to four different polarizations other than normal
13、(N); these are designated B, C, E and F. The alternative method is angular disposition of the insert which provides up to four different polarizations other than normal (N); these are designated W, X, Y and Z and are intended for replacement purposes only. SeeAppendix A of this specification for pol
14、arization arrangement drawings and availability for each connector. Housing (shell) material is aluminium alloy with a standard finish of olive drab chromate conversion over the plating finishes as specified in4.1. The performance of connectors is normally only assessed using mated pairs with the sa
15、me plating finish and from the same source. Galvanic corrosion may occur if connectors with dissimilar metal finishes are intermated. It is the users responsibility to ensure compatibility between alternative finishes. 4 Marking of the component and package 4.1 Connector reference numbers. The marki
16、ng shall be in accordance with1.1.6 of BS9520. The individual reference number required by1.1.6 c) of BS9520 consists of abbreviations to identify individual connectors, accessories or tools in accordance with4.1 and4.2. Style number: As shown inA.2. Housing (shell) size/contact arrangement: Four di
17、gits as shown on the appropriate outline drawing inA.1. Contact style: M=male contact. F=female contact. Polarization: Letter assigned to a particular arrangement of housing (shell) keys and keyways or to a particular angular disposition of an insert (seeA.1). Variant: A digit denoting any variation
18、 from the basic specification. 0=standard connector cadmium plated 1=standard connector zinc cobalt plated 2=standard connector pure zinc plated. Example reference number: C20022255 MNO. NOTEWhere the connector is supplied complete with an accessory, the reference number shall also include the appli
19、cable accessory style number (see4.2 andA.3). Example reference number: C20022255 MNO A2010 4.2 Accessory and tool reference numbers. The individual reference numbers consist of abbreviations asfollows. Style number: As shown inA.3 for accessories andA.4 for tools. (A=accessory, T=tool). Housing (sh
20、ell) size: Quoted for accessories. Two digits as inA.1.BS9522N0001:1982 BSI 05-2000 3 Contact size: Quoted for filler plugs or tools. Two digits as inA.3 orA.4. Variant: Quoted for accessories. Use the following code: 0=accessories for the standard connector cadmium plated 1=accessories for the stan
21、dard connector zinc cobalt plated 2=accessories for the standard connector pure zinc plated. Example reference numbers: A2009080 T201716 4.3 Packaging. Packaging shall include the manufacturers assembly instructions, including wire preparation, crimping and contact insertion if requested. 5 Ordering
22、 information The following information shall be given when ordering parts complying with the requirements of this detail specification. a) The number of this detail specification, i.e.BS9522 N0001. b) The individual reference number as described in clause4. c) Details of marking that may be required
23、 in addition to or as an alternative to that specified in clause4. d) Requirements for the provision of assembly instructions. 6 Outline drawings SeeAppendix A of this specification for the following. A.1 Contact arrangements and polarization availability A.2 Connector outline dimensions, panel cut-
24、outs and mass A.3 Accessories and contacts, outline dimensions and mass A.4 Assembly tools A.5 Gauges NOTEOutline drawings include a cross-reference to the relevant National Supervising Inspectorate control drawings. 7 Ratings 7.1 Electrical 7.1.1 Current a) Maximum current per individual contact in
25、 isolation 1)at an ambient temperature of85 C: contact size20:7.5A contact size16:10A contact size12:20A b) Maximum current per contact through all contacts simultaneously at an ambient temperature of85 C: contact size20:5 A contact size16:10 A contact size12:20 A The performance of any connectors l
26、isted in this detail specification shall at all times exceed the maximum continuous bunched rating of the appropriate size wire or cable of equivalent temperature rating, and this bunched rating shall be the determining factor. 1) That is, when only one contact per connector is electrically loaded.B
27、S9522N0001:1982 4 BSI 05-2000 7.1.2 Voltage 7.2 Environmental 7.3 Endurance 8 Characteristics 8.1 Connector range (seeA.1 andA.2) 8.2 Electrical Sea level 1013mbar a 8500m (27900ft) 320mbar 21340m (70000ft) 44mbar Voltage rating b I II I II I II Working voltage c(nominal) d.c. or a.c. peak 700 1200
28、550 650 330 380 Voltage proof d.c. or a.c. peak 2100 3000 1100 1300 660 760 a 1mbar=10 2N/m 2 =100PA. b SeeA.1. c Establishment of electrical safety factors is the responsibility of the user. Environmental classification 55/125/56 Low air pressure severity 44mbar Vibration severity 10Hz to5000Hz,0.7
29、5mm(10g n ) Duration30h Shock severity 981m/s 2 (100g n ) Duration6ms Acceleration severity 490m/s 2 (50g n ) Bump severity 390m/s 2 (40g n )4000 10 bumps Mechanical operation 500 operations Electrical load and temperature, long term current as in7.1.1 b) 1000h at85 C Electrical load and temperature
30、, short term (no electrical load) 250h at125 C Maximum contact resistance (initially) 5m7 Maximum contact resistance (after conditioning) 10m7 Minimum insulation resistance (initially) 5000M7, method A or method B a (see1.2.4.4 of BS9520) Minimum insulation resistance (after conditioning) 100M7, met
31、hod A or method B a (see1.2.4.4 of BS9520) Minimum insulation resistance (hot, mated) 3M7, method A or method B a (see1.2.4.4 of BS9520) Maximum housing (shell) electrical continuity (mated specimens which include C2002 or C2004) (initially) 5m7 Maximum housing (shell) electrical continuity (mated s
32、pecimens which include C2002 or C2004) (after conditioning) 10m7 Maximum housing (shell) electrical continuity (mated specimens which include C2001 or C2003) (initially and after conditioning) 200m7 a Method B values shall be recorded.BS9522N0001:1982 BSI 05-2000 5 8.3 Mechanical Engaging and separa
33、ting force, connector Contact retention (in insert) Contact holding force Insert retention in housing (shell), torsional Housing (shell) size N m (lbf in) max. min. max. min. 08 10 12 14 16 18 20 22 24 0.90 1.36 1.80 2.26 2.71 3.16 3.61 4.06 4.97 0.22 0.22 0.46 0.90 0.90 0.90 1.13 1.36 1.58 (8) (12)
34、 (16) (20) (24) (28) (32) (36) (44) (2) (2) (4) (8) (8) (8) (10) (12) (14) Insert retention in housing (shell), axial 517kN/m 2 (75lbf in 2 ) min. Contact size N min. (lbf) min. 20 16 12 67 112 112 (15) (25) (25) Contact size N min. 20 16 12 0.21 0.56 0.83 Housing (shell) size N m min. (lbf in) min.
35、 08 10 12 14 16 18 20 22 24 0.90 1.13 1.36 1.58 1.81 2.04 2.26 2.48 2.71 (8) (10) (12) (14) (16) (18) (20) (22) (24)BS9522N0001:1982 6 BSI 05-2000 Grounding contact spring holding force 2) Wire seal and conductor accommodation 8.4 Fluid resistance. The connectors shall be resistant to the following
36、fluids. Isopropanol, white spirit, dichloromethane, trichloroethylene, kerosene, petrol, hydraulic fluids (normal and silicone based), lubricating oils (mineral and ester based), petroleum jelly and de-icing fluids. 9 Certified test records (CTRs) Certified test records (CTRs) shall be prepared in a
37、ccordance with1.1.11 of BS9520. 10 Quality assessment procedure Group C tests need not be carried out for Qualification Approval or when subsequent group D tests are performed. 11 Inspection requirements Samples subjected to tests marked “(D)” shall not be accepted for release under BS9000 (see20.2
38、of BS9000-1:1981). Unless otherwise specified, tests shall be performed at an ambient temperature of between15 C and35 C. Fitting (and wiring) of contacts shall be in accordance with the manufacturers instructions. Polytetrafluoroethylene (PTFE) extruded wire complying with the requirements of BS G2
39、10 shall be used. (To ensure that the wiring operation has been carried out satisfactorily it is advisable to apply insulation resistance and contact resistance tests.) Housing (shell) size N min. 08 10 12 14 16 18 20 22 24 1.17 1.37 1.57 1.76 1.96 2.15 2.35 2.55 2.74 2) Applicable only to styles C2
40、002 and C 2004. Contact size Wire insulation Conductor a min. o.d. max. o.d. min. o.d. max. o.d. mm (in) mm (in) mm mm 20 16 12 1.19 1.68 2.46 (0.047) (0.066) (0.097) 2.16 2.77 3.61 (0.085) (0.109) (0.142) 0.56 0.81 1.63 1.06 1.56 2.23 a Seemanufacturers assembly instructions, which may extend the r
41、anges of conductor diameters.BS9522N0001:1982 BSI 05-2000 7 Inspection BS9520 reference and conditions of test Requirements as in BS9520 GROUP A To be applied on a sampling basis lot-by-lot except subgroup A0 Subgroups A2, A3 and A4 are not applicable Subgroup A0 100% inspection Unless required for
42、test, contacts need not be fitted Voltage proof Visual examination 1.2.4.5 1.2.2 a) Method A or B Voltage as in7.1.2 of this specification. Duration=5s (This requirement may be demonstrated immediately prior to final assembly) As in1.2.4.5 As in1.2.2 a) Subgroup A1 Visual examination Inspection leve
43、l S-3, AQL1.5% Contacts need not be fitted 1.2.2 b) As in1.2.2 b) Subgroup A5 CTR information 1.1.11 The result from the test in subgroup A1 shall be reported as attributes information GROUP B To be applied on a sampling basis lot-by-lot Subgroups B3 to B7 are not applicable Subgroup B1 Inspection l
44、evel S-4, AQL1% Gauging procedure Insulation resistance Engaging and separating force, connector Contact holding force 1.2.3.3.2 1.2.4.4 1.2.5.3 1.2.5.9 Method A(500 50V) or MethodB(500 50V) Forces are specified in8.3 of this specification With3 sizings and using gauges as prescribed in A.5 of this
45、specification As in1.2.3.3.2 5000M7 min. a As in1.2.5.3 As in1.2.5.9 Subgroup B2 (D) Inspection level S-4, AQL4% Samples from subgroup B1 may be used. Only contacts required for test need be fitted Housing (shell) electrical continuity Insert retention in housing (shell), axial Insert retention in h
46、ousing (shell), torsional Grounding contact spring holding force b 1.2.4.3 1.2.5.5 1.2.5.6 1.2.5.16 Mated specimens which include C2002 or C2004 Mated specimens which include C2001 or C2003 Pressure as specified in8.3 of this specification Torque as specified in8.3 of this specification Using gauges
47、 as specified in A.5.4 and A.5.5 of this specification 5m7 max. 200m7 min. As in1.2.5.5 As in1.2.5.6 As in1.2.5.16 a Method B values shall be recorded. b Applicable only to styles C2002 and C2004.BS9522N0001:1982 8 BSI 05-2000 Inspection BS9520 reference and conditions of test Requirements as in BS9
48、520 Subgroup B8 CTR information 1.1.11 Results from the tests in subgroup B1 shall be reported as attributes information. Results from the contact resistance, housing (shell) continuity and insert ageing tests of subgroup B2 shall be reported as attributes information GROUP C To be applied on a samp
49、ling basis at three-monthly intervals The issue number of the manufacturing drawing shall be checked against that on the approval certificate Subgroup C1 Dimensions, outline Inspection level S-3, AQL4% Contacts need not be fitted 1.2.3.1 As in A.2 and A.3 of this specification Subgroup C3 Inspection level S-3, AQL4% Samples from subgroup C1 with contacts fitted may be used Contact resistance Rapid change of temperature Damp heat, steady state 1.2.4.2 a) 1.2.6.8 1.2.6.15 55 C to125 C 21days. Working voltage as specified in7.1.2 of this specificat
