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1、BRITISH STANDARD BS 9522 N0001:1982 Incorporating Amendment No. 1 Detail specification for Multi-contact circular electrical connectors for d.c. and low frequency applications Bayonet coupling with front release, rear removable crimp contacts Full assessment level UDC 621.315.683 Licensed Copy: Lond
2、on South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 BSI 05-2000 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 Brit
3、ish Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 45 and a back cover. This standard has
4、been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Amendments issued since publication Amd. No.Date of issueComments 6821September 1991 Indicated by a sideline in the margin Licensed Copy: London South
5、Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 BSI 05-2000i Contents Page 1Pattern number1 2Related documents1 3Description of connector and intended application1 4Marking of the component and package2 5Ordering inform
6、ation3 6Outline drawings3 7Ratings3 8Characteristics4 9Certified test records (CTRs)6 10Quality assessment procedure6 11Inspection requirements6 Appendix A Outline drawings16 Appendix B Arrangement of preferred specimens in minimum quantities for group D tests43 Appendix C Preferred compatibility ga
7、uging plan45 Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI ii blank Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS
8、 9522 N0001:1982 BSI 05-20001 1 Pattern number The specification number without the letters BS is used as the pattern number. This range of connectors is known as Pattern 9522 N0001. 2 Related documents BS 6001, Sampling procedures and tables for inspection by attributes. BS 9000, General requiremen
9、ts for electronic components of assessed quality. BS 9520:1982, Electrical connectors of assessed quality for frequencies below 3 MHz: generic data and methods of test. PD 9002, BS 9000 component selection guide. BS G 210, PTFE insulated equipment wires C with silver plated copper conductors. 3 Desc
10、ription 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 applications. The connectors employ contacts that are r
11、ear 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 contacts. Specification obtainable from: BRITISH STAND
12、ARDS INSTITUTION 101 PENTONVILLE ROAD LONDON N1 9ND TELEPHONE 01-837-8801: TELEX 2321845 pages ELECTRONIC COMPONENTS OF ASSESSED QUALITY DETAIL SPECIFICATION IN ACCORDANCE WITH BS 9520. MANUFACTURERS TYPE NUMBER PD 9002 For ordering information see clause 5 TYPICAL CONNECTORS MULTI-CONTACT CIRCULAR
13、ELECTRICAL CONNECTORS. Bayonet coupling with front release rear removable crimp contacts. ENVIRONMENTAL CATEGORY 55/125/56 FULL ASSESSMENT For marking information see clause 4 For outline drawings see A.2 Refer to Qualified Products List PD 9002 for details of manufacturers approved to this specific
14、ation. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 2 BSI 05-2000 Polarization is effected by housing (shell) keys and keyways, or by angular disposition of the insert. The preferred metho
15、d is housing (shell) keys and keyways, which provides up to four different polarizations other than normal (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 designate
16、d W, X, Y and Z and are intended for replacement purposes only. See Appendix A of this specification for polarization 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 finish
17、es as specified in 4.1. The performance of connectors is normally only assessed using mated pairs with the same 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 be
18、tween alternative finishes. 4 Marking of the component and package 4.1 Connector reference numbers. The marking shall be in accordance with 1.1.6 of BS 9520. The individual reference number required by 1.1.6 c) of BS 9520 consists of abbreviations to identify individual connectors, accessories or to
19、ols in accordance with 4.1 and 4.2. Style number: As shown in A.2. Housing (shell) size/contact arrangement: Four digits as shown on the appropriate outline drawing in A.1. Contact style: M = male contact. F = female contact. Polarization: Letter assigned to a particular arrangement of housing (shel
20、l) keys and keyways or to a particular angular disposition of an insert (see A.1). Variant: A digit denoting any variation from the basic specification. 0 = standard connector cadmium plated 1 = standard connector zinc cobalt plated 2 = standard connector pure zinc plated. Example reference number:
21、C 2002 22 55 MNO. NOTEWhere the connector is supplied complete with an accessory, the reference number shall also include the applicable accessory style number (see 4.2 and A.3). Example reference number: C 2002 22 55 MNO A 2010 4.2 Accessory and tool reference numbers. The individual reference numb
22、ers consist of abbreviations as follows. Style number: As shown in A.3 for accessories and A.4 for tools. (A = accessory, T = tool). Housing (shell) size: Quoted for accessories. Two digits as in A.1. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+
23、00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 BSI 05-20003 Contact size: Quoted for filler plugs or tools. Two digits as in A.3 or A.4. Variant: Quoted for accessories. Use the following code: 0 = accessories for the standard connector cadmium plated 1 = accessories for the standard conn
24、ector zinc cobalt plated 2 = accessories for the standard connector pure zinc plated. Example reference numbers: A 2009 08 0 T 2017 16 4.3 Packaging. Packaging shall include the manufacturers assembly instructions, including wire preparation, crimping and contact insertion if requested. 5 Ordering i
25、nformation 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. BS 9522 N0001. b) The individual reference number as described in clause 4. c) Details of marking that may be require
26、d in addition to or as an alternative to that specified in clause 4. d) Requirements for the provision of assembly instructions. 6 Outline drawings See Appendix A of this specification for the following. A.1 Contact arrangements and polarization availability A.2 Connector outline dimensions, panel c
27、ut-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
28、 in isolation1) at an ambient temperature of 85 C: contact size 20: 7.5A contact size 16: 10A contact size 12: 20A b) Maximum current per contact through all contacts simultaneously at an ambient temperature of 85 C: contact size 20: 5 A contact size 16: 10 A contact size 12: 20 A The performance of
29、 any connectors listed 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 elec
30、trically loaded. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 4 BSI 05-2000 7.1.2 Voltage 7.2 Environmental 7.3 Endurance 8 Characteristics 8.1 Connector range (see A.1 and A.2) 8.2 Electr
31、ical Sea level 1 013 mbara 8 500 m (27 900 ft) 320 mbar 21 340 m (70 000 ft) 44 mbar Voltage ratingbIIIIIIIII Working voltagec (nominal) d.c. or a.c. peak7001 200550650330380 Voltage proof d.c. or a.c. peak2 1003 0001 1001 300660760 a 1 mbar = 102 N/m2= 100 PA. b See A.1. c Establishment of electric
32、al safety factors is the responsibility of the user. Environmental classification55/125/56 Low air pressure severity44 mbar Vibration severity10 Hz to 5 000 Hz, 0.75 mm (10 gn) Duration 30 h Shock severity981 m/s2(100gn) Duration 6 ms Acceleration severity490 m/s2(50gn) Bump severity390 m/s2(40gn) 4
33、 000 10 bumps Mechanical operation500 operations Electrical load and temperature, long term current as in 7.1.1 b) 1 000 h at 85 C Electrical load and temperature, short term (no electrical load) 250 h at 125 C Maximum contact resistance (initially)5 m7 Maximum contact resistance (after conditioning
34、)10 m7 Minimum insulation resistance (initially)5 000 M7, method A or method Ba (see 1.2.4.4 of BS 9520) Minimum insulation resistance (after conditioning)100 M7, method A or method Ba (see 1.2.4.4 of BS 9520) Minimum insulation resistance (hot, mated)3 M7, method A or method Ba (see 1.2.4.4 of BS 9
35、520) Maximum housing (shell) electrical continuity (mated specimens which include C 2002 or C 2004) (initially) 5 m7 Maximum housing (shell) electrical continuity (mated specimens which include C 2002 or C 2004) (after conditioning) 10 m7 Maximum housing (shell) electrical continuity (mated specimen
36、s which include C 2001 or C 2003) (initially and after conditioning) 200 m7 a Method B values shall be recorded. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 BSI 05-20005 8.3 Mechanical En
37、gaging and separating 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
38、1.58 (8) (12) (16) (20) (24) (28) (32) (36) (44) (2) (2) (4) (8) (8) (8) (10) (12) (14) Insert retention in housing (shell), axial517 kN/m2(75 lbf in2) 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
39、 in) min. 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) Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522 N0001:1982 6 BSI 05-2000 Gro
40、unding contact spring holding force2) Wire seal and conductor accommodation 8.4 Fluid resistance. The connectors shall be resistant to the following fluids. Isopropanol, white spirit, dichloromethane, trichloroethylene, kerosene, petrol, hydraulic fluids (normal and silicone based), lubricating oils
41、 (mineral and ester based), petroleum jelly and de-icing fluids. 9 Certified test records (CTRs) Certified test records (CTRs) shall be prepared in accordance with 1.1.11 of BS 9520. 10 Quality assessment procedure Group C tests need not be carried out for Qualification Approval or when subsequent g
42、roup D tests are performed. 11 Inspection requirements Samples subjected to tests marked “(D)” shall not be accepted for release under BS 9000 (see 20.2 of BS 9000-1:1981). Unless otherwise specified, tests shall be performed at an ambient temperature of between 15 C and 35 C. Fitting (and wiring) o
43、f contacts shall be in accordance with the manufacturers instructions. Polytetrafluoroethylene (PTFE) extruded wire complying with the requirements of BS G 210 shall be used. (To ensure that the wiring operation has been carried out satisfactorily it is advisable to apply insulation resistance and c
44、ontact 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 C 2002 and C 2004. Contact size Wire insulationConductora min. o.d.max. o.d.min. o.d.max. o.d. mm(in)mm(in)mmmm 20 16 12 1.19 1.68 2.46 (0.047) (
45、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 See manufacturers assembly instructions, which may extend the ranges of conductor diameters. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:14:39 GMT+00:00 2006, Uncontroll
46、ed Copy, (c) BSI BS 9522 N0001:1982 BSI 05-20007 InspectionBS 9520 reference and conditions of testRequirements as in BS 9520 GROUP ATo be applied on a sampling basis lot-by-lot except subgroup A0 Subgroups A2, A3 and A4 are not applicable Subgroup A0100 % inspection Unless required for test, contac
47、ts need not be fitted Voltage proof Visual examination 1.2.4.5 1.2.2 a) Method A or B Voltage as in 7.1.2 of this specification. Duration = 5 s (This requirement may be demonstrated immediately prior to final assembly) As in 1.2.4.5 As in 1.2.2 a) Subgroup A1 Visual examination Inspection level S-3,
48、 AQL 1.5 % Contacts need not be fitted 1.2.2 b)As in 1.2.2 b) Subgroup A5 CTR information1.1.11The result from the test in subgroup A1 shall be reported as attributes information GROUP BTo be applied on a sampling basis lot-by-lot Subgroups B3 to B7 are not applicable Subgroup B1 Inspection level S-
49、4, AQL 1 % 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 50 V) or Method B (500 50 V) Forces are specified in 8.3 of this specification With 3 sizings and using gauges as prescribed in A.5 of this specification As in 1.2.3.3.2 5 000 M7 min.a As in 1.2.5.3 As in 1.2.5.9 Subgroup B2 (D)Inspection level S-4, AQL 4 % Samples from subgroup B1 may be used. Only contacts required for test need be fitted Housing (shell) electrical continuity In
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