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1、BRITISH STANDARD BS 9520:1983 Incorporating Amendment Nos. 1, 2, 3, 4 and 5 Specification for Electrical connectors of assessed quality for d.c. and low frequency application: generic data, methods of test and capability approval procedures UDC 621.315.683 Licensed Copy: London South Bank University
2、, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 This British Standard, having been prepared under the direction of the Electronic Components Standards Committee, was published under the authority of the Board of BSI and comes into effect on
3、 28 February 1983 BSI 02-2000 First published September 1970 First revision February 1974 Second revision February 1983 The following BSI references relate to the work on this standard: Committee reference ECL/21 Draft for comment 80/28568 DC ISBN 0 580 12908 X Cooperating organizations The Electron
4、ic Components Standards Committee, under whose direction this British Standard was prepared, consists of representatives from the following: British Electrical and Allied Manufacturers Association (BEAMA) Department of Industry (Computers Systems and Electronics) Electricity Supply Industry in Engla
5、nd and Wales Electronic Components Industry Federation* Electronic Engineering Association* Institution of Electronic and Radio Engineers Ministry of Defence* National Supervising Inspectorate* Post Office* Society of British Aerospace Companies Limited* Telecommunication Engineering and Manufacturi
6、ng Association (TEMA)* The organizations marked with an asterisk in the above list were directly represented on the Technical Committee entrusted with the preparation of this British Standard. Amendments issued since publication Amd. No.Date of issueComments 4817April 1985 5681November 1987 6555Apri
7、l 1991 6329April 1992 7418February 1993Indicated by a sideline in the margin Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 BSI 02-2000i Contents Page Cooperating organizationsInside front cover F
8、orewordvii Section 1. Principles and mandatory procedures1 1.1General matters1 1.1.1Scope1 1.1.2Related documents1 1.1.3Terminology1 1.1.3.1General terms2 1.1.3.2Connector accessory terms2 1.1.3.3Connector terms3 1.1.3.4Contact and termination terms5 1.1.3.5Mounting terms7 1.1.3.6Tool terms7 1.1.4Le
9、tter symbols, signs and abbreviations7 1.1.5Graphical symbols7 1.1.6Marking of the component and package7 1.1.7Eligibility for qualification approval7 1.1.8Structurally similar components8 1.1.9Delayed delivery8 1.1.10Supplementary procedures for qualification approval8 1.1.10.1Procedure in the even
10、t of failure at group C or group D inspection8 1.1.10.2Release before completion of group B tests8 1.1.11Certified test records8 1.1.12Standard ratings and characteristics8 1.1.12.1General8 1.1.12.2Electrical ratings8 1.1.12.3Environmental ratings8 1.1.12.4Endurance ratings9 1.1.12.5Electrical chara
11、cteristics9 1.1.13Unchecked parameters9 1.2Test procedures9 1.2.1Measurement conditions9 1.2.1.1General conditions9 1.2.1.2Airframe connectors: wiring of specimens, class S, H and N only10 1.2.1.3Order of tests10 1.2.2Visual examination10 1.2.3Dimensioning and gauging procedures10 1.2.3.1Dimensions,
12、 outline10 1.2.3.2Dimensions, detail and materials10 1.2.3.3Gauging procedure10 1.2.3.3.1Mechanical compatibility compliance10 1.2.3.3.2Mechanical compatibility assurance10 1.2.3.3.3Polarizing gauging10 1.2.3.3.4Orientation gauging11 1.2.4Electrical test procedures11 1.2.4.1Mounting11 Licensed Copy:
13、 London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 ii BSI 02-2000 Page 1.2.4.2Contact resistance11 1.2.4.3Housing (shell) electrical continuity11 1.2.4.4Insulation resistance12 1.2.4.5Voltage proof12 1.2.4.6Current
14、 overload13 1.2.4.7Shielding effectiveness13 1.2.4.8Current switching13 1.2.5Mechanical test procedures13 1.2.5.1General13 1.2.5.2Mass13 1.2.5.3Engaging and separating force, connector13 1.2.5.4Contact retention (in insert)13 1.2.5.5Insert retention in housing (shell) axial14 1.2.5.6Insert retention
15、 in housing (shell) torsional14 1.2.5.7Mechanical impact (free connectors only)14 1.2.5.8Cable clamping (for connectors with cable fixing devices)14 1.2.5.8.1General14 1.2.5.8.2Resistance to cable rotation14 1.2.5.8.3Resistance to cable pull tensile14 1.2.5.8.4Resistance to cable bend14 1.2.5.8.5Res
16、istance to cable torsion15 1.2.5.9Contact holding force (for resilient contacts only)15 1.2.5.10Probe damage (applicable only to connectors having female contacts)15 1.2.5.11Insert ageing (for removable contact types only)15 1.2.5.12Compass safe distance15 1.2.5.13Static load transverse (fixed conne
17、ctors only)15 1.2.5.14Moulding strength test15 1.2.5.15Coupling pin strength15 1.2.5.16Grounding contact spring holding force15 1.2.5.17Contact dislodgement by cable nutation (contact walk-out)16 1.2.5.18Contact gauge location and retention within insert16 1.2.5.19Strength of insertion/extraction to
18、ols16 1.2.5.20Coupled strength (connectors with locking devices)16 1.2.5.21Accessory thread strength16 1.2.5.22External bending moment16 1.2.5.23Insert grommet bonding17 1.2.5.24Cable flexing17 1.2.5.25Male contact protection17 1.2.5.26Male contact stability17 1.2.5.27Engaging and separating (for tw
19、ist-pull coupling connectors having lanyard or lever release)18 1.2.5.28Locking integrity18 1.2.5.29Torsional overload (locking devices)18 1.2.5.30Misuse of contact insertion/extraction tool18 1.2.5.31Termination torsion18 1.2.5.32Guide key retention18 1.2.5.33Locking (safety) wire pull out18 1.2.6E
20、nvironmental test procedure18 Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 BSI 02-2000iii Page 1.2.6.1General18 1.2.6.2Bump19 1.2.6.3Vibration19 1.2.6.3.1Vibration: general19 1.2.6.3.2Vibration:
21、 airframe applications19 1.2.6.3.2.1Specimens: selection and wiring arrangement19 1.2.6.3.2.2Sinusoidal excitation test procedure19 1.2.6.3.2.3Random motion excitation test procedure20 1.2.6.3.2.4Engine mounted connectors vibration test procedure21 1.2.6.4Shock22 1.2.6.5Acceleration, steady state22
22、1.2.6.6Robustness of termination22 1.2.6.6.1General22 1.2.6.6.2Wire, strip, tag or screw terminations22 1.2.6.6.3Solder bucket terminations22 1.2.6.6.4Wire wrap terminations22 1.2.6.7Soldering22 1.2.6.7.1Solderability22 1.2.6.7.2Resistance to soldering heat22 1.2.6.8Rapid change of temperature23 1.2
23、.6.9Flammability23 1.2.6.10Fire resistance failure23 1.2.6.11Temperature overload23 1.2.6.12Climatic sequence: general24 1.2.6.12.1Conditioning sequence24 1.2.6.12.2Recovery (all humidity categories)24 1.2.6.12.3Extended recovery24 1.2.6.12.4Detail specification24 1.2.6.13Immersion (at low air press
24、ure)25 1.2.6.14Sealing, immersion25 1.2.6.15Damp heat (steady state)25 1.2.6.15.1Conditioning25 1.2.6.15.2Tests immediately after conditioning26 1.2.6.15.3Tests after recovery26 1.2.6.15.4Detail specification26 1.2.6.16Mould growth26 1.2.6.17Corrosion, salt mist26 1.2.6.18Dust27 1.2.6.19Pressure sea
25、ling27 1.2.6.19.1Pressure sealing (air leakage)27 1.2.6.19.2Pressure sealing (gas leakage)27 1.2.6.20Resistance to fluids28 1.2.6.20.1Application28 1.2.6.20.2Solvent resistance28 1.2.6.20.3Resistance to contaminating fluids28 1.2.6.21Corrosion, industrial atmosphere28 1.2.6.22Climatic sequence: airf
26、rame application29 Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 iv BSI 02-2000 Page 1.2.6.22.1Specimen selection and preparation29 1.2.6.22.2Conditioning cycles29 1.2.6.22.3Tests30 1.2.6.23Cold3
27、0 1.2.6.24Thermal shock30 1.2.6.25Cold handling (airframe)30 1.2.7Endurance test procedures31 1.2.7.1Mechanical operation31 1.2.7.2Electrical load and temperature31 1.2.7.3Mechanical load and temperature31 Section 2. General rules for the preparation of detail specifications32 2.1Basic information32
28、 2.1.1Object and form of detail specification32 2.1.2Originator of the detail specification32 2.1.3Detail specification number32 2.1.4Description of the component and intended application32 2.1.5Drawings32 2.1.5.1Pattern illustration32 2.1.5.2Outline drawings32 2.1.5.3Control drawings32 2.1.6Ratings
29、 (including limiting conditions of use)32 2.1.7Characteristics32 2.1.8Related documents32 2.1.9Additional information32 2.2Inspection requirements33 2.3Certified test records33 2.4Instructions for ordering components33 Section 3. Capability approval procedure33 3.1General33 3.1.1Introduction33 3.1.2
30、Eligibility for capability approval33 3.1.3Delayed delivery33 3.1.4Supplementary procedures for capability approval33 3.1.5Capability approval procedure chart33 3.2Manufacturing approval35 3.3Capability approval35 3.3.1Category of capability approval35 3.3.2Capability approval plan35 3.4Specificatio
31、ns37 3.4.1General37 3.4.2“Catalogue” items37 3.4.3Customer detail specification (CDS)37 3.5Maintenance of capability approval37 3.5.1General37 3.5.2Process control testing37 3.5.3Capability boundary testing37 3.6Changes of approval37 3.6.1General37 Licensed Copy: London South Bank University, London
32、 South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 BSI 02-2000v Page 3.6.2Design verification of new patterns and approval of new processes37 3.6.3Permanent extension of approval37 3.6.4Temporary extension of approval41 3.7Release for delivery41 Appen
33、dix A Guide to the presentation of drawing information42 Appendix B Typical jig for bump and vibration tests56 Appendix C Typical contact test prod-tool57 Appendix D Equipment for dust test58 Appendix E Fire-resistance failure test fixture assembly59 Appendix F Method of test for moulding strength62
34、 Appendix G Apparatus and method of test for combined humidity, temperature and pressure tests63 Appendix H Vibration test curves67 Appendix J Contact dislodgement by cable nutation (contact walk-out)71 Appendix K Method of test for accessory thread strength72 Appendix L Method of test for external
35、bending moment73 Appendix M Specimens for type tests: preparation of leads; cables to be used74 Appendix N Recommended method of test for current overload76 Appendix O Method of test for male contact stability77 Appendix P Method of test for mechanical load and temperature78 Appendix Q Method of tes
36、t for locking integrity78 Appendix R Method of test for current switching79 Appendix S Method of test for termination torsion80 Appendix T Suggested method of test for guide key retention81 Appendix U Example abstract81 Figure A Capability approval procedure chart34 Figure 1 Circular connectors52 Fi
37、gure 2 Accessories53 Figure 3 Rectangular connectors54 Figure 4 Printed board edge connectors55 Figure 5 Telephone plug connectors55 Figure 6 Mounting block and plate for bump and vibration tests56 Figure 7 Typical contact test prod-tool57 Figure 8 Measuring device for dust test58 Figure 9 Layout of
38、 test rig for fire resistance failure test59 Figure 10 Dimensions of test rig for fire resistance failure test60 Figure 11 Wiring diagram for fire resistance failure test61 Figure 12 Application of force in moulding strength test62 Figure 13 Typical test schedule for combined humidity, temperature a
39、nd pressure tests64 Figure 14 Test cycle for combined humidity, temperature and pressure tests66 Figure 15 Resonance search curve67 Figure 16 Sinusoidal test curve68 Figure 17 Random motion test curve69 Figure 18 Vibration test levels: engine mounted connectors70 Licensed Copy: London South Bank Uni
40、versity, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 vi BSI 02-2000 Page Figure 19 Test fixture for contact walk-out test71 Figure 20 Accessory thread strength test72 Figure 21 External bending moment test73 Figure 22 Preparation of measu
41、rement leads74 Figure 23 Connector test rig (schematic) for current overload test76 Figure 24 Application of gauge for male contact stability test77 Figure 25 Test rig for mechanical load and temperature test78 Figure 26 Test rig for locking integrity78 Figure 27 Circuit diagram for current switchin
42、g test79 Figure 28 Application of torque in termination torsion test80 Figure 29 Permitted distortion in termination torsion test80 Figure 30 Guide key and method of application81 Figure A.0 Example of mechanical compatibility information to be included in the detail specification44 Table 1 Design v
43、erification38 Table 2 Capability boundary test40 Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9520:1983 BSI 02-2000vii Foreword This revised British Standard, which supersedes BS 9520:1974, has been prepa
44、red under the direction of the Electronic Components Standards Committee, and is the generic specification for the low-frequency electrical connectors in the system of standards for electronic components of assessed quality. The revision is necessary in the light of changes in test requirements for
45、low-frequency electrical connectors for electronic equipment. It also includes additional tests for airframe-fit connectors. It consists of two sections, the first of which prescribes mandatory requirements relating to terminology and definitions, test procedures, inspection procedure and general da
46、ta. This section shall be used for inspection purposes as and when required by the detail specification. The second section prescribes general rules necessary for the preparation of detail specifications. This section also covers inspection requirements and certified test records. This standard call
47、s for the use of substances and/or test procedures that may be injurious to health if adequate precautions are not taken. It refers only to technical suitability and in no way absolves either the supplier or the user from statutory obligations relating to health and safety at any stage of manufactur
48、e or use. 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 obligations. Summary of pages This document
49、comprises a front cover, an inside front cover, pages i to viii, pages 1 to 82 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. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00:00 2006, Uncontrolled Copy, (c) BSI viii blank Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:12:17 GMT+00: