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1、BRITISH STANDARD BS 9522:1990 Rules for the preparation of detail specifications for Circular electrical connectors of assessed quality for d.c. and low frequency applications. Full, basic and full plus airframe assessment levels Licensed Copy: London South Bank University, London South Bank Univers
2、ity, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522:1990 BSI 03-2000 ISBN 0 580 35802 X Foreword This revised British Standard prescribes the rules for the preparation of detail specifications for circular electrical connectors for d.c. and low frequency applications. It is s
3、upplementary to BS 9520 “Specification for electrical connectors of assessed quality for d.c. and low frequency application: generic data, methods of test and capability approval procedures”. Examples of detail specifications, in the BS 9522 range are BS 9522 N0001, N0003 and F0039. This revision up
4、dates the rules document in the light of changes in test requirements for connectors for electronic equipment and supersedes BS 9522:1984, which is withdrawn. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for the
5、ir 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 50 and a back cover. This standard has been updated (see copyright date) and
6、 may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Amendments issued since publication Amd. No.DateComments Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (
7、c) BSI BS 9522:1990 BSI 03-2000i Contents Page ForewordInside front cover 1Scope1 2General1 3Quality assessment procedure5 4Inspection requirements6 Appendix A Alternative method for sequential quality conformance testing and maintenance of qualification approval41 Table 1 Mandatory inspection requi
8、rements for full assessment level6 Table 2 Mandatory inspection requirements for basic assessment level16 Table 3 Comparative table of tests19 Table 4 Mandatory inspection requirements for full assessment level plus airframe requirements23 Licensed Copy: London South Bank University, London South Ba
9、nk University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI ii blank Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522:1990 BSI 03-20001 1 Scope This British Standard prescribes those sp
10、ecial rules which in conjunction with the general rules contained in section 2 of BS 9520:1983 are required for the preparation of detail specifications for circular electrical connectors of assessed quality for frequencies below 3 MHz at the full, basic and full plus airframe assessment levels. 2 G
11、eneral 2.1 Contacts Connectors designed to intermate, but which differ in having removable or non-removable contacts with solder, crimp, wire wrap, push-on etc., terminations, may be included in one detail specification. The types of contact shall be indicated in the title of the connector specifica
12、tion, and for removable contacts the direction of release and removal from the connector, e.g. front release, rear removable, shall be stated. Removable contacts shall be defined in connector detail specifications by means of outline drawings and shall be identified either: a) by reference to the co
13、ntact detail specification to which the contacts are qualified in the series BS 9521: “Specification for removable contacts of assessed quality for electrical connectors as defined by BS 9520: generic data, methods of test and rules for the preparation of detail specifications” e.g. BS 9521 F0001; o
14、r b) by means of digits indicating contact size, wire accommodation and contact style, preceded by the connector pattern number e.g. BS 9522 F0001/20-20M; or c) where a) or b) cannot be applied, by an accessory number. 2.2 Assessment level The detail specification shall show the relevant assessment
15、level, basic, full etc. (see 2.1.4 of BS 9520). Each detail specification shall refer to only one assessment level. The performance of connectors is normally only assessed with mated pairs from the same manufacturer and in such cases the detail specification shall include a statement to this effect.
16、 In other cases, where manufacturers wish to claim functional compatibility and their connectors have been tested to demonstrate such compatibility, this fact and the tests employed shall be stated on the facing sheet of the detail specification. In cases where a manufacturer produces only one half
17、of a mated connector, such connectors may be tested with an approved mating part to demonstrate functional compatibility. In such cases, the detail specification shall include a statement to this effect. In cases where two or more manufacturers wish to include a claim of functional compatibility of
18、differing connector styles, and their connectors are tested to demonstrate such compatibility, the detail specification shall identify the appropriate agreed tests and include a statement to this effect. See also 2.1.4 of BS 9520. 2.3 Title Connectors to detail specifications in this series have the
19、 following title: “Multi-contact, circular electrical connectors”. Typical supplementary information in the title is as follows: “Bayonet coupling with front release, rear removable crimp contacts”. See the example detail specifications quoted in the foreword for the method of presentation of inform
20、ation required to be shown on the front page. (See also BS 9000-2 and PD 9004, Circular letters Nos. 15 and 16.) 2.4 Pattern number The pattern number of a connector or range of connectors shall consist of the relevant detail specification number without the letters BS e.g. Pattern 9522 N-. Licensed
21、 Copy: London South Bank University, London South Bank University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522:1990 2 BSI 03-2000 2.5 Description of the connector and intended application The description of the connector shall make reference to the method of coupling, pola
22、rization (and orientation where applicable), contact type (crimp, solder, etc., removable, non-removable), material or finish. For connectors having removable contacts the manner of insertion, release and removal of the contacts shall be stated. Where compliance with the detail specification is depe
23、ndent on a full complement of contacts being fitted and/or by the use of dummy contacts or unwired contacts with filler plugs, this shall be stated. The description of intended application shall make reference to major performance characteristics of the connector, such as un-sealed or sealed e.g. ba
24、rrier or barrier and panel sealed, environment resistant, shielded etc., and attention may also be drawn to particular uses, e.g. general purpose application. 2.6 Making of the component and package The detail specification shall state that the marking shall be in accordance with 1.1.6 of BS 9520. T
25、he individual reference number required by 1.1.6 c) of BS 9520 consists of abbreviations to identify individual connectors accessories and tools. It is not intended that this reference number shall describe every feature of the connector. An explanation of the reference shall be included in each det
26、ail specification similar to the following: 2.6.1 Connector reference numbers: Style numberA letter C denoting Circular, followed by four digits. A typical description of a style is C 1234: Connector, fixed single hole mounting (crimp contacts). (The detail specification shall designate style and sh
27、all relate this number to a control drawing in the CC or FC series, e.g. CC/C.1234). Housing (shell) size/contact arrangement A pair of digits denoting a particular housing (shell) followed by three digits denoting a particular contact arrangement for that particular housing (shell) size. These arra
28、ngements shall be shown in the outline drawing section of the detail specification. In order to facilitate automatic recognition, it is necessary to standardize the number of digits used within the reference number e.g. 833 and 106 will be expressed as C 1234 08 033 and C 1234 10 006. Contact style
29、(letter)M = Male contact F = Female contact H = Hermaphroditic contact Termination styleC = Crimp S = Solder Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522:1990 BSI 03-20003 2.6.2 Accessory add tool re
30、ference numbers 2.6.3 Connector supplied complete with accessory. Where a connector is supplied complete with an accessory, the accessory reference number is added to that of the connector, e.g. C1234 20 41 MNO A 2468. 2.6.4 Packaging. Packaging shall include upon request the manufacturers assembly
31、instructions, including wire preparation crimping and contact insertion details. 2.7 Ordering information For ordering information see 2.4 of BS 9520. 2.8 Drawings The detail specification shall contain drawings, in appendices as required by 2.1.5 and Appendix A of BS 9520. W = Wire wrap P = Push on
32、 PolarizationLetter or digit denoting a particular arrangement of keys and keyways on housings (shells) and bodies or orientation of insert in housings, e.g. N,A,B,C,D, or 0,1,2, VariantA letter or digit to denote variation from basic specification, e.g. housing (shell) finish, contact finish etc. D
33、etail specification shall designate variants. Where no variation exists 0 shall be used. Example of reference number:C 1234 20 41 MS NO. Style number:A letter A denoting accessory or letter T denoting tool, followed by four digits. A typical description of a style is A2468 Grommet Nut assembly or T3
34、579 Contact Insertion tool. (The detail specification shall designate styles and shall relate this number to a control drawing in the CC or FC series, e.g. CC/A2468 CC/T2018.) Housing (shell) size:Two digits (quoted for accessories). Contact size:Two digits (quoted for filler plugs or tools.) Varian
35、t:Quoted for accessories. Digit as for connector in 2.6.1. Example accessory tool reference numbers: A 2468 18 0 T 3579 20 Example removable contact reference numbers BS 9521 F0001 20 20 M see 2.1 a) BS 9522 N0001 20 20 M see 2.1 b) A2466 see 2.1 c) Licensed Copy: London South Bank University, Londo
36、n South Bank University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522:1990 4 BSI 03-2000 2.9 Ratings (including conditions of use) The following ratings shall be stated (in accordance with 1.1.12 of BS 9520) and the applicability requirements of Table 1 and Table 2 of this
37、specification. 2.9.1 Electrical. A recommended maximum working current per individual contact sizes (in isolation) at a specified ambient temperature. Maximum current per contact (for each contact size) through all contacts simultaneously at a specified ambient temperature. Working and proof voltage
38、s shall be given for stated air pressure(s). 2.9.2 Environmental Climatic classification Low air pressure severity Vibration severity Bump severity Shock severity Acceleration severity1) 2.9.3 Endurance 2.10 Characteristics The following characteristics shall be stated (in accordance with 1.1.12 of
39、BS 9520), and the conditions under which they apply. Initial and final values shall both be stated where differences after conditioning are permitted. 2.10.1 Electrical Maximum contact resistance Minimum insulation resistance Maximum housing (shell) electrical continuity resistance 2.10.2 Mechanical
40、 Engaging and separating force, connector Insert retention in housing (shell): test load1) Contact retention (in insert): test load1) Contact holding force Pressure sealing (air leakage)1) Pressure sealing (air leakage)1) Wire/cable accommodation 2.10.3 Resistance to fluids. The detail specification
41、 shall state the fluids to which resistance is claimed. See Tables 1 and 2 of BS 2011-2.1R for basic and full assessment. For airframe connectors see BS G 202. 2.11 Certified test records (for full assessment level only) See Appendix C of BS 9000 for an example layout. 2.12 Additional information Ad
42、ditional drawings, notes etc., needed for the clarification of the detail specification may be given. This information is not required to be verified by the inspection requirements. 1) Where applicable. Mechanical operation Electrical load and temperature: long term (at stated current and temperatur
43、e) Electrical load and temperature: short term (no electrical load and at upper temperature severity). Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 04:34:07 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 9522:1990 BSI 03-20005 3 Quality assessment procedure 3.
44、1 Selection of specimens The specimens for each subgroup should contain representative styles and the smallest, medium and largest size for which approval is sought. The overall sample shall include the greatest contact density for each voltage and current rating for which approval is sought in thes
45、e sizes. For group D the detail specification shall include a table which indicates the combinations of connectors and accessories to be used in each set and which set is to be tested in which subgroup(s). 3.1.1 Full assessment level a) For subgroup D0, one specimen of each piece-part of the connect
46、or range submitted for approval. For subgroup D1, three specimens of connector for each reference number. However, this may be modified provided a sampling plan, agreed with the National Supervising Inspectorate (NSI), is appended to the detail specification. The layout of this should preferably be
47、similar to that in Appendix C of the example detail specification (BS 9522 N0001 or N0003). b) The minimum sample for subgroup D2 to D92) inclusive is 60 specimen mated pairs complete with appropriate accessories. The minimum number of specimens for each of the subgroups D2, D3, D4, D5 and D6 is 15
48、pairs except in the case of Table 4 where subgroup D3 samples shall be used for subgroup D4. For Table 1, subgroup D3 samples may be used for subgroup D4. For subgroup D6(ii) it is three samples for each contact size and these may be taken from the subgroup D3 test samples. For subgroup D7 and D92)
49、it is five mated pairs; for subgroup D8(i) it is three mated pairs and these can be taken from the subgroup D2 test samples. For subgroup D8(ii) it is two mated pairs and these shall be selected from the larger sizes of subgroup D2 test samples. Alternatively, separate samples may be used for subgroup D8(ii) tests. 3.1.2 Basic assessment level a) For subgroup D0, one specimen of each piece-part required for the connector range submitted for approval. For subgroup D1, three specimens of connector for each reference number. However, this may be modified provid