SAE AS 39029 117-2016 CONTACTS ELECTRICAL CONNECTOR SOCKET CRIMP REMOVABLE ENGINE APPLICATION (FOR MIL-DTL-38999 SERIES I III AND IV CONNECTORS).pdf

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1、 AEROSPACE STANDARD CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) AS39029/117Copyright 2016 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transm

2、itted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE

3、WEB ADDRESS: http:/www.sae.org ISSUED2016-05THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C1 FEDERAL SUPPLY CLASS 5999 AS39029/117 SHEET 1 OF 8 PROCUREMENT SPECIFICATION: AS39029 SAE Technical Standards BoardRules providethat:“This reportis publishedbySAE toadvancethestateoftechnicalandengineering scie

4、nces. The use ofthis report isentirely voluntary, andits applicability andsuitability for any particularuse, includingany patentinfringement arising therefrom,is the soleresponsibility of theuser.”SAE reviews eachtechnical reportatleast every fiveyears atwhichtimeitmay berevised,reaffirmed, stabiliz

5、ed,orcancelled. SAE invites yourwrittencomments andsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS39029/117 RATIONALE NEW CONTACTS REQUIRED FOR AIRCRAFT ENGINE APPLICATIONS. NOTICE THE COMPLETE REQUIREMENTS FOR PR

6、OCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS39029. FIGURE 1 - SOCKET CONTACT AEROSPACE STANDARD AS39029/117 SHEET 2 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)

7、 FIGURE 1 - SOCKET CONTACT (CONTINUED) TABLE 1 - FIGURE 1 DIMENSIONS BIN CODE MATING END SIZE WIRE BARREL SIZE A REF B DIA MIN C DIA D DIA E DIA F DIA MAX G DIA H 1/ 632 638 22 22D .855 .031 .062 .060 .022 .018 .0355 .0335 .062 .048 .046 .005 .003 634 640 20 20 .0415 .094 .091 .032 .026 .048 .046 .0

8、78 .070 .068 .010 .005 635 641 16 16 .064 .130 .127 .042 .036 .068 .066 .113 .103 .101 636 642 12 12 .0955 .182 .179 .102 .098 .161 .151 .148 .016 .005 637 643 10 10 1.021 .1265 .242 .238 .052 .046 .140 .134 .215 .213 .207 1/ IF A BLEND RADIUS IS USED MATING END SIZE 22 SHALL BE .010 .005, SIZE 20 S

9、HALL BE .015 .005, AND SIZE 16 SHALL BE .020 .005. TABLE 1 - FIGURE 1 DIMENSIONS (CONTINUED) BIN CODE MATING END SIZE WIRE BARREL SIZE J K L MIN M N P DIA. MIN S 632 638 22 22D .626 .616 .141 MIN .585 - 50 44 .047 .237 .231 634 640 20 20 .209 MIN .078 .072 47 40 .053 635 641 16 16 .088 .082 .084 636

10、 642 12 12 .118 637 643 10 10 .385 .355 .115 .108 NA .146 .405 .395 AEROSPACE STANDARD AS39029/117 SHEET 3 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) REQUIREMENTS: ALL REQUIREMENTS SHALL CONSIST OF THIS SPECI

11、FICATION AND THE LATEST ISSUE OF AS39029. 1. CONTACT SHALL BE A CLASS B, TYPE A CONTACT IN ACCORDANCE WITH FIGURE 1 AND TABLE 1. a. DIMENSIONS ARE IN INCHES AND SHOWN AFTER PLATING. METRIC UNITS ARE PROVIDED IN TABLE 7 FOR GENERAL INFORMATION ONLY (SEE SPECIFICATION NOTE). b. IF A BLEND RADIUS IS US

12、ED, CRIMP BARREL END SIZE 20 SHALL BE .015 .005, AND SIZE 16 SHALL BE 020 .005. c. SHOULDER DIMENSION .029/.033 DOES NOT APPLY TO BIN CODE 632 AND 638 (SEE FIGURE 1). d. DIAMETERS E AND G SHALL BE CONCENTRIC WITHIN .003 (TIR) AT LEAST MATERIAL CONDITION (LMC) FOR BIN CODES 636 AND 642 e. DIAMETERS E

13、 AND G SHALL BE CONCENTRIC WITHIN .001 (TIR) AT THE LEAST MATERIAL CONDITION (LMC) FOR ALL BIN CODES EXCEPT CODES 636 AND 641 f. DIMENSION .041/.036 (SEE DETAIL T) SHALL BE CONCENTRIC TO DIAMETER G WITHIN .003 TIR (RFS). g. DIMENSION K SHALL DEFINE THE LOCATION OF WIRE STOP ON A WIRE STRIPPER TOOL h

14、. DIMENSION L MINIMUM IS THE POINT AT WHICH A SQUARE ENDED PIN OF THE SAME BASIC DIAMETER AS THE MATING CONTACT FIRST ENGAGES THE SOCKET CONTACT SPRING. i. A FULL RADIUS IS PERMISSIBLE FOR SIZE 10 (BIN CODES 636 AND 641), ANGLE (N). SEE DETAIL X. j. CONTACT SHALL BE A ONE PIECE CONSTRUCTION WITH NO

15、MULTIPLE PART CONSTRUCTION EXCEPT FOR AN OPTIONAL HOOD PROVIDED THE HOOD DOES NOT ACT AS A POINT OF ENGAGEMENT WITH THE MATING PIN CONTACT. k. MECHANICAL PRESSURE MEMBER SHALL BE SHROUDED. HOOD, IF USED, SHALL COMPLY WITH THE REQUIREMENTS HEREIN. HOOD SHALL NOT EXCEED CONTACT BODY DIAMETER. OPTIONAL

16、 DESIGN HOOD MAY BE CORROSION RESISTANT STEEL. 2. CONTACT MATERIAL SHALL BE IN ACCORDANCE WITH AS39029 EXCEPT AS FOLLOWS (SEE TABLE 2). a. CONTACT PLATING FOR BIN CODES 632 AND 634 THROUGH 637 SHALL BE GOLD PLATED 100 MICROINCHES MINIMUM THICKNESS OVER 50 MICROINCHES MINIMUM THICKNESS NICKEL UNDERPL

17、ATE. b. CONTACT PLATING FOR BIN CODES 638 AND 639 THROUGH 643 SHALL BE IN RHODIUM PLATED 50 MICROINCHES MINIMUM THICKNESS IN ACCORDANCE WITH ASTM B634 OVER 150 MICROINCHES MINIMUM THICK NICKEL UNDERPLATE. c. THE INTERIOR OF THE CRIMP BARREL AT THE CRIMP LOCATION SHALL BE 3 MICROINCHES MINIMUM FOR LO

18、CALIZED GOLD PLATING. d. LOCALIZED RHODIUM PLATING IS NOT PERMITTED. 3. CONTACT MARKING AND RATINGS ARE IN ACCORDANCE WITH TABLE 2. TABLE 2 - CONTACT MARKING AND RATINGS 1/ BIN CODE COLOR BANDS MATING END SIZE WIRE BARREL SIZE TYPE CLASS CONTACT PLATING 1ST 2ND 3RD 632 BLUE ORANGE RED 22 22D A B GOL

19、D OVER NICKEL 634 BLUE ORANGE YELLOW 20 20 635 BLUE ORANGE GREEN 16 16 636 BLUE ORANGE BLUE 12 12 637 BLUE ORANGE VIOLET 10 10 638 BLUE ORANGE GRAY 22 22D RHODIUM OVER NICKEL 640 BLUE YELLOW BLACK 20 20 641 BLUE YELLOW BROWN 16 16 642 BLUE YELLOW RED 12 12 643 BLUE YELLOW ORANGE 10 10 1/ OPERATING T

20、EMPERATURE RANGE: -65 C (-85 F) TO 200 C (392 F). AEROSPACE STANDARD AS39029/117 SHEET 4 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) 4. THE CONTACT SHALL BE CRIMPED ON WIRE AND REMOVED FROM THE CONNECTOR USING

21、 TOOLS SPECIFIED IN TABLE 3. TABLE 3 - CRIMPING, INSERTION, AND REMOVAL TOOLS BIN CODE WIRE BARREL SIZE BASIC CRIMPING TOOL POSITIONER INSERTION TOOL REMOVAL TOOL WIRED CONTACTS UNWIRED CONTACTS 632 638 22D M22520/2-01 M22520/2-07 M81969/14-01 1/ M81969/8-01 2/ M81969/8-301 3/ M81969/14-01 1/ M81969

22、/8-02 4/ M81969/8-302 5/ M81969/30-09 M22520/7-01 M22520/7-05 M22520/7-01 M22520/7-05 634 640 20 M22520/7-01 M22520/7-08 M81969/14-10 1/ M81969/8-05 2/ M81969/8-305 3/ M81969/14-10 1/ M81969/8-06 4/ M81969/8-306 5/ M81969/30-11 M22520/2-01 M22520/2-10 M22520/1-01 M22520/1-04 RED 635 641 16 M22520/1-

23、01 M22520/1-04 BLUE M81969/14-03 1/ M81969/8-07 2/ M81969/8-307 3/ M81969/14-03 1/ M81969/8-08 4/ M81969/8-308 5/ M81969/30-12 M22520/7-01 M22520/7-04 636 642 12 M22520/1-01 M22520/1-04 YELLOW M81969/14-04 1/ M81969/8-09 2/ M81969/8-309 3/ M81969/14-04 1/ M81969/8-10 4/ M81969/8-310 5/ M81969/30-13

24、637 643 10 M22520/45-01 POSITIONER BUILT INTO BASIC TOOL M81969/14-05 1/ M81969/8-11 2/ M81969/8-311 3/ M81969/14-05 1/ M81969/8-12 4/ M81969/8-312 5/ M81969/30-14 1/ ALL PLASTIC INSERTION AND REMOVAL TOOL 2/ METAL (ANGLED) INSERTION TOOL 3/ METAL (STRAIGHT) INSERTION TOOL (RECOMMENDED FOR LIMITED A

25、CCESS CONNECTOR APPLICATIONS) 4/ METAL (ANGLED) REMOVAL TOOL 5/ METAL (STRAIGHT) REMOVAL TOOL (RECOMMENDED FOR LIMITED ACCESS CONNECTOR APPLICATIONS) 5. CONTACT PERFORMANCE (TYPES A CONTACTS) CONTACT PERFORMANCE SHALL BE IN ACCORDANCE WITH AS39029 WITH THE FOLLOWING EXCEPTIONS: a. RESISTANCE TO TEST

26、 PROBE DAMAGE (GROUP I) INSERTION DEPTH SHALL BE IN ACCORDANCE WITH TABLE 4. TABLE 4 - PROBE DAMAGE INSERTION DEPTH CONTACT MATING END SIZE INSERTION DEPTH INCHES +.020 -.000 22, 20 .083 .125 1/ 16 .135 12 .166 10 .166 1/ INDICATED DIMENSIONS REPRESENT AND INCH DEPTHS. b. CONTACT RESISTANCE SHALL BE

27、 AS SPECIFIED IN AS39029. THE CONTACTS SHALL BE MEASURED AT AMBIENT TEMPERATURE (25 5C) AND UNDISTURBED WHILE STILL WITHIN THE CONNECTOR. THE MEASURING POINTS SHALL BE AT A TOTAL DISTANCE OF 6 INCHES APART. THE CONTACT RESISTANCE SHALL MEET THE REQUIREMENTS OF AS39029 AT THE CURRENTS SPECIFIED. AERO

28、SPACE STANDARD AS39029/117 SHEET 5 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) c. CONTACT DURABILITY (GROUP II) SHALL BE 1500 CYCLES. d. VIBRATION FOLLOWED BY SHOCK (GROUP II) CONTACT SPECIMENS: THE NUMBER OF

29、CONTACT SAMPLE UNITS TO BE INSPECTED SHALL BE THREE TIMES THE REQUIRED QUALIFICATION TEST SAMPLES SPECIFIED IN AS39029. TEST FIXTURE: MIL-DTL-38999L ADM. 2 OR LATER COMPOSITE CONNECTOR MATED PAIRS WITH STRAIN RELIEF ACCESSORIES RATED AT 200 C ARE RECOMMENDED AS CONTACT TEST FIXTURES. THE COMPOSITE C

30、ONNECTOR IS RECOMMENDED TO ACCOMMODATE THE 1500 CYCLE DURABILITY REQUIREMENT THUS ELIMINATING THE NEED TO REMOVE THE CONTACTS FOR VIBRATION. VIBRATION REQUIREMENT: 1. DURING EACH VIBRATION AND SHOCK TEST, THERE SHALL BE NO DISCONTINUITIES IN EXCESS OF 1 MICROSECOND. 2. CONTACT RESISTANCE (25 C) IS R

31、EQUIRED. 3. THERE SHALL BE NO EXPOSURE OF CONTACT BASE METAL. VIBRATION TEST METHOD: 1. DIVIDE THE CONTACTS INTO THREE GROUPS (1, 2, 3) AND MOUNT EACH GROUP IN THE NUMBER OF TEST FIXTURES AS NEEDED. 2. THE GROUP 1 CONTACTS SHALL BE TESTED TO A SIMPLE HARMONIC MOTION FROM 10 TO 2000 Hz IN EACH OF THR

32、EE MUTUALLY PERPENDICULAR AXES. THE LEVEL OF VIBRATION SHALL BE A VELOCITY OF 254 MM/SEC FROM 10 TO 50 Hz; 1.5 MM DOUBLE AMPLITUDE FROM 50 TO 140 Hz, AND 60 G FROM 140 TO 2000 Hz. THE ENTIRE FREQUENCY RANGE FROM 10 TO 2000 Hz AND BACK SHALL BE TRAVERSED IN 20 MINUTES. THE VIBRATION SHALL BE APPLIED

33、A DURATION OF 12 HOURS IN EACH OF THE THREE MUTUALLY PERPENDICULAR AXES FOR A TOTAL OF 36 HOURS. EACH AXIS OF VIBRATION SHALL BE ACCOMPLISHED BY VIBRATING FOR 4 HOURS AT AMBIENT ROOM TEMPERATURE, 4 HOURS AT -65 C 5 C, AND 4 HOURS AT +200 C 5 C. CONTACTS SHALL BE CONTINUOUSLY MONITORED FOR DISCONTINU

34、ITY IN ACCORDANCE WITH EIA-364-46. 3. THE GROUP 2 CONTACTS SHALL BE TESTED IN ACCORDANCE WITH EIA-364-28 TEST CONDITION VI, LETTER J AND CONTINUOUSLY MONITORED FOR DISCONTINUITY IN ACCORDANCE WITH EIA-364-46. DURATION SHALL BE 8 HOURS IN THE LONGITUDINAL DIRECTION AND 8 HOURS IN A PERPENDICULAR DIRE

35、CTION FOR A TOTAL OF 16 HOURS. THE TEMPERATURE SHALL BE 200 C 5 C DURING THE VIBRATION. 4. THE GROUP 3 CONTACTS SHALL BE TESTED IN ACCORDANCE WITH EIA-364-28 TEST CONDITION V USING THE VIBRATION ENVELOPE SHOWN IN FIGURE 2 AND CONTINUOUSLY MONITORED FOR DISCONTINUITY IN ACCORDANCE WITH EIA-364-46. DU

36、RATION SHALL BE 8 HOURS IN THE LONGITUDINAL DIRECTION AND 8 HOURS IN A PERPENDICULAR DIRECTION FOR A TOTAL OF 16 HOURS, AND THE TEMPERATURE SHALL BE 25 C 5 C DURING THE VIBRATION TEST. 5. FOLLOWING EACH VIBRATION TEST, THE CONTACTS SHALL BE INDIVIDUALLY MEASURED FOR CONTACT RESISTANCE AT 25 C 5 C. T

37、HE CONTACTS SHALL REMAIN UNDISTURBED WHILE STILL WITHIN THE FIXTURE. AEROSPACE STANDARD AS39029/117 SHEET 6 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) FIGURE 2 - RANDOM VIBRATION ENVELOPE SHOCK (HIGH IMPACT)

38、AFTER VIBRATION TEST METHOD: GROUP 3 CONTACTS SHALL BE SUBJECTED TO THE TEST SPECIFIED IN MIL-S-901, GRADE A WITH THE FOLLOWING MODIFICATIONS AND ADDITIONS: 1. CONTACTS SHALL BE WIRED IN ONE OR MORE SERIES CIRCUIT(S) WITH 100 MILLIAMPERES MAXIMUM CURRENT FLOW THROUGH THE SERIES CIRCUIT(S) DURING HIG

39、H-IMPACT SHOCK AND MONITORED FOR ANY DISCONTINUITIES. 2. A DETECTOR CAPABLE OF DETECTING ALL DISCONTINUITIES IN EXCESS OF 1 MICROSECOND SHALL BE USED. 3. IF MATED CONNECTORS ARE USED AS A CONTACT FIXTURE, THE MOUNTING FIXTURE SHALL BE IN ACCORDANCE WITH MIL-S-901, LIGHTWEIGHT. THE MATED CONNECTORS S

40、HALL BE TERMINATED WITH AT LEAST 80% OF WIRED CONTACTS AND INCLUDE STRAIN RELIEF ACCESSORIES. 4. 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 THE MOUNTING FIXTURE OF NOT LESS THAN 36 INCHES (914.4 MM).

41、 5. FOLLOWING THE SHOCK TEST, THE CONTACTS SHALL BE INDIVIDUALLY MEASURED FOR CONTACT RESISTANCE AT 25 C 5 C. THE CONTACTS SHALL REMAIN UNDISTURBED WHILE STILL WITHIN THE FIXTURE. VISUAL EXAMINATION: 1. FOLLOWING THE COMPLETION OF THE VIBRATION AND SHOCK TESTS THE INDIVIDUAL CONTACTS SHALL BE CAREFU

42、LLY REMOVED FROM THE FIXTURE AND VISUALLY EXAMINED FOR EVIDENCE OF BASE METAL USING A X10 MAGNIFICATION. AEROSPACE STANDARD AS39029/117 SHEET 7 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) 6. INITIAL QUALIFICAT

43、ION, RETENTION OF QUALIFICATION, AND QUALITY CONFORMANCE INSPECTIONS: a. INITIAL QUALIFICATION SHALL BE IN ACCORDANCE WITH AS39029 AND HERE IN. b. THE MANUFACTURERS RELIABILITY ASSURANCE PROGRAM FOR AS39029/117 AND ASSEMBLY PROCEDURES SHALL COMPLY WITH THE AS9100 AEROSPACE STANDARD FOR QUALITY MANAG

44、EMENT SYSTEM REQUIREMENTS. OTHER ESTABLISHED AND INDUSTRY RECOGNIZED QUALITY ASSURANCE STANDARDS THAT ASSURE ALL PRODUCTS PRODUCED CONFORM TO THE CONTRACT REQUIREMENTS ARE ACCEPTABLE. HOWEVER, IF USED, IT IS THE RESPONSIBILITY OF THE MANUFACTURER TO PROVIDE EVIDENCE OF COMPLIANCE TO AS9100. THE QUAL

45、IFYING ACTIVITY (QA) AUTHORITY RESERVES THE RIGHT TO MONITOR, MEASURE, AND VALIDATE COMPLIANCE AT THEIR DISCRETION. c. RETENTION OF QUALIFICATION SHALL BE IN ACCORDANCE WITH AS39029 (RETENTION OF QUALIFICATION TESTING PERFORMED BY QUALIFYING ACTIVITY (ALL CONTACT TYPES AS SPECIFIED) EXCEPT GROUP II

46、OF (AS39029 QUALIFICATION INSPECTION TYPES A AND B CONTACTS) SHALL BE PERFORMED EVERY 72 MONTHS. THE QUALIFYING ACTIVITY MAY PERFORM OR MONITOR THE ADDED GROUP II TESTS. d. INSPECTION OF THE GOLD PLATE THICKNESS IN THE INTERIOR OF THE CRIMP BARREL IS NOT REQUIRED FOR EXTERIOR CONTACT 100 MICROINCHES

47、 MINIMUM GOLD THICKNESS. 7. CONTACT PART NUMBERS AND SUPERSEDING INFORMATION IS IN ACCORDANCE TABLE 5. TABLE 5 - CONTACT PART NUMBERS AS39029 PART NUMBER BIN CODE SUPERSEDED PART NUMBERS M39029/117-632 632 NONE M39029/117-634 634 M39029/117-635 635 M39029/117-636 636 M39029/117-637 637 M39029/117-63

48、8 638 NONE M39029/117-640 640 M39029/117-641 641 M39029/117-642 642 M39029/117-643 643 8. CONTACT MATES DIRECTLY WITH AN AS39029/118 PIN AS SHOWN IN TABLE 6. TABLE 6 - CONTACT MATING PART NUMBERS AS39029/117 SOCKET BIN CODE AS39029/118 MATING PIN BIN CODE 632 644 634 646 635 647 636 648 637 649 638

49、650 640 652 641 653 642 654 643 655 9. APPLICATIONS a. THIS CONTACT IS INTENDED FOR USE IN THE HIGH TEMPERATURE AND VIBRATION ENVIRONMENTS OF AIRCRAFT ENGINES, BUT THERE IS NO RESTRICTION FOR GENERAL APPLICATIONS. AEROSPACE STANDARD AS39029/117 SHEET 8 OF 8 CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, ENGINE APPLICATION, (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS) SPECIFICATION NOTES: 1. REVISION INDICATOR: A CHANGE BAR (I) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WH