SAE AS 39029 118-2016 CONTACTS ELECTRICAL CONNECTOR PIN CRIMP REMOVABLE ENGINE APPLICATION (FOR MIL-DTL-38999 SERIES I III AND IV CONNECTORS).pdf

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1、AEROSPACE STANDARDCONTACTS, ELECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)AS39029/118Copyright 2016 SAE InternationalAll rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in

2、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 WEB ADDRESS:

3、 http:/www.sae.orgISSUED2016-06THIRD ANGLE PROJECTIONCUSTODIAN: AE-8/AE-8C1FEDERAL SUPPLY CLASS5999AS39029/118SHEET 1 OF 7PROCUREMENT SPECIFICATION: AS39029SAE Technical StandardsBoardRulesprovidethat:“ThisreportispublishedbySAE toadvancethestateoftechnicalandengineering sciences. The use of thisrep

4、ort isentirelyvoluntary, andits applicability andsuitability for any particularuse, includingany patent infringement arising therefrom,isthe soleresponsibility of theuser.”SAE reviews eachtechnical reportatleastevery fiveyears atwhichtimeitmay berevised,reaffirmed,stabilized,orcancelled.SAEinvites y

5、ourwritten comments andsuggestions.SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS39029/118RATIONALENEW CONTACTS REQUIRED FOR AIRCRAFT ENGINE APPLICATIONS.NOTICETHE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HER

6、EIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS39029.FIGURE 1 - PIN CONTACTAEROSPACE STANDARDAS39029/118SHEET 2 OF 7CONTACTS, ELECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)TABLE 1 FIGURE 1 DIMENSIONSBIN CODEMATING END S

7、IZEWIRE BARREL SIZEARADIUSBDIACDIADDIAEDIAFDIAGDIAH1/KMIN M ST(REF)64465022 22D.020 .010.0305 .0295.062 .060.022 .018.0355 .0335.011 MAX.048 .046.005 .003.141 -.237 .231.53164665220 20.025 .015.041 .039.094 .091.032 .026.048 .046.015 MAX.070 .068 .010 .005.209.078 .07264765316 16.025.020.0635 .0615.

8、130 .127 .042 .036).068 .066.030 .011.103 .101.209.088 .08264865412 12.095 .093.182 .179.102 .098.062 .043.151 .148 .016 .00564965510 10.126 .124.242 .238.052 .040.140 .134.094 .074.213 .207.355.115 .108.405 .395.6471/ IF A BLEND RADIUS IS USED MATING END SIZE 22 SHALL BE .010 .005, SIZE 20 SHALL BE

9、 .015 .005, AND SIZE 16 SHALL BE .020 .005.REQUIREMENTS: ALL REQUIREMENTS SHALL CONSIST OF THIS SPECIFICATION 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 PROVID

10、ED IN TABLE 6 ARE GIVEN FOR GENERAL INFORMATION ONLY (SEE SPECIFICATION NOTES). b. IF A BLEND RADIUS IS USED, 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 CODES -646 AND -652 (SEE FIGURE 1). d. DIAMETERS E AND G SHA

11、LL BE CONCENTRIC WITHIN 0.003 (TIR) AT LEAST MATERIAL CONDITION (LMC) FOR BIN CODES -644 AND -650.e. DIAMETERS E AND G SHALL BE CONCENTRIC WITHIN 0.001 (TIR) AT THE LEAST MATERIAL CONDITION (LMC) FOR ALL BIN CODES EXCEPT CODES -646 AND -652.f. DIMENSION .041/0.036 (SEE DETAIL T) SHALL BE CONCENTRIC

12、TO DIAMETER G WITHIN 0.003 TIR (RFS).g. DIMENSION “K” SHALL DEFINE THE LOCATION OF WIRE STOP ON A WIRE STRIPPER TOOL. 2. CONTACT MATERIAL SHALL BE IN ACCORDANCE WITH AS39029 EXCEPT AS FOLLOWS (SEE TABLE 2).a. CONTACT PLATING FOR BIN CODES 644, 646-650 SHALL BE GOLD PLATED 100 MICRO-INCHES MINIMUM TH

13、ICKNESS OVER 50 MICRO-INCHES MINIMUM THICKNESS NICKEL UNDERPLATE (SEE TABLE 2). b. CONTACT PLATING FOR BIN CODES 650, 651-655 SHALL BE IN RHODIUM PLATED 50 MICROINCHES MINIMUM THICKNESS IN ACCORDANCE WITH ASTM B634 OVER 150 MICROINCHES MINIMUM THICK NICKEL UNDERPLATE (SEE TABLE 2). c. THE INTERIOR O

14、F THE CRIMP BARREL AT THE CRIMP LOCATION SHALL BE 3 MICROINCHES MINIMUM FOR LOCALIZED GOLD PLATING.d. LOCALIZED RHODIUM PLATING IS NOT PERMITTED.AEROSPACE STANDARDAS39029/118SHEET 3 OF 7CONTACTS, ELECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CO

15、NNECTORS)3. CONTACT MARKING AND RATINGS ARE IN ACCORDANCE WITH TABLE 2.TABLE 2 - CONTACT MARKING AND RATINGS 1/BIN CODECOLOR BANDS MATINGENDSIZEWIREBARRELSIZE TYPE CLASS CONTACT PLATING1ST2ND3RD644 BLUE YELLOW YELLOW 22 22DABGOLD OVER NICKEL646 BLUE YELLOW BLUE 20 20647 BLUE YELLOW VIOLET 16 16648 B

16、LUE YELLOW GRAY 12 12649 BLUE YELLOW WHITE 10 10650 BLUE GREEN BLACK 22 22DRHODIUM OVER NICKEL652 BLUE GREEN RED 20 20653 BLUE GREEN ORANGE 16 16654 BLUE GREEN YELLOW 12 12655 BLUE GREEN GREEN 10 101/ OPERATING TEMPERATURE RANGE: -65 C (-85 F) TO 200 C (392 F).4. THE CONTACT SHALL BE CRIMPED ON WIRE

17、 AND REMOVED FROM THE CONNECTOR USING TOOLS SPECIFIED IN TABLE 3.TABLE 3 - CRIMPING, INSERTION, AND REMOVAL TOOLSBIN CODEWIRE BARREL SIZEBASIC CRIMPING TOOL POSITIONER INSERTION TOOLREMOVAL TOOLWIRED CONTACTSUNWIRED CONTACTS644 650 22DM22520/2-01 M22520/2-09 M81969/14-01 1/M81969/8-01 2/M81969/8-301

18、 3/M81969/14-01 1/M81969/8-02 4/M81969/8-302 5/M81969/30-09M22520/7-01 M22520/7-07646 652 20M22520/1-01 M22520/1-04 RED M81969/14-10 1/M81969/8-05 2/M81969/8-305 3/M81969/14-10 1/M81969/8-06 4/M81969/8-306 5/M81969/30-11M22520/2-01 M22520/2-10M22520/7-01 M22520/7-08647 653 16M22520/1-01M22520/1-04BL

19、UEM81969/14-03 1/M81969/8-07 2/M81969/8-307 3/M81969/14-03 1/M81969/8-08 4/M81969/8-308 5/M81969/30-12M22520/7-01 M22520/7-04648 654 12 M22520/1-01M22520/1-04YELLOWM81969/14-04 1/M81969/8-09 2/M81969/8-309 3/M81969/14-04 1/M81969/8-10 4/M81969/8-310 5/M81969/30-13649 655 10 M22520/45-01POSITIONER BU

20、ILT INTO BASIC TOOLM81969/14-05 1/M81969/8-11 2/M81969/8-311 3/M81969/14-05 1/M81969/8-12 4/M81969/8-312 5/M81969/30-141/ ALL PLASTIC INSERTION AND REMOVAL TOOL 2/ METAL (ANGLED) INSERTION TOOL 3/ METAL (STRAIGHT) INSERTION TOOL (RECOMMENDED FOR LIMITED ACCESS CONNECTOR APPLICATIONS) 4/ METAL (ANGLE

21、D) REMOVAL TOOL 5/ METAL (STRAIGHT) REMOVAL TOOL (RECOMMENDED FOR LIMITED ACCESS CONNECTOR APPLICATIONS)AEROSPACE STANDARDAS39029/118SHEET 4 OF 7CONTACTS, ELECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)5. CONTACT PERFORMANCE (TYPES A

22、CONTACTS)CONTACT PERFORMANCE SHALL BE IN ACCORDANCE WITH AS39029 WITH THE FOLLOWING EXCEPTIONS:a. CONTACT RESISTANCE SHALL BE AS SPECIFIED IN AS39029. THE CONTACTS SHALL BE MEASURED AT AMBIENT TEMPERATURE (25 C 5 C) AND UNDISTURBED WHILE STILL WITHIN THE CONNECTOR. THE MEASURING POINTS SHALL BE AT A

23、 TOTAL DISTANCE OF 6 INCHES APART. THE CONTACT RESISTANCE SHALL MEET THE REQUIREMENTS OF AS39029 AT THE CURRENTS SPECIFIED.b. CONTACT DURABILITY (GROUP II) SHALL BE 1500 CYCLES.c. VIBRATION FOLLOWED BY SHOCK (GROUP II) CONTACT SPECIMENSTHE NUMBER OF CONTACT SAMPLE UNITS TO BE INSPECTED SHALL BE THRE

24、E TIMES THE REQUIRED QUALIFICATION TEST SAMPLES SPECIFIED IN AS39029. TEST FIXTUREMIL-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 CONNECTOR IS RECOMMENDED TOACCOMMODATE THE 1500 CYCLE

25、 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 REQUIRED.3. THERE SHALL BE NO EXPOSURE OF CONTACT BASE

26、METAL.VIBRATION TEST METHOD:1. DIVIDE THE CONTACTS INTO THREE GROUPS (1, 2, 3) AND MOUNT EACH GROUP IN THE NUMBER OF TEST FIXTURES ASNEEDED. 2. THE GROUP 1 CONTACTS SHALL BE TESTED TO A SIMPLE HARMONIC MOTION FROM 10 TO 2000 Hz IN EACH OF THREE MUTUALLY PERPENDICULAR AXES. THE LEVEL OF VIBRATION SHA

27、LL 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 A DURATION OF 12 HOURS IN EACH OF THE THREE MUTUALLY PERPEN

28、DICULAR 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 DISCONTINUITY IN ACCORDANCE WITH EIA-364-46.3. THE GROUP 2 CONTACTS S

29、HALL 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 INTHE LONGITUDINAL DIRECTION AND 8 HOURS IN A PERPENDICULAR DIRECTION FOR A TOTAL OF 16 HOURS. THE TEMPERATURE SHALL BE 200 5C

30、 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. DURATION SHALL BE 8 HOURS IN THE LONGITUDINAL DIRECTION AND 8 HOURS

31、IN A PERPENDICULAR DIRECTION FOR A TOTAL OF 16 HOURS. AND THE TEMPERATURE SHALL BE 25 5C DURING THE VIBRATION TEST.AEROSPACE STANDARDAS39029/118SHEET 5 OF 7CONTACTS, ELECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)FIGURE 2 - RANDOM VIB

32、RATION ENVELOPE5. FOLLOWING EACH VIBRATION TEST, THE CONTACTS SHALL BE INDIVIDUALLY MEASURED FOR CONTACT RESISTANCEAT 25 C 5 C. THE CONTACTS SHALL REMAIN UNDISTURBED WHILE STILL WITHIN THE FIXTURE.SHOCK (HIGH IMPACT) AFTER VIBRATION TEST METHOD:GROUP 3 CONTACTS SHALL BE SUBJECTED TO THE TEST SPECIFI

33、ED 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 HIGH-IMPACT SHOCK AND MONITORED FOR ANY DISCONTINUITIES. 2. A DETECTOR CAPABLE OF DETEC

34、TING 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 SHALL BE TERMINATED WITH AT LEAST 80% OF WIRED CONTACTS AND INCLUDE STRAIN RELIEF ACCE

35、SSORIES. 4. THE CABLE OR WIRE BUNDLE SHALL BE SUPPORTED ON A STATIONARY FRAME IN SUCH A MANNER TO PROVIDE AFREE FLEXING CABLE LENGTH BETWEEN THE FRAME AND THE MOUNTING FIXTURE OF NOT LESS THAN 36 INCHES (914.4 MM).5. FOLLOWING THE SHOCK TEST, THE CONTACTS SHALL BE INDIVIDUALLY MEASURED FOR CONTACT R

36、ESISTANCE AT 25 C 5 C. THE CONTACTS SHALL REMAIN UNDISTURBED WHILE STILL WITHIN THE FIXTURE.AEROSPACE STANDARDAS39029/118SHEET 6 OF 7CONTACTS, ELECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)VISUAL EXAMINATION:1. FOLLOWING THE COMPLETI

37、ON OF THE VIBRATION AND SHOCK TESTS THE INDIVIDUAL CONTACTS SHALL BE CAREFULLY REMOVED FROM THE FIXTURE AND VISUALLY EXAMINED FOR EVIDENCE OF BASE METAL USING A X10 MAGNIFICATION. 6. INITIAL QUALIFICATION, RETENTION OF QUALIFICATION, AND QUALITY CONFORMANCE INSPECTIONS:a. INITIAL QUALIFICATION SHALL

38、 BE IN ACCORDANCE WITH AS39029 AND HERE IN.b. THE MANUFACTURERS RELIABILITY ASSURANCE PROGRAM FOR AS39029/118 AND ASSEMBLY PROCEDURES SHALL COMPLY WITH THE AS9100 AEROSPACE STANDARD FOR QUALITY MANAGEMENT SYSTEM REQUIREMENTS. OTHER ESTABLISHED AND INDUSTRY RECOGNIZED QUALITY ASSURANCE STANDARDS THAT

39、 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 QUALIFYING ACTIVITY (QA) AUTHORITY RESERVES THE RIGHT TO MONITOR, MEASURE, AND VALIDATE COMPLIANCE AT THE

40、 QA 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 OF (AS39029 QUALIFICATION INSPECTION TYPES A AND B CONTACTS) SHALL BE PERFORMED EVERY 72 MONTHS. THE

41、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 MINIMUM GOLD THICKNESS.7. CONTACT PART NUMBERS AND SUPERSEDING INFORMATION IS IN ACCORDANCE TABLE 4.T

42、ABLE 4 - CONTACT PART NUMBERSAS39029 PART NUMBER BIN CODESUPERSEDED PART NUMBERSM39029/118-644 644NONEM39029/118-646 646M39029/118-647 647M39029/118-648 648M39029/118-649 649M39029/118-650 650NONEM39029/118-652 652M39029/118-653 653M39029/118-654 654M39029/118-655 6558. CONTACT MATES DIRECTLY WITH A

43、N AS39029/118 PIN AS SHOWN IN TABLE 5.TABLE 5 - CONTACT MATING PART NUMBERSMATING END SIZEAS39029/118 MATING PIN BIN CODEAS39029/117 SOCKET BIN CODE22 644 63220 646 63416 647 63512 648 63610 649 63722 650 63820 652 64016 653 64112 654 64210 655 643AEROSPACE STANDARDAS39029/118SHEET 7 OF 7CONTACTS, E

44、LECTRICAL CONNECTOR, PIN,CRIMP REMOVABLE, ENGINE APPLICATION(FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)9. APPLICATIONSa. THIS CONTACT IS INTENDED FOR USE IN THE HIGH TEMPERATURE AND VIBRATION ENVIRONMENTS OF AIRCRAFT ENGINES, BUT THERE IS NO RESTRICTION FOR GENERAL APPLICATIONS.10. SPECIFIC

45、ATION NOTESa. REVISION INDICATOR: A CHANGE BAR (I) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMP

46、LETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS, NOR IN DOCUMENTS THAT CONTAIN EDITORIAL CHANGES ONLY.b. IF METRIC UNITS ARE REQUIRED CONVERSION SHOULD BE BASED ON 25.4 MILLIMETERS/INCH. SEE TABLE 6 FOR SOFTMETRIC CONVERSION UNI

47、TS USED HEREIN. IN CASE OF CONFLICTS ENGLISH UNITS APPLY.TABLE 6 - ENGLISH UNITS CONVERTED TO SOFT METRIC UNITSENGLISH UNITSMETRICUNITSENGLISH UNITSMETRICUNITSENGLISH UNITSMETRICUNITSENGLISH UNITSMETRICUNITSENGLISH UNITSMETRICUNITS.000050 0.00127 .0410 1.0414 .0840 2.1336 .1340 3.4036 .2420 6.1468.0

48、010 0.0254 .0420 1.0668 .0880 2.2352 .1350 3.429 .3550 9.017.000150 0.00381 .0460 1.1684 .0910 2.3114 .1400 3.556 .3850 9.779.0020 0.0508 .0470 1.1938 .0940 2.3876 .1410 3.5814 .3950 10.033.0030 0.0762 .0480 1.2192 .0955 2.4257 .1460 3.7084 .4000 10.16.0040 0.1016 .0500 1.27 .0980 2.4892 .1480 3.759

49、2 .4050 10.287.0050 0.127 .0520 1.3208 .1010 2.5654 .1510 3.8354 .4400 11.176.0060 0.152 .0530 1.3462 .1020 2.5908 .1610 4.0894 .4700 11.938.0100 0.254 .0600 1.524 .1030 2.6162 .1660 4.2164 .5000 12.7.0150 0.381 .0620 1.5748 .1080 2.7432 .1790 4.5466 .5850 14.859.0160 0.4064 .0640 1.6256 .1130 2.8702 .1800 4.572 .6160 15.6464.0200 0.508 .0660 1.6764 .1150 2.921 .1820 4.6228 .6260 15.9004.0290 0.7366 .0680 1.7272 .1180 2.9972 .2070 5.2578 .8550 21.717.0310 0.7874 .0690 1.7526 .1220 3.0988 .2090 5.3086 1.0210 25.9334.0330 0.8382 .0700 1.