SAE AS95234A pdf download.Connectors , Electrical , Reverse Bayonet General Specification for.
1.2.1 The SAE International PIN is a copyright part number which cannot be used except for products being qualified by the qualifying activity (see 6.2.1) or is approved for qualification (see 6.2.3).
2. APPLICABLE DOCUMENTS
The following publications form a part of SAE AS95234A to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of SAE AS95234A and references cited herein, the text of this document takes precedence. Nothing in SAE AS95234A, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.
2.8 Definitions
2.8.1 QUALIFICATION INSPECTION
Qualification Inspection is a process that demonstrates that a component is capable of fully conforming to all the requirements defined in a standard. Qualification Inspection includes definition of the measurements, tests, analysis, and associated data which provides consistent rationale for acceptance of a particular supplier’s design as meeting the standard requirements typically prior to acquisition by the purchaser.
2.8.2 QUALIFIED PRODUCTS LIST
A Qualified Products List is a list of suppliers (manufacturers) whose products have been evaluated to a defined process and who are authorized to provide those products to a purchaser upon request. When a Qualified Products List is specified, only approved suppliers (manufacturers) are authorized to provide products under the part number defined in the component standard. A Qualified Products List is established and maintained by a qualifying activity.
2.8.3 QUALIFYING ACTIVITY
A qualifying activity is a function established by a purchaser or group of purchasers (i.e., government, etc.) that has a defined process used to consistently evaluate all suppliers’ (manufacturers’) products in accordance with the component standard.
2.8.4 QUALITY CONFORMANCE INSPECTION
Quality conformance inspection is a process which includes measurements, non-destructive tests, analysis, and assoclated data that will provide verification that a particular individual component continually conforms to the requirements defined in the standard.
2.8.5 QUALIFICATION BY SIMILARITY
An alternative qualification inspection process accomplished without completing all of the measurements, tests, and analysis requirements defined in the standard. Acceptance and the extent of similarity is determined by the qualifying activity. Similarity is established through a rationale that certain designs, materials, and/or processes are identical to those already approved through qualification of the components. Verification testing for the new product is not required for designs, materials, and/or processes already approved. When a Qualified Products List is being established the qualification by similarity rationale shall be approved by the qualifying activity prior to initiation of the remaining portions of the qualification inspection process.
2.8.6 PURCHASER
A purchaser is an activity that can issue a purchase order or contract (le., government. etc.).
2.8.7 SUPPLIER (MANUFACTURER)
A supplier (manufacturer) is an original component manufacturer or a value added component manufacturer which has design and production control of the processes used to produce the final component in accordance with the standard.
2.8.8 ASSEMBLY PLANT
A plant established by the supplier (manufacturer) or operated by a distributor authorized by the supplier (manufacturer) to perform specified functions pertaining to the suppliers (manufacturer’s) identified qualified products in accordance with supplier’s (manufacturer’s) specified assembly procedures, test methods, processes, controls, and storage, handling, and packaging techniques.
3. REQUIREMENTS
3.1 Detail Specification (see 2.1)
X – Nickel with fluorocarbon polymer additives in accordance with AMS2454 over a suitable underplate to withstand 500 hours of salt spray testing. Color shall be non-reflective. Final finish shall be electrically conductive.
V – Pure dense electrodeposited aluminum in accordance with MIL-DTL-83488, Type II, to withstand 500 hours of salt spray testing. Color shall be non-reflective. Final finish shall be electrically conductive. (Not for use on grounding finger connector.)
Z – Zinc nickel in accordance with ASTM B841 over suitable underplate to withstand 500 hours of salt spray testing. Color shall be black, conductive, and non-reflective. Final finish shall be electrically conductive.
3.3.4 Finish Material and Designation for Corrosion Resistant Steel Connector
Corrosion resistant steel base material and applicable finishes are available for all detail specifications.
B – Black cadmium in accordance with AMS-QQ-P-416, Type II, Class 3, and designed to withstand 500 hour salt spray
testing.
S – Passivated in accordance with AMS-OQ-P-35, ASTM A967, orAMS2700, and design to withstand 500 hour salt spray
testing.
XS – Nickel with fluorocarbon polymer additives in accordance with AMS2454 over a suitable underplate to withstand
500 hours of salt spray testing. Color shall be non-reflective. Final finish shall be electrically conductive.
VS – Pure dense electrodeposited aluminum in accordance with MIL-DTL-83488, Type II, to withstand 500 hours of salt spray testing. Color shall be non-reflective. Final finish shall be electrically conductive (Not for use with grounding finger connectors).
ZS – Zinc nickel in accordance with ASTM B841 over suitable underplate to withstand 500 hours of salt spray testing. Color shall be black, conductive, and non-reflective. Final finish shall be electrically conductive.
3.3.5 Connector Insert
3.3.5.1 Crimp Contact Connector
The mating face of the crimp contact connector pin insert shall be resilient elastomer. Insert matenal shall be a suitable rigid dielectric material.
3.4.6.1 Coupling Ring Retention System
When retaining rings or other devices (i.e., wave spring washer, grounding spring washer, etc.) are used in the coupling ring retention system for plugs, the retention devices shall be metal, positively captivated or utilized in such a manner that the plugs shall remain electrically functional as an assembled connector in the event of a retention device failure.
3.4.6.2 Coupling Ring Engagement and Disengagement
Counterpart connectors of any arrangement and accessories shall be capable of being fully engaged and disengaged without the use of tools. Engagement of connectors shall be defined as full insertion of pins into sockets and proper sealing of the mating insert faces. Full engagement shall be indicated by an audible click at the completion of the coupling cyde, and a positive detent shall be included in the coupling mechanism to lock connectors in the engaged position. Connector pairs shall be coupled by means of a reverse bayonet coupling ring. Coupling shall be accomplished by clockwise rotation of the coupling ring; uncoupling by counterclockwise rotation. The reverse bayonet coupling ring shall be knurled to provide a gripping surface. When the connectors are fully engaged and the coupling ring is in the locked position, mated yellow dots (see Appendix 2) shall align on the receptacle and plug.
3.4.6.3 Shell Polarization
Polarization of connectors shall be accomplished by matched integral key arid keyway of counterpart connectors. The polarization of counterpart connectors shall take place before coupling rings are engaged.
3.4.6.4 Engagement Seal
Pin contact connectors with resilient interfaces shall contain sealing means so that the engaged contacts meet the requirements herein. The design of the seal shall be such that in mated connectors all air paths between adjacent contacts and between contacts and shells are eliminated. There shall be interfacial mating of the engaged connector insert to provide dielectric under compression. Plug connectors shall have a peripheral seal to ensure shell to shell sealing.
3.4.7 Wire Sealing
Connectors shall be provided with a wire sealing grommet capable of sealing on wires of the sizes specified in Table 1.
4.3.5 Qualification Sample (see 4.3,4 for exceptions)
For each connector tested the supplier shall use the same materials, manufacturing procedures, and methods of inspection as would be used to provide the connector to a purchaser. Each connector subjected to qualification testing shall be provided with a counterpart connector for those tests requiring mating assemblies. The counterpart connectors provided for this purpose shall be new, previously qualified connectors or new connectors submitted for qualification testing. Suppliers not producing mating connectors shall submit data substantiating that tests were performed with approved counterpart connectors. Specimens of each item submitted for qualification shall be tested in the sequence when specified in Tables 7 or 8. The wire types shall be AS22759. or AS81044/12 tin or nickel coated conductors. The connector sample shall include the following designs:
a. A minimum of two connector specimens for each shell size range (see Table 9) and configurations specified in the detail specification. One connector shall have the pin insert in the plug and the socket insert in the receptacle. The other connector shall have the inserts reversed.
b. For crimp contact connectors, two cavities of each sample shall contain unwired contacts and sealing plugs in accordance with MS27488. As a minimum one connector shall be terminated with tin conductor wire and one with nickel conductor wire in accordance with Table 1.
c. The sdder connectors shall be terminated with tin conductor wire in accordance with Table 1.
d. All crimp contact sizes with a minimum of six contacts for each size or as limited by the highest density insert for a contact size. Fifty percent of each contact size shall be wired with minimum diameter wire and 50% with maximum diameter wire in accordance with Table 1.
e. All solder contact sizes with a minimum of six contacts for each size or as limited by the highest density insert for a contact size. Solder connector contacts, except shell H. shall be soldered in accordance with J-STD-OO1.
1. Highest density insert for each service rating.
g. All shell materials and finishes.
AS95234 includes reverse bayonet coupling, high current electrical connectors that are water tight and principally used in shipboard, ground vehicles and ground support equipment applications at -55 ‘C and +125 ‘C (-67 ‘F and +257 ‘F). The upper temperature is the maximum internal hot spot temperature resulting from any combination of electrical load and ambient conditions. Connectors include front release crimp contacts and solder contacts in sizes 16-16 through 0-0. AS95234 connectors are typically intermateable with similar reverse bayonet couple connectors, but are not interchangable, because these connectors have defined AS85049 accessory threads. Suppliers should be contacted to determine to what extent these connectors can be mated with similar reverse bayonet couple connectors. These connector are not for aerospace applications (refer to AS50881).
6.1.1 Crimp Contact Connectors
Crimp contact connectors should have contacts installed in all positions when the connector is wired. Sealing plugs should be installed in the grommet holes when no wire is attached to the contact.
6.1.2 Crimp and Solder Connector lnterrnateable
Counterpart solder and crimp contact connectors are intended to be intermateable.
6.1.3 Wire Usage and Sealing with contacts
6.1.3.1 Size 6 Wire Soldered to a Size 4 Contact
It is intended that size 6 wire should be crimped or soldered to a size 4 contact because no size 6 contacts are provided and size 4 is the next larger.
6.1.3.2 Sealing on Smaller Wire Diameter Insulation
Satisfactory performance of connectors will be obtained if wire sizes are governed by Table 1. When the connector must be sealed to provide an environment resistant or water pressure joint on wire diameters smaller than specified in Table 1, A1R1329 is recommended to be followed A length of shrink AMS-DTL-2305315 Class 1 and 3.18,/li, /12 Class 3,4, and 5, or /18 Class 2 and 3 sleeving is recommended to be installed in back of the contact and shall protrude through the environmental or water proof seal. Elastomer grommets are generally qualified to seal on wires and electrical cables having smooth extruded insulations. Only one wire or cable per grommet hole is recommended. Sealing on tape wrapped, braided, striped, or other than smooth circular insulations should be specifically tested for compatibility. The connector is considered sealed, if the outermost sealing feature (web) is in full contact with the wire, when visually inspected. The wire should be installed so that transverse loads will not destroy the integrity of the sealing feature.