BS 9520:1983

Foreword
Cooperating organizations
Specification
Section one. Principles and mandatory procedures
1.1 General matters
1.1.1 Scope
1.1.2 Related documents
1.1.3 Terminology
1.1.3.1 General terms
1.1.3.2 Connector accessory terms
1.1.3.3 Connector terms
1.1.3.4 Contact and termination terms
1.1.3.5 Mounting terms
1.1.3.6 Tool terms
1.1.4 Letter symbols, signs and abbreviations
1.1.5 Graphical symbols
1.1.6 Marking of the component and package
1.1.7 Eligibility for qualification approval
1.1.8 Structurally similar components
1.1.9 Delayed delivery
1.1.10 Supplementary procedures for qualification
          approval
1.1.10.1 Procedure in the event of failure at group C or
          Group D inspection
1.1.10.2 Release before completion of group B tests
1.1.11 Certified test records
1.1.12 Standard ratings and characteristics
1.1.12.1 General
1.1.12.2 Electrical ratings
1.1.12.3 Environmental ratings
1.1.12.4 Endurance ratings
1.1.12.5 Electrical characteristics
1.1.13 Unchecked parameters
1.2 Test procedures
1.2.1 Measurement conditions
1.2.1.1 General conditions
1.2.1.2 Airframe connectors: wiring of specimens,
          class S, H and N only
1.2.1.3 Order of tests
1.2.2 Visual examination
1.2.3 Dimensioning and gauging procedures
1.2.3.1 Dimensions outline
1.2.3.2 Dimensions, detail and materials
1.2.3.3 Gauging procedure
1.2.4 Electrical test procedures
1.2.4.1 Mounting
1.2.4.2 Contact resistance
1.2.4.3 Housing (shell) electrical continuity
1.2.4.4 Insulation resistance
1.2.4.5 Voltage proof
1.2.4.6 Current overload
1.2.4.7 Shielding effectiveness
1.2.4.8 Current switching
1.2.5 Mechanical test procedures
1.2.5.1 General
1.2.5.2 Mass
1.2.5.3 Engaging and separating force, connector
1.2.5.4 Contact retention (in insert)
1.2.5.5 Insert retention in housing (shell) axial
1.2.5.6 Insert retention in housing (shell) torsional
1.2.5.7 Mechanical impact (free connectors only)
1.2.5.8 Cable clamping (for connectors with cable
          fixing devices)
1.2.5.9 Contact holding force (for resilient contacts
          only)
1.2.5.10 Probe damage (applicable only to connectors
          having female contacts
1.2.5.11 Insert ageing (for removable contact types
          only)
1.2.5.12 Compass safe distance
1.2.5.13 Static load transverse (fixed connectors only)
1.2.5.14 Moulding strength test
1.2.5.15 Coupling pin strength
1.2.5.16 Grounding contact spring holding force
1.2.5.17 Contact dislodgement by cable nutation (contact
          walk-out)
1.2.5.18 Contact gauge location and retention within
          insert
1.2.5.19 Strength of insertion/extraction tools
1.2.5.20 Coupled strength (connectors with locking
          devices)
1.2.5.21 Accessory thread strength
1.2.5.22 External bending moment
1.2.5.23 Insert grommet bonding
1.2.5.24 Cable flexing
1.2.5.25 Male contact protection
1.2.5.26 Male contact stability
1.2.5.27 Engaging and separating (for twist-pull)
          coupling connectors having lanyard or lever
          release)
1.2.5.28 Locking integrity
1.2.5.29 Torsional overload (locking devices)
1.2.5.30 Misuse of contact insertion/extraction tool
1.2.5.31 Termination torsion
1.2.5.32 Guide key retention
1.2.5.33 Locking (safety) wire pull out
1.2.6 Environmental test procedure
1.2.6.1 General
1.2.6.2 Bump
1.2.6.3 Vibration
1.2.6.4 Shock
1.2.6.5 Acceleration, steady state
1.2.6.6 Robustness of termination
1.2.6.7 Soldering
1.2.6.8 Rapid change of temperature
1.2.6.9 Flammability
1.2.6.10 Fire resistance failure
1.2.6.11 Temperature overload
1.2.6.12 Climatic sequence: general
1.2.6.13 Immersion (at low air pressure)
1.2.6.14 Sealing, immersion
1.2.6.15 Damp heat (steady state)
1.2.6.16 Mould growth
1.2.6.17 Corrosion, salt mist
1.2.6.18 Dust
1.2.6.19 Pressure sealing
1.2.6.20 Resistance to fluids
1.2.6.21 Corrosion, industrial atmosphere
1.2.6.22 Climatic sequence: airframe application
1.2.6.23 Cold
1.2.6.24 Thermal shock
1.2.6.25 Cold handling (airframe)
1.2.7 Endurance test procedures
1.2.7.1 Mechanical operation
1.2.7.2 Electrical load and temperature
1.2.7.3 Mechanical load and temperature
Section two. General rules for the preparation of detail
specifications
2.1 Basic information
2.1.1 Object and form of detail specification
2.1.2 Originator of the detail specification
2.1.3 Detail specification number
2.1.4 Description of the component and intended
          application
2.1.5 Drawings
2.1.5.1 Pattern illustration
2.1.5.2 Outline drawings
2.1.5.3 Control drawings
2.1.6 Ratings (including limiting conditions of use)
2.1.7 Characteristics
2.1.8 Related documents
2.1.9 Additional information
2.2 Inspection requirements
2.3 Certified test records
2.4 Instructions for ordering components
Section three. Capability approval procedure
3.1 General
3.1.1 Introduction
3.1.2 Eligibility for capability approval
3.1.3 Delayed delivery
3.1.4 Supplementary procedures for capability
          approval
3.1.5 Capability approval procedure chart
3.2 Manufacturing approval
3.3 Capability approval
3.3.1 Category of capability approval
3.3.2 Capability approval plan
3.4 Specifications
3.4.1 General
3.4.2 'Catalogue' items
3.4.3 Customer detail specification (CDS)
3.5 Maintenance of capability approval
3.5.1 General
3.5.2 Process control testing
3.5.3 Capability boundary testing
3.6 Changes of approval
3.6.1 General
3.6.2 Design verification of new patterns and
          approval of new processes
3.6.3 Permanent extension of approval
3.6.4 Temporary extension of approval
3.7 Release for delivery
Appendices
A. Guide to the presentation of drawing information
B. Typical jig for bump and vibration tests
C. Typical contact test prod-tool
D. Equipment for dust test
E. Fire-resistance failure test fixture assembly
F. Method of test for moulding strength
G. Apparatus and method of test for combined humidity,
     temperature and pressure tests
H. Vibration test curves
J. Contact dislodgement by cable nutation (contact
     walk-out)
K. Method of test for accessory thread strength
L. Method of test for external bending moment
M. Specimens for type tests: preparation of leads;
     cables to be used
N. Recommended method of test for current overload
O. Method of test for male contact stability
P. Method of test for mechanical load and temperature
Q. Method of test for locking integrity
R. Method of test for current switching
S. Method of test for termination torsion
T. Suggested method of test for guide key retention
U. Example abstract
Tables
1. Design verification
2. Capability boundary tests
Numerous figures