AWG #28 <> AWG #22 - Page 1
Forum section: electronics / projects

author: Flow
author_rank: Newbie
timestamp: April 28, 2022, 11:11:16 am
content: Hello folksI am looking to understand if this is even possible and if it is what would be a reliable solution suitable for a high vibration, high moisture, aviation environment.I need a 6 way cable to cable connector for this rotary position sensor to an engine loom.This is the sensor.https://www.cw-industrialgroup.com/Library/Technical-Data-Sheets/Penny-Giles/NRH305-Technical-Information-11-17.aspxIt has a 6 core FDR25 cable with type 44A AGW #28 wire.The engine loom is AWG #22 (MIL-W-22759/16-22-9)What are the options here?

author: radar_macgyver
author_rank: Frequent Contributor
timestamp: April 28, 2022, 01:24:22 pm
content: Use a suitable38999 Series III connector- with the right options, these are specified for aero-engine use. From the Amphenol catalog, 22D contacts may be used from 22 to 28 AWG. A 9-35 insert is the smallest one with six 22D contacts. One side would have an inline receptacle (shell style 01) and the other side a cable-mount (06). You'd also need suitablebackshells, depending on your engine cable loom. On the sensor side, an M85049/18 series backshell will work, but is going to be big and heavy. You could instead use a shrink boot adapter (M85049/69) and a heatshrink boot (202K121).Get in touch with a specialist connector vendor. In the US, PEI-Genesis is my go-to.

author: Flow
author_rank: Newbie
timestamp: April 28, 2022, 07:46:37 pm
content: Just great info there thank you.If we wanted to break out the sensors two channels into two 3 pin inline connectors for dual ECUs, would you use the same series and maybe move to a 4 pin 11-54 insert or stick with the 9-35 and partially pin out or move to a different solution?

author: radar_macgyver
author_rank: Frequent Contributor
timestamp: April 29, 2022, 05:50:53 am
content: I don't see a benefit in moving to the 11-54, the service rating stays the same (and doesn't matter in this application anyway since they're low-voltage signals), so I would stick to the lower weight 9-35. Also, this may not apply to your exact application, but it makes more sense to me to have the disconnection point be at the sensor rather than at the ECUs. If the sensor goes bad, you disconnect it at one place, rather than two.

author: Flow
author_rank: Newbie
timestamp: April 29, 2022, 09:00:58 am
content: Thanks again, we are stuck with the plug-less sensor for now. I have reached out to the vendor you recommended for a 2x 3 pin suggestion. The initial prototype used dual Sure Seal 3 pin connectors but they are not fit for purpose.

author: Flow
author_rank: Newbie
timestamp: May 05, 2022, 08:28:40 pm
content: How does this look for a 38999 2M solution? Is there anything you would tweak here for an inline cable to cable connection?Plug: 2M801-007-16C-5-3-S-A with #23 Sockets 10-597345-735 and Black 2M809-155 Gromet sealing plugsReceptical: 2M801-009-01C-5-3-P-A with #23 Pins 10-597346-735 and Black 2M809-155 Gromet sealing plugsBackshells: 2M809S060-1I would prefer a composite solution if possible though.Does anyone know of any comparable solutions in composite from another vendor?We have M22520/1-01 Crimpers with M22520/1 Series Positioners TH1A/TH163/UH2-5 for 12-26 AWG Wire. Will that tool work initially with a bit of fiddling for the #23 contacts or will we need to procure M22520/2-01 Crimpers and M22520/2-12 Positioners.

author: radar_macgyver
author_rank: Frequent Contributor
timestamp: May 06, 2022, 01:22:59 pm
content: Can't say much about the 2M connectors, haven't used those myself but they look like they meet all your requirements. 38999-compatible composite connectors are available from Amphenol in their CTV series.The crimp range available on the M22520/01 won't be enough for the finer wire gauges, I would suggest getting the smaller crimper. If you're budget-constrained, get the adjustable positioner and do a few test crimps to figure out the correct crimp location. If this is for a ground test/prototype and the end result won't see any flight hours, you could get a cheap crimper and locator from the likes of JRready (clones of DMC).

author: Flow
author_rank: Newbie
timestamp: May 06, 2022, 07:34:21 pm
content: Additionally, what do you think of the Amphenol Pegasus range, they seem to have shell 5, 3 pin 22D compostite options.SJS830210P and SJS830230P. Any other vendors that might be able to meet the requirements?

author: radar_macgyver
author_rank: Frequent Contributor
timestamp: May 07, 2022, 10:59:03 pm
content: Those look pretty neat, have not used them so can't say much other than they are tiny! They look like single-source parts though.