High-Density Circular Power Connector for Critical Systems
Product Overview
The YM Military Aviation Connector Y3A-2255ZJ10 is a premium high-density circular connector engineered for mission-critical power distribution and signal transmission in demanding aerospace, defense, and industrial applications. Specifically designed for integration with Aviation Microswitch control systems, Military Aviation Band Switch interfaces, and drone power management units, this connector combines advanced electrical performance with superior environmental protection. As a key component in YM's comprehensive aviation portfolio—which includes complementary products like Aviation Temperature Sensor and Aviation Hours Timer systems—the Y3A-2255ZJ10 delivers reliable performance where both high-current capacity and signal integrity are essential.
Core Advantage: High-density circular design with exceptional current-carrying capacity and advanced sealing technology, providing reliable interconnection for power-intensive applications in harsh environmental conditions.
Technical Specifications
- Model: Y3A-2255ZJ10
- Connector Type: High-Density Circular Power Connector
- Physical Characteristics:
- Shell Size: Optimized circular diameter for high contact density
- Material: Aluminum alloy with MIL-spec hard anodizing
- Mounting: Panel mount with reinforced flange design
- Weight: 35-65 grams (depending on configuration)
- Shell Protection: Corrosion-resistant finish per MIL-STD-810
- Contact System:
- Contact Configuration: Circular arrangement with mixed contact sizes
- Contact Types: Power contacts (large), signal contacts (standard), coaxial options
- Contact Positions: 22-55 positions (configurable mix)
- Current Rating: Power contacts: 25A, Signal contacts: 7.5A
- Contact Resistance: ≤3mΩ for power contacts, ≤8mΩ for signal contacts
- Contact Material: Copper alloy with selective gold plating
- Electrical Performance:
- Voltage Rating: 1000V AC/DC at sea level
- Insulation Resistance: >10,000 MΩ at 1000V DC
- Dielectric Strength: 2500V RMS for 60 seconds
- EMI/RFI Shielding: >100dB effectiveness (100MHz-1GHz)
- Current Capacity: Up to 25A per power contact, 300A total system capacity
- Temperature Rise: <30°C at rated current
- Environmental & Mechanical:
- Ingress Protection: IP69K (resistant to high-pressure, high-temperature washdown)
- Operating Temperature: -65°C to +200°C
- Sealing System: Quad-seal technology (interface, insert, wire, secondary)
- Vibration Resistance: 10-2000Hz, 25G (MIL-STD-1344 Method 2007)
- Shock Resistance: 100G, 6ms duration
- Coupling Mechanism: Heavy-duty bayonet with positive locking
- Mating Cycles: 1000 cycles minimum
- Flammability Rating: Self-extinguishing per MIL-STD-2031
Product Features & Advantages
- Advanced Quad-Seal Protection: Four-layer sealing system provides superior environmental protection specifically designed for integration with Aviation Oxygen Valve and Aviation Oil Sealed Valve systems in extreme conditions.
- High-Current Power Distribution: Engineered for power-intensive applications, capable of handling currents up to 25A per contact for systems like Aviation Magnetic Valve controls and propulsion systems.
- Mixed Contact Technology: Supports combination of power, signal, and coaxial contacts within single connector, ideal for complex systems integrating Military Aviation Encoding switch controls with power distribution.
- Enhanced Thermal Management: Optimized contact design and materials minimize temperature rise at high currents, ensuring reliable operation in temperature-critical applications.
- Superior EMI/RFI Shielding: Advanced shielding with 360° coverage provides excellent electromagnetic compatibility for sensitive equipment like Military Electronic Horn and Aviation Press Meter systems.
- Quick-Disconnect Bayonet Coupling: Heavy-duty bayonet mechanism allows rapid mating/unmating while maintaining secure connection in high-vibration environments, featuring visual locking indicators.
Our Manufacturing Advantage: YM leverages specialized manufacturing capabilities developed through producing Military Aviation connector systems and Aviation Microswitch components, enabling precise fabrication of high-current circular connectors with enhanced performance features.
How to Integrate the Y3A-2255ZJ10 Connector
- Power Requirements Analysis: Assess current and voltage requirements for both power and signal circuits. This connector is ideal for systems combining Aviation Temperature Sensor monitoring with Aviation Haulage Pressure Sensor power needs.
- Contact Configuration Planning: Design contact mix based on application requirements, considering power distribution for systems like Aviation Cold Air Solenoid Valve controls alongside control signals.
- Thermal Management Planning: Ensure adequate heat dissipation for high-current applications, considering ambient temperature and ventilation requirements.
- Precision Cable Preparation: Use appropriate crimping tools for different contact sizes. Follow specific procedures for high-current power cable termination and proper strain relief installation.
- System Integration and Testing: Connect to target systems and perform comprehensive testing including current-carrying capacity verification, temperature rise measurement, insulation resistance, and environmental sealing validation.
Application Scenarios
The Y3A-2255ZJ10 enables reliable power and signal distribution in demanding aviation and industrial applications:
- Aircraft Power Distribution Units (PDUs): Main interconnection for Aircraft Electrical Systems, handling both high-current power distribution and control signaling for Aviation Magnetic Valve and lighting systems.
- Drone Propulsion and Battery Systems: Provides robust connections for high-current motor controllers, battery management systems, and flight control units in UAV applications.
- Railway Traction Power Systems: Used in power distribution cabinets for train propulsion systems, integrating high-current power with control signaling.
- Industrial Power Control Cabinets: Provides reliable high-current connections in industrial control panels requiring both power distribution and signal transmission in harsh environments.
- Military Vehicle Power Networks: Interfaces in armored vehicle electrical systems handling high-current power distribution for weapons, communications, and propulsion systems.
- Ground Power and Charging Systems: Used in aircraft ground power units and charging systems for Aviation Copper Fuse Holder protection and Aviation Ammeter monitoring applications.
Value for Buyers: Provides reliable high-current performance in compact form factor, reduces installation complexity through consolidated power/signal connections, offers superior environmental protection for harsh conditions, ensures thermal stability at rated currents, and provides quick-disconnect capability for maintenance efficiency.
Certifications & Compliance
Manufactured in our SGS-audited, ISO 9001:2015 and AS9100D certified facility, the Y3A-2255ZJ10 meets and exceeds MIL-DTL-38999 Series IV specifications for high-performance circular connectors. Our production processes ensure full compliance with RoHS, REACH, and aerospace material requirements. We support comprehensive qualification testing including high-current performance validation and provide project-specific certifications (UL, CE, MIL-qualification) as needed, maintaining standards consistent with our production of other aviation components like Aviation Oxygen Valve and Military Aviastion Temperature Sensor systems.
Customization Options
YM provides extensive customization capabilities for the Y3A-2255ZJ10 to meet specific application requirements:
- Custom Contact Configurations: Design specialized contact arrangements with specific power/signal/coaxial mixes for applications involving Aviation Microswitch arrays or complex control systems.
- High-Current Optimization: Specialized contact designs for extreme current requirements beyond standard ratings, with enhanced thermal management features.
- Environmental Enhancement Packages: Additional sealing options, specialized materials, or protective coatings for specific extreme environmental conditions.
- Special Coupling Mechanisms: Custom bayonet designs, threaded couplings, or quick-disconnect mechanisms based on specific application requirements.
- Material and Finish Options: Stainless steel shells, titanium components, or specialized platings for specific corrosion resistance, weight, or thermal requirements.
- Complete Assembly Solutions: Pre-assembled connector systems with integrated backshells, cable management, and protective features for specific installation requirements.
Our proven OEM/ODM expertise with aviation components, including Aviation Button Switch and Military Aviation Encoding switch systems, enables us to provide tailored high-current connector solutions for your specific application requirements.
Production & Quality Assurance
Every Y3A-2255ZJ10 connector undergoes rigorous manufacturing and validation processes:
- Precision CNC Machining: Shells and components produced using multi-axis CNC machining with tight tolerances for reliable mating and sealing performance.
- Advanced Contact Manufacturing: Power contacts manufactured using precision forging and plating processes for optimal current-carrying capacity and durability.
- Enhanced Surface Treatments: Specialized plating including silver plating for power contacts and gold plating for signal contacts, with MIL-spec surface preparation.
- Precision Assembly Processes: Controlled assembly ensuring proper contact alignment, sealing installation, and mechanical integrity with 100% inspection.
- Comprehensive Electrical Testing: Testing includes contact resistance measurement, insulation resistance, dielectric strength, and high-current temperature rise verification.
- Environmental Validation: Sample testing for vibration, shock, salt spray, thermal cycling, and sealing performance to validate operation in extreme conditions.
- High-Current Performance Testing: Validation of current-carrying capacity and temperature rise characteristics under sustained load conditions.
This comprehensive quality assurance program ensures connectors meet the stringent standards required for integration with other precision aviation components like Aviation Hours Timer and Aviation Haulage Pressure Sensor systems, delivering reliable performance in the most demanding high-current applications.
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