The ACT96WH35SN is a 100-position circular connector plug from the DEUTSCH connector family associated with TE Connectivity. It is designed for demanding interconnection applications where a high contact count, mechanical retention and environmental resistance are important.
The connector uses female crimp contacts, a composite shell and a threaded coupling system. Its specified operating temperature range extends from -65°C to 175°C, making it suitable for applications exposed to substantial temperature variation.
The complete ACT96WH35SN Part Number is important for component identification because the DEUTSCH ACT family contains numerous connector configurations with different contact counts, shell arrangements, mounting styles and contact variants.
The ACT96WH35SN is a 100-position plug assembly with female socket contacts.
Its contact system uses crimp termination rather than solder termination. This makes it suitable for harness manufacturing processes where individual contacts are crimped onto wires and then inserted into the connector housing.
The connector uses a size H shell with a 23-35 shell size/insert designation.
The large contact count allows many electrical circuits to be combined into one circular interconnection rather than distributing them across several smaller connectors.
This can simplify harness routing and reduce the number of separate connector interfaces within a system.
The 100-position configuration is one of the defining characteristics of the ACT96WH35SN.
High-density circular connectors are useful when a system contains numerous power, signal or control circuits that need to pass between two assemblies.
Instead of using many individual connectors, a high-contact-count circular connector can consolidate the interface into a single mechanically secured connection.
The actual electrical loading must still be evaluated on a contact-by-contact basis. The number of available positions does not mean that every contact can automatically carry the maximum allowable current simultaneously.
The ACT96WH35SN uses crimp termination.
Crimp contacts provide a mechanically retained electrical connection between the conductor and contact. In production harnesses, this allows wires to be terminated separately before being installed into the connector housing.
For high-volume or serviceable harness assemblies, this approach can offer advantages over soldered connections.
Correct crimp tooling, conductor preparation and contact insertion are essential to achieving reliable electrical and mechanical performance. The connector housing alone does not determine the quality of the completed harness.
The contact system uses gold mating surfaces.
Gold is commonly used on connector mating interfaces where stable electrical contact and resistance to surface oxidation are important.
The mating contact finish should be considered together with the connector's intended environment, mating frequency and electrical requirements.
For replacement applications, the contact plating and contact type should be matched rather than selecting a mechanically similar connector with a different contact system.
The ACT96WH35SN uses a composite shell with an olive-drab cadmium finish.
The shell provides the mechanical structure around the contact insert and participates in the connector's environmental and mechanical protection.
The composite construction is particularly relevant when connector weight is an important design consideration.
When replacing the connector, shell material and mechanical dimensions should be checked alongside the electrical specifications because visually similar circular connectors may use different materials and coupling arrangements.
The ACT96WH35SN uses a threaded coupling mechanism.
A threaded coupling provides a positive mechanical connection between the plug and its mating connector.
This is useful in systems where vibration, movement or repeated environmental stress could make a simpler friction-fit connection unsuitable.
The mating connector must have the corresponding compatible coupling interface. A connector with the same number of contacts is not necessarily a mechanically compatible replacement.
The specified operating temperature range for ACT96WH35SN is approximately -65°C to 175°C.
This broad temperature range makes the connector suitable for applications where ordinary commercial connectors may not provide sufficient environmental capability.
The connector should nevertheless be evaluated as part of the complete system. Cable insulation, crimp contacts, backshells, seals and the mating connector all have their own environmental limitations.
A connector's temperature specification should therefore not be interpreted as the temperature rating of the complete cable assembly.
The ACT96WH35SN is a free-hanging, in-line connector rather than a PCB-mounted connector.
This configuration is particularly useful for cable-to-cable or harness-to-harness interconnections.
The connector can be integrated into a wiring harness without occupying a PCB footprint, allowing the electronic assemblies at either end of the harness to remain mechanically independent.
This characteristic also makes the ACT96WH35SN different from panel-mount or board-mount members of the DEUTSCH connector family.
The combination of 100 contacts, crimp termination, threaded coupling and environmental capability makes the ACT96WH35SN relevant to complex wiring harness applications.
It can be considered for aerospace, defense, industrial equipment and other systems requiring a high-density circular cable interface.
The connector architecture is particularly useful where multiple signal circuits must pass through a single detachable harness connection.
For systems exposed to vibration or wide temperature changes, the mechanical connector specification is just as important as the electrical contact specification.
The ACT96WH35SN is commonly specified with 5A contact current capability under the applicable conditions.
This rating should not be interpreted as a blanket 5A rating for all 100 contacts simultaneously.
Actual allowable current depends on factors such as the contact arrangement, conductor size, ambient temperature, number of energized contacts and applicable derating requirements.
For a high-density harness, thermal analysis may therefore be required when many contacts carry current simultaneously.
Selecting a mating connector for ACT96WH35SN requires more than matching the 100-position count.
The shell configuration, insert arrangement, contact gender, coupling mechanism, contact type and keying must all be compatible.
The ACT family includes numerous variations that may look similar while having different mating characteristics.
For this reason, the complete ACT96WH35SN Part Number should be used when identifying the required connector rather than relying on the generic description "100-position circular connector."
A replacement for ACT96WH35SN should be evaluated against the complete mechanical and electrical interface.
The most important factors include the 100-position configuration, shell size, insert arrangement, female contact configuration, crimp termination, mating interface, mounting style and environmental requirements.
A connector with fewer or more positions cannot be considered an equivalent replacement simply because its shell looks similar.
For an existing harness, the contact layout and mating geometry are especially important because an apparently compatible connector may still produce an incorrect circuit arrangement.
The complete ACT96WH35SN designation is useful for sourcing and BOM management because the ACT connector family contains many closely related configurations.
The base ACT96 designation identifies the connector family, while the remaining characters distinguish the particular shell, insert, contact and configuration details.
When purchasing replacement components, the exact Part Number should therefore be retained throughout the procurement process.
This reduces the risk of receiving a connector from the same family that has a different contact arrangement or mechanical configuration.
The main value of the ACT96WH35SN is its combination of 100 electrical positions, crimp contacts, threaded coupling, composite construction and wide operating-temperature capability.
It is intended for applications where a large number of circuits need to be consolidated into a mechanically secure circular connector.
For new harness designs, the key selection factors are contact count, current requirements, signal type, wire size, environmental conditions and mating configuration.
For replacement projects, maintaining the exact ACT96WH35SN configuration is even more important because small differences within the DEUTSCH ACT family can affect both the mechanical interface and electrical connectivity.
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