BS EN 2593-001:2014 BSI Standards Publication Aerospace series — Bases for 10 A electromagnetic plugin relays, two and four poles double thrown Part 001: Technical specification BS EN 2593-001:2014 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 2593-001:2014 The UK participation in its preparation was entrusted to Technical Committee ACE/6, Aerospace avionic electrical and fibre optic technology A list of organizations represented on this committee can be obtained on request to its secretary This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application © The British Standards Institution 2014 Published by BSI Standards Limited 2014 ISBN 978 580 87665 ICS 49.060 Compliance with a British Standard cannot confer immunity from legal obligations This British Standard was published under the authority of the Standards Policy and Strategy Committee on 31 December 2014 Amendments issued since publication Date Text affected BS EN 2593-001:2014 EN 2593-001 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM December 2014 ICS 49.060 English Version Aerospace series - Bases for 10 A electromagnetic plug-in relays, two and four poles double thrown - Part 001: Technical specification Série aérospatiale - Socles pour relais électromagnétiques 10 A, embrochables, deux et quatre pôles inverseurs Partie 001: Spécification technique Luft- und Raumfahrt - Fassungen für steckbare, elektromagnetische Relais, 10 A, zwei- und vierpolige Wechselschalter - Teil 001: Technische Lieferbedingungen This European Standard was approved by CEN on 22 November 2014 CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels © 2014 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members Ref No EN 2593-001:2014 E BS EN 2593-001:2014 EN 2593-001:2014 (E) Contents Page Foreword Introduction Scope Normative references Terms and definitions Design .5 Description .6 Definition drawings and mass 7 Qualification tests Quality assurance 9 Designation and marking 12 10 Delivery conditions 12 11 Packaging 12 12 Storage 12 BS EN 2593-001:2014 EN 2593-001:2014 (E) Foreword This document (EN 2593-001:2014) has been prepared by the Aerospace and Defence Industries Association of Europe - Standardization (ASD-STAN) After enquiries and votes carried out in accordance with the rules of this Association, this Standard has received the approval of the National Associations and the Official Services of the member countries of ASD, prior to its presentation to CEN This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by June 2015, and conflicting national standards shall be withdrawn at the latest by June 2015 Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom BS EN 2593-001:2014 EN 2593-001:2014 (E) Introduction The relay bases defined by this standard are derived from MIL-S-12883/40 and MIL-S-12883/41, latest issue Scope This European Standard specifies the characteristics, installation and mounting dimensions for plug-in relay bases for use with two and four poles double throw relays in accordance with EN 2548-001 Relay bases in accordance with this standard shall be used at ambient temperatures between −70 °C and 125 °C and at altitudes up to 25 000 m Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies EN 2349 (all parts), Aerospace series — Requirements and test procedures for switching devices 1) EN 2548-001, Aerospace series — Relays, electromagnetic, 10 A (resistive load), with or without suppressor, 2) plug-in type, two and four poles double throw — Part 001: Technical specification EN 2593-003, Aerospace series — Bases for 10 A electromagnetic plug-in relays, two and four poles double throw — Part 003: According to EN 2548-003 — Base with non-captive fixation stud, metric — Dimensions — 2) Product standard EN 2593-004, Aerospace series — Bases for 10 A electromagnetic plug-in relays, two and four poles double throw — Part 004: According to EN 2548-004 — Base with melded-in fixation stud, unified — Dimensions — 2) Product standard EN 2593-005, Aerospace series — Bases for 10 A electromagnetic plug-in relays, two and four poles double throw — Part 005: According to EN 2548-005 — Base with melded-in fixation stud, metric — Dimensions — 2) Product standard EN 3155-017, Aerospace series — Electrical contacts used in elements of connection — Part 017: Contacts, electrical, relay base, female, type A, crimp, class P — Product standard MIL-S-12883/40, Socket, plug-in electronic components, socket for MIL-R-6106 and MIL-R-83726 relays, square pattern 3) MIL-S-12883/41, Socket, plug-in electronic components, socket for MIL-R-6106 relays 3) 1) Published as ASD-STAN Prestandard at the date of publication of this standard by Aerospace and Defence Industries Association of Europe-Standardization (ASD-STAN) (www.asd-stan.org) 2) In preparation at the date of publication of this standard 3) Published as DoD National (US) Mil Department of Defense (http://www.defenselink.mil/) BS EN 2593-001:2014 EN 2593-001:2014 (E) Terms and definitions For the purposes of this document, the terms and definitions given in EN 2349-100 apply Design 4.1 General The construction of the relay bases shall be such, that the associated components, under any circumstances, cannot be separated during its normal operational life The retaining clip shall ensure a correct and permanent holding of the crimp contacts 4.2 Dimensions See EN 2593-003, EN 2593-004 and EN 2593-005 4.3 Crimp contacts for electrical connections See product standards 4.4 Cables See product standards 4.5 4.5.1 Mechanical characteristics General See product standards 4.5.2 Mounting torque (hardware) See product standards 4.5.3 Mass (including crimp contact and hardware) See product standards 4.5.4 Insertion force See product standards 4.5.5 Extraction force See product standards 4.6 4.6.1 Sealing plug General See product standards BS EN 2593-001:2014 EN 2593-001:2014 (E) 4.6.2 Configurations See product standards 4.6.3 Dimensions See product standards 4.6.4 Quantities See product standards 4.7 Insertion and extraction tools 4.7.1 General See product standards 4.7.2 Plastic tool See product standards 4.7.3 Metal tool See product standards 4.8 Metal parts All metal parts used shall meet the requirements of EN 2349-100 The materials of the hardware (nuts and lock-washers) shall be non-magnetic corrosion resistance steel 5.1 Description Materials/Features The relay base assembly consists of: socket body: the material shall be a thermoplast, non-flammable, according to EN 2349-100 and this specification; sealing rubber: the material shall be silicon rubber, non-flammable, according to EN 2349-100 and this specification The sealing rubber shall seal wires with external diameters as shown in the product standard; crimp contacts: in accordance with EN 3155-017 The crimp contacts shall be selected to accommodate cables as defined in 4.3 The finish of the crimp contacts shall be: gold-plated — Thickness: 1,27 µm 5.2 Interface seal The relay and base interface shall be sealed by a silicon rubber The rubber prevents any environmental influence such as fluids between: relay and base; base and wiring BS EN 2593-001:2014 EN 2593-001:2014 (E) The rubber shall provide an additional electrical isolation between relay terminals and housing The hardness of the rubber shall not cause any damage or mechanical deformations when tightening the relay on its base The silicon rubber shall be a part of the plug-in relays in accordance with EN 2548-001 5.3 Polarizing holes 5.3.1 Two-pole bases The relay bases shall be provided with polarizing holes to accept the polarizing pins used on the two-pole relays only The shape of the polarizing holes shall accept the polarizing pins used on the 28 V d.c and 115 V a.c coil relays of EN 2548-001 The purpose of the polarizing pins and holes is to prevent installation of 28 V d.c or 115 V a.c coil relays into the non-mating relay base The polarizing pin shall ensure the correct installation of the relay to its base 5.3.2 Four-pole bases The keying of the four-pole d.c and a.c coil relay bases shall be provided by different coil terminal positions They shall also ensure installation of relay on its base in one position only On a four-pole version this fool proofing shall be ensured by the contact pins position Definition drawings and mass For the dimensions and mechanical characteristics, reference is made to the product standards Qualification tests The relay bases shall meet the applicable requirements of EN 2349-100 as shown in Table The qualification test shall be performed together with the mating relay BS EN 2593-001:2014 EN 2593-001:2014 (E) Table — Qualification tests EN 2349- a Designation of the test Requirements 201 Visual inspection See product standard 202 Dimensions See product standard 501 Strength of attachment bolts See product standard 504 Contact flexibility and resistance to elongation Applicable 413 Vibration, sinusoidal See product standard 413 Vibration, non-sinusoidal See product standard 414 Shock See product standard 415 Acceleration See product standard 411 Temperature change Applicable 402 Corrosion, salt spray Applicable 407 Cold, low air pressure and moist heat Applicable 409 Ozone resistance Applicable 410 Attack by mould Applicable 405 Resistance to chemicals Applicable 302 Insulation resistance See product standard 303 Dielectric strength See product standard 307 Contact voltage drop 306 Overload (a.c and d.c.) 317 Switching performance a 602 Circuit breaker compatibility (10 A thermal circuit breaker) a See product standard a Applicable Applicable Contact load resistive A Load duration max 15 1h 50 5s 100 1,2 s 250 0,2 s 350 0,1 s 503 Mating and unmating forces EN 2548-XXXX2X: < 36 N EN 2548-XXXX4X: < 36 N 502 Robustness of terminations Gold plating : 1,27 µm To be tested with the mating relay BS EN 2593-001:2014 EN 2593-001:2014 (E) Quality assurance 8.1 General In order to show evidence to meet the requirements of EN 2349-100 and this specification, the manufacturer is responsible for: the selection of suitable materials; establishment of manufacturing and control process; performance of qualification tests (see Table 1); maintaining the qualification by periodic retention of qualification (see Table 5); performing final inspection tests (see Table 3); performing batch acceptance tests (see Table 4) The manufacturer shall maintain documentation and/or records to show evidence at any time that the products manufactured according to product standards meet the required quality level The documentation shall be maintained by the manufacturer for a period of five years minimum 8.2 8.2.1 Qualification procedure General The test samples shall be series production units, selected by random from a batch All test results shall be recorded 8.2.2 Test sequence The qualification test samples shall be in accordance with Table 5, considering the requirements as per Table In case one sample fails to meet the requirements, it shall be replaced by a new test sample and the whole test sequence related to the failed unit to be repeated In case two or more samples fail to meet the requirement, the qualification test is to be suspended The qualification authority shall be informed accordingly The failed units shall be investigated and the necessary corrective actions introduced The complete qualification program has to be repeated with modified test samples Table — Product acceptance test EN 2349- Designation of the test Code 201 Visual inspection A 202 Dimensions – 302 Insulation resistance E 303 Dielectric strength F BS EN 2593-001:2014 EN 2593-001:2014 (E) 8.2.3 Samples preparation Prior starting the qualification test, each sample shall pass the inspection test according to Table The samples shall be numbered 8.3 8.3.1 Acceptance and inspection conditions Product acceptance tests Each relay base in accordance with this specification shall be subjected to the product acceptance test according to Table prior to delivery 8.3.2 Batch acceptance test In case of contractual requirements, the batch inspection shall be performed For conditions, reference is made to Table Table — Batch acceptance EN 2349- 8.4 Designation of the test Code Acceptance level AQL 201 Visual inspection A 4,0 202 Dimensions A 4,0 302 Insulation resistance E 1,5 303 Dielectric strength F 1,5 Maintenance of qualification To maintain type qualification, the qualification test according to Table shall be performed every three years after initial qualification Table — Qualification maintenance Checking according to Table Acceptance standard 1 1 – 407 Cold, low air pressure and moist heat 2 – – – E 306 Overload – – 2 – F 413 Sinusoidal vibrations – – – – F 503 Mating and unmating forces – – – – A EN 2349Table 10 Sample number test sequence Designation of the test EN 2593-001:2014 (E) Table — Type qualification procedure Sampling Designation of the Test EN 2349 10 11 12 Inspection according to Table of EN 2349 Test sequences Product acceptance Table 1 1 1 1 1 1 — Thermal shock 411 – – – – – – – – – – – A Shock 414 – – – – – – – – – – – F Vibration, sinusoidal 413 – – – – – – – – – – – F Random vibration 413 – – – – – – – – – – – F Salt spray 402 – – – – – – – – – – – — Cold humid heat pressure 407 – – – – – – – – – – E Ozone 409 – – – – – – – – – – – — Resistance to chemical agent 318 – – – – – – – – – – – – A Mould growth 410 – – – – – – – – – – – – — Acceleration 413 – – – – – – – – – – – – Overload (d.c./a.c.) 306 – – – 4 – – – – – – F Rupture 310 – – – – – – – – – – – — Circuit breaker compatibility 602 – – – – – – 3 – – — Insertion and extraction force 503 – – – – – – – – – – E Crimp contact finish 502 – – – – – – 2 – – – – — NOTE Additional samples may be used if necessary NOTE Digits mentioned in each column indicate in which order tests shall be carried out for each sample from to 12 NOTE Two samples for each type of fungus or chemical agent shall be used every time 11 BS EN 2593-001:2014 EN 2593-001:2014 (E) 9.1 Designation and marking Designation EXAMPLE Description block RELAY, BASE Identity block EN2593-001 A D Number of this standard Rated voltage: Code A: 28 V d.c (see EN 2548-XXX) Code B: 115 V a.c (see EN 2548-XXX) Number of poles: or (see EN 2548-XXX) Delivery conditions: Code A: with contacts EN 3155-017F1616 Code B: with contacts EN 3155-017F1620 Code C: without contacts for contact size 16/16 Code D: without contacts for contact size 16/20 NOTE: If necessary, the code I9005 shall be placed between the description block and the identity block 9.2 Marking Marking shall be made on the relay base body Unless otherwise specified, this marking shall include the EN-reference defined in 9.1, the date of manufacture (year-week), the manufacturer's name or trademark, and the terminals identification 10 Delivery conditions All accessories shall be packed separately 11 Packaging Relay bases and accessories shall be delivered in individual plastic bags 12 Storage The relay bases shall be stored in their original package under normal conditions The store room shall be protected against ultra-violet rays 12 This page deliberately left blank NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW British Standards Institution (BSI) BSI is the national body responsible for preparing British Standards and other standards-related publications, information and services BSI is incorporated by Royal Charter British Standards and other standardization products are published by BSI Standards Limited About us Revisions We bring together business, industry, government, consumers, innovators and others to shape their 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