Bsi bs en 03155 035 2012

BS EN 3155-035:2012 BSI Standards Publication Aerospace series — Electrical contacts used in elements of connection Part 035: Contacts, electrical, triaxial, size 08, female, type D, crimp, class R— Product standard BS EN 3155-035:2012 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 3155-035:2012 It supersedes BS EN 3155-035:2006 which is withdrawn The UK participation in its preparation was entrusted to Technical Committee ACE/6, Aerospace avionic electrical and fibre optic technology A list of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 2012 Published by BSI Standards Limited 2012 ISBN 978 580 76580 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 March 2012 Amendments issued since publication Date Text affected BS EN 3155-035:2012 EN 3155-035 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM March 2012 ICS 49.060 Supersedes EN 3155-035:2006 English Version Aerospace series - Electrical contacts used in elements of connection - Part 035: Contacts, electrical, triaxial, size 08, female, type D, crimp, class R- Product standard Série aérospatiale - Contacts électriques utilisés dans les organes de connexion - Partie 035: Contacts électriques triaxiaux, taille 08, femelles, type D, sertir, classe R Norme de produit Luft- und Raumfahrt - Elektrische Kontakte zur Verwendung in Verbindungselementen - Teil 035: Elektrische triaxiale, Grösse 08, Buchsenkontakte, Typ D, crimpbar, Klasse R Produktnorm This European Standard was approved by CEN on 24 December 2011 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, 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 Management Centre: Avenue Marnix 17, B-1000 Brussels © 2012 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members Ref No EN 3155-035:2012: E BS EN 3155-035:2012 EN 3155-035:2012 (E) Contents Page Foreword 3 Introduction 4 Scope 4 Normative references 4 Terms and definitions 5 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.7.1 4.7.2 4.8 4.9 Requirements characteristics 5 Specific characteristics 5 Dimensions and mass 5 Marking by colour code 7 Material, surface treatment 7 Typical cables 7 Cable stripping and wiring method .8 Tooling 10 Crimping tools 10 Insertion/Extraction tools 10 Tests 10 Gauges 13 Designation 14 Marking 14 Conditioning 14 Technical specification .15 BS EN 3155-035:2012 EN 3155-035:2012 (E) Foreword This document (EN 3155-035:2012) 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 September 2012, and conflicting national standards shall be withdrawn at the latest by September 2012 This document supersedes EN 3155-035:2006 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, 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 3155-035:2012 EN 3155-035:2012 (E) Introduction The electrical contacts defined in this standard are derived from and interchangeable with those of standard SAE AS 39029/95 They are also interchangeable with those of standard EN 3155-043 Scope This European Standard specifies the required characteristics, tests and tooling applicable to female electrical triaxial contacts, size 08, type D, crimp, class R, used in element of connection according to EN 3155-002 It should be used together with EN 3155-001 The associated male contacts are defined in EN 3155-034 and EN 3155-042 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 2591 (all parts), Aerospace series — Elements of electrical and optical connection — Test methods EN 3155-001, Aerospace series — Electrical contacts used in elements of connection — Part 001: Technical specification EN 3155-002, Aerospace series — Electrical contacts used in elements of connection — Part 002: List and utilization of contacts EN 3155-034, Aerospace series — Electrical contacts used in elements of connection — Part 034: Contacts, electrical, triaxial, size 08, male, type D, crimp, class R — Product standard EN 3155-042, Aerospace series — Electrical contacts used in elements of connection — Part 042: Contacts, electrical, triaxial, size 08, male 042, type D, solder, class P — Product standard EN 3155-043, Aerospace series — Electrical contacts used in elements of connection — Part 043: Contacts, electrical, triaxial, size 08, female 043, type D, solder, class P — Product standard EN 3682-001, Aerospace series — Connectors, plug and receptacle, electrical, rectangular, interchangeable insert type, rack to panel, operating temperature 150 °C continuous — Part 001: Technical specification MIL-DTL-22520G, Crimping tools, terminal, hand or power actuated, wire termination, and tool kits general specification for 1) MIL-I-81969/14, Installing and removal tools, connector electrical contact, type III, class 2, composition B 1) 1) Published by: Department of Defense (DOD), The Pentagon, Washington D.C 20301, USA BS EN 3155-035:2012 EN 3155-035:2012 (E) SAE AS 39029/95, Contacts, electrical connector, concentric twinax, pin, size (for DOD-C-83527 connector) 2) TR 6058, Aerospace series — Cable code identification list 3) Terms and definitions For the purposes of this standard, the terms and definitions given in EN 3155-001 apply 4.1 Requirements characteristics Specific characteristics Type D contacts are for application where contacts with a screening feature are requested and class R corresponds to an operating temperature range from – 65 °C to 150 °C 4.2 Dimensions and mass See Figure Dimensions and tolerances are given in millimetres and apply after surface treatment Mass of the contact: 6,9 g max 2) Published as SAE National (US) Society of Automotive Engineers http://www.sae.org/ 3) Published as ASD-STAN Technical Report at the date of publication of this standard by Aerospace and Defence Industries Association of Europe-Standardization (ASD-STAN), (www.asd-stan.org) BS EN 3155-035:2012 EN 3155-035:2012 (E) a Diameter of outside after wiring b Point of contact with a flat-ended gauge pin of diameter 5,54 ± 0,005 c Diameter compatible with an outer pin diameter 5,54 ± 0,02 d Point of contact with a flat-ended gauge pin of diameter 0,76 ± 0,005 e Diameter compatible with a centre pin of diameter 0,76 ± 0,013 f Protection of the entrance of the centre contact shall be ensured, either at insert level, or at contact level, by a restricted entry Figure Key Key 4,91 on ferrule 4,86 Figure — Ferrule for cable group A 4,91 on ferrule 4,86 Figure — Ferrule for cable group B BS EN 3155-035:2012 EN 3155-035:2012 (E) 4.3 Marking by colour code Not applicable 4.4 Material, surface treatment  Outer body material (female) : copper alloy  Intermediate contact (male) : copper alloy  Center contact (female) : copper alloy  Crimp ferrule : copper alloy  Surface treatment : gold on appropriate undercoat, thickness of protection not specified, selective protection permitted  Dielectric : PTFE 4.5 Typical cables See Figure and Table Figure Table Dimensions of cable Cable code group Permissible cable code according to TR 6058 max max A – 0,55 0,62 1,3 braid of 0,1 coated copper wire overall diameter: mm max 3,5 WJ 0,55 0,62 1,3 braid of 0,1 coated copper wire overall diameter: 3,5 mm max 3,4 3,9 WV 0,55 0,62 1,3 braid of 0,1 coated copper wire high immunity tape overall diameter: 3,75 max 3,6 4,1 A B B Braid composition C max BS EN 3155-035:2012 EN 3155-035:2012 (E) 4.6 Cable stripping and wiring method A Fit the supplied guide ring on the cable Insulation should be stripped back Slide crimp ring over cable B Comb braid and fold back over crimp ring cut out fillers C Strip conductors as shown D Position the blue conductor core in outer contact Key 0,5 mm to mm Key Blue core White core Use tool M22520/2-01 locator EN4008-009 Key Crimping BS EN 3155-035:2012 EN 3155-035:2012 (E) E Feed the white conductor through the angled hole, fit insulator and position white conductor core in inner contact Use tool M22520/2-01, locator M22520/2-37 Key Crimping F Fit split insulator around crimp buckets Ensuring flange is positioned at front face of contact G Insure central insulator, intermediate contact and outer insulator are located inside the body Insert assembly into body H Crimp braid and outer jacket using tool M25520/5-01 and dies M22520/5-45 selector/cavity B Length of crimping: mm Key Crimping BS EN 3155-035:2012 EN 3155-035:2012 (E) 4.7 Tooling 4.7.1 Crimping tools Conform to MIL-DTL-22520G, see Table These selector numbers given in Table shall be used for qualification of the contacts and in service, unless otherwise specified by the user Table 4.7.2 Contact Crimping tool Positioner Selector setting/cavity Centre M22520/2-01 M22520/2-37 Intermediate M22520/2-01 EN4008-009 Outer M22520/5-01 M22520/5-45 B Insertion/Extraction tools Conform to MIL-I-81969/14-06 4.8 Tests Tests according to EN 2591-100, see Table Table — Tests EN 2591- Designation of the test Not applicable Applicable According to EN 3155-001 101 Visual examination X 102 Examination of dimensions and mass X 201 Contact resistance - low level X Remarks With cable code Contact Maximum contact resistance mΩ Initial After tests Centre 15 30 Intermediate 15 30 Outer Not applicable (continued) 10 BS EN 3155-035:2012 EN 3155-035:2012 (E) Table (continued) EN 2591202 Designation of the test Not applicable Contact resistance at rated current Applicable According to EN 3155-001 Remarks X Maximum contact resistance mΩ Contact (25 + 30 ) °C (150 + 30 ) °C Initial After tests After tests Centre 15 30 45 Intermediate 15 30 45 Outer Rated current A 12 204 Discontinuity of contacts in the microsecond range X Method B Duration of discontinuity: ≤ 100 ns Test duration: throughout the duration of tests EN 2591-402 and EN 2591-403 206 Measurement of insulation resistance X Method C, mated contacts Measurements between centre contact and intermediate and between intermediate contact and outer contact At ambient temperature: ≥ 000 MΩ At high temperature: ≥ 000 MΩ at maximum specified temperature 207 Voltage proof test X Method C Withstand voltage at sea level: 000 V r.m.s between centre contact and intermediate contact and 500 V r.m.s between intermediate contact and outer contact Withstand voltage at altitude: 125 V r.m.s at a pressure of 4,7 kPa (21 000 m) Leakage current: mA 212 Surface transfer impedance X 301 Endurance at temperature X Method B Duration : 000 h 305 Rapid change of temperature X TA = (150 ± 2) °C 306 Mould growth X 307 Salt mist X 315 Fluid resistance X TB = (− 65 ± 2) °C See Table According to EN 3682-001 11 BS EN 3155-035:2012 EN 3155-035:2012 (E) EN 2591- Designation of the test Not applicable Applicable According to EN 3155-001 Remarks 402 Shock X Method A, severity 300, see EN 3682-001, Figures 37, 38 and 39 403 Sinusoidal and random vibration X According to EN 3682-001, Subclause 7.2.2 406 Mechanical endurance X 417 Tensile strength (crimped connection) X Cable according to TR 6058 code XY Contact Centre Tensile values in N 36 Intermediate 36 Outer 113 (continued) 12 BS EN 3155-035:2012 EN 3155-035:2012 (E) Table (concluded) EN 2591418 Designation of the test Not applicable Applicable According to EN 3155-001 Gauge insertion/extraction forces (female contacts) X Gauge 501 Soft solderability 503 Contact deformation after crimping Remarks Intermediate contacts Gauge as described in Figure and Table Minimum extraction force N Initial After test Maximum insertion force N Initial After test maximum NA NA 8,34 10 minimum 0,83 0,69 NA NA X X Cable size in accordance with Table Intermediate contact concentricity tolerance shall not exceed 0,28 mm Intermediate contact and outer body Crimping zone shall not exceed 0,15 mm expansion 4.9 508 Measurement of thickness of coating on contacts X 509 Adhesion of coating on contacts X 513 Magnetic permeability X The measured thickness shall be recorded Gauges Defined in Figure and Table Dimensions and tolerances are in millimetres Key Ra 0,15 µm to Ra 0,25 µm Radius Figure 13 BS EN 3155-035:2012 EN 3155-035:2012 (E) Table Used on Gauge A max 0,775 0,77 0,2 0,754 0,749 0,2 max 5,563 5,558 0,8 5,517 5,512 0,8 Centre contact Outer contact ØB Flat max Designation EXAMPLE Description block Identity block CONTACT ELECTRICAL EN3155-035F08AB Number of this standard Type of contact: F = female Contact size code Cable code group (see Table 1) Code for delivery mode (see Table 5) NOTE If necessary, the code I9005 shall be placed between the description block and the identity block Table Code Delivery mode A Without sleeve B With sleeve EN4530-005-1 C With sealing sleeve EN4530-005-2 Marking See EN 3155-001 Conditioning The contacts are packaged and identified individually Conditioning shall provide protection of the contacts against any eventual damage 14 BS EN 3155-035:2012 EN 3155-035:2012 (E) Packaging shall include:  the manufacturer's name;  the designation defined in Clause 5;  the manufacturer's reference;  the manufacturing date code (year-week) Technical specification See EN 3155-001 15 BS EN 3155-035:2012 EN 3155-035:2012 (E) APPENDIX AMENDMENT RECORD SHEET Issue Draft 09/2009 NOTE 16 Modified paragraph Modification summary Justification Key d: 0,61 ± 0,005 becomes 0,76 ± 0,005 4.2 Key e: 0,61 ± 0,013 becomes 0,76 ± 0,013 Modifications to the last standard issue are indicated by a vertical line in the margin Taping error This page deliberately 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