BS EN 3645-002:2015 BSI Standards Publication Aerospace series — Connectors, electrical, circular, scoop-proof, triple start threaded coupling, operating temperature 175 °C or 200 °C continuous Part 002: Specification of performance and contact arrangements BS EN 3645-002:2015 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 3645-002:2015 It supersedes BS EN 3645-002:2007 which is withdrawn The UK participation in its preparation was entrusted to Technical Committee ACE/6, Aerospace avionic electrical and fibre optic technology A list of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 2015 Published by BSI Standards Limited 2015 ISBN 978 580 86337 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 30 June 2015 Amendments issued since publication Date Text affected BS EN 3645-002:2015 EN 3645-002 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM June 2015 ICS 49.060 Supersedes EN 3645-002:2007 English Version Aerospace series - Connectors, electrical, circular, scoop-proof, triple start threaded coupling, operating temperature 175 °C or 200 °C continuous - Part 002: Specification of performance and contact arrangements Série aérospatiale - Connecteurs électriques circulaires, contacts protégés, accouplement par filetage, pas rapide trois filets, température d'utilisation 175 °C ou 200 °C continu - Partie 002: Spécification de performances et arrangements des contacts Luft- und Raumfahrt - Elektrische Rundsteckverbinder, kontaktgeschützt, Drei-gangige Gewinde-Schnelkupplung, Betriebstemperatur 175 °C oder 200 °C konstant - Teil 002: Leistungsdaten und Kontaktanordnungen This European Standard was approved by CEN on 28 June 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 © 2015 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members Ref No EN 3645-002:2015 E BS EN 3645-002:2015 EN 3645-002:2015 (E) Contents Page Foreword Introduction Scope Normative references Terms and definitions Description and codification of class 5 Operating conditions .7 Type codes 11 Polarization 11 Housing sizes and contact arrangements 12 Contact arrangements 15 10 Contacts 26 11 Filler plugs 27 12 Rear accessories 27 13 Tooling 27 14 Assembly and wiring instructions 27 BS EN 3645-002:2015 EN 3645-002:2015 (E) Foreword This document (EN 3645-002:2015) 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 December 2015, and conflicting national standards shall be withdrawn at the latest by December 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 This document supersedes EN 3645-002:2007 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 3645-002:2015 EN 3645-002:2015 (E) Introduction This family of connectors is derived from MIL-DTL-38999/30C series III, with which it is intermateable and interchangeable Scope This European Standard defines the performances and contact arrangements for threaded ring coupling circular connectors, fire-resistant or non fire-resistant, intended for use in a temperature range from − 65 °C to 175 °C or 200 °C continuous 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 2591-209, Aerospace series — Elements of electrical and optical connection — Test methods — Part 209: Current temperature derating EN 3155-002, Aerospace series — Electrical contacts used in elements of connection — Part 002: List and utilization of contacts EN 3155-008, Aerospace series — Electrical contacts used in elements of connection — Part 008: Contacts, electrical, male, type A, crimp, class S — Product standard EN 3155-009, Aerospace series — Electrical contacts used in elements of connection — Part 009: Contacts, electrical, female, type A, crimp, class S — Product standard EN 3155-010, Aerospace series — Electrical contacts used in elements of connection — Part 010: Contacts, electrical, triaxial, size 8, male, type D, crimp, class R — Product standard 1) EN 3155-011, Aerospace series — Electrical contacts used in elements of connection — Part 011: Contacts, electrical, triaxial, size 8, female, type D, crimp, class R — Product standard 1) EN 3155-012, Aerospace series — Electrical contacts used in elements of connection — Part 012: Contacts, electrical, triaxial, size 8, male, type D, solder, class R — Product standard EN 3155-013, Aerospace series — Electrical contacts used in elements of connection — Part 013: Contacts, electrical, triaxial, size 8, female, type D, solder, class R — Product standard EN 3155-024, Aerospace series — Electrical contacts used in elements of connection — Part 024: Contacts, electrical, triaxial, size 8, male, type D, crimp, class S — Product standard 1) In preparation at the date of publication of this standard BS EN 3645-002:2015 EN 3645-002:2015 (E) EN 3155-025, Aerospace series — Electrical contacts used in elements of connection — Part 025: Contacts, electrical, triaxial, size 8, female, type D, crimp, class S — Product standard EN 3197, Aerospace series - Design and installation of aircraft electrical and optical interconnection systems EN 3645 (all parts), Aerospace series — Connectors, electrical, circular, scoop-proof, triple start threaded coupling, operating temperature 175 °C or 200 °C continuous EN 3660-002, Aerospace series — Cable outlet accessories for circular and rectangular electrical and optical connectors — Part 002: Index of product standards EN 4529-002, Aerospace series - Elements of electrical and optical connection - Sealing plugs - Part 002: Index of product standards MIL-DTL-38999/30C, Connectors, electrical, circular, threaded, plug, lanyard release, fail-safe, removable crimp contacts, sockets, series III, metric 2) AS39029/106B, Contacts, electrical connector, socket, crimp-removable (for MIL-DTL-38999 series I, III and IV and MIl-DTL-55302 and AS29600 series A connectors) 3) AS39029/107B, Contacts, electrical connector, pin, crimp-removable (for MIL-DTL-38999 series I, III and IV, MIL-DTL-55302 and AS29600 series A connectors) 3) Terms and definitions For the purposes of this document, the terms and definitions given in EN 3645-001 apply Description and codification of class See Table 2) Published by: DoD National (US) MIL Department of Defense http://www.defenselink.mil/ 3) Published by: SAE National (US) Society of Automotive Engineers http://www.sae.org/ BS EN 3645-002:2015 EN 3645-002:2015 (E) Table Model Description W Receptacles and plugs, cadmium-plated aluminium alloy, olive drab — 500 h salt spray — Plug with grounding spring — Crimp, removable contacts — Maximum operating temperature 175 °C continuous J Receptacles and plugs, cadmium-plated composite, olive drab — 000 h salt spray — Plug with grounding spring — Crimp, removable contacts — 500 matings — Maximum operating temperature 175 °C continuous Z Receptacles and plugs, zinc-nickel plated aluminium alloy, non reflective black — 500 h salt spray — Plug with grounding spring — Crimp, removable contacts — Maximum operating temperature 175 °C continuous K Receptacles and plugs, passivated stainless steel — 500 h salt spray — Plug with grounding spring — Fire-resistant — Crimp, removable contacts — Maximum operating temperature 200 °C continuous F Receptacles and plugs, nickel-plated aluminium alloy — 48 h salt spray — Plug with grounding spring — Crimp, removable contacts — Maximum operating temperature 200 °C continuous M Receptacles and plugs, nickel-plated composite — 000 h salt spray — Plug with grounding spring — Crimp, removable contacts — 500 matings — Maximum operating temperature 200 °C continuous Y Hermetic receptacle, passivated stainless steel — Solder contacts — Maximum operating temperature 200 °C continuous T Receptacles and plugs, nickel fluorocarbon polymer plated aluminium alloy, non reflective — 500 h salt spray — Plug with grounding spring — Crimp, removable contacts — Maximum operating temperature 175 °C continuous K Protective cover for plug in passivated corrosion resisting steel — Maximum operating temperature 200 °C continuous F Protective cover for receptacle or plug in nickel-plated aluminium alloy — Maximum operating temperature 200 °C continuous Z Protective cover for receptacle or plug, zinc-nickel plated aluminium alloy, non-reflective black – Maximum operating temperature 175 °C continuous W Protective cover for receptacle or plug in olive-green cadmium-plated aluminium alloy — Maximum operating temperature 175 °C continuous T Protective cover for receptacle or plug in nickel fluorocarbon polymer plated aluminium alloy, non reflective — Maximum operating temperature 175 °C continuous K Dummy receptacle in passivated stainless steel — Maximum operating temperature 200 °C continuous F Dummy receptacle in nickel-plated aluminium alloy — Maximum operating temperature 200 °C continuous Z Dummy receptacle, zinc-nickel plated aluminium alloy, non-reflective black – Maximum operating temperature 175 °C continuous W Dummy receptacle in olive-green cadmium-plated aluminium alloy — Maximum operating temperature 175 °C continuous T Dummy receptacle in nickel fluorocarbon polymer plated aluminium alloy, non reflective — Maximum operating temperature 175 °C continuous Connector Protective cover Dummy receptacle BS EN 3645-002:2015 EN 3645-002:2015 (E) 5.1 Operating conditions Combinations of plugs and receptacles Table shows the combinations marked by (X) which achieve the characteristics specified for each model For other combinations, the characteristics of the pair of connectors are those of the component with the lowest performance Other combinations may be used subject to the approval of the Design Authority Table Receptacle model 5.2 Plug model W F J M K Z T W X — X — — X — F — X — X — — — J X — X — — — — M — X — X — — — Y — — — X X — — K — — — — X — — Z X — — — X X — T — — — — — — X Combinations of protective covers and connectors See Table Table Flight cap for receptacle Receptacle model Dummy receptacle Flight cap for plug J W W J W Z F K Z T M F Y K Z W T Plug model W Z F K Z T M F K Z W T BS EN 3645-002:2015 EN 3645-002:2015 (E) 5.3 Permissible cables The sealing performance of these connectors is achieved with the cables of dimensions given in Table 4, using the accessories wiring tools specified Table Dimensions in millimetres Outer diameters of cables Contact size a max 22 0,75 1,37 20 1,01 2,11 16 1,65 2,77 12 2,47 3,61 10 3,42 5,21 a a The cables for size contacts are specified in the contact product standard NOTE The use of cables exceeding the maximum diameter indicated is prohibited Cables smaller than the minimum diameter may be used, subject to a concession, provided that the requirements of EN 3197 are observed 5.4 Operating characteristics 5.4.1 5.4.1.1 Electrical conditions Withstand voltage See Table Table Rating M Pressure Rating N Rating I Rating II Mated Unmated Mated Unmated Mated Unmated Mated Unmated Vrms Vrms Vrms Vrms Vrms Vrms Vrms Vrms 300 300 000 000 800 800 300 300 12,1 kPa (15 000 m) 800 550 600 400 000 600 000 800 4,7 kPa (21 000 m) 800 350 600 260 000 400 000 500 1,1 kPa (30 000 m) 800 200 600 200 000 200 000 200 Sea level 5.4.1.2 Insulation resistance At ambient temperature the insulation resistance shall be ≥ 000 MΩ BS EN 3645-002:2015 EN 3645-002:2015 (E) 16 09G01 Rating N/A triaxial contact, size or 09Q01 quadrax contact, size 09N35 Rating M contacts, size 22 09N98 Rating I contacts, size 20 Figure Figure Figure 11N01 Rating N triaxial contact, size or 11Q01 and 11L01 quadrax contact size 11N02 and 11G02 Rating I contacts, size 16 11N05 Rating I contacts, size 20 Figure Figure Figure 11N12 Rating II contact, size 12 11N35 Rating M 13 contacts, size 22 11N98 Rating I contacts, size 20 Figure Figure Figure BS EN 3645-002:2015 EN 3645-002:2015 (E) 11N99 Rating I contacts, size 20 11N04 Rating l contacts size 20 13N04 and 13G04 Rating I contacts, size 16 Figure 10 Figure 11 Figure 12 13N08 Rating I contacts, size 20 13N26 Rating M contacts, size 12 contacts, size 22 13N35 Rating M 22 contacts, size 22 Figure 13 Figure 14 Figure 15 13N98 Rating I 10 contacts, size 20 15N05 and 15G05 Rating II contacts, size 16 15N15 Rating I 14 contacts, size 20 contact, size 16 Figure 16 Figure 17 Figure 18 17 BS EN 3645-002:2015 EN 3645-002:2015 (E) 18 15N18 Rating I 18 contacts, size 20 15N19 Rating I 19 contacts, size 20 15N35 Rating I 37 contacts, size 22 Figure 19 Figure 20 Figure 21 15N97 Rating I contacts, size 20 contacts, size 16 17N02 Rating N triaxial contact, size 38 contacts, size 22 17N06 and 17G06 Rating I contacts, size 12 Figure 22 Figure 23 Figure 24 BS EN 3645-002:2015 EN 3645-002:2015 (E) 17N08 and 17G08 Rating II contacts, size 16 17N20 Rating M contacts, size 12 16 contacts, size 22 17G22 or 17N22 Rating M contacts, size contacts, size 12 17Q22 or 17L22 Rating M contacts, size contacts, size 12 Figure 25 Figure 26 Figure 27 17N26 Rating I 26 contacts, size 20 17N35 Rating M 55 contacts, size 22 17N75 or 17G75 Rating M triaxial contacts, size Figure 28 Figure 29 Figure 30 19 BS EN 3645-002:2015 EN 3645-002:2015 (E) 20 17N99 Rating I contacts, size 16 21 contacts, size 20 19N11 Rating I 11 contacts, size 16 19N12 Rating M contacts, size 20 contacts, size 16 contacts, size Figure 31 Figure 32 Figure 33 19N17 Rating M 10 contacts, size 22 contact, size 20 contacts, size 16 contacts, size 19Q31 or 19L31 Rating M 12 contacts, size 22 contact, size 12 quadrax contacts, size 19N35 Rating M 66 contacts, size 22 Figure 34 Figure 35 Figure 36 BS EN 3645-002:2015 EN 3645-002:2015 (E) 19N32 Rating M 32 contacts, size 20 21N11 Rating I 11 contacts, size 12 21N12 Rating I contacts, size 12 contacts, size 20 Figure 37 Figure 38 Figure 39 21N16 or 21G16 Rating II 16 contacts, size 16 21L20 Rating M 18 contacts size 20 contacts quadrax size 21N35 Rating M 79 contacts, size 22 Figure 40 Figure 41 Figure 42 21 BS EN 3645-002:2015 EN 3645-002:2015 (E) 22 21N39 Rating I 37 contacts, size 20 contacts, size 16 21N41 Rating I 41 contacts, size 20 21R48 Rating M power contacts, size Figure 43 Figure 44 Figure 45 21N75 or 21G75 Rating M triaxial contacts, size or 21Q75 or 21L75 Rating M quadrax contacts, size 23N05 or 23G05 coaxial or triaxial, size 23N06 or 23G06 coaxial or triaxial, size or 23Q06 or 23L06 quadrax, size Figure 46 Figure 47 Figure 48 BS EN 3645-002:2015 EN 3645-002:2015 (E) 23N21 Rating II 21 contacts, size 16 23N35 Rating M 100 contacts, size 22 23N53 Rating I 53 contacts, size 20 Figure 49 Figure 50 Figure 51 23N54 Rating M 40 contacts, size 22 contacts, size 16 contacts, size 12 23N55 Rating I 55 contacts, size 20 25N04 Rating I 48 contacts, size 20 contacts, size 16 Figure 52 Figure 53 Figure 54 23 BS EN 3645-002:2015 EN 3645-002:2015 (E) 25N07 Rating N 97 contacts, size 22 triaxial contacts, size or 25L07 97 contacts, size 22 quadrax contacts, size 25G08 or 25N08 Rating M triaxial contacts, size or 25L08 or 25Q08 quadrax contacts, size 25N11 Rating N contacts, size 20 power contacts, size 10 Figure 55 Figure 56 Figure 57 24 25L17 Rating N 36 contacts, size 22 quadrax contacts, size 25N19 Rating I 19 contacts, size 12 Figure 58 Figure 59 BS EN 3645-002:2015 EN 3645-002:2015 (E) 25N20 Rating N 10 contacts, size 20 13 contacts, size 16 contacts, size 12 triaxial contacts, size or 25L20 Rating N 10 contacts, size 20 13 contacts, size 16 contacts, size 12 quadrax contacts, size 25N24 Rating I 12 contacts, size 16 12 contacts, size 12 25N26 Rating I 16 contacts, size 20 contacts, size 12 triaxial contacts, size Figure 60 Figure 61 Figure 62 25N29 or 25G29 Rating I 29 contacts, size 16 25N35 Rating M 128 contacts, size 22 25N37 or 25G37 Rating I 37 contacts, size 16 Figure 63 Figure 64 Figure 65 25 BS EN 3645-002:2015 EN 3645-002:2015 (E) 25N43 Rating I 23 contacts, size 20 20 contacts, size 16 25N46 Rating I 40 contacts size 20 contacts, size 16 triaxial contacts, size 25N61 Rating I 61 contacts, size 20 Figure 66 Figure 67 Figure 68 10 Contacts The maximum operating temperature of the connector shall be limited to that specified in the contact product standard Removable contacts which can be used with the various classes of connectors are indicated in EN 3155-002 EXAMPLE For the 175 °C and 200 °C classes (500 operations) Male contacts, type A, according to EN 3155-008 Female contacts, type A, according to EN 3155-009 Triaxial, male contacts, type D, crimped, according to EN 3155-010 and EN 3155-024 Triaxial, female contacts, type D, crimped, according to EN 3155-011 and EN 3155-025 Triaxial, male contacts, type D, soldered, according to EN 3155-012 Triaxial, female contacts, type D, soldered, according to EN 3155-013 EXAMPLE For the 175 °C and 200 °C classes (1 500 operations) Male contacts, type A, according to AS39029/107B Female contacts, type A, according to AS39029/106B 26 BS EN 3645-002:2015 EN 3645-002:2015 (E) 11 Filler plugs Filler plugs defined in EN 4529-002 shall be used in the grommet cavities which correspond to unwired contacts 12 Rear accessories The rear accessories and the conditions in which they are used are defined in EN 3660-002 13 Tooling The tooling for crimping, installing and extracting removable contacts is indicated in the standards for contacts 14 Assembly and wiring instructions See EN 3197 27 This page deliberately left blank 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 combined experience and expertise into standards -based solutions Our British Standards and other publications are updated by amendment or revision The knowledge embodied in our standards has been carefully assembled in a dependable format and refined through our open consultation process Organizations 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