BS EN 3682-001:2013 BSI Standards Publication Aerospace series — Connectors, plug and receptacle, electrical, rectangular, interchangeable insert type, rack to panel, operating temperature 150 °C continuous Part 001: Technical specification BS EN 3682-001:2013 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 3682-001:2013 It supersedes BS EN 3682-001:2006 which is withdrawn The UK participation in its preparation was entrusted to Technical Committee ACE/6, Aerospace avionic electrical and fibre optic technology A list of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 2013 Published by BSI Standards Limited 2013 ISBN 978 580 81717 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 September 2013 Amendments issued since publication Date Text affected BS EN 3682-001:2013 EN 3682-001 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM September 2013 ICS 49.060 Supersedes EN 3682-001:2006 English Version Aerospace series - Connectors, plug and receptacle, electrical, rectangular, interchangeable insert type, rack to panel, operating temperature 150 °C continuous - Part 001: Technical specification Série aérospatiale - Connecteurs électriques rectangulaires rackables, fiches et embases, inserts interchangeables, température d'utilisation 150 °C continu - Partie 001: Spécification technique Luft- und Raumfahrt - Elektrischer Rechtecksteckverbinder, freie und feste Bauform, auswechselbare Isolierkörper, Gestell-Einschubsteckverbinder, Betriebstemperatur 150 °C konstant - Teil 001: Technische Lieferbedingungen This European Standard was approved by CEN on May 2013 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 Management Centre: Avenue Marnix 17, B-1000 Brussels © 2013 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members Ref No EN 3682-001:2013: E BS EN 3682-001:2013 EN 3682-001:2013 (E) Contents Page Foreword Introduction Scope Normative references Terms and definitions Description 5 Design 6 Definition drawings and masses 7 Tests 47 Quality assurance 65 Designation and marking 69 10 Delivery conditions 70 11 Packaging 70 12 Storage 70 BS EN 3682-001:2013 EN 3682-001:2013 (E) Foreword This document (EN 3682-001:2013) 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 March 2014, and conflicting national standards shall be withdrawn at the latest by March 2014 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 3682-001:2006 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 3682-001:2013 EN 3682-001:2013 (E) Introduction This family of connectors is derived from MIL-C-83527 with which it is intermateable and interchangeable It offers a comprehensive range of contact arrangements The plug is fitted with a grounding spring system which is replaceable in the field It is particularly for use on rack application in zones of severe environmental conditions on board aircraft, applying EN 2282 Scope This European Standard specifies the general characteristics, the conditions for qualification, acceptance and quality assurance, as well as the test programs and groups for connectors intended for use in a temperature range from – 65 °C to 150 °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 2282, Aerospace series — Characteristics of aircraft electrical supplies EN 2267-002, Aerospace series — Cables, electrical, for general purpose — Operating temperatures between − 55 °C and 260 °C — Part 002: General EN 2591 (all parts), Aerospace series — Elements of electrical and optical connection — Test methods EN 3155 (all parts), Aerospace series — Electrical contacts used in elements of connection EN 3197, Aerospace series - Design and installation of aircraft electrical and optical interconnection systems EN 3682 (all parts), Aerospace series — Connectors, plug and receptacle, interchangeable insert type, rack to panel, operating temperature 150 °C continuous electrical, rectangular, EN 3909, Aerospace series — Test fluids and test methods for electric components and sub-assemblies EN 4529-002, Aerospace series — Elements of electrical and optical connection — Sealing plugs — Part 002: Index of product standards EN 9133, Aerospace series — Quality management systems — Qualification procedure for aerospace standard parts MIL-C-83527 (all parts), Connectors, plug and receptacle, electrical, rectangular multiple insert type, rack to panel, environment resisting, 150 °C total continuous operating temperature 1) MIL-L-15719, (Amendment 3), Military specification, lubricating grease (High temperature, electric motor, ball and roller bearings) 1) MIL-STD-454, Military standard — Standard General Requirements for Electronic Equipment 1) 1) Published by: DoD National (US) Mil Department of Defense http://www.defenselink.mil/ BS EN 3682-001:2013 EN 3682-001:2013 (E) Terms and definitions For the purposes of this document, the terms and definitions given in EN 2591-100 and the following apply 3.1 LRU Line Replaceable Unit 4.1 Description General The pair of connectors has the following characteristics: a metal to metal bottoming (see Figure 1); the interface between the plug and the receptacle connectors provides a seal between contacts when mated; when mated together, the connector pair and cable passage grommets are leak tight; inserts (except 1-70C1) are provided with an O-ring seal which provides sealing between the housing and the insert low insertion force contacts; size 22 male contacts are mechanically protected by their installation in the insert; shielding continuity is provided between mated connectors housings; field replaceable inserts; EMI grounding springs are removable and field replaceable The connectors use sizes 22, 20, 16 and 12 crimp contacts; sizes 5, 12 and 16 coaxial contacts, size triaxial contacts, quadrax contacts and fibre optical contacts Polarization posts and keys are provided to ensure correct connection, and these may be turned around, as required, by the user, giving 99 different connection combinations 4.2 Receptacle The receptacle has three polarization keys Depending upon its housing size, the receptacle will have 2, 4, or inserts Size 22 contacts in the receptacle are always female contacts All larger contact sizes are male contacts BS EN 3682-001:2013 EN 3682-001:2013 (E) 4.3 Plug The plug has three polarization posts Depending upon its housing size, the plug will have 2, or inserts Size 22 contacts in the plug are always male contacts All larger contact sizes are female contacts The plug is fitted with field replaceable grounding spring systems 4.4 Materials and surface treatment 4.4.1 General When dissimilar metals are in close contact, adequate protection against corrosion shall be used for the electromotive force of the cell not to exceed 0,25 V 4.4.2 Housings Connector housing material shall be protected against corrosion by a protective coating, enabling the specified test criteria to be met 4.4.3 Contacts Removable contacts, see EN 3682-002 4.4.4 Non-metallic materials The materials used for inserts, seals and grommets shall have a hardness and the mechanical and electrical characteristics consistent with the required use 5.1 Design Housings Connector housing shall be a one piece unit The plug shall be fitted with a resilient peripheral seal to provide environmental peripheral sealing and stabilizing between mating housings Electrical contact between the housings shall occur before electrical contact engagement 5.2 Inserts Insert shall be interchangeable and made of a rigid dielectric material or metallic material when specified Cross-sections and angle radii shall be sufficient to ensure that no cracking, chipping or breakage can occur in normal use The insert shall be rear removable from the housing and shall be mechanically retained in the housing The removal of an insert from the shell shall be done by using no other tool than a screwdriver To install the insert in the shell, it will be necessary to lubricate the O-ring with a lubricant such as specified by MIL-L-15719 The mating face of the insert shall ensure that a good sealing is provided when connectors are mated together The interfacial seal shall be bonded on the insert for size 22 female contacts and on the insert for male contacts of other sizes BS EN 3682-001:2013 EN 3682-001:2013 (E) The grommet shall permit sealing for all cable diameters indicated in EN 3682-002 and shall not be removable For sizes and contacts, the insert contact cavity and the grommet shall accept the sealing boots described in EN 4529-002 The mechanical contact retention system shall be integrated in the hard insert Connectors shall be designed to allow the installation and removal of individual contacts without having to remove the insert from the housing Inserts shall be for rear release rear removable contacts Insertion, extraction tools are those specified in EN 3155 standard series All inserts (except 2-62Q2) having both size quadrax contacts cavities and size 22 contacts cavities have a step on their front face Inserts for receptacle connectors have the size 22 contact cavities at a higher elevation than the other contact sizes cavities Inserts for plug connectors have the size 22 contact cavities recessed compared to the other contact cavity sizes Definition drawings and masses General dimensions and masses of plug, receptacle and inserts are given in the product standards 6.1 Connector mating dimensions Connectors mated conditions are shown in Figure Contact position is defined in Figure BS EN 3682-001:2013 EN 3682-001:2013 (E) Dimensions are in millimetres Key Grounding spring system Receptacle assembly Plug assembly Metal to metal bottoming on both sides of polarizing key retaining plate Stabilizer X = 21,64 initial engagement max Figure — Connector mated conditions BS EN 3682-001:2013 EN 3682-001:2013 (E) Dimensions in millimetres Key J hook (see Note 4) Rear panel mounted connector 2,54 max connector mounting surface 2,54 max over connector mounting hardware NOTE LRU shall be dummy loaded to (27,22 ± 0,23) kg with centre of gravity as shown NOTE Connector location shall be based on datum boss of connector flange NOTE LRU shall be constructed such that dummy load is evenly distributed and the sides properly supported to simulate a rigid body NOTE Connector shall be mounted to the LRU using screws and locknuts Screws shall be torqued to 0,17 kg/m to 0,23 kg/m Other hardware may be used if equivalent strength and locking features are maintained Figure 43 — Dummy loaded LRU, rear panel mounted connector configuration 58 BS EN 3682-001:2013 EN 3682-001:2013 (E) Dimensions in millimetres Key J hook (see Note 4) 7,37 recess to connector mounting surface front panel mounted connector 2,54 max connector mounting surface 2,54 max over connector mounting hardware NOTE LRU shall be dummy loaded to (27,22 ± 0,23) kg with centre of gravity as shown NOTE Connector location shall be based on datum boss of connector flange NOTE LRU shall be constructed such that dummy load is evenly distributed and the sides properly supported to simulate a rigid body NOTE Connector shall be mounted to the LRU using screws and locknuts Screws shall be torqued to 0,17 kg/m to 0,23 kg/m Other hardware may be used if equivalent strength and locking features are maintained Figure 44 — Dummy loaded LRU, front panel mounted connector configuration 59 Spectral density acceleration (G /Hz) BS EN 3682-001:2013 EN 3682-001:2013 (E) Frequency (Hz) Key dB per octave dB per octave − dB per octave Spectral density acceleration (G /Hz) Figure 45 — Functional vibration test Frequency (Hz) Key dB per octave dB per octave − dB per octave Figure 46 — Endurance vibration test 60 BS EN 3682-001:2013 EN 3682-001:2013 (E) A 11 000 N B 000 N C 300 N Figure 47 — Transversal and axial load 61 BS EN 3682-001:2013 EN 3682-001:2013 (E) Dimensions in millimetres Key Ra 0,10 to Ra 0,20 Figure 48 Table 61 Sizing gauge Housing cavities A B C D E F + 0,01 + 0,01 ± 0,05 ± 0,05 max max A, C, E 45,44 32,94 48,27 35,77 50,50 38 B, D, F 34,26 32,94 37,09 35,77 39,30 38 Measurement gauge Housing cavities 62 A B C D E F − 0,01 − 0,01 ± 0,05 ± 0,05 max max A, C, E 45,54 33,05 48,27 35,77 50,50 38 B, D, F 34,37 33,05 37,09 35,77 39,30 38 BS EN 3682-001:2013 EN 3682-001:2013 (E) Dimensions in millimetres Key See note NOTE Gauge hardened tool steel, finish Ra 0,8 µm, design of rear extension is optional but shall have a groove provided as indicated Figure 49 — Gauge contact stability male contact Table 62 Contact size 20 A B ∅C + 0,013 0 − 0,005 15,67 16 12 17,30 E ∅G ∅K ∅J + 0,005 0 − 0,005 − 0,005 + 0,005 + 0,013 0,99 2,08 0,84 1,73 1,75 3,96 1,56 3,30 2,62 2,79 5,12 2,36 4,72 3,84 3,76 5,04 D spherical 1,20 63 BS EN 3682-001:2013 EN 3682-001:2013 (E) Dimensions in millimetres Key See note NOTE Gauge hardened tool steel, finish Ra 0,8 µm, design of rear extension is optional but shall have a groove provided as indicated Figure 50 — Gauge contact stability female contact Table 63 Contact size 22 64 A ∅C + 0,013 + 0,005 10,18 1,73 D 0,10 E ∅G ∅K − 0,005 + 0,005 + 0,005 0,84 1,27 1,52 BS EN 3682-001:2013 EN 3682-001:2013 (E) Quality assurance 8.1 General See EN 9133 8.2 Qualification 8.2.1 Sampling and definition of specimens 14 pairs of connectors (plug-receptacle), representative of the class, connector housing size and contacts layout for which qualification is required, are inspected and tested according to Table 57, in the sequence specified Three complete pairs of connectors are subjected to test groups 1, 2, and One pair of size connectors, with a modified shell according to Figure 40, is subjected to group tests Two complete pairs of connectors are subjected to test group Table 64 below summarizes the specimen breakdown among the test groups and gives details regarding the way to perform test EN 2591-315 (Fluid resistance) Table 64 Test group Number of specimens to be tested Fluid resistance test mated pair to be tested with fluid Group mated pairs mated pair to be tested with fluid mated pair to be tested with fluid Group 2 mated pairs mated pair to be tested with fluid mated pair to be tested with fluid mated pair to be tested with fluid 13 Group 3 mated pairs mated pair to be tested with fluid 11 mated pair to be tested with Azeotrope R113AzM mated pair to be tested with fluid 15 Group mated pairs mated pair to be tested with fluid chlorobromethane mated pair to be tested with fluid 19 Group mated pair according to Figure 36 Not applicable Group mated pairs Not applicable 65 BS EN 3682-001:2013 EN 3682-001:2013 (E) 8.2.2 Preparation of specimens Unless otherwise specified in the tests, the specimens shall be wired with cables, the outside diameter of which is in accordance with the maximum indicated in EN 3682-002 The connectors shall be wired with round cables free from any roughness likely to contribute to the penetration of humidity or liquid to the inside of the connector The cables shall conform to EN 2267-002 and cables dimensions shall comply with EN 3682-002 Cable length shall be about m Unless otherwise specified, for signal and power contacts (sizes 22, 20, 16 and 12), half the number of each contact size in each connector shall be wired with the cable of the smallest cross-section allowable The other half shall be wired with the cable of the largest cross-section allowable Coaxial, triaxial and quadrax contacts shall be wired with cables specified by EN 3682-002 8.2.3 Qualification test sequence The qualification tests are defined in Table 65 and shall be carried out in the sequence indicated Test EN 2591-306 is to be performed on materials and is not included in the groups below If the materials used comply with group fungus inert materials of MIL-STD-454 requirement 4, test EN 2591-306 is not performed Table 65 (1 of 3) Tests EN 2591- Remarks Group Visual examination 101 Examination of dimensions and mass 102 All test specimen Magnetic permeability 513 Size cavity grounding 205 See 7.2.1 Measurement of insulation resistance 206 Ambient and max operating temperatures Voltage proof test 207 At sea level and low atmosphere pressure Group Mating and unmating forces 408 Rapid change of temperature 305 Voltage proof test 207 Measurement of insulation resistance 206 Functional vibration 403 Shock 402 Mechanical endurance 406 Contact resistance - low level 201 Contact resistance at rated current 202 Measurement of insulation resistance 206 Voltage proof test 207 Ozone resistance 316 Measurement of insulation resistance 206 Fluid resistance 315 Contact retention in insert 409 Insert retention in housing 410 Visual examination 101 66 Sea level See 7.2.2 Ambient and max operating temperatures BS EN 3682-001:2013 EN 3682-001:2013 (E) Table 65 (2 of 3) Tests EN 2591- Remarks Group Mating and unmating forces 408 Rapid change of temperature 305 Voltage proof test 207 Damp heat steady state 304 Measurement of insulation resistance 206 Ambient and max operating temperatures Vibration endurance 403 See 7.2.2.3 Contact resistance - low level 201 Contact resistance at rated current 202 Stability of male contact in insert 419 Fluid resistance 315 Contact retention in insert 409 Insert retention in housing (axial) 410 Visual examination 101 Sea level Group Mating and unmating forces Static load 408 404 / 405 See 7.2.3 Measurement of insulation resistance 206 Ambient temperature Voltage proof test 207 Sea level Salt mist 307 Contact retention system effectiveness (removable contact walkout) 426 Endurance at temperature 301 Fluid resistance 315 Contact retention in insert 409 Insert retention in housing (axial) 410 Visual examination 101 Group Mating and unmating forces Durability of contact retention system and seals 408 407 / 412 Endurance vibration 403 Salt mist 307 Fluid resistance 315 Insert retention in housing (axial) 410 Visual examination 101 See 7.2.2 67 BS EN 3682-001:2013 EN 3682-001:2013 (E) Table 65 (3 of 3) Tests EN 2591- Remarks Group Rapid change of temperature 305 Housing electrical continuity 205 Shielding effectiveness from 100 MHz to GHz 213 Visual examination 101 Group Holding force of grounding spring system 413 Immersion at low air pressure 314 Interfacial sealing 324 Measurement of insulation resistance 206 Ambient temperature Voltage proof test 207 Sea level Climatic sequence 302 Measurement of insulation resistance 206 Ambient temperature Voltage proof test 207 Sea level Sand and dust 308 Flammability 317 Contact retention in insert 409 8.3 8.3.1 Maintenance of qualification Tests The tests shall be carried out every 36 months after qualification on specimen taken at random The manufacturer shall submit, to the mandated body, the results of tests which shall be carried out in accordance with Table 66 8.3.2 Sampling distribution All housing (shell) sizes shall be tested according to Table 66 68 BS EN 3682-001:2013 EN 3682-001:2013 (E) Table 66 Tests EN 2591- Remarks Group Visual examination 101 Examination of dimensions and mass 102 Mating and unmating forces 408 Contact resistance - low level 201 Contact resistance at rated current 202 Measurement of insulation resistance 206 Voltage proof test 207 Housing (shell) electrical continuity 205 Immersion at low air pressure 314 Endurance vibration 403 Salt mist 307 Contact resistance - low level 201 Contact resistance at rated current 202 Measurement of insulation resistance 206 Voltage proof test 207 Visual examination 101 8.4 See 7.2.2.3 Acceptance Unless otherwise specified by the user, the batch and production inspections are left to the manufacturer’s option For acceptance, the test EN 2591-101 shall be carried out by the manufacturer, to 100 %, prior to delivery 8.5 Quality control Inspections which are intended to maintain the required quality level are in their entirety the responsibility of the manufacturer, ranging from materials through delivery of the product The quality department of the manufacturer shall be able to demonstrate, at any time, that the product complies with the manufacturing documentation and with the product concerned There shall be a monitoring system in place for the various inspection phases This shall be evidenced by documents kept available by the manufacturer for a period of five years and submitted to the national official services on request 9.1 Designation and marking General principle of designation See product standard 69 BS EN 3682-001:2013 EN 3682-001:2013 (E) 9.2 Marking Marking shall be applied to the connectors This marking shall include: the identity block as defined in the product standard; the date of manufacture (year - week); the manufacturer's name or trademark 10 Delivery conditions Connectors may be delivered with or without contacts In the case of delivery with contacts, the manufacturer shall supply the following additional items: one contact per size for arrangements ≤ 26 contacts; two contacts per size for arrangements > 26 contacts; unless otherwise specified in the order, sealing plugs, the quantity of which shall be 15 % of the number of contacts or a minimum of one sealing plug per size; protective cap(s) Housings (shells) supplied bare are supplied with insulator retaining plates, coding accessories, assembly screws and the convenient number of protective covers (see EN 3682-004 to EN 3682-009) 11 Packaging The connectors with, if applicable, their contacts, filler plugs and tools shall be packed in transparent inert plastic bags The contacts and filler plugs shall be packed in a transparent inert bag 12 Storage Storage shall be in a place free from ultra-violet rays Every five years, an inspection shall be carried out in accordance with EN 2591-101 The connector shall be repacked in accordance with 11 and the date of inspection shall be marked on the packaging 70 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 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