BSI Standards Publication BS EN 4199 001 2013 Aerospace series — Bonding straps for aircraft Part 001 Technical specification BS EN 4199 001 2013 BRITISH STANDARD National foreword This British Standa[.]
BS EN 4199-001:2013 BSI Standards Publication Aerospace series — Bonding straps for aircraft Part 001: Technical specification BS EN 4199-001:2013 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 4199-001:2013 It supersedes BS EN 4199-001:2006 which is withdrawn The UK participation in its preparation was entrusted to Technical Committee ACE/6, Aerospace avionic electrical and fibre optic technology A list of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 80147 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 28 February 2013 Amendments issued since publication Date Text affected BS EN 4199-001:2013 EN 4199-001 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM January 2013 ICS 49.060 Supersedes EN 4199-001:2006 English Version Aerospace series - Bonding straps for aircraft - Part 001: Technical specification Série aérospatiale - Tresses de métallisation pour avion Partie 001: Spécification technique Luft- und Raumfahrt - Masseverbinder für Luftfahrzeuge Teil 001: Technische Lieferbedingungen This European Standard was approved by CEN on November 2012 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 4199-001:2013: E BS EN 4199-001:2013 EN 4199-001:2013 (E) Contents Page Foreword Scope Normative references Terms and definitions 4 Required characteristics .4 Design .5 Tests Quality assurance Designation 11 Marking 11 10 Packaging 11 BS EN 4199-001:2013 EN 4199-001:2013 (E) Foreword This document (EN 4199-001:2013) 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 July 2013, and conflicting national standards shall be withdrawn at the latest by July 2013 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 4199-001:2006 According to the CEN/CENELEC Internal Regulations, the national standards organisations 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 4199-001:2013 EN 4199-001:2013 (E) Scope This European Standard specifies the general characteristics of bonding straps with flat or round braided copper conductor, and terminal lugs, crimped on both ends, for use on aircraft 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 3373-001, Aerospace series — Terminal lugs and in-line splices for crimping on electric conductors — Part 001: Technical specification EN 3475 (all parts), Aerospace series — Cables, electrical, aircraft use — Test methods EN 9133, Aerospace series — Quality management systems — Qualification procedure for aerospace standard parts IEC 60050-581, International Electrotechnical Vocabulary — Part 581: Electromechanical components for electronic equipment 1) Terms and definitions For the purposes of this document, the terms and definitions given in IEC 60050-581 and the following apply a flat or round braided copper conductor, tin or nickel plated; crimped on terminal lugs at both ends Required characteristics 4.1 General See product standard 4.2 Temperature range See Table 1) Published by: IEC International International Electrotechnical Commission http://www.iec.ch/ BS EN 4199-001:2013 EN 4199-001:2013 (E) Table Class Temperature range T − 65 °C to 150 °C Tin plated copper braided conductor and tin plated copper terminal lugs N − 65 °C to 260 °C Nickel plated copper braided conductor and nickel plated copper terminal lugs 4.3 Material/finish Material Materials shall be suitable for the intended use and as specified in the product standard 4.4 Finish See product standard 4.5 Dimensions and mass See product standard Design Bonding straps for aircraft shall be designed and assembled in a careful and competent manner so as to withstand normal handling during installation and maintenance in service In order to achieve good reliable crimped connections the correct crimping tool shall be used When using bonding straps on equipment or installations generating or processing frequencies greater than 100 kHz, care shall be taken not to exceed a length to width ratio of five to one for reasons of electromagnetic compatibility Tests 6.1 Tests on the braids The tests of EN 3475 listed in Table shall be applicable for testing of round and flat braid conductors used in the construction of bonding straps Table EN 3475- Designation of the test Details 201 Visual examination No visible deformations 202 Mass Mass, shall be carried out on each batch of material 203 Dimensions Including correct braid angle when applicable see product standard 301 Ohmic resistance per unit length Table, see product standard 512 Flexure endurance As specified in the product standard BS EN 4199-001:2013 EN 4199-001:2013 (E) 6.2 Tests on the bonding strap assemblies The tests of EN 2591, applicable in the context of this standard as well as the details necessary for implementing them and for inspecting bonding straps are given in Table of this standard Table EN 2591101 Designation of the test Visual examination Details Initial examined details to be examined: identification of materials in accordance with product standard; identification; appearance; marking; surface finish; final examination 102 Examination of dimensions and mass As defined in product standard 218 Ageing of terminal lugs and in-line splices by temperature and current cycling Test current and initial voltage drop as specified in product standard Maximum deviation at end of test shall not exceed that specified in EN 2591-218 301 Endurance at temperature Method B 305 Rapid change of temperature 20 h in dry heat at temperature of (150 ± 5) °C for tin plated or (260 ± 5) °C for nickel plated bonding straps No deviation from tensile strength listed in this standard and from maximum permissible voltage drop specified in the appropriate product standard Temperature cycles: Five cycles after variations − 65 °C to 150 °C for tin plated, − 65 °C to 260 °C for nickel plated bonding straps No deviation from tensile strength listed in this standard and from maximum permissible voltage drop specified in the appropriate product standard 307 Salt mist 48 h or as specified in the product standard No deviation from maximum permissible voltage drop specified in the appropriate product standard 403 Sinusoidal and random vibration Not applicable 417 Tensile strength (crimped connection) EN 3373-001, terminal lugs on both ends The specimen shall not break at a value less than that specified in the product standard BS EN 4199-001:2013 EN 4199-001:2013 (E) 6.3 Ohmic resistance The ohmic resistance and test current values for complete bonding strap assemblies shall be defined in the product standard The resistance shall be calculated from the voltage drop readings measured in accordance with Figure or Figure at (20 ± 3) °C Figure — Bonding straps with flat braid conductor 6.4 Figure — Bonding straps with round braid conductor Mechanical fatigue test Specimens shall be bonding straps assembled with a terminal at each end, the dimension between the stud holes being 250 mm centre to centre The specimen shall be mounted on the test apparatus as shown in Figure 3, the axis of the terminal lugs passing through the pivot point of the apparatus One test cycle shall consist of one flex to 50° upwards, return to neutral position followed by flex to 50° downwards and then return to the neutral, starting, position The specimen shall be flexed for the number of cycles detailed in the product standard A visual examination and test 6.3 shall be performed after the required number of cycles has been completed Failure of the specimen is deemed to be a complete fracture or when the resistance reading exceeds the specified requirement by more than 20 % The results shall be reported BS EN 4199-001:2013 EN 4199-001:2013 (E) 6.5 Mechanical fatigue test apparatus See Figure Top view Key screw and washer articulation mobile part of tool fixed part of tool spacer up + 50° down − 50° Figure — Mounting device BS EN 4199-001:2013 EN 4199-001:2013 (E) Quality assurance 7.1 General See EN 9133 7.2 7.2.1 Qualification General Qualification testing shall be carried out at the commencement of manufacture or at recommencement if there has been a stoppage in manufacture for more than three years or if there has been any change in components or tooling The tests shall be carried out in the sequences listed in Tables and on representative types and sizes of conductors and assemblies as agreed with the Mandated Body Qualification of other types and sizes closely related to those already qualified may be obtained directly by similarity or by carrying out a reduced range of tests by agreement with the Mandated Body 7.2.2 Qualification of braids and conductors See Table Table EN 3475- 7.2.3 Designation of the test Details 201 Visual examination No visible deformations, correct angle of braid where applicable 202 Mass See product standard 203 Dimensions See product standard 301 Ohmic resistance per unit length See product standard 512 Flexure endurance See product standard Qualification of bonding strap assemblies See Table Only bonding straps assembled from certified components and using certified calibrated tooling shall be qualified BS EN 4199-001:2013 EN 4199-001:2013 (E) Table Designation of the test EN 2591- Group Visual examination Examination of dimensions and mass Voltage drop (see 6.3) 12 specimens 101 102 – Group Tensile strength (crimped connection) 417 218 Tensile strength (crimped connection) 417 Group See product standard specimens – 307 305 301 101 – 417 Group Salt mist Mechanical fatigue test (see 6.4) Visual examination Voltage drop (see 6.3) a Tensile strength (crimped connection) See product standard specimens Ageing of terminal lugs and in-line splices by temperature and current cycling Salt mist Rapid change of temperature Endurance at temperature Visual examination Voltage drop (see 6.3) a Tensile strength (crimped connection) See product standard See product standard specimens Group Mechanical Fatigue (see 6.4) Remarks 10 % of the required number of flex cycles specified in the product standard 48 h or as product standard – – – See product standard See product standard specimens 307 – 101 – 417 48 h or as product standard See product standard – See product standard See product standard a The maximum value of resistance measured in test groups and shall be not greater than the maximum value specified for initial resistance plus 20 % when measured using the current specified in the product standard 7.3 Maintenance of qualification The sequence of tests shall be required at a minimum of three years for equipment in production or when production is restarted in the event of a stoppage in manufacture for more than three years For braid, the tests in Table shall be carried out and for bonding straps assemblies, the tests in group of Table 10 BS EN 4199-001:2013 EN 4199-001:2013 (E) 7.4 Acceptance Tests The tests listed in Tables and shall be carried out on each batch of material, whichever is the smaller 7.4.1 Tests for round and flat braid conductors See Table Table EN 3475- 7.4.2 Designation of the test Details 201 Visual examination All specimens 203 Dimensions All specimens 301 Ohmic resistance per unit length All specimens Tests for bonding strap assemblies See Table Table EN 2591- Details 101 Visual examination All specimens 102 Examination of dimensions and mass All specimens (Dimensions only) Ohmic resistance (see 6.3) One specimen per production batch – Designation of the test Designation See product standard Marking See product standard 10 Packaging Bonding straps shall be so packed as to avoid any damage 11 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 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