BS EN 4199-004:2014 BSI Standards Publication Aerospace series — Bonding straps for aircraft Part 004: Round bonding straps, copper, tin plated -65 °C up to 150 °C and nickel plated -65 °C up to 260 °C — Product Standard BS EN 4199-004:2014 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 4199-004:2014 It supersedes BS EN 4199-004:2009 which is withdrawn The UK participation in its preparation was entrusted to Technical Committee ACE/6, Aerospace avionic electrical and fibre optic technology A list of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 2014 Published by BSI Standards Limited 2014 ISBN 978 580 87288 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 November 2014 Amendments issued since publication Date Text affected BS EN 4199-004:2014 EN 4199-004 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM November 2014 ICS 49.060 Supersedes EN 4199-004:2009 English Version Aerospace series - Bonding straps for aircraft - Part 004: Round bonding straps, copper, tin plated -65 °C up to 150 °C and nickel plated -65 °C up to 260 °C - Product Standard Série aérospatiale - Tresses de métallisation pour avion Partie 004 : Tresse ronde, en cuivre étamé de -65 °C 150 °C et en cuivre nickelé de -65 °C 260 °C - Norme de produit Luft- und Raumfahrt - Masseverbinder für Luftfahrzeuge Teil 004: Runde Masseverbinder aus Kupfer verzinnt -65 °C bis 150 °C aus Kupfer vernickelt -65 °C bis 260 °C Produktnorm This European Standard was approved by CEN on 11 October 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 4199-004:2014 E BS EN 4199-004:2014 EN 4199-004:2014 (E) Contents Page Foreword Scope Normative references Terms and definitions 4 Required characteristics .4 Quality assurance 14 Designation 14 Marking 14 Packaging 14 BS EN 4199-004:2014 EN 4199-004:2014 (E) Foreword This document (EN 4199-004:2014) 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 May 2015, and conflicting national standards shall be withdrawn at the latest by May 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 4199-004:2014 EN 4199-004:2014 (E) Scope This standard defines the required characteristics for round bonding straps in tin plated and nickel plated version, in different cross sections and lengths, with terminal lugs on both ends (same or different types) for aerospace applications It shall be used together with EN 4199-001 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 3373-001, Aerospace series — Terminal lugs and in-line splices for crimping on electric conductors — Part 001: Technical specification EN 4199-001, Aerospace series — Bonding straps for aircraft — Part 001: Technical specification EN 4199-006, Aerospace series — Bonding straps for aircraft — Part 006: Round braid copper conductors for bonding straps, tin plated up to 150 °C or nickel plated up to 260 °C — Product standard EN 9133, Aerospace series — Quality management systems — Qualification procedure for aerospace standard parts ISO 3:1973, Preferred numbers — Series of preferred numbers Terms and definitions For the purposes of this document, the terms and definitions given in EN 4199-001 apply 4.1 Required characteristics Temperature range Bonding straps, copper, tin plated braid conductor and terminal lugs, class T : −65 °C up to 150 °C Bonding straps, copper, nickel plated braid conductor and terminal lugs, class N : −65 °C up to 260 °C BS EN 4199-004:2014 EN 4199-004:2014 (E) 4.2 Cross section of the braid See Table Table Cross section Code mm Terminal lug size Test Current Tensile Test A N A 1,4 Code 012/AWG16 22 180 B 3,5 Code 030/AWG12 45 450 C 4,5 Code 050/AWG10 52 700 D Code 090/AWG-8 64 080 E 13 Code 140/AWG06 95 540 Cross section code A (1,4 mm2) with terminal lugs for Code 012 or AWG16 cables 4.3 4.3.1 Dimensions and masses See Figure 1, Table and Table Dimensions and tolerances are in millimetres Key Terminal lug Terminal lug Figure BS EN 4199-004:2014 EN 4199-004:2014 (E) Table Assemblies Combination Variant Code End Mass (g) End Lengths 63 80 100 125 160 200 250 315 400 M N P Q R S T U V 3,50 1,75 1,95 2,20 2,55 3,00 3,50 4,15 5,00 6,10 #6 3,50 1,95 2,20 2,45 2,80 3,20 3,75 4,40 5,25 6,35 4,83 #6 3,50 1,95 2,15 2,40 2,75 3,20 3,70 4,35 5,20 6,30 1/4 6,35 #6 3,50 2,25 2,45 2,70 3,05 3,50 4,00 4,65 5,50 6,60 E #8 4,17 #8 4,17 2,20 2,40 2,65 3,00 3,45 3,95 4,60 5,45 6,55 F #10 4,83 #8 4,17 2,15 2,40 2,65 2,95 3,40 3,95 4,60 5,45 6,55 G ¼ 6,35 #8 4,17 2,45 2,70 2,95 3,25 3,70 4,25 4,90 5,75 6,85 H #10 4,83 #10 4,83 2,10 2,35 2,60 2,95 3,40 3,90 4,55 5,40 6,50 J 1/4 6,35 #10 4,83 2,45 2,65 2,90 3,25 3,70 4,20 4,85 5,70 6,80 K 1/4 6,35 1/4 6,35 2,75 2,95 3,20 3,55 4,00 4,50 5,15 6,00 7,10 L 5/16 7,94 #10 4,83 2,30 2,61 2,80 3,15 3,55 4,05 4,70 5,40 6,65 M 5/16 7,94 5/16 7,94 2,60 2,75 2,90 3,25 3,75 4,30 4,90 5,70 6,90 Stud Ø Stud Ø A #6 3,5 #6 B #8 4,17 C #10 D Table Terminals Stud Ø K W #6 3,50 4,40 6,30 #8 4,17 7,10 8,70 #10 4,83 7,10 8,70 1/4 6,35 11,10 11,90 5/16 7,94 11,10 11,90 Terminal thickness: 0,84 4.3.2 Recommended lengths (R10 series as per standard ISO 3) and maximum resistance See Table Table Length L 63 80 100 125 160 200 250 315 400 Resistance (mΩ) 1,16 1,45 1,79 2,22 2,81 3,49 4,34 5,45 6,89 BS EN 4199-004:2014 EN 4199-004:2014 (E) 4.3.3 Other lengths possible (exceptional cases) See Table Table 190 3,32 Length L Resistance (mΩ) 254 4,36 260 4,51 280 4,82 304 5,24 320 5,53 460 7,97 570 9,78 IMPORTANT — Only tin plating for terminal lugs and braid code A Cross section code B (3,5 mm2) with terminal lugs for Code 030 or AWG12 cables 4.4 4.4.1 Dimensions and masses See Figure 2, Table and Table Dimensions and tolerances are in millimetres Key Terminal lug Terminal lug Figure Table Assemblies Combination Variant Code End Mass (g) End Lengths 80 100 125 160 200 250 400 500 N P Q R S T V X 3,50 5,70 6,35 7,15 8,30 9,60 11,25 16,10 19,35 #6 3,50 5,65 6,30 7,10 8,25 9,55 11,20 16,05 19,30 4,83 #6 3,50 5,60 6,25 7,05 8,20 9,50 11,10 16,00 19,25 1/4 6,35 #6 3,50 5,65 6,30 7,15 8,35 9,55 11,10 16,05 19,15 E #8 4,17 #8 4,17 5,60 6,25 7,05 8,20 9,50 11,10 16,00 19,25 Stud Ø Stud Ø A #6 3,5 #6 B #8 4,17 C #10 D F #10 4,83 #8 4,17 5,20 5,80 6,30 7,60 8,20 10,40 15,20 18,40 G 1/4 6,35 #8 4,17 4,25 4,90 5,70 6,85 8,15 9,80 14,65 17,90 H #10 4,83 #10 4,83 5,50 6,15 6,95 8,10 9,40 11,00 15,90 19,15 J 1/4 6,35 #10 4,83 6,10 6,75 7,55 8,70 10,00 11,60 16,50 19,75 K 1/4 6,35 1/4 6,35 6,70 7,35 8,15 9,30 10,60 12,20 17,20 20,35 BS EN 4199-004:2014 EN 4199-004:2014 (E) Table Terminals Stud Ø K W #6 3,50 4,40 6,30 #8 4,17 7,10 8,70 #10 4,83 7,10 8,70 1/4 6,35 11,10 11,90 5/16 7,94 11,10 11,90 Terminal thickness: 0,84 4.4.2 Recommended lengths (R10 series as per standard ISO 3) and maximum resistance See Table Table Length L Resistance (mΩ) 4.4.3 80 0,48 100 0,59 125 0,72 160 0,91 200 1,43 250 1,40 400 2,21 500 2,75 Other lengths possible (exceptional cases) See Table Table Length L 180 220 280 350 450 600 650 700 Resistance (mΩ) 1,02 1,24 1,54 1,94 2,48 3,29 3,56 3,83 See product standard 4.5 4.5.1 Cross section code C (4,5 mm2) with terminal lugs for Code 050 or AWG10 cables Dimensions and masses See Figure 3, Table 10 and Table 11 BS EN 4199-004:2014 EN 4199-004:2014 (E) Dimensions and tolerances are in millimetres Key Terminal lug Terminal lug Figure Table 10 Assemblies Combination Variant Code End Mass (g) End Lengths 80 100 125 160 200 250 400 N P Q R S T V 3,50 6,60 7,45 8,55 10,05 11,80 14,00 20,50 #6 3,50 6,50 7,40 8,50 10,00 11,75 13,90 20,45 4,83 #6 3,50 6,50 7,35 8,45 9,95 11,70 13,90 20,40 1/4 6,35 #6 3,50 6,60 7,50 8,65 10,25 12,05 14,30 21,05 E #8 4,17 #8 4,17 6,50 7,35 8,45 9,95 11,70 13,90 20,40 F #10 4,83 #8 4,17 6,40 7,30 8,40 9,90 11,65 13,80 20,35 G 1/4 6,35 #8 4,17 6,50 7,40 8,55 10,15 11,95 14,20 20,90 H #10 4,83 #10 4,83 6,35 7,25 8,30 9,85 11,60 13,80 20,30 J 1/4 6,35 #10 4,83 6,40 7,30 8,40 10,00 11,80 14,10 20,80 K 1/4 6,35 1/4 6,35 7,00 7,90 8,95 10,55 12,50 14,80 21,50 Stud Ø Stud Ø A #6 3,5 #6 B #8 4,17 C #10 D Table 11 Terminals Stud Ø K W #6 3,50 7,60 9,50 #8 4,17 7,60 9,50 #10 4,83 7,60 9,50 1/4 6,35 11,90 13,50 Terminal thickness: 1,07 4.5.2 Recommended lengths (R10 series as per standard ISO 3) and maximum resistance See Table 12 BS EN 4199-004:2014 EN 4199-004:2014 (E) Table 12 4.5.3 Length L 80 100 125 160 200 250 400 Resistance (mΩ) 0,36 0,44 0,54 0,68 0,84 1,04 1,64 Other lengths possible (exceptional cases) See Table 13 Table 13 Length L 180 240 320 350 380 Resistance (mΩ) 0,76 0,97 1,32 1,44 1,56 See product standard Cross section code D (7mm2) with terminal lugs for Code 090 or AWG08 cables 4.6 4.6.1 Dimensions and masses See Figure 4, Table 14 and Table 15 Dimensions and tolerances are in millimetres Key Terminal lug Terminal lug Figure 10 BS EN 4199-004:2014 EN 4199-004:2014 (E) Table 14 Assemblies Combination Variant Code End Mass (g) End Lengths 63 80 100 125 160 200 250 315 400 500 630 800 M N P Q R S T U V X Y Z 17,50 20,40 24,10 29,00 34,75 42,25 52,00 13,15 15,15 17,45 20,35 24,10 29,00 34,70 42,20 52,00 10,40 11,55 13,00 15,00 17,30 20,15 23,90 28,80 34,55 42,00 51,80 9,55 10,55 11,70 13,15 15,15 17,45 20,30 24,05 28,95 34,70 42,15 51,95 4,83 9,40 10,40 11,50 12,95 14,95 17,25 20,15 23,90 28,75 34,50 42,00 51,75 1/4 6,35 9,20 10,20 11,35 12,75 14,75 17,10 19,95 23,70 28,60 34,30 41,80 51,60 7,94 #10 4,83 9,90 10,90 12,00 13,45 15,50 17,75 20,65 24,40 29,30 35,00 42,50 52,25 7,94 5/16 7,94 10,20 11,20 12,35 13,80 15,80 18,10 21,00 24,70 29,60 35,35 42,85 52,60 Stud Ø Stud Ø E #8 4,17 #8 4,17 9,60 10,60 11,75 13,20 15,20 F #10 4,83 #8 4,17 9,60 10,60 11,70 G 1/4 6,35 #8 4,17 9,40 H #10 4,83 #10 4,83 J 1/4 6,35 #10 K 1/4 6,35 L 5/16 M 5/16 Table 15 Terminals Stud Ø K W #8 4,17 9,10 11,90 #10 4,83 9,10 10,30 1/4 6,35 9,10 11,90 5/16 7,94 10,30 14,30 Terminal thickness: 1,30 4.6.2 Recommended lengths (R10 series as per standard ISO 3) and maximum resistance See Table 16 Table 16 Length L 63 80 100 125 160 200 250 315 400 500 630 800 Resistance (mΩ) 0,22 0,27 0,33 0,40 0,51 0,63 0,78 0,97 1,23 1,53 1,92 2,43 4.6.3 Other lengths possible (exceptional cases) See Table 17 Table 17 Length L 175 180 260 280 300 460 570 582 Resistance (mΩ) 0,55 0,57 0,81 0,86 0,92 1,42 1,74 1,80 See product standard 11 BS EN 4199-004:2014 EN 4199-004:2014 (E) Cross section code E (13 mm2) with terminal lugs for Code 140 or AWG06 cables 4.7 4.7.1 Dimensions and masses See Figure 5, Table 18 and Table 19 Dimensions and tolerances are in millimetres Key Terminal lug Terminal lug Figure Table 18 Assemblies Combination Variant Code End Mass (g) End Lengths 80 100 125 160 200 250 N P Q R S T 4,83 21,00 23,60 26,80 31,25 36,40 42,80 #10 4,83 20,75 23,30 26,50 31,00 36,10 42,50 6,35 1/4 6,35 20,50 23,05 26,25 30,75 35,85 42,25 5/16 7,94 #10 4,83 21,40 24,00 27,15 31,65 36,75 43,20 M 5/16 7,94 5/16 7,94 21,80 24,35 27,55 32,05 37,15 43,55 N 1/4 7,94 1/4 6,35 21,15 23,70 26,90 31,40 36,50 42,90 Stud Ø Stud Ø H #10 4,83 #10 J 1/4 6,35 K 1/4 L Table 19 Terminals Stud Ø K W #10 4,83 13,50 11,90 1/4 6,35 13,50 11,90 5/16 7,94 13,50 15,90 Terminal thickness: 1,52 12 BS EN 4199-004:2014 EN 4199-004:2014 (E) 4.7.2 Recommended lengths (R10 series as per standard ISO 3) and maximum resistance See Table 20 Table 20 4.7.3 Length L 80 100 125 160 200 250 Resistance (mΩ) 0,14 0,16 0,20 0,25 0,31 0,38 Other lengths possible (exceptional cases) See Table 21 Table 21 4.8 Length L 180 220 300 345 650 Resistance (mΩ) 0,28 0,34 0,44 0,51 0,96 Braid assembly variant (protection) See Table 22 Table 22 4.9 Code Conductor Terminals Use temperature T Tinned Tinned 150 °C max N Nickel Nickel 260 °C max Material Round braid copper conductor: see EN 4199-006 Terminal lugs: the terminal lugs shall be qualified as per EN 3373-001 13 BS EN 4199-004:2014 EN 4199-004:2014 (E) Quality assurance 5.1 Qualification Product qualification: see EN 9133 Technical specification: see EN 4199-001 Number of cycles for mechanical fatigue test is 250 000 minimum The maximum value of resistance measured on completion of test groups and shall be not greater than the value specified for initial resistance plus 20 % when measured using a current specified in 4.2 5.2 Periodic test Acceptance tests: see EN 4199-001 Designation EXAMPLE Description block Identity block STRAP BONDING EN4994-004 - BJSN Number of this standard Cross section code (see Table 1) Combination variant code (See Table 2, Table 6, Table 10, Table 14 and Table 18) Length (See Table 2, Table 6, Table 10, Table 14 and Table 18) Finish (see Table 22) NOTE If necessary, the code I9005 shall be placed between the description block and the identity block Marking Designation block and manufacturer's name or trademark, on the packaging Packaging See EN 4199-001 14 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 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