Bsi bs en 03155 035 2012

BSI Standards PublicationAerospace series — Electrical contacts used in elements of connection Part 035: Contacts, electrical, triaxial, size 08, female, type D, crimp, class R— Product

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

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It supersedes BS EN 3155-035:2006 which is withdrawn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 0 580 76580 3 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

NORME EUROPÉENNE

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, à 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

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä I S C H E S K O M I T E E FÜ R N O R M U N G

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

Contents Page

Foreword 3

Introduction 4

1 Scope 4

2 Normative references 4

3 Terms and definitions 5

4 Requirements characteristics 5

4.1 Specific characteristics 5

4.2 Dimensions and mass 5

4.3 Marking by colour code 7

4.4 Material, surface treatment 7

4.5 Typical cables 7

4.6 Cable stripping and wiring method 8

4.7 Tooling .10

4.7.1 Crimping tools 10

4.7.2 Insertion/Extraction tools .10

4.8 Tests .10

4.9 Gauges .13

5 Designation .14

6 Marking .14

7 Conditioning .14

8 Technical specification .15

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

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

1 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

2 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

SAE AS 39029/95, Contacts, electrical connector, concentric twinax, pin, size 8 (for DOD-C-83527 connector) 2)

TR 6058, Aerospace series — Cable code identification list 3)

3 Terms and definitions

For the purposes of this standard, the terms and definitions given in EN 3155-001 apply

4 Requirements characteristics

4.1 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 1

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)

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 1

Key Key

1 44,,8691 on ferrule 1 44,,8691 on ferrule

Figure 2 — Ferrule for cable group A Figure 3 — Ferrule for cable group B

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

4.5 Typical cables

See Figure 4 and Table 1

Figure 4 Table 1

Cable

code

group

Permissible

cable code

according to

TR 6058

Dimensions of cable

A B

Braid composition C

A – 0,55 0,62 1,3 1 braid of 0,1 coated copper wire overall diameter: 3 mm max 3 3,5

B

WJ 0,55 0,62 1,3 2 braid of 0,1 coated copper wire overall diameter: 3,5 mm max 3,4 3,9

2 braid of 0,1 coated copper wire

1 high immunity tape overall diameter:

3,75 max

3,6 4,1

4.6 Cable stripping and wiring method

A Fit the supplied guide ring on the cable

Insulation should be stripped back

Slide crimp ring 1 over cable

Key

1 0,5 mm to 1 mm

B Comb braid and fold back over crimp ring cut out fillers

Key

1 Blue core

2 White core

C Strip conductors as shown

Key

1 Crimping

D Position the blue conductor core

in outer contact 2 Use tool M22520/2-01 locator EN4008-009

Key

1 Crimping

E Feed the white conductor through the angled hole, fit insulator and position white conductor core in inner contact

3 Use tool M22520/2-01, locator M22520/2-37

F Fit split insulator 4around crimp buckets

Ensuring flange is positioned at front face of contact

intermediate contact and outer insulator are located inside the body 5

Insert assembly into body

Key

1 Crimping

H Crimp braid and outer jacket using tool M25520/5-01 and dies M22520/5-45 selector/cavity B Length of crimping: 6 mm

4.7 Tooling

4.7.1 Crimping tools

Conform to MIL-DTL-22520G, see Table 2

These selector numbers given in Table 2 shall be used for qualification of the contacts and in service, unless otherwise specified by the user

Table 2 Contact Crimping tool Positioner setting/cavity Selector

4.7.2 Insertion/Extraction tools

Conform to MIL-I-81969/14-06

4.8 Tests

Tests according to EN 2591-100, see Table 3

Table 3 — Tests

EN 2591- Designation of the test applicable Not

Applicable According to

EN 3155-001 Remarks

102 Examination of dimensions

201 Contact resistance - low

level

Contact

Maximum contact resistance

mΩ

(continued)

EN 2591- Designation of the test applicable Not

Applicable According to

EN 3155-001 Remarks

202 Contact resistance at rated

current

X

Contact

Maximum contact resistance

mΩ

Rated current

A (25+03) °C (150+03) °C

Initial After

tests After tests Centre 15 30 45

1 Intermediate 15 30 45

204 Discontinuity of contacts in

the microsecond range

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:

≥ 5 000 MΩ

At high temperature:

≥ 2 000 MΩ at maximum specified temperature

Method C Withstand voltage at sea level:

1 000 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: 2 mA

212 Surface transfer impedance X

301 Endurance at temperature X Method B

Duration : 1 000 h

305 Rapid change of

temperature

X TA= (150 ± 2) °C

TB= (− 65 ± 2) °C

According to EN 3682-001

EN 2591- Designation of the test applicable Not

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

417 Tensile strength (crimped

connection) X Cable according to TR 6058 code XY

Contact Tensile values in N

min

(continued)

Table 3 (concluded)

EN 2591- Designation of the test applicable Not

Applicable According to

EN 3155-001 Remarks

418 Gauge insertion/extraction

forces (female contacts) X Intermediate Gauge as described in Figure 5 and contacts

Table 4

Gauge

Minimum extraction force

N

Maximum insertion force

N Initial After test Initial After test

501 Soft solderability X

503 Contact deformation after

crimping

X Cable size in accordance with Table 1

Intermediate contact concentricity tolerance shall not exceed 0,28 mm

Intermediate contact and outer body

Crimping zone shall not exceed 0,15 mm expansion

508 Measurement of thickness of

coating on contacts X The measured thickness shall be recorded

509 Adhesion of coating on

contacts

X

4.9 Gauges

Defined in Figure 5 and Table 4

Dimensions and tolerances are in millimetres

Key

1 Ra 0,15 µm to Ra 0,25 µm

2 Radius

Figure 5

Table 4

Flat

max

Centre contact

Outer contact

5 Designation

EXAMPLE

Description block CONTACT ELECTRICAL

Identity block 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 5

B With sleeve EN4530-005-1

C With sealing sleeve EN4530-005-2

6 Marking

See EN 3155-001

7 Conditioning

The contacts are packaged and identified individually Conditioning shall provide protection of the contacts against any eventual damage

Packaging shall include:

 the manufacturer's name;

 the designation defined in Clause 5;

 the manufacturer's reference;

 the manufacturing date code (year-week)

8 Technical specification

See EN 3155-001