Bsi bs en 03646 001 2015

BSI Standards PublicationAerospace series — Connectors, electrical, circular, bayonet coupling, operating temperature 175 °C or 200 °C continuous Part 001: Technical specification... NOR

BSI Standards Publication

Aerospace series — Connectors, electrical, circular, bayonet coupling, operating temperature 175 °C or 200 °C continuous

Part 001: Technical specification

This British Standard is the UK implementation of EN 3646-001:2015.

It supersedes BS EN 3646-001:2007 which is withdrawn

The UK participation in its preparation was entrusted to TechnicalCommittee ACE/6, Aerospace avionic electrical and fibre optictechnology

A list of organizations represented on this committee can beobtained on request to its secretary

This publication does not purport to include all the necessaryprovisions of a contract Users are responsible for its correctapplication

© The British Standards Institution 2015

Published by BSI Standards Limited 2015ISBN 978 0 580 89601 9

Amendments/corrigenda issued since publication

NORME EUROPÉENNE

English Version Aerospace series - Connectors, electrical, circular, bayonet

coupling, operating temperature 175 °C or 200 °C continuous - Part 001: Technical specification

Série ắrospatiale - Connecteurs électriques circulaires

à accouplement par bạonnettes, température d'

utilisation 175 °C ou 200 °C continu - Partie 001:

This European Standard was approved by CEN on 8 June 2015

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

C O M I T É E UR O P É E N DE N O R M A L I SA T I O N

E UR O P Ä I SC H E S KO M I T E E F ÜR N O R M UN G

Contents Page

European foreword 3

Introduction 4

1 Scope 5

2 Normative references 5

3 Terms and definitions 5

4 Description 6

5 Design 7

6 Definition drawings and masses 8

7 Tests 31

8 Quality assurance 42

9 Designation and marking 47

10 Delivery conditions 47

11 Packaging 47

12 Storage 47

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 2016, and conflicting national standards shall be withdrawn at the latest by May 2016

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 3646-001:2007

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

Introduction

This family of connectors is derived from MIL-DTL-26482, series 2, the NAS 1599 bayonet connector with which it is intermateable and which uses AS-39029 for the contacts It is particularly suitable for use on aircraft applying EN 2282

These connectors are distinguishable from MIL-DTL-26482 and NAS 1599 by:

— being of a lower mass;

— having reduced dimensions;

— accepting smaller cables

1 Scope

This standard specifies the general characteristics, the conditions for qualification, acceptance and quality assurance, as well as the test programmes and groups for bayonet coupling circular connectors, intended for use in an operating temperature range of –65 °C to 175 °C or 200 °C continuous according

to the class and models

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 2266-002, Aerospace series — Cables, electrical, for general purpose — Operating temperatures

between −55 °C and 200 °C — Part 002: General

EN 2282, Aerospace series — Characteristics of aircraft electrical supplies

EN 2591-100*, Aerospace series — Elements of electrical and optical connection — Test methods —

Part 100: General

EN 3155-001, Aerospace series — Electrical contacts used in elements of connection — Part 001:

Technical specification

EN 3197, Aerospace series — Installation of aircraft electrical and optical interconnection systems

EN 3646-002, Aerospace series — Connectors, electrical, circular, bayonet coupling, operating

temperature 175 °C or 200 °C continuous — Part 002: Specification of performance and contact arrangements

EN 9133, Aerospace series — Quality management systems — Qualification procedure for aerospace

standard parts

ISO 263, Inch screw threads — General plan and selection for screws, bolts and nuts — Diameter range

0,06 to 6 in

ISO 4524-1, Metallic coatings — Test methods for electrodeposited gold and gold alloy coatings —

Part 1: Determination of coating thickness

AS 39029, Contacts, electrical connector, general specification for1 )

MIL-DTL-26482H, Connector, electrical, (circular, Miniature, quick disconnect, environment resisting),

receptacles and plugs, general specification for2 )

MIL-HDBK-454N, General guidelines for electronic equipment2 )

NAS 1599, (Inactive) Connectors, general purpose, electrical, miniature circular, environment resisting,

200 °C maximum temperature3 )

3 Terms and definitions

For the purposes of this document, the terms and definitions given in EN 2591-100 apply

* And all parts quoted in this standard

1)

4 Description

4.1 General

Different variants of materials, housings and contact arrangements are provided according to the models depending on the service conditions

These connectors use crimp or solder contacts of size 20, size 16 and size 12

The receptacles and plugs contain either male contacts or female contacts

The contacts fitted in the model Y receptacles are exclusively of the male non removable solder type The connectors are polarized by means of keyways and keys When all the male contacts are in place, polarization is obtained by different angular positions of the insulator in relation to the main slot or locking key and shall occur before the coupling ring can carry out its function

The visual check of coupling is obtained by viewing the locking pins through the inspection holes in the coupling ring of the plug

4.2 Receptacle

The receptacle may be attached by:

— square flange;

— nut, with sealing by O-ring at the attachment;

— round soldered or brazed flange for model Y connectors

The receptacle contains five keyways in which the keys of the plug engage The main keyway is fixed and is wider than the others Polarization is ensured by the different angular positions of the inserts

The plug of models RS and WS is fitted with a grounding spring device ensuring electrical continuity between the coupled connector housings

4.4.3 Contacts

Unless otherwise specified, the contacts shall be in ferrous alloy for models Y and in copper alloy for the other models

They shall be gold-plated on an appropriate undercoat Selective protection is authorized provided that

it is sufficient to ensure that performance is respected

Measurement of the thickness of the protective treatment shall be effected in accordance with ISO 4524-1

Receptacles for attachment by nut shall contain an O-ring seal The nut shall have holes for the passage

of locking wire

The threads shall conform to ISO 263

The coupling ring shall be designed so that the male and female contacts engage when it is turned clockwise and disengaged when it is turned counter-clockwise The coupling ring shall be knurled The cable outlets shall compress the connector grommets without distorting it

6 Definition drawings and masses

The general dimensions and the masses of receptacles, plugs and protective covers are given in the product standards

6.1 Receptacle mating dimensions

The mating dimensions of receptacles are shown in Figure 1 and details A and B as well as in Table 1, Table 2 and Table 3

Dimensions and tolerances are in millimetres

Table 1 — Receptacle — Mating dimensions

2,84 2,69 3,00 2,89

6.2 Plug mating dimensions

The mating dimensions of plugs are shown in Figure 2 and Figure 3 and in Table 4 and Table 5

Dimensions and tolerances are in millimetres

C – Coupling ring bayonet groove detail

Table 4 — Plug — Mating dimensions

6.3 Receptacle and plug polarization

See Figure 3, Figure 4 and Figure 5 and Table 5 and Table 6

Dimensions and tolerances are in millimetres

Figure 3 — Polarization

Table 5 — Polarization dimensions Housing

size

B

+ 0,05 – 0,10

J

+ 0,08 – 0,20

L

+ 0,13 – 0,15

M

+ 0,13 – 0,02

Figure 4 — Front face view

female insulator Figure 5 — Front face view male insulator

EN 2591-207

Size and number

of contacts

Polarization (α) Polarization code

90 –

63

45 –

112

155 –

270 – –

119

138

318 –

144

126 –

180

203

270 –

184 –

155

315

180 – –

275 –

241

222

333 –

252

225 –

292

295 –

273 –

234 –

331 – –

338 –

340

265

347 –

333 –

6

349

288 –

314 – –

324

6.4 Dimensions of the rear part

6.4.1 Model with three teeth

The dimensions of the rear part of receptacles and plugs for models with three teeth with threads for mounting cable outlets are shown in Figure 6 and in Table 7

The centre-line of one of the three teeth shall be diametrically opposite to the centre-line of the master keyway

Dimensions and tolerances are in millimetres

6.4.2 Model with teeth over the entire periphery

The dimensions of the rear part of receptacles and plugs for model with teeth over the entire periphery with threads for mounting cable outlets are shown in Figure 7 and in Table 7

Table 7 — Rear part dimensions

The following tolerances apply to the inserts fitted in the housings:

— centre of each hole;

— centre of each contact end

Identification of the contact position shall be permanently designed in contrasting colour on the front face of the insert of interfacial seal and on the rear face of the wire sealing grommet Identification shall not be recessed or raised on the sealing surfaces

Symbols for contact sizes are given in EN 3155-001

18-08

8 contacts, size 12 11 contacts, size 16 18-11

Contact mm X mm Y Contact mm X mm Y Contact mm X mm Y Contact mm X mm Y

16 contacts, size 16

22-21

21 contacts, size 16 36 contacts, size 20 22-36

Contact mm X mm Y Contact mm X mm Y Contact mm X mm Y Contact mm X mm Y

size

– 0,41 ± 0,79

7 Tests

The tests of EN 2591-100, applicable in the context of this standard as well as the details necessary for implementing them and for inspecting connector characteristics, are given in Table 9

Table 9 (1 to 8)

EN 2591- Designation of the test Details

101 Visual examination Initial examination: examination of connectors,

fittings, loose parts (contacts, etc.) Details to be examined:

102 Examination of dimensions and

mass According to Clause 6 and product standard The checking of inaccessible dimensions on the

finished product shall be carried out on part pieces or given by the quality organization of the manufacturer concerned

201 Contact resistance — Low level Not applicable

202 Contact resistance at rated

current Crimp contacts: defined by the standards for contacts specified in EN 3646-002

Solder contacts (hermetic connectors): measuring points on the cable, nearest to the contacts

Contact size Current Maximum contact resistance

in mΩ

A Initial After tests

EN 2591-301 and

EN 2591-307

20 5 12 15

16 10 8 10

12 17 5 6

203 Electrical continuity at microvolt

204 Discontinuity of contacts in the

microsecond range Duration of micro-discontinuity: Method B ≤ 1 µs

Test time: throughout the duration of tests

EN 2591-301, EN 2591-402 and EN 2591-403

205 Housing (shell) electrical 5 mΩ — plug with grounding spring system and

Table 9 (2 to 8)

EN 2591- Designation of the test Details

206 Measurement of insulation

resistance Method A, connectors uncoupled, unless otherwise indicated below

Minimum insulation resistance:

— at ambient temperature: 1 000 MΩ (unmated connectors);

— maximum operating temperature: 500 MΩ (unmated connectors);

207 Voltage proof test Method A, connectors uncoupled except for tests

EN 2591-314 and EN 2591-324 and during

EN 2591-302 where they shall be mated For tests at low pressure, voltage is applied after

30 min at the pressure indicated

Voltage value

Pressure

Rating I Rating II Mated

V r.m.s Unmated V r.m.s V r.m.s Mated Unmated V r.m.s Sea level

12,1 kPa (15 000 m) 4,7 kPa (21 000 m) 1,1 kPa (30 000 m)

Maximum leakage current: 2 mA

208 Temperature rise due to rated current Not applicable

209 Current temperature derating Not applicable

210 Electrical overload Crimp contacts: defined by the standards for

contacts specified in EN 3646-002 Solder contacts (hermetic connectors):

Table 9 (3 to 8)

EN 2591- Designation of the test Details

212 Surface transfer impedance Not applicable

213 Shielding effectiveness from

100 MHz to 1 GHz Receptacle and plug with grounding spring system fitted with screening connection

Frequency

MHz

Minimum attenuation

dB Models RS and WS

214 Lightning strike current and

216 Engagement depth of contacts Not applicable

217 Voltage drop under specified

current for terminal lugs and in-line splices

Not applicable

218 Ageing of terminal lugs and

in-line splices by temperature and current cycling

Not applicable

219 Voltage strength for insulated

terminal lugs and in-line splices Not applicable

220 Contact/conductor joint ageing

by current and temperature cycling

Not applicable

301 Endurance at temperature Method B, test under load except for model Y

Temperature: 175 °C or 200 °C according to class Duration: 1 000 h

303 Cold/low pressure and damp

304 Damp heat steady state Not applicable

305 Rapid change of temperature Connectors mated