Bsi bs en 04199 001 2013

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[.]

BSI Standards Publication

Aerospace series — Bonding straps for aircraft

Part 001: Technical specification

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It supersedes BS EN 4199-001:2006 which is withdrawn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 0 580 80147 1 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

NORME EUROPÉENNE

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 3 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

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

Contents Page

Foreword 3

1 Scope 4

2 Normative references 4

3 Terms and definitions 4

4 Required characteristics 4

5 Design 5

6 Tests 5

7 Quality assurance 9

8 Designation 11

9 Marking 11

10 Packaging 11

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

1 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

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 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)

3 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

4 Required characteristics

4.1 General

See product standard

4.2 Temperature range

See Table 1

1) Published by: IEC International International Electrotechnical Commission http://www.iec.ch/

Table 1

Class Temperature

range Material/finish

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

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

5 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

6 Tests

6.1 Tests on the braids

The tests of EN 3475 listed in Table 2 shall be applicable for testing of round and flat braid conductors used in the construction of bonding straps

Table 2

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

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 3 of this standard

Table 3

EN 2591- Designation of the test Details

101 Visual examination 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

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

305 Rapid change of

temperature

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

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 1 or Figure 2 at (20 ± 3) °C

Figure 1 — Bonding straps with flat

braid conductor

Figure 2 — Bonding straps with round

braid conductor

6.4 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

6.5 Mechanical fatigue test apparatus

See Figure 3

Top view

Key

1 screw and washer

2 articulation

3 mobile part of tool

4 fixed part of tool

5 spacer

6 up + 50°

7 down − 50°

Figure 3 — Mounting device

7 Quality assurance

7.1 General

See EN 9133

7.2 Qualification

7.2.1 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 4 and 5 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 4

Table 4

EN 3475- 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

7.2.3 Qualification of bonding strap assemblies

See Table 5

Only bonding straps assembled from certified components and using certified calibrated tooling shall be qualified

Table 5 Designation of the test EN 2591- Remarks Group 0 12 specimens

Visual examination 101

Examination of dimensions and mass 102 See product standard

Voltage drop (see 6.3) – See product standard

Group 1 3 specimens

Tensile strength (crimped connection) 417 See product standard

Group 2 3 specimens

Ageing of terminal lugs and in-line splices by

temperature and current cycling

218 See product standard

Tensile strength (crimped connection) 417

Group 3 3 specimens

Mechanical Fatigue (see 6.4) –

10 % of the required number of flex cycles specified in the product standard

Salt mist 307 48 h or as product standard

Rapid change of temperature 305 –

Endurance at temperature 301 –

Visual examination 101 –

Voltage drop (see 6.3) a – See product standard

Tensile strength (crimped connection) 417 See product standard

Group 4 3 specimens

Salt mist 307 48 h or as product standard

Mechanical fatigue test (see 6.4) – See product standard

Visual examination 101 –

Voltage drop (see 6.3) a – See product standard

Tensile strength (crimped connection) 417 See product standard

a The maximum value of resistance measured in test groups 3 and 4 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 4 shall be carried out and for bonding straps assemblies, the tests in group 4 of Table 4

7.4 Acceptance Tests

The tests listed in Tables 6 and 7 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 6

Table 6

EN 3475- Designation of the test Details

201 Visual examination All specimens

203 Dimensions All specimens

301 Ohmic resistance per unit length All specimens

7.4.2 Tests for bonding strap assemblies

See Table 7

Table 7

EN 2591- Designation of the test 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

8 Designation

See product standard

9 Marking

See product standard

10 Packaging

Bonding straps shall be so packed as to avoid any damage

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