SAE ARP 6807-2017 Guide for Identification of Terminal Lugs in Electrical Wiring Interconnect Systems (EWIS).pdf

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1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/ARP6807 AEROSPACE RECOMMENDED PRACTICE ARP6807 Issued 2017-11 Guide for Identification of Term

5、inal Lugs in Electrical Wiring Interconnect Systems (EWIS) RATIONALE The document provide a process to identify AS7928 Class 1 terminal lugs used in established aerospace Electrical Wiring Interconnect System (EWIS) applications. AS7928 does not require a part number on terminals. Class 1 components

6、 are controled by color codes, wire gage size, and configuration. 1. SCOPE The intent of the SAE Aerospace Recommended Practice (ARP) is to provide a process for users to identify the part number of AS7928 terminal lugs installed in civilian or military applications, although it can also can be used

7、 to identify terminals that have been stored incorrectly. This ARP is subject to change to keep pace with experience and technical advances of AS7928 terminals. A current set of tables are provided to list and identify current AS7928 terminal lug configurations per the associated specification detai

8、l sheet and terminal lug configuration. Specific configuration details, graphic, size and marking information for each individual terminal lug is provided to assist the product user with accurate selection for replacement or identification. 1.1 Purpose Failure to select a suitable terminal lug repla

9、cement, may negatively impact reliabilty (service life) or performance of individual EWIS components and the entire system in which it is installed. This ARP provides a process for users to identify the correct AS7928 installed terminal part number. The ARP is not intended to provide information on

10、what terminal to be used in a specific enviroment or application. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect

11、on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1 SAE

12、Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. AIR1351 Manufacturers Identification of Aerospace Electrical and Electronic Wiring Devices and Accessories AS7928

13、 Terminals, Lug: Splices, Conductor: Crimp Style, Copper, General Specification For SAE INTERNATIONAL ARP6807 Page 2 of 16 AS7928/1 Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, for Thin Wall Wire, Type II Class 1 for 105 C Tot

14、al Conductor Temperature AS7928/2 Terminals, Lug and Splices, Conductor, Crimp Style, Copper, Insulated, Rectangular Tongue, for Thin Wall Wire, Type II, Class 1 for 105 C Total Conductor Temperature AS7928/4 Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Ring T

15、ongue, Bell-Mouthed, Type II, Class 1 (for 150 C) Total Conductor Temperature) AS7928/5 Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric (Permanent, Type II, Class 1) for 105 C Total Conductor Temperature AS7928/6 Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electr

16、ic (Permanent, Type II, Class 1) for 150 C Total Conductor Temperature AS7928/7 Terminal Lug and Splices, Conductor, Crimp Style, Copper, Terminal Lug, Crimp Style, Copper, Uninsulated, Ring Tongue Type I, Class 1 for 175 C Total Conductor Temperature AS7928/8 Terminals, Lug and Splices, Conductor,

17、Crimp Style, Copper Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, For Thin Wall Wire, Tin Whisker Resistant, Type II Class 1 For 105 C Total Conductor Temperature AS7928/9 Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style, Copper, Insulated, Rectangu

18、lar Tongue, For Thin Wall Wire, Tin Whisker Resistant, Type II Class 1 For 105 C Total Conductor Temperature AS7928/10 Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric, Tin Whisker (Permanent, Type II, Class 1) For 105 C Total Conductor Temperature AS7928/11 Terminals, Lug, Crimp

19、 Style, Copper, Uninsulated, Ring Tongue, Tin Whisker Resistant, Type I Class 1, For 175 C Total Conductor Temperature AS7928/12 Terminals, Lug, Crimp Style, Copper, Insulated, Ring Tongue Bell-Mouthed, Electric, Tin Whisker Resistant (Permanent, Type II, Class 1) For 105 C Total Conductor Temperatu

20、re AS7928/13 Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Tin Whisker Resistant, Ring Tongue Bell-Mouthed, (Permanent, Type II, Class 1) For 105 C Total Conductor Temperature AS7928/14 Terminal, Electric, Permanent, Crimp Style, Tin-Coated Copper, Insulated, E

21、nvironment Resistant, Class 1 150 C, Heatless Sealing AS17143 Terminal, Lug, Crimp Style, Copper, Insulated, Rectangular Tongue, Type II, Class 1 For 105 C Total Conductor Temperature AS20659 Terminal, Lug, Crimp Style, Copper, Uninsulated, Ring Tongue, Type I, Class 1, For 175 C Total Conductor Tem

22、perature AS21004 Terminal, Lug, Uninsulated, Rectangular Tongue, Crimp Style, Copper, Type I, Class 1 For 175 C Total Conductor Temperature) AS25036 Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell-Mouthed, Type II, Class 1 (For 105 C Total Conductor Temperature) SAE INTERNATIONAL AR

23、P6807 Page 3 of 16 3. TERMINAL LUG IDENTIFICATION LIMITATIONS SAE AS7928 includes Class 1 and Class 2 insulated and uninsulated crimp-style copper terminal lugs for stranded conductors. This ARP only addresses identification of Class 1 terminals. If terminal identification cannot be determined from

24、this process, the terminal is either a Class 2 component or a non-standard component. An engineering analysis is required to identify these types of terminals. 3.1 Terminal Lug Identification The specified characteristics of the AS7928 Terminals allow each terminal to be uniquely identified. Those c

25、haracteristics are listed in 3.2.1. By understanding and identifying these features, a user can identify the specific SAE part number and supplier of a given terminal. At the moment, there is no way to distinguish between parts that are tin-whisker resistant and those that are not, but these will be

26、 revised and color bands will be added. Figure 1 shows the characteristic features necessary for identification. Figure 2 shows the process steps to be followed. Representative terminal lugs and features Figure 1 - Representation of heatless sealed terminal (The Environmentally Sealed, Type II termi

27、nal lug is defined in AS7928/14. It is cold applied and is filled with a silicone gel material). SAE INTERNATIONAL ARP6807 Page 4 of 16 Table 1 - Clearance hole sizes Stud size Clearance Hole Diameter Stud Dia Minimum Maximum 2 .086 .090 .098 4 .112 .114 .122 5 .125 .129 .137 6 .138 .142 .152 8 .164

28、 .168 .178 10 .190 .193 .203 12 .216 .220 .236 1/4 .250 .260 .275 5/16 .312 .323 .338 3/8 .375 .385 .400 7/16 .437 .448 .463 1/2 .500 .510 .525 5/8 .625 .651 .666 3/4 .750 .770 .785 7/8 .875 .895 .910 3.2 Configuration Breakdown Once the above features are understood (see specification sheets for ad

29、ditional details), one can use this document to identify the part number for the terminal in question. The part number along with the manufacturer marking can fully identify the terminal lug. To accomplish this, follow the steps below on the unidentified installed terminal: 3.2.1 Identify the follow

30、ing as applicable: a. Round or rectangular tongue b. Insulated or non-insulated c. Color of insulation sleeve d. Presence and color of a wire size color band e. Presence of a colored end cap f. Presence of a wire support g. Wire size or wire range of the terminal h. Stud size i. Terminal length j. T

31、ongue width SAE INTERNATIONAL ARP6807 Page 5 of 16 3.2.2 Using Figure 2, identify the appropriate specification detail sheet and table for the terminal lug. 3.2.3 Use the corresponding table to identify the dash number (configuration) of the terminal lug. 3.2.4 If a table contains multiple terminal

32、lugs with the same wire size, and stud size, an additional column for either the terminal lug or tongue width is included to complete the terminal lug identification. 3.3 To identify the manufacturer, locate the manufacturers mark on the tongue of the terminal. This will be a letter, group of letter

33、s, or symbol that will be unique to each manufacturer. Once this has been located, find the associated mark in AIR1351. Figure 2 - Decision tree for terminal identification SAE INTERNATIONAL ARP6807 Page 6 of 16 Table 2 - AS7928/1 and AS7928/8 part numbers PART NUMBER M7928/1 M7928/8 WIRE SIZE INSUL

34、ATION COLOR WIRE SIZE COLOR STUD SIZE TERMINAL LENGTH (MAX) STUD DIA -1 26 YELLOW BLACK 2 .086 .740 -2 4 .112 .786 -3 6 .138 .886 -4 8 .164 .886 -5 10 .190 .886 -6 24 YELLOW BLUE 2 .086 .740 -7 4 .112 .786 -8 6 .138 .886 -1 8 .164 .886 -10 10 .190 .886 -70 22 RED GREEN 2 .086 .790 -11 4 .112 .801 -1

35、2 6 .138 .801 -13 6 .138 .911 -14 8 .164 .956 -15 10 .190 .956 -16 1/4 .250 1.136 -17 5/16 .312 1.136 -18 3/8 .375 1.366 -19 1/2 .500 1.366 -71 20 RED RED 2 .086 .790 -20 4 .112 .801 -21 6 .138 .801 -22 6 .138 .911 -23 8 .164 .956 -24 10 .190 .956 -25 1/4 .250 1.136 -26 5/16 .312 1.136 -27 3/8 .375

36、1.366 -28 1/2 .500 1.366 -72 18 RED WHITE 2 .086 .790 -29 4 .112 .801 -30 6 .138 .801 -31 6 .138 .911 -32 8 .164 .956 -33 10 .190 .956 -34 1/4 .250 1.136 -35 5/16 .312 1.136 -36 3/8 .375 1.366 -37 1/2 .500 1.366 SAE INTERNATIONAL ARP6807 Page 7 of 16 -38 16 BLUE BLUE 4 .112 .820 -39 6 .138 .820 -40

37、6 .138 .956 -41 8 .164 .956 -42 10 .190 .961 -43 1/4 .250 1.131 -44 5/16 .312 1.131 -45 3/8 .375 1.271 -46 1/2 .500 1.366 -47 14 BLUE GREEN 4 .112 .820 -48 6 .138 .820 -49 6 .138 .956 -50 8 .164 .956 -51 10 .190 .961 -52 1/4 .250 1.131 -53 5/16 .312 1.131 -54 3/8 .375 1.271 -55 1/2 .500 1.366 -56 12

38、 YELLOW YELLOW 6 .138 1.198 -57 8 .164 1.198 -58 10 .190 1.198 -59 1/4 .250 1.400 -60 5/16 .312 1.400 -61 3/8 .375 1.492 -62 1/2 .500 1.492 -63 10 YELLOW BROWN 6 .138 1.198 -64 8 .164 1.198 -65 10 .190 1.198 -66 1/4 .250 1.400 -67 5/16 .312 1.400 -68 3/8 .375 1.492 -69 1/2 .500 1.492 SAE INTERNATION

39、AL ARP6807 Page 8 of 16 Table 3 - AS7928/4 and AS7928/13 part numbers PART NUMBER M7928/4 M7928/13 WIRE SIZE RANGE WIRE SIZE COLOR STUD SIZE TERMINAL LENGTH (MAX) STUD DIA -143 26-24 YELLOW 2 .086 .74 -144 4 .112 .755 -145 6 .138 .855 -146 8 .164 .855 -147 10 .190 .865 -159 22-18 RED 2 .086 .755 -14

40、8 4 .112 .755 -101 6 .138 .755 -102 6 .138 .865 -149 8 .164 .910 -103 10 .190 1.090 -150 1/4 .250 1.090 -104 5/16 .312 1.090 -105 3/8 .375 1.320 -151 1/2 .500 1.320 -152 16-14 BLUE 4 .112 .774 -106 6 .138 .774 -107 6 .138 .910 -153 8 .164 .910 -108 10 .190 .915 -154 1/4 .250 1.085 -109 5/16 .312 1.0

41、85 -110 3/8 .375 1.225 -155 1/2 .500 1.320 -111 12-10 YELLOW 6 .138 1.120 -156 8 .164 1.120 -112 10 .190 1.120 -157 1/4 .250 1.322 -113 5/16 .312 1.322 -114 3/8 .375 1.414 -158 1/2 .500 1.414 -115 8 RED 10 .190 1.402 -116 1/4 .250 1.446 -117 5/16 .312 1.544 -118 3/8 .375 1.544 -119 6 BLUE 10 .190 1.

42、599 -120 1/4 .250 1.599 -121 5/16 .312 1.762 -122 3/8 .375 1.762 SAE INTERNATIONAL ARP6807 Page 9 of 16 -123 4 YELLOW 1/4 .250 1.812 -124 5/16 .312 1.879 -125 3/8 .375 1.879 -126 2 RED 1/4 .250 2.069 -127 3/8 .375 2.069 -128 1/2 .500 2.269 -129 1 WHITE 1/4 .250 2.150 -130 3/8 .375 2.150 -131 1/2 .50

43、0 2.370 -132 0 BLUE 1/4 .250 2.401 -133 3/8 .375 2.401 -134 1/2 .500 2.525 -135 00 YELLOW 5/16 .312 2.525 -136 3/8 .375 2.750 -137 1/2 .500 2.750 Table 4 - AS20659 and AS7928/11 part numbers 1/ Tin finish terminal has no color mark PART NUMBER MS20659 M7928/11 WIRE SIZE CRIMP BARREL COLOR MARK 1/ ST

44、UD SIZE TONGUE WIDTH (MAX) NICKEL FINISH STUD DIA -167 / -267 22-18 GREEN BAND OR DASH 2 .086 .260 -138 / -238 4 .112 .260 -101 / -201 6 .138 .260 -102 / -202 10 .190 .320 -161 / -261 5/16 .312 .540 -125 / -225 3/8 .375 .540 -162 / -262 1/2 .500 .733 -139 / -239 16-14 4 .112 .266 -103 / -203 6 .138

45、.327 -126 / -226 6 .138 .266 -104 / -204 10 .190 .327 -163 / -263 5/16 .312 .540 -127 / -227 3/8 .375 .540 -164 / -264 1/2 .500 .733 -165 / -265 12-10 6 .138 .317 -105 / -205 10 .190 .391 -106 / -206 5/16 .312 .547 -128 / -228 3/8 .375 .598 -166 / -266 1/2 .500 .733 SAE INTERNATIONAL ARP6807 Page 10

46、 of 16 Table 4 - AS20659 and AS7928/11 part numbers (continued) PART NUMBER MS20659 M7928/11 WIRE SIZE STUD SIZE TONGUE WIDTH (MAX) STUD DIA -140 / -240 8 8 .164 .429 -107 / -207 10 .190 .429 -141 / -241 1/4 .250 .478 -108 / -208 5/16 .312 .590 -129 / -229 3/8 .375 .590 -142 / -242 1/2 .500 .833 -13

47、0 / -230 6 10 .190 .503 -109 / -209 1/4 .250 .503 -131 / -231 5/16 .312 .623 -110 / -210 3/8 .375 .623 -143 / -243 1/2 .500 .833 -144 / -244 4 10 .190 .628 -111 / -211 1/4 .250 .628 -132 / -232 5/16 .312 .648 -112 / -212 3/8 .375 .648 -145 / -245 1/2 .500 .833 -146 / -246 2 10 .190 .711 -113 / -213

48、1/4 .250 .711 -147 / -247 5/16 .312 .711 -114 / -214 3/8 .375 .711 -148 / -248 7/16 .437 .804 -133 / -233 1/2 .500 .804 -115 / -215 1 1/4 .250 .783 -149 / -249 5/16 .312 .783 -116 / -216 3/8 .375 .783 -150 / -250 7/16 .437 .887 -134 / -234 1/2 .500 .887 -117 / -217 0 1/4 .250 .853 -151 / -251 5/16 .

49、312 .853 -118 / -218 3/8 .375 .853 -152 / -252 7/16 .437 .903 -135 / -235 1/2 .500 .903 -153 / -253 00 1/4 .250 .956 -119 / -219 5/16 .312 .956 -120 / -220 3/8 .375 .956 -154 / -254 7/16 .437 .956 -136 / -236 1/2 .500 .956 -155 / -255 000 5/16 .312 1.053 -121 / -221 3/8 .375 1.053 -156 / -256 7/16 .437 1.053 -122 / -222 1/2 .