ASD-STAN TR 4654-003-2014 Aerospace series Connectors electrical EN 4644 specific products Part 003 Inserts with PC tails electrical contacts (Edition 2).pdf

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1、ASD-STAN Technical Report Rapport Technique ASD-STAN ASD-STAN Fachbericht TR 4654-003 Edition 2 October 2014 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONRue Montoyer 10 - 1000 Brussels - Tel. 32 2 775 8126 - Fax. 32 2 775 8131 - www.asd-stan.orgICS: Super

2、sedes edition 1 of October 2012 Descriptors: ENGLISH VERSION Aerospace series Connectors electrical, EN 4644 specific products Part 003: Inserts with PC tails electrical contacts Srie arospatiale Connecteurs lectriques, EN 4644 produits spcifiques Partie 003 : Inserts avec contacts lectriques picots

3、 Luft- und Raumfahrt Elektrische Steckverbinder, spezielle EN 4644-Produkte Teil 003: Einstze fr elektrische PC tails-Kontakte This Technical Report was drawn up by the Electrical Domain of ASD-STAN. The reason which led to the publication of the document as a Technical Report is explained in the fo

4、reword. Edition approved for publication 1stOctober 2014 Electrical Domain Copyright 2014 by ASD-STAN Page 2 TR 4654-003:10-2014 Contents Page 1 Scope 4 2 Normative references 4 3 Terms and definitions .4 4 Required characteristics .5 5 Recommended tests 7 6 Recommended qualification .15 7 Marking .

5、18 8 Technical specification .18 Page 3 TR 4654-003:10-2014 Foreword The main task of ASD-STAN Technical Committees is to prepare EN Standards, in exceptional circumstances however, the publication of Technical Report of one of the following types may be proposed: Type 1, the subject is still under

6、technical development requiring wider exposure; Type 2, a Technical Committee has collected data of a different kind from that which is normally published as a European Standard. The Electrical Domain decided to publish this document in the form of a Technical Report of type 2 in order to facilitate

7、 the updating of this document. Page 4 TR 4654-003:10-2014 1 Scope This Technical Report is describing the characteristic of rectangular insert with PC tail male contacts. Electrical PC tails contacts are derived from EN 3155-076 and are completely mate able with EN 3155-077. Rectangular insert are

8、derived from EN 4644-003 and shall be used in connectors defined by EN 4644-001. 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 undat

9、ed references, the latest edition of the referenced document (including any amendments) applies. EN 2266-003, Aerospace series Cables, electrical, for general purpose Operating temperatures between 55 C and 200 C Part 003 Ink jet printable Product standard EN 2267-003, Aerospace series Cables, elect

10、rical, for general purpose Operating temperatures between 55 C and 260 C Part 003: Ink jet printable Product standard EN 2591(all parts), Aerospace series Elements of electrical and optical connection Test methods EN 3155-076, Aerospace series Electrical contacts used in elements of connection Part

11、076: Contacts, electrical, male, type A, crimp, class R Product standard EN 3155-077, Aerospace series Electrical contacts used in elements of connection Part 077: Contacts, electrical, female, type A, crimp, class R Product standard EN 4644 (all parts), Aerospace series Connector, electrical and op

12、tical, rectangular, modular, rectangular inserts, operating temperature 175 C (or 125 C) continuous 1)TR 4654-001, Aerospace series Connectors, electrical, EN 4644 specific products Part 001: Technical specification 2)3 Terms and definitions For the purposes of this document, the terms and definitio

13、ns given in TR 4654-001 apply. 1) Published as ASD-STAN Prestandard at the date of publication of this standard by Aerospace and Defence Industries Association of Europe-Standardization (ASD-STAN), (www.asd-stan.org). 2) Published as ASD-STAN Technical Report at the date of publication of this stand

14、ard by Aerospace and Defence Industries Association of Europe-Standardization (ASD-STAN), (www.asd-stan.org). Page 5 TR 4654-003:10-2014 4 Required characteristics 4.1 Dimensions Remaining dimensions are according to EN 4644-003. Key 1 PC tail contacts grid pattern middle axis NOTE H and J are tinne

15、d areas Figure 1 Page 6 TR 4654-003:10-2014 Table 1 Code PC tail type aDimensions Insert for female or male contacts 0,50 E1 Straight E 16,25 E2 Straight E 19,45 E3 Straight E 21,26 N1 Right angle E 18,51 F 11,60 N2 Right angle E 25,75 F 13,00 N3 Right angle E 18,51 F 13,00 N4 Right angle E 25,75 F

16、11,60 N4 Right angle E 23,30 F 11,60 N4 Right angle E 23,30 F 13,00 aOn each insert, position between PC tail contacts are the same as position between cavities described in EN 4644-001 clause “contact arrangements”. Table 2 Size 22 Size 20 Size 16 Size 12 Size 8 Size 5 Contact termination: Gold cla

17、ss G 0,67 0,60 1,05 0,98 1,62 1,55 2,07 2.00 3,65 3,59 3,65 3,59 Recommended PC diameter min. 0,80 1,20 1,75 2,20 3,80 3,80 Contact termination: Tin class G max. 0,75 1,20 1,75 2,20 / / Recommended PC diameter min. 0,90 1,35 1,95 2,50 / / Table 3 Classes Dimensions Female contact Male contact N and

18、T inserts H max. 21,05 13,25 J max. 17,30 E and H inserts H max. 29,30 22 J max. 17,30 Page 7 TR 4654-003:10-2014 4.2 Insert polarization See EN 4644-003. 4.3 Class There are 4 environmental categories of inserts: N: Non environmental: Insert without interfacial seal and without rear grommet; E: Env

19、ironmental: Insert with rear grommet for male and socket insert, and with interfacial seal for male insert; T: Semi environmental: male insert with interfacial seal, without grommet; Non environmental: male insert without interfacial seal and with rear grommet. 4.4 Contacts termination There are sev

20、eral possible termination for PC tail contacts: Tin class T: pure tin; P: tin lead. Gold class F: gold flash; G: gold 0,8 m min.; H: gold 1,27 m min. 5 Recommended tests Test from EN 4644-001 are applicable except tests that have no link with insert and pin contacts (see Table 3). EN 2591 (all parts

21、) tests are mainly applicable on crimping contacts. Some adjustment would have to be done on PC tail contacts. Solderability performance of PC tail contacts would be evaluated by each customer per his own requirements and rules. Page 8 TR 4654-003:10-2014 Table 4 (1 to 8) EN 2591- Designation of the

22、 test Details 101 Visual examination Applicable, naked eye. 102 Examination of dimensions and mass Applicable see product standard. 201 Contact resistance - low level Applicable. Defined by the standards for contacts specified in EN 4644-002. 202 Contact resistance at rated current Applicable. Defin

23、ed by the standards for contacts specified in EN 4644-002. 203 Electrical continuity at microvolt level Applicable to shielded contact. Requirements defined by the standard for contacts specified in EN 4644-002. 204 Discontinuity of contacts in the microsecond range Duration 1 s. Method B. Test time

24、: throughout the duration of tests EN 2591-402 and EN 2591-403. Except 10 ns for quadrax contacts. 205 Housing (shell) electrical continuity Already qualified in EN 4644-001. 206 Measurement of insulation resistance Method A on unmated connectors. 5 000 M at ambient temperature. 200 M at elevated te

25、mperature (125 C). 207 Voltage proof test Method A, connectors mated and unmated except after test EN 2591-314 where they shall be mated. Maximumleakage current Pressure Connector mated V r.m.s Connector unmated V r.m.s Environmental connectors 1mA Sea level 1 500 1 500 12,1 kPa (15 000 m) 800 600 4

26、,7 kPa (21 000 m) 800 300 Semi environmental connectors 1mA Sea level 1 500 1 500 12,1 kPa (15 000 m) 600 600 4,7 kPa (21 000 m) 300 300 Non environmental connectors 1mA Sea level 1 500 12,1 kPa (15 000 m) 600 4,7 kPa (21 000 m) 300 208 Temperature rise due to rated current Not applicable. 209 Curre

27、nt temperature derating Not applicable for qualification. Page 9 TR 4654-003:10-2014 Table 3 (2 to 8) EN 2591- Designation of the test Details 210 Electrical overload Contact size Current A Duration S 22 10 50 40 0,6 20 15 75 16 26 130 12 46 230 211 Capacitance Not applicable. 212 Surface transfer i

28、mpedance Not applicable. 213 Shielding effectiveness from 100 MHz to 1 GHz Not applicable. 214 Lightning strike, current and voltage pulse Applicable. 3 kA 1 600 Volts. 216 Engagement depth of contacts Contact size Minimal engagement mm 22 1,27 20 16 1,50 12 8 5 220 Contact/conductor joint ageing by

29、 current and temperature cycling Not applicable. 221 Voltage Standing Wave Ratio (VSWR) Not applicable. 222 Insertion Loss (I.L.) Not applicable. 223 Measurement of characteristic impedance of a coaxial connector or contact Not applicable. 224 RF leakage Not applicable. 225 RF high potential withsta

30、nding voltage Not applicable. 226 Corona level Not applicable. Page 10 TR 4654-003:10-2014 Table 3 (3 to 8) EN 2591- Designation of the test Details 301 Endurance at temperature Method B, no load. Temperature: 125 C. Duration: 1 000 h. 302 Climatic sequence Not applicable 303 Cold/low pressure and d

31、amp heat Not applicable. 304 Damp heat steady state Not applicable. 305 Rapid change of temperature Connectors mated, 5 cycles. Classes A, B, E and F. TA (17505) C. TB ( 6550) C. Classes C and D connectors. TA (12505) C. TB ( 6550) C. 306 Mould growth Test conducted on materials. Method A. Duration:

32、 28 d. Growth: 0. No prior washing. No surface etching. 307 Salt mist The connectors shall be suspended in the test chamber with non-metallic cords, so that no accumulation of condensed saline solution can occur. The connectors unmated shall be exposed to the salt mist for 96 h except for class C co

33、nnectors which shall be exposed to the salt mist for 48 h. 308 Sand and dust Already qualified in EN 4644. 309 Dry heat Not applicable. 310 Cold Not applicable. 311 Low air pressure Not applicable. 312 Air leakage Not applicable. 313 Artificial rain Not applicable. 314 Immersion at low air pressure

34、Not applicable. 315 Fluid resistance Applicable, for types of fluids number of cycles, temperature and duration of immersion for the third phase: see fluids described in EN 4644-001. 316 Ozone resistance Not applicable. 317 Flammability Applicable Method A. Page 11 TR 4654-003:10-2014 Table 3 (4 to

35、8) EN 2591- Designation of the test Details 318 Fire-resistance Not applicable. 319 Gastightness of solderless wrapped connections Not applicable. 320 Simulated solar radiation at ground level Not applicable. 321 Damp heat, cyclic test Not applicable to non environmental connectors. Connector mated

36、Minimum temperature: ( 65 2) C. Maximum temperature: (125 2) C. 322 Hermeticity Not applicable. 323 Thermal shock Not applicable. 324 Interfacial sealing Not applicable. 325 Ice resistance Not applicable. 401 Acceleration, steady state Not applicable. 402 Shock The element of connection shall have a

37、ll its contacts wired in series using cables according to EN 2267-003. The elements of connection fitted with appropriate cable clamps shall be mated and mounted on the shock apparatus using appropriate mounting systems. The elements of connection are not fitted with any accessories. The cables are

38、clamped at a minimum of 200 mm from the rear of the connector. Size 2 disconnect connectors: coupling torque = 1,1/1,3 Nm. Rack and panel connectors have to be mated with a Fscompression force between shells. In order to take into account the reaction force exerted by the environmental inserts (inte

39、rfacial seal compression) and of inserts fibre optic contacts the following formula has to be used: Fm x Fs y Fi z Fowhere Fm maximum connector mating force; Fs maximum shell mating force per cavity 250 N; x number of insert cavities; Fi interfacial seal counter reaction force 150 N; y number of env

40、ironmental inserts; Fo fibre optic counter reaction force (see the appropriate EN optical standard); z number of fibre optic contacts. Method A. Severity 300 for disconnect size 2 classes A, B and C except for connectors fitted with quadrax contacts and rack and panel connectors where severity is 50

41、. Severity 50 for the others connectors sizes and classes. Number of shocks: three shocks in each direction shall be applied along the three mutually perpendicular axes of the element of connection. EN 2591-204 throughout the test. Page 12 TR 4654-003:10-2014 Table 3 (5 to 8) EN 2591- Designation of

42、 the test Details 403 Sinusoidal and random vibration The element of connection shall have all its contacts wired in series using cables according to EN 2266-003.The elements of connection fitted with appropriate cable clamps shall be mated and mounted on the shock apparatus using appropriate mounti

43、ng systems. The elements of connection are not fitted with any accessories. The cables are clamped at a minimum of 200 mm from the rear of the connector. Size 2 disconnect connectors: coupling torque 1,1/1,3 Nm. Rack and panel connectors have to be mated with a Fscompression force between shells. In

44、 order to take into account the reaction force exerted by the environmental inserts (interfacial seal compression) and of inserts fibre optic contacts the following formula has to be used: Fm x Fs y Fi z Fo where Fm maximum connector mating force; Fs maximum shell mating force per cavity 250 N; x nu

45、mber of insert cavities; Fi interfacial seal counter reaction force 150 N; y number of environmental inserts; Fo fibre optic counter reaction force (see the appropriate EN optical standard); z number of fibre optic contacts. Method B Test curve 3, level G, 8 hours in each 3 directions for disconnect

46、 application connectors. Disconnect connectors fitted with quadrax contacts or rack and panel connectors shall be tested according to Method B test curve 2 level E. 404 Transverse load Already qualified in EN 4644. 405 Axial load Already qualified in EN 4644. 406 Mechanical endurance Number of matin

47、g and unmating operations: Size 1, 2 for Disconnect application: 100 mating/unmating Size 2, 3 and 4 for rack and panel application: 500 mating/unmating The rate shall not exceed five cycles/min. 407 Durability of contact retention system and seals Not applicable. Page 13 TR 4654-003:10-2014 Table 3

48、 (6 to 8) EN 2591- Designation of the test Details 408 Mating and unmating forces Maximum mating forces. Rack and panel connectors: Fm x Fs y Fi z Fo where Fm maximum connector mating force; Fs maximum shell mating force per cavity 250 N; x number of insert cavities; Fi interfacial seal counter reac

49、tion force 150 N; y number of environmental inserts; Fo fibre optic counter reaction force (see the appropriate EN optical standard); z number of fibre optic contacts. Disconnect panel connectors: Size 1 and 2 connectors: Method A. Torques shall be within the limits indicated below with tolerances of 0,1 N.m. Initial After mechanica