ASD-STAN/D 2
Date: 2025-02
prEN 3545‑001:2025
Secretariat: DIN
Aerospace series — Connectors, electrical, rectangular, with sealed and non-sealed rear, plastic housing, locking device, operating temperatures −55 °C to 175 °C — Part 001: Technical specification
Luft- und Raumfahrt — Elektrische Rechtecksteckverbinder mit und ohne hintere Abdichtung, Plastikgehäuse, Verriegelungssystem, Betriebstemperaturen von –55 °C bis 175 °C — Teil 001: Technische Lieferbedingungen
Série aérospatiale — Connecteurs électriques, rectangulaires, étanches et non étanches à l'arrière, à boîtier en plastique, à verrouillage, températures d'utilisation –55 °C à 175 °C — Partie 001 : Spécification technique
CCMC will prepare and attach the official title page.
Contents Page
4.2 Male and female housings 10
5.3 Attachments, polarizing features 12
8.1 Tests according to EN 2591‑100 20
8.2 Special test – Retention of coding and attachment system in insert 28
9.2 Conditions for initial qualification 28
9.2.2 Sampling and specification of specimens 28
9.2.3 Preparation of specimens 29
9.2.4 Programme of qualification tests 29
9.3 Conditions for acceptance testing and inspection 32
9.5 Periodic checks for maintenance of qualification 32
This document (prEN 3545‑001:2025) has been prepared by ASD-STAN.
After enquiries and votes carried out in accordance with the rules of this Association, this document has received the approval of the National Associations and the Official Services of the member countries of ASD-STAN, prior to its presentation to CEN.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 3545‑001:2008.
prEN 3545‑001:2025 includes the following significant technical changes with respect to EN 3545‑001:2008:
— Test 2591-406 Mechanical endurance details added;
— Qualification tests (Table 6): Group 7 compatibility test for zinc-nickel components added.
1.0 Scope
This document specifies the technical requirements of rectangular connectors with sealed and non-sealed rear, plastic housing, locking device, for operating temperatures from –55 °C to 175 °C.
2.0 Normative references
The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document. 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 2591‑100, Aerospace series — Elements of electrical and optical connection — Test methods — Part 100: General
EN 2591‑101, Aerospace series — Elements of electrical and optical connection — Test methods — Part 101: Visual examination
EN 2591‑102, Aerospace series — Elements of electrical and optical connection — Test methods — Part 102: Examination of dimensions and mass
EN 2591‑201, Aerospace series — Elements of electrical and optical connection — Test methods — Part 201: Contact resistance — Low level
EN 2591‑202, Aerospace series — Elements of electrical and optical connection — Test methods — Part 202: Contact resistance at rated current
EN 2591‑203, Aerospace series — Elements of electrical and optical connection — Test methods — Part 203: Electrical continuity at microvolt level
EN 2591‑204, Aerospace series — Elements of electrical and optical connection — Test methods — Part 204: Discontinuity of contacts in the microsecond range
EN 2591‑205, Aerospace series — Elements of electrical and optical connection — Test methods — Part 205: Housing (shell) electrical continuity
EN 2591‑206, Aerospace series — Elements of electrical and optical connection — Test methods — Part 206: Measurement of insulation resistance
EN 2591‑207, Aerospace series — Elements of electrical and optical connection — Test methods — Part 207: Voltage proof test
EN 2591‑208, Aerospace series — Elements of electrical and optical connection — Test methods — Part 208: Temperature rise due to rated current
EN 2591‑209, Aerospace series — Elements of electrical and optical connection — Test methods — Part 209: Current temperature derating
EN 2591‑210, Aerospace series — Elements of electrical and optical connection — Test methods — Part 210: Electrical overload
EN 2591‑213, Aerospace series — Elements of electrical and optical connection — Test methods — Part 213: Shielding effectiveness from 100 MHz to 1 GHz
EN 2591‑216, Aerospace series — Elements of electrical and optical connection — Test methods — Part 216: Engagement depth of contacts
EN 2591‑301, Aerospace series — Elements of electrical and optical connection — Test methods — Part 301: Endurance at temperature
EN 2591‑302, Aerospace series — Elements of electrical and optical connection — Test methods — Part 302: Climatic sequence
EN 2591‑304, Aerospace series — Elements of electrical and optical connection — Test methods — Part 304: Damp heat steady state
EN 2591‑305, Aerospace series — Elements of electrical and optical connection — Test methods — Part 305: Rapid change of temperature
EN 2591‑306, Aerospace series — Elements of electrical and optical connection — Test methods — Part 306: Mould growth
EN 2591‑307, Aerospace series — Elements of electrical and optical connection — Test methods — Part 307: Salt mist
EN 2591‑308, Aerospace series — Elements of electrical and optical connection — Test methods — Part 308: Sand and dust
EN 2591‑309, Aerospace series — Elements of electrical and optical connection — Test methods — Part 309: Dry heat
EN 2591‑310, Aerospace series — Elements of electrical and optical connection — Test methods — Part 310: Cold
EN 2591‑311, Aerospace series — Elements of electrical and optical connection — Test methods — Part 311: Low air pressure
EN 2591‑312, Aerospace series — Elements of electrical and optical connection — Test methods — Part 312: Air leakage
EN 2591‑313, Aerospace series — Elements of electrical and optical connection — Test methods — Part 313: Artificial rain
EN 2591‑314, Aerospace series — Elements of electrical and optical connection — Test methods — Part 314: Immersion at low air pressure
EN 2591‑315, Aerospace series — Elements of electrical and optical connection — Test methods — Part 315: Fluid resistance
EN 2591‑316, Aerospace series — Elements of electrical and optical connection — Test methods — Part 316: Ozone resistance
EN 2591‑317, Aerospace series — Elements of electrical and optical connection — Test methods — Part 317: Flammability
EN 2591‑318, Aerospace series — Elements of electrical and optical connection — Test methods — Part 318: Fire-resistance
EN 2591‑319, Aerospace series — Elements of electrical and optical connection — Test methods — Part 319: Gastightness of solderless wrapped connections
EN 2591‑320, Aerospace series — Elements of electrical and optical connection — Test methods — Part 320: Simulated solar radiation at ground level
EN 2591‑321, Aerospace series — Elements of electrical and optical connection — Test methods — Part 321: Damp heat, cyclic test
EN 2591‑322, Aerospace series — Elements of electrical and optical connection — Test methods — Part 322: Hermeticity
EN 2591‑323, Aerospace series — Elements of electrical and optical connection — Test methods — Part 323: Thermal shock
EN 2591‑324, Aerospace series — Elements of electrical and optical connection — Test methods — Part 324: Interfacial sealing
EN 2591‑401, Aerospace series — Elements of electrical and optical connection — Test methods — Part 401: Acceleration, steady state
EN 2591‑402, Aerospace series — Elements of electrical and optical connection — Test methods — Part 402: Shock
EN 2591‑403, Aerospace series — Elements of electrical and optical connection — Test methods — Part 403: Sinusoidal and random vibration
EN 2591‑404, Aerospace series — Elements of electrical and optical connection — Test methods — Part 404: Transverse load
EN 2591‑405, Aerospace series — Elements of electrical and optical connection — Test methods — Part 405: Axial load
EN 2591‑406, Aerospace series — Elements of electrical and optical connection — Test methods — Part 406: Mechanical endurance
EN 2591‑407, Aerospace series — Elements of electrical and optical connection — Test methods — Part 407: Durability of contact retention system and seals
EN 2591‑408, Aerospace series — Elements of electrical and optical connection — Test methods — Part 408: Mating and unmating forces
EN 2591‑409, Aerospace series — Elements of electrical and optical connection — Test methods — Part 409: Contact retention in insert
EN 2591‑410, Aerospace series — Elements of electrical and optical connection — Test methods — Part 410: Insert retention in housing (axial)
EN 2591‑411, Aerospace series — Elements of electrical and optical connection — Test methods — Part 411: Insert retention in housing (torsional)
EN 2591‑412, Aerospace series — Elements of electrical and optical connection — Test methods — Part 412: Contact insertion and extraction forces
EN 2591‑413, Aerospace series — Elements of electrical and optical connection — Test methods — Part 413: Holding force of grounding spring system
EN 2591‑414, Aerospace series — Elements of electrical and optical connection — Test methods — Part 414: Unmating of lanyard release connectors
EN 2591‑415, Aerospace series — Elements of electrical and optical connection — Test methods — Part 415: Test probe damage (female contacts)
EN 2591‑416, Aerospace series — Elements of electrical and optical connection — Test methods — Part 416: Contact bending strength
EN 2591‑417, Aerospace series — Elements of electrical and optical connection — Test methods — Part 417: Tensile strength (crimped connection)
EN 2591‑418, Aerospace series — Elements of electrical and optical connection — Test methods — Part 418: Gauge insertion/extraction forces (female contacts)
EN 2591‑419, Aerospace series — Elements of electrical and optical connection — Test methods — Part 419: Stability of male contacts in insert
EN 2591‑420, Aerospace series — Elements of electrical and optical connection — Test methods — Part 420: Mechanical strength of rear accessories
EN 2591‑421, Aerospace series — Elements of electrical and optical connection — Test methods — Part 421: Free fall
EN 2591‑424, Aerospace series — Elements of electrical and optical connection — Test methods — Part 424: Stripping force, solderless wrapped connections
EN 2591‑425, Aerospace series — Elements of electrical and optical connection — Test methods — Part 425: Unwrapping capability, solderless wrapped connections
EN 2591‑426, Aerospace series — Elements of electrical and optical connection — Test methods — Part 426: Contact retention system effectiveness
EN 2591‑427, Aerospace series — Elements of electrical and optical connection — Test methods — Part 427: Robustness of protective cover attachment
EN 2591‑502, Aerospace series — Elements of electrical and optical connection — Test methods — Part 502: Restricted entry
EN 2591‑503, Aerospace series — Elements of electrical and optical connection — Test methods — Part 503: Contact deformation after crimping
EN 2591‑505, Aerospace series — Elements of electrical and optical connection — Test methods — Part 505: Contact protection effectiveness (scoop-proof)
EN 2591‑506, Aerospace series — Elements of electrical and optical connection — Test methods — Part 506: Use of tools
EN 2591‑513, Aerospace series — Elements of electrical and optical connection — Test methods — Part 513: Magnetic permeability
EN 3155‑001,[1] Aerospace series — Electrical contacts used in elements of connection — Part 001: Technical specification
EN 3155‑003, Aerospace series — Electrical contacts used in elements of connection — Part 003: Contacts, electrical, female, type A, crimp, class S — Product standard
EN 3155‑008, Aerospace series — Electrical contacts used in elements of connection — Part 008: Contacts, electrical, male, type A, crimp, class S — Product standard
EN 3155‑070, Aerospace series — Electrical contacts used in elements of connection — Part 070: Contacts, electrical, male, type A, crimp, class S — Product standard
EN 3155‑071, Aerospace series — Electrical contacts used in elements of connection — Part 071: Contacts, electrical, female, type A, crimp, class S — Product standard
EN 3197,1 Aerospace series — Design and installation of aircraft electrical and optical interconnection systems
EN 3545‑002, Aerospace series — Connectors, electrical, rectangular, with sealed and non-sealed rear, plastic housing, locking device, operating temperatures - 55 °C to 175 °C — Part 002: Specification of performance and contact arrangements
EN 4529‑002, Aerospace series — Elements of electrical and optical connection — Sealing plugs — Part 002: Index of product standards
EN 9133, Aerospace series — Quality Management Systems — Qualification Procedure for Aerospace Standard Products
AS 1241C,[2] Fire resistant phosphate ester hydraulic fluid for aircraft
SAE AMS 1424G,2 Deicing/anti-icing fluid, aircraft, SAE type I
MIL-PRF-7870C,[3] Lubricating oil, general purpose, low temperature
MIL-PRF-23699F,3 Lubricating oil, aircraft turbine engine, synthetic base — NATO code number O-156
MIL-PRF-87937D,3 Cleaning compounds, aerospace equipment
FED-STD-H28A,3 Screw-thread standards for federal services
3.0 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 2591‑100 apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at https://www.electropedia.org/
4.0 Description
4.1 General
A pair of connectors comprises:
— a male housing fitted with female crimp contacts (code F);
— a female housing fitted with male crimp contacts and having an interfacial seal which provides sealing at each contact when the connectors are mated (code M).
These housings are fitted with polarizing systems permitting 36 combinations.
They are able to take a cable clamp and comprise a locking device at each end.
There are two types of connectors:
— sealed, grommet provided for sealing of cables at the rear (code E);
— non-sealed, grommet provided for non abrasion of cables at the rear (code D).
4.1.1 Male and female housings
There is one size of housing and twelve contact arrangements as shown in Table 1.
According to also Figures 2 to Figure 13.
Table 1 — Contact arrangement and housing size
Arrangement number | Number of contacts | |||||||
|---|---|---|---|---|---|---|---|---|
Size 22a | Size 22b | Size 20 | Size 16 | Size 12 | Size 10 | Size 8 | ||
01 | 0 | 0 | 50 | 0 | 0 | 0 | 0 | |
02 | 78 | 0 | 0 | 0 | 0 | 0 | 0 | |
03 | 39 | 0 | 0 | 10 | 0 | 0 | 0 | |
04 | 0 | 0 | 0 | 21 | 0 | 0 | 0 | |
05 | 0 | 0 | 0 | 0 | 13 | 0 | 0 | |
06 | 0 | 0 | 0 | 0 | 0 | 7 | 0 | |
07 | 0 | 0 | 0 | 0 | 0 | 0 | 5 | |
08 | 0 | 0 | 18 | 0 | 0 | 0 | 3 | |
09 | 0 | 0 | 25 | 12 | 0 | 0 | 0 | |
12 | 78 | 78 | 0 | 0 | 0 | 0 | 0 | |
13 | 39 | 39 | 0 | 10 | 0 | 0 | 0 | |
16 | 0 | 0 | 0 | 0 | 0 | 7 | 0 | |
a Contacts size 22 according to EN 3155‑003 and EN 3155‑008. b Contacts size 22 according to EN 3155‑003 and EN 3155‑008 or EN 3155‑070 and EN 3155‑071. | ||||||||
4.1.2 Materials
4.1.3 General
The materials which are not specified or are not specially described, shall be as light as possible for the required application.
Materials are chosen according to safety criteria as specified by the authority of certification.
When dissimilar metals are in close contact, adequate protection against corrosion shall be provided such that the electromotive force of the galvanic couple shall not exceed 0,25 V.
4.1.4 Housings
These are made of rigid material with high dielectric qualities which will not deteriorate under normal conditions of operation and ageing.
4.1.5 Contacts
Contacts shall comply with the requirements of EN 3155‑001.
5.0 Design
5.1 Housings
In the sealed and non-sealed types, the grommet shall be attached to the housing.
Identification of the various positions used for coding by the position indicator which appears on the attachments is given in EN 3545‑002.
Identification of the contact cavities shall be consistent with Figures 3 to 14 in EN 3545‑002.
5.1.1 Contacts
Removable contacts shall be inserted and extracted via the rear of the connector.
The insertion and extraction tools shall be introduced via the rear of the connector. For connectors which are not sealed at the rear, it shall be possible to insert the contact without a tool, unless the mechanical strength of the wires prevents this.
5.1.2 Attachments, polarizing features
They are constituted by two integral elements, which are removable from each housing with the aid of metal tools specified by EN 3545‑008 and provide:
— rapid attachment of housings to boards;
— attachment of male housings to female housings;
— necessary polarization between male and female housings.
The threads shall comply with FED-STD-H28A.
It shall be impossible to mate housings when these are polarized differently.
5.1.3 Cable clamp
The cable clamp, made of insulating material, shall be easy to fit and remove, shall be independent of the housing attachment system and shall not require any special fastener.
The wires are held by means of a cable tie or lacing cord.
6.0 Dimensions and masses
The general dimensions and the mass of the various elements which make up a pair of connectors are given in product standards.
Dimensions shall be according to Table 1.
Dimensions and tolerances are in millimetres.
Key
1 | 0,9 min. (see NOTE 1) | 6 | Connector with male contacts |
2 | 2,4 max. for contact size 20 2,3 max. for other sizes (see NOTE 2) | 7 | Male coding and attachment system |
3 | 1 to 1,9 (see NOTE 3) | 8 | Female coding and attachment system |
4 | 0,03 to 0,58 for arrangements 01 to 06 0,05 to 0,60 for arrangements 07 and 08 | 9 | Connector with female contacts |
5 | 1,27 min. for quadrax contacts (see NOTE 1) | a | Applicable dimensions for contact arrangement 07 and 08 |
NOTE 1 Electrical engagement of contacts.
NOTE 2 Extreme limit position of electrical point of female contact.
NOTE 3 Extreme limit position of male contact, maximum axial clearance: 0,5
Figure 1 — Dimensions
7.0 Contact arrangements
7.1 General
The theoretical positions in the various contact arrangements are specified in Figures 2 to 13, which show the front face (mating) of female housings (male contacts).
Identification of the contact cavities consists of:
— identification of the end cavities in each row;
— identification of the 10th cavity and its multiples using the following symbols (except for arrangements 04, 05, 06, 07 and 09);
— oblique line joining together size 22 contact cavities,
— opposite chevrons for size 20 contact cavities.
— Arrangement 01
50 contacts, size 20
According to Figure 2.
Figure 2 — Arrangement 01
7.1.1 Arrangement 02
78 contacts, size 22 according to EN 3155‑003 and EN 3155‑008.
According to Figure 3.
Figure 3 — Arrangement 02
7.1.2 Arrangement 03
39 contacts, size 22 according to EN 3155‑003 and EN 3155‑008.
10 contacts, size 16
According to Figure 4.
Figure 4 — Arrangement 03
7.1.3 Arrangement 04
21 contacts, size 16.
According to Figure 5.
Figure 5 — Arrangement 04
7.1.4 Arrangement 05
13 contacts, size 12
According to Figure 6.
Figure 6 — Arrangement 05
7.1.5 Arrangement 06
7 contacts, size 10
According to Figure 7.
Figure 7 — Arrangement 06
7.1.6 Arrangement 07
5 contacts, size 8 (indexed or not)
According to Figure 8.
NOTE Identification of the polarization key of the size 8 contact only on the rear grommet.
Figure 8 — Arrangement 07
7.1.7 Arrangement 08
18 contacts, size 20
3 contacts, size 8 (indexed or not)
According to Figure 9.
NOTE Identification of the polarization key of the size 8 contact only on the rear grommet.
Figure 9 — Arrangement 08
7.1.8 Arrangement 09
25 contacts, size 20
12 contacts, size 16
According to Figure 10.
Figure 10 — Arrangement 09
7.1.9 Arrangement 12
78 contacts, size 22 according to EN 3155‑003 and EN 3155‑008 or EN 3155‑070 and EN 3155‑071.
According to Figure 11.
Figure 11 — Arrangement 12
7.1.10 Arrangement 13
39 contacts, size 22 according to EN 3155‑003 and EN 3155‑008 or EN 3155‑070 and EN 3155‑071.
10 contacts, size 16
According to Figure 12.
Figure 12 — Arrangement 13
7.1.11 Arrangement 16
7 contacts, size 10
According to Figure 13.
NOTE This connector is offering a longer body than arrangement 06
Figure 13 — Arrangement 16
8.0 Tests
8.1 Tests according to EN 2591‑100
The tests in EN 2591‑100 applicable in the context of this document, as well as the details necessary for implementing them and for inspecting the connector characteristics, are given in Table 2. Fluid resistance tests shall be according to Table 3.
Table 2 — Tests
Part of the EN 2591-series | Designation of the test | Details | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
EN 2591‑101 | Visual examination | Initial examination; examination of connectors, accessories, loose parts (contacts, etc.) Details to be examined: — identification; — appearance; — marking; — surface finish. Final examination: no loosening of parts, no cracks, no trace of carbon, no excessive wear or no detached part shall be observed. | |||||||||||||||
EN 2591‑102 | 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. | |||||||||||||||
EN 2591‑201 | Contact resistance – Low level | As per EN 3155‑001 | |||||||||||||||
EN 2591‑202 | Contact resistance at rated current | As per EN 3155‑001 | |||||||||||||||
EN 2591‑203 | Electrical continuity at microvolt level | Not applicable | |||||||||||||||
EN 2591‑204 | Discontinuity of contacts in the microsecond range | Method B Duration of discontinuity: ≤ 1 µs Test duration: throughout the duration of tests EN 2591‑402 (Shock) and EN 2591‑403 (Vibration) | |||||||||||||||
EN 2591‑205 | Housing (shell) electrical continuity | Not applicable | |||||||||||||||
EN 2591‑206 | Measurement of insulation resistance | Method C – Connectors mated, unless otherwise specified below — at ambient temperature: 5 000 MΩ min. — during tests EN 2591‑301, EN 2591‑314, EN 2591‑324: 1 000 MΩ min. (connectors mated) — after tests EN 2591‑301, EN 2591‑314, EN 2591‑315, EN 2591‑324: 1 000 MΩ min. — after test EN 2591‑304: 100 MΩ min. — during test EN 2591‑403: 5 000 MΩ min. | |||||||||||||||
EN 2591‑207 | Voltage proof test | Method C, connectors mated and unmated according to table below | |||||||||||||||
|
| Pressure | Contact size | Connectors |
| ||||||||||||
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| Mated | Unmated |
| |||||||||||||
V r.m.s. | V r.m.s. | ||||||||||||||||
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| Ambient |
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| — Initial measurement and after test EN 2591‑304 | 22 20,16,12,10,8 | – – | 1 500 1 500 |
| |||||||||||
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| After test EN 2591‑324 | 22 20,16,12,10,8 | 1 500 1 500 | – – |
| |||||||||||
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| During test EN 2591‑311 | 22,20,16,12,10,8 | – | 600 |
| |||||||||||
|
| Maximum leakage current 2 mA Where unmated connectors are used, the requirements in EN 3197 shall be followed. | |||||||||||||||
EN 2591‑208 | Temperature rise due to rated current | Not applicable | |||||||||||||||
EN 2591‑209 | Current temperature derating | See Table 2 of EN 3545‑002. Not applicable for qualification. Heating due to current flow shall not cause the maximum temperature to be exceeded. | |||||||||||||||
EN 2591‑210 | Electrical overload | As per EN 3155‑001 | |||||||||||||||
EN 2591‑213 | Shielding effectiveness from 100 MHz to 1 GHz | Not applicable | |||||||||||||||
EN 2591‑216 | Engagement of contacts | Not applicable | |||||||||||||||
EN 2591‑301 | Endurance at temperature | Method B Test under load: applicable Temperature: (175 ± 3) °C Duration: 1 000 h | |||||||||||||||
EN 2591‑302 | Climatic sequence | Not applicable | |||||||||||||||
EN 2591‑303 | Cold/low pressure and damp heat | Not applicable | |||||||||||||||
EN 2591‑304 | Damp heat steady-state | Connectors mated Severity: 56 d d.c. polarization voltage: 5 V | |||||||||||||||
EN 2591‑305 | Rapid change of temperature | Connectors mated TA ≥ = ( TB = ( | |||||||||||||||
EN 2591‑306 | Mould growth | Not applicable | |||||||||||||||
EN 2591‑307 | Salt mist | The unmated connectors shall be suspended in the test chamber with non-metallic cords, so that no accumulation of condensed saline solution can occur; the position of the contacts shall nevertheless be horizontal Duration: 48 h | |||||||||||||||
EN 2591‑308 | Sand and dust | Not applicable | |||||||||||||||
EN 2591‑309 | Dry heat | Not applicable | |||||||||||||||
EN 2591‑310 | Cold | Not applicable | |||||||||||||||
EN 2591‑311 | Low air pressure | Applicable – Pressure 14,7 kPa | |||||||||||||||
EN 2591‑312 | Air leakage | Not applicable | |||||||||||||||
EN 2591‑313 | Driving rain (artificial) | Not applicable | |||||||||||||||
EN 2591‑314 | Immersion at low air pressure | Applicable | |||||||||||||||
EN 2591‑315 | Fluid resistance | See Table 3 for types of fluids, number of cycles, temperature and time of immersion and temperature for the third phase. | |||||||||||||||
EN 2591‑316 | Ozone resistance | Applicable | |||||||||||||||
EN 2591‑317 | Flammability | Test performed on connectors with sealed and non-sealed rear, without contacts and with cable clamp Method A | |||||||||||||||
EN 2591‑318 | Fire-resistance | Not applicable | |||||||||||||||
EN 2591‑319 | Gastightness of solderless wrapped connections | Not applicable | |||||||||||||||
EN 2591‑320 | Simulated solar radiation at ground level | Not applicable | |||||||||||||||
EN 2591‑321 | Damp heat, cyclic test | Not applicable | |||||||||||||||
EN 2591‑322 | Hermeticity | Not applicable | |||||||||||||||
EN 2591‑323 | Thermal shock | Not applicable | |||||||||||||||
EN 2591‑324 | Interfacial sealing | The rear of non-sealed connectors is sealed with resin except the central hole. The connectors are mated. A locking torque in the range 0,06 daN.m to 0,10 daN.m is applied to the locking screws. Pressure: 14,7 kPa | |||||||||||||||
EN 2591‑401 | Acceleration, steady-state | Not applicable | |||||||||||||||
EN 2591‑402 | Shock | The connectors are mounted on a panel, 1 mm deep. A tightening torque in the range 0,125 daN.m to 0,150 daN.m is applied to the locking screws. Mounting method: The connector is mounted on the table of the shock generator using a standard mounting arrangement. The mounting shall be as rigid as possible. The wires equipping the two connectors shall be attached to the generator Table 200 mm from the connector (without intermediate binding). Method A: severity 50 Number of shocks in each direction: 6 | |||||||||||||||
EN 2591‑403 | Sinusoidal and random vibration | The connectors are mounted on a panel, 1 mm deep. A tightening torque in the range 0,125 daN.m to 0,150 daN.m is applied to the locking screws. Mounting method: The connector is mounted on the vibration generator table using a standard mounting arrangement. The mounting shall be as rigid as possible. The wires equiping the two connectors shall be attached 200 mm from each connector at a non-vibrating point (without intermediate binding). Method A, Figure 1; 20 gn (level 2) Duration: 4 h per axis | |||||||||||||||
EN 2591‑404 | Transverse load | Not applicable | |||||||||||||||
EN 2591‑405 | Axial load | Not applicable | |||||||||||||||
EN 2591‑406 | Mechanical endurance | In each cycle, after full manual connection of connectors, torque the locking screws to (0,08 ± 0,02) daN.m Number of cycles: 100 The rate shall not exceed 6 cycles/min. Rate: 5 mm/s | |||||||||||||||
EN 2591‑407 | Durability of contact retention system and seals | Not applicable | |||||||||||||||
EN 2591‑408 | Mating and unmating forces | Methods A and B Temperature for method B: – 25 °C Rate: 5 mm/s | |||||||||||||||
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| Arrangement | Number of contacts | Mating and unmating forces |
| |||||||||||
No. | |||||||||||||||||
N | |||||||||||||||||
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| min. | max. |
| ||||||||||
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| 01 | 50 | 14,5 | 166 |
| ||||||||||
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| 02 | 78 | 23,4 | 210 |
| ||||||||||
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| 03 | 49 | 14,0 | 162 |
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| 04 | 21 | 08,8 | 182 |
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| 05 | 13 | 09,2 | 113 |
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| 06 | 07 | 06,0 | 121 |
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| 07 | 05 | 07,1 | 227 |
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| 08 | 21 | 8,3 | 238 |
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| 09 | 37 | 14 | 162 |
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| 12 | 78 | 23,4 | 210 |
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| 13 | 49 | 14 | 162 |
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| 16 | 07 | 6 | 121 |
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EN 2591‑409 | Contact retention in insert | Preload: 2 N The load is applied from the front face towards the rear face. Force: 40 N for contact size 22 60 N for contact size 20 110 N for contact sizes 16, 12, 10 and 8 Displacement < 0,3 mm during application of the load | |||||||||||||||
EN 2591‑410 | Insert retention in housing (axial) | Value of load applied: 350 N | |||||||||||||||
EN 2591‑411 | Insert retention in housing (torsional) | Not applicable | |||||||||||||||
EN 2591‑412 | Contact insertion and extraction forces | See 5.2. | |||||||||||||||
|
|
| Contact size | Maximum insertion and extraction forces in daN |
| ||||||||||||
|
|
| Sealed connector | Non-sealed connector |
| ||||||||||||
|
|
| 22 | 01,5 | 0,25 |
| |||||||||||
|
|
| 20 | 01,5 | 0,25 |
| |||||||||||
|
|
| 16 | 03,0 | 0,60 |
| |||||||||||
|
|
| 12 | 07,0 | 0,80 |
| |||||||||||
|
|
| 10 | 09,0 | 1,00 |
| |||||||||||
|
|
| 08 | 30,0 | – |
| |||||||||||
|
|
| |||||||||||||||
EN 2591‑413 | Holding force of grounding spring system | Not applicable | |||||||||||||||
EN 2591‑414 | Unmating of lanyard release connectors | Not applicable | |||||||||||||||
EN 2591‑415 | Test probe damage (female contacts) | Not applicable | |||||||||||||||
EN 2591‑416 | Contact bending strength | Not applicable | |||||||||||||||
EN 2591‑417 | Tensile strength (crimped connection) | Not applicable | |||||||||||||||
EN 2591‑418 | Gauge insertion/extraction forces (female contacts) | See contact standard. | |||||||||||||||
EN 2591‑419 | Stability of male contacts in insert | Not applicable | |||||||||||||||
EN 2591‑420 | Mechanical strength of rear accessories | Phase A only – Application of a torque of 4,7 N.m on the end of the cable clamp in front of the binding zone | |||||||||||||||
EN 2591‑421 | Free fall | Applicable | |||||||||||||||
EN 2591‑424 | Stripping force, solderless wrapped connections | Not applicable | |||||||||||||||
EN 2591‑425 | Unwrapping capability, solderless wrapped connections | Not applicable | |||||||||||||||
EN 2591‑426 | Contact retention system effectiveness (removable contact walkout) | Multistrand steel cable of a cross section which can fit in the contact bucket Force applied: 13 N (all contact sizes) | |||||||||||||||
EN 2591‑427 | Robustness of protective cover attachment | Not applicable | |||||||||||||||
EN 2591‑502 | Restricted entry | Not applicable | |||||||||||||||
EN 2591‑503 | Contact deformation after crimping | Not applicable | |||||||||||||||
EN 2591‑505 | Contact protection effectiveness (scoop-proof) | Not applicable | |||||||||||||||
EN 2591‑506 | Use of tools | Not applicable | |||||||||||||||
EN 2591‑513 | Magnetic permeability | ≤ 2 | |||||||||||||||
) °C
) °CTable 3 — Resistance to fluids
Fluid | Immersion | Stoving | Number of cycles | ||||
|---|---|---|---|---|---|---|---|
Category | References | Duration | Temp. | Temp. | |||
°C | °C | ||||||
min | |||||||
Fuel | JP5 | NATO F-44 | 5 | + 2 0 | 25 | 85 | 7 |
Synthetic hydraulic fluid | SAE AS 1241C | Skydrol 500 B4 Skydrol LD 4 | 15 | + 5 0 | 85 | 100 | 5 |
Mineral lubricant | MIL-PRF-7870C | NATO O-142 | 15 | + 5 0 | 120 | 125 | 5 |
Synthetic lubricant | MIL-PRF-23699F | NATO O-156 | 15 | + 5 0 | 150 | 125 | 5 |
Cleaning products | MIL-PRF-87937D, diluted | — | 15 | + 5 0 | 25 | 25 | 5 |
25 % Propanol + 75 % White spirit | |||||||
Methyl Ethyl Ketone | ASTM0740 | 5 | + 2 0 | 2 | |||
De-icing fluid | SAE AMS 1424G | NATO S-742 | 15 | + 5 0 | 50 | 100 | 5 |
Extinguishing fluid | Bromotrifluoromethane | DUPONT FE1301 | 15 | + 5 0 | − 15 | 25 | 5 |
Cooling fluid | Coolanol | — | 15 | + 5 0 | 50 | 25 | 5 |
8.1.1 Special test – Retention of coding and attachment system in insert
According to Table 4.
Table 4 — Retention of coding and attachment system in inserts
Title | Details |
|---|---|
Retention of coding and attachment system in insert | After performing 15 cycles of fitting/removing the coding and attachment system, a force of 20 daN is applied progressively on the mating face side. The coding and attachment system shall remain in their housing and no defect liable to impair operation shall be found. |
9.0 Quality assurance
9.1 General
Quality assurance shall be according to EN 9133.
9.1.1 Conditions for initial qualification
9.1.2 General
Qualification of a model is obtained:
— either when the specimens of this model as specified in 9.2.2 have satisfied the applicable tests in groups 0 to 6;
— or by extension of qualification approval for versions not submitted at the time of initial qualification:
— for a new contact arrangement, only test groups 0, 1, 2, 3 and 4 then need to be performed;
— for sealed connectors, only test EN 2591‑102, group 1 up to test EN 2591‑324 inclusive, and their requirements (tests EN 2591‑206 and EN 2591‑207), groups 4 and 6 then need to be performed.
9.1.3 Sampling and specification of specimens
The specimens of the model to be qualified are divided equally, on the one hand into each of the contact arrangements and on the other, into pairs of sealed and non-sealed connectors (see Table 5).
The specimens are pairs of connectors and unless otherwise specified are fitted with contacts, cable clamps, attachment and coding systems:
Table 5 specifies the sample distribution for the simultaneous qualification of the sealed and unsealed versions.
In the event of the first qualification of a single version, all the test groups shall be performed on samples from the accepted version.
Table 5 — Sampling and specification of specimens
Test group | Number of specimens (pairs) per arrangement | |
|---|---|---|
Non-sealed type (D) | Sealed type (E) | |
0 | Complete sample | |
1 | – | 6 pairs wireda |
2 | 6 pairs wireda | – |
3 | 6 pairs wireda | – |
4 | 1 wired pair per fluid typeb ≥ c | |
5 | 1 wired pairb ≥ c | |
6 | 1 non-wired pairb | 1 non-wired pair |
a The sample shall be representative of all contacts arrangements and sizes submitted for qualification. b To be done on one contact arrangement only. c One pair including one sealed connector and one non-sealed connector. | ||
9.1.4 Preparation of specimens
In order to achieve consistency in testing, the connectors shall be wired with round cables, free from any roughness likely to cause the penetration of humidity or liquid to the inside of the connector. The cables shall conform to EN 2266‑002 in the case of cables for general use, operating temperature 200 °C and their dimensions shall comply with Table 1 of EN 3545‑002. They shall be approximately 1 m in length.
Half of the specimens shall be wired with cable the external diameter of which is closest to the maximum diameter, the other half shall be wired with cable the external diameter of which is closest to the minimum diameter.
9.1.5 Programme of qualification tests
The qualification tests are specified in Table 6 and shall be performed in the order indicated.
Table 6
Tests | Part of the EN 2591-series | Remarks |
|---|---|---|
Group 0 |
| All models |
Visual examination | EN 2591‑101 |
|
Examination of dimensions and mass | EN 2591‑102 | To be performed on one pair per layout, in sealed and un-sealed versions |
Contact insertion and extraction forces | EN 2591‑412 | To be performed on one pair per layout, in sealed and un-sealed versions |
Measurement of insulation resistance | EN 2591‑206 | Only specimens of group 6 |
Voltage proof test | EN 2591‑207 | Only specimens of group 6 |
Contact resistance - Low level | EN 2591‑201 |
|
Contact resistance at rated current | EN 2591‑202 |
|
Mating and unmating forces | EN 2591‑408 | On specimens of groups 2, 4 and 6 |
Visual examination | EN 2591‑101 |
|
Group 1 |
|
|
Rapid change of temperature | EN 2591‑305 |
|
Visual examination | EN 2591‑101 |
|
Interfacial sealing | EN 2591‑324 |
|
Measurement of insulation resistance | EN 2591‑206 | Immersed connectors |
Voltage proof test | EN 2591‑207 | Immersed connectors |
Insert retention in housing (axial) | EN 2591‑410 |
|
Contact retention in insert | EN 2591‑409 |
|
Mechanical strength of rear accessories | EN 2591‑420 |
|
Contact retention system effectiveness (removable contact walkout) | EN 2591‑426 |
|
Visual examination | EN 2591‑101 |
|
Group 2 |
|
|
Contact retention in insert | EN 2591‑409 |
|
Retention of coding and attachment system in insert | − | See 8.2. |
Rapid change of temperature | EN 2591‑305 |
|
Low air pressure | EN 2591‑311 |
|
Mechanical endurance | EN 2591‑406 |
|
Mating and unmating forces | EN 2591‑408 |
|
Engagement of contacts | EN 2591‑216 |
|
Shock | EN 2591‑402 |
|
Sinusoidal and random vibration | EN 2591‑403 |
|
Damp heat steady-state | EN 2591‑304 |
|
Measurement of insulation resistance | EN 2591‑206 |
|
Voltage proof test | EN 2591‑207 |
|
Visual examination | EN 2591‑101 |
|
Group 3 |
|
|
Electrical overload | EN 2591‑210 |
|
Endurance at temperature | EN 2591‑301 |
|
Contact resistance at rated current | EN 2591‑202 |
|
Measurement of insulation resistance | EN 2591‑206 |
|
Voltage proof test | EN 2591‑207 |
|
Visual examination | EN 2591‑101 |
|
Group 4 |
|
|
Fluid resistance | EN 2591‑315 |
|
Measurement of insulation resistance | EN 2591‑206 | Except after synthetic hydraulic fluids |
Mating and unmating forces | EN 2591‑408 |
|
Contact retention in insert | EN 2591‑409 |
|
Visual examination | EN 2591‑101 |
|
Group 5 |
|
|
Ozone resistance | EN 2591‑316 |
|
Measurement of insulation resistance | EN 2591‑206 |
|
Visual examination | EN 2591‑101 |
|
Group 6 |
|
|
Salt mist | EN 2591‑307 |
|
Free fall | EN 2591‑421 |
|
Mating and unmating forces | EN 2591‑408 |
|
Flammability | EN 2591‑317 |
|
Visual examination | EN 2591‑101 |
|
Group 7 (compatibility test for Zinc/Nickel components): Mechanical endurance | EN 2591‑406 | Coding and attachment systems non installed in connectors. Only 20 cycles |
Salt mist | EN 2591‑307 | This test, substantiate male and female coding and attachment system. Pair one cadmium 006 and one zinc/nickel 005 Pair one cadmium 005 and one zinc/nickel 006 Unpair One cadmium 005 and one zinc/nickel 006 unpair one cadmium 005 and one zinc/nickel 006 |
Visual examination | EN 2591‑101 | Uncoupling the coding and attachment system |
9.2 Conditions for acceptance testing and inspection
Unless otherwise specified in the contract, the manufacturer shall be responsible for carrying out all the batch and production inspections.
Production inspections shall be done systematically on all productions prior to delivery according to
EN 2591‑101.
9.2.1 Quality control
These inspections which are intended to maintain the required quality level are, in their entirety, the responsibility of the manufacturer, ranging from materials through to delivery of the product.
The quality department of the manufacturer shall be able to demonstrate, at any given time, that the product complies with the manufacturing documentation and with the individual specification of the particular product.
There shall be a monitoring system in place for the various inspection phases. This shall be evidenced by documents kept available by the manufacturer for a period of five years and submitted to the national Official Services on request.
9.2.2 Periodic checks for maintenance of qualification
These checks are done by sampling as follows: the cycle is two years or after the manufacture of 50 000 connectors (all contact sizes and arrangements combined).
The manufacturer shall undertake to send the authorizing body a summary of all the tests done in accordance with Table 7, together with the associated documents.
An inspection batch comprises at least four pairs of connectors per contact size and arrangements, spread over groups 1 and 2 as shown in Table 7.
Table 7 — Qualification maintenance sampling
Test group | Number of specimens (pairs) per arrangement |
|---|---|
1 | 2 wired pairs |
2 | 2 wired pairs |
Table 8 — Qualification maintenance tests
Tests | Part of the EN 2591-series | Remarks |
|---|---|---|
Group 1 |
|
|
Visual examination | EN 2591‑101 |
|
Examination of dimensions and mass | EN 2591‑102 |
|
Measurement of insulation resistance | EN 2591‑206 |
|
Voltage proof test | EN 2591‑207 |
|
Mechanical endurance | EN 2591‑406 |
|
Interfacial sealing | EN 2591‑324 |
|
Measurement of insulation resistance | EN 2591‑206 |
|
Voltage proof test | EN 2591‑207 |
|
Mating and unmating forces | EN 2591‑408 |
|
Group 2 |
|
|
Visual examination | EN 2591‑101 |
|
Retention of coding and attachment system in insert | − | See 8.2. |
Endurance at temperature | EN 2591‑301 |
|
Measurement of insulation resistance | EN 2591‑206 |
|
Voltage proof test | EN 2591‑207 |
|
Contact retention in insert | EN 2591‑409 |
|
Visual examination | EN 2591‑101 |
|
If an inspection batch fails the periodic check, the manufacturer shall undertake remedial action on the connector, on the manufacturing process or on both if necessary. The tests specified in Table 8 are then repeated to confirm that the remedial action has been effective.
10.0 Designation and marking
10.1 Designation
According to product standards.
10.1.1 Marking
Marking shall be applied to the connectors and cable clamps.
Unless there are specific contractual requirements, the marking shall include:
— the designation in accordance with product standards;
— the date of manufacture (year/week);
— the manufacturer's name or trade mark.
11.0 Delivery conditions
Unless otherwise specified in the order, connectors delivered with contacts are supplied with filler plugs according to EN 4529‑002, the quantity of which shall be 15 % of the number of contacts, with a minimum of one per contact size.
When specially requested in the order, connectors shall be delivered complete with a plastic protective cover on the connection areas (front faces).
12.0 Packaging
The connectors with, if applicable, their contacts, coding and attachment systems, shall be packed in transparent, inert plastic bag.
The contacts and filler plugs shall be packed in a rigid box to prevent damage.
Designation affixed on the packaging of connectors shall include:
— the identity block specified in 10.1;
— the manufacturer's name or trade mark;
— the manufacturer's part number;
— the date of manufacture (year/week).
13.0 Storage
Storage shall be in a place free from ultraviolet rays.
Every five years, an inspection shall be made in accordance with test EN 2591‑101.
The date of inspection shall be marked on the connector which shall be re-packed in accordance with Clause 12.
EN 3545‑008, Aerospace series — Connectors, electrical, rectangular, with sealed and non-sealed rear, plastic housing, locking device, operating temperatures - 55 C to 175 C — Part 008: Tools for assembly/removal of coding and attachment system — Product standard
Published as ASD-STAN prEN at the date of publication of this document, available at: https://www.asd-stan.org/. ↑
Published by Society of Automotive Engineers (SAE), available at: https://www.sae.org/. ↑
Published by Department of Defense (DOD), available at: https://assist.dla.mil/online/start/. ↑
