1、BRITISH STANDARD BS 3214:1974 Incorporating Amendment Nos. 1, 2 and 3 Specification for Locking connectors forbattery operated vehicles, excluding industrial trucks, (320ampere rating) UDC 629.113.65:621.316.541BS3214:1974 This British Standard, having been approved by the Electrical Industry Standa
2、rds Committee, was published under the authority of the Executive Board on 18 June 1974 BSI 09-1999 First published February 1960 First revision June 1974 The following BSI references relate to the work on this standard: Committee references ELE/56 andELE/56/6 Draft for comment 71/25227 ISBN 0 580 0
3、8374 8 Co-operating organizations The Electrical Industry Standards Committee under whose supervision this British Standard was prepared consists of representatives from the following Government department and scientific and industrial organizations: Associated Offices Technical Committee Associatio
4、n of Consulting Engineers Association of Manufacturers of Domestic Electrical Appliances Association of Mining Electrical and Mechanical Engineers Association of Supervisory and Executive Engineers British Electrical and Allied Manufacturers Association British Electrotechnical Approvals Board for H
5、ousehold Equipment British Radio Equipment Manufacturers Association British Railway Board British Steel Corporation Crown Agents for Oversea Governments and Administrations Department of Employment (HM Factory Inspectorate) Department of the Environment Department of Trade and Industry, Electricity
6、 Department of Trade and Industry (Standards, Weights and Measures Division) Electric Cable Makers Confederation Electrical Contractors Association Electrical Contractors Association of Scotland Electrical Research Association Electricity Supply Industry in England and Wales* Electronic Engineering
7、Association Engineering Equipment Users Association Institution of Electrical Engineers Institution of Electrical and Electronics Technician Engineers Lighting Industry Federation Limited Ministry of Defence National Inspection Council for Electrical Installation Contracting Oil Companies Materials
8、Association Post Office South of Scotland Electricity Board The organization marked with an asterisk in the above list, together with the following, were directly represented on the committee entrusted with the preparation on this British Standard: Accumulator Makers Association British Industrial T
9、ruck Association Electrical Installation Equipment Manufacturers Association Electric Vehicle Association of Great Britain Ltd. Society of Motor Manufacturers and Traders Ltd. Amendments issued since publication Amd. No. Date of issue Comments 3640 October 1981 4873 July 1985 6125 July 1989 Indicate
10、d by a sideline in the marginBS3214:1974 BSI 09-1999 i Contents Page Co-operating organizations Inside front cover Foreword ii Section 1. General 1 Scope 1 2 Definitions 1 Section 2. General requirements 3 Rating 1 4 Construction 1 5 Materials 1 6 Marking 1 Section 3. Design of connector sections 7
11、Case 2 8 Contacts 2 9 Interior 2 Section 4. Tests 10 Routine test 2 11 Type test 2 Figure 1 Fixed section 4 Figure 2 Locking section 5 Figure 3 Free section 6 Figure 4 Interior moulded (back half) 7 Figure 5 Main contact 7 Figure 6 Main spring 8 Figure 7 Interior moulded (front half) 9 Figure 8 Pilo
12、t contact 10 Figure 9 Pilot spring 10 Figure 10 Sleeve 11 Figure 11 Locking section with fixed section (a) inserted and(b)fullyhomeand locked 12 Publications referred to Inside back coverBS3214:1974 ii BSI 09-1999 Foreword This British Standard has been prepared under the authority of the Electrical
13、 Industry Standards Committee. It is based on proposals submitted by the Electric Vehicle Association of Great Britain Ltd. and is a revision in metric terms of a standard originally published in1960. Certification. Attention is drawn to the certification facilities described on the inside back cove
14、r of this standard. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This
15、 document comprises a front cover, an inside front cover, pages i and ii, pages1 to 12, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover.BS3214:
16、1974 BSI 09-1999 1 Section 1. General 1 Scope This British Standard specifies locking connectors designed for use in battery electric vehicles (excluding industrial trucks) with a nominal battery voltage not exceeding96V. The connectors are intended for operation at ambient temperatures between10 C
17、and 40 C. NOTEThe titles of the British Standards referred to in this standard are listed on the inside back cover. 2 Definitions For the purposes of this British Standard the following definitions apply: 2.1 connector section one of the three interconnecting sections of a locking connector 2.2 lock
18、ing section the portion of the locking connector fitted with the locking handle 2.3 fixed section the portion of the locking connector fitted with a mounting bracket 2.4 free section the portion of the locking connector not fitted with either a mounting bracket or a locking handle Section 2. General
19、 requirements 3 Rating The rating for continuous operation of the main contacts shall be320A at a maximum direct voltage of125V. Pilot contacts shall be rated at 20 A at a maximum direct voltage of125V. 4 Construction Each connector section shall have four contacts, namely, two main current-carrying
20、 contacts and two pilot contacts. The pilot contacts make before and break after the main contacts. The locking section shall include a device for maintaining full contact pressure and preventing accidental removal of the plug. The design shall comply with that shown in Figure 1, Figure 2 and Figure
21、 3. Provision shall be made on all connector sections to prevent the polarity on the output side being reversed relative to the input. A cable sleeve conforming to the design shown in Figure 10 shall be fitted to each free connector section and to each locking section not intended to be fixed into p
22、osition. The fitting of a cable sleeve to the fixed section and to the locking section when in the fixed condition is optional. NOTEIt is recommended that the insulation of the cables fitted to the main contacts should be removed only to the extent that any gap between the ends of the contact and th
23、e cable insulation does not exceed5mm when the cable is fitted to the contact. 5 Materials 1) The materials used for the manufacture of current carrying parts shall be as follows: 2) The insulating material used in the construction of the locking connector shall be a tough, moulding material that wi
24、ll not support combustion and that gives a plastic yield not exceeding6mm when tested at a temperature of100 C by Method102A of Part1of BS2782:1970. 3) Parts made of ferrous metal shall be protected against rusting. Special attention should be given to springs which should be protected with zinc in
25、accordance with the requirements of BS1706:1960 Zn3. 4) The insulating material used in the construction of the cable sleeve shall be a tough flexible material, resistant to battery electrolyte, hydraulic fluids, lubricating oils and weather. The material shall not support combustion. Suitable mater
26、ials include polychloroprene which should be based on polychloroprene complying with the requirements for RS2sheath given in Table 3 of BS6899:1984. 6 Marking All connector sections shall be clearly and indelibly marked with the following information: 1) The number of this British Standard, i.e.BS32
27、14. 2) The name or trade mark of the manufacturer. 3) The signs + and to indicate polarity. Main contacts.High conductivity copper rod, condition H, complying with the requirements of BS1433-C101, BS1433-C102 or BS1433-C103, or other material of at least equal conductivity. Pilot contacts. Brass rod
28、, condition M, complying with the requirements of BS2874-CZ121or other material of at least equal conductivity.BS3214:1974 2 BSI 09-1999 The locking section shall, in addition, be clearly and indelibly marked with the current rating and the voltage of the main contacts, i.e. 320A,125V d.c. Section 3
29、. Design of connector sections 7 Case The case shall be of mild steel or other suitable robust material. The essential dimensions are shown in Figure 1, Figure 2 and Figure 3. 8 Contacts The main and pilot contacts shall be cylindrical, spring-loaded and shall be manufactured from a suitable materia
30、l in accordance with clause5 1). Main contacts may if necessary be faced with a suitable material to enable them to meet the requirements of11.2. The dimensions of the main contacts shall be as shown in Figure 5 and Figure 6 and the dimensions of the pilot contacts shall be as shown in Figure 8 and
31、Figure 9. The contacts shall be so fixed in the body of the plug as to prevent them from working loose, but shall be self-adjusting with regard to pitch and contact making. Each contact shall be formed in one piece and shall comply with the dimensions in Figure 5 and Figure 8. The size of the cable
32、holes in the pilot and main contacts shall provide nominal allowance for the soldering of conductors with maximum cross-sectional areas of2.5mm 2and70mm 2respectively. Where conductors are required to be compression jointed into pilot or main contacts this shall be specified by the purchaser and the
33、 diameter of the cable hole and dimensions of the cable barrel shall be subject to agreement between purchaser and supplier. 9 Interior The interiors shall be of insulating material and shall either fully comply with the dimensions shown in Figure 4 and Figure 7 or shall be interchangeable with the
34、interiors dimensioned in Figure 4 and Figure 7 in which case there shall be no protrusion outside the peripheral dimensions of Figure 4 and Figure 7. Section 4. Tests 10 Routine test 10.1 High voltage test. Each connector section shall withstand an alternating voltage of2000Vr.m.s. of approximately
35、sine wave form and having a frequency between25Hz and100Hz applied between: 1) line terminals, 2) line terminals and pilot terminals, 3) line terminals and casing, 4) pilot terminals, 5) pilot terminals and casing. 11 Type test 11.1 General. Type tests shall be performed on representative samples of
36、 connector section having pilot cables of2.5mm 2and main cables of 50 mm 2cross-sectional area and1m length, connected into their respective contacts. The mechanical operation of the contacts shall be checked by fully inserting the free section or fixed section, as appropriate, into the locking sect
37、ion and then withdrawing it. This shall be repeated five times after which each contact shall be inspected to ensure that it moves freely within its housing. Records of type tests shall be accepted as evidence of compliance with the requirements of this standard. 11.2 Temperature rise test. The lock
38、ing connector shall first be subjected to overload by passing currents of450A through the main contacts and30A through the pilot contacts for a period of1h in an ambient temperature of40 C. After allowing the assembly to cool to a temperature of20 C, currents of320A and20A shall be passed through th
39、e main and pilot contacts respectively for a further period of1h in an ambient temperature of40 C.40 C. The temperature rise measured immediately after the conclusion of this second period of current heating shall not exceed65 C. The temperature rise shall be measured by thermocouples attached by a
40、low melting point alloy or by some equally effective means of attachment. 11.3 Mechanical drop test. An assembled unit consisting of a free section fully inserted in a locking section shall be dropped from a height of 1 m on to a concrete floor, such that the locking lever is uppermost and does not
41、make contact with the concrete floor. This test shall be repeated six times after which the locking lever shall not have moved from the closed position.BS3214:1974 BSI 09-1999 3 The above test shall be repeated with an individual free section and an individual locking section socket after which the
42、samples shall show no serious damage and in particular, no part shall have become cracked, detached or loosened. Small chips or dents in the enclosure shall be neglected if they do not affect the insertion of the free section into the locking section or its withdrawal.BS 3214:1974 4 BSI 09-1999 Figu
43、re 1 Fixed sectionBS 3214:1974 BSI 09-1999 5 Figure 2 Locking section BS 3214:1974 6 BSI 09-1999 Figure 3 Free sectionBS3214:1974 BSI 09-1999 7 Figure 4 Interior moulded (back half) Figure 5 Main ContactBS3214:1974 8 BSI 09-1999 Figure 6 Main SpringBS 3214:1974 BSI 09-1999 9 Figure 7 Interior moulde
44、d (front half) BS3214:1974 10 BSI 09-1999 Figure 8 Pilot contact Figure 9 Pilot springBS 3214:1974 BSI 09-1999 11 Figure 10 Sleeve BS 3214:1974 12 BSI 09-1999 Figure 11 Locking section with fixed section (a) inserted and (b) fully home and lockedBS3214:1974 BSI 09-1999 Publications referred to This
45、standard makes reference to the following British Standards: BS 1433, Copper for electrical purposes. Rod and bar. BS 2782, Methods of testing plastics. BS 2874, Copper and copper alloys. Rods and sections (other than forging stock). BS 3673, Spring retaining rings. BS 3673-2, Carbon steel E clips.
46、BS 6899, Specification for rubber insulation and sheath of electric cables. BSI Certification Trade Mark The Kitemark The Kitemark is the registered certification trade mark of the British Standards Institution. A licence to use the Kitemark on or in relation to a product will be granted to any manu
47、facturer or producer who demonstrates that he can and will be able consistently to make that product to a specified British Standard. His capability of doing so is initially assessed by inspection of his production process, quality control organization and test facilities, and by independent testing
48、 of a sample of the product against all the criteria of the relevant standard. The licensee is required to accept, and to operate in accordance with, a BSI scheme of supervision and control which identifies the tests to be carried out during manufacture and on the completed product, and specifies th
49、e frequency of such testing. BSI carries out unannounced inspection visits to the manufacturers works and audit testing of the product, and may withdraw the licence for any failure of the manufacturer to comply with the relevant standard or with the requirements of the scheme of supervision and control. The presence of the Kitemark on or in relation to a product is an assurance that the goods have been produced under a system of supervision, control and testing, operated during manufacture and incl
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