1、 Reference number ISO 461-1:2003(E) ISO 2003INTERNATIONAL STANDARD ISO 461-1 Second edition 2003-06-01 Aircraft Connectors for ground electrical supplies Part 1: Design, performance and test requirements Aronefs Prises de courant dalimentation au sol Partie 1: Exigences concernant la conception, le
2、fonctionnement et les essais ISO 461-1:2003(E) PDF disclaimer This PDF file may contain embedded typefaces. In accordance with Adobes licensing policy, this file may be printed or viewed but shall not be edited unless the typefaces which are embedded are licensed to and installed on the computer per
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5、 Secretariat at the address given below. ISO 2003 All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from either ISO at t
6、he address below or ISOs member body in the country of the requester. ISO copyright office Case postale 56 CH-1211 Geneva 20 Tel. + 41 22 749 01 11 Fax + 41 22 749 09 47 E-mail copyrightiso.org Web www.iso.org Published in Switzerland ii ISO 2003 All rights reservedISO 461-1:2003(E) ISO 2003 All rig
7、hts reserved iiiContents Page Foreword iv Introduction v 1 Scope 1 2 Normative references . 1 3 Terms and definitions. 1 4 Design and performance requirements 2 5 Inspection and testing 3 6 Marking and ordering procedures. 6 ISO 461-1:2003(E) iv ISO 2003 All rights reservedForeword ISO (the Internat
8、ional Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has bee
9、n established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical stand
10、ardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. The main task of technical committees is to prepare International Standards. Draft International Standards adopted by the technical committees are circulated to the member bodies for
11、 voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all
12、 such patent rights. ISO 461-1 was prepared by Technical Committee ISO/TC 20, Aircraft and space vehicles, Subcommittee SC 1, Aerospace electrical requirements. This second edition cancels and replaces the first edition (ISO 461-1:1985), which has been technically revised. This edition brings the do
13、cument up to date in terms of the connectors now being used on aircraft and anticipates future requirements. The testing regime for connectors has been changed to reflect existing industry practices. ISO 461 consists of the following parts, under the general title Aircraft Connectors for ground elec
14、trical supplies: Part 1: Design, performance and test requirements Part 2: Dimensions ISO 461-1:2003(E) ISO 2003 All rights reserved vIntroduction Throughout this part of ISO 461, the minimum essential criteria are identified by the use of the imperative or the key word “shall”. Recommended criteria
15、 are identified by the use of the key word “should” and, while not mandatory, are considered to be of primary importance in providing serviceable, economical and practical connectors. Deviation from the recommended criteria should occur only after careful consideration, extensive testing and thoroug
16、h service evaluation have shown alternative methods to be satisfactory. INTERNATIONAL STANDARD ISO 461-1:2003(E) ISO 2003 All rights reserved 1Aircraft Connectors for ground electrical supplies Part 1: Design, performance and test requirements 1 Scope This part of ISO 461 specifies the design, perfo
17、rmance and test requirements for electrical connectors used to supply electrical power from a ground source to an aircraft. NOTE ISO 461-2 specifies the dimensions of the connectors. 2 Normative references The following referenced documents are indispensable for the application of this document. For
18、 dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 461-2, Aircraft Connectors for ground electrical supplies Part 2: Dimensions ISO 7137, Aircraft Environmental conditions and test procedure
19、s for airborne equipment 1)3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 aircraft fixed connector (receptacle) connector, installed in an aircraft, which accepts an electrical power supply via the ground supply free connector from an extern
20、al ground source 3.2 ground supply free connector (plug) connector, fitted to cables from the external ground source of electrical power, which, when properly fitted to the aircraft fixed connector, permits an electrical supply to be passed to the aircraft 1) Endorsement, in part, of the publication
21、 EUROCAE ED-14/RTCA DO-160 (a document published jointly by the European Organization for Civil Aviation Electronics and the Radio Technical Commission for Aeronautics). ISO 461-1:2003(E) 2 ISO 2003 All rights reserved4 Design and performance requirements 4.1 General 4.1.1 Construction The ground su
22、pply free connector shall be robust in construction and capable of withstanding heavy mechanical shocks and hard wear in use, and shall be designed to provide safe handling, for example by the avoidance of sharp edges. 4.1.2 Fungus resistance Materials used in the construction of fixed and free conn
23、ectors shall be fungus-inert. 4.1.3 Metallic materials Metals used shall be corrosion-resistant or treated to resist corrosion. 4.1.4 Dissimilar materials Dissimilar materials used in intimate contact shall be protected against electrolysis and electrolytic corrosion. 4.1.5 Temperatures Aircraft fix
24、ed connectors and ground supply free connectors shall be capable of engagement, disengagement and operation at ambient temperatures between 65 C and + 65 C. They shall be capable of operating at 105 C, allowing for the temperature rise due to current carried by the connectors. 4.1.6 Automatic uncoup
25、ling Style 4 connectors shall be equipped with a positive-coupling device which will release automatically, without damage to the aircraft fixed connector or its mounting, should the aircraft or ground supply move before uncoupling has been carried out. 4.2 Polarity or phase sequence Indications of
26、polarity or phase shall be permanently marked on the aircraft fixed connectors and the ground supply free connectors at points adjacent to the contacts, as indicated in the relevant figures in ISO 461-2. The markings shall be permanent and legible and shall be marked on the front and rear of the ins
27、ert of the aircraft fixed connector. 4.3 Current ratings 4.3.1 Each of the main current-carrying contacts of the fixed and free connectors (as distinct from any cables connected to them) shall be capable of carrying up to 300 A (Styles 1, 2 and 3) or 350 A (Style 4) continuously, i.e. for 1 h or mor
28、e (direct current or r.m.s. alternating current). 4.3.2 Each of the control male and female contacts shall be capable of carrying 35 A continuously. 4.4 Control current female contact The control current female contact of the d.c. ground supply free connector may be in two sections, insulated electr
29、ically from each other, connected only by the entry of the control male contact of the aircraft fixed connector, or the female contact may be of a one-piece construction. ISO 461-1:2003(E) ISO 2003 All rights reserved 34.5 Voltage rating The aircraft fixed connectors and ground supply free connector
30、s shall be capable of working continuously at the voltages specified in ISO 461-2. 4.6 Replaceability of contacts in the ground supply free connectors All the ground supply free connectors shall be capable of being replaced or repaired such that the existing cables attached to the ground supply free
31、 connector may be reused. 5 Inspection and testing 5.1 Inspection Connectors shall be examined to ensure that they meet the requirements of this part of ISO 461 and the dimensional requirements of ISO 461-2. 5.2 Testing 5.2.1 Type tests Type tests shall be carried out to prove conformance to the req
32、uirements of this part of ISO 461. Unless otherwise indicated, the tests shall be conducted at an ambient temperature between 15 C and 25 C. The tests specified in 5.3.1 to 5.3.10 shall be conducted on 11 test samples (A to K) using the sample allocation and the test order given in Table 1. Each sam
33、ple shall consist of an aircraft fixed connector and an appropriate ground supply free connector. 5.2.2 Quality control tests Quality control tests shall be made on one fixed and free connector per 100, at least once a year. The sample shall be subjected to the tests specified in 5.3.4.1 and 5.3.6.
34、If the sample fails any test, the batch shall be deemed not to conform to the requirements of this part of ISO 461. Table 1 Type testing Allocation of samples and order of testing Sample and test order Test A B C Engagement and disengagement forces (see 5.3.1) 1 Side-load test (see 5.3.2) 2 Enduranc
35、e (see 5.3.3) 3 Current overload and voltage drop test (see 5.3.4) 4 Salt spray test (see 5.3.5) 1 High-voltage and insulation resistance test (see 5.3.6) 2 Vibration test (aircraft fixed connector only) (see 5.3.7) 3 Shock test (ground supply free connector only) (see 5.3.8) 1 Extremes of temperatu
36、re Engagement and disengagement test (see 5.3.10) 2 Fluid susceptibility test (initial qualification only) (see 5.3.9) Samples D to K (one per fluid) ISO 461-1:2003(E) 4 ISO 2003 All rights reserved5.3 Tests 5.3.1 Engagement and disengagement forces 5.3.1.1 Styles 1, 2 and 3 Two test fixed connector
37、s shall be constructed for each configuration of ground supply free connector, each fixed connector having male contacts of hardened and ground steel, with a surface finish of between 0,1 m and 0,4 m (4 in and 16 in), mounted at the centres shown in the appropriate figure in ISO 461-2, except that t
38、he tolerance on contact position shall be 0,025 mm ( 0,001 in). No shrouds shall be fitted. One test fixed connector shall have male contacts of the maximum tolerance dimension 0,005 mm ( 0,000 2 in) and the other test fixed connector shall have male contacts of the minimum tolerance dimension 0,005
39、 mm ( 0,000 2 in). Fully engage and disengage the ground supply free connector being tested 50 times using the maximum size test fixed connector followed by 5 times using the minimum size test fixed connector. Engagement and complete separation may be accomplished by machine. Measure the force neces
40、sary to engage and disengage the ground supply free connector on the first and last insertion of each test fixed connector. For 3-pin connectors, the engaging force shall not be greater than 223 N (50 lbf) and the disengaging force shall be between 134 N and 223 N (30 lbf to 50 lbf). For 5- and 6-pi
41、n connectors, the engaging force shall not be greater than 445 N (100 lbf) and the disengaging force shall be between 267 N and 445 N (60 lbf to 100 lbf). The rate of insertion and withdrawal shall be 177 mm/min to 229 mm/min (7 in/min to 9 in/min). 5.3.1.2 Style 4 The engaging force shall not be gr
42、eater than 534 N (120 lbf) and the disengaging force shall be between 400 N and 534 N (90 lbf to 120 lbf). 5.3.2 Side-load test 5.3.2.1 Styles 1, 2 and 3 After the test described in 5.3.1.1, engage the ground supply free connector with an appropriate aircraft fixed connector mounted with its axis ho
43、rizontal. With the main current-carrying male contacts one-third engaged, apply a side load of 890 N (200 Ibf) to the extremity of the ground supply free connector body. No damage or permanent deformation of the fixed or free connector shall ensue from this test. 5.3.2.2 Style 4 After the test descr
44、ibed in 5.3.1.2, engage and latch the ground supply free connector with an appropriate aircraft fixed connector mounted with its axis horizontal. Apply a side load of 890 N (200 lbf) to the extremity of the ground supply free connector body. No damage or permanent deformation of the fixed or free co
45、nnector or the latching mechanism shall ensue from this test. 5.3.3 Endurance After the tests described in 5.3.1 and 5.3.2, fully engage and disengage the ground supply free connector 500 times with an appropriate aircraft fixed connector mounted with its axis horizontal. Engagement and disengagemen
46、t shall be at a rate not exceeding 15 cycles/min. Measure the voltage drop at the end of this test. It shall meet the requirements of 5.3.4.2. ISO 461-1:2003(E) ISO 2003 All rights reserved 55.3.4 Current overload and voltage drop test 5.3.4.1 Current overload Connect a mated connector pair to a pow
47、er supply and circuitry to pass a d.c. or a.c. r.m.s. current through the contacts of the connector. The cables between the power supply and the large contacts shall be size 00 gauge or larger and the cables for the small contacts size 12 gauge or larger. The current through the large contacts shall
48、 be 700 A (Styles 1, 2 and 3) or 900 A (Style 4) and through the small contacts shall be 35 A. Maintain the current at these levels for 3 min. During application of the current overloads and after the overloads have been removed, there shall be no shorting, loss of continuity, burning, rupture or ot
49、her damage detrimental to either the free or fixed connector. Smoke shall not be cause for failure if the connector operation is not otherwise impaired. After removal of the overload current, allow the connectors to cool to ambient temperature and test the connectors for voltage drop at rated current levels in accordance with 5.3.4.2. 5.3.4.2 Voltage drop at rated current Use the same circuit as was used for the current overload test to provide a d.c. or a.c. r.m.s. current through the contacts of
