1、BRITISH STANDARD AEROSPACE SERIES BS 2G202: 1988 Specification for Design and performance requirements for airframe-fit electrical connectors for d.c. and low frequency a.c. applications UDC 629.7.064.5:621.315.68BS2G202:1988 This British Standard, having been prepared under the directionof the Aero
2、space Standards Committee, was published under the authorityofthe Board ofBSI and comes into effect on 29February1988 BSI 10-1999 The following BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment85/79176 DC ISBN 0 580 15942 6 Committees responsible for thi
3、s British Standard The preparation of this British Standard was entrusted by the Aerospace Standards Committee (ACE/-) to Technical Committee ACE/6, upon which the following bodies were represented: BEAMA Ltd. British Rubber Manufacturers Association Civil Aviation Authority Electric Cable Makers Co
4、nfederation Electronic Components Industry Federation Ministry of Defence National Supervising Inspectorate Society of British Aerospace Companies Limited British Airways Amendments issued since publication Amd. No. Date of issue CommentsBS2G202:1988 BSI 10-1999 i Contents Page Committees responsibl
5、e Inside front cover Foreword ii 1 Scope 1 2 Definitions 1 3 Classification 1 4 Materials and finishes 1 5 Environmental requirements 1 6 Mechanical requirements 2 7 Electrical requirements 3 8 Identification 4 9 Fixings and accessories 4 10 Assembly tools 6 11 Packaging 6 12 Rules for the preparati
6、on of detail specifications 6 13 Declaration of design and performance (DDP) 6 Appendix A Example declaration of design and performance 7 Figure 1 Examples of contact position identification 5 Table 1 List of test fluids 2 Table 2 Sealing positions for connectors 4 Publications referred to Inside ba
7、ck coverBS2G202:1988 ii BSI 10-1999 Foreword This revision of this British Standard, having been prepared under the direction of the Aerospace Standards Committee, specifies requirements for the design of connectors shown by experience to be necessary for aerospace use. Airframe-fit electrical conne
8、ctors were introduced into the BS9000 series of standards by the publication of BS9540 in1983 which covered their design, performance and testing. It has now been decided to withdraw BS9540 and to include airframe-fit connectors in BS9520 which covers their qualification approval and production acce
9、ptance tests. British Standard G202 has been revised to specify the design and performance requirements for airframe-fit connectors, thus keeping them under the full control of the relevant Aerospace Technical Committee. This revision supersedes British Standard G202:1968 and BS9540:1983, which are
10、withdrawn. 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 document
11、 comprises a front cover, an inside front cover, pagesi andii, pages1 to8, 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.BS2G202:1988 BSI 10-
12、1999 1 1 Scope This British Standard specifies design and performance requirements for airframe-fit electrical connectors, including engine connectors, for d.c. and low frequency a.c applications. It applies only to connectors complying with BS9520. Appendix A gives information that enables the manu
13、facturer to prepare the required declaration of design and performance for submission to the appropriate design authority. NOTE 1This specification has to be used in conjunction with detail specifications prepared in accordance with the airframe-fit requirements of BS9521, BS9522 and BS9523. Generic
14、 data and methods of test are given in BS9520. NOTE 2The titles of the publications referred to in this standard are listed on the inside back cover. 2 Definitions For the purposes of this British Standard, the definitions given in BS9520 apply. 3 Classification Connectors shall be classified as fol
15、lows: NOTE 1A second letter denoting a particular combination of upper temperature category and housing finish or upper temperature category and seal material may be included as prescribed in the detail specification. The preferred temperature categories are: 40 C to105 C 65 C to175 C 65 C to200 C 6
16、5 C to260 C 65 C to350 C NOTE 2See also 6.8. NOTE 3Standard atmospheric pressure is equivalent tobetween860mbar and1060mbar (1mbar=100N/m 2 =100Pa). 4 Materials and finishes Materials and finishes shall be as specified by the control drawing or drawings, prepared by the manufacturer in accordance wi
17、th BS9520 and shall comply with the performance requirements of the detail specification. However, where the materials and finishes are not specified, they shall be selected so that they comply with the performance requirements of the detail specification, prepared by the manufacturer in accordance
18、with BS9520. Dissimilar metals shall not be used in intimate contact unless protection is afforded to prevent corrosion. 5 Environmental requirements 5.1 General The connectors and their accessories (excluding contact insertion/removal and unwired contact removal tools) shall comply with the perform
19、ance requirements specified in the detail specification when subjected to any one or any natural combination of the conditions specified in5.2, 5.3, 5.4, 5.5, 5.6 and, if applicable,5.8. NOTEConnectors complying with this standard are not explosion-proof in accordance with BS4683 and should not ther
20、efore be disengaged when carrying current in explosive atmospheres. However, correctly engaged (mated) connectors and their accessories should not normally constitute an explosive hazard in such atmospheres. 5.2 Temperature category Electrical connectors shall be capable of operating at their upper
21、temperature category for a period of1000h continuously. The upper temperature is the maximum internal hot spot temperature resulting from any combination of electrical load and ambient temperature. 5.3 Altitude Electrical connectors shall be suitable for operationat altitudes from300m to not lesstha
22、n+21500m. 5.4 Vibration Connectors shall be tested in accordance with the appropriate category of vibration test, as follows: a) for military applications the sinusoidal excitation procedure shall be used and the connectors shall comply with1.2.6.3.2.2 of BS9520:1983; b) for civil applications the r
23、andom motion excitation procedure shall be used and the connectors shall comply with1.2.6.3.2.3 of BS9520:1983; Class S: barrier sealed (unmated) to a maximum leakage rate of1cm 3 /h at1atmosphere; Class H: hermetically sealed (unmated) to a maximum leakage rate of1 10 7cm 3 /s at a differential pre
24、ssure of1atmosphere; Class N: an environmentally resistant connector, which although complying with1.2.6.12 (climatic sequence) and1.2.6.13 (immersion at low air pressure) of BS9520:1983 may not contain an integral barrier seal; Class K: a connector with the characteristics defined for class N and c
25、omplying with1.2.6.10 of BS9520:1983; Class U: unsealed.BS2G202:1988 2 BSI 10-1999 c) for engine mounted connectors the engine mounted connector vibration procedure shall be used and the connectors shall comply with1.2.6.3.2.4 of BS9520:1983. 5.5 Resistance to fluids Connectors shall be designed and
26、 constructed in accordance with1.2.6.20 of BS9520:1983 in respect of resistance to airframe fluids. Fluids to be used for the tests shall be as given in Table 1. 5.6 Corrosion salt mist When tested in accordance with test severity1 of BS2011-2.1Kb:1977, electrical connectors shall comply with1.2.6.1
27、7 of BS9520:1983. NOTEConnectors having electroless nickel finish need not comply with this requirement. 5.7 Compass safe distance Connectors and accessories, when tested in accordance with1.2.5.12 of BS9520:1983 shall have a compass safe distance of125mm unless otherwise specified in the detail spe
28、cification. 5.8 Dust Connectors, when tested in accordance with1.2.6.18 of BS9520:1983 shall comply with the requirements of visual examination, engagement and separation. 6 Mechanical requirements 6.1 Styles Ranges shall include male or female contacts in fixed and free styles. 6.2 Engagement 6.2.1
29、 General. Connectors shall be capable of complying with the relevant requirements of the detail specification after at least500engagements. Low profile non-scoop proof connectors fitted with grounding fingers shall be capable of complying with the relevant requirements of the detail specification af
30、ter at least250engagements. Correct engagement shall be achieved by the combined use of the systems specified in6.2.2 and6.2.3. 6.2.2 Contact engagement. The control drawings shall define the position of the electrical engagement range of the contact relative to the reference plane. On new designs t
31、he parallel part of the male contacts shall always exceed the range by at least0.75mm, and the electrical contact point (point of maximum pressure) of the female contacts shall always lie within the range under all tolerance conditions. Connectors shall comply with these requirements when the free m
32、ember has moved to the outward limit of any travel permitted by the engaged coupling device. Table 1 List of test fluids Fluid Immersion temperature Time of immersion Exposure temperature a b c d e f g h i Aircraft fuel. A mixture of70% iso-octane and30% toluene (to BS805) by volume Phosphate ester-
33、based synthetic hydraulic fluid, Skydrol500 B4 to ASF No.1559 a Ester based synthetic turbine lubricant; D.Eng.RD2487 or D.Eng. RD2497 b Hydraulic fluid: mineral-based to DEF STAN91-48 c Cleaning fluid; isopropyl alcohol to BS1595-1 De-icing fluid; Kilfrost ABC to DTD900/4907 d Cleaning fluid;1,1,1-
34、trichloroethane to BS4487 Sullage fluid, AMS1475 e Silicone-based synthetic hydraulic fluid; Versilube F50 f C 40 1 70 1 150 2 80 1 50 1 50 1 50 1 20 1 80 1 min 5to7 15to20 15to20 5to7 15to20 15to20 15to20 15to20 15to20 C 200 3 125 2 150 2 150 2 50 1 50 1 50 1 20 1 150 2 NOTEOther fluids listed in B
35、ritish Standard3G100-2-3.12 are being considered for future inclusion in this standard. a Obtainable from Monsanto plc,14 Tothill Street, London SW1H 9LH. b Details of specifications and suppliers obtainable from Procurement Executive, Ministry of Defence, AD Eng T1, St. Giles Court,1-13 St. Giles H
36、igh Street, London WC2H8LD. c Defence standards are obtainable from Ministry of Defence, Directorate of Standardization, Kentigern House,65 Brown Street, Glasgow G28EX. DEF STAN91-48 supersedes DTD585 and is equivalent to US Department of Defence specification MIL-11-5606. d Obtainable from Kilfrost
37、 Ltd.,11/13 South Road, Southall, Middlesex UB11SZ. e Obtainable from American Technical Publishers Ltd.,68A Wilbury Way, Hitchin, Herts SG40TP. f Obtainable from Alfa Chemicals Ltd.,15 Moor Park Avenue, Preston, Lancashire PR16AS.BS2G202:1988 BSI 10-1999 3 6.2.3 Polarization. The connector shall be
38、 so designed that the only engagement sequence is housings (shells), keys and keyways, coupling devices and finally contacts. In addition, the connector shall comply with the following. a) A minimum of five keys and keyways shall be provided on all new designs of shell size8 and larger. NOTEThis req
39、uirement may be relaxed on established designs. b) The keys and keyways shall ensure that the axis of the free housing (shell) remains substantially coincident with the axis of the fixed housing (shell) after the search for correct polarization. c) Alternative polarizations shall be provided within
40、each housing (shell) size by orientating keys with respect to the master key to prevent cross-mating. d) It shall not be possible to engage keys or make contacts or start the coupling device between differing polarizations in the same housing (shell) size. e) Orientation shall not be by insert rotat
41、ion in new designs of connector. f) Designations of polarizations for a particular pattern of connectors shall be either by alpha or numeric series as specified in the detail specification. 6.3 Coupling The coupling arrangement shall ensure: a) that full engagement and disengagement can be achieved
42、without the use of tools; b) that free and fixed housings (shells) are retained in the correct position when engaged and that correct engagement can be visually checked. 6.4 Thread form Screw threads other than coupling threads shall comply with established International Standards. 6.5 Locking Where
43、 coupling nuts and accessories contain wire locking facilities, adequate material shall be provided around any wire locking hole to prevent the wire from breaking out. Screw coupling connectors for new designs shall incorporate a mechanism to prevent uncoupling under shock or vibration. 6.6 Inserts
44、Inserts for housing female contacts should be of the hard-faced restricted entry type to prevent penetration by misplaced or oversized male contacts. 6.7 Contacts Contacts shall comply with the connector detail specification or with a detail specification prepared in accordance with BS9521. Where cr
45、imp type contacts are used, the resulting crimp shall comply with British Standard 4G178-1:1984. 6.8 Sealing NOTESealing is not applicable to class U connectors. 6.8.1 Connectors. The electrical connectors shall be sealed at the points given in Table 2. 6.8.2 Filler plugs. The detail specification s
46、hall define any filler plugs required and their use. Where connectors have resilient interfacial seals a full complement of male contacts shall be fitted together with filler plugs behind all unwired contacts. 6.8.3 Displacement of seals. The control drawings shall define the positional tolerance of
47、 the mating faces necessary to ensure displacement of any interfacial and/or peripheral seals. New connector designs shall ensure seal compression when the free member has moved to the outward limit of any travel permitted by the engaged coupling device. 7 Electrical requirements NOTEElectromagnetic
48、 compatibility (EMC). Performance requirements and methods of test for electromagnetic interference (EMI) and electromagnetic pulse (EMP) are under consideration. 7.1 Working voltage The working voltage of the engaged connector between contacts, and between contacts and shell, under any natural comb
49、ination of the environmental conditions given in clause5 shall be at least350V d.c. or a.c. peak. 7.2 Current rating Current-temperature derating curves shall be established for each contact size in accordance with test5b of BS5772-3:1979 for those connectors in the range that have the highest contact density and the greatest current loading per unit of insert area. The curve that shows maximum derating shall be attributed to the whole range of connectors. BS2G202:1988 4 BSI 10-1999 Table 2 Sealing positions for connectors 7.3 C
