1、BRITISH STANDARD AEROSPACE SERIES BSG255:1994 ISO8668-5: 1992 Specification for Type3 terminal junction systems UDC629.7.064.5:621.316.541BSG255:1994 This BritishStandard, having been prepared under the directionof the Aerospace Standards Policy Committee, waspublished under the authorityof the Stan
2、dards Boardand comes into effect on 15May1994 BSI01-2000 The following BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment89/78815 DC ISBN 0 580 23323 5 Committees responsible for this BritishStandard The preparation of this BritishStandard was entrusted b
3、y the Aerospace Standards Policy Committee (ACE/-) to Technical Committee ACE/6, upon which the following bodies were represented: British Airways British Cable Makers Confederation British Rubber Manufacturers Association Civil Aviation Authority (Airworthiness Division) Electronic Components Indus
4、tries Federation Ministry of Defence Society of British Aerospace Companies Ltd. Amendments issued since publication Amd. No. Date CommentsBSG255:1994 BSI 01-2000 i Contents Page Committees responsible Inside front cover National foreword ii Section 1. General 1.1 Scope 1 1.2 Normative references 1
5、1.3 Identification 1 Section 2. Design requirements 2.1 Description 2 Section 3. Type approval tests 3.1 Samples for type approval tests 6 3.2 Test details 6 Section 4. Production and quality tests 4.1 Production acceptance tests 9 4.2 Production quality tests 9 Figure 1 Tool indentor Sizes22D,22 an
6、d20 3 Figure 2 Tool indentor Sizes22,20,16 and12 4 Figure 3 Probe damage tool and bending moment 7 Figure 4 Feed-back module, size22D 10 Figure 5 Feed-back module, size22D Bussing arrangements 11 Figure 6 Feed-back module size22 13 Figure 7 Feed-back module, size22 Bussing arrangements 14 Figure 8 F
7、eed-back module, size20 15 Figure 9 Feed-back module, size20 Bussing arrangements 16 Figure 10 Feed-back module, size16 17 Figure 11 Feed-back module, size16 Bussing arrangements 18 Figure 12 Feed-back module, size12 19 Figure 13 Feed-back module, size12 Bussing arrangements 21 Figure 14 Feed-throug
8、h module, size22D 22 Figure 15 Feed-through module, size22D Bussing arrangements 23 Figure 16 Feed-through module, size22 25 Figure 17 Feed-through module, size22 Bussing arrangements 26 Figure 18 Feed-through module, size20 27 Figure 19 Feed-through module, size20 Bussing arrangements 28 Figure 20
9、Feed-through module, size16 29 Figure 21 Feed-through module, size16 Bussing arrangements 30 Figure 22 Feed-through module, size12 31 Figure 23 Feed-through module, size12 Bussing arrangements 33 Figure 24 Grounding modules, bracket mounting, sizes22D,22,20 and16 34 Figure 25 Grounding module, brack
10、et mounting, size12 35 Figure 26 Grounding modules, bracket mounting Bussing arrangements 36 Figure 27 Grounding modules, stud mounting, sizes22D,22 and20 37 Figure 28 Grounding module, stud mounting, size16 38 Figure 29 Grounding module, stud mounting, size12 39 Figure 30 Grounding modules, stud mo
11、unting Bussing arrangements 40 Figure 31 Anti-rotation plate 41 Figure 32 In-line junction splice, two-wire 42BSG255:1994 ii BSI 01-2000 Page Figure 33 In-line junction splice, four-wire 43 Figure 34 Feed-back modules Tracks, standard weight 44 Figure 35 Feed-back modules Tracks, lightweight 46 Figu
12、re 36 Feed-through modules Tracks, standard weight 48 Figure 37 Feed-through modules Tracks, lightweight 50 Figure 38 Mounting bracket, size1 52 Figure 39 Mounting bracket, size2 53 Figure 40 Male (pin) crimp-removable contacts 54 Figure 41 Grommet sealing plugs 57 Figure 42 Insertion/extraction too
13、ls 58 Table 1 2 Table 2 5 Table 3 6 Table 4 7 Table 5 8 List of references Inside back coverBSG255:1994 BSI 01-2000 iii National foreword This BritishStandard has been prepared under the direction of the Aerospace Standards Policy Committee. It is identical with ISO8668-5:1992 Aircraft Terminal junc
14、tion systems Part5: Detail specification for type3 system published by the International Organization for Standardization (ISO). The Technical Committee has reviewed the provisions of ISO8668-1:1986, ISO8668-2:1986 and ISO1966:1973, to which normative reference is made in the text, and has decided t
15、hat they are acceptable for use in conjunction with 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 immunit
16、y from legal obligations. Cross-references International Standard Corresponding BritishStandard ISO7137:1992 BS3G229:1993 Schedule for environmental conditions and test procedures for airborne equipment (Identical) IEC512-8:1984 BS5772 Basic testing procedures and measuring methods for electromechan
17、ical components for electronic equipment Part8:1985 Connector tests (mechanical) and mechanical tests on contacts and terminations (Identical) Summary of pages This document comprises a front cover, an inside front cover, pagesi toiv, pages1to60, an inside back cover and a back cover. This standard
18、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.iv blankBSG255:1994 BSI 01-2000 1 Section 1. General 1.1 Scope This part of ISO8668 establishes the specific characteristics of a Terminal Junction
19、System(TJS), designated as type3, and particularly designed for aircraft applications. This part of ISO8668 shall be read in conjunction with ISO8668-1 and ISO8668-2. 1.2 Normative references The following standards contain provisions which, through reference in this text, constitute provisions of t
20、his part of ISO8668. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this part of ISO8668 are encouraged to investigate the possibility of applying the most recent editions of the standards listed below. Members
21、 of IEC and ISO maintain registers of currently valid International Standards. ISO1966:1973, Crimped joints for aircraft electrical cables. ISO7137:1987, Aircraft Environmental conditions and test procedures for airborne equipment 1) . ISO8668-1:1986, Aircraft Terminal junction systems Part1: Charac
22、teristics. ISO8668-2:1986, Aircraft Terminal junction systems Part2: Tests. IEC512-8:1984, Electromechanical components for electronic equipment; basic testing procedures and measuring methods Part8: Connector tests (mechanical) and mechanical tests on contacts and terminations. 1.3 Identification 1
23、.3.1 Basic components comprising the type3 system shall be identified as follows: 1.3.2 The designations of the individual items comprising the type3 system shall be as shown on the corresponding figures. 1) Endorsement, in part, of the publication EUROCAE ED-14B/RTCA DO-160B (a document published j
24、ointly by the European Organisation for Civil Aviation Electronics and the Radio Technical Commission for Aeronautics). Identification Basic component description FBM Feed-back module FTM Feed-through module FBT Feed-back track FTT Feed-through track GM Grounding module JS Junction splice MB Module
25、mounting bracket PC Pin contact (male) CT Tool for contact insertion and extraction SP Sealing plug for grommet cavityBSG255:1994 2 BSI 01-2000 Section 2. Design requirements 2.1 Description 2.1.1 General The type3 Terminal Junction System (TJS) shall comply with the requirements specified in ISO866
26、8-1 and ISO8668-2. The TJS shall provide environment-proof terminations in modules and in-line junctions (splices) for joining wires attached to specified crimp-removable male (pin) contacts. The TJS components shall have integral female (socket) contacts internally bussed in prescribed configuratio
27、ns specified in the figures. The following components shall comprise the TJS system, Design details shall be in accordance with the figures: Feed-back junction modules Feed-through junction modules Feed-back grounding modules In-line junctions (splices) Tracks for mounting modules Brackets for mount
28、ing modules Crimp male contacts (pins) Insertion/extraction tools Sealing plugs 2.1.2 Sizes The modules, in-line junctions (splices) and contacts are specified in five sizes:22D,22,20,16 and12. The size number is the maximum gauge wire that the male (pin) contact wire barrel can accommodate. 2.1.3 C
29、ontacts 2.1.3.1 Contacts shall be finish gold-plated to a minimum of1,274m(0,000050in) over a suitable underplate, other than silver. 2.1.3.2 Female (socket) contacts shall be integral within the modules and in-line junctions, bussed in various configurations, as specified. 2.1.3.3 Male (pin) contac
30、ts shall comply with Figure 40 and shall be designed for crimping (see2.1.3.4) to the following conductor sizes and for insertion/extraction with tools used for rear release contacts in cylindrical connectors (see Figure 42). Except for size12, the mating end of the male contacts shall be larger tha
31、n the wire barrel size in accordance with Table 1. Table 1 2.1.3.4 Contacts shall be designed so that their barrels can be crimped with indentors conforming to Figure 1 and Figure 2 on specified wire sizes. Contacts crimped on copper wire to aircraft quality, stranded, silver or tin coated shall com
32、ply with the tensile requirements of3.2.5.4. Contact size Mating end Wire barrel Conductor sizes 22D 22 20 16 12 20 16 16 14 12 22D 22 20 16 12 28 to22 26 to22 24 to20 20 to16 14 to12BSG255:1994 BSI 01-2000 3 Indentor gauging limits (with tool in fully closed position) Wire size Contact sizes 22D an
33、d22 20 A GO B NO GO A GO B NO GO 0,003 ( 0,0001) 0,003 ( 0,0001) 28 0,3302 (0,013) 0,4572 (0,018) 26 0,4064 (0,016) 0,5334 (0,021) 24 0,4826 (0,019) 0,6096 (0,024) 0,6604 (0,026) 0,7874 (0,031) 22 0,5588 (0,022) 0,6858 (0,027) 0,762 (0,03) 0,889 (0,035) 20 0,8636 (0,034) 0,9906 (0,039) Figure 1 Tool
34、 indentor Sizes22D,22 and20BSG255:1994 4 BSI 01-2000 Indentor gauging limits (with tool in fully closed position) Wire size Contact sizes 22,20,16 and12 A GO B NO GO 0,003 ( 0,0001) 22 0,9144 (0,036) 1,0414 (0,041) 20 0,9906 (0,039) 1,1176 (0,044) 18 1,143 (0,045) 1,27 (0,05) 16 1,3208 (0,052) 1,447
35、8 (0,057) 14 1,4986 (0,059) 1,6256 (0,064) 12 1,7272 (0,068) 1,8542 (0,073) Figure 2 Tool indentor Sizes22,20,16 and12BSG255:1994 BSI 01-2000 5 2.1.4 Tracks (rails) and brackets It shall be possible to mix and accommodate all sizes of modules in their respective mounting tracks and brackets, Tracks
36、shall be designed to allow the removal of individual modules without having to remove other modules in the installed track. Tracks shall accommodate from three to15 modules from size22D to size16. Size12 modules occupy the space of three smaller modules. Brackets shall accommodate one or three modul
37、es, as specified. 2.1.5 Grounding modules All integral contacts shall be bussed in common and shall be conductive to a common mounting plate or stud, as specified. 2.1.6 Temperature rating The TJS components shall comply with the class3 requirements specified in ISO8668-1 for a temperature range of6
38、5 C to+200 C. 2.1.7 Sealing The modules and in-line junctions shall have integral grommets designed to provide moisture seals on wires or sealing plugs, having smooth insulation, of the diameters specified in Table 2. 2.1.8 Contact retention Retention of the male (pin) contact shall be provided by a
39、 metal sleeve having a minimum of two tines integral with the module or splice housing. The retention system shall provide mechanical integrity when tested with both axial and side loads on the crimped wire in accordance with ISO8668-2. There shall be no electrical discontinuity during this test. 2.
40、1.9 Resistance to probe damage The modules and splices shall withstand test probe damage incidental to use when tested in accordance with3.2.3. 2.1.10 Oversize pin protection An oversize pin shall not enter the module or splice housing when tested in accordance with3.2.1. 2.1.11 Contact durability T
41、he TJS component shall tolerate100 cycles of probe insertion/extraction without damage when tested in accordance with3.2.2. Table 2 Dimensions in millimetres (inches) Module or splice size Finished wire diameter min. max. 22D 22 20 16 12 0,76(0,030) 0,86(0,034) 0,96(0,038) 1,52(0,060) 2,21(0,087) 1,
42、37(0,054) 1,68(0,066) 2,11(0,083) 2,57(0,101) 3,74(0,147)BSG255:1994 6 BSI 01-2000 Section 3. Type approval tests 3.1 Samples for type approval tests 3.1.1 Samples shall be selected in accordance with the requirements specified in ISO8668-1. 3.1.2 A family of parts comprising one type may be approve
43、d based on similarity to a representative part which has been fully tested. 3.1.3 Modules of the same type and size, differing only in bussing arrangements, may be approved by similarity to approved bussing arrangements C1 or38, as applicable. 3.2 Test details Tests and their sequence shall be carri
44、ed out in accordance with ISO8668-1 and ISO8668-2. The additional tests specified in3.2.1 to3.2.5 shall be incorporated. 3.2.1 Oversize pin: Test No.20 Specimens Nos.11 and12 (see the table in ISO8668-1:1986) shall be subjected to this test after completion of the indicated tests. The grommet shall
45、be removed for this test and an attempt shall be made to axially insert the oversize probe specified in Table 3. A force of13,35N 0,05N (3lbf 0,125lbf) shall be applied. Four socket contact cavities shall be tested. The probe shall neither make electrical engagement to the socket under test nor dama
46、ge the assembly. Table 3 3.2.2 Contact durability: Test No.21 Specimens Nos.1 and2 (see the table in ISO8668-1:1986) shall be subjected to100 cycles of durability testing on each of four contacts with the applicable test probe specified in Table 4. A cycle shall consist of one insertion and one with
47、drawal. The socket contact shall then be subjected to the contact resistance, rated current, test No.5b, specified in ISO8668-2:1986. 3.2.3 Probe damage: Test No.22 Specimens Nos.11 and12 (see the table in ISO8668-1:1986) shall be subjected to this test after completion of the indicated tests. The g
48、rommet shall be removed for this test and a probe, specified in Figure 3, shall be inserted to impose the specified bending moment at each of the three depths specified in Figure 3. The procedure shall be carried out in accordance with IEC512-8:1984, test16A, except that the module or in-line juncti
49、on shall be suitably mounted instead of the specified collet. Following this stress, the socket contact shall comply with the contact resistance test Nos.5a and5b specified in ISO8668-2:1986. 3.2.4 Resistance to fluids: Test No.18 The wired specimen shall be subjected to immersion in the fluids specified in ISO7137, under the fluids susceptibility test procedure, for the time and at the temperature conditions specif
