SIST EN 2591-218:2004

• Abstract:

  This standard specifies a method for ageing terminal lugs and in-line splices by temperature and current cycling.; It shall be used together with EN 2591-100.

• Status: Published
• Publication Date: 30-Apr-2004
• ICS: 49.060 - Aerospace electric equipment and systems
• Technical Committee: I08 - Imaginarni 08
• Current Stage: 6060 - National Implementation/Publication (Adopted Project)
• Start Date: 01-May-2004
• Due Date: 01-May-2004
• Completion Date: 01-May-2004
• Ref Project: EN 2591-218:2002 - Aerospace series - Elements of electrical and optical connection - Test methods - Part 218: Ageing of terminal lugs and in-line splices by temperature and current cycling

• Refers: SIST EN 2591-217:2004 - Aerospace series - Elements of electrical and optical connection - Test methods - Part 217: Voltage drop under specified current for terminal lugs and in-line splices
• Effective Date: 28-Jan-2026
• Refers: SIST EN 2591-100:2024 - Aerospace series - Elements of electrical and optical connection - Test methods - Part 100: General
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-027:2019 - Aerospace series - Electrical contacts used in elements of connection - Part 027: Contacts, electrical, female, type A, crimp, class R - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-024:2009 - Aerospace series - Electrical contacts used in elements of connection - Part 024: Contacts, electrical, triaxial, size 8, male, type D, crimp, class S - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-071:2019 - Aerospace series - Electrical contacts used in elements of connection - Part 071: Contacts, electrical, female, type A, crimp, class S - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 4644-001:2012 - Aerospace series - Connector, electrical and optical, rectangular, modular, rectangular inserts, operating temperature 175 °C (or 125 °C) continuous - Part 001: Technical specification
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3373-010:2009 - Aerospace series - Terminal lugs and in-line splices for crimping on electric conductors - Part 010: Terminal lugs, ring shaped, tin plated, for crimping on copper conductors, temperature up to 150 °C for metric and inch stud series - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3660-004:2023 - Aerospace series - Cable outlet accessories for circular and rectangular electrical and optical connectors - Part 004: Cable outlet, style A, straight, unsealed with clamp strain relief - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3660-012:2008 - Aerospace series - Cable outlet accessories for circular and rectangular electrical and optical connectors - Part 012: Grommet nut, style A for EN 3372 - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-076:2012 - Aerospace series - Electrical contacts used in elements of connection - Part 076: Contacts, electrical, male, type A, crimp, class R - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-077:2020 - Aerospace series - Electrical contacts used in elements of connection - Part 077: Contacts, electrical, female, type A, crimp, class R - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 4639-102:2008 - Aerospace series - Connectors, optical, rectangular, modular, multicontact, 1,25 diameter ferrule, with removable alignment sleeve holder - Part 102: Optical contact for cable EN 4641-102 - Operating temperatures between - 55 °C and 100 °C - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3646-001:2009 - Aerospace series - Connectors, electrical, circular, bayonet coupling, operating temperature 175 °C or 200 °C continuous - Part 001: Technical specification
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-071:2008 - Aerospace series - Electrical contacts used in elements of connection - Part 071: Contacts, electrical, female, type A, crimp, class S - Product standard
• Effective Date: 28-Jan-2026
• Referred By: SIST EN 3155-076:2020 - Aerospace series - Electrical contacts used in elements of connection - Part 076: Contacts, electrical, male, type A, crimp, class R - Product standard
• Effective Date: 28-Jan-2026

SIST EN 2591-218:2004 is a SIST standard for aerospace electrical and optical connection elements. It specifies a test method for ageing terminal lugs and in-line splices by temperature and current cycling, and it is intended for use together with EN 2591-100.

What does SIST EN 2591-218:2004 specify?

SIST EN 2591-218:2004 covers one ageing test method for terminal lugs and in-line splices in the aerospace series. It tells the user how to prepare specimens, how to cycle them by current and temperature, and how to judge the result by voltage-drop measurements and limits.

The document is organized into scope, normative references, specimen preparation, the test method, and requirements. Its method distinguishes between crimped terminal lugs and in-line splices on copper cable and on aluminium cable, because the severity and the acceptance checks are not the same for both cases.

What are the key requirements of SIST EN 2591-218:2004?

Clause 3 requires specimens to be fitted with their normal accessories and wired in accordance with the technical specification. In practice, the test must reflect the intended assembly, so the sample setup matters as much as the connector itself.

Clause 3 also requires the technical specification to state the number of specimens, the cable type, the installation and wiring arrangement, the cycling current, the accessories fitted, and the initial and final measurements. This is the test-plan checklist that defines what must be agreed before the ageing run starts.

Clause 4.1 sets the severity for crimped terminal lugs and in-line splices on copper cable according to the operating temperature given in the product standard. In practice, the hotter the intended service condition, the tougher the cycling regime.

Clause 4.1 also applies a fixed cycling severity to crimped terminal lugs and in-line splices on aluminium cable. This gives one common ageing regime for all aluminium-cable specimens covered by the standard.

Clause 5 describes the cycling sequence: d.c. voltage is increased to bring the conductor to the ageing temperature, then reduced to return to a low-temperature condition, and the cycle is repeated. In practice, the joint is stressed by repeated heating and cooling under electrical load, which is what reveals weak crimps or unstable interfaces.

Clause 6 sets the acceptance checks. For copper cable, the voltage drop in each crimp is measured in accordance with EN 2591-217 and must stay within the technical specification, with an additional D max limit defined by the severity level. For aluminium cable, voltage-drop measurements are taken at the specified cycle checkpoints, and the terminal lug or in-line splice must remain cooler than the cable.

The standard also notes that the test is hazardous because of the currents and voltages used. In practice, the test set-up and operator protection need to be planned carefully.

What terms does SIST EN 2591-218:2004 define?

• terminal lugs - Connection parts used to terminate a conductor so it can be attached to equipment or another connection point.
• in-line splices - Connection parts used to join two conductors end to end in the cable run.
• crimped - Joined by mechanical compression, so the quality of the crimp is central to the test result.
• temperature and current cycling - Repeated heating and cooling driven by electrical current, used here to age the connection under service-like stress.
• voltage drop - The loss of voltage across the connection, used as the main indicator of contact quality after ageing.
• d.c. - Direct current, the current form used in the cycling and measurement steps.
• severity - The test level chosen for the specimen, based on the cable type and operating temperature.

Who uses SIST EN 2591-218:2004?

SIST EN 2591-218:2004 is used by aerospace connector manufacturers, cable assembly suppliers, test laboratories, and quality teams that need to verify terminal lugs and in-line splices. Buyers and engineers use it when they need a common ageing test for copper or aluminium cable terminations and when they want to define the required specimen setup and acceptance checks in a technical specification.

What changed in SIST EN 2591-218:2004 from the previous edition?

SIST EN 2591-218:2004 is identified as the Slovenian standard corresponding to EN 2591-218:2002.

Which standards are used with SIST EN 2591-218:2004?

• EN 2591-100 - Provides the general test-method framework that this part is to be used with.
• EN 2591-217 - Gives the voltage-drop measurement method used for the copper-cable acceptance check.

What does the SIST EN 2591-218:2004 document contain?

SIST EN 2591-218:2004 contains specimen-preparation rules, a temperature/current cycling procedure, and acceptance criteria for copper and aluminium cable terminations. Table 1 links the copper-cable operating temperature to the cycling severity, and Figure 1 illustrates the D max limit used in the copper-cable result check. The document also gives the cycle points used for aluminium-cable voltage-drop measurements. It is written for test and qualification work, so the practical focus is on how to set up the specimens, run the ageing sequence, and decide whether the connection remains acceptable after cycling.

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Aerospace series - Elements of electrical and optical connection - Test methods - Part 218: Ageing of terminal lugs and in-line splices by temperature and current cyclingLuft- und Raumfahrt - Elektrische und optische Verbindungselemente - Prüfverfahren - Teil 218: Alterung von Kabelschuhen und Stoßverbindern durch zyklische Temperatur- und StrombelastungSérie aérospatiale - Organes de connexion électrique et optique - Méthodes d'essais - Partie 218: Vieillissement des cosses et des prolongateurs par cyclage en température et en courantAerospace series - Elements of electrical and optical connection - Test methods - Part 218: Ageing of terminal lugs and in-line splices by temperature and current cycling49.060Aerospace electric equipment and systemsICS:Ta slovenski standard je istoveten z:EN 2591-218:2002SIST EN 2591-218:2004en01-maj-2004SIST EN 2591-218:2004SLOVENSKI
STANDARD
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 2591-218June 2002ICS 49.060English versionAerospace series - Elements of electrical and optical connection- Test methods - Part 218: Ageing of terminal lugs and in-linesplices by temperature and current cyclingSérie aérospatiale - Organes de connexion électrique etoptique - Méthodes d'essais - Partie 218: Vieillissementdes cosses et des prolongateurs par cyclage entempérature et en courantLuft- und Raumfahrt - Elektrische und optischeVerbindungselemente - Prüfverfahren - Teil 218: Alterungvon Kabelschuhen und Stoßverbindern durch zyklischeTemperatur- und StrombelastungThis European Standard was approved by CEN on 8 February 2002.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2002 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 2591-218:2002 ESIST EN 2591-218:2004
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