SIST EN 3645-001:2022
(Main)Aerospace series - Connectors, electrical, circular, scoop-proof, triple start threaded coupling, operating temperature 175 °C or 200 °C continuous - Part 001: Technical specification
Aerospace series - Connectors, electrical, circular, scoop-proof, triple start threaded coupling, operating temperature 175 °C or 200 °C continuous - Part 001: Technical specification
This document specifies the general characteristics, the conditions for qualification, acceptance and quality assurance, as well as the test programs and groups for threaded ring coupling circular connectors, fire resistant, intended for use in a temperature range from -65 °C to 175 °C continuous or 200 °C continuous according to the classes.
Luft- und Raumfahrt - Elektrische Rundsteckverbinder, kontaktgeschützt, dreigängige Gewinde-Schnellkupplung, Betriebstemperatur 175 °C oder 200 °C konstant - Teil 001: Technische Lieferbedingungen
Dieses Dokument legt die allgemeinen Eigenschaften, die Bedingungen für Qualifikation, Annahme und Qualitätssicherung sowie Prüfprogramme und gruppen für Rundsteckverbinder mit Gewinde-Schnell¬kupplung, feuerbeständig, bestimmt für die Anwendung in einem Temperaturbereich von −65 °C bis 175 °C konstant oder 200 °C konstant, entsprechend den Klassen, fest.
Série aérospatiale - Connecteurs électriques circulaires, à contacts protégés, à accouplement par filetage, à pas rapide à trois filets, température d'utilisation 175 °C ou 200 °C continu - Partie 001 : Spécification technique
Le présent document spécifie les caractéristiques générales, les conditions de qualification, d’acceptation et d’assurance qualité, ainsi que les programmes et les groupes d’essais des connecteurs circulaires à accouplement par bague filetée, résistants au feu, destinés à une utilisation dans une plage de températures comprises entre -65 °C et 175 °C continu, ou 200 °C continu suivant les classes.
Aeronavtika - Konektorji, električni, okrogli, zaščiten kontakt, hitra spojka z navojem, stalna delovna temperatura 175 °C ali 200 °C - 001. del: Tehnična specifikacija
Ta dokument določa splošne značilnosti, pogoje kvalifikacije, sprejemljivosti in zagotavljanja kakovosti ter preskusne programe in skupine za okrogle konektorje, priključene z navojnim obročkom, ognjevzdržne, za uporabo pri stalnih temperaturah med –65 °C in 175 °C ali pri stalni temperaturi 200 °C, odvisno od razreda.
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 3645-001:2022
01-november-2022
Nadomešča:
SIST EN 3645-001:2019
Aeronavtika - Konektorji, električni, okrogli, zaščiten kontakt, hitra spojka z
navojem, stalna delovna temperatura 175 °C ali 200 °C - 001. del: Tehnična
specifikacija
Aerospace series - Connectors, electrical, circular, scoop-proof, triple start threaded
coupling, operating temperature 175 °C or 200 °C continuous - Part 001: Technical
specification
Luft- und Raumfahrt - Elektrische Rundsteckverbinder, kontaktgeschützt, dreigängige
Gewinde-Schnellkupplung, Betriebstemperatur 175 °C oder 200 °C konstant - Teil 001:
Technische Lieferbedingungen
Série aérospatiale - Connecteurs électriques circulaires, à contacts protégés, à
accouplement par filetage, à pas rapide à trois filets, température d'utilisation 175 °C ou
200 °C continu - Partie 001 : Spécification technique
Ta slovenski standard je istoveten z: EN 3645-001:2022
ICS:
31.220.10 Vtiči in vtičnice, konektorji Plug-and-socket devices.
Connectors
49.060 Letalska in vesoljska Aerospace electric
električna oprema in sistemi equipment and systems
SIST EN 3645-001:2022 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 3645-001:2022
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SIST EN 3645-001:2022
EN 3645-001
EUROPEAN STANDARD
NORME EUROPÉENNE
September 2022
EUROPÄISCHE NORM
ICS 49.060 Supersedes EN 3645-001:2019
English Version
Aerospace series - Connectors, electrical, circular, scoop-
proof, triple start threaded coupling, operating
temperature 175 °C or 200 °C continuous - Part 001:
Technical specification
Série aérospatiale - Connecteurs électriques Luft- und Raumfahrt - Elektrische Rundsteckverbinder,
circulaires, à contacts protégés, à accouplement par kontaktgeschützt, dreigängige Gewinde-
filetage, à pas rapide à trois filets, température Schnellkupplung, Betriebstemperatur 175 °C oder 200
d'utilisation 175 °C ou 200 °C continu - Partie 001 : °C konstant - Teil 001: Technische Lieferbedingungen
Spécification technique
This European Standard was approved by CEN on 22 November 2021.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC 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
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2022 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 3645-001:2022 E
worldwide for CEN national Members.
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 7
4 Description . 7
4.1 General. 7
4.2 Receptacle. 8
4.3 Plug . 8
4.4 Materials and surface treatment . 8
4.4.1 General. 8
4.4.2 Housing . 8
4.4.3 Contacts . 8
4.4.4 Non-metallic materials . 9
4.4.5 Surfaces treatments . 9
5 Design . 9
5.1 Housings . 9
5.2 Inserts . 10
6 Definition drawings and masses . 10
6.1 General. 10
6.2 Receptacle mating dimensions . 10
6.3 Plug mating dimensions . 13
6.4 Receptacle and plug polarization . 16
6.5 Dimensions of the rear part of the connectors . 17
6.5.1 Accessory interface dimensions . 17
6.5.2 Size 8 cavity - rear dimensions . 19
6.6 Contact arrangements . 20
6.7 Contact dimensions . 66
6.7.1 Removable contacts . 66
6.7.2 Fixed contacts . 66
7 Tests . 67
7.1 Tests according to EN 2591-100 . 67
7.2 Special tests . 81
7.2.1 Lanyard release connectors . 81
7.2.2 Resistance to fluids . 81
7.3 Gauges to test the holding force of the grounding spring system of the housing . 83
7.4 Gauges to test the stability of male contacts in insert . 84
8 Quality assurance . 85
8.1 General. 85
8.2 Qualification . 85
8.2.1 General. 85
8.2.2 For MIL-DTL-38999 QPL manufacturer . 86
8.2.3 For non MIL-DTL-38999 QPL manufacturer . 86
2
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
8.2.4 Sampling and definition of specimens . 87
8.2.5 Preparation of specimens . 88
8.2.6 Program of qualification tests . 89
8.3 Maintenance of qualification . 103
8.3.1 General . 103
8.3.2 Recognition of MIL-DTL-38999 . 103
8.3.3 Fuel resistant class . 104
8.3.4 Sampling distribution . 104
8.4 Routine tests during production . 104
8.5 Inspections . 105
8.6 Value added distributors . 105
9 Designation and marking . 105
9.1 General principle of designation . 105
9.2 Marking . 105
10 Delivery conditions . 106
11 Packaging . 106
12 Storage . 106
Bibliography . 107
3
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
European foreword
This document (EN 3645-001:2022) has been prepared by the Aerospace and Defence Industries
Association of Europe — Standardization (ASD-STAN).
After enquiries and votes carried out in accordance with the rules of this Association, this
document has received the approval of the National Associations and the Official Services of the
member countries of ASD, prior to its presentation to CEN.
This document shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by March 2023, and conflicting national standards shall be
withdrawn at the latest by March 2023.
Attention is drawn to the possibility that some of the elements of this document may be the subject
of patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 3645-001 :2019.
The main changes with respect to the previous edition are listed in the following table.
Table X — Main changes introduced
prEN/EN Edition Publication Modification
Number Date
prEN 3645 P5 2021-12-01 Introduction of Hexavalent Chromium free (in both
-001 manufacturing process and final product) plating classes and
related compatibility testing with legacy Cadmium plated items
Addition of optional marking for insulators according to MIL
standard
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the
following countries are bound to implement this document: Austria, Belgium, Bulgaria, Croatia,
Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland,
Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Türkiye and the United Kingdom.
4
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
Introduction
This family of connectors is derived from MIL-DTL-38999 series III, with which it is intermateable and
interchangeable. It is particularly suitable for use in zones of severe environmental conditions on board
aircraft, applying EN 2282.
These connectors are distinguishable from MIL-DTL-38999 by:
a compatibility with size 8 power and quadrax contacts;
self-extinguishing materials;
compatibility with reduced diameter cables;
additional reinforced fuel resistant insert type;
additional insert with grounded cavities.
5
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
1 Scope
This document specifies the general characteristics, the conditions for qualification, acceptance and
quality assurance, as well as the test programs and groups for threaded ring coupling circular
connectors, fire resistant, intended for use in a temperature range from -65 °C to 175 °C continuous or
200 °C continuous according to the classes.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 2267-002, Aerospace series — Cables, electrical, for general purpose — Operating temperatures
between -55 °C and 260 °C — Part 002: General
EN 2346 (all parts), Aerospace series — Cable, electrical, fire resistant — Operating temperatures
between -65 °C and 260 °C
EN 2591-*, Aerospace series — Elements of electrical and optical connection — Test methods
EN 3155-001:2016, Aerospace series — Electrical contacts used in elements of connection — Part 001:
Technical specification
EN 3197, Aerospace series — Design and installation of aircraft electrical and optical interconnection
1)
systems
EN 3645-002, Aerospace series — Connectors, electrical, circular, scoop-proof, triple start threaded
coupling, operating temperature 175 °C or 200 °C continuous — Part 002: Specification of performance
and contact arrangements
EN 3909, Aerospace series — Test fluids and test methods for electrical and optical components and sub-
assemblies
2)
ISO 68-1, ISO general purpose screw threads — Basic profile — Part 1: Metric screw threads
2)
ISO 261, ISO general purpose metric screw threads — General plan
2)
ISO 262, ISO general purpose metric screw threads — Selected sizes for screws, bolts and nuts
ISO 965-2, ISO general purpose metric screw threads — Tolerances — Part 2: Limits of sizes for general
2)
purpose external and internal screw threads — Medium quality
ISO 27874, Metallic and other inorganic coatings — Electrodeposited gold and gold alloy coatings for
2)
electrical, electronic and engineering purposes — Specification and test methods
* All parts quoted in this document.
1)
Published as ASD-STAN Standard at the date of publication of this document by AeroSpace and Defence
industries Association of Europe — Standardization (ASD-STAN), https://www.asd-stan.org/.
2)
Published by: ISO International Organization for Standardization http://www.iso.ch/.
6
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
MIL-DTL-38999, Connectors, electrical, circular, miniature, high density, quick disconnect (bayonet,
threaded, and breech coupling), environment resistant, removable crimp and hermetic solder contacts,
3)
general specification for
MIL-DTL-38999/62, Sealing boot, size 8, pin or socket, shielded crimp contacts, electrical connector,
3)
circular, metric
3)
MIL-HDBK-454, General guidelines for electronic equipment
3)
MIL-STD-1373, Screw-thread, modified, 60°, stub, double
MIL-STD-1560, Defence logistics agency: Insert Arrangements for MIL-DTL-38999, MIL-DTL-27599, and
3)
SAE-AS29600 Series A Electrical Circular Connectors
TR 4865, Aerospace series — Suitable cable outlet to be mated on EN 3645 connector (layout type: 21R48)
4)
for the qualification of electrical contact product standards EN 3155-065 and EN 3155-083
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 2591-100 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
• ISO Online browsing platform: available at https://www.iso.org/obp
• IEC Electropedia: available at https://www.electropedia.org/
4 Description
4.1 General
Different variants of materials, housings and contact arrangements are provided according to the
classes depending on the service conditions.
The pair of connectors is characterized:
by shell-to-shell bottoming;
by its triple threaded and self-locking coupling system;
by plugs with shielding ring providing protection against radioelectrical interference;
by the scoop-proof shells.
These connectors use the following contacts:
crimped sizes 22, 20, 16, 12, 10 and 8;
soldered (model Y) sizes 22, 20, 16 and 12;
3)
Published by: DEFENSE LOGISTICS AGENCY DLA Land and Maritime (US)
https://landandmaritimeapps.dla.mil/Programs/MilSpec/DocSearch.aspx.
4)
Published as ASD-STAN Technical Report at the date of publication of this document by AeroSpace and Defence
industries Association of Europe — Standardization (ASD-STAN), http://www.asd-stan.org/.
7
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
coaxial crimped or soldered sizes 16, 12 and 8;
For arrangements comprising the letter G or
triaxial crimped or soldered size 8; Q, all contacts are grounded to the receptacle
housing
quadrax crimped size 8.
The receptacles and plugs contain either male contacts or female contacts.
The contacts fitted in the class Y receptacles are exclusively of the male solder type.
The connectors are polarized by means of keyways and keys; polarization shall be obtained before the
male contacts enter the insert of the female contacts and before the coupling ring is engaged. The
position of the keying arrangement is given in Table 7.
The visual check of coupling is obtained by masking of a red colour band on the receptacle.
4.2 Receptacle
The receptacle housing may be attached:
square flange;
nut, with sealing by O-ring at the attachment; round soldered or brazed flange for class Y connectors.
4.3 Plug
The coupling ring is permanently fitted to the plug and allows coupling and uncoupling of the
connectors. The lanyard release version may also be uncoupled by pulling on the lanyard.
The plug is fitted with a self-locking mechanism and a grounding spring device ensuring electrical
continuity between the coupled connector housings.
An anti-decoupling device shall be provided to maintain complete coupling.
4.4 Materials and surface treatment
4.4.1 General
When dissimilar metals are in close contact, adequate protection against corrosion shall be used for the
electromotive force of the cell not to exceed 0,25 V (see EN 3197).
4.4.2 Housing
The material of the housings for the connectors and fittings may be either aluminium alloy, passivated
stainless steel or composite. Aluminium alloy and composite shall be plated as defined by the class
(composite coupling rings and Hex nut may be unplated) (see EN 3645-002).
4.4.3 Contacts
Unless otherwise specified, the non-removable contacts shall be in ferrous alloy for class Y and in
copper alloy for the other classes.
They shall be gold-plated on an appropriate undercoat. Selective protection is authorised provided that
it is sufficient to ensure that the specified performance is achieved.
Measurement of the thickness of the protective plating shall be effected in accordance with ISO 27874.
NOTE In the past, the determination of coating thickness was described in ISO 4524-1, which has been withdrawn.
For removable contacts, see EN 3645-002.
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
4.4.4 Non-metallic materials
The materials used for insert, seals and grommets shall have a hardness and mechanical and electrical
characteristics consistent with the required use.
4.4.5 Surfaces treatments
Label chrome 6 free (not applicable for class W & J):
None of the hexavalent chromium compounds listed hereafter shall be added by any actor of the Supply
Chain or used in the manufacturing process.
The manufacturing process begins with the creation of the materials from which the design is made.
Manufacturing processes include treating (such as heat treating or plating), machining, moulding or
reshaping the material.
5)
Table 2 — Hexavalent chromium compound list
Substance name CAS number
Acids generated from chromium trioxide and their 7738-94-5
oligomers. Names of the acids and their oligomers:
13530-68-2
chromic acid, dichromic acid, oligomers of chromic
acid and dichromic acid.
Chromium trioxide 1333-82-0
Potassium dichromate 7778-50-9
Sodium chromate 7775-11-3
Sodium dichromate 7789-12-0
10588-01-9
Dichromium tris(chromate) 24613-89-6
Pentazinc chromate octahydroxide 49663-84-5
Potassium hydroxyoctaoxodizincatedichromate 11103-86-9
Strontium chromate 7789-06-2
5 Design
5.1 Housings
The connector housings shall be one-piece. They shall contain teeth at the rear over their entire periphery
and shall accommodate the rear accessories. The receptacle shall be fitted with a seal for sealing the
coupled housings.
Jam-nut receptacles shall contain an O-ring seal. The nut shall have holes for the passage of locking wire.
During coupling the grounding spring shall be engaged a minimum of 1,02 mm in the receptacle before
the contacts engage.
5) The CAS Registry Number, also referred to as CASRN or CAS Number, is a unique numerical identifier assigned
by the Chemical Abstracts Service, a division of the American Chemical Society.
9
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
Except for the triple start threads, which shall conform to standard MIL-STD-1373, threads shall
conform to standards ISO 68-1, ISO 261, ISO 262 and ISO 965-2.
The coupling ring shall be designed so that the male and female contacts engage when it is turned in a
clockwise direction and disengage when turned anticlockwise. The coupling threads may have a
lubricant applied during manufacture.
Full locking of the connectors shall occur at about 360°. On completion of tightening of the coupling
ring, mechanical contact shall exist between the receptacle and plug housings. A red band shall be
located on the receptacle so as to be visible when unmated and fully covered when completely mated.
The receptacle has five keyways which engage with corresponding keys on the plug. The major key is
fixed and is wider than the others. Polarization is ensured by the different positions which the minor
keys may take. The position of the insert is fixed relative to the major key.
A blue-coloured band indicating that the crimped contacts of the connectors are rear-releasable shall be
provided:
in front of the flange on square flange receptacles;
on the flange of jam-nut receptacles;
on the coupling ring of plugs.
This band shall be positioned so that at least one is visible when the connectors are fitted and when
they are mated or unmated. Hermetic receptacles do not require blue colour band.
5.2 Inserts
The insert for contacts shall be non-removable; it shall be mechanically held in the housing. Sealing
shall be provided between the housing and insert.
The front face of the insert shall be such that sealing is ensured when the connectors are coupled.
The interfacial seal of the insert of the male contacts shall be bonded on the hard insert.
The grommet shall permit sealing for all cable diameters indicated in EN 3645-002 and shall not be
removable.
The mechanical contacts retention system shall be integrated in the hard insert.
The design of non-hermetic connectors shall permit individual installation of the contacts without
removal of the insert or grommet. Fitting and removal of the contacts shall be from the rear with the
tools specified in the contact product standards.
Contact position identification shall be permanent and contrasted on the front face of the insert or the
interfacial seal and on the rear face of the grommet as indicated in 6.6.
The marking shall not be recessed or raised on the surfaces providing a seal.
6 Definition drawings and masses
6.1 General
The general dimensions and the masses of receptacles, plugs and protective covers are given in the
product standards.
6.2 Receptacle mating dimensions
The mating dimensions of receptacles are shown in Figure 1 and details V and W as well as in Table 3 and
Table 4.
10
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
Dimensions and tolerances are in millimetres.
Key
a The distance between the front face of the shell and the point where the right end of a gauge with a diameter
equal to the nominal diameter of a male contact comes into contact with the elastic part of the female contact.
Figure 1 — Receptacle — Coupling dimensions
11
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SIST EN 3645-001:2022
EN 3645-001:2022 (E)
Table 3 — Receptacle — Dimensions (1 of 2)
Housing A dia. B dia. C dia. D dia. D dia. E dia. E dia. F dia.
size (except classes (classes J and (except classes (classes J and
J and M) M only) J and M) M only)
+ 0,13
max. max.
−0,25
14,42 11,36 11,43 12,63 12,70
09 14,55 7,24 15,88
14,14 11,20 11,20 12,34 12,34
17,60 14,61 14,68 15,88 15,95
11 17,73 10,49 19,05
17,32 14,45 14,45 15,60 15,60
20,77 17,45 17,52 19,66 19,73
13 20,90 13,39 22,23
20,49 17,30 17,30 19,38 19,38
23,95 20,63 20,70 22,84 22,91
1
...
SLOVENSKI STANDARD
oSIST prEN 3645-001:2021
01-oktober-2021
Aeronavtika - Konektorji, električni, okrogli, zaščiten kontakt, hitra spojka z
navojem, stalna delovna temperatura 175 °C ali 200 °C - 001. del: Tehnična
specifikacija
Aerospace series - Connectors, electrical, circular, scoop-proof, triple start threaded
coupling, operating temperature 175 °C or 200 °C continuous - Part 001: Technical
specification
Luft- und Raumfahrt - Elektrische Rundsteckverbinder, kontaktgeschützt, dreigängige
Gewinde-Schnellkupplung, Betriebstemperatur 175 °C oder 200 °C konstant - Teil 001:
Technische Lieferbedingungen
Ta slovenski standard je istoveten z: prEN 3645-001
ICS:
31.220.10 Vtiči in vtičnice, konektorji Plug-and-socket devices.
Connectors
49.060 Letalska in vesoljska Aerospace electric
električna oprema in sistemi equipment and systems
oSIST prEN 3645-001:2021 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 3645-001:2021
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oSIST prEN 3645-001:2021
DRAFT
EUROPEAN STANDARD
prEN 3645-001
NORME EUROPÉENNE
EUROPÄISCHE NORM
July 2021
ICS 49.060 Will supersede EN 3645-001:2019
English Version
Aerospace series - Connectors, electrical, circular, scoop-
proof, triple start threaded coupling, operating
temperature 175 °C or 200 °C continuous - Part 001:
Technical specification
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee ASD-
STAN.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations
which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC
Management Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 3645-001:2021 E
worldwide for CEN national Members.
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oSIST prEN 3645-001:2021
prEN 3645-001:2021 (E)
Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 7
4 Description . 7
4.1 General. 7
4.2 Receptacle. 8
4.3 Plug . 8
4.4 Materials and surface treatment . 8
4.4.1 General. 8
4.4.2 Housing . 8
4.4.3 Contacts . 9
4.4.4 Non-metallic materials . 9
4.4.5 Surfaces treatments . 9
5 Design . 10
5.1 Housings . 10
5.2 Inserts . 10
6 Definition drawings and masses . 11
6.1 General. 11
6.2 Receptacle mating dimensions . 11
6.3 Plug mating dimensions . 14
6.4 Receptacle and plug polarization . 17
6.5 Dimensions of the rear part of the connectors . 18
6.5.1 Accessory interface dimensions . 18
6.5.2 Size 8 cavity - rear dimensions . 20
6.6 Contact arrangements . 21
6.7 Contact dimensions . 67
6.7.1 Removable contacts . 67
6.7.2 Fixed contacts . 67
7 Tests . 68
7.1 Tests according to EN 2591-100 . 68
7.2 Special tests . 82
7.2.1 Lanyard release connectors . 82
7.2.2 Resistance to fluids . 82
7.3 Gauges to test the holding force of the grounding spring system of the housing . 84
7.4 Gauges to test the stability of male contacts in insert . 85
8 Quality assurance . 86
8.1 General. 86
8.2 Qualification . 86
8.2.1 General. 86
8.2.2 For MIL-DTL-38999 QPL manufacturer . 87
8.2.3 For non MIL-DTL-38999 QPL manufacturer . 87
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8.2.4 Sampling and definition of specimens . 88
8.2.5 Preparation of specimens . 89
8.2.6 Program of qualification tests . 90
8.3 Maintenance of qualification . 105
8.3.1 General . 105
8.3.2 Recognition of MIL-DTL-38999 . 105
8.3.3 Fuel resistant class . 106
8.3.4 Sampling distribution . 106
8.4 Routine tests during production . 106
8.5 Inspections . 107
8.6 Value added distributors . 107
9 Designation and marking . 107
9.1 General principle of designation . 107
9.2 Marking . 107
10 Delivery conditions . 108
11 Packaging . 108
12 Storage . 108
Bibliography . 109
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European foreword
This document (prEN 3645-001:2021) has been prepared by the Aerospace and Defence Industries
Association of Europe — Standardization (ASD-STAN).
After enquiries and votes carried out in accordance with the rules of this Association, this
document has received the approval of the National Associations and the Official Services of the
member countries of ASD-STAN, prior to its presentation to CEN.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 3645-001:2019.
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Introduction
This family of connectors is derived from MIL-DTL-38999 series III, with which it is intermateable and
interchangeable. It is particularly suitable for use in zones of severe environmental conditions on board
aircraft, applying EN 2282.
These connectors are distinguishable from MIL-DTL-38999 by:
a compatibility with size 8 power and quadrax contacts;
self-extinguishing materials;
compatibility with reduced diameter cables;
additional reinforced fuel resistant insert type;
additional insert with grounded cavities.
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1 Scope
This document specifies the general characteristics, the conditions for qualification, acceptance and
quality assurance, as well as the test programs and groups for threaded ring coupling circular
connectors, fire resistant, intended for use in a temperature range from -65 °C to 175 °C continuous or
200 °C continuous according to the classes.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 2267-002, Aerospace series — Cables, electrical, for general purpose — Operating temperatures
between -55 °C and 260 °C — Part 002: General
EN 2346 (all parts), Aerospace series — Cable, electrical, fire resistant — Operating temperatures
1)
between -65 °C and 260 °C
*
EN 2591- , Aerospace series — Elements of electrical and optical connection — Test methods
EN 3155-001:2016, Aerospace series — Electrical contacts used in elements of connection — Part 001:
Technical specification
EN 3197, Aerospace series — Design and installation of aircraft electrical and optical interconnection
1)
systems
EN 3645-002, Aerospace series — Connectors, electrical, circular, scoop-proof, triple start threaded
coupling, operating temperature 175 °C or 200 °C continuous — Part 002: Specification of performance
and contact arrangements
EN 3909, Aerospace series — Test fluids and test methods for electrical and optical components and sub-
assemblies
EN 9133, Aerospace series — Quality management systems — Qualification procedure for aerospace
standard products
2)
ISO 68-1, ISO general purpose screw threads — Basic profile — Part 1: Metric screw threads
2)
ISO 261, ISO general purpose metric screw threads — General plan
2)
ISO 262, ISO general purpose metric screw threads — Selected sizes for screws, bolts and nuts
ISO 965-2, ISO general purpose metric screw threads — Tolerances — Part 2: Limits of sizes for general
2)
purpose external and internal screw threads — Medium quality
ISO 27874, Metallic and other inorganic coatings — Electrodeposited gold and gold alloy coatings for
2)
electrical, electronic and engineering purposes — Specification and test methods
1)
Published as ASD-STAN Standard at the date of publication of this document by AeroSpace and Defence
industries Association of Europe — Standardization (ASD-STAN), http://www.asd-stan.org/.
*
All parts quoted in this document.
2)
Published by: ISO International Organization for Standardization http://www.iso.ch/.
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MIL-DTL-38999, Connectors, electrical, circular, miniature, high density, quick disconnect (bayonet,
threaded, and breech coupling), environment resistant, removable crimp and hermetic solder contacts,
3)
general specification for
MIL-DTL-38999/62, Sealing boot, size 8, pin or socket, shielded crimp contacts, electrical connector,
3)
circular, metric
3)
MIL-HDBK-454, General guidelines for electronic equipment
3)
MIL-STD-1373, Screw-thread, modified, 60°, stub, double
MIL-STD-1560, Defence logistics agency: Insert Arrangements for MIL-DTL-38999, MIL-DTL-27599, and
3)
SAE-AS29600 Series A Electrical Circular Connectors
TR 4865, Aerospace series — Suitable cable outlet to be mated on EN 3645 connector (layout type: 21R48)
4)
for the qualification of electrical contact product standards EN 3155-065 and EN 3155-083
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 2591-100 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
• ISO Online browsing platform: available at https://www.iso.org/obp
• IEC Electropedia: available at https://www.electropedia.org/
4 Description
4.1 General
Different variants of materials, housings and contact arrangements are provided according to the
classes depending on the service conditions.
The pair of connectors is characterized:
by shell to shell bottoming;
by its triple threaded and self-locking coupling system;
by plugs with shielding ring providing protection against radioelectrical interference;
by the scoop-proof shells.
3)
Published by: DEFENSE LOGISTICS AGENCY DLA Land and Maritime (US)
https://landandmaritimeapps.dla.mil/Programs/MilSpec/DocSearch.aspx.
4)
Published as ASD-STAN Technical Report at the date of publication of this document by AeroSpace and Defence
industries Association of Europe — Standardization (ASD-STAN), http://www.asd-stan.org/.
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These connectors use the following contacts:
crimped sizes 22, 20, 16, 12, 10 and 8;
soldered (model Y) sizes 22, 20, 16 and 12;
coaxial crimped or soldered sizes 16, 12 and 8;
For arrangements comprising the letter G or
triaxial crimped or soldered size 8;
Q, all contacts are grounded to the receptacle
housing
quadrax crimped size 8.
The receptacles and plugs contain either male contacts or female contacts.
The contacts fitted in the class Y receptacles are exclusively of the male solder type.
The connectors are polarized by means of keyways and keys; polarization shall be obtained before the
male contacts enter the insert of the female contacts and before the coupling ring is engaged. The
position of the keying arrangement is given in Table 6.
The visual check of coupling is obtained by masking of a red colour band on the receptacle.
4.2 Receptacle
The receptacle housing may be attached:
square flange;
nut, with sealing by O-ring at the attachment; round soldered or brazed flange for class Y
connectors.
4.3 Plug
The coupling ring is permanently fitted to the plug and allows coupling and uncoupling of the
connectors. The lanyard release version may also be uncoupled by pulling on the lanyard.
The plug is fitted with a self-locking mechanism and a grounding spring device ensuring electrical
continuity between the coupled connector housings.
An anti-decoupling device shall be provided to maintain complete coupling.
4.4 Materials and surface treatment
4.4.1 General
When dissimilar metals are in close contact, adequate protection against corrosion shall be used for the
electromotive force of the cell not to exceed 0,25 V (see EN 3197).
4.4.2 Housing
The material of the housings for the connectors and fittings may be either aluminium alloy, passivated
stainless steel or composite. Aluminium alloy and composite shall be plated as defined by the class
(composite coupling rings and Hex nut may be unplated) (see EN 3645-002).
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4.4.3 Contacts
Unless otherwise specified, the non-removable contacts shall be in ferrous alloy for class Y and in
copper alloy for the other classes.
They shall be gold-plated on an appropriate undercoat. Selective protection is authorized provided that
it is sufficient to ensure that the specified performance is achieved.
Measurement of the thickness of the protective plating shall be effected in accordance with ISO 27874.
NOTE In the past, the determination of coating thickness was described in ISO 4524-1, which has been
withdrawn.
For removable contacts, see EN 3645-002.
4.4.4 Non-metallic materials
The materials used for insert, seals and grommets shall have a hardness and mechanical and electrical
characteristics consistent with the required use.
4.4.5 Surfaces treatments
Label chrome 6 free (not applicable for class W & J):
None of the hexavalent chromium compounds listed hereafter shall be added by any actor of the Supply
Chain or used in the manufacturing process.
The manufacturing process begins with the creation of the materials from which the design is made.
Manufacturing processes include treating (such as heat treating or plating), machining, moulding or
reshaping the material.
5)
Table 1 — Hexavalent chromium compound list
Substance name CAS number
Acids generated from chromium trioxide and their 7738-94-5
oligomers. Names of the acids and their oligomers:
13530-68-2
chromic acid, dichromic acid, oligomers of chromic
acid and dichromic acid.
Chromium trioxide 1333-82-0
Potassium dichromate 7778-50-9
Sodium chromate 7775-11-3
Sodium dichromate 7789-12-0
10588-01-9
Dichromium tris(chromate) 24613-89-6
Pentazinc chromate octahydroxide 49663-84-5
Potassium hydroxyoctaoxodizincatedichromate 11103-86-9
Strontium chromate 7789-06-2
5)
The CAS Registry Number, also referred to as CASRN or CAS Number, is a unique numerical identifier assigned
by the Chemical Abstracts Service, a division of the American Chemical Society.
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5 Design
5.1 Housings
The connector housings shall be one-piece. They shall contain teeth at the rear over their entire periphery
and shall accommodate the rear accessories. The receptacle shall be fitted with a seal for sealing the
coupled housings.
Jam-nut receptacles shall contain an O-ring seal. The nut shall have holes for the passage of locking
wire.
During coupling the grounding spring shall be engaged a minimum of 1,02 mm in the receptacle before
the contacts engage.
Except for the triple start threads, which shall conform to standard MIL-STD-1373, threads shall
conform to standards ISO 68-1, ISO 261, ISO 262 and ISO 965-2.
The coupling ring shall be designed so that the male and female contacts engage when it is turned in a
clockwise direction and disengage when turned anticlockwise. The coupling threads may have a
lubricant applied during manufacture.
Full locking of the connectors shall occur at about 360°. On completion of tightening of the coupling
ring, mechanical contact shall exist between the receptacle and plug housings. A red band shall be
located on the receptacle so as to be visible when unmated and fully covered when completely mated.
The receptacle has five keyways which engage with corresponding keys on the plug. The major key is
fixed and is wider than the others. Polarization is ensured by the different positions which the minor
keys may take. The position of the insert is fixed relative to the major key.
A blue-coloured band indicating that the crimped contacts of the connectors are rear-releasable shall be
provided:
in front of the flange on square flange receptacles;
on the flange of jam-nut receptacles;
on the coupling ring of plugs.
This band shall be positioned so that at least one is visible when the connectors are fitted and when
they are mated or unmated. Hermetic receptacles do not require blue colour band.
5.2 Inserts
The insert for contacts shall be non-removable; it shall be mechanically held in the housing. Sealing
shall be provided between the housing and insert.
The front face of the insert shall be such that sealing is ensured when the connectors are coupled. The
interfacial seal of the insert of the male contacts shall be bonded on the hard insert.
The grommet shall permit sealing for all cable diameters indicated in EN 3645-002 and shall not be
removable.
The mechanical contacts retention system shall be integrated in the hard insert.
The design of non-hermetic connectors shall permit individual installation of the contacts without
removal of the insert or grommet. Fitting and removal of the contacts shall be from the rear with the
tools specified in the contact product standards.
Contact position identification shall be permanent and contrasted on the front face of the insert or the
interfacial seal and on the rear face of the grommet as indicated in 6.6.
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The marking shall not be recessed or raised on the surfaces providing a seal.
6 Definition drawings and masses
6.1 General
The general dimensions and the masses of receptacles, plugs and protective covers are given in the
product standards.
6.2 Receptacle mating dimensions
The mating dimensions of receptacles are shown in Figure 1 and details V and W as well as in Table 2 and
Table 3.
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Dimensions and tolerances are in millimetres.
Key
a The distance between the front face of the shell and the point where the right end of a gauge with a diameter
equal to the nominal diameter of a male contact comes into contact with the elastic part of the female contact.
Figure 1 — Receptacle — Coupling dimensions
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Table 2 — Receptacle — Dimensions (1 of 2)
Housing A dia. B dia. C dia. D dia. D dia. E dia. E dia. F dia.
(except classes (classes J and (except classes (classes J and
size
J and M) M only) J and M) M only)
+ 0,13
max. max.
− 0,25
14,42 11,36 11,43 12,63 12,70
09 14,55 7,24 15,88
14,14 11,20 11,20 12,34 12,34
17,60 14,61 14,68 15,88 15,95
11 17,73 10,49 19,05
17,32 14,45 14,45 15,60 15,60
20,77 17,45 17,52 19,66 19,73
13 20,90 13,39 22,23
20,49 17,30 17,30 19,38 19,38
23,95 20,63 20,70 22,84 22,91
15 24,08 16,56 25,40
23,67 20,44 20,44 22,56 22,56
28,30 23,80 23,87 26,01 26,08
17 28,52 19,74 30,16
27,97 23,64 23,64 25,73 25,73
29,89 26,47 26,54 28,63 28,70
19 30,12 22,00 31,75
29,56 26,31 26,31 28,40 28,40
33,07 29,64 29,71 31,85 31,92
21 33,30 25,17 34,73
32,74 29,49 29,49 31,57 31,57
36,24 32,82 32,89 35,03 35,10
23 36,47 28,35 38,10
35,91 32,66 32,66 34,75 34,75
39,42 35,99 35,06 38,20 38,27
25 39,65 31,52 41,28
39,09 35,84 35,84 37,92 37,92
Table 2 — Receptacle — Dimensions (2 of 2)
M dia. N dia. P dia. R dia. S dia.
Contact
size
max.
1,35 1,88 0,97 1,70
22 0,71
1,27 1,75 0,89 1,60
1,91 2,44 1,32 2,26
20 0,97
1,83 2,31 1,24 2,16
2,49 3,02 1,88 2,84
16 1,52
2,41 2,90 1,80 2,74
3,30 3,84 2,69 3,66
12 2,34
3,23 3,71 2,62 3,56
4,09 4,62 3,48 4,45
10 3,12
4,01 4,50 3,40 4,34
6,50 7,06 5,84 6,81
8 5,49
6,38 6,93 5,77 6,71
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Table 3 — Receptacle — Thread
BB - Thread
a
External threading
Designation
Class 2A
Class 2A thread
See
Housing
Thread Apparent Actual External Diameter Diameter
b
size
Note
size pitch pitch diameter on side at thread end
inch inch inch max. min. max. min. max. min.
09 0,625 0 15,83 15,63 15,17 14,97 14,41 14,05
11 0,750 0 19,01 18,80 18,35 18,14 17,58 17,23
13 0,875 0 22,18 21,98 21,52 21,32 20,
...
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