oSIST prEN 3155-001:2023
(Main)Aerospace series - Electrical contacts used in elements of connection - Part 001: Technical Specification
Aerospace series - Electrical contacts used in elements of connection - Part 001: Technical Specification
This document specifies:
- the electrical, mechanical, environmental and dimensional characteristics of electrical contacts used in elements of connection, including coaxial, triaxial and quadrax contacts;
- the conditions for qualification, acceptance testing and quality assurance;
- the test programs and groups.
It is applicable to removable crimp contacts, wrap contacts, solder contacts used in connectors or in other elements of electrical connection.
In case of conflict or missing information between the EN 3155 001 and the product standards, the product standard takes precedence.
Luft- und Raumfahrt - Elektrische Kontakte zur Verwendung in Verbindungselementen - Teil 001: Technische Lieferbedingungen
Série aérospatiale - Contacts électriques utilisés dans les organes de connexion - Partie 001: Spécification technique
Le présent document spécifie :
— les caractéristiques électriques, mécaniques, d'environnement et dimensionnelles des contacts électriques utilisés dans les organes de connexion, y compris les contacts coaxiaux, triaxiaux et quadrax ;
— les conditions de qualification, d’essais de réception et d'assurance qualité ;
— les programmes et les groupes d'essais.
Elle s'applique aux contacts à sertir amovibles, aux contacts pour connexions enroulées, aux contacts à souder utilisés dans les connecteurs ou dans d'autres organes de connexion électrique.
En cas de conflit ou d’information manquante entre l’EN 3155 001 et les normes de produits, la norme de produit doit prévaloir.
Aeronavtika - Električni kontakti za uporabo v veznih elementih - 001. del: Tehnična specifikacija
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
oSIST prEN 3155-001:2023
01-september-2023
Nadomešča:
SIST EN 3155-001:2016
Aeronavtika - Električni kontakti za uporabo v veznih elementih - 001. del:
Tehnična specifikacija
Aerospace series - Electrical contacts used in elements of connection - Part 001:
Technical Specification
Luft- und Raumfahrt - Elektrische Kontakte zur Verwendung in Verbindungselementen -
Teil 001: Technische Lieferbedingungen
Série aérospatiale - Contacts électriques utilisés dans les organes de connexion - Partie
001: Spécification technique
Ta slovenski standard je istoveten z: prEN 3155-001
ICS:
49.060 Letalska in vesoljska Aerospace electric
električna oprema in sistemi equipment and systems
oSIST prEN 3155-001:2023 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 3155-001:2023
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oSIST prEN 3155-001:2023
DRAFT
EUROPEAN STANDARD
prEN 3155-001
NORME EUROPÉENNE
EUROPÄISCHE NORM
June 2023
ICS 49.060
English Version
Aerospace series - Electrical contacts used in elements of
connection - Part 001: Technical Specification
Série aérospatiale - Contacts électriques utilisés dans Luft- und Raumfahrt - Elektrische Kontakte zur
les organes de connexion - Partie 001: Spécification Verwendung in Verbindungselementen - Teil 001:
technique Technische Lieferbedingungen
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, Türkiye 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
© 2023 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 3155-001:2023 E
worldwide for CEN national Members.
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Contents Page
European foreword . 3
1 Scope . 4
2 Normative references . 4
3 Terms and definitions . 5
4 Conditions of use . 7
4.1 Types of contact . 7
4.2 Temperature classes. 7
4.3 Permissible wires and cables . 8
5 Design and description . 8
5.1 Design . 8
5.2 Materials . 10
5.3 Metallic protective plating. 10
6 Dimensions and mass . 12
7 Operation . 12
8 Tests . 12
9 Quality assurance . 24
9.1 General. 24
9.2 Conditions for qualification . 24
9.3 Inspection conditions for manufacturing lots . 38
9.4 Maintenance of qualification . 38
10 Designation and marking . 47
10.1 Designation . 47
10.2 Marking . 48
11 Delivery conditions . 48
12 Packaging . 48
13 Storage . 49
Annex A (informative) Symbols of contact sizes in contact arrangement drawings . 50
Bibliography . 51
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European foreword
This document (prEN 3155-001:2023) 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 3155-001:2016.
The main changes compared to the previous edition are as follows:
— Update of normative references;
— Introduction of contact size 23 with barrel 22;
— Revision of test 101 and 417 in Table 2;
— Removal of remarks in Table 5, Table 6 and Table 7;
— Introduction of test 418 prior to test 201 in Group 2 of Table 8;
— Removal of tests 221, 222 and 223 and introduction of test 508 in group 2 of Table 11;
— Editorial revision of the document.
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1 Scope
This document specifies:
— the electrical, mechanical, environmental and dimensional characteristics of electrical contacts used
in elements of connection, including coaxial, triaxial and quadrax contacts;
— the conditions for qualification, acceptance testing and quality assurance;
— the test programs and groups.
It is applicable to removable crimp contacts, wrap contacts, solder contacts used in connectors or in other
elements of electrical connection.
In case of conflict or missing information between the EN 3155-001 and the product standards, the
product standard takes precedence.
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 2083, Aerospace series - Copper and copper alloys conductors for electrical cables - Product standard
EN 2242, Aerospace series - Crimping of electric cables with conductors defined by EN 2083, EN 4434 and
EN 2346
EN 2424, Aerospace series - Marking of aerospace products
EN 2591 (all parts), Aerospace series — Elements of electrical and optical connection — Test methods
EN 3197, Aerospace series - Design and installation of aircraft electrical and optical interconnection systems
EN 4434, Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product
standard (Normal and tight tolerances)
EN 9133, Aerospace series - Quality Management Systems - Qualification Procedure for Aerospace Standard
Products
EN ISO 27874, Metallic and other inorganic coatings - Electrodeposited gold and gold alloy coatings for
electrical, electronic and engineering purposes - Specification and test methods (ISO 27874:2008)
ISO 2859-1, Sampling procedures for inspection by attributes — Part 1: Sampling schemes indexed by
acceptance quality limit (AQL) for lot-by-lot inspection
ISO 8843, Aircraft — Crimp-removable contacts for electrical connectors — Identification system
1
IEC 60352-1, Solderless connections — Part 1: Wrapped connections — General requirements, test
methods and practical guidance
1 Published by: IEC International Electrotechnical Commission https://www.iec.ch/
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2
TR 3198, Aerospace series — Manufacturers' identification monograms and marks for EN aerospace
products
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 2591-100 and the following
apply.
ISO and IEC maintain terminology 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/
3.1
LSP
Length of Selective Protection
3.2
point of electrical contact
position of point of application of the force which provides contact pressure
3.3
contact active area
part of the contact which allows current to pass between the contact male and female
3.4
contact transition area
all mechanical liaisons that contribute to electrical performance and which are different from contact
active area defined in 3.3
3.5
coaxial contact male or female
assembly of two contacts arranged coaxially enabling the connection of coaxial, shielded or bifilar cables
Note 1 to entry: See Figure 1.
Note 2 to entry: Male coaxial contact where the outer contact is male; the central contact(s) may be male or female.
Note 3 to entry: Female coaxial contact where the outer contact is female; the central contact(s) may be male or
female.
Key
1 Centre contact
2 Outer contact
Figure 1 — Coupling face of coaxial contact male or female
2 Published as ASD-STAN Technical Report at the date of publication of this European
Standard.http://www.asd-stan.org/
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3.6
triaxial contacts male or female
assembly of three contacts arranged coaxially, enabling the connection of shielded triaxial or bifilar cables
Note 1 to entry: See Figure 2.
Note 2 to entry: Male triaxial contact where the outer contact is male; the central contact(s) may be male or female.
Note 3 to entry: Female triaxial contact where the outer contact is female; the central contact(s) may be male or
female.
Key
1 Centre contact
2 Intermediate contact
3 Outer contact
Figure 2 — Coupling face of triaxial contacts male or female
3.7
bifilar contact (twinax)
assembly of three contacts, two of which are parallel, the third being peripheral to these, enabling the
connection of shielded bifilar cables
Note 1 to entry: See Figure 3.
Note 2 to entry: Male twinax contact where the outer contact is male; the central contacts may be male or female.
Note 3 to entry: Female twinax contact where the outer contact is female; the central contacts may be male or
female.
Key
1 Twin parallel contacts
2 Outer contact
Figure 3 — Coupling face of bifilar contact (twinax)
3.8
quadrax contact
assembly of five contacts, four of which are parallel, the fifth being peripheral to these, enabling the
connection of shielded quadrax cables
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Note 1 to entry: See Figure 4.
Note 2 to entry: Male quadrax contact where the outer contact is male; the central contacts may be male or female.
Note 3 to entry: Female quadrax contact where the outer contact is female; the central contacts may be male or
female.
Key
1 Four parallel contacts
2 Outer contact
Figure 4 — Coupling face of quadrax contact
4 Conditions of use
4.1 Types of contact
The contact specified shall be one of the following types:
— Type A: Removable contact for general application;
— Type B: Non-removable contact, See Note;
— Type C: Removable contact for thermocouple;
— Type D: Removable contact with screening feature (including the coaxial contacts, triaxial contacts
and bifilar contacts). These have no characteristic impedance and are therefore not recommended
for use at high frequency;
— Type E: Removable contact with screening feature, including coaxial, triaxial, bifilar and quadrax
contacts. These have matched impedance.
NOTE Type B contacts are specified in the connector specifications.
4.2 Temperature classes
The contacts specified shall be from one of the classes specified below:
— class P: maximum operating temperature 125 °C;
— class R: maximum operating temperature 150 °C;
— class S: maximum operating temperature 200 °C;
— class T: maximum operating temperature 260 °C;
— class U: maximum operating temperature 350 °C.
The minimum operating temperature shall be −65 °C, unless otherwise specified in the product standard.
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4.3 Permissible wires and cables
4.3.1 The conductors which are acceptable in the crimping barrels and the coding by means of colour
bands are specified in ISO 8843. The contact detail specification shall state the acceptable conductors for
each size of contact.
4.3.2 The type of cable, coaxial, triaxial, etc. shall be specified in the product standard.
5 Design and description
5.1 Design
5.1.1 General
This document covers male and female contacts of all types and technologies: cylindrical or rectangular
entry contacts, flat contacts of the blade type, etc., stamped, formed or machined contacts.
Stamped and formed technology for body contact are not allowed.
5.1.2 Mating end of female contact, cylindrical contacts
Unless otherwise stated in the product standard, the mating end of female contacts from size 08 to 24,
shall be of the restricted entry type and shall not permit the introduction of a gauge which has a diameter
0,13 mm greater than the maximum diameter of the male contact.
5.1.3 Mating end of male contacts, cylindrical contacts
Unless otherwise stated in the product standard, the mating end of the male contacts shall be
approximately spherical. A flat is permitted at the end; its dimensions are given in Table 1.
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Table 1 — Gauge dimensions for male contact
Pin active area Pin active area
Diameter of flat at Diameter of flat at
contact Contact
Contact Contact
the mating end the mating end
diameter diameter
size size
mm mm mm mm
0,394 2,01 0,99
a
28 0,19 max. 14
0,368 1,96 0,61
0,521 2,41 1,57
a
26 0,25 max. 12
0,495 2,36 1,19
0,65 3,20 2,08
a
24 0,30 max. 10
0,62 3,15 1,57
0,705 3,63 2,18
23 0,30 max. 8
0,659 3,58 1,68
0,775 4,55 2,44
22 0,35 max. 6
0,750 4,50 1,93
1,04 0,51 5,74 2,79
20 4
0,99 0,13 5,69 2,29
1,61 0,81
16 — — —
1,56 0,43
a
Inner contact of type D or type E.
5.1.4 Solder buckets
The buckets shall be designed so that during soft soldering operations, the liquid solder cannot run
towards the end of the contact.
5.1.5 Crimp barrels
Barrels shall be designed to accept the range of permissible conductors according to ISO 8843, EN 2083
and EN 4434.
The use of a reducing sleeve is not recommended; this remains the responsibility of the user and shall be
subject to acceptance by the relevant OEMs.
5.1.6 Terminations for wrapped connections
The terminations for wrapped connections shall comply with IEC 60352-1.
5.1.7 Surface roughness (see EN ISO 21920-1)
The surface roughness after coating in the male contact zone shall not exceed Ra = 0,8 µm (or N6); in the
other zones, it shall not exceed Ra = 1,6 µm (or N7).
5.1.8 Engagement sequence
The engagement sequence for coaxial and quadrax contacts shall be outer contact, then inner contacts.
Unless otherwise specified in the product standard, the engagement sequence for triaxial contacts shall
be: outer contact, intermediate contact, centre contact.
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5.2 Materials
The materials used in the manufacture of contacts shall be consistent with those indicated in the
definition document. When dissimilar metals are in close contact, the electromotive force of the galvanic
couple shall not exceed 0,25 V, see EN 3197.
5.3 Metallic protective plating
5.3.1 General
Except contact type C contact.
The protective coating may be either uniform over the entire surface of the contact, or it may be selective.
The entire contact shall have a nickel undercoat and gold overcoat, with the exception of fittings or
retaining features such as springs or spring clips which shall be made of a corrosion resisting material.
Three functional areas are specified with their minimum gold plating thickness requirements as follows:
— Crimping area;
— Transition area;
— Active area;
— See description in paragraph from 5.3.2 to 5.3.4.
5.3.2 Crimping area
Crimping area shall be protected as follows:
Inside barrel: EN ISO 27874 Ni 0,76 µm min./Au(99,0) 0,1 µm minimum in crimping area (from the
extremity of the crimp barrel to the inspection hole).
Inside barrel: EN ISO 27874 Ni 0,76 µm min./Au(99,0) 0,05 µm minimum after inspection hole up to the
bottom of the drilled barrel.
Outside barrel: EN ISO 27874 Ni 0,76 µm min./Au(99,0) 0,1 µm minimum in crimping area.
5.3.3 Transition area
Transition area are specified in 3.4 and Figure 7 and shall be protected as follows:
EN ISO 27874 Ni 1,25 µm min./Au(99,0) 0,2 µm minimum (or 0,1 µm on each side of interfaces).
5.3.4 Active area
Active areas are specified in 3.3 and Figure 5, Figure 6 and shall be protected as follows:
EN ISO 27874 Ni 1,25 µm min./Au(99,0) 0,8 µm minimum.
As specified in the product standards, the gold plating on contact for the LSP areas shall be in accordance
with the above requirements. In the other zones, the thickness of the protections is generally not
specified, but the minimum shall be as per 5.3.1.1 and 5.3.1.2.
A change in colour of the gold plating is not a reason for rejection excepted in active areas [see Figure 5b),
key 4, male active area] and X [see Figure 5c), key 6, female active area].
The gold plating thickness shall be sufficient to fulfil the performances required in this specification.
However, and unless otherwise specified in the product standard, it shall never be lower than 0,8 µm.
It is a supplier responsibility to define the right gold thickness to meet the performances tests required
in this technical specification if the 0,8 µm minimum are not sufficient to pass the expected requirements.
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5.3.5 All other areas
All other areas shall be protected as follows:
EN ISO 27874 Ni 0,76 µm min./Au(99,0) 0,1 µm minimum.
a) Engaged pin/ socket contact
b) Detail A: male contact c) Detail A: female contact
d) e)
Key
1 Male contact with maximum diameter
2 Pressure element
3 Engagement of contacts (given in connector technical specification)
4 Male active area (Y) see product standard
5 First point of electrical contact (Point at which a square ended minimum gauge pin of the same basic diameter
as the mating contact first engages the female contact spring member)
6 Female active area (X = 1 mm length min. of gold plating)
7 Position of the first point and the maximum length of electrical contact (Point at which a square ended
minimum gauge pin of the same basic diameter as the mating contact first engages the female contact
spring member as specified in the contact product standard)
8 Length of Selective Protection "LSP" which shall include the length of the Key 4 (for male) or 6 (for female) and
the radius/chamfer at the extremity
Figure 5 — Contact with integrated pressure element
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Key
1 Contact active area X = contact active area Y
Figure 6 — Female contact with separate pressure elements
Key
1 Electrical contact transition area
NOTE See Figure 5 for Detail A.
Figure 7 — Contact with separate pressure element
For contact types D and E.
Inner contact and outer contact bodies according to Figure 5, Figure 6 and applicable standard products.
6 Dimensions and mass
The dimensions of the contacts and their mass are specified in the product standard.
7 Operation
The tools for connecting and installing the contacts are specified in the product standard.
8 Tests
Tests shall be in accordance with Table 2.
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Table 2 — Qualification tests
EN 2591- Test Details
101 Visual examination Initial examination: before and after wiring
Details to be examined and documented:
— identification of materials in accordance with
definition document;
— identification;
— aspect before and after wiring (No breaking
strand at the rear of the barrel);
— marking;
— surface roughness in accordance with 5.1.7.
For crimped terminations, after wiring, the crimp
joint shall be examined (10 times magnification)
for cracking exposing the base metal, except type C
contact.
Intermediate and final examination:
Details to be examined and documented:
— gold plating shall be present at electrical contact
point and transition area.
There shall be no crack, burr, peeling or blister.
No breaking strand at the rear of the barrel.
No displacement (rotation is accepted without
disassembly) of the hood on body socket contact.
102 Examination of dimensions and mass In accordance with the product standard.
201 Contact resistance - low level Applicable to type A contacts of size 20 and smaller
and to types D and E contacts.
— Types A, D and E contacts
Unless otherwise specified in the product standard,
the contact resistance shall not exceed the
maximum values given below (in mΩ).
Type A
Contact size
Initially After tests
≤ 24 — a — a
23 8 11
22 8 11
20 5 7
a To be specified in the product
standard.
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EN 2591- Test Details
The contact resistance values for types D and E
shall be specified in the product standard.
202 Contact resistance at rated current Applicable to types A, D and E contacts.
— Types A, D and E contacts
Unless otherwise specified in the product standard,
the contact resistance shall not exceed the
maximum values given below (in mΩ).
— Type A
At ambient
At high temperature
temperature
Contact size
After Class P Class R Class S Class T Class U
Initially
tests 125 °C 150 °C 200 °C 260 °C 350 °C
— — — — — — —
24
a a a a a a a
23 8 11 a a 14 a a
—
22 8 11 12 12,8 13,6 14,4
a
—
20 5 7 7,5 8 8,5 9
a
—
16 3 5 4,5 4,8 5,1 5,4
a
—
≥ 12 2 3 3 3,2 3,4 3,6
a
a To be specified in the product standard.
— Types D and E: The contact resistance values shall be specified in the product standard.
203 Electrical continuity at microvolt level See product standard.
204 Discontinuity of contacts in the No discontinuity ≥ 1 µs
microsecond range
For types D and E contacts: duration of
discontinuity specified in the product standard.
Method B or Method A
Test duration: throughout the duration of tests
EN 2591-402 (Shock) and EN 2591-403
(Vibrations).
205 Housing (shell) electrical continuity Not applicable
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EN 2591- Test Details
206 Measurement of insulation resistance Method C – Contact type D or E
Otherwise specified in the product standard, the
value shall be:
— at room temperature ≥ 5 GΩ;
— at high temperature ≥ 2 GΩ at the maximum
temperature specified.
207 Voltage proof test Method C – Contact types D and E
The values for:
— voltage to apply;
— pressure;
— leakage current.
shall be specified in the product standard.
208 Temperature rise due to rated current Not applicable
209 Current temperature derating Not applicable
210 Electrical overload Contact wired and not fitted into the connector
Cylindrical contacts type A.
Current Duration Current Duration
Contact size Contact size
A s A s
66 40
28 Not applicable 10
330 0,6
92 40
26 Not applicable 8
460 0,6
5 40 120 40
24 6
25 0,6 600 0,6
10 40 160 40
23 4
50 0,6 800 0,6
10 40 200 40
22 2
50 0,6 1 000 0,6
15 40 300 40
20 0
75 0,6 1 500 0,6
26 40 370 40
16 2/0
130 0,6 1 850 0,6
36 40 450 40
14 4/0
180 0,6 2 250 0,6
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EN 2591- Test Details
46 40
12 — — —
230 0,6
Other types of contacts: in accordance with the
product standard.
Capacitance Applicable to types D and E contacts unless
211
otherwise specified in the product standard.
212 Surface transfer impedance Types D and E, see product standard.
Shielding effectiveness from 100 MHz
213 to Types D and E, see product standard.
1 GHz
Lightning strike, current and voltage
214 Not applicable
pulse
216 Engagement depth of contacts Not applicable
Voltage drop under specified current Not applicable
217
for terminal lugs and in-line splices
Ageing of terminal lugs and in-line Not applicable
218 splices by temperature and current
cycling
Voltage strength for insulated terminal Not applicable
219
lugs and in-line splices
220 Contact/conductor joint ageing by See product standard.
current and temperature cycling
221 Voltage Standing Wave Ratio (VSWR) Type E, see product standard.
222 Insertion Loss (I.L.) Type E, see product standard.
223 Measurement of characteristic Type E, see product standard.
impedance of a coaxial connector or
contact
224 RF leakage Not applicable
225 RF high potential withstanding voltage Not applicable
226 Corona level Not applicable
301 Endurance at temperature Method B,
Except:
Mated contact shall not be fitted into the connector.
Contact shall not be wired in serial.
Test under load not applicable
Temperature: according to product standard.
Duration: according to pro
...
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