SIST EN 2591-219:2004

• Abstract:

  This standard specifies a method for checking the voltage strength of insulated terminal lugs and in-line splices.; 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 2591-219:2002 - Aerospace series - Elements of electrical and optical connection - Test methods - Part 219: Voltage strength for insulated terminal lugs and in-line splices

• 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 3155-076:2020 - 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
• 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 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 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 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 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 3155-081:2019 - Aerospace series - Electrical contacts used in elements of connection - Part 081: Contacts size 22 for EN 2997, electrical, female, type A, crimp, class T - Product standard
• 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 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 3155-027:2019 - 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

SIST EN 2591-219:2004 is the Slovenian standard identical to EN 2591-219:2002, a European Standard in the aerospace series from CEN. It specifies a test method for checking the voltage strength of insulated terminal lugs and in-line splices. The standard is used together with EN 2591-100, which provides the general rules for this family of test methods.

What does SIST EN 2591-219:2004 specify?

SIST EN 2591-219:2004 specifies one laboratory test method for voltage strength on insulated terminal lugs and in-line splices. In practice, it tells users how to prepare the specimen, how to immerse the crimped area, how to apply the voltage, and what result counts as a pass.

The document is organized into five clauses:

• Scope
• Normative references
• Preparation of specimens
• Method
• Requirement

That structure matters because the standard is very compact: the key information for test setup and acceptance is concentrated in clauses 3 to 5, while clause 2 points to the general companion standard.

What are the key requirements of SIST EN 2591-219:2004?

SIST EN 2591-219:2004 requires the specimen to be assembled with its normal accessories and wired according to the technical specification. The technical specification must state the number of specimens, the cable type, the installation and wiring arrangement, and the voltage strength to be used. This is the information a test lab needs before starting, and it is also what a buyer or quality manager should check in a procurement or qualification plan.

Specimen preparation

For terminal lugs, the spade end may be cut flush with the insulator to ease the test. The exposed end is then insulated with beeswax or another watertight material, but the covering must not extend over the barrel deformed by the crimping tool. For in-line splices, the shortest cable is cut flush with the insulator and that end is insulated in the same way. This preparation keeps the test focused on the insulated crimped area.

Test medium and electrode arrangement

The crimped component is immersed in an aqueous solution containing 5 % sodium chloride, to a depth that covers the crimped area. A voltage is applied between the specimen and an immersed electrode placed no more than 50 mm away. In practice, this sets a reproducible wet test condition and a defined electrical path for checking insulation performance.

Voltage application

The voltage is increased gradually, at a rate not exceeding 500 V/s, to 1 500 V at 50 Hz, or to the voltage strength stated in the technical specification. The voltage is then held for at least 60 s. This means the test is a controlled withstand check, not a brief flash test, and the actual test voltage may be specified by the product document.

Acceptance requirement

The acceptance criterion is simple: there shall be no burn-out of the insulation. That makes the result easy to judge in test reports and qualification records.

What terms does SIST EN 2591-219:2004 define?

SIST EN 2591-219:2004 uses a small set of key terms that are central to the test:

• Insulated terminal lug - a terminal lug with an insulating element, tested here for voltage strength after crimping and preparation.
• In-line splice - a splice used to join conductors in line, also tested here for voltage strength.
• Crimped component - the specimen area formed by the crimping process that is immersed and stressed electrically.
• Specimen - the test item prepared and wired for the method.
• Technical specification - the document that states the test details for the product being evaluated.
• Voltage strength - the ability of the insulated assembly to withstand the applied electrical stress without insulation burn-out.

Who uses SIST EN 2591-219:2004?

SIST EN 2591-219:2004 is used by aerospace manufacturers, test laboratories, and quality teams working with electrical and optical connection elements. It is relevant when qualifying insulated terminal lugs and in-line splices, setting up routine test plans, or checking whether a connector design can withstand the required voltage in service conditions.

It is also useful for buyers and specifiers who need to define a clear acceptance test in a product technical specification. Because the test conditions and pass criterion are explicit, it helps align supplier testing with project requirements.

Which standards are used with SIST EN 2591-219:2004?

SIST EN 2591-219:2004 is used with:

• EN 2591-100 - the general standard for aerospace series test methods for electrical and optical connection elements.

EN 2591-100 provides the common framework that this part relies on, so users should read it together with this voltage strength test.

What does the SIST EN 2591-219:2004 document contain?

SIST EN 2591-219:2004 contains a short test method rather than a long set of design rules. It gives the specimen preparation steps, the immersion arrangement in 5 % sodium chloride solution, the electrode distance limit, the voltage ramp, the hold time, and the acceptance criterion.

For laboratories, that means the document is mainly a procedure for testing and reporting. For engineering and quality users, it is the reference for defining a controlled withstand test for insulated terminal lugs and in-line splices in the aerospace field.

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 219: Voltage strength for insulated terminal lugs and in-line splicesLuft- und Raumfahrt - Elektrische und optische Verbindungselemente - Prüfverfahren - Teil 219: Spannungsfestigkeit für Kabelschuhe und Stoßverbinder mit IsolierhülseSérie aérospatiale - Organes de connexion électrique et optique - Méthodes d'essais - Partie 219: Tenue en tension des cosses et des prolongateurs isolésAerospace series - Elements of electrical and optical connection - Test methods - Part 219: Voltage strength for insulated terminal lugs and in-line splices49.060Aerospace electric equipment and systemsICS:Ta slovenski standard je istoveten z:EN 2591-219:2002SIST EN 2591-219:2004en01-maj-2004SIST EN 2591-219:2004SLOVENSKI
STANDARD
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 2591-219June 2002ICS 49.060English versionAerospace series - Elements of electrical and optical connection- Test methods - Part 219: Voltage strength for insulatedterminal lugs and in-line splicesSérie aérospatiale - Organes de connexion électrique etoptique - Méthodes d'essais - Partie 219: Tenue en tensiondes cosses et des prolongateurs isolésLuft- und Raumfahrt - Elektrische und optischeVerbindungselemente - Prüfverfahren - Teil 219:Spannungsfestigkeit für Kabelschühe und Stoßverbindermit IsolierhulseThis 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 2591-219:2002 ESIST EN 2591-219:2004
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