BS-G-204-1967.pdf

BRITISH STANDARD AEROSPACE SERIES BS G 204:1967 Incorporating Amendment No. 1 Specification for Copper terminal ends for crimping to electric cables with copper conductors UDC 629.7.064.5:621.315.684.669.3 Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 204:1967 This British Standard, having been approved by the Aerospace Industry Standards Committee and endorsed by the Chairman of the Engineering Divisional Council, was published under the authority of the General Council of the Institution on 29 December 1967 © BSI 04-2000 The following BSI references relate to the work on this standard. Committee reference ACE/6 Draft for comment D65/10970 ISBN 0 580 34546 7 Foreword This British Standard has been prepared at the request of the Aerospace Industry to give details of the requirements for copper terminal ends suitable for crimping to aircraft electric cables with copper conductors. Details of the requirements for aluminium terminal ends for crimping to aircraft electric cables with aluminium conductors are given in BS G 184 to BS G 188, Aluminium terminal ends and in-line connectors for hexagonal crimping to aircraft aluminium electrical cables. This standard should be read in conjunction with BS G 178, Crimped joints for aircraft electric cables and wires, and makes reference to the following British Standards: BS A 125-A 168, Stiffnuts (unified threads) for aircraft. BS 2G 100, General requirements for electrical equipment and indicating instruments for aircraft. BS G 177, Nyvin type electrical cables for aircraft. BS G 189, Tersil type electrical cables for aircraft. BS G 192, Efglas type electric cables with copper conductors for aircraft. BS G 203, Unified screws with captive facing and locking washers. BS 1432, Copper for electrical purposes. Strip with drawn or rolled edges. BS 9001, Sample procedures and tables for inspection by attributes for electronic parts of assessed quality. NOTEIn Table 1 either inch or metric dimensions may be regarded as the standard. In all other cases the values in British units are to be regarded as the standard. A table is given in Appendix C to provide a ready means of calculating the millimetre equivalents of the inch dimensions. More accurate conversions should be based on the tables in BS 350, “Conversion factors and tables”. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 10 and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Amendments issued since publication Amd. No.Date of issueComments 423February 1970Indicated by a sideline in the margin Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 204:1967 © BSI 04-2000i Contents Page ForewordInside front cover Section 1. Design requirements 1Scope1 2Definitions1 3Material1 4Finish and hardness1 5Dimensions and construction1 6Insulation support1 7Pre-insulated terminal ends1 8Bending test on terminal ends1 9Marking2 10Identification2 11Declarations2 Section 2. Tests 12Batch sampling tests2 13Installation and performance2 Appendix A Bending test on terminal ends made from sheet or tube9 Appendix B Installation design recommendations10 Appendix C Conversion of inches to millimetres10 Figure 13 Figure 25 Figure 37 Figure 49 Table 1 Dimensions of class 1 ring-tongue terminal ends for cable sizes 24123 Table 2 Dimensions of class 2 ring-tongue terminal ends for cable sizes 27126 Table 3 Dimensions of class 2 ring-tongue terminal ends for cable sizes 1000008 Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI ii blank Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 204:1967 © BSI 04-20001 Section 1. Design requirements 1 Scope 1.1 This British Standard gives details of the dimensional and other requirements for copper terminal ends, of the ring-tongue type, suitable for crimping to aircraft electrical cables with copper conductors to form joints which satisfy the requirements of BS G 178. 1.2 Two classes of terminal ends are listed: Class 1 (at present restricted to terminal ends for size 12 cables and smaller), intended for future use, and designed to be crimped with any suitable approved crimping tool. To achieve this, precise requirements are stipulated for dimensions, material and finish. Class 2, based on existing designs, and with comparatively wide tolerances on some dimensions. Certain dimensions (i.e. barrel diameter and bore before crimping) are not specified, but the maximum dimensions at any point across the section of the crimp or insulation grip after crimping is specified. (See also Note 6 to Figure 2). 2 Definitions For the purposes of this British Standard the definitions in BS G 178 apply. 3 Material 3.1 Class 1 terminal ends shall be made from high-conductivity copper complying with the appropriate requirements of BS 1432, Grades C.101 or C.102. Grain size shall not exceed 0.040 mm. 3.2 Class 2 terminal ends may be made from any grade of copper or copper alloy, but the material used shall be declared, as required by Clause 11. 4 Finish and hardness 4.1 Class 1 terminal ends shall be plated with either tin, silver, nickel or gold as appropriate for the cable and temperature conditions. There shall be no visible defect. 4.2 The finish shall be such that all terminations covered by the declaration required by Clause 11 shall be capable of meeting the appropriate requirements of BS G 178. 4.3 The material hardness of complete Class 1 terminal ends shall be within the range of 60100 V.P.N. 5 Dimensions and construction 5.1 The dimensions of Class 1 terminal ends, before and after crimping, shall conform to the requirements of Table 1 and Figure 1. 5.2 The dimensions of Class 2 terminal ends, after crimping, shall conform to the requirements of Table 2 and Figure 2 or Table 3 and Figure 3, as appropriate. 5.3 The palm surfaces shall be parallel within 0.005 in (0.1 mm) total indicator reading, and flat over the area of the palm width and linear dimension W (see Figure 1). 5.4 Stud holes shall be free from burrs and rough edges. 5.5 The design of the terminal end shall be such that adequate engagement of the cable conductor in the completed joint can be readily established. 6 Insulation support 6.1 Terminal ends for cables of sizes 2712 inclusive shall include a barrel or part of a barrel so designed that it will enclose and support the outside of the cable insulation. 6.2 The length of the cable insulation support barrel for Class 1 terminal ends shall be in accordance with the relevant dimensions in Table 1. 6.3 The length of the cable insulation support barrel for Class 2 terminal ends shall be such that, after crimping, a length of cable insulation is enclosed within the barrel. 7 Pre-insulated terminal ends 7.1 On pre-insulated terminal ends the insulation, after crimping, shall extend beyond the cable insulation support barrel (i.e. beyond the dimension L shown in Figure 1, Figure 2 or Figure 3) for a distance of: 0.05 in to 0.15 in (1.3 mm to 3.8 mm) for Class 1 terminal ends. 0.05 in minimum (1.3 mm) for Class 2 terminal ends. 7.2 Class 1 pre-insulated terminal ends shall be colour coded as specified in Table 1. 8 Bending test on terminal ends When terminal ends are made from material in strip, sheet or tube form, a bending test as described in Appendix A shall be applied to at least 3 terminal ends of each material, finish, type and size. Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 204:1967 2 © BSI 04-2000 9 Marking Class 1 terminal ends shall be, and Class 2 preferably shall be, marked with the cable size number and with a mark identifying the manufacturer. In addition, nickel-plated terminal ends shall be colour coded purple in a readily identifiable manner. Such marking shall not be applied to any part of the conductor crimping barrel which is subject to deformation. 10 Identification 10.1 Class 1 terminal ends shall be identified on drawings and for ordering purpose by a reference to this standard i.e. BS G 204, to the part number listed in Table 1, and by a suffix denoting the finish which shall be as follows: t tin plated s silver plated n nickel plated g gold plated Example: BS G 204/214n, denotes a nickel plated pre-insulated terminal end, suitable for use with size 16 or size 18 cable and 1/4 in diameter stud. 10.2 Class 2 terminal ends shall be identified for ordering purposes by a manner agreed between the manufacturer and the purchaser. 11 Declarations 11.1 The manufacturer of the terminal ends shall prepare a standard form of declaration of design and performance as required by BS 2G 100-1, for each type, size and material of terminal end. 11.2 The declaration shall include particulars of approved drawings1), material, finish, temperature range, and known types and sizes of cable, crimping tools and dies which may be used to make terminations which satisfy the requirements of BS G 178. Section 2. Tests 12 Batch sampling tests 12.1 General. In addition to meeting the Design Requirements of Section 1, the following Batch Sampling tests shall be carried out by the manufacturer on each and every production batch of terminal ends. Batch Sampling tests shall be carried out in accordance with the requirements of BS 9001, “Sampling procedures and tables for inspection by attributes for electronic parts of assessed quality”. Sampling procedure shall be the single sampling plan to Table II, of BS 9001. The Inspection Level and A.Q.L. shall be as indicated in the following table: Test specimens shall be prepared in accordance with Clause 10 b) 1) of BS 2G 178. The crimping tool used shall be one which, in conjunction with the particular terminal ends being tested, and an appropriate cable as defined in Clause 11.2 of this standard, complies with the requirements of BS 2G 178. 12.2 Dielectric strength of insulating sleeve. Tests shall be conducted in accordance with Clause 18 d) of BS 2G 178. 12.3 Inspection of crimped joints. Inspection shall be in accordance with Clause 11 of BS 2G 178. 13 Installation and performance 13.1 When crimped to the appropriate cable by an approved process, the terminal ends shall make a termination suitable for use in locations in which the stabilized cable conductor temperature does not exceed the value specified in the relevant cable specification, i.e. 105 °C, 190 °C, 260 °C. 13.2 The completed terminations shall comply with the requirements of BS G 178. 13.3 Recommendations for the installation of the terminations are given in Appendix B. 1) For terminal ends used on aircraft subject to British civil or military airworthiness requirements, the declaration and drawings have to be approved by the Air Registration Board (through a design authority approved by the Board) or by the Ministry of Technology (A.D. Elec.) as appropriate. Requirement Clause (BS G 204) Inspection level (Table 1 of BS 9001) A.Q.L. (Table H.A. of BS 9001) Materials Finish Dimensions Insulation support Pre-insulation Bending Marking Dielectric strength of insulated terminal ends 3 4.1 5 6 7 8 9 19 S-4 S-4 S-4 S-4 S-4 S-4 S-4 S-4 1.0 1.0 1.0 4.0 4.0 1.0 4.0 4.0 Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 204:1967 © BSI 04-20003 Table 1 Dimensions of class 1 ring-tongue terminal ends for cable sizes 24-12 Third angle projection NOTE 1Contours within the lines shown chain dotted are at the discretion of the manufacturer. NOTE 2Dimension D to be constant within 0.005 in (0.1 mm) over the area of palm diameter W. NOTE 3For pre-insulated terminal ends the insulation, after crimping, is to extend beyond dimension L for a distance between 0.05 in and 0.15 in (1.3 mm and 3.8 mm). Figure 1 1234567891011121314151617 Part No.a Colour code (pre-insulated) Preferred cable size(s) Stud size (unified) Stud hole size C Palm diameter W Dimension to start of conductor crimp barrel X Length of conductor crimp barrel B Dimension to end of cable insulation support after crimping barrel L Internal diameter of conductor crimp barrel before crimping F Non-insulated Pre-insulated in ± 0.003 mm ± 0.1 in ± 0.005 mm ± 0.1 in ± 0.01 mm ± .0.2 in ± 0.01 mm ± 0.2 in ± 0.040 mm ± 1 in +0.005 0 mm +0.1 0 101201Black244400.1223.10.2175.50.1894.80.164.00.47412.00.0290.75 1022026320.1483.80.2566.50.2185.50.50312.8 106206Red22204400.1223.10.2175.50.1894.80.49912.7 1072076320.1483.80.2566.50.2185.50.52813.40.0481.25 10820810320.2025.10.3358.50.2686.80.164.00.57814.7 109209 1/4 in 0.2676.80.43311.00.3378.60.64716.4 110210 5/16 in 0.3308.40.53213.50.41610.60.72618.4 111211Blue18164400.1223.10.2175.50.1894.80.54913.9 1122126320.1483.80.2566.50.2185.50.57814.7 11321310320.2025.10.3358.50.2686.80.164.00.62816.00.0661.70 114214 1/4 in 0.2676.80.43311.00.3378.60.69717.7 115215 5/16 in 0.3308.40.53213.50.41610.60.77619.7 117217Yellow14126320.1483.80.2566.50.2185.50.62816.0 11821810320.2025.10.3358.50.2686.80.164.00.67817.20.0982.50 119219 1/4 in 0.2676.80.43311.00.3378.60.74718.9 120220 5/16 in 0.3308.40.53213.50.41610.60.82621.0 a See Clause 10 for suffix. Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:24:36 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 204:1967 4 © BSI 04-2000 Table 1 Dimensions of class 1 ring-tongue terminal ends for cable sizes 2412 1819202122232425262728293031323334353637 External diameter of conductor crimp barrel before crimping E Internal diameter of cable insulation bucket before crimping J External diameter of cable insulation bucket before crimping K Palm thickness D Maximum overall diameter of crimp barrel after crimping (in any plane) O Maximum overall diameter of cable insulation support after crimping (in any plane) N UninsulatedInsulated in +0.005 0 mm +0.1 0 UninsulatedInsulatedUninsulatedInsulatedUninsulatedInsulated in ± 0.005 mm ± 0.1 in ± 0.01 mm ± 0.2 in +0.01 0.02 mm +0.2 0.4 in +0.01 0.02 mm +0.2 0.4 inmminmminmminmminmm NominalMaximumMaximumMaximumMaximum 0.0932.350.1333.40.0581.50.1223.10.1624.10.0320.800.1503.80.1704.40.2005.10.2406.1 0.1122.850.1523.850.1052.70.1694.30.2095.30.0320.800.1503.80.1704.40.2005.10.2406.1 0.1383