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IS 13835 (1993): Aircraft - Connectors for groundelectrical supplies-design, performance and testrequirements [TED 14: Aircraft and Space Vehicles]

.

IS 13835 : 1993

Indian Standard

AIRCRAFT - CONNECTORS FOR GROUND ELECTRICAL SUPPLIES - DESI-GN,

PERFORMANCE AND TEST REQUIREMENTS

UDC 629”7*064*5 : 62 1.3 16.541 l

@ BIS 1993

BUR-EAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

August 1993 Price Group 4

Aircraft Electrical Equipments Sectional Committee, TED -15

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Aircraft Electrical Equipments Sectional Committee had been approved by the Transport Engineering Division Council.

Jn order to achieve international coordination on the subject this standard is harmonized with IS0 461 ( Part 1 ) : 1985 ‘Aircraft connectors for ground electrical supplies - Part 1 : Design, performance and test requirements’ issued by the International Organization for Standardization ( IS0 ).

The committee responsible for the preparation of this standard is given in Annex B.

In reporting the results of a test or analysis made in accorda.tce with this standard, if the final value, observed or calculated, is to be rounded off, it shall be done in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised ).’

1s 13835 : 1993

Indian Sta,adard

1 SCOPE

This standard specifies the design, performance and test requirements for electrical connectors used to supply electrical power from a ground source to an aircraft.

2 REFERENCES

The following Indian Standards are necessary adjuncts to this standard:

IS No.

7915 : 1976

-Title

Dimensions for connection for aircraft ground electrical supplies

Saltmist ,

8252 Environmental tests for air- (Part 10) : 1979 craft equipment : Part 10

8252 Environmental tests for air- ( Part 14 ) : 1982 craft equipment : Part 14

Mechanical vibration

3 DEFINITIONS

For the purposes of this standard the following definitions shall apply.

3.1 Aircraft Fixed Connector ( Receptacle )

The connector installed in an aircraft, which accepts an electrical power supply via the ground supply free connector from an external ground source.

3.2 Ground Supply Free Connector ( Plug )

The connector fitted to cables from the external ground source of electrical power, which, when properly fitted to the aircraft fixed connector, permits and electrical supply to be passed to the aircraft.

4 DESTGN AND PERFORMANCE REQUIREMENTS

4.1 General

4.1.1 The ground supply free connector sha!l be robust in construction and capable of with- standing heavy mechanical shocks and hard wear in use, and shall be designed to provide safe handling, for example, by the avoidance of sharp edges.

4.1.2 Aircraft fixed connectors and ground supply free connectors shall be capable of enga- gement, disengagement and operation at ambient temperatures between - 65°C and + 65°C. They shall be capable: of operating at 105”C, allowing for the temperature rise due to current carried by the connectors.

4.2 Polarity of Phase Sequence

Indications of polarity or phase shall be perma- nently marked on the aircraft fixed connectors and the ground supply free connectors at points adjacent to the contacts, as indicated in the relevant figures in IS 7915 : 1976. The markings shall be recessed and shall be marked on the front and rear of the insert of the aircraft fixed connector.

4.3 Current Ratings

4.3.1 Each of the main current-carrying male and female contacts of the fixed and free connectors ( as distinct ~from any cables connected to them ) shall be capable of carry- ing the following currents ( direct current or rms alternating current ).

- 450 A continuously for one hour or more, and

-- 1 500 A for one minute.

4.3.2 Each of the control male and female contacts shall be capable of carrying 35 A continuously.

4.4 Control Current Female Contact

The control current female contact of the d.c. ground supply free connector shall be in two sections, insulated electrically from each other, connected only bv the entry of the control male contact of the a&raft fixed co inector.

4.5 Sealing

The aircraft fixed connector when fitted to the’ aircraft may be required to form a seal in the pressurized structure. The plug shall therefore provide a pressure seal at altitudes up to 31000 m.

4.6 Voltage Rating

The aircraft fixed connectors and ground supply free connectors shall be capable of working

1

IS 13835 : 1993

continuously at the voltages specified in IS 7915 j 1976.

4.7 Replaceability of Female Contacts

All the female contacts in the ground supply free connectors shall be detachable and capable of being replaced.

5 INSPECTION AND TESTlNG

5.1 Inspection

Connectors shall be examined to ensure that they meet the requireme::ts of this standard at;d the dimensional requirements of IS 7915 : 1976.

5.2 Testing

5_.2.1 Type Tests

Type tests shall be made to prove compliance with the requirements of this standard. Unless otherwise indicated, the tests shall be cor.ducted at an ambient temperature between 15 and 25°C. The tests specified in 5.3.1 to 5.3.11 shall be conducted on eleven test samples ( A to K ) using the sample allocation and the test order given i.? the Table Il. Each sample shall consist of an aircraft fixed connector and an appro- priate ground supply free connector.

5.2.2 Quality Cvntrol Tests

Quality control tests shall be made on one sample fixed and free connector p3r 100, atleast once a year. The sample shall be subjected to the tests specified in 5.3.4.1, 5.3.6 and 5.3.8.

If the sample fails in any test, the batch shall be deemed not to comply with the requirements of this standard.

5.3 Tests

5.3.1 Engagement and Disengagement Forces

Two test fixed connectors shall be constructed for each configuration of ground supply free connector, each fixed connector having male contacts cf hardened and ground steel, with a surface finish of between, 0.1 and 0.4 pm mount- ed at the centres shown in the appropriate figure in IS 7915 : 1976 except that the tolerance on contact position shall be f0.025 mm. No shrouds shall be fitted.

One test fixed connector shall have male contacts of the maximum tolerance f0.005 mm and the other test fixed connector shall have male con- tacts of the minimum tolerance f0.005 mm.

Fully engage and disengage the ground supply free connector being tested 50 times usinn the maximum size test- fixed connector folkwed by 5 times using the minimum size test fixed connector.

Measure the disengage the the first and _

.

force necessary to engage and ground supply free connector on last insertion of each test fixed

connector. For 3-pin connector, it shall not be less than 122 N or greater than 356 N. For 5 and 6-pin connectors, it shall be not less than 178 N or greater than 623 N. ‘The rate of inser- tion and withdrawal shall not exceed 76 mm/ min.

Table 1 Type Testing - Allocation of Samples and Order of Testing

( Clause 5.2.1 )

Test Sample and Test Order

~__h__~ A B C

Engagement and disengagement forces 1 ( see 5.3.1 ) Side load tests ( see 5.3.2 ) 2 Endurance test ( see 5.3.3 ) 3 Temperature rise and voltage drop test 4 ( see 5.3.4 ) Salt spray test ( see 5.3.5 ) tligh voltage and insulation resis;ance

1

2 test (see 5.3.6 ) Vibration test (aircraft fixed connector 3 only ) [ see 5.3.7 ] Temperature and pressure test ( aircraft fixed connector only ) [ see 5.3.8 ]

4

Shock test (ground supply free 1 connector only ) [ see 5.3.9 ] Fluids susceptibility test ( initial Samples D to qualification only ) [ see 5.3.10 ]

K* %hper Extremes of temperatures - Engage- 2 ment and disengagement test (see 5.3.11 )

5.3.2 Side Load Tests

After the test described in 5.3.1, engage the ground supply free connector with an appropri- ate aircraft fixed connector mounted with its axis horizontal.

With the main current-carrying male contacts one third engaged, apply a side load of 890 N to the extremity of the ground supply free con- nector body. No damage or permanent deformation of the fixed or free connector shall ensure from this test.

5.3.3 Endurance Test

After the tests described in 5.3.1 and 5.3.2, fully engage and disengage the ground supply free connector 500 times with an appropriate aircraft fixed connector mounted with its axis horizontal. Engagement and disengagement shall be at a rate not exceeding 15 cycles/mi::.

Measure the voltage drop at the end of this test. It shall meet the requirements of 5.3.4.1 (b).

.5.3.4 Temperature Rise and Voltage Drop Test

After tests described in 5.3.4.1 and 5.3.4.2 shall be conducted with two size 00 cables not less than 1.8 m in length connected to each termina- tion of each of thz main current-carrying male and female contacts, and with one size 10 cables connected to the termination of each section of each of the control current-carrying fcmale contacts. These tests shall be conducted at an ambient temperature of 65%.

NOTE -This test is intended as a test on the male and female contacts acd therefore, for the purposes of this test only, it will be necessary to make each of the main cable terminations on both the aircraft fixed connector and the ground supply free connector suitable for carrying two size 00 cables.

5.3.4.1 Pass a current of 450 A through each of the main current-carrying male and~female con- tacts and 35 A through each of the control current-carrying male and female contacts for a period of one hour. At the end of this time, the following requirements shall be met:

a)

b)

The temperature rise of each of the cables, measured on the outside of the conductors underneath the insulation at a point 100 mm from the end of each cable termination to the unit, shall not exceed 40°C.

The voltage drop along each of the main current-carrying contacts, measured at the cable connections, shall not exceed 20 mV when carrying 450 A. On the control current-carrying contacts, the voltage drop shall not exceed 10 mVwhen carrying 35 A.

5.3.4.2 After the test described in 5.3.4.1, cool to the ambient temperature specified in 5.2.1, then pass a current of 1 500 A through each of the main current-carrying male and female contacts for a period of one minute. At the end of this time, the temperature rise shall not exceed 40°C. Upon reducing the current to 450 A, the voltage drop along each of the main current-carrying male and female contacts measured at the cable connections shall not exceed 40 mV.

5.3.5 Salt Spray Test

One aircraft fixed connector and one grcund supply free connector, disengaged, shall be subjected to the salt spray test, as defined in IS 8252 ( Part 10 ) : 1979.

After completion of the 48 h exposure, leave the fixed and free connector in normal labora- tory atmospheric conditions, at a temperature

.

IS 13835 : 1993

of between 15 and 25°C. After a period of between one hour and one and a half hours, engage the items and measure the voltage drop. It shall meet the requirements of 5.3.4.1 (b).

5.3.6 High Voltage and Insulation Resistance Tests

Immediately following the salt spray tests described in 5.3.5. the mated fixed and free connectors shall be subjected to the following high voltage and insulation resistance tests.

5.3.6.1 Apply 2000 V rms, 50/60 Hz a. c., for one minute between adjacent contacts and be- tween all co&acts connected together and the shroud. There shall be no electrical breakdown.

5.3.6.2 Carry out an insulation test at 500 V d.c. between all adjacent contacts and between all contacts connected together and the shroud, during which the insulation resistance shall be not less than 100 MQ.

5.3.6.3 Carry out an insulation test at 500 V d. c. between the two halves of each of the control current female contacts, during which the insulation resistance shall be pot less than 20 MQ.

5.3.7 Vibration Test ( Aircraft Fixed Connector Only )

One aircraft fixed connector shall be subjected to the vibration test defined in IS 8252 ( Part 14 ) : 1982 except that there is no require- ment to operate the equipment under test.

Wire the fixed connector to two size 00 cables, one to each main current-carrying male contact, and with a size 16 cable to the control male contact. The cables shall be secured to the vibration table at a distance of not less than 400 mm from the fixed connector.

At the conclusion of the test, there shall be no signs of loosening of fixings or cable terminations.

5.3.8 Temperature and Pressure Test ( Aircraft Fixed Connector Only )

Mount the aircraft fixed connector on a suitable panel in such a way that a differential_ air pressure can be applied between the two sides of the panel and leakage through the connector can be measured.

NOTE - This test is intended to detect-leakage through the connector and not the connector Panel interface.

Place the aircraft fixed connector in suitable chamber. Heat the chamber to 105 f l°C over a period of three hours, and maifltain at that temperature for at least sixteen hours. Allow the chamber and specimen contained in

3

Is13835:1993

it to cool naturally for seven hours. Then reduce the temperature of the chamber to 65 -& 1°C during the next sixteen hours, and maintain at the temperature for at least four hours. Repeat this temperature cycle. At the end ofthe second 4 h period and while the aircraft fixed connector is still at the minimum temperature, apply a differential air pressure of 140 kPa between the two sides of the mounting panel, the positive pressure being applied on the aircraft side. The leaka.ge of the aircraft plug shall not exceed 1 cm3/min.

5.3.9 Shock Test ( Ground SuppIy Free Connector Only )

Drop the ground supply free connector, with six m of attached cable, ten times from a height of 3.6 m on to a concrete surface. For the test the free end of the cable shall be fixed at a point allowing the cable to assume an angle of approximately 45” before the ground supply connector is released. The ground supply free connector shall then be subjected to the requi- ments of 5.3.11 using an app:opriate aircraft fixed connector.

53.10 Fluid Susceptibility Test ( Initial Qualij- cation Only )

Aircraft fixed connectors and ground supply free connectors shall be subjected, unmated, to the spray test defined in Annex A using test

categories XC, XD, XF, XG, XJ, XL and XM. No fluid test marking requirements exist. Additionally they shall be tested in trichloro- ethane. Operation and compliance with Annex A shall be demonstrated as follows:

a) clean the connectors using trichloro- ethane and wipe dry with a clean dry cloth;

b) they shall then meet the requirements of the high voltage and insulation resistance test ( see 5.3.6 );

c) it shall be shown, to the satisfaction of the Approval Authority, that the com- plete connectors can be engaged and disengaged by hand.

53.11 Extremes of Temperatures - Engagemenl and Disengagement Test It shall be shown, to the satisfaction of the Approval Authority, that the complete connec- tors can be engaged and disengaged by hand at a temperature of -65°C and +65”C.

6 MARKING

The connector housing shall be clearly marked, by either embossing or engraving, with the number of this standard and the style number. as specified in IS 7915 : 1976.

Example; IS 33!!35 IA

ANNEX A

( Clause 5.3.10 ) FLUIDS SUSCEPTIBILITY TEST

A-l GENERAL

Fluids susceptibility test shall only be perfor- med when the equipment will be installed in areas where fluid contamination could be commonly encountered. The fluids contained herein are representative of commonly used fluids encountered in airborne and ground opera- tions. Fluids not listed herein and for which susceptibility tests are indicated shall be includ- ed in the relevant equipment specification and are considered unique.

A-l S Precautions

A-1.1.1 Since many contaminants may have flash points within the test temperature range, care shall be taken to ensure that adequate safety measures are taken to limit the possi- bility of fire or explosion.

A-1.1.2 Since contaminants may themselves, or in combination with the test sample, be toxic. Due consideration shall be given to this possi- bility before commencing the tests.

A-2 CATEGORIES OF EQUIPMENT

A-2.1 Category X

Certain airborne equipments do not have to meet any Auid tests to meet environmerital requirements in the normal operation of civil and many non-civil transport aircraft. In such cases the equipment is not affected by fluids or no fiuid is likely to be in contact with the equipment due to its location and use. When equipment has not experienced fluid tests for either the assembled part or its component, parts shall be identified as Category X.

4

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IS 13835 : 1993

A-2.2 Other Categories \

A-2.2.1 Since equipment may be tested for sus- ceptibility to contamination by several fluids, a series of letters are used on the name plate to ider,tify the fluids for which the equipment has been tested.

A-2.2.2 There are five generai classes of fluids covered in this Annex. In addition, there are 10 specific fluids that are used to test these classes. Table 2 shows the classes of fluids tested and the specific fluids used in these tests.

Table 2 Classes of Fluid ( Clause A-2.2.2 )

Spray Test Category

Test Fluid Class of Con~~inatinp - _

XA Aviation jet a fuel XB

Fuels Aviation piston engine fuel

xc Both of above fuels separately xx No fuel tests required -_--_ - XD Mineral-based hydraulic fluid XE Non-mineral based C synthetic ) hydraulic fluid XF

Ilydraulic fluids Phosphate ester-based ( synthetic ) hydra.ulic fluid

XG Silicate ester-based ( synthetic ) hydraulic fluid XH All of above hydraulic fluid separately ’ xx No hydraulic fluid test. required

XT Mineral-based oil Lubricating oils XJ Synthetic oil

XK Both of above lubrication oils separately

xx No lubrication oil tests required

XL Denatured alcohol Alcohol xx No denatured alcohol tests required

De-icing Auid XM

xx Ethylene glycol No ethylene glycol tests required

A-3 TEST PROCEDURE

A-3.1 Spray Test

Connect the equipment mechanically and elec- trically as defined in the relevant equipment specification.

62” and 70°C for a period of 160 hours. At the end of this period the test specimen shall be returned to room temperature and operated for a period of two hours.

Spray the equipment with the appropriate fluid one or more times per day as necessary to maintain a wetted condition for a period 24 hours. The spray shall be a fine mist, main- tained at the temperature shown in Table 3, applicable to the test fluid and shall be directed toward every major surface, seal and connector of the equipment sample under test. At the end of 24 hours, operate the equipment for at least 10 minutes.

Following the two-hour period, DETERMINE COMPLIANCE WITH THE APPLICABLE EQUIPMENT PERFORMANCE STANDARD

A-4 USE OF MATERIAL SPECIMENS

A-4.1 Material specimen tests may be used in lieu of equipment tests. The results of these tests shall assure that the material wilI perform its intended function of protecting the equip- ment from malfunctioning when exposed to the relevant fluids as explained in the equipment test procedures ( see A-3 ).

A-5 MARKING

Following this 24-hour period and without A-5.1 For a means of identifying which fluid removing the excess fluid, the test specimen tests were performed, name plates shall indicate shall be placed in an appropriate chamber and the particular environmental test categories for subjected to a constant temperature between which the equipment has beei tested.

IS 13835 : 1993

Table 3 Categories of Fluid Test

( Clause A-3.1 )

Class of Co;;h;inating Test Category Test Tekrgay OC Test Fluid

No test X No fluid tests performed

Fuels

A B

C

D

Hydraulic fluids

E

F

G

20 - 25 20 - 25

20 - 25

45 - 50

65 - 70

65 - 70

65 - 70

Lubricating oils

Alcohol

H

I

J

K

L

see above

65 - 70

65 - 70

65 - 70

20 - 25

Aviation jet a fuel Aviation piston engine fuel

Both of the above fuels separately

Mineral-based hydraulic fluid

Non-mineral-based ( synthetic ) hydraulic fluid Phosphate ester-based hydraulic fluid

( synthetic )

Silicate ester-based ( synthetic ) hydraulic fluid All of above hydraulic fluid separately

Mineral-based oil

Synthetic oil

Both of above lubricating oils separately

Denatured alcohol ’

De-icing fluid M 45 - 50 Ethylene glycol

6

.

IS 13835 : 1993

ANNEX B

( Foreword )

COMMITTEE COMPOSITLON

Aircraft Electrical Equipment Sectional Committee, TED 15

Chairman

SHRI S. B. NIYOGI

Members

DR D. R. ARORA

SHRI Z. A. ASIF SHRI S. P. BHATTACHARYA ( Alternate )

SHRI S. K. BHARIJ SHRI I(. K. SINHA ( Alternate )

SHRI R. K. GUPTA SHRI P. S. RAMAN ( Alternate )

SHRI B. K. JOSHI SHRI ANAND PRAKASH ( Alternate )

SHRI S. K. KAPUR SHRI YASHVIR KUMAR ( Alternate )

SHRI MADAN MOHAN SHRI S. K. GARG ( Alternate )

MANAGER ( DESIGNS ELEC. SYS ) MANAGER ( DESIGNS AVIONICS ) ( Alternate )

SHRI C. SITAPATI RAO SHRI K. SLJRENDAR ( Alternate )

DR K. SUDHAKAR RAO SHRI A. BOSE ( Alternate )

SHRI K. V. R. RAO SHRI A. J. BASU ( Alternate 1

SHRI A. J. SETH

SQN LDR L. D. SHARMA SQN LDR P. S. R. NAIR ( Alternate )

SHRI K. SUBRAMANYAM SHRI K. SRIDHAR ( Alternate )

DR V. K. TIKKU SHRI S. BHATTACHARYA ( Alternate )

SHRI N. S. VIJAYARAGHAVAN. Director ( TED)

Representing

Directorate of Technical Development and Production ( Air ), New Delhi

Hindustan Aeronautics Ltd, Korva

Hindustan Aeronautics Ltd, Lucknow

Directorate General of Technical Development ( DGTD ), New Delhi

Delton Cables Ltd, New Delhi

Directorate General of Civil Aviation, New Delhi

Indian Airlines, New Delhi

Air India, Bombay c

Hindustan Aeronautics Ltd, Nasik

Electronic Testing and Development Centre, Hyderabaci

Indian Space Research Organization, Trivandrum

lccab Industries Ltd, Pune

Hindustan Aeronautics Ltd. Kanpur

Directorate of Common System, New Delhi

Aeronautical Development Establishmat ( R & D ), Bangalore

National lnsulated Cables Co of lndia Ltd, Calcutta

Director General, BIS ( Ex-officio Member )

Member Secretary

SHRI D. L. BHOLA Assistant Director ( TED ), BIS

7

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