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1、BRITISH STANDARD BS EN 50109-2-4:1996 Incorporating Amendment No. 1 Hand crimping tools Tools for the crimp termination of electric cables and wires for low frequency and radio frequency applications Part 2: Particular requirements Section 2.4 Centre contacts of RF connectors, series SMZ The Europea
2、n Standard EN 50109-2-4:1995 has the status of a British Standard ICS 25.140.30 Licensed Copy: sheffieldun sheffieldun, na, Mon Nov 06 06:52:21 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS EN 50109-2-4:1996 This British Standard, having been prepared under the direction of the Electrotechnical Sect
3、or Board, was published under the authority of the Standards Board and comes into effect on 15 February 1996 BSI 03-2000 The following BSI references relate to the work on this standard: Committee reference EPL/46/4 Draft announced in BSI News October 1995 ISBN 0 580 25213 2 Committees responsible f
4、or this British Standard The preparation of this British Standard was entrusted by Technical Committee EPL/46, Cables, wires and waveguides, RF connectors and accessories for communication and signalling, to Subcommittee EPL/46/4, RF connectors, on which the following bodies were represented: AEA Te
5、chnology BEAMA Electrical Cable they shall also comply with the requirements of this Part 2-4, as stated in 4.2 to 4.11, as follows. 4.2 Indentor operation The design of the crimping tool shall be such that, under load, all indentors travel with uniform and simultaneous movement, to meet the final t
6、olerances prescribed in Figure A.2. 4.3 Contact positioner A spring-loaded positioner shall be provided for the proper location of the centre contact assembly during the crimping operation. The contact shall remain correctly positioned during the complete crimping cycle. See Figure A.4, for dimensio
7、ns, displacement and spring-thrust requirements. 4.4 Connector locator A means of supporting the connector, perpendicular to the plane of the tool, shall be provided. See Figure A.4. 4.5 Outline dimensions and mass Crimping tools shall conform to the dimensions and mass specified in Figure A.1, alth
8、ough they need not necessarily be of the physical configuration depicted. 4.6 Operating force (crimping cycle) The crimping tool shall be designed such that it will pass the Operating Force (crimping cycle) test as given in 6.7 of Part 1 and 5.2.5 of this Part 2-4. 4.7 Overload force The crimping to
9、ol shall be designed such that it will pass the Overload force test as given in 6.8 of Part 1, but uprated to 200 % of the maximum operating force, and 5.2.7 of this Part 2-4. Licensed Copy: sheffieldun sheffieldun, na, Mon Nov 06 06:52:21 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 50109-2-4:1995
10、 4 BSI 03-2000 4.8 Indentors The dimensions and arrangement of the indentors shall be in accordance with Figure A.2, when tested using the gauges prescribed in Figure B.1. Surface texture shall be assessed as described in ISO 468 and ISO 4287-1. 4.9 Crimped joints The crimping tool shall be designed
11、 such that it will ultimately produce crimped joints complying with the requirements of the appropriate connector specification. However, to eliminate the possibility of variable test results, the crimping tool is tested independently of any connector piece parts, according to the procedures given i
12、n 6.7 of Part 1 and 5.2.5 and 5.2.6 of this Part 2-4. 4.10 Ratchet and tool stop adjustment 4.10.1 The manufacturer shall adjust the tool such that the positional accuracy of the indentors in relation to both ratchet release and tool stop-point shall comply with the requirements detailed in the foll
13、owing procedure. 4.10.2 The tool shall be closed on the NOT GO gauge pin detailed in Annex B WITHOUT ACTUALLY CRIMPING IT NOR ATTEMPTING TO DO SO. The gentle force applied to the NOT GO gauge pin by the indentors shall be sufficient to retain the gauge without allowing the tool to return to the full
14、y-open position, i.e. the ratchet shall not release on the NOT GO gauge. 4.10.3 Subsequently, to confirm the accuracy of the indentor positioning, the tool shall meet the gauging requirements detailed in 5.2.4. 4.11 User access The crimping tool shall be designed NOT to allow easy user adjustment or
15、 dismantling of the ratchet and stop mechanisms nor the indentor assembly. Any adjustment facilities required by the manufacturer shall be sealed from user intervention, such that unauthorized adjustment would be readily detectable. 5 Test and acceptance requirements 5.1 Type approval A manufacturer
16、 shall obtain Type Approval before supplying tools in accordance with this Part 2-4. Application for Type Approval shall be made to the National Supervising Inspectorate. 5.2 Design acceptance requirements 5.2.1 General The requirements of clauses 5, 6 and 7 of Part 1, with the exception of 6.6, 6.1
17、0 and 6.11, apply. 5.2.2 Application Application for Design Acceptance shall be accompanied by the requisite number of specimens (see 6.2 of Part 1) and the information listed under a), b) and c) below, details of which shall form part of the manufacturers own documentation: a) detail dimensions and
18、 drawings where applicable; b) details of materials and finish; c) evidence, in the form of a report, shall be submitted, justifying the potential for successful completion of the Design Acceptance test programme. 5.2.3 Sample size and test sequence The sample size and test sequence shall be in acco
19、rdance with the requirements of 6.1 and 6.2 of Part 1. One of the samples shall have the contact locator removed to permit the Mechanical Endurance test 5.2.8 to be carried out. 5.2.4 Gauging For the requirements of the gauging procedure referred to in 6.4c of Part 1, the space between the opposing
20、closed indentors shall be measured with a gauge which conforms to the requirements of Figure B.1 of this Part 2-4, using the following procedure. The tool shall be gauged in the fully closed position, i.e. when the tool stop is encountered. The specified GO GAUGE shall pass cleanly through the close
21、d indentors and the specified NOT GO gauge shall not pass through. 5.2.5 Operating force (crimping cycle) For the requirements of the test specified in 6.7 of Part 1, the test shall be carried out with the test piece and locator jig specified in Figure C.1 and Figure C.2. The force applied to the cr
22、imping tool during this test shall be not greater than 200 N when applied to the handles at a point between 30 mm and 35 mm from the remote (distal) ends of the handles. 5.2.6 Run-out After successfully crimping a test piece, the run-out (axial alignment) shall be measured in accordance with Figure
23、C.3. The run-out shall not exceed 0,28 mm Total Indicator Reading (TIR); this includes a manufacturing tolerance of 0,13 mm TIR for the test piece. Licensed Copy: sheffieldun sheffieldun, na, Mon Nov 06 06:52:21 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 50109-2-4:1995 BSI 03-20005 5.2.7 Overload
24、 force For the requirements in 6.8 of Part 1, a force shall be applied to the handles of the crimping tool at a point between 30 mm and 35 mm from their remote ends. This force shall be increased at a rate not exceeding 25 N/s until it reaches 400 N. This 400 N force shall be maintained for a period
25、 of not less than 30 s. 5.2.8 Mechanical endurance a) for the requirements of the mechanical endurance test described in 6.9 of Part 1, the crimping tool shall be subjected to 50 000 cycles of operation at a rate of between 10 and 20 cycles per minute. During this test the tool shall be continually
26、fed with test wire, meeting the requirements of C.3. It will be necessary for the tool manufacturer to remove the spring-loaded contact locator, to enable the test wire to pass right through the tool. A guide tube of appropriate diameter shall be substituted to keep the wire central. The guide tube
27、shall be designed to ensure minimal production of metallic swarf from the test wire as it passes through. The test wire shall be advanced sufficiently after each cycle so that a new surface is presented to the indentors for each crimp. The force on the handles shall be as specified in 5.2.5 of this
28、Part 2-4. b) no adjustments, repairs nor lubrication shall be permitted during the 50 000 cycles of this test. However, extraneous foreign matter shall be removed at 10 000 cycle intervals. c) after the completion of each 10 000 cycles during the mechanical endurance test, the crimping tool shall be
29、 loaded with a test piece conforming to the requirements of C.1 and the tool manually operated. The test piece shall be subsequently examined and measured for compliance with the requirements of Figure A.3. d) after completion of the 50 000 cycles of the mechanical endurance test and the tests detai
30、led in 5.2.8 c) above, the crimping tool shall be tested for compliance with the requirements of 6.9 a), 6.9 b) and 6.9 d) of Part 1. For the gauging operation, the gauge specified in 5.2.4 of this Part 2-4 shall be used. The run-out requirements of 5.2.6 shall be met by a manually crimped test piec
31、e. 5.3 Certification All manufacturers supplying crimping tools to this Part 2-4, shall be in possession of a valid Type Approval Certificate issued by the National Supervising Inspectorate. Consideration to awarding Type Approval will be given by the National Supervising Inspectorate on successful
32、completion of clause 5. 5.4 Manufacturing changes 5.4.1 Type Approval Type Approval is granted only to products manufactured at the stated location(s), using materials, design and manufacturing processes current at the date of application and against the issue of the manufacturers documentation curr
33、ent at the time Type Approval is granted. 5.4.2 Changes to documentation Once Type Approval has been granted, no change to the documentation nor the product shall be made by the manufacturer without the written agreement of the Supervising Inspectorate. Such changes may require re-assessment of the
34、Type Approval. 5.4.3 Withdrawal of Type Approval The National Supervising Inspectorate reserves the right to withdraw Type Approval at any time, should a manufacturer fail to demonstrate his continuing ability to maintain that level of quality and reliability demonstrated by the specimens through wh
35、ich Type Approval was granted. 5.5 Production tests 5.5.1 General Subclause 7.2 of Part 1 applies. 5.5.2 Specific tests The following tests, which are additional to those encompassed by 5.5.1 above, shall be performed on a sampling basis, as detailed in 7.2.2 of Part 1 and be complied with. 5.5.3 Ov
36、erload force See 5.2.7. 6 Calibration procedure The following calibration procedure shall be applied to crimping tools in accordance with this Part 2-4. 6.1 Frequency Calibration of crimping tools to this Part 2-4, shall be performed at intervals determined by the user, based upon the tool usage. In
37、tervals of not greater than the one year are recommended. 6.2 Registration Upon receipt by the calibration department, the serial number of the tool shall be recorded. 6.3 Operation An initial assessment of the tool shall be made in the “as received” condition. Licensed Copy: sheffieldun sheffieldun
38、, na, Mon Nov 06 06:52:21 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 50109-2-4:1995 6 BSI 03-2000 6.3.1 The operating cycle (full closure mechanism) of the tool shall be checked. The tool shall operate smoothly throughout the crimping cycle, with the ratchet mechanism releasing only at, or slight
39、ly after, the tool-stop position (i.e. with some degree of force applied to the handles). 6.3.2 Visual inspection, up to 10 magnification, of the indentors during the operating cycle should reveal essentially simultaneous movement without uneven travel, and correct retraction after ratchet release.
40、The indentor profiles shall not be chipped, deformed nor in any way visually questionable. 6.3.3 The contact locator shall be checked for correct function and smooth operation. The spring thrust and displacement requirements detailed in Figure A.4, shall be checked. 6.3.4 If the tool is found to be
41、grossly out of adjustment, the user shall be informed immediately, to enable the option of early field investigation into faulty crimp joints to be exercised. 6.4 GO/NOT GO gauge The GO/NOT GO gauge supplied with the tool and illustrated in Annex B shall itself be gauged in accordance with ISO 286.
42、If the gauge does not meet its own gauging requirements, it shall be replaced. 6.5 Gauging procedure and requirements 6.5.1 The tool shall be initially “bedded down” by performing three crimps on test wire in accordance with C.3, followed by gauging procedure in accordance with 5.2.4. 6.5.2 Any crim
43、ping tool not meeting the gauging requirements shall be forwarded to the tool manufacturer for overhaul or replacement. Alternatively, the tool may be adjusted by appropriately trained personnel in accordance with the manufacturers instructions. 6.5.3 After setting up the tool to meet the requiremen
44、ts of 4.10.2, the gauging procedure of 7.5 shall be repeated. If the tool still fails to meet the gauging requirements, it shall be forwarded to the tool manufacturer for overhaul or replacement. 6.6 Crimped joints Crimping tools to this Part 2-4 have been designed to produce crimped joints complyin
45、g with the requirements of specification CECC 22000. Subsequent to successful completion of the tool operation and gauging (6.3 and 6.5 respectively), three crimp joints shall be produced, using coaxial cables appropriate to the connector Variant. The termination procedure shall be in accordance wit
46、h that detailed in the appropriate connector specification. 6.6.1 The three terminations shall be visually assessed for cracking within the crimp region, longitudinal deformation of the whole contact and significant deviation from joint symmetry as indicated by Figure A.3. 6.6.2 Each joint shall mee
47、t the requirements of the appropriate connector specification in respect of: a) crimp termination resistance: to be measured in accordance with CECC 22000, clause 4.9, Crimp Resistance Test. Requirement: 3 milliohms maximum. To be followed by: b) tensile test: as defined in the appropriate connector
48、 specification. 6.7 Test results The crimp resistance and tensile test results shall be logged against the serial number of the tool, and the tool returned to the user, duly marked with a calibration label. 7 Marking, labelling and packaging 7.1 Instruction leaflet 7.1.1 An instruction leaflet showi
49、ng the correct use of the crimping tool and its associated GO/NOT GO gauge shall be included with each tool. This shall be accomplished by means of pictures and/or sketches rather than a lengthy written dissertation. Any periodic or routine operator-performed maintenance that is required shall be shown in the leaflet. 7.1.2 Any special requirements for the day-to-day use of the GO/NOT GO gauge, and operator instructions with respect to re-calibration procedures, shall be included in the leaflet, if requested by the customer. 7.2 Packaging Unless otherwise requested by the cu