SIST EN 3155-022:2009

Overview

EN 3155-022:2006 is a CEN product standard in the Aerospace series that defines rectangular male electrical contacts (type A, crimp, class R) used in elements of connection per EN 3155-002. It specifies required characteristics, materials, dimensions, tests and tooling for size 22 contacts. The standard is intended to be used together with EN 3155-001 (technical specification) and pairs with female contacts in EN 3155-023; these male contacts also mate with size 22 non-removable solder female contacts in EN 3218-005 / EN 3218-006.

Key topics and technical requirements

• Contact type and class: Type A (general application), Class R (operating temperature −65 °C to 150 °C).
• Dimensions & mass: Detailed dimensional requirements apply after surface treatment; mass of one contact ≤ 0.1 g.
• Material & plating: Body of copper alloy with gold over an appropriate undercoat (selective protection acceptable).
• Permissible cable sizes: Table of conductor sizes (examples: 0.60 mm2 / AWG 20, 0.40 mm2 / AWG 22, 0.25 mm2 / AWG 24, 0.15 mm2 / AWG 26) and rated currents.
• Crimping tooling: Conformance to MIL‑DTL‑22520 series and EN 4008‑011 positioners is required; qualification selector numbers are provided for crimp tool selection and qualification.
• Insertion/extraction tool: Standardized tool geometry; tip must accept a pin of Ø 2.08 ± 0.12 mm after insertion into a 1.98 ± 0.12 mm hole to a depth of minimum 5.84 mm.
• Cable preparation: Stripped length = 5.2 ± 0.2 mm.
• Electrical and environmental tests: Tests referenced to EN 2591 series include visual/dimensional checks, contact resistance (initial ≤ 8 mΩ, ≤ 10 mΩ after certain tests), endurance at 150 ± 2 °C for 1 000 h, rapid temperature change (−65 to 150 °C), salt mist, fluid resistance, shock and vibration, and defined electrical overload tests (e.g., 15 A for 300 s; 75 A for 1 s; 150 A for 0.35 s).

Applications and who uses this standard

• Aerospace connector manufacturers specifying and producing size‑22 rectangular male crimp contacts.
• Harness and cable assemblers ensuring correct crimp tooling, conductor selection and stripping for reliable terminations.
• Design and systems engineers integrating connectors in avionics and airborne electrical systems where temperature and environmental performance are critical.
• Qualification and test laboratories performing EN 2591 test methods and supplier audits.

Related standards

• EN 3155-001 (technical specification) - mandatory companion document
• EN 3155-002 (contact list & utilization)
• EN 3155-023 (female crimp contacts)
• EN 3218-005 / EN 3218-006 (size 22 solder female contacts)
• MIL‑DTL‑22520 and EN 4008‑011 (crimping tool specifications)
• EN 2591 series (test methods)

Keywords: EN 3155-022:2006, aerospace electrical contacts, rectangular male contacts, crimp class R, crimping tools, insertion/extraction tool, connector contacts, EN 3155 series.