7.

ELECTRICAL CABLES & CONNECTORS

7.1 CONTINUITY AND INSULATION TESTING

7.1.1 USING A VOLTMETER (CONTINUOUS CIRCUIT)

If a voltmeter is connected across the lamp, as shown in Figure 1, the voltmeter will
read zero. Since no current can flow in the circuit because of the open resistor, there is
no voltage drop across the lamp. This illustrates a troubleshooting rule that should be
remembered: -
When a voltmeter is connected across a good (not defective) component in an open
circuit, the voltmeter will read zero.

BREAK

Volts

Fig 1

7.1.2 USING A VOLTMETER (OPEN CIRCUIT)

In this case the voltmeter is connected across the open resistor, as shown in Figure 2. The
voltmeter has closed the circuit by shunting (paralleling) the burned-out resistor, allowing
current to flow. Current will flow from the negative terminal of the battery, through the switch,
through the voltmeter and the lamp, back to the positive terminal of the battery.
Volts

BREAK

Fig 2

80
 7.1.3 USING AN OHMMETER - OPEN CIRCUIT FAULT

This type of open circuit malfunction can also be traced by using an ohmmeter. When
an ohmmeter is used, the circuit component to be tested must be isolated and the
power source removed from the circuit. In this case, as shown in Figure 3, these
requirements can be met by opening the circuit switch.

BREAK

Ohms

Fig 3
The ohmmeter is zeroed and placed across (in parallel with) the lamp. In this circuit,
some value of resistance is read. This illustrates another important troubleshooting
point: -

When an ohmmeter is properly connected across a circuit component and a

resistance reading is obtained, the component has continuity and is not open.

When the ohmmeter is connected across the open resistor, as shown in Figure 4, it
indicates infinite resistance, or a discontinuity. Thus, the open circuit has been located
with both a voltmeter and an ohmmeter.
An open in a series circuit will cause the current flow to stop. A short circuit, or 'short',
will cause the opposite effect. A short across a series circuit produces a greater than
normal current flow.
Ohms

BREAK

Fig 4
7.1.4 A SHORTED RESISTOR

81
Figure 5 is a circuit designed to light a lamp. A resistor is connected in the circuit to limit
current flow. If the resistor is shorted, as shown in the illustration, the current flow will
increase and the lamp will become brighter. If the applied voltage were high enough,
the lamp would burn out, but in this case the fuse would protect the lamp by opening
first.

Fig 5
Usually a short circuit will produce an open circuit by either blowing (opening) the fuse
or burning out a circuit component. But in some circuits, such as that illustrated in
Figure 6, there may be additional resistors which will not allow one shorted resistor to
increase the current flow enough to blow the fuse or burn out a component.

With one resistor shorted out, the circuit will still function since the power dissipated by
the other resistors does not exceed the rating of the fuse.

R1
R2

R3

NOTE; CIRCUIT CURRENT DOES

NOT EXCEED FUSE RATING

Fig 6
To locate the shorted resistor while the circuit is functioning, a voltmeter could be used.
When it is connected across any of the un-shorted resistors, a portion of the applied
voltage will be indicated on the voltmeter scale. When it is connected across the
shorted resistor, the voltmeter will read zero.
7.1.5 LOCATING A SHORTED RESISTOR IN SERIES

82
The shorted resistor shown in Figure 7 below can be located with an ohmmeter. First
the switch is opened to isolate the circuit components.
Ohms

R1

50

Ohms
0

R2
R4 R3

Ohms Ohms
10 50

Fig 7
The circuit in Figure 7 is shown with an ohmmeter connected across each of the
resistors. Only the ohmmeter connected across the shorted resistor shows a zero
reading, indicating that this resistor is shorted.

7.1.6 TROUBLESHOOTING PARALLEL CIRCUITS

The procedures used in troubleshooting a parallel circuit are sometimes different from
those used in a series circuit. Unlike a series circuit, a parallel circuit has more than
one path in which current flows. A voltmeter cannot be used, since when it is placed
across an open resistor, it will read the voltage drop in a parallel branch. But an
ammeter or the modified use of an ohmmeter can be employed to detect an open
branch in a parallel circuit. Figure 8 shows a parallel circuit with a break across R3.
If the open resistor shown in Figure 8 was not visually apparent, the circuit would
appear to be functioning properly, since current would continue to flow in the other two
branches of the circuit.

30V 30 30 30
R3
R1

R2

2 AMPS

Fig 8
To determine that the circuit is not operating properly, the total resistance, total current,
and the branch currents of the circuit should be calculated as if there were no open in
the circuit: -

83
 1 1 1 1
Total Resistance = + +
RT R1 R2 R3
1 1 1 1
= + +
RT 30 30 30
1 3 30
= RT = RT = 10
RT 30 3
V 30
Total Current is therefore I = = = 3 Amperes
R 10

Total Current in each branch should be

3Amperes
since each branch is of equal resistance
3

Current for each branch = 1 Ampere

7.1.7 MEASURING THE CURRENT

An ammeter placed in the circuit (see Figure 8) to read total current would show two
amperes instead of the calculated three amperes. Since one ampere of current should
be flowing through each branch, it is obvious that one branch is open. If the ammeter is
connected into the branches, one after another, the open branch will be located by a
zero ammeter reading.

A modified use of the ohmmeter can also locate this type of open circuit. If the
ohmmeter is connected across the open resistor, as shown in Figure 9, an erroneous
reading of continuity would be obtained. Even though the circuit switch is open, the
open resistor is still in parallel with R 1 and R2, and the ohmmeter would indicate that the
open resistor had a resistance of 15 ohms, the equivalent resistance of the parallel
combination of R1 and R2.
Ohms

30V 15
R2

R3
R1

30 30

Fig 9

84
7.1.8 OPENING THE CIRCUIT

Thus, it is necessary to open the circuit as shown in Figure 10 below, in order to check
the resistance of R3. In this way the resistor is not shunted (paralleled) and the reading
on the ohmmeter will indicate infinite resistance. On the other hand, if an open should
occur in this circuit (Figure 10) between the battery and point A, or between the battery
and point B, current would not flow in the circuit.

OPEN
CIRCUIT
A

INFINITE

Ohms
30V 30 30

R1

R2

R3
B

Fig 10

7.1.9 SHORT CIRCUIT IN PARALLEL

As in a series circuit, a short in a parallel circuit will usually cause an open circuit by
blowing the fuse. But, unlike a series circuit, one shorted component in a parallel circuit
will stop current flow by causing the fuse to open. This can be seen by referring to the
circuit in Figure 11.

BREAK

R1

R2

Fig 11
If resistor R3 is shorted, a path of almost zero resistance will be offered to the current,
and all the circuit current will flow through the branch containing the shorted resistor.
Since this is practically the same as connecting a wire between the terminals of the
battery, the current will rise to an excessive value, and the fuse will open. Since the
fuse opens almost as soon as a resistor shorts out, there is no time to perform a current
or voltage check. Thus, troubleshooting a parallel dc circuit for a shorted component
should be accomplished with an ohmmeter. But, as in the case of checking for an open
resistor in a parallel circuit, a shorted resistor can be detected with an ohmmeter only if
one end of the shorted resistor is disconnected.

85
7.1.10 DOUBLESHOOTING SERIES PARALLEL CIRCUITS

Troubleshooting a series parallel resistive circuit involves locating malfunctions similar

to those found in a series or a parallel circuit.

In the circuit shown in Figure 12, an open circuit has occurred in the series portion of
the circuit. When an open occurs anywhere in the series portion of a series parallel
circuit, current flow in the entire circuit will stop. In this case, the circuit will not function,
and the lamp, L1, will not be lit.

BREAK

R1

R2

Fig 12

If an open occurs in the parallel portion of a series parallel circuit, as shown in Figure
13, part of the circuit will continue to function. In this case, the lamp will continue to
burn, but its brightness will increase.

R1

BREAK
R2

Fig 13

86
If a break occurs in the branch containing the lamp, as shown in Figure 14, the circuit
will continue to function with increased resistance and decreased current, but the lamp
will not burn.

R1

BREAK

R2

Fig 14

7.1.11 VOLTMETER & OHMMETER (SERIES/PARALLEL CIRCUITS)

To explain how the voltmeter and ohmmeter can be used to troubleshoot series parallel
circuits, the circuit shown in Figure 15 has been labeled at various points. By
connecting a voltmeter between points A and D, the battery and switch can be checked
for open circuits.
By connecting the voltmeter between points A and B, the voltage drop across R 1 can be
checked. This voltage drop is a portion of the applied voltage. If R 1 is open, the reading
between B and D will be zero. The conductor between the positive terminal of the
battery and point E, as well as the fuse, can be checked for continuity by connecting the
voltmeter between points A and E. If the conductor or fuse is open, the voltmeter will
read zero.

A B C

R1

BREAK

R2

D E F

Fig 15

If the lamp is burning, it is obvious that no open circuit exists in the branch containing
the lamp, and the voltmeter could be used to detect an open in the branch containing R 2
by removing lamp L1 from the circuit.

87
Troubleshooting the series portion of a series parallel circuit presents no difficulties, but
in the parallel portion of the circuit, misleading readings can be obtained.

An ohmmeter can be used to troubleshoot the circuit given in Figure 16. With the switch
open, the series portion of the circuit can be checked by placing the ohmmeter leads
between points A and B. If R1 or the conductor is open, the ohmmeter will read infinity;
if not, the value of the resistor will be indicated on the ohmmeter. Between points D and
E the fuse and conductor can be checked for continuity, but in the parallel portion of the
circuit, care must be exercised, since misleading ohmmeter indications can be obtained.
To check between points B and E, the branch must be disconnected at one of these
points, and while one of these points and the switch are open, the branch containing the
lamp can be checked with the ohmmeter.
A short in the series part of a series parallel circuit will cause a decrease in total
resistance, which will cause total current to increase. In the circuit shown in Figure 16
below, the total resistance is 100 ohms and the total current is two amperes. If R 1
became shorted, total resistance would become 50 ohms, and the total current would
double to four amperes. In the circuit shown, this would cause the three-amp fuse to
blow, but with a five-amp fuse the circuit would continue to function. The result would be
the same if R2 or R3 were to become shorted. The total resistance in either case would
drop to 50 ohms.

50
A B C
R1

200V 100
R2

R2

100

D
3A

E F
CIRCUIT CURRENT = 2A

Fig 16

From this, it can be stated that when a short occurs in a series parallel circuit, the total
resistance will decrease and the total current will increase. A short will normally cause
an open circuit by either blowing the fuse or burning out a circuit component and, as in
the case of an open circuit, a short in a series parallel circuit can be detected with either
an ohmmeter or a voltmeter.

The precautions to be observed when using an ammeter are summarised as follows:

Always connect an ammeter in series with the element through which the current
flow is to be measured.

Never connect an ammeter across a source of voltage, such as a battery or

generator. Remember that the resistance of an ammeter, particularly on the higher
ranges, is extremely low and that any voltage, even a volt or so, can cause very high
current to flow through the meter, causing damage to it, or you.

88
 Use a range large enough to keep the deflection less than full scale. Before
measuring a current, form some idea of its magnitude, then switch to a large enough
scale, or start with the highest range and work down until the appropriate scale is
reached. The most accurate readings are obtained at approximately half scale
deflection.

Many millimeters have been ruined by attempts to measure amperes, so be sure to

read the lettering, either on the dial or on the switch positions, and choose the
proper scale before connecting the meter in the circuit.

Observe proper polarity when connecting the meter in the circuit. Current must flow
through the coil in a definite direction in order to move the indicator needle up-scale.
Current reversal, because of incorrect connection in the circuit, results in a reversed
meter deflection and frequently causes bending of the meter needle. Avoid improper
meter connections by observing the polarity markings on the meter.

Voltmeters are current measuring instruments, designed to indicate voltage by

measuring the current flow through a resistance of known value, and they are
connected across, or in parallel with a circuit.

7.1.12 PRECAUTIONS WHEN USING THE VOLTMETER

If the approximate value of the voltage to be measured is not known, it is best, as in

using the ammeter, to start with the highest range of the voltmeter and progressively
lower the range until a suitable reading is obtained.
Figure 17 shows a multimeter properly connected to a circuit to measure the voltage
drop across a resistor. The function switch is set at the dc volt position and the range
switch is placed in the 50-volt position.

A Multimeter Connected to Measure a Circuit Voltage Drop

BLACK
RED

DCV 50V

0 -30 VOLT
VARIABLE
RANGE

Figure 17

89
The function of a voltmeter is to indicate the potential difference between two points in a
circuit. When the voltmeter is connected across a circuit, it shunts the circuit. If the
voltmeter has low resistance, it will draw an appreciable amount of current. The
effective resistance of the circuit will be lowered, and the voltage reading will
consequently be lowered.
When voltage measurements are made in high resistance circuits, it is necessary to use
a high resistance voltmeter to prevent the shunting action of the meter. The effect is
less noticeable in low resistance circuits because the shunting effect is less. The unit of
voltmeter sensitivity is ohms per volt.

7.1 13 INSULATION TESTING

Insulation testing is not simply a matter of measuring the resistance, in ohms, between
two points that are reputedly in electrical contact. Under working conditions the
insulation of an electrical installation is subjected to electrical stress. This stress can
cause a reduction in effective resistance between the points under consideration. It is
important that comparable conditions of electrical stress should be established when
insulation resistance is being measured.

Any insulation tester must have an output voltage that is equal to (and for preference
appreciably higher than) the working voltage of the circuit under test. Insulation tests
should be carried out after circuit installation and where specified in the Maintenance
Manual. The test should be carried out with a 250 V tester. The output of the tester
should be controlled so that the testing voltage cannot exceed 300 V.

A) INSULATION TESTING PROCEDURE

Before beginning an insulation test the following preparations should be made:

All switches in the circuit concerned should be 'ON'.
All items of ancillary equipment, which are supplied by the system, should be
disconnected. Filaments should be removed.
Components such as cutouts and relays, which are normally open, should have their
terminals bridged.
Remove the appropriate fuse or trip the appropriate circuit breaker.
One lead of the tester should be connected to earth and the other to the terminal on
the circuit side of the fuse holder or CB.

The insulation resistance values are likely to vary with changes in the temperature and
humidity of the local atmosphere. Results of tests and the weather conditions at the
time should be recorded.

B) AFTER TESTING

Immediately after an insulation test, functioning checks should be made on all the
services subjected to the test. If the insulation test or subsequent functioning tests
should reveal a fault, the fault should be rectified and the insulation and functioning
tests should be repeated in that sequence on the affected circuits.

Also remember to test the insulation tester before and after the test. Here are the tests:
Turn the handle with test leads touching and the reading should be - no resistance.
Turn the handle with the leads apart - the needle will move towards infinity.

There is another type of insulation tester, which is not hand wound. This is the battery
insulation tester.

90
 7.2. BONDING

Bonding is the electrical interconnection of metallic parts of an aircraft, normally at earth

potential, for the safe distribution of electrical charges and currents.

It provides a means of protection against charges as a result of the build-up of

precipitation static and electrostatic induction resulting from lightning strikes, so that the
safety of the aircraft, or its occupants, is not endangered. The means provided are such
as to:
minimise damage to the aircraft structure or components,
prevent the passage of such electrical currents as would cause dangerous
malfunctioning of the aircraft or its equipment,
prevent the production of high potential differences within the aircraft. Bonding also
reduces the possibility of electric shock from the electrical supply system, reduces
interference with the functioning of essential services (e.g. radio communications
and navigational aids) and provides a low resistance electrical return path for electric
current in earth-return systems.

7.2.1 PRIMARY AND SECONDARY CONDUCTORS

Primary conductors are the conductors which are required to carry lightning discharge
current, whilst secondary conductors are those provided for other forms of bonding.

7.2.2 BONDING OF AIRCRAFT OF METALLIC CONSTRUCTION

The skin of an all-metal aeroplane is considered adequate to ensure protection against

lightning discharge provided that the method of construction is such that it produces
satisfactory electrical contact at the joints.

NOTE: An electrical contact with a resistance less than 0.05 ohm is considered
satisfactory.

7.2.3 BONDING OF AIRCRAFT OF NON-METALLIC CONSTRUCTION

With regard to aircraft of non-metallic or composite construction, a cage, consisting of

metallic conductors with surge carrying capabilities, must be provided to form part of the
aircraft structure. Metal parts of the aircraft should be bonded to this cage.

7.2.4 GROUND DISCHARGE METHODS

The earth system, which in the case of metallic construction is normally the aircraft
structure, must be automatically connected to ground on landing. This is normally
achieved through the nose wheel tyre, which is impregnated with an electrically
conducting compound.

NOTE: On some aircraft a static discharge whip, or similar device trailed from a landing
wheel assembly, is used to give ground contact on landing.

7.2.5 ELECTROSTATIC CHARGES

The reduction or removal of electrostatic charges, which build up on such surfaces as

glass fibre reinforced plastic, can be achieved by the application of a special paint,
which produces a conductive surface.

91
 7.2.6 BONDING CONDUCTORS

Solid bonding strip and braided bonding cord are selected by cross-sectional area.
Cords are usually made of braided copper, or aluminium, fitted at each end with
connecting tape or lugs. These should be used for bonding connections between
moving parts, or parts subjected to vibration. Cords are suitable for use as primary or
secondary conductors. Figure 18 shows a selection of bonding methods.

BONDING STRIP

METAL CLIP

RUBBER HOSE
CLIP

BONDING LEAD OF
SUFFICIENT LENGTH PIPE CLIP
MAIN TO PERMIT LEVER
SURFACE MOVEMENT
BONDING LEAD
SPIRALLED PRIOR
TO FITTING

CONTROL
SURFACE

FLIGHT CONTROL SURFACE SHOCK-MOUNTED EQUIPMENT

Bonding methods
Figure 18

7.2.7. BONDING TEST

The bonding test is carried out using the test equipment described in Module 7.3.

Since the length of a standard bonding tester lead is 60 feet, the measurement between
the extremities of larger aircraft may have to be done by selecting one or more main
earth points successively. In this case, the resistance value between the main earth
points chosen should be checked before proceeding to check the remote point.

The test lead should be used to check the resistance between selected points. The
values necessary are usually specified in the bonding test schedule, or the
manufacturer's publication for the aircraft concerned.

92
When the pronged ends of the test lead are brought into contact with the aircraft part,
the test-meter will indicate, in ohms, the resistance of the bond.

To ensure good electrical contact at the test prongs it may be necessary to penetrate or
remove a small area of a non-conducting protective coating. After test, any damage to
the protective coating must be restored.

If the resistance at a bond connection is excessive, rectification action will depend on

the-type of connection.

NOTE: Corrosion tends to form at bonding or earth connection and is often the cause
of excessive resistance.

7.2.8 PRIMARY AND SECONDARY CONDUCTOR TESTING

Table 1 below gives an idea of values obtained during a bonding test.

Test Condition Maximum Resistance

Between extremities of the fixed portions of aircraft Estimated and declared by
of non-metallic or composite construction. manufacturer.
Between extremities of the fixed portions of metallic
Primary aircraft.
Conductors Between bonded components and portions of main 0.05 ohm
earth system to which they are connected.
Between metallic parts normally in contact with 1 ohm
flammable fluids and main earth system and
between the parts themselves.
Between isolated conducting parts, which may be 0.5 megohm or 100,000
subjected to appreciable electrostatic charging and ohms per sq ft of surface
the main earth system. area whichever is the less
Between equipment supplied from an unearthed
Secondary system, of any voltage, and the main earth system.
Conductors Between equipment containing circuits carrying 50 1 ohm
volts (rms or dc) or more, and the main earth
system.

Note. Where readings are looked for beyond the range of the Bonding Tester, e.g. 0.5
megohm, the use of an instrument such as a 250 Volt Insulation Tester may be required,
as stipulated by the bonding test schedule.

7.2.9 BONDING TESTING OF COMPOSITE PANELS

Typical tests include checking of the electrical bonding of external composite panels to
the rest of the airframe and measurement of the surface electrical resistance of each
panel.

The recommended procedure for the check of the electrical bonding of an external
composite panel with or without non-conductive finish paint on the anti-static paint is to
use a Resistivity - Continuity Test Set.

The test consists of connecting the ground lead of the test set to the adjacent primary
metal structure and the other lead on to the composite panel. The test set will indicate:
A green light - if there is electrical continuity with the structure and the
resistance value is not more than 1OOk.

93
 An orange light - if there is electrical continuity with the structure and the
resistance value is more than 1OOk and less than or equal to 20QM.
A red light - if there is no electrical continuity and the resistance value is
more than 200M.

Alternatively if there is no non-conductive paint finish then the test can be done with an
ohmmeter /Meg Ohmmeter. The Ohmmeter 1OOk - 500 volts - 1 mA (max), with 2
rounded point prods would be used to check the electrical resistance of fairings (but not
antenna fairings and radomes).

The Megohmmeter 200M - 500 volts - 1 mA (max) with 2 rounded point prods would
be used to measure the electrical resistance of antenna fairings and radomes.

Apply one prod to the composite panel typically 100mm from the edge of the panel from
the bonding joint, put the other prod to the adjacent primary metalstructure near the
panel.

Masurarea rezistentei electrice pe suprafata folosind o banda conductiva

Note the resistance values and ensure they are not higher than the maximum permitted
values, eg not greater than lOOkQ for fairings (not antenna fairings and radomes) not
greater than 200MQ for antenna fairings and radomes.

The recommended procedure for the measurement of the surface electrical resistance
of an external composite panel with or without non-conductive finish paint on the anti-
static paint is to use the same resistivity continuity test set.

This basically involves applying the probe to the panel and making sure the measured
values are not higher than the maximum permitted values. The probe should be placed
on several different areas of the panel.

An alternative method, and only if the anti-static paint is not covered with nonconductive
finish paint, is to measure the resistance with an ohmmeter/megohmmeter or with
conductive tape.

94
 7.3 CRIMPING TOOLS

There is a great variety of crimping tools at present on the market. The following pages
are extracts from the BAe 146 Wiring Manual. References are made to appendices not
contained herein but procedures and processes are described for a variety of hand and
hydraulic crimping tools.

7.3.1 TOOLING FOR PIDG THIN WALL WIRE TERMINALS

Note: PIDG = Pre Insulated Diamond Grip

Table 2 lists the tools used with each wire size and terminal.

Tool Wire Dot Tool Handle Terminal Code

Part No Size Code Colour Insulation
Colour
576778 24-22 2 dots 1 handle black Brown BR
1 handle brown
576779 20 1 dot 1 handle grey Grey GY
1 handle purple
576780 18 2 dots 1 handle orange Orange O
1 handle black
576781 16 1 dot Both handle orange Orange O
576782 14 2 dots 1 handle white White W
1 handle black
576783 12 1 dot Both handles white White W
576784 10 1 dot Both handle black Black BK
47386-4 22-16 - Both handles red Red R
90035-3 22-16 - Both handle black Red R

Table 2

7.3.2. CRIMPING PRODURE

(a) Strip wires to a length of 0.22 in. (5.53 mm) to 0.25 in. (6.35 mm).
(b) Locate terminal in the crimping tool. Take up tool handle pressure until terminal is
held but not deformed. Insert the stripped wire so that the conductor strands are
just visible on the terminal palm before and after crimping. Completely close the
tool handles until the ratchet releases. Open the tool handles and remove the
crimped joint.

7.3.2 INSULATION SUPPORT CRIMPING ADJUSTMENT

(a) The insulation support crimping section of the tool has three positions:
1 = Tight, 2 = Medium, 3 = Loose.
(b) Insert insulation adjustment pin in No 3 position.
(c) Place terminal of the type to be used in the crimping dies.
(d) Insert an unstripped cable of the type to be used into the insulation support
portion of the terminal. Complete the crimping cycle by closing the tool handles
until the ratchet releases. Remove the terminal and check the insulation grip by
bending the cable back and forth once. The terminal insulation support sleeve
should retain its grip on the cable insulation. If the wire pulls out, set the
adjustment pin to position 2 and repeat the test. If necessary, fit adjustment pin

95
 in position 1 to achieve the desired support. Do not use a tighter setting than
required.

7.3.4 COLOUR AND DOT CODE

Tools and terminals are colour coded according to wire size for identification purposes
and in addition, the crimping tool leaves one or two raised dots on the terminal
insulation as a check that the correct tool has been used for that particular cable size.
Table 2 shows the wire size, tool part number, handle colours, terminal insulation
colours and dot code which are to be complied with to ensure a correctly crimped joint.

7.3.5 TOOL MAINTENANCE

(a) Check the die crimping areas for broken or chipped condition. Any tool showing
these signs must be withdrawn from use and returned to the makers for
rectification.
(b) Lubricate all pins, pivot points and bearing surfaces with light machine oil as
follows:
Tools in full daily use: - lubricate daily
Tools in occasional daily use: - lubricate weekly
Tools used weekly or occasionally: - lubricate monthly

In all cases, it is most important that before use excess oil is wiped from the tool,
especially in the crimping areas.

Figure 19 and 20 shows two different types of crimping tool. Figure 21 shows a close
up of the crimping jaws for the tool shown in figure 20.

96
 CARI-CRIMP WIRE SIZE
RATCHET STAMPED
HERE

COLOUR
CODED
HANDLES

LOCATOR
INSULATION CRIMPING
ADJUSTMENT PIN
SHOWN IN POSITION 3

CRIMPING TOOL PART N O 576778-84 INCLUSIVE

COLOUR
CODED
HANDLES

CRIMPING TOOL PART NO 47386-4 & 90035-3

INSULATION
0.007
DIES
LOCATOR

0.007

WIRE BARREL
DIES

DIE & LOCATOR

CLEARANCES

Typical Crimping Tools

Figure 19

97
 TWO SETS OF JAWS

BARREL CRIMPING JAWS

WHICH ARE PRESET AND NOT ADJUSTABLE

INSULATION GRIPPING JAWS WHICH ARE

ADJUSTABLE TO THE VARIOUS CABLE
INSULATION DIAMETERS BY MEANS OF
THE ADJUSTMENT PINS

WIRE RANGE AND CRIMP TYPE

(22 - 16 PIDG SHWON

ADJUSTMENT PINS
ADJUSTED FOR CORRECT SUPPORT
POS 1 - SMALL INSULATION DIAMETERS
POS 2 - MEDIUM INSULATION DIAMETERS
POS 3 - LARGE INSULATION DIAMETERS

USE THE SAME POSITION FOR BOTH PINS

NOTE: START AT POSITION 2. IF THE INSULATION
SUPPORT IS CORRECT IT WILL NOT FRACTURE OR
BREAK AT THE POINT SHOWN WHEN BENT AT 90.
IF A FRATURE OR BREAK APPERS RESET TO POSITION 3.
IF INSULATION IS NOT SECURE, RESET TO POSITION 1.
CHECK AT
THIS POINT

90

CERT-CRIMP RATCHET
TO ASSURE COMPLETION OF CRIPPING OPERATION.
ANY MOVEMENT OF THE HANDLES IN ONE DIRECTION
MUST BE CARRIED TO COMPLETION BEFORE
ATTEMPTING ANY MOVEMENT IN THE
OPPOSITE DIRECTION. TOOL CANNOT BE OPENED,
OR WORK MOVED FROM THE TOOL AFTER RATCHET
HAS
BEEN ENGAGED, UNTIL THE TOOL HAS BEEN
SQUEEZED
SHUT TO COMPLETE CRIMPING OPERATION.

COLOUR CODING

RED HANDLES - USED FOR RED INSULATED TERMINALS,

SIZE 22 - 16. TOOL No 47386.

BLUE/GREEN HANDLES - USED FOR BLUE INSULATED

TERMINALS, SIZE 16 - 14. TOOL No 47387.

BLACK HANDLES - USED FOR BLACK INSULATED

TERMINALS, SIZE 24 - 22. TOOL 575091

Tooling for Nylobond PIDG Terminals (Size 24 14

Figure 20

98
 LOCATOR

SLOT FOR
TRANSVERSE
CRIMPING
IF REQUIRED

Tooling for Nylobond PIDG Terminals (Size 24 14)

Figure 21

7.3.6 "CERTI-CRIMP" RATCHET INSPECTION

The ratchet feature on AMT hand tools should be checked to ensure that the ratchet does
not release prematurely, allowing the dies to open before they have bottomed.

To check the ratchet, proceed as follows :-

(a) Thoroughly clean the bottoming surfaces of the dies.
(b) Make a test crimp using the maximum load, i.e. using maximum wire size for the
tool being used in the appropriate sized terminal. When the crimp is made,
squeeze the handle until the ratchet is free, but do not release the pressure on
the tool handles.

If a 0.001 in shim can be inserted between the bottoming surfaces of the dies, or
there is no opening at all, the ratchet mechanism is satisfactory.

(c) If the clearance between the bottoming surfaces of the dies is greater than 0.001, the
dies are considered as not bottoming and the tool must be withdrawn from use
and returned to the makers (AMP Tool Repair Department).

A) DIE AND LOCATOR CLEARANCE

The clearance between the dies, and locator and die face, should be checked with feeler
gauges and clearance should not exceed the dimension as shown on Figure 19. The
clearance between the dies should be checked before the dies bottom.

If the clearances are exceeded then the tool must be withdrawn from use and returned to
the tool makers (AMP Tool Repair Department).

99
 B) TOOL GAUGING FOR CONDUCTOR CRIMP JAWS

Before commencing gauge checks ensure that the dies are clean and free from particles.

To ensure dies are correctly positioned, a terminal of the correct type should be crimped
prior to gauging checks.

To gauge, close the tool handles until the ratchet is free but do not release the pressure and
the handles.

The "NO GO" plug gauge may partially enter the conductor crimp dies but not pass through.
The "GO" plug gauge should pass through the dies. Any tool failing these checks must be
withdrawn from use. Figure 22 shows the GO/NO GO gauge.

1.5748 1.8288

1.3208 1.3208

0.6350 0.8890

GO - NO GO GAUGE
DIMENSIONS IN mm
TOLERANCES GO GAUGE
+ 0.0127 - - 0.0000 TOLERANCES NO GO GAUGE
+ 0.0000 - 0.127

GO/NO GO Gauge
Figure 22

Before crimping: check for correct combination of tool, terminal and cable. Check
insulation support setting as given on previous page.

Open jaws fully and insert terminal, as shown in Figure 21a, with the palm of the terminal
protruding through the locator and the barrel butting up to the locator. For transverse
crimping, place terminal palm through slot shown in Figure 21b.

Close handles until terminal is just gripped. Insert stripped cable into barrel, ensuring that
approx. 0.03 of conductor protrudes on to the terminal palm. Hold wire in position and close
handles fully until ratchet releases.

NOTE: (1) It is most important that cable stripping is carried out correctly i.e. correct
lengths stripped, no conductors cut or damaged, and all cotton and glass
cloth tails removed.

100
 (2) It is most important that only bare conductor is in the terminal crimp barrel.
Do not force insulation into barrel when fitting cable to terminal. See Figure
23 for correct position.

0.03 OF CABLE INSULATION

BUTTING TO THE ONE DOT CODE
CONDUCTOR (PALM END)
CRIMP BARREL ONLY

INSULATION COLOUR
OUTER RED
INNER COPPER PLASTIC
INSULATION SIZE 22 - 16
SLEEVE

TWO DOT CODE

(PALM END)

INSULATION COLOUR TWO DOT CODE INSULATION COLOUR

BLACK (PALM END) BLUE

SIZE 24 - 22 SIZE 16 - 14

Terminal Crimp Barrels

Figure 23

Crimping Instructions for A-MP Tool No 59239, Size 12-10, Yellow

Strip cables to required length, ensure no strands are cut or severed and all strands of
insulation removed. To open tool handles, squeeze until ratchet releases. Note that once
ratchet engages, handles cannot be opened until crimping action is completed. Figure 24
shows the crimping tool.

Place terminal in crimping dies as shown in Figure 25a and close handles until it is held
firmly. Do not deform terminal. Insert stripped cable into terminal, hold in position and
complete crimping action until ratchet releases

Correctly crimped joints will be as shown in Figure 25c.

For "in line" splice joints, position as shown in Figure 25b and crimp each half of splice.
This means two crimping operations.

101
 WIRE SIZE RANGE
COLOUR CODED STAMPED HERE
HANDLES
(YELLOW)

INSULATION GRIP ADJUSTMENT PIN LOCATOR

POSITION 1 - SMALL INSULATION DIAMETER

POSITION 2 - MEDIUM INSULATION DIAMETER
POSITION 3 - LARGE INSULATION DIAMETER

90
INSULATION SUPPORT
IS CORRECT IF A BREAK
OR FRACTURE DOES
NOT APPEAR WHEN BENT
AT 90

A-MP Crimping Tool 59239 Size 12-10 (Yellow)

Figure 24

WINDOW IDENT
TERMINAL BARREL
ON SPLICE SLIDES
RESTS AGAINST
OVER INNER
INNER LOCATOR
LOCATOR

WHEN SLIDING SPLICE

OVER INNER LOCATOR
MAKE SURE END OF
SPLICE IS FLUSH
WITH EDGE OF OUTER
LOCATOR

WIRE TERMINAL DOT

SIZE COLOUR CODE
12 - 10 YELLOW ONE

A-MP Tool No 59239

Figure 25

102
Figure 26 and 27 show other types of crimping tools avaialable. Figure 28 shows the
location of the splice in the crimping jaws.

Tooling for "Stratotherm" Terminals Uninsulated with Insulation Support

Size 22 to 10
TWO SETS OF JAWS:
BARREL CRIMPING JAWS AND
INSULATION GRIPPING JAWS,
WHICH ARE ADJUSTABLE BY
ADJUSTMENT PINS. ADJUST
PINS FOR CORRECT SUPPORT.

POSITION 1 FOR SMALL INSULATION DIAMETERS

POSITION 2 FOR MEDIUM INSULATION DIAMETERS
POSITION 3 FOR LARGE INSULATION DIAMETERS

TO CHECK, START WITH BOTH PINS IN NO 2

POSITION.
INSERT UNSTRIPPED CABLE INTO INSULATION
GRIP PORTION OF TERMINAL AND CRIMP.
IF SUPPORT IS CORRECT, INSULATION
SHOULD HOLD WHEN CABLE IS BENT AT 90.
IF NOT HELD, RESET BOTH PINS TO POSITION 1
AND RECHECK. SHOULD A FRACTURE OR
BREAK OCCUR WHEN BOTH PINS
ARE SET IN NUMBER TWO POSITION, RESET
BOTH PINS TO POSITION 3 AND RECHECK.

CHECK AT
THIS POINT

90

"CERTI-CRIMP" RATCHET TO
ASSURE COMPLETION OF
CRIMPING OPERATION. ONCE
RATCHET IS ENGAGED HANDLES
CANNOT BE OPENED UNTIL THEY
ARE FULLY CLOSED.

TOOL PART NO 46673 FOR SIZE 22/16 TERMINALS.

TOOL PART NO 46988 FOR SIZE 16/14 TERMINALS.

Figure 26

103
A-MP Tooling for "Stratotherm" Terminals Uninsulated with Insulation
Support (Size 12-10) Crimping Tool (Part No 59461)

TERMINAL BARREL
RESTS AGAINST
LOCATOR

LOCATOR

INSULATION
SUPPORT
ADJUSTMENT
PIN SHOWN IN
POSITION 3

CERTI-CRIMP
RATCHET

CHECK AT
THIS POINT

90

Figure 27

104
 7.4 CRIMPING OPERATION

Strip cables to required length. Ensure no strands are damaged or severed and all
strands of insulation removed.

To open tool handles, squeeze until ratchet releases. Note that once ratchet engages
handles cannot be opened until crimping action is completed.

Place terminal in crimping jaws as shown in Figure 28 close handles until terminal is
held. Do not deform. Insert stripped cable into crimp barrel, hold in position and
complete crimp by closing handles until ratchet releases.

Insulation support pins are to be adjusted according to cable insulation diameter.

1. Position 1 for small insulation diameters
2. Position 2 for medium insulation diameters
3. Position 3 for large insulation diameters.

Insulation support is correct if a break or fracture does not occur when cable is bent at
90.

Before crimping check for correct combination of tool, terminal, cable and Insulation
support setting.

Open jaws fully and insert terminal in jaws, as shown in Figure 28, the palm of the
terminal protruding through the locator and the barrel butting up to the locator.

Close tool handles until terminal is just gripped. Do not deform. Insert stripped cable
into barrel, ensuring that approximately 0.03" of conductor protrudes on to terminal palm.
Hold cable in position and close tool handles until ratchet releases.

NOTES: It is important that stripping is carried out correctly, i.e. correct stripping length, no
conductors cut or damaged, and all cotton and glass "Tails" of insulation removed.

When fitting stripped cable to terminal, only bared conductor is to be in crimp barrel. Do not
force insulation into crimp barrel.

For "inline" splice joints, position the splice in tool jaw and crimp each half separately (two
operations). Joint to be insulated after crimping.

105
EDGE OF TERMINAL LOCATOR
BARREL RESTS
AGAINST LOCATOR

PUSH LOCATOR UP
SO THAT THE TERMINAL
TONGUE WILL SLIDE
THROUGH THE SLOT
IN THE LOCATOR
TERMINAL TONGUE SLIDES
THROUGH THE SLOT
IN THE LOCATOR

Figure 28

106
 7.5 SEALED IN-LINE CRIMP

This Specification describes the tools and methods used to provide an immersion resistant
sealed in-line crimp splice for single wire splicing.

7.5.1 TOOLS AND EQUIPMENT

All tools shall be checked and tested in accordance with applicable requirements and carry
the current tool check identification marks.

7.5.2 PREPARATION

Personnel who have been instructed and tested in the correct use of crimping tools shall
only carry out crimping of splices. Only tools, which carry the current tool, check
identification marks shall be used. The crimping surfaces and moving parts of crimping
tools shall be kept clean and free of particles of metal, etc. Moving parts shall be lubricated
with light machine oil as necessary. Operators shall make no adjustments, or alterations, to
crimping tools.

7.5.3 OPERATION

Check that correct inline splice barrel, sealing sleeve, and marker sleeve have been
provided. Strip wires to a length of 8mm to 9mm (5/16 in approximately). When splicing
Fenwal supplied Fire Zone Wire, strip the outer cover a further 6mm to 7mm ( in
approximately) as shown Figure 29.

OUTER COVER
REMOVED OVER
THIS AREA

6 - 7 mm 5 - 9 mm
(1/4 inch) (5/16 inch)

Figure 29

Stripping to be in accordance with 20-41-08 Crimping Tool Raychem AD-1377S.

Procedure
- Lightly twist together wires entering splice from the same side.
- Slide sealing and marker sleeves onto one of the wires to be spliced.
- Squeeze crimping tool handles together until ratchet releases.
- Place barrel of crimp splice in correct colour crimp location of tool.
- Insert wires into crimp barrel and crimp.
- Do not allow wire insulation to enter the crimp barrel. Slide sealing sleeve centrally
over the crimped splice.

107
 Shrink sealing sleeve to 20-41-07. Heat should be applied until insert melts and flows
axially along the wire. Remove from heat source immediately this occurs.
7.5.4 INSPECTION

All crimped joints shall be visually inspected for:

(a) Correct combination of cable, tool and terminal.
(b) Correct form and location of crimp.
(c) Adequate insertion of conductor strands in crimp barrel.
(d) Freedom from fracture, roughs and sharp edges and flash.
(e) Absence of damage to the conductor or insulation.

7.5.5 REQUIREMENTS

When using in-line crimps certain points should be noted:

(a) Each barrel must carry only one cable unless specifically permitted by the
airworthiness authority.
(b) The crimp must be fitted horizontally or positioned so that the ingress of moisture
is not possible.
(c) Additional sleeving is not permitted to achieve the above.
(d) Ensure operating temperatures are not exceeded.
(e) Specific approval must be obtained from the appropriate airworthiness authority
before using in:
Screened cables
Coaxial cables
Multi cored cables.
Cables greater than size 10.
Thermocouple cables.
HV cables (above 250M rms).
Fire resistance cables in protective zones.
Totally enclosed cables, that cannot be inspected.

(f) Use of in-line is currently restricted to size 10 (35A) or smaller.

(g) Low temperature connectors must not be crimped on size 12 or larger EFGLAS.
(h) Repair schemes are restricted to:
Minimum distance between joints in one cable is 12ft.
No more than 2 joints permitted in 10ft.
Maximum joints; runs of 20ft 3, runs of 200ft 5, runs over 200ft 8

(i) On installation whereever possible observe the following:

All joints must be accessible for visual inspection.
Joints should be positioned so as not to touch:
(a)One another.
(b)Ducting.
(c) Straps.
(d)Other features.

(e) Joints must if possible be positioned on the outside of the loom

(f) All fixing attachments must be approved
(g) Joints must be staggered. If this is not possible then positive seperation must be
carried out using insulation or cable clips.

Figure 41 shows examples of crimping in cable looms

108
 DO NOT PUT
CABLE LACING
ON TOP OF
THE SPLICES

DISTRIBUTE SPILCES
IN A CBLE BUNDLE
EVENLY ON THE OUTSIDE
OF THE BUNDLE

2 CM
MINIMUM

3 - PHASE CABLE SIZE

POWER SUPPLY AWG 8 OR
LARGER

1 CM
MINIMUM

3 - PHASE CABLE SIZE

AWG 8 OR
POWER SUPPLY
LARGER

Crimps in cable looms

Fig 41

109
 7.6 HEAVY DUTY TERMINALS

Crimping of Hellermann Deutsch Terminals and Splices - (S1006 and Sl213)

Crimp Tool = Hellermann 12TC ) Bowthorpe - Hellermann Ltd

Foot Pump = Hellermann FP1 ) Imberhorne Lane
) East Grinstead RH19 1RW

Crimping of ERMA Terminals and Splices

Hydraulic Hand Crimping Tool, ) ERMA Ltd

ERMA 19600 ) 152 Mount Pleasant
) Alperton
) Wembley HA0 1RS
) (01-903-4561)

Crimping of AMP Terminals and Splices

Hydraulic Hand Crimping Tool ) AMP of Great Britain Ltd

AMP 69062 MOD AF ) Terminal House
) Stanmore Middlesex
Crimping of AMP Terminals and Splices ) (01-954-2356)
)
Hand Crimping Tool )
AMP 46447 )

Inhibitor compound Erma Part No. ) ERMA Ltd

13,000 (DTD 5003) ) As above

7.6.1 RECOMMENDED SAFETY PRECAUTIONS

Ensure that pressure hoses in the Hellermann Crimp Tool - Foot Pump equipment are in
good condition and that all connections are tight.

Ensure that all tools are inspected at the correct intervals.

7.6.2 CRIMPING OF HELLERMANN DEUTSCH TERMINALS & SPLICES

IMPORTANT: Using large cutters capable of cutting the cable with a single cutting
action, NOT a hacksaw, cut at least 25.4 mm (1.0 in) off the cable end,
immediately before crimping the conductor.

(a) Slide the appropriate sized and type shrink sleeve over the cable and strip the
insulation from the cable to the dimension given in Table 4.

Warning: The minimum of time shall elapse between the stripping of the cable and it being
crimped into the terminal. Inhibitor compound is not required with these terminals. Great
care shall be taken to ensure that no conductor strands are severed or damaged during
stripping and that no visible insulating material remains on the conductor before insertion
into the terminal.

(b) Open the dies.

110
(c) On the terminal, remove the tape from over the inspection hole and the sealing cap
from the bore opening (end fitting is supplied with this protection).

(d) Place the terminal, palm downward with the die edge 0.05 - 0.10 in from the edge of
the inspection hole.

(e) Operate the foot pump sufficiently to close the dies to firmly hold the terminal without
deforming it. Check that the die end face is still at the 0.05 - 0.10 in dimension from
the inspection hole

(e) Insert the stripped end of the wire into the crimp barrel and check that the wire is fully
bottomed, i.e. visible through the inspection hole. Approximately 0.15 in of conductor
is to be left outside the termination to allow for expansion during the crimping
operation (see Figure 37). Continue the crimping operation until the dies close and
the foot pump pressure relief valve breaks.

(f) Open the die by releasing the hydraulic fluid pressure and remove the terminal.
Remove any excess flash from the hexagon with a blunt edged tool. Submit for
inspection.

(g) For size 000 terminals and splices, replace in the tool with the end face of the die
approximately 0.06 in from the termination open end and make a second crimp (see
Figure 37). Remove any excess flash from the hexagon with a blunt edged tool.
Submit for inspection.

(h) Cover the terminal/wire joint with the appropriate size and type shrink sleeve.

7.6.3 CRIMPING OF HELLERMANN DEUTSCH TERMINALS

Refer to figure 37. Take the crimp die set and select the upper die as shown (the thicker of
the set) and slide it into the crimping head upper channel until the spring loaded ball in the
head engages with the groove in the die. The die should be centralised in the head.

Select the lower die, and engage the die shoulders in the crimping head lower channel, and
press the die home until, riding over the first spring loaded plunger, it butts against the
second plunger. At this point, the first plunger should re-emerge, thus capturing the lower
die between the two plungers.

HELLERMANN DIE SET CONDUCTOR NO OF CRIMPS

PART NO STRIPPING LENGTH
HC12530 0CA 1.04 in minimum 1 per barrel
HC13531 000CA 1.44 in 2 per barrel

HC13536 0CA 1.04 in minimum 1 each

HC13535 000CA 1.44 in 2 each

Table 4

111
 SPRING LOADED SLIDE UPPER DIE
UPPER DIE IN SO THAT THE SECOND CRIMP FIRST CRIMP
RETENTION BALL RETENTION BALL
ENGAGES IN THE
DIE GROOVE

0.050
0.100"
0.060"

CRIMP

UPPER DIE

SLIDE LOWER DIE

IN SO THAT IT IS
CAPTURED BETWEEN
THE TWO RETENTION
STOPS
TWO SPRING LOADED
LOWER DIE
RETENTION STOPS
(PRESS TO RELEASE) LOWER DIE

DIE SET
HELLERMANN DEUTSCH 12TC

Hellermann Deutsch 12TC

Figure 37

7.6.4 CRIMPING OF ERMA AND AMP TERMINALS

IMPORTANT: Using large cutters capable of cutting the cable with a single cutting
action, NOT a hacksaw, cut at least 25.4 mm (1.0 in) off the cable end,
immediately before crimping the conductor.

(a) Slide the appropriate sized and type shrink sleeve S1205 over the cable and strip the
insulation from the cable in accordance with S29-102 and to the dimension given in
the table at the front of this appendix.

Warning: The minimum of time shall elapse between the stripping of the cable and its
crimping into the terminal. Inhibitor compound is required on erma terminal 23406 only.
Great care shall be taken to ensure that no conductor strands are severed or damaged
during stripping, and that no visible insulating material remains on the conductor before
insertion into the terminal.

(b) Ensure that the dies are open, (a) by turning the knob of the Erma Crimping Tool anti-
clockwise (b) by rotating the reservoir handle of the Amp Crimping Tool 69062 anti-
clockwise (c) by squeezing the handles of the Amp Tool 46447 until the ratchet
releases. Insert the terminal, close the valve and pump a few strokes or squeeze the
handles of the 46447 tool until the crimping barrel of the terminal is lightly gripped at
the same time checking that the dies are placed centrally along the crimping barrel of
the terminal.

(c) Insert the cable, stripped to the length quoted in the table and to the conditions of 20-
44-03 into the crimping barrel of the terminal and check either through the open end
112
 of the barrel or through the inspection window that the cable is correctly inserted.
Note that with terminal 23406 only, the barrel end of the conductor and the bore of
the barrel of the terminal are to be lightly coated with inhibitor compound before
insertion (see Appendix 1).

(d) Pump the lever until the dies are fully closed, this being indicated by an audible
"click" as the safety valve operates and the pressure against the lever is released. In
the case of the AMP Tool 69062 the indication is by a sudden reduction in hand load.

When using AMP tool 46447 close the handles until the ratchet releases when the crimp is
complete.

(e) Open the valve by turning the knob or reservoir handle as appropriate anti-clockwise
when the ram and the lower die will retract automatically allowing withdrawal of the
crimped terminal and cable.

(f) Cover the terminal/wire joint with appropriate size and type shrink sleeve S1205 to
the requirements of 526-5014.

(f) Submit the competed crimped terminal for inspection.

113
 7.6.5 CRIMPING OF ERMA AND AMP TERMINALS

Table 5 details ERMA and AMP terminals.

ERMA WIRE ERMA ERMA STRIP AMP LTD AMP AMP

TERMINAL SIZE CRIMP DIE SET LENGTH TERM NOS CRIMP DIE SET
NO TOOL & CODE SEE NOTE 2 TOOL & CODE
12442/2 6 19600 19567HG .43" -
12159/2 0 19600 19571HK 1.18" -
12158/2 6 19600 19567HG .43" -
12160/2 00 19600 19572HL .90" -
12318/2 8 19600 19566HF .35" 323165 69062 N/A 8
12331/2 6 19600 19567HG .45" - -
12117/2 8 19600 19566HF .35" - -
12120/2 6 19600 19567HG .45" 323170 69062 N/A 6
12123/2 4 19600 19568HH .53" 323173 69062 N/A 4
12343/2 00 19600 19572HL .93" -
12118/2 8 19600 19566HF .35" 323167 69062 N/A 8
12124/2 4 19600 19568HH .53" 323174 69062 N/A 4
12133/2 0 19600 19571HK .83" -
12136/2 00 19600 19572HL .93" -
12139/2 000 19600 19573H 1.03" -
12142/2 0000 19600 M 1.17" -
12127/2 2 19600 19574HN -
12337/2 14 29030 19569HI -
12111/2 12 29030 29213HC -
12115/2 10 19600 29214HD 323064 46447
12122/2 6 19600 19565HE .45" 323172 69062 N/A 6
12134/2 0 19600 19567HG .83" -
12137/2 00 19600 19571HK .93" -
12143/2 0000 19600 19572HL 1.17" -
12389/2 12 29030 19574HN -
12116/2 10 19600 29214HD -
19565HE
23406 0 19600 19973LM 1.35" -
12196/2 8 19600 19566HF .34" -
12197/2 6 19600 19567HG .43" -
12195/2 10 19600 19565HE -

114
 Table 5

NOTE 1: /2 to part number indicates nickel plated by ERMA Ltd.

NOTE 2: AMP parts must be crimped using AMP tools.

ERMA parts must be crimped with ERMA tools.

7.6.6 INSERTION OF DIES IN ERMA CRIMPING TOOL

From the table select the correct crimping die set for the required cable and terminal. The
die set number and code is clearly marked and the code is engraved in the die faces so that
it is impressed on the crimping barrel of the terminal during crimping. Figure 38 shows an
ERMA hydraulic Crimping tool.

PUMP
UPPER DIE HANDLE

RELEASE
LOWER DIE VALVE
ADAPTOR

ERMA Hydraulic Crimping Tool

Figure 38

To fit the dies, remove the adaptor by sliding it out of the dovetails. Close the manual valve
by turning the knob clockwise as far as it will go. Pump a few strokes with the pump lever
until the ram moves upward to disclose a hexagon socket grub screw on each side.
Slacken the two screws so that the lower die can be inserted in the circular recess so that
the screws fit into the dimples on either side of the die. Tighten the screws to lock the dies.
Check that the screws are below the surface of the ram.

Open the valve by turning the knob anti-clockwise when the ram with the lower die will
retract. To fit the upper die insert the spigot into the adaptor until held firmly in position by a
spring loaded ball. Slide the adaptor, with the die, into the dovetails where it will be located
and held by spring loaded balls.

7.6.7 ERMA TOOL OPERATION

115
The tool is used in much the same manner as any other crimping tool, with the exception
that the pump has to be operated several times before the crimping operation is complete.
When the correct pressure is attained a ratchet operates preventing any further increase in
pressure.

Once the crimping operation has been completed, the pressure is released by operating a
pressure relief valve on the side of the tool. When the pressure is released the jaws open
and the crimped cable can be removed for inspection.

PREPARATION OF AMP CRIMPING TOOL 69062

This hand operated hydraulic crimping tool has a four-position upper die and a common

LATCH
NEST LOCK

THUMB
KNOB

RESERVOIR
HANDLE

ROTATE CLOCKWISE MOVABLE

TO BEGIN CRIMP HANDLE

ROTATE
COUNTER-CLOCKWISE
TO RETURN THE RAM

lower die for crimping terminal sizes 9, 6, 4 and 2. Figure 39 shows an AMP Crimping Tool
69062
.

Figure 39
AMP Crimping Tool 69062

Operation

1. Open the tool by pressing the latch.

2. Pull back the nest lock and turn the thumb knob until the required die appears and the
lock springs into place. The head cannot be closed until this has occurred. The wire
size number appears on each portion of the nest.
3. Close the head.
4. Rotate the reservoir handle clockwise to close the hydraulic fluid pressure return port so
that when the movable handle is pumped the dies begin to close. A sudden decrease in
effort indicates that the crimping is complete.
5. Rotate the reservoir handle anti-clockwise to release the hydraulic pressure when the
dies will open.

116
 7.7 TESTING OF CRIMPED JOINTS

Typically, tensile and voltage drop tests are made on not less than two specimens of each
and every combination of crimp barrel, conductor, tool, die, locator or positioner.

7.7.1 TENSILE TEST

Each sample shall be tested in a suitable tensile testing machine in which an axial pull is
applied and in which the jaws separate at a steady rate of between one and two inches per
minute. Each specimen shall be tested to destruction and shall not fail below a minimum
load. Examples of loads (and milli-volt drop values) are given in the table below.

The test samples shall have any insulation grip (if applicable) rendered inoperative by
removing the cable insulation.

Pull off loads, test currents and voltage drop values for copper conductor crimps when using
Milli-volts Specification cable strandings. Ref: MIL-T-7928E. Table 6 details the pull off
loads, test currents and voltage drop values for copper conductor crimps.

Wire Size Test Current Voltage drop (Max) Pull off load
Milli-volts lbs
26 3 8 7
24 4.5 8 10
22 9 7 15
20 11 6 19
18 16 5 38
16 22 7 50
14 32 6 70
12 41 5 110
10 55 5 150
8 73 5 225
6 101 5 300
4 135 5 400

Table 6

7.7.2 VOLTAGE DROP TEST

The appropriate test current, given on the table on the previous page at an open circuit
voltage of not more than 30V, is passed through the specimen. Milli-volt drop checks are
carried out using test probes between a point adjacent to the forward end of the crimp barrel
and a point on the conductor immediately behind the crimp barrel. The milli-volt drop must
not exceed the figures in the table of examples on the previous page. Figure 40 shows a
test arrangement.

117
 VOLTMETER
mV

DCV mV
CALIBRATED TEST
PROBES & LEADS

CONDUCTOR
TERMINAL

BUSBAR

INSULATED
BLOCK

Voltage Drop Test

Figure 40

7.7.3 Routine Inspection of Crimped Joints

Every crimped joint must be visually inspected for the following:

(a) Correct combination of cable, tool termination and correct die marks, if applicable.
(b) Correct form and location of crimp.
(c) Adequate insertion of conductor strands in crimp barrel.
(d) Absence of insulation or other non-conducting material in the crimp barrel.
(e) Freedom from fracture, flash, rough or sharp edges.
(g) Absence of damage to the conductor or insulation.
(g) Insulation properly gripped by insulation crimp if applicable.

118
 7.8 CONNECTOR PIN REMOVAL AND INSERTION

There is a vast range of electrical connectors used in aircraft electrical/avionics systems.

This section describes a range of plastic removal/insertion tools used to remove or insert
the pins of some connectors.

7.9.1 PLASTIC INSERTION TOOL

A typical insertion/extraction tool is shown at Figure 42.

Insertion/Extraction Tool
Figure 42

Plastic insertion and extraction tools were introduced to prevent damage to contact retaining
clips and insert materials, and are colour coded for contact size, i.e. Red, size 20; Blue, 16
and Yellow 12 and 22. In composite tools the extractor is always White.

119
Instructions for plastic tools

Installing (coloured end):

Figure 43a Hold the insertion half of the tool (coloured) between the thumb and forefinger
and lay the wire to be inserted along the slot, leaving about " protruding from the end of
the tool to the crimp barrel of the contact.

Figure 43b Squeeze the wire hard into the tool at the tip, between the thumb and
forefinger, and at the same time, quickly pull the protruding wire with the other hand away
from the tool.

Figure 43c The wire will now have snapped into place. Pull it back through the tool until
the tip seats on the back end of the crimp barrel.

Figure 43d Holding the connector with the rear seal facing you slowly push the contact
straight into the connector seal.

Figure 43e A firm stop will be evident when the contact positively seats in the connector.

Figure 43

120
Removal (White end)

Figure 44a With the rear of the connector facing you, lay the wire of the contact to be
removed along the slot of the removal half (White) of the tool, leaving about " from the end
of the tool to the rear of the connector.

Figure 44b Squeeze the wire hard into the tool between the thumb and forefinger about
"
From the tip and at the same time quickly pull the connector away from the tool with the
other hand.

Figure 44c The wire will now have snapped into place. Slide the tool down over the wire
and into the rear seal and push it slowly into the connector until a positive resistance is felt.
At this time the contact retaining clip is in the unlock position.

Figure 44d Press the wire of the contact to be removed against the serrations of the
plastic tool and pull both the tool and the contact-wire assembly out of the connector.

Caution: Do not tip, spread or rotate the tool while it is in the connector.

Figure 44

121
Figure 45A, B shows a comparison of front release and rear release contacts.

PIN SOCKET

A - REAR RELEASE

PIN SOCKET

B - FRONT RELEASE

Front/Rear release Contacts

Figure 45

122
Figure 46a shows the front release system and 46b shows the front release system.
Rear/Front release System

Figure 46

123
 7.8.2 TWEEZER TYPE INSERT/EXTRACT TOOLS

Figure 47 shows the tweezer type insert/extract tools and their Part No.

COLOUR CONTACT SIZE PART No

YELLOW 12 MS27- 495A12

BLUE 16 MS27- 495A16

RED 20 MS27- 495A20

BROWN 22 MS27- 495A22

BLACK 22D, 22M MS27- 495A22D or 22M

Tweezer Type Insert/Extract Tools

Figure 47
Instructions

To Install Contacts:

Open the tool tips by squeezing the handles and the tips around the wire insulation. Slide
the tool along the wire until the tip end butts against the shoulder on the contact.

Carefully push the contact forward and directly in line with the grommet hole until the
contact is felt to snap into position.

Slide the tool back along the wire insulation until it clears the grommet and remove the tool
from the wire.

124
To Remove Contacts:

Open the tool tips sufficiently to place around the wire insulation. Slide the tool down the
wire until the tool tips enter the grommet and come to a positive stop (see Figure 48). A
slight increase in resistance will be noticed just before contact.

Holding the tool tips firmly against the positive stop on the contact, grip the wire and
simultaneously remove the tool, contact and wire.

Caution: The tips on the installing and removal tools used on small contacts have very thin
wall sections. This causes them to have sharp edges which can cut the wire installation or
connector sealing grommet. Do not squeeze, spread, tip ot rotate the tweezers while
entering the connector grommet.
Figure 48 shows the insert/extract operation.

INSERT TOOL OPERATION

Insert/Extract Tool Operation

Figure 48

125
 7.9 SOLDERING

7.9.1 GENERAL

Soldering is the process of joining metallic surfaces through the use of solder without direct
fusion of the base metals. Solder is a non-ferrous fusible tin alloy, which melts when
sufficient heat is applied to it and becomes solid when the heat is removed.

7.9.2 DEFINITION

Wetting - Adhesion of liquid solder to a solid surface.

De-Wetting - The condition is a soldered area in which the liquid solder has not closely
adhered.

Cold Solder Connection Referred to as a Dry Joint. It is the unsatisfactory

connection resulting from de-Wetting and exhibiting an abrupt rise of solder from the
surface being soldered.

Disturbed Solder Connection - Unsatisfactory connection as a result of movement of the

conductor during the hardening of the solder.

Flux A substance, such as Borax or Resin, used to help metals fuse together by
preventing oxidation during soldering.

Resin Soldered Connection - Unsatisfactory connection that has trapped flux.

Overheated Joint An unsatisfactory connection, characterized by a rough solder

surface.

Heat sink A thermal shunt with good heat dissipation characteristics, used to conduct
heat away from the component being soldered.

Tinning The coating of a surface with a uniform layer of solder.

Wicking A method in which a piece of copper braid is applied to the melted solder. The
copper braid acts as a wick to absorb and remove the solder.

Figure 49 shows some soldered joints in cross-section

126
 SOLDER JOINT INSUFFICIENT SOLDER REHEATED
TOO COLD SOLDER TOO OFTEN

TO MUCH CORRECTLY
DRY JOINT
SOLDER MADE JOINT

.Soldered Joints
Figure 49

7.9.3 SOLDERING IRONS

For soldering irons, the following specifications must be met:

1. Use a constant temperature soldering iron that has an insulation transformer in its power
supply. Magnetic fields can damage electrical components.

2. If ESDS are to be soldered, a potential free solder station with temperature regulator
must be used. Also the ground of the soldering station must connected to the ground of
the PCB. This ensures that the component and the soldering iron have the same ground
potential.

3. Use a solder bit, which is appropriate for the degree of heat required. Improper choice
of a solder bit can result in severe damage to electronic components or the PCB itself.

4. A sponge for cleaning the tip of the solder bit must be kept wet and regularly cleaned.
Use only distilled water.

Figure 50 shows a typical soldering iron and transformer pack

127
 BIT CLEANING SOLDERING
SPONGE IRON HOLDER

SOLDERING
IRON
TRANSFORMER
POWER SUPPLY
SOLDER
BIT

Figure 50

7.9.4 HEAT SINKS

Semi-conductors, fine resistors, capacitors etc. can be damaged by heat during soldering.
The proper use of heat sinks can, to large extent, prevent the transference of heat from the
connection, which is being soldered to the component. Heat sinks are made from a heat
conducting material, such as copper, and are pinched to the conductor, between the
component and the end being soldered. In some cases the tip of a pair of long nose pliers
will be sufficient, but this method must only be used if the heat sinks are not available.

Heat Disposal Clips

Figure 51

128
 7.9.5 ANTI-WICKING PLIERS

Anti-wicking pliers are used to prevent thermal damage of the insulation, and flow of solder
under the insulation. Figure 52 shows Anti-Wicking pliers.

ALSO PREVENTS THE FLOW

OF SOLDER UNDER THE
INSULATION

ANTI-WICKING PLIERS ARE USED TO

PREVENT THERMAL DAMAGE
OF THE INSULATION

Anti-Wicking Pliers
Figure 52

7.9.6 SOLDER REMOVAL GUNS

When soldered components are to be replaced, especially on printed circuit boards, all
solder is removed from the connection. To this so a Solder Removal Gun can be used.
The solder removal gun consists of a pump type plunger in a sealed tube. The plunger can
be pushed down against a spring where a spring-loaded release knob holds the plunger in
the down position. When the release knob is pressed, the plunger is free to move upwards.
When the plunger is released, suction is created at the tip of the gun, sucking the heated
solder into the gun. Figure 53 shows a solder removal gun.

TRIGGER
NOTCH FOR
MECHANISM TRIGGER
BARREL
PISTON

P.T.F.E.
NOZZLE TENSION END CAP
SPRING VENT

ROD TO CLEAR
NOZZLE IF IT
GETS BLOCKED

129
To remove solder from a connection proceed as follows:
(a) Push the plunger to the down position
(b) Heat the connection until the solder becomes liquid. Do not overheat.
(c) Hold the tip of the solder removal gun very close to the melted solder and press the
release knob.
(d) Repeat steps (a) to (c) until the solder is removed.

Figure 54 shows solder removal gun operation.

SOLDER
REMOVAL
GUN

RELEASE
KNOB

Solder Removal Gun Operation

Figure 54

130
 7.9.7 TINNING

Strip the wire, then heat the wire until the solder runs freely. Remove the soldering iron heat
immediately to avoid possible damage to the insulation. When tinned, the strands of the
wire must be clearly visible and follow their original normal cable routing. The solder must
not extend beyond the area indicated in Figure 55.

FLUX
CORE - SOLDER

CABLE - INSULATION
SOLDERING
BIT

WHEN TINNED STRANDS

CLEARLY VISIBLE AND 1 - 2.5mm TO BE
HELD IN CORE ROUTING COMPLETELY
FREE OF SOLDER

Tinning of a Wire
Figure 55

7.9.8 SOLDERING PREPARATION

(a) Tinning and soldering must be done in a clean area, this ensures that components do
not become contaminated.
(b) Take care that there is sufficient ventilation during the soldering. Harmful vapors
(metal vapour) are produced during soldering operations.
(c) Tools and equipment must be free from oil, grease and other impurities.
(d) Install the correct solder bit into the soldering iron.
(e) Switch the soldering iron on. Do not use until it has reached its operating
temperature.
(f) When the surface to be soldered has gained the correct temperature, add a small
amount of solder and allow it to distribute itself regularly over the parts to be
connected.
(g) Take away the soldering iron from the connection and allow the solder to cool slowly
without moving the parts. Never force the cooling process.
(h) Too much solder can be removed by using the solder removal gun.
(i) Clean the connections as soon as possible.

7.9.9 SOLDERING OF CONNECTORS

(a) Push a suitable shrink sleeve over the wire.

(b) Heat the solder cup of the connector to be soldered and fill it with solder (see figure
57). Start at the bottom of the connector and work up as shown in figure 56.

131
(c) Strip the wire to the required length.
(d) Tin the wire as described in paragraph 2.3.
(e) Heat the solder cup until the solder melts, tilting the soldering iron bit to allow entry of
the wire and slowly insert the wire.
(f) Hold the wire firmly in place and remove the soldering iron bit from the solder pot.
(g) Make sure that the finished connection is correct (see figure 56).
(h) Push the heat shrink sleeve over the soldered connection and shrink the sleeve (see
Figure 58).

Figure 56 shows the connection order for soldering connectors.

INSULATION
CLEARANCE
1 - 2.5 mm

POINT OF
ENTRY

WIRE MUST BE
INSERTED
TO THE END
OF THE CUP

Connection Order
Figure 56

FLUX
FLUX CORE-SOLDER

SOLDER

45

SOLDER
FLUX SOLDER

FLUX GAS
BUBBLE

SOLDER

CORRECT INCORRECT

Filling the Solder Pot

Figure 57

132
 7.9.10 HEAT SHRINKABLE SLEEVES

Always use the smallest possible size that slides easily over the assembly. The sleeves are
to be cut to a length, so that, when shrunk, they completely cover the connections and
extend approximately 10mm (0.4inch) over the insulation. Figure 58 shows insulation

SLEEVE AFTER
SHRINKING

10mm

CONNECTOR

SLEEVE BEFORE
SHRINKING L

sleeve before and after shrinking.

Heat Shrink Sleeving

Figure 58

7.9.11 SOLDERED CONNECTIONS

The construction of the pins and sockets in a MIL or other type of connections may be
designed for the solder connections to the electric wires. At the end of the pin or socket is a
small solder pocket. Figure 59 shows a typical solder MS connector

When using the soldering method you must remove enough insulation so that none extends
into the solder pocket. With the wire in the pocket, solder is applied with a small pointed
soldering iron or soldering gun. The solder should be of the resin core type and should be
applied to the pocket as it is heated with the soldering iron.

As soon as the solder starts to flow smoothly into the pocket and penertrates the wire, the
soldering iron should be removed to avoid the possibility of burning the insulation of either
the wire being inserted or adjacent wires. Only enough solder should be applied to fill the
pocket, and all small drops of solder should be removed from between the pins.

After each pin is soldered, a plastic sleeve insulator should be pushed down over the
soldered joint and metal pin to prevent the possibility of short circuiting. The insulating
sleeves should be tied or clamped to prevent them from slipping off the pins

133
 SOLDER

1/8
MAX 1/32
MIN

SOLDERING
PINS
IRON
(POTS)

SOLDER

GAS

RESIN

SOLDER

WRONG RIGHT

SOLDER

SLEEVING

.
MS Soldered Methods
Figure 59

Note:
(a) The flux used for soldering is corrosive and can weaken the connections over a
period of time.
(b) Errors such as too much heat, too much solder, not enough heat, and a lack of
connection cleanliness are difficult to eliminate.
(c) The soldering process can destroy gold-plated contacts.
(d) Solder wicking into the wire strands can create additional stress in the wire.

134
 7.10 COAXIAL CABLES

Antennas are connected to most of the radio receivers and transmitters with a special type
of shielded wire called Coaxial Cable. Coaxial cables contain two or more separate
conductors. The inner most conductor may be solid or stranded copper wire, and may be
plain, tinned, silver plated or even gold plated. The remaining conductors are in the form of
tubes, usually of fine braid. The insulation is usually teflon or polyethylene. Outer coverings
or jackets serve to weatherproof the cables and protect them from fluids, and mechanical
and electrical damage. Figure 60 shows a typical coaxial cable.

OUTER
SOLID INNER INSULATOR
CENTER INSULATOR JACKET
CONDUCTOR

BRAID OUTER
CONDUCTOR

Coaxial Cable
Figure 60

Coaxial cables have several advantages over standard cables. Firstly, they are shielded
against electrostatic and magnetic fields. An electrostatic field does not extend beyond the
outer conductor and the magnetic fields due to current flow in the inner and outer
conductors cancel each other out. Secondly, since coaxial cables do not radiate, then
likewise they will not pick up any energy or be influenced by magnetic fields. Thirdly,
coaxial cables have specific values of; impedance, capacitance per unit length and
attenuation per unit length.

7.10.1 COAXIAL STRIPPING PROCEDURES

OUTER JACKET Once the outer jacket has been removed, the following should be
checked:

The outer jacket must not be chafed or incised.

The outer jacket must have been cut off flat all round and at right angles to the
longitudinal direction of the cable.
The outer jacket must not be frayed.
The strands of the underlying shield must not be notched or cut off.

SHIELD After stripping the shield the following must be checked:

The shield must have been cut off evenly all round.
The braiding of the shield must not be damaged.
The underlying dielectric must not be chafed, compressed or incised.

135
DIELECTRIC After stripping the dielectric the following must be checked:

The dielectric must not be chafed, incised or compressed.

The dielectric must have been cut off flat all round the cable.
The dielectric must not be frayed.
The core wires must not be notched or cut off.

Figure 61 shows the process of stripping a coaxial cable.

OUTER JACKET
FRAYED
REMOVAL

CHAFED
OR CUT FLAT &
STRAIGHT

INCORRECT

CORRECT
DAMAGED

UNEVEN
INCORRECT

SHIELD
REMOVAL

CORRECT

COMPRESSED
& INCISED

NOTCHED

INCORRECT

DIELECTRIC
REMOVAL

CORRECT

Coaxial Cable Stripping

Figure 61

136
There are a number of sizes and types of coaxila cable used for electronic installation, and
each type must be terminated in a way specified by the manufacturer of the connectors.
BNC connectors are perhaps the most widely used type. Figure 62 shows the method used
in their installation.
CABLE

1/8"
1/8"
NUT BRAID

1/2"
JACKET

CONTACT

1/8"

BODY
SLEEVE

BNC Coaxial Connector Installation

Figure 62

Refering to Figure 62:

(a) Fit the nut over the cable and cut the ends of the cable square.
(b) Remove one half inch of the outer jacket.
(c) Push the braid back and remove one-eighth inch of the insulation.
(d) Taper the braid over the end of the insulation.
(e) Slide the sleeve over the end of the cable, fit the inner shoulder of the sleeve square
against the end of the jacket.
(f) Comb the braid back over the taper of the sleeve.
(g) Remove the insulation from the conductor leaving one-eighth inch of the insulation
sticking out beyond the sleeve and one-eighth inch of the conductor sticking out of
the insulation.
(h) Solder the contact to the conductor.
(i) Push the body of the conductor over the contact and the end of the cable.
(j) Hold the cable and the body and screw the nut into the body.

The minimum bend radius for co-axial cables states a minimum bend radius of 6x the
outside diameter (for flexible cables) and 10x for semi rigid cables.

137
 7.10. 2 COAXIAL CABLE TESTING

The relationship to the length of a coaxial cable and its impedance is critical. If the
impedance of the line does not match the load impedance, not all the energy fed down the
line flows into the load. Some of the energy is reflected back to the source, forming
standing waves on the line. Every half wave along the line, high V and Low I points appear,
also between these points will be Low V and High I. The ratio of the voltage across the line
at the High V points to that at the Low V points is known as the Voltage Standing-Wave
Ratio (VSWR).

If a coaxial cable is damaged (either crushed, pinched or cut), it will effect the impedance of
the cable; this in turn will result in low power transmissions. Measuring the VSWR on the
line will identify the position of the damage. To measure the VSWR a Time Domain Meter
(TDM) is used.

7.10. 3 TIME DOMAIN REFLECTOMETER (TDR)

A Time Domain Meter is a sampling oscilloscope using Time Domain Reflectometry method.
It sends a narrow pulse down the line measuring the time it takes for a return reflected
signal from any anomalies (either crushed, pinched or cut.) in the line to appear. Time is
then converted into distance to locate the discontinuity.

Any time two metallic conductors are placed close together, they form a transmission line
which has a characteristic impedance. ATDR looks for a change in impedance which can be
causedby a variety of circumstances, including cable damage, watter ingress, change in
cable type, improper installation and even manufaruring flaws.

The impedance of the cable is determined by the conductor diameter, the spacing of the
conductors from each other and the tipe of dielectric material or insulation that is used to
separate the conductors
If the conductor are manufactured with exact spacing and the dielectric is constant, then the
cale impedance will be constant. If the conductors are randomly spaced or the dielectric
changes along the cable, then the impedance will also vary along the cable.

138
7.11 WIRING

Aircraft wiring installation have to be able to withstand extremes of environmental

conditions. This section discusses means of protection and support for electrical cables
used in aircraft.

PTFE - Politetrafluoretilena, polimer fluorurat termoplastic, inert, avand aspectul fildesului

PTFE Cables

EFGLAS electrical cables consist of Nickel Plated Copper Conductors, PTFE Insulation and
a glass braid tape and impregnated glass yarn for added strength. Capable of operating in
temperatures from -70C to +260C with a voltage rating of 600V.

7.11.1 MADE UP CABLING

Cable looms and cabling made up on the bench must be inspected before installation in the
aircraft to verify the following.

That all cables, fittings, etc have been obtained from an approved source, have been
satisfactorily tested and have not deteriorated in storage or been damaged in handling.

That all crimped joints and soldered joints have been made in accordance with the relevant
drawings, are clean and sound and insulating materials have not been damaged by heat
etc.

That all connectors and cable looms conform to drawing requirements in respect of
materials, terminations, length, angle of outlets, orientation of contact assemblies,
identification and protection of connections.

That cable-loom binding is secure. That continuity, resistance and insulation tests are
carried out in accordance with drawing requirements.

139
7.11.2 INSTALLATION OF ELECTRICAL WIRING

The following paragraphs describe how cables and cable bundles must be installed and
protected. This is a general description and the maintenance manual of the aircraft you are
fitting cables/cable bundles to must be used.

A) GENERAL

The cable bundles must be fixed to the structure with cable clamps without extra
protection.

Note; Gas and fluid lines are not part of the structure.

Use conduits only as a protection for cable bundles.

Install and protect cable bundles in such a way that they are accessible for inspection
and maintenance.

Install and protect cable bundles in such a way as to prevent any form of damage, such
as caused by:
(a) Touching.
(b) Chafing.
(c) Hammering.
(d) Sliding.
(e) Kinking.
(f) High ambient Temperatures.

Cable bundles, including the means for fastening and protection, must be resistant to the
circumstances and substances, which exist in their surroundings.

B) INSTALLATION OF CABLE BUNDLES

Assemble the cable to bundles with bundle ties or bundle lacing tape.

To prevent damage to the cable bundles, sufficient space must be kept between the
bundles and the surrounding parts.

Install cable bundles with a minimum clearance of 1cm (0.4inch) to prevent chafing
against sharp edges.

At least 15cm (6inch) separation is required between cables and lines carrying fuel or
oxygen.

At least 7.5cm (3inch separation is required between cables and control cables.

Maintain a minimum 13mm (0.5inch) separation between cables and water lines, pitot
static lines, etc.

Note; where mechanical support is provided which will prevent the actual contact, the
minimum distance can be reduced to less than 13mm.

Maintain a 5cm (2inch) minimum separation between cables and insulated bleed air ducts.
Provide a mechanical support to prevent any possible contact between the cable bundle
and the insulated bleed-air duct.

140
 C) CABLE CLAMPS

Metal cable clamps must have a flexible rubber cushion.

Plastic cable clamps must only be used inside the pressure cabin in places where the load
on the clamp is minimal, as in cable trays, panels and Electrical Power Centre (EPC) areas.

D) INSTALLATION

Make sure that mounting the ends of the flexible rubber cushion are linked together.
This is necessary to prevent the metal of the cable clamps damaging the cables.
Install the mounting bolt on the top of the clamp.
Make sure that after mounting, the cable clamp fully encloses the cable bundle. This is
necessary to prevent the bundle from sliding in the cable clamp.
Make sure that the maximum outer diameter of the cable bundle dows not exceed the
inner diameter of the cable bundle.
Mount the cables at the correct angles.
Lay the cables parallel and tightly together inside the cable clamp.
Ensure the correct distance between clamps is used.

The cabling must be adequately supported throughout its length and a sufficient number of
cable clamps must be provided for each run of cable to ensure that the unsupported lengths
will not vibrate unduly.

The minimum bend radius should not be less than that stated in the appropriate
specification (eg SAE specifies - for cable groups - 10x the largest cable diameter in the
group). For single cables 10x the diameter is given by the same standard. At terminal
blocks, where the cable is suitably supported at each end of the bend, the minimum radius
may be 3x.

Note; The distance between two cable clamps can vary between 10 to 30 cm (4 12 inch)
inside the pressure cabin. This depends on the routing, thickness and stiffness of the
bundle. Figure 63 shows the required distance of the cable clamps

30cm
MAX

30cm
MAX

30cm
MAX

Cable Clamp Spacing

Figure 63

141
 E) CONDUIT (METALLIC & PVC)

When using conduit for cable bundle protection they must be installed in such a way that
they can not be used as a hand hold, or as a foot rest by passengers or maintenance
personnel. The use of plastic conduit can only be used if the use of metallic conduits is
impossible.

The inner diameter of the conduit must be 25% larger than the maximum outer diameter of
the cable bundle. To prevent damage to the cables, the ends of the plastic conduits must
be provided with adapters. The end of the metallic conduit must be flared and smooth.
Figure 64 shows both metallic and PVC conduit in use on modern aircraft.

MINIMUM BEND
CABLE RADIUS
CONDUIT (FOUR TIMES
INSIDE
DIAMETER)
CONDUIT
CLAMP

ADAPTOR

INSIDE
DIAMETER

CLAMP
ADAPTOR

NON-METALLIC
CONDUIT
CABLE CLAMP
ON STRUCTURE

NON-METALLIC
CONDUIT

5 cm
MAX

BRACKET
METALLIC
CONDUIT

CABLE
CLAMP METALLIC
CONDUIT

CLAMP

Metallic & PVC Conduit

142
 Figure 64

F) CONDUIT DRAINAGE

Where tubing is used, a drainage hole 1/8 inch diameter should be made at the lowest point
in the tubing, after this is established. This prevents condensed moisture from running
along the cables and finding its way into the electrical apparatus. When this is not possible,
the cable should incorporate a downward loop immediately after leaving the apparatus.
Where conduits, tubes or ducts are used, they should be installed so that any moisture
accumulating in them will drain away harmlessly, and the cables used in them should be
capable of withstanding such moisture as may be encountered. Figure 65 shows a
drainage hole in the cable conduit.

LINE REPLACEMENT
UNIT (LRU) CABLE
CONDUIT

DRAIN
HOLE

PLUG
CONNECTION

Conduit Drain Hole

Figure 65

143
 G) NTERFERENCE

Cables should be installed so as to reduce electrical interference to a minimum and to avoid

confusion between circuits on different types of services. The spacing between any aircraft
unscreened cable and unscreened radio aerial lead should normally be not less than 18
inches.

H) PROTECTION OF CABLING

The cables must be protected from abrasion, mechanical strain and excessive heat and
against fuel, oil etc, water in either liquid or vapour form and from the weather. Cables
should be spaced from the skin of the aircraft by at least half-inch to avoid damage from the
high skin temperatures likely to be reached in the tropics. The cables should not be run near
a hot engine, or other components, unless a cooled air space or a heat barrier is interposed.
Figures 66 and 67 show different methods of protecting cables.

APPROVED
GROMMET
CABLE
CLAMP

CLEARANCE
1/4 MIN

ANGLE BRACKET
WITH TWO POINT WIRES LESS
FASTENING THAN 1/4 FROM
HOLE EDGE

Cable Protection (Bulkhead Hole)

Figure 66

144
 PLUMBING LINE

ANGLE
BRACKET

1/2 MAXIMUM
WITH NORMAL
HAND PRESSURE

Support Of Cabling
Figure 67

Cables must not be supported on, nor must they be allowed to bear on, sharp edges such
as screw heads or ends, the edges of panels, metal fittings, bulkheads, etc.

Where cables are led through metal fittings or bulkheads, the edges of the holes through
which they pass must be radiused and smoothed and fitted with an insulating bush or
sleeve. Cables which are drawn through holes or tubes must be an easy fit requiring only a
moderate, steady pull, care being taken to keep the cables parallel to each other and to
avoid the formation of kinks which may fracture the conductor.

Conduits, ducts and trays used for carrying cabling should have smooth internal surfaces.
Rigid ducts, etc should be adequately flared at the outlets or bushed with insulating
material.

145
 I) SUPPORT OF CABLING

The cabling must be adequately supported throughout its length, and a sufficient number of
clips or supports must be provided for each run of cables to ensure that the unsupported
lengths will not vibrate unduly, leading to fracture of the conductors, or failure of the
insulation or covering.

Cables must be fitted and clipped so that no tension is applied in any circumstances of
flight, adjustment or maintenance. Loops or slackness will not occur in any position where
they might be caught and strained by normal movement of persons in the aircraft, or during
normal flying, maintenance or adjustment. Figures 68 and 69 show methods of support.

DANGEROUS ANGLES

45 45 X
MA
X MA
SAFE ANGLES

Support Of Cabling
Figure 68

146
 MS 21919 CABLE CLAMPS

Z MEMBER
ANGLE
MEMBER

WIRE PINCHED
IN CLAMP

Support Of Cabling
Figure 69

147
 J) SPIRAL BINDING

Spiral binding (Spi-wrap) is used for forming, and the protection of, cable looms. The
binding is supplied in a spiral form. Twelve inches of one inch inside diameter binding will
cover a one inch bundle for twelve inches. Some types have beaded edges to prevent
damage to the cable.

K) FITTING SPIRAL BINDING

No special equipment is needed when fitting spiral binding. Select the correct size binding
for the loom to be covered and ensure the cables are straight in the cable bundle with no
cross-overs.

Wrap the binding round the bundle for the required length. On large bundles the binding
may be secured at each end by fitting the last loop of the spiral in the cable bundle. The
ends should be cut leaving no sharp edges. Normally, the binding will be fitted 'butted' with
each turn close to the next. Table 7 shows that spiral binding is available for use over a
large temperature range.

Item Material Supplier Remarks

Nylowrap Nylon British Insulated Temperature range
Spiral Binding Colour Natural Callender's -20C to + 105C
Nylon White Cables Ltd
Leigh
Lancs
Efwrap PTFE British Insulated Temperature range
Spiral Binding Colour Black Callender's -20C to + 105C
Cables Ltd
Leigh
Lancs

Table 7

L) TYWRAPS

These are used to tie cable looms and are made of Nylon or PVC. Once wrapped tight
around the loom, they will stay locked, but cannot be unlocked. The inner surfaces are
designed to grip the cable loom and stay in place without slipping. They are also available
in colours for loom identification and coding. Fewer ties are needed in comparison with
normal whipping methods, because of the wide gripping surface of Tywraps.

NOTE: The locking device in a Tywrap is a metal insert integral with the Tywrap itself.
Experience has shown on some aircraft that over tightening can cause the metal insert to
damage the cable upon which the Tywrap is being used. Some cables damaged in this way
are likely to give rise to dangerous conditions. This being the case, all plastic Tywraps are
being used in some areas.

148
 M) CABLE CONDUITS (SUPERFLEXIT)

Conduits made from PTFE are suitable for use where the operating temperature range is
from -70C to +240C. Conduits made from PVC are suitable for use where the operating
temperature range is from -20C to +70C.

The conduit is normally supplied plain but it is available with internal or external tinned
copper braid. (Stainless steel full or partial external braided conduits are not suitable for this
type of attachment.)

The method of attaching the conduit to the connector/end termination is by a stainless steel
Isoclip. A Viton sleeve is fitted over the end termination spigot before fitting the conduit to
prevent cutting into the conduit and to obtain a seal up to (30 psi) 207 KN/m.

The method of attaching the conduit with external tinned copper braid is as for plain conduit.

The method of attaching internal tinned copper braid depends on whether continuity is
required between fittings or not.

To obtain continuity through the braid to shell of connector/end assembly, the braiding is
fitted onto the spigot, the Viton inner sleeve fitted over the braid, the conduit pushed over
the Viton sleeve and all parts retained by Isoclip.

For insulating the tinned copper braid from the connector/end assembly, the braid is fitted
onto the spigot after the Viton sleeve has been fitted.

PROCEDURE

1. Cut the conduit cleanly and squarely.

2. Using the approved Superflexit tool, and the Tool spigots deconvolute 14.5 mm (.57 in)
1 mm (.040 in) of the conduit. This is the required length of deconvoluted conduit for
fitting over the Viton sleeve and the connector end termination.
3. Push the Viton sleeve onto the spigot of the end fitting, allowing approximately 1.5 mm
(.062 in) to protrude beyond the end of the spigot. This sleeve is used as a resilient
member between the deconvoluted end of the conduit and the metal spigot to prevent
cutting the conduit and to obtain a seal.
4. Place the outer Viton sleeve over the conduit/conduit braid and slide back enough to
make space for the Isoclip.
5. Place the Isoclip onto the conduit and then push the deconvoluted portion over the Viton
sleeve and bring the Isoclip forward so that it is positioned as shown.
6. Place the Isoclip assembly tool (see Figure 60) over the Isoclip with the tensioner in the
twisted end of the Isoclip as shown in Figure 71.
7. Wind the knob until a gap appears in the shaft, the edges of the gap lining up with any
pair of markings on either side of the shaft window to ensure that the correct tension is
put an the clip.
8. Compress the lever on the tool to cut off the excess wire on the Isoclip as shown in
Figure 71 and bend back the wire with the top of the tool as shown in Figure 71. Ensure
that the cut ends are dressed down so as not to protrude.
9. Slip the outer Viton sleeve forward over the Isoclip and deconvoluted end of the conduit.

149
 INSPECTION

Ensure that the conduit used is properly assembled and is to the requirements of the
drawing.

SAFETY PRECAUTIONS

The relevant clauses of the factory act shall be strictly adhered to, when working with
electrical equipment. Figure 70 shows an Isoclip tool and Figure 61 shows the procedure
for attaching isoclips.

Isoclip Tool
Figure 70

CONNECTOR VITON OUTER VITON

END FITTING SPIGOT SLEEVE ISOCLIP SLEEVE

TENSIONER

Procedure for Attaching Isoclips

Figure 71

150
 N) HEAT SHRINK TUBING

INTRODUCTION

Heat shrink tubing is available in a variety of sizes and temperature ranges. The example
shown is an extract from the BAe 146 Wiring Manual. This is general purpose, flexible, heat
shrinkable sleeving.

GENERAL CHARACTERISTICS:

Self extinguishing (Raychem Type 1) (Hellermann Type 1) Spec: MIL I 23053B/5

Temperature Range: 55C to + 135C continuous. Up to 300C for short duration (1
hour).
Shrinking Temperature: Min 121C, Recommended temp 250C - 300C.
Shrink Factor: 50% of supplied diameter.
Fluid Resistance: Skydrol 500. Kerosene, Hydraulic fluid.
Colours: Yellow, Black, Red, White, and Blue.
Length: Four feet lengths.

Notes:

1. Select the largest size, which will snugly fit the item to be covered.

2. Wall thickness will be less if recovery is restricted during shrinking.

Std Supplied After Wall Part No & Ordering information

Code Dia Shrinking Thickness Raychem Hellermann
Dia (Nominal)` RNF100 Type 1 FP301-1
inch inch inch
001 0.046 0.023 .016 3/64" Yellow SFM12 Yellow
002 0.063 0.031 .017 1/16" Yellow SFM16 Yellow
003 0.093 0.046 .020 3/32" Yellow SFM24 Yellow
004 0.125 0.062 .020 1/8" Yellow SFM32 Yellow
005 0.187 0.093 .020 3/16" Yellow SFM48 Yellow
006 0.250 0.125 .025 1/4" Yellow SFM64 Yellow
007 0.375 0.187 .025 3/8" Yellow SFM95 Yellow
008 0.500 0.250 .025 1/2" Yellow SFM127 Yellow
009 0.750 0.375 .030 3/4" Yellow SFM190 Yellow
010 1.000 0.500 .035 1" Yellow SFM254 Yellow
011 1.500 0.750 .040 1" Yellow SFM381 Yellow
012 2.000 1.000 .045 2" Yellow SFM508 Yellow
013 3.000 1.500 .050 3" Yellow SFM762 Yellow
014 4.000 2.000 .055 4" Yellow SFM1016Yellow

Table 8

151
 THERMOGUNS

Thermoguns are needed for the shrinkage of the sleeves. The following is a list and
description of various equipment.

THERMOGUN MODEL No 1502A Description: Details of electrical supply stamped

on gun body. Self-contained motor heater and
turbine, i.e., no separate air supply is required.
Four temperature settings, Nos 1, 2, 3 and 4.
Recommended Use: General purpose.

THERMOGUN MODEL No 1509 Description: Similar to Model

(900W) 1502A temperature (max) 480C.

THERMOGUN MODEL No 1511 Description: Similar to Model 1509

(1100W) temperature (max) 590C.

THERMOGUN MODEL No CV1980 Description: Similar to Model 1511

(1200W) (Part No 989540) except for barrel design. Temperature (max) with
air regulator closed 630C.

THERMOPISTOL MODEL 35L Description: Details of electrical supply marked on

pistol. Separate controlled air supply necessary.
Low temperature model, green handle for
identification purposes. Temperature ranges
150C - 300C.
Recommended use:
General purpose for small sleeves and small parts.
Not preferred for solder sleeves and high
temperature sleeves.

THERMOPISTOL MODEL P50H Description: Details of electrical supply marked on

pistol. Separate controlled air supply necessary.
High temperature model, yellow handle for
identification purposes.
Temperature range: 240C - 400C.
Recommended use:
Preferred for high temperature sleeves and solders
sleeves.

MINI-GUN CV5302 (680W) Temperature range

(Part No 991831) without reflector 175C
With PR25 reflector 340C

MINI-GUN CV5720 (700W) Temperature range

(Part No 991608) without reflector 240C
with PR25 reflector 430C

152
 REFLECTORS FOR USE WITH THERMOGUNS

Figure 72 shows different reflectors.

Thermogun Reflectors
Figure 72

REFLECTOR PR13C

Recommended Use: For smaller sizes of all types of sleeve and solder sleeves.

REFLECTOR PR24

Recommended Use: For moulded parts and tubes up to 1 in supplied bore.

REFLECTOR PR25

Recommended Use: For low temperature solder sleeves and smaller products.

REFLECTOR PR26

Recommended Use: For miniature solder sleeve terminations and small products.

153
 7.11 SAFETY REGULATION GROUP

CAA Safety Regulation Group Airworthiness Information Leaflet Ref: AD/IL/0140/1-25

Subject Title: AIRCRAFT ELECTRICAL CABLES

Purpose: This Leaflet provides guidance material on the approval or acceptance of aircraft
electrical cables.

References: Reference Documents are listed in paragraph 2.

Forward

Recent advances made in the performance of dielectric materials has led to the
development of aircraft cables which differ significantly from those in service in older aircraft
types. Experience gained to data on the operation of existing aircraft cables and on the
recent developments, has shown that there are a number of areas where it is considered
general guidance material would be beneficial. RF cables are not considered in this Leaflet.

154
1. Introduction

2. Applicable Requirements
2.1 Design Responsibility
2.2 Approval of Cables
2.3 Modification and Repair

3. Classification of Cables
3.1 Airframe Cables
3.2 Interconnect Cables
3.3 Equipment Wire
3.4 Fire Resistant Cables
3.5 Fireproof Cables
3.6 Multicore Screened and Jacketed Cables
3.7 Data Bus

4. Specification and Cable Type Identification

4.1 British Standard Specifications
4.2 UK Military Specifications
4.3 US Military Specifications
4.4 Constructors Specifications
4.5 International Standards
4.6 Cable Manufacturers Specifications

5. Cable Performance
5.1 Application
5.2 Temperature
5.3 Cable Size
5.4 Voltage Rating
5.5 Flammability and Toxicity
5.6 Wet Arc Tracking
5.7 Mechanical Properties
5.8 Fluid Contamination

6. Cable Construction
6.1 Conductors
6.2 Conductor Plating
6.3 Dielectrical Materials/Cable Types

7. Cable Failures
7.1 Wet Arc Tracking
7.2 Minyvin
7.3 BMS 13-28
7.4 Abrasion
7.5 Conductor Knuckling Through
7.6 Red Plague
7.7 Glycol Fires
7.8 Poor Solderability

155
1. Introduction

The recent advances made in performance of dielectric materials has led to the
development of aircraft cables which differ significantly from those in service in older aircraft
types. Experience gained to date on the operation of existing aircraft cables and on the
recent developments, has shown that there are a number of areas where it is considered
general guidance material would be beneficial. This Leaflet is intended to provide such
guidance on the approval or acceptance of electrical cables and to assist in the supervision
of cable manufacturers.

2. Applicable Requirements

The applicable airworthiness code will depend on the type of aircraft in which the cable is to
be installed. This may be BCAR Section D, BCAR Section K, BCAR Section G to HAR 25.

The following list is provided for guidance purposes only:

BCAR Section D6-13 paragraph 7.1 Cables and Associated Fittings and Equipment
BCAR Section K6-13 paragraph 7.1 Cables and Associated Fittings and Equipment
BCAR Section G6-14 paragraph 7.1 Cables and Associated Fittings and Equipment

CS 25
(CS- Certification Specification )

25.1309 Equipment, Systems and Installation.

25.1353 Electrical Equipment and Installation.
25.1354 Distribution System.
25.1359 Electrical System Fire and Smoke Protection.

See also NPA 25DF-191, Miscellaneous Electrical Requirements

156
2.1 Design Responsibility

For the purposes of the control of design, electrical cables are considered to be an item of
equipment and therefore the requirements of BCAR Section A A4-8 or B4-8* apply. In
general, all cables used for inter-connection within the airframe and power plant are classed
as Controlled items and paragraph 2.2 of this Leaflet considers this in specific terms.

2.2 Approval of Cables

BCAR Section A4-8/B4-8* (CAP 553/CAP 554) Procedures.

Cables manufacturers seeking approval of their products need to hold appropriate Terms of
Approval under an Organisational Approval to BCAR Section A A8-1.

Controlled items such as aircraft cables may be certified under Component or Accessory
Approval procedure. Where a produce is widely used, the Accessory Approval procedure
will generally be applicable. In this case, the CAA will assess the design in relation to the
specification and to the requirements of the CAA, which will align wherever possible to
Standards which have been agreed Nationally or Internationally.

A user who has, or has access to, a design organisation holding appropriate Terms of
Approval may elect to employ cables which they may certify under the Component
procedure.

2.3 Modification and Repair

Cables used as replacements, or used for modifications of an aircraft, should be of a type

approved by the constructor for that particular aircraft type unless an approved design
authority selects an alternative.

3. Classification of Cables

Listed below are the broad classifications used for aircraft cables. Regrettably, there is little
International Standardisation of terminology and it should be noted that the term wire is
used in the USA whereas most other countries talk of cable. Other significant differences
in terminology are stated where appropriate.

3.1 Airframe Cables

Cables designated as Airframe are intended to be sufficiently robust to satisfy the

requirements of Open airframe wiring and the general wiring of Powerplants. However, in
recent years there has been a strong trend towards very thin insulation, which is harder and
stiffer than insulation such as PVC.
There are two basic methods of applying cable insulation, namely wrapping and extruding.
These methods in themselves can produce different handling characteristics and in
paragraphs 5 and 6 of this Leaflet, this and other factors defining cable performance are
reviewed. In the USA, the term Medium Weight-Interconnect may be used for Airframe
Cables.

3.2 Interconnect Cables

Interconnect is a term adopted by the BSI to designate cables, which may be used in
protected areas of wiring such as the interconnection of equipment within racks. Such cable
would normally be installed within an assembly, which would then be positioned into an

157
aircraft. It would not, therefore, be subject to pulling through and other such stressful
exercises.

Interconnect cables employ thinner insulation than airframe types, which saves weight and
space and increases flexibility, the latter being most important where looms (bundles) are
required to turn through small radii into electrical connectors. However, all the constraints
given in paragraph 3:1 for airframe cable also apply here.

3.3 Equipment Wire

This cable, invariably known as wire, is intended to be used within equipment and,
therefore, is very flexible and suitable for soldering. It is not designed for use as
interconnect wiring but design organisations do, on occasions, select a particular type for
use in protected areas of an airframe. .

3.4 Fire Resistant Cables

This type of cable is required to retain a defined level of electrical insulation in the presence
of fire for five minutes, as defined in BCAR Section D1-2 paragraph 1.17,2 and CS-
Definitions. Fire Resistance should not be confused with high temperature and fire
resistant types should only be employed where this property is required because other
characteristics, such as fluid resistance, will usually be poorer than could be expected from
a non-fire resistant high temperature cable.

Fire-resistant. - With respect to materials, components and equipment, means the capability
to withstand the application of heat by a flame, as defined for Fire proof, for a period of 5
minutes without any failure that would create a hazard to the aircraft.

For materials this may be considered to be equivalent to the capability of withstanding a fire
at least as well as aluminium alloy in dimensions appropriate for the purposes for which
they are used.

3.5 Fireproof Cables

These cables are required to operate for fifteen minutes in a designated fire as defined in
BCAR D6 paragraph 6.5.1 and JAR 1 and are for use in designated fire zones. BCAR D6-
13 paragraph 6.6.2 and JAR 25.1359 define a fire zone. As for Fire Resistant types, they
should only be used where necessary.

Fireproof. With respect to materials, components and equipment, means the capability to
withstand the application of heat by a flame, for a period of 15 minutes without any failure
that would create a hazard to the aircraft. The flame will have the following characteristics:
-
Temperature 1100C 80C
-
Heat Flux Density 116 KW/m 10 KW/m2

For materials this is considered to be equivalent to the capability of withstanding a fire at

least as well as steel or titanium in dimensions appropriate for the purposes for which they
are used.

3.6 Multicore Screened and Jacketed Cables

Airframe and interconnect cables may be supplied in a multicore form of generally up to four
cores, the cores being twisted together. the multicore may be jacketed (sometimes known
as a sheath) or it may be screened and jacketed. The screening is usually a braid, which

158
gives 85% surface coverage, but screening to a higher standard may be used, and on
replacement of such cables, the standard must not be degraded. The cores are coloured
for identification as defined in BS G230.

3.7 Data Bus

Data Bus cables are designed to specific requirements, which will not, as a general
principle, allow for replacement by any other type other than that specified by the Design
Authority for the installation. (This requirement will also apply to the terminations of such
cable).

4. Specifications and Cable Type Identification

Because of the large number of specifications, which exist for aircraft cables, it is impractical
to list these in this Leaflet. Significant differences can occur between cables complying with
the same basic form of requirements and even with the BSI G series of standards, there
are problems in attempting to offer guidance on interchangeability between products.

4.1 British Standards Specifications

Aircraft cable specifications are issued in the Aerospace G Series of British Standards and
are referenced in the BSI Year Book. The majority of cables used on British built aircraft
now in service will have been produced to such G specifications e.g. BS G221 for Minyvin.

Newer Standards are based upon general requirements given in BS G230. A series of
Detailed Standards numbered sequentially from G232 has now been published and these
define cable design requirements and physical characteristics. The CAA grants Accessory
Approval to cables which comply with these standards but an additional Manufacturers
Detailed Specification, which defines the precise construction, will also be required by the
CAA. This may be on a commercial in confidence basis.

BS G230 includes a listing of Manufacturers Identification Marks and also a Letter Code for
year of manufacture.

4.2 UK Military Specifications

Cables produced for the MOD will include aircraft types, which are identified as EL.XXXX or
D.E.F.XX-XX Pt XX. Military aircraft produced by a European consortium may have their
own cable specifications and a typical example is the Panavia project, which has produced
PAN specifications

4.3 US Military Specifications

The designation of US Military Specifications for cable is usually MIL-W-XXX. Each MIL
Spec has a number of slash sheets and the requirements of such individual sheets can
encompass a large range of cables. It is absolutely essential to know the full designation of
any MIL Specification cable and to replace like with like. As stated previously, CAA
Accessory Approval cannot be granted against MIL Specifications and users should be
made aware that the use of such cables may be difficult to justify for other than direct
replacement purposes and where the original selection has an approval.

159
4.4 Constructors Specifications

Aircraft constructors may publish specifications and some of the most frequently seen of
these are:-
Boeing - BMS XXXX
Douglas - BXS XXX
Airbus Industrie - AR XXXX or ASNE XXXX
BAC (Concorde) - BAS XXXX

It has to be emphasised that these cables are approved in relation to the aircraft on which
they are installed by the Constructor, i.e. a cable which is approved for use by one
Constructor may not necessarily be acceptable to another.

4.5 International (including European) Standards

The official body for the standardisation of aircraft equipment, including cable, is the ISO
(International Standards Organisation). The BSI contributes to the work of the ISO but it
has to be said that few, if any, ISO cable standards are employed by industry. Within
Europe, the SBAC works in association with other manufacturers in the organisation known
as AECMA (Association Europeanne Des Constructeurs De Material Aerospatialle).
AECMA seeks to promote their own standards and they publish European Normes as EN
specifications. These have not yet been widely adopted, at least within the UK, but
preliminary specifications may be published and these are known as prEN Standards. ISO
and EN Standards may be recognised for installation Approval purposes except that it is not
usually within the boundaries of the CAA to grant product approval against a specification
not controlled by BSI or a recognised (Approved) organisation.

4.6 Cable Manufacturers Specifications

The CAA will accept specifications from Approved Organisations and will grant, where
appropriate, approval against such specifications. The organisation controlling the
specification has to be a Primary Company (BCAR Section A A8-1) or a suitably supervised
overseas organisation BCAR Section B B4-8 paragraph 5.4 (CAP 554)*

5 Cable Performance

The definition of cable performance has increased in complexity and precision with the
reduction of insulation thickness and weight. Some of the cables now used for airframe
wiring have no more than 0.006 of insulation thickness and thus there is little margin for
error in manufacture or in an aircraft installation. The operating temperature dictates to a
large extent the materials and constructions used, but installation requirements need to be
satisfied by defining properties such as resistance to insulation cut-through and abrasion.
It follows that cables need to be selected with care and the factors detailed below should be
considered in relation to any intended duty.

5.1 Application

Obviously, a primary consideration in cable selection is to determine the class of cable

required within the classification given in paragraph 3. It should be noted that under one
generic name there may be a range of insulation thicknesses which will be appropriate for
Airframe or for Interconnect cable and thus correct identification, by part number, is
particularly important.

160
5.2 Temperature

The temperature rating of a cable must be defined to permit comparison with the worst case
requirements of the application. It follows that the location of a cable, relative to hot air
ducts and local hot spots such as power transformers and some filament lighting, must be
known. Cables have a specified maximum continuous operating temperature, and for many
types, this may be achieved by any combination of ambient temperature plus temperature
rise due to I2R losses. However, it should be noted, that in general, it is undesirable to
contribute more than a 40C rise by electrical heating and that operating temperature and
installed life are directly related. The temperature rating of an airframe cable is determined
by its construction as noted in paragraph 6, and will be classified at one of the following
temperatures:- 105C (obsolescent cable types), 135C, 150C, 210C and 260C.
Clearly this temperature rating has to be known when evaluating any design application.

5.3 Cable Size

Cable is usually identified by a size number, which approximates to the A.W.G. (American
Wire Gauge) size of the conductor. However, some cables enjoy a number, which refers to
the square millimetres of a conductor cross section, which is a system used extensively for
commercial cables. The size of cable is the primary determinate of the electrical protection
level set by the circuit breaker or fuse, and should never be reduced below the level
established by proper co-ordination data.
Current rating data usually relates to a temperature rise of 40 oC above ambient as stated
above and due allowance must be made for such electrical heating. Manufacturers data will
normally include conductor resistance in ohms per km at 20 oC and a temperature correction
may be necessary if accurate voltage drop calculations are necessary.

It should be noted that cable size relates only to the conductor and thus the overall
diameter and surface finish for a given size may vary slightly between cable types. Such
differences in overall diameter may have an effect on cable sealing in connectors and
pressure bungs, and also the selection of pre-insulated terminal ends where a dielectric
crimp provided.

5.4 Voltage Rating

All cables have a rated voltage and some, such as equipment wires, may be specified by
voltage. Particular reference should be made to the specified voltage of any cable where
higher than normal potentials may be used, examples being discharge lamp circuits and
windscreen heating.

5.5 Flammability and Toxicity

All cables are required to have a defined level of resistance to burning when exposed to
standard flame tests. In addition to the requirements of flammability, there exists within
BCARs, EASAs and FARs, general requirements relating to the hazards of smoke and
toxicity.

5.6 Wet Arc Tracking

A requirement has now been formulated to assess the resistance to failure of cables when
subjected to a combination of insulation damage and fluid contamination. The propensity of
some insulating materials to track has long been studied in high voltage systems but it has
now been found necessary, following a failure as detailed in paragraph 7.

161
Tracking can also occur under dry conditions and this is being studied. This failure mode
reinforces the need for good cable installation and maintenance practices.

5.7 Mechanical Properties

The assessment of cable insulations includes the ability to withstand the pressure of a sharp
edge (cut-through), and for the ability to withstand scraping with a defined blade. It is these
tests which figure significantly in assessing airframe cable and which are the controlled
methods of replacing assessment by scraping with the thumb nail. Installation of looms of
thin wall hard dielectric cable has to have regard to the reluctance of such looms to be set
in position, especially if the supporting structure is flimsy. It must not, however, be assumed
that this apparent strength is translated into the ability to withstand physical abuse.

5.8 Fluid Contamination

Cables are required to display a defined level of resistance to the effects of commonly used
aircraft fluids but this is not to say that cables can withstand continuous contamination,
which should be avoided. A related hazard is that presented by sealing compounds because
these may contain agents which are aggressive to cable insulation. It follows that where a
new cable type is introduced, the compatibility with such compounds should be checked.
Equally, the use of a new fluid on an aircraft, e.g. new types of hydraulic fluid, should be
considered in relation to the ability of cables to withstand contamination.

6. Cable Construction

6.1 Conductors

For equipment interconnection and airframe cables, the conductors are normally of the
stranded type and are usually made from plated copper. However, size 24 and smaller sizes
of conductor will be of copper alloy having a higher tensile strength. Fire resistant cables
may also be of copper alloy or copper conductors throughout all applicable sizes.

The total conductor consists of plated strands which are circular in section and which are
laid up into one of a number of stranded forms. Aluminium conductors are also available for
cables of size 8 and larger but such cables have not been without any problems. Any
modification which involves conversion from copper to aluminium should be classed as
major and thoroughly investigated, especially in regard to termination techniques.
Obviously, aluminium cables will need to be significantly larger in cross section than copper
for a given electrical load, because of the higher electrical resistance of aluminium.

6.2 Conductor Plating

Plating is employed on copper, copper alloy and aluminium conductors to improve

resistance to corrosion and to assist termination techniques. Very often it is the plating
which will determine the temperature rating of a given cable and the figures given below are
those widely recognised within the UK.
Tin plated copper maximum continuous temperature - 135 oC.
Silver plated copper maximum continuous temperature - 200 oC.
Nickel plated copper maximum continuous temperature - 260 oC.
Nickel Clad plated copper maximum continuous temperature - 260 oC.

Nickel clad copper is used instead of nickel plate on fire resistant cable to provide a thicker
nickel element.

162
The temperature figures quoted above may have to be varied downwards because of
limitations imposed by the cable insulation..

6.3 Dielectrical Materials/Cable Types

Insulation material is applied to conductors by one of two basic methods, extrusion and
wrapping. In general terms, extrudable materials are heat meltable and are not employed
for higher temperature applications. It follows that towards the upper limit of their operating
temperature, their mechanical strength, when measured by abrasion or cut through, can be
significantly less than that measured at room temperature. Airframe categories of cable
usually have a double extrusion which are not always of the same material. A double
extrusion is also claimed to impart crack stopping qualities.

The most commonly used wrapped insulation material is Kapton*, which is the registered
trade name to an aromatic polyimide produced by Dupont. Many cable manufacturers
world-wide use Kapton, either singly or in combination with other materials to give a so
called hybrid construction. Single or double tapes are spirally wound over the conductor to a
defined overlap to give the required tape thicknesses at any one point. Kapton is naturally
copper coloured and it is usual to apply a top coat to provide a coloured surface which will
accept print and also give added protection to the cable.

*Kapton is a Du-Pont trademark

The process of wrapping insulation provides good control of insulation wall thickness and
there are now cable types which employ only 4 layers of Kapton, giving a total wall
thickness of approximately 0.006 inches, and these are being employed throughout the
airframe of some recently certified aircraft types.

7. Cable Failures

The following types of failure and quality faults are amongst those seen in recent years.

7.1 Arc Tracking

Airworthiness Notice No. 12 Appendix No. 32 has drawn the attention of Industry to the
problem of wet arc tracking of damaged cables subjected to fluid contamination.
Observation of this Appendix and the actions of cable manufacturers should resolve the
problem, but the greatest need is to ensure that hot stamp printing is properly controlled.
Inter-connect and Equipment Wires should not be hot stamp printed.

7.2 Minyvin

Some batches of Minyvin have in the past shown a tendency to shed the outer nylon sheath
because of splitting along a flow line inadvertently introduced during manufacture. In dry
areas of aircraft, replacement of such cable is not a matter of urgency but if moisture,
especially hydraulic fluid, is present then cable must be replaced. In areas which are
exposed and prone to fluid contamination, such as undercarriage bays, modifications to
introduce a more suitable cable have been raised on some aircraft types.

163
7.3 BMS 13-28

Larger sizes of this mineral-filled PTFE cable, especially those used on Boeing 707, 727
and 737 aircraft, tend to experience complete insulation failure due to a longitudinal splitting
of the total dielectric. Replacement by BMS13-58 or EFGLAS to BS G222 under
modification action is desirable.

7.4 Abrasion

Some types of cable have shown a tendency to wear through the insulation at a point
where the cable rubs on cable or cable rubs on structure. Areas of high vibration induce this
failure mechanism and it may be supposed that the stiffer construction of some cables tends
to produce a greater contact force and transmit vibration where previously it was damped.
Careful cable loom tying and clipping is necessary to alleviate this.

7.5 Conductor Knuckling Through'

Some earlier cable constructions tended to exhibit knuckling of conductors which could be
severe enough to penetrate the insulation. This was induced by applying excessive pull
through forces and care should be taken not to put cables under tension. FEPSIL to BS
G206, which is now obsolescent, requires particular care in manufacture and installation to
avoid this defect.

7.6 Red Plague

Cables with silver plated conductors can exhibit the aptly named Red Plague if the plating
has been damaged and then exposed to moisture. Consequently, silver plated conductors
are generally unsuitable for use in unpressurised areas (see 7.7).

7.7 Glycol Fires

It is known that should de-icing fluid contaminate silver plated conductors, an electrical fire
can result. Accordingly, silver plated conductors should not be employed in areas where de-
icing fluid can be present.

7.8 Poor Solderability

It should be recognised that the quantity of free tin or plated conductors rapidly reduces with
time. The replacement of soldered connections during aircraft maintenance will probably
require that conductors are tinned as part of the process. The loss of free tin starts as the
cable is manufactured and thus prolonged storage should be avoided.

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