1 ELECTRICAL CABLES & CONNECTORS

Electrical cables and connectors is a subject covering an extensive range of

equipment and items. This module discusses salient points within the subject.
Although there is a great variety of equipment and items depending on
manufacturer, the basic rules of usage and applicability remain the same.

1.1 CONTINUITY AND INSULATION TESTING

Module 7.4 discusses the basic and more sophisticated instruments for
carrying out these tests. The methods of testing remain the same whichever
instrument is used.

1.1.1 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

Voltmeter Across Lamp in an Open Circuit

Figure 1
1.1.2 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

Voltmeter Across Resistor in an Open Circuit

Figure 2
1.2 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

Using an Ohmmeter to check a Circuit Component

Figure 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.

Ohms
BREAK

Using an Ohmmeter to Locate an Open in a Circuit Component

Figure 4

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.
1.3 A SHORTED RESISTOR

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.

A Shorted Resistor
Figure 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

A Short that Does Not Open the Circuit

Figure 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.
1.3.1 LOCATING A SHORTED RESISTOR IN SERIES

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

Using an Ohmmeter to Locate a Shorted Resistor

Figure 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.
1.4 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.

30V 30 30 30

R1

R3
R2

2 AMPS

Finding an Open Branch in a Parallel Circuit

Figure 8
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.

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: -

1 1 1 1
Total Resistance = + +
RT R1 R2 R3

1 1 1 1
= + +
RT 30 30 30

1 3 30
= RT = RT = 10 Ω
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

1.4.1 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 R 1 and R2.

Ohms
30V 15

R3
R1

R2
30 30

A Misleading Ohmmeter Indication

Figure 9
1.5 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

R3
R2

Opening a Branch Circuit to obtain an Accurate Ohmmeter Reading

Figure 10
1.6 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.

30V
R1

R2

R3
30 30 30

A Shorted Component causes the Fuse to Open

Figure 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.
1.7 TROUBLESHOOTING 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, L 1, will not be lit.

BREAK

R1

R2

An Open in the Series Portion of a Series Parallel Circuit

Figure 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

An Open in the Parallel Portion of a Series Parallel Circuit

Figure 13

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

An Open Lamp in a Series Parallel Circuit

Figure 14
1.8 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
R1 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

Using the Voltmeter to Troubleshoot a Series Parallel Circuit

Figure 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 R2 by removing lamp L1 from the circuit.
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 R1 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

Finding a Short in a Series Parallel Circuit

Figure 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.

 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.
1.9 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.

BLACK
RED

DCV 50V

0 -30 VOLT
VARIABLE
RANGE

A Multimeter Connected to Measure a Circuit Voltage Drop

Figure 17

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’.
1.10 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.

1.10.1 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.

1.10.2 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.

1.11 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.

1.11.1 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.

1.11.2 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.
1.11.3 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.

1.11.4 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.

1.11.5 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.
 1.12 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
1.13 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. 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.
1.14 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 Estimated and declared
of aircraft of non-metallic or composite by manufacturer.
construction.
Primary Between extremities of the fixed portions
Conductors of metallic aircraft.
Between bonded components and 0.05 ohm
portions of main earth system to which
they are connected.
Between metallic parts normally in 1 ohm
contact with flammable fluids and main
earth system and between the parts
themselves.
Between isolated conducting parts, which 0.5 megohm or 100,000
may be subjected to appreciable ohms per sq ft of
electrostatic charging and the main earth surface area whichever
Secondary system. is the less
Conductors Between equipment supplied from an
unearthed system, of any voltage, and
the main earth system. 1 ohm
Between equipment containing circuits
carrying 50 volts (rms or dc) or more, and
the main earth system.

Table 1

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.
1.15 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.

1.15.1 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

(a) Strip wires to S29-102 Section 3 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.
1.15.2 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 in position 1 to
achieve the desired support. Do not use a tighter setting than required.

1.15.3 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 1 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.

1.15.4 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.

CARI-CRIMP WIRE SIZE

RATCHET STAMPED
HERE

COLOUR
CODED
HANDLES

LOCATOR
INSULATION CRIMPING
ADJUSTMENT PIN
SHOWN IN POSITION 3

CRIMPING TOOL PART NO 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
 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
 LOCATOR

SLOT FOR
TRANSVERSE
CRIMPING
IF REQUIRED

Tooling for “Nylobond” PIDG Terminals (Size 24 – 14)

Figure 21

1.16 "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.

(c) 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.

(d) 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).
1.16.1 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).

1.16.2 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.

(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.

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

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.

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
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
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
1.17 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 26 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.
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
1.18 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.

1.18.1 TOOLS AND EQUIPMENT

All tools shall be checked and tested in accordance with BS G178 and carry
the current tool check identification marks.

1.18.2 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.

1.18.3 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 (¼ 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.
 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.

 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.

INSPECTION

All crimped joints shall be visually inspected for:

(a) Correct combination of cable, tool and terminal.

(b) Correct form and location of crimp.

(b) 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.

1.19 BICC/BURNDY TYPE M1OS-1

The BICC/Burndy Type M1OS-1 is a hand-crimping tool to be used with

BICC/Burndy size 12 contacts to size 24 contacts (inclusive).

1.19.1 TOOL DESCRIPTION

The crimp tool contains a ratchet type mechanism, which ensures that once
the crimp cycle has been started, the crimp tool cannot be opened until the
crimping operation has been completed. After full closure, the handle and
jaws return to the fully open position. Figure 30 shows a BICC/Burndy Type
M1OS-1 crimping tool.

VIEW “A”

BICC/Burndy Type M1OS-1 Crimping Tool

Figure 30
1.19.2 PERIODIC IN-SERVICE CHECK OF TOOL

Use GO/NO GO to gauges Part Numbers J74482 and J74483.

Fully close the tool handles. Maintaining a firm pressure on the handles,
insert the GO gauge between the crimping jaws. The gauge should pass
freely.
With the tool jaws in the same position insert the NO GO gauge. It should not
enter between the jaws. DO NOT crimp gauge as this may cause damage to
the crimping jaws.

1.19.3 CRIMPING PROCEDURE

Select correct stop bushing and die nest for the contact to be crimped.
Fit die nest and stop bushing to the tool and secure with screws supplied.
Insert contact into the die nest. Insert stripped wire into contact ensuring that
the wire is to full depth of crimp barrel. Close handle until it bottoms on
positive stop.

1.19.4 INSPECTION

When fitting Terminals S1018-004 to 12 or 14-gauge cable, pull off and milli-
volt drop tests to BSG 178 must be carried out on one of each batch
manufactured. This is required because the sleeve fitted over the crimped
portion of the terminal prevents inspection of the entry of the cable into the
terminal.

1.20 BICC/BURNDY TYPE MR8-13

The BICC/Burndy Type MR8-13 is a hand-crimping tool, with a fixed die, to be

used with BICC/Burndy Size 10 contacts.

1.20.1 TOOL DESCRIPTION

The crimp tool contains a ratchet type mechanism, which ensures that once
the crimp cycle has been started the crimp tool cannot be opened until the
crimping operation has been completed. After full closure the handle and
jaws return to the fully open position. Periodic in-service checks of tool. Use
the GO/NO GO gauge, Part Number J74481.

Fully close the tool handles. Maintaining a firm pressure on the handle insert
the GO gauge between the crimping jaws. The gauge should pass freely.
With the tool jaws in the same position insert the NO GO gauge. It should not
enter between the jaws. DO NOT crimp gauge as this may cause damage to
the crimping jaws.
 VIEW “A”

Crimping Tool MR8-13

Figure 31

1.20.2 CRIMPING PROCEDURE

Close tool handles to open die jaws. Insert contact into the No 10 contact
groove (identified by yellow dot) and close tool handle to allow die groove to
grip contact.
Insert stripped wire into contact ensuring that wire is to full depth of crimp
barrel.
Close handle until it bottoms on positive stop.
1.21 BICC/BURNDY TYPE MR4-20

The BICC/Burndy Type MR4-20 is a hand-crimping tool, with fixed die, to be

used with BICC/Burndy size 8 contacts.

1.21.1 TOOL DESCRIPTION

The crimp tool contains a ratchet type mechanism, which ensures that once
the crimp cycle has been started the crimp tool cannot be opened until the
crimping has been completed. After full closure the handle and jaws return to
the fully open position. Periodic in-service checks of tool. Use GO/NO GO
gauge Part Number J74480. Fully close the tool handles, maintaining a firm
pressure on the handles insert the GO gauge between the crimping jaws.
The gauge should pass freely. With the tool jaws in the same position insert
the NO GO gauge. It should not enter between the jaws. DO NOT crimp
gauge as this may cause damage to the crimping jaws.

THUMBGRIP TO
HOLD JAW OPEN

Crimping Tool MR4-20

Figure 32
1.21.2 CRIMPING PROCEDURE

Close tool handles to open die jaws and use thumb grip to hold crimp jaw
open.
Insert contact into die and release thumb grip. Insert stripped wire into
contact ensuring that the wire is to full depth of crimp barrel. Close handle
until it bottoms on positive stop.

1.22 DANIELS CRIMPING TOOL AF 8

Daniels crimping tool AF 8 is designed for size 12 through 22 contacts using

12 through 26 AWG conductors. The tool has eight indentor closures
controlled by a selector knob. The selector knob must be raised to rotate and
can be locked in any one position.

The 'THIA' type preset turret head assembly has three colour coded
positioners enclosed in one indexing turret. A universal turret - UH2-5 is also
available for contacts not covered by preset turret head location. The
distinctive colour of both the crimp tool and head assembly is blue.

1.22.1 CRIMPING PROCEDURE

After selecting the required contact, rotate the turret to the correct colour
positioner. Raise the selector knob and rotate to the desired selector number.
The selector number is listed below the wire size and opposite the contact
number on the data plate.

Insert the contact and wire into the crimping tool, on the opposite side from
the turret head assembly. Close handle until it bottoms and ratchet releases.
Release handle and the tool will return to the open position.

Remove crimped contact and wire from the crimping tool.

Reference should be made to the latest manufacturer’s data sheet for the
required 'THIA' heads.
1.22.2 TOOL DESCRIPTION

Figure 33 shows an AF 8 crimping tool

9/64 ALLEN
WRENCH

TURRET HEAD
ASSEMBLY

TRIGGER

SELECTOR
RETAINER KNOB
DATA
RING
PLATE

TAPPED
HOLES
INSERT CONTACT TO
BE CRIMPED THIS SIDE

AF8 Crimping Tool

Figure 33
1.22.3 TURRET HEAD

TURRET HEAD ASSEMBLY Contact

Accommodated (Ref)
IDENTIFICATION POSITIONER
Part No Colour A B C
M22520/1- BLUE 20 RED 16 BLUE 12 YELLOW MS24254P
02 MS24255S
Daniels THIA MIL-C-83723/33
MIL-C-83723/34

Table 3

NOTE:

 Turret head must be released (raised) to change position and depressed

to the locked position before crimping takes place.

 Contacts not capable of being crimped with this turret-head locator can be
crimped using the UH 1 (MS 27828-2) adjustable turret-head.
 1.22.4 UNIVERSAL HEAD M22520/1-05

G R EEN “G O ” R E D “N O G O ”

M F R S N A M E & P /N
M 2 2 5 0 1 /1 -0 5 GAUGE 'A ' " G O " 'B ' " N O G O " C R IM P SELEC TO R
U S E W IT H M 2 2 5 0 /1 -0 1 PART NO D IA M E T E R D IA M E T E R TOOL NO
C R IM P IN G T O O L M 2 2 5 2 0 /3 - 1
D a n ie ls G 1 2 5 .0 3 9 0 .0 4 4 0 D a n ie ls A F 8 4
o n ly o n e g a u g e n e c e s s a r y fo r p e rio d ic in - s e r v ic e in s p e c tio n
SELECTO R NO 'A ' " G O " D IA . 'B ' " N O G O " D IA
1 .0 2 8 0 .0 3 3 0
2 .0 3 2 0 .0 3 7 0
3 .0 3 6 0 .0 4 1 0
4 .0 3 9 0 .0 4 4 0
5 .0 4 5 0 .0 5 0 0
6 .0 5 2 0 .0 5 7 0
7 .0 5 9 0 .0 6 4 0
8 .0 6 8 0 .0 7 3 0
9 /6 4 H E X
SOCKET in - s e r v ic e in s p e c tio n g a u g e lim its

PART NO C O L O U R C O N T A C T A C C O M M O D A T E D (R E F ) RED
GREEN
M 2 2 5 2 0 /1 - 0 5 BLUE O T H E R T H A N M IL IT A R Y
D a n ie ls U H 2 -5 STANDARD CONTACTS “N O G O ”
“G O ”

“ G O ” G A U G IN G “ N O G O ” G A U G IN G

Figure 34

NOTE: This head can be used for contacts not covered by the preset turret
head locators. The principle of use is that the contact will be positioned by
means of the thread adjusting screw (1) to ensure that the crimping jaws will
engage on the centre of the contact crimp barrel. The wire size adjuster must
be set for the conductor size being crimped.

Close handles to fully closed position. Insert "GO" gauge as shown. Gauge
must pass freely between indentor tips. Close handles to fully closed position.
Insert "NO GO" gauge as shown. Gauge must not enter between indentor
tips.

CAUTION: DO NOT CRIMP GAUGE.

1.23 DANIELS AFM 8 (M22520/2-01) TOOL

Daniels AFM 8 lightweight miniature crimping tool is designed for size 20

contacts and smaller using 20 through 32 AWG conductors.

The tool is equipped with eight separate indentor closures controlled by a

selector knob on the side of the tool. The indentor closure (selector number)
is chosen from the data plate on the positioner.

Individual positioners are bayonet locked into the tool and may be changed
easily and quickly.

Positioner and selector knob may be safety-wire locked in any one position,
and the double acting ratchet ensures a reliable crimp. The distinctive colour
is blue.

1.23.1 CRIMPING PROCEDURE

Select correct positioner. Insert the positioner into the tool, and lock with the
safety wire clip.

The selector setting is listed below the wire size on the data plate at the
exposed end of the positioner. Raise and rotate the selector knob until the
number is in line with selector number arrow.

Insert contact and wire into the crimping tool from the side opposite the
positioner. Close handle until it bottoms against the positive stop. Release
handle, and remove contact from crimping tool.

Reference should be made to the latest manufacturers data sheet for the required contact and positioner
numbers.
 S E L E C T O R
K N O B
P O S IT IO N E R

D A T A
P L A T E

S P E C N O C R IM P T O O L W E IG H T IN -S E R V IC E G A U G E T Y P E P O S IT IO N E R

M 2 2 5 2 0 /2 -0 1 D a n ie ls A F M 8 1 lb D a n ie ls G 1 2 5 'K '
M 2 2 5 2 0 /3 -1

AFM 8 Crimping Tool

Figure 35
 G R E E N “G O ” R E D “N O G O ”

G AU G E 'A ' " G O " 'B ' " N O G O " C R IM P SELEC TO R

PART N O D IA M E T E R D IA M E T E R TO O L NO
D a n ie ls G 1 2 5
M 2 2 5 2 0 /2 -1 0390 0440 D a n ie ls A F M 8 8
M 2 2 5 2 0 /3 -1
o n ly o n e g a u g e n e c e s s a r y f o r p e r io d i c i n - s e r v i c e in s p e c tio n
SELECTO R NO 'A ' " G O " D IA . 'B ' " N O G O " D IA
1 0 130 0 1 8 0
2 0 160 0 2 1 0
3 0 190 0 2 4 0
4 0 220 0 2 7 0
5 0 260 0 3 1 0
6 0 300 0 3 5 0
7 0 340 0 3 9 0
8 0 390 0 4 4 0
in - s e r v ic e in s p e c tio n g a u g e lim its

R ED
G REEN

“N O G O ”
“G O ”

“ G O ” G A U G IN G “ N O G O ” G A U G IN G

Figure 36

Close handles to fully closed position. Insert "GO" gauge as shown. Gauge
must pass freely between indentor tips. Close handles to fully closed position.
Insert "NO GO" gauge as shown. Gauge must not enter between indentor
tips.

CAUTION: DO NOT CRIMP GAUGE.

1.24 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

1.24.1 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.

1.24.2 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.

(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

(f) 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.

(g) 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.

(h) 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.

(i) Cover the terminal/wire joint with the appropriate size and type shrink
sleeve.
1.24.3 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.

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

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

1.24.4 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 it’s 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 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.

(g) Submit the competed crimped terminal for inspection.

1.24.5 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 -

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.
1.25 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.
1.26 ERMA TOOL OPERATION

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.

1.26.1 PREPARATION OF AMP CRIMPING TOOL 69062

This hand operated hydraulic crimping tool has a four-position upper die and a
common lower die for crimping terminal sizes 9, 6, 4 and 2. Figure 39 shows
an AMP Crimping Tool 69062.

LATCH
NEST LOCK

THUMB
KNOB

RESERVOIR
HANDLE

ROTATE CLOCKWISE MOVABLE

TO BEGIN CRIMP HANDLE

ROTATE
COUNTER-CLOCKWISE
TO RETURN THE RAM

AMP Crimping Tool 69062

Figure 39
1.26.2 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.
1.27 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.

1.27.1 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
1.27.2 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.

VOLTMETER
mV

DCV mV
CALIBRATED TEST
PROBES & LEADS

CONDUCTOR
TERMINAL

BUSBAR

INSULATED
BLOCK

Voltage Drop Test

Figure 40

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.

(f) Absence of damage to the conductor or insulation.

(g) Insulation properly gripped by insulation crimp if applicable.

1.28 IN-LINE SPLICING

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

Each barrel must carry only one cable unless specifically permitted by the
airworthiness authority.

The crimp must be fitted horizontally or positioned so that the ingress of

moisture is not possible.

Additional sleeving is not permitted to achieve the above.

Ensure operating temperatures are not exceeded.

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.

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

Low temperature connectors must not be crimped on size 12 or larger

EFGLAS.

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
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.

Joints must if possible be positioned on the outside of the loom.

All fixing attachments must be approved.

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

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

AWG 8 OR
POWER SUPPLY
LARGER

1 CM
MINIMUM

3 - PHASE CABLE SIZE

AWG 8 OR
POWER SUPPLY
LARGER

Crimps in cable looms

Figure 41
1.28.1 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.

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.
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 ½"
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
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 ½" 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 ¼"
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
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
Figure 46a shows the front release system and 46b shows the front release
system.

Rear/Front release System

Figure 46
1.29 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.

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
1.30 SOLDERING

1.30.1 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.

1.30.2 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.

SOLDER JOINT INSUFFICIENT SOLDER REHEATED

TOO COLD SOLDER TOO OFTEN

TO MUCH CORRECTLY
DRY JOINT
SOLDER MADE JOINT

Soldered Joints
Figure 49
1.30.3 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.

BIT CLEANING SOLDERING

SPONGE IRON HOLDER

SOLDERING
IRON
TRANSFORMER
POWER SUPPLY
SOLDER
BIT

Soldering Iron
Figure 50
1.30.4 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
1.30.5 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
 1.30.6 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.

Solder Removal Gun

Figure 53

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
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
1.30.7 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.
Tinning of a Wire
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

1.30.8 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.

1.30.9 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.

(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

1.30.10 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 before and after shrinking.

SLEEVE AFTER
SHRINKING

10mm

CONNECTOR

SLEEVE BEFORE
SHRINKING L

Heat Shrink Sleeving

Figure 58
1.30.11 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.

SOLDER

1/8”
MAX 1/32”
MIN

SOLDERING
PINS
IRON
(POTS)

SOLDER

GAS

RESIN

SOLDER

WRONG RIGHT

SOLDER

SLEEVING

MS Soldered Methods
Figure 59
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.

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.
1.31 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.
1.32 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.

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
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.

1.33 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.

1.33.1 TIME DOMAIN METER

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.
1.34 WIRING PROTECTION TECHNIQUES

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.

1.34.1 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.

1.35 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.

1.35.1 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.

1.35.2 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.
1.35.3 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.

1.35.4 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.

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

1.36 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

Figure 64
1.36.1 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
1.36.2 INTERFERENCE

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.

1.36.3 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
 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.
1.37 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
 MS 21919 CABLE CLAMPS

“Z” MEMBER
“ANGLE”
MEMBER

WIRE PINCHED
IN CLAMP

Support Of Cabling
Figure 69
1.38 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.

1.38.1 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 -20°C to + 105°C
Nylon White Cables Ltd
Leigh
Lancs
Efwrap PTFE British Insulated Temperature range
Spiral Binding Colour Black Callender's -20°C to + 105°C
Cables Ltd
Leigh
Lancs

Table 7
1.39 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.

1.40 CABLE CONDUITS (SUPERFLEXIT)

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

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/m².

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.
1.40.1 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.
1.40.2 INSPECTION

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

1.40.3 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.

Icoclip Tool
Figure 70
CONNECTOR VITON OUTER VITON
END FITTING SPIGOT SLEEVE ISOCLIP SLEEVE

TENSIONER

Procedure for Attaching Isoclips

Figure 71
1.41 HEAT SHRINK TUBING

1.41.1 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.

1.41.2 GENERAL CHARACTERISTICS:

Self extinguishing (Raychem Type 1) (Hellermann Type 1) Spec: MIL I

23053B/5

 Temperature Range: 55°C to + 135°C continuous. Up to 300°C for short

duration (1 hour).

 Shrinking Temperature: Min 121°C, Recommended temp 250°C - 300°C.

 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 Dia Thickness Raychem Hellermann
(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 1½" 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

1.41.3 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) 480°C.

THERMOGUN MODEL No 1511 Description: Similar to Model 1509

(1100W) temperature (max) 590°C.

THERMOGUN MODEL No CV1980 Description: Similar to Model 1511

(1200W) (Part No 989540) except for barrel design.
Temperature (max) with air regulator
closed 630°C.
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 150°C - 300°C.
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: 240°C - 400°C.
Recommended use:
Preferred for high temperature
sleeves and solders sleeves.

MINI-GUN CV5302 (680W) Temperature range

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

MINI-GUN CV5720 (700W) Temperature range

(Part No 991608) without reflector 240°C
with PR25 reflector 430°C
1.41.4 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 1½ 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.
1.42 CAA 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.
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
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

JAR 25

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

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.

The same paragraph numbers will apply for BCAR 23 and BCAR 29 where applicable.

See also Airworthiness Notice No 12 Appendix No 32. Electrical Cable Failure and Appendix No 42,
Maintenance and re-installation of Pipes and Cable Looms.

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. A Declaration of
Design and Performance (DDP) will be required and this should be related to a design specification
controlled either by the cable manufacturer or the installing Design Authority. A National or
International “Standard” may also be employed, but this will usually need to be supplemented by a
Detailed Specification where the “Standard” relates to performance rather than construction. BCAR
Section A A4-8/B4-8* does include a procedure for granting Appliance Registration to equipment
which is designed and produced under the control of an overseas Airworthiness Authority (B4-8
paragraph 5.4*). Such registrations have been granted in respect of cables and are the equivalent of
Accessory Approval. The CAA does not normally grant Approvals against Standards or Specifications
over which it has no control or influence, or where such an approval could be in conflict with the
interests of another Authority. Accessory Approval does not automatically authorise the installation of
a product, each application having to be approved as noted in paragraph 2.3 below.

*The CAA has revised the current Requirements of BCAR Section A at issue 29 by dividing the
Certification and Approval Procedures into two Sections, namely:

Section A (CAP 553): Airworthiness Procedures where the CAA has primary responsibility for Type
Approval of the product.

Section B (CAP 554: Airworthiness Procedure where the CAA does not have primary responsibility for
Type Approval of the product.

These three documents will remain concurrent until 30 June 1990 at which time BCAR Section A (CAP
460) at issue 29 will be withdrawn.

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. This selection should recognise the various factors detailed in this Information Leaflet.
This is most readily achieved by obtaining a Declaration of Design and Performance (DPP) from the
manufacturer if that manufacturer is suitably CAA Approved. The user should also take steps to ensure
that the quality of cable is satisfactory and the preferred method of achieving this is by obtaining a
CAA Approved Certificate from the manufacturer.

This release should define a cable by reference to its specification. For aircraft constructed overseas,
the manufacturing sources approved by the aircraft constructor as satisfactory for his requirements for
quality should be used.

Verification of product quality from the Airworthiness Authority of the country of origin should be
available and should be used where possible. (Airworthiness Notices Nos. 11 and 39 should be
observed as appropriate).

It is important to recognise that the certification requirements for electrical installations and the design
standard achieved by aircraft constructors have advanced with time, especially in relation to fire
hazards. Consequently, it is not correct to assume that every cable type in use has a current approval
for use on all aircraft. For example, cables with PVC insulation such as Nyvin, NIL-W-5086 (all
types), or BMS 13-13, should not be used on aircraft certified with new technology cables employing
insulation which is less likely to emit noxious fumes. This aspect is further considered in paragraph
5.5.

Users who do not hold an appropriate design approval but who nevertheless seek approval for work
under an AAN, will normally be expected to employ cable selected by a design authority or employ a
cable which has CAA Accessory Approval, (or an Appliance Registration from some overseas sources).
Appendix A of this leaflet lists the cable types which currently hold Accessory Approval but this list is
constantly being updated and should not be used without reference to the Systems and Equipment
Design Department, Safety Regulation Group Gatwick. All Manufacturers of Accessory Approved
cable have good technical literature and provide service support to their customers. It is stressed that
CAA Accessory Approval for a cable does not absolve the user from his responsibility to make a
correct assessment of the product against the intended duty.

It is important to be aware that generalised claims by Stocklists and others that a cable type is
‘approved’ or ‘qualified’ is likely to be of little value unless substantiated by the procedures prescribed
in this Information Leaflet. Thus the “Approval” of a cable design by, say, an overseas military agency
has no significance to a UK civil user.

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.
Such ‘stiff’ cables are perfectly satisfactory if the installation is designed to accept them but they may
very well be quite unsuitable for an older airframe design requiring, say, flexing over hinges. It follows
that even if all the major declared characteristics such as overall diameter and temperature rating are
acceptable, the apparently equivalent cables may still not be interchangeable.

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 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.

The term ‘Hook-up’ is commonly used in the USA to designate cables of this general type, and the
designation ‘Light Weight-Interconnect’ may also be applied.
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. There
is a considerable range of such cables, which vary, in basic construction and performance and they
should always be very closely defined. In general, the types in aircraft use are produced by CAA
Approved Organisations who provide ‘CAA Release’ to British Standard G210 or an equivalent
specification. Some manufacturers have sought ‘Accessory Approval’ for BS G210 cable and this has
been granted, but is not a CAA requirement that any form of design approval be applied to this cable
when it is used for its intended purpose, (which is within equipment enclosures where the equipment
itself is subject to control). It follows that it can be manufactured and released by a Supplier, approved
to BCAR A8-2. The term ‘Module Wire’ is sometimes used for this class of cable in the USA.

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 JAR 1. ‘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.

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.

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 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. The following information has been
compiled to assist in the recognition of the original specifications.

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.

This information is reproduced for convenience as Appendix B of this Information Leaflet.

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.
These military specification are mentioned for information and it should be noted that the CAA does
not normally validate such specifications for the reasons given in paragraph 2.3.
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.

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.

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 40°C 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:-

 105°C (obsolescent cable types), 135°C, 150°C, 210°C and 260°C.

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.
Manufacturers publish rating data for single cables in free air, and for bundles of three cables in free
air. By study of the short term and continuous ratings for a given cable type and size, the correct
protection can be determined (CAA Airworthiness Notice No. 12 and appendix No. 32 should be
observed). Current rating data usually relates to a temperature rise of 40oC 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 20oC 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, JARs and FARs,
general requirements relating to the hazards of smoke and toxicity. In recent years, greater emphasis
has been placed upon these characteristics and whilst they are not yet defined in many civil cable
specifications, it is generally true that new cable types have been more thoroughly investigated, albeit
on an empirical or subjective basis as noted in paragraph 2.3.
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.

BS G230 now includes a test to determine resistance to Wet Arc Tracking (Test No. 42), and
Airworthiness Notice No. 12, Appendix No. 32 will be used to keep Industry advised of the CAA
position on this subject. (See also paragraphs 6.3 and 7 of this Leaflet).

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. As noted earlier, differing constructions result in marked changes in
handling properties especially with regard to stiffness and ‘springiness’. 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. Contamination of cables by toilet or galley waste has to be rigorously prevented or
corrected as detailed in Airworthiness Notice No. 12 Appendix No. 32.
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 - 135oC.

 Silver plated copper maximum continuous temperature - 200oC.

 Nickel plated copper maximum continuous temperature - 260oC.

 Nickel Clad plated copper maximum continuous temperature - 260oC.

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

The temperature figures quoted above may have to be varied downwards because of limitations
imposed by the cable insulation. Higher figures, notably 150oC for tin plating, are sometimes quoted in
the USA but performance at such temperatures, especially in regard to stable crimp resistance and
solderability is the subject of debate, if not dispute. It should be noted that the plating used on crimped
terminal ends must be compatible with the conductor plating of the cable, and information should be
sought from termination manufacturers.
6.3 Dielectrical Materials/Cable Types

It is not practicable to review, in this Leaflet, the performance of all of the

many types of cable constructions available except in general terms.
Extensive studies have been made, especially in the USA, in an attempt to
determine an optimum cable type. The conclusion drawn is that there is not
an overall best cable and that all the materials studied have advantages and
disadvantages. This is little help to a user who is seeking to resolve the
conflicting guidance and advice offered by organisations which have a keen
commercial interest in the decisions of an intending purchaser. This
Information Leaflet is intended to alert staff to the difficulty of making a sound
judgement in what has traditionally been considered to be a simple subject.
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. Radiation
cross linking of processed material is employed on high performance cables and this eliminates
melting, increases strength and allows for thinner wall thickness. Cables employing such construction
perform well on the British Standard test for wet arc tracking - see paragraph 5.6.

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. It
follows that it is totally incorrect to talk of Kapton cables without further definition. Some
constructions, notably cables made in the USA to MIL-W-81381/11, have been the subject of adverse
comment and it is possible that the use of this particular type will be discontinued in some
environments. This would not reflect general rejection of cables containing Kapton because most
constructions provide good overall performance including excellent mechanical strength, especially the
newer higher hybrid types.

*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. The CAA has not granted an Accessory Approval as ‘Airframe’
types to such cables, these having been accepted on a ‘Component’ basis.
Paragraph 2.3 reviewed the special case of PVC insulated cables such as Minyvin (BSG221) and all
PVC cables are now classed as ‘Obsolescent - unsuitable for new designs’.

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.

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 problem (see Airworthiness Notice No. 12 Appendix No. 42).

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 Solder ability

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.