A I R C R A F T ELECTRICAL CABLES

LIST O F CONTENTS PAGE

INTRODUCTION 4

REQUIREMENTS 4

CABLE C O D I N G 9

INSPECTION AND R E P A I R 15
SELF-APPRAISAL QUESTIONS 27
OBJECTIVES

On completion of t h i s lesson the student will

Recall the requirements

L ...,.- -- which a p p l y t o aircraft cables.
List t h e chamcteristics of the range
--. - . of cables*installed i n aircraft on the British Register.
Identify and explain the Positional coding --+- - and the Series Coding.
a

Recall the items to be c h e c k e d h h e n i n q p e t i n g aircraft 9bl.i.. -

L

Identify and explain the crimp 'DOT1 G d e .

Identify and inspect for ;&iceability a PI-%--crimping tool.
Recall the method of identifying a correct1 formed crimp connection. .-.
%+ .-.--
Recall t h e purpose and limitations of 'IN-LINEn connectors.
.er-b --L.r.#

Describe the procedure and l i s t the equipment u$ed to carry out a rnillivolt drop test on a crimped ..-. . connection.
- m - __
Identify and describe a typical earth
--a > - point.
Describe how an earth point is tested ar;d repaired.
-_ _ _____---.-

RECOMMENDED FURTHER READING

CAIP EEL/3 -1
BCAR SECTION J.
,--
I-<--
E/ecfk,zd' .
AIRCRAFT CABLES
 AIRCRAFT ELECTRICAL CABLES
INTRODUCTION

In the early days the cables used in aircraft were manufactured t o a similar standard to
those used in t h e automobile industry. It was soon learnt that these cables didn't stand
up to t h e severe climatic and environmental conditions encountered during aircraft oper-
ation and therefore cables had to be designed expecially for aircraft use. A variety of
cable types have been developed, the choice of cable for a particular function will be
governed by i t s purpose and location.
LS
REQUIREMENTS a

Reliability is of prime consideration for aircraft cables since t h e performance and safety
of a n aircraft and i t s occupants can be dependant upon electrically operated systems of
which cables form an essential part. Great care therefore must be exercised during the
manufacture of these cables and stringent tests are applied to ensure maximum reliability,

Listed below are a number of qualities which an aircraft cable must possess.

/$ MINIMUM WEIGHT AND DIMENSIONS

A large modern aircraft may require many miles of electrical wiring and even S mall re-
ductions in the s i z e and weight of a cable will result i n a considerable saving therefore
allowing a n increased payload,

RESISTAM TO FLUIDS

The likelihood of an aircraft cable encountering a variety of aircraft fluids i n high, It

is therefore important that aircraft cables are able to withstand the effects of:- water,
engine oils, hydraulic oils , fuel solvents, etc,

a NON -1NFLAM MABILITY

Wiring is necessary in high firerisk areas such a s engine nacelles, and APU bays. Such
wiring should not cause the fire to spread and for this reason the protective covering
should be of self extinguishing material,
 AIRCRAFT ELECTRICAL CABLES
WIDE RANGE OF OPERATING TEMPERATURES
During flight some cables could experience a large range of temperatures and must remain
flexible in t h i s range.

Y) RESISTANT TO ABRASION
An aircraft cable must possess a number of 'physicai' qualities and i n particular must
have high resistance t o the abrasion that might be induced by aircraft vibration. Cables
should also be physically strong and easily workable.

ELECTRICAL REQUIREMENTS

Attention must be paid to providing a conductor with a low volts drop and a n insulator
-
with a high insulation resistance.

RATING

The normal current rating of a cable can be defined as , t h e amount of current it will carry
without sustaining a temperature rise sufficient to cause t h e value of insulation re-
sitance to deteriorate to a n unacceptable level or without exceeding a specified voltage
drop. Earlier cables either had the current rating stamped on the outer sheath or had a
colour identification related to t h e current rating. However, because a cables current
carrying capacity is influenced by a number of factors other than electrical. load current
it is nowadays the practice of cable manufacturers t o use a classification based on the
.
American wire gauge (AWG) Modern aircraft cables then have a wire gauge number
stamped on the outside. The electrical designer will take into account the factors listed
below before choosing a particular size cable for a particular job.

rl The electrical loading of the cable

The amount of heat generated by neighbouring cables
The number of cables i n the loom
The ambient temperature of t h e surroundings a i r
1 Whether the cable is enclosed or in free a i r

L The thermal conductivity of the cable.

5
 AIRCRAFT ELECTRICAL CABLES

A l l t h e cables shown can be used in circuits of u p t o 600 volts rms a t 1600 Hz with the
exception of Minyvin which is suitable for use i n circuits of up t o 300 volts rms a t 1600
HZ

Certain sizes of cable are available with metal braid screening (Met-types) or metal braid
screening with outer sheath (Met-Sheath type). Conductor sizes and cable types, a l s o
codes for the manufacturer and year of manufacture are indicated by printing on the outer
sheath, Tersil and Nyvin type cables are available with aluminium conductors t o save
weight and are called Tersilal and Nyvinal raspectively .

KP 150 is a new type (approx 1970) of general performance airframe cable, produced t o
meet the ever-growing demand for smaller and lighter cables with wider
erature ranges than existing types. It provides the following
and small An operating temperature range of - 65OC to
tained u p t o 200 OC. Rated for operation up t o 600 volts a t 2000 Hz It.
is easy to s t r i p , print and its flexability a s s i s t s loom making and installation. It poss--
esses good resistance to mechanical damage in service. It is immune to attack by air-
craft fluids, and does not support c o m b u s t i o n ~
(
The conductor is formed from strands of copper or copper alloy. Conductor sizes a m
based on the proposed International Standard Organisation (ISO)metric sizes for airframe
wiring cable conductors , which are already adopted a s the basis for future Bdtish
Standards.

The insulation 'is a combination of FEP and Polyimide (Kapton 6 16) tapes. The taped
cable is heat treated to melt t h e FEP and seal the layers t o form an inseparable mass
which is impervious t o fluids.

A layer of special polyurethane lacquer, coloured WHITE is applied overall. On each

cable is printed, in green,the following code: the reference (KP 150), country of origin'
(G for Gt Britain), manufacturer (BB for BICC) and year of manufactum (H = 1970) followed
by the cable s i z e eg
,L
d.. Jf&
&?I-
 CHARACTERISTICS OF A SELECTION OF
AIRCRAFT ELECTRICAL CABLES

PURPOSE, AND
OTHER QUALITIES
Orange -75 to 1 9 0 ° C should For u s e in(hlgh temp
1 3 7 not be flexed below h i g h firerisk areas :!
-55 "C. Fireres istant Resistant t o ~ n a s t
can withstand 1100 O C aircraft fluids.
FEPSIL for 5 minutes.
b
Green -75 to 190°C should For u s e in high t e m p
1 3 5 8 not be flexed below high f i ~ r i s kareas
-55 " C , fireresistarlt Resistant to most
can withstand 1100 " C aircraft f1u.ids lrnproved
for 5 minutes. handling qualities
NYVIN
White -75 t o 105 OG should
not be flexed below
;General aircraft wiring. )
Resistant to ester based
-30 *C. fluids,

White -75 " C t o 105 'C General aircraft wiring,

2 L 5 6 Resistant t o ester based

- - ..
-.-.c.~-.~c"urrr-.~.,,>,,,~a--~~~r#
.
..-,..* -.a, , - . r r r r r r r d r r
EFGLAS
r..,, rr>*~.-~.,*c.F r....
f"'
A..----*-..--
White -90 "C t o 250 OC
fluids Improved handling.

For flexing i n cold areas

suitable for flexjng ie, undercarriage,
t o -75 OC. landing l a m p s . For high
temp areas
Low surface friction
1 Nickel plated copper strand 4 pvc 7 Glass braid/PTP/varnish
Resistant t o corrosive
2 Timed copper strand 5 Glass braid 8 FEY strnas pheres and aircraft
3 Silicone rubber 6 Nylon 9 PTFE/glas s/PTFE fluids,

PTFE: Pol ytetra fluoroeth ylene PVC: Polyvinyl chloride

PTP: Polyethyleneterephthalate FEP:.. .- Fluorinated ethylene propylene
 CABLE CODING

POSITIONAL CODING

The aircraft is divided into electrical zones. Each

zone is given an alphabetical reference or code.
Electrical control panels, connector groups, etc. bear
a two letter reference The first letter is the zone
.l

letter the second letter identifying the panel within

the zone. HOME & AWAY IDENT CODING SYSTEM
Sub panels of main panel assemblies are each alloted
a reference a s is each item of equipment contained on
the panel or sub panel. -2H: CD 10 HA :B3 2H: CD 10 HA :B3
-
A A A A 4
Every cable has its size and type printed i n red, and
a homeB and 'away' identification printed in black.
f
Cables used in 38' a . c. circuits have coloured tracers
t - TERMINAL CODE - ---
for phase identification: -
PANEL CODE - --
RED TRACER A phase ROUTING CHART --
YELLOW TRACER E3 phase
BLUE TRACER C phase PANEL CODE -
The A, C. neutral does not have a coloured tracer,

The code a l s o includes the routing chart number of

* TERMINAL CODE 1
the circuit with which the cable is associated.
 CABLE CODING

EXAMPLES OF 'HOME8 AND AWAY CODING.

lConnector Black to Equipment 1

Idmlificotion Slpever Shown 0 Represent Pink Seporotor S I e ~ v e s L

/denlrf,cot,an Slervss Shown d C P h a r ~ S/eeves and
Repres~nt C o l o ~ r ~ A Corry the Pbosp
/dPntrficution Letter
/denhficofion Sleeves Shown Represent Spocer SIPPVPS
ldent,f;colion Slerrer Shown Represent E w t h C06le /dentif~cot,on Sleeves

Wiring Reference Item Numbers, in C/rc/es, o r e Pointed on or Neor to the Component

 SERIES CODING (ATA 100)

The first letter is the '1

The first number is the _circuit functf on letter The second number is
i n this c a s e D.C. POWER, the
-W
2 system,

*
The second letter is The third, and last The last letter indicates
number is the cable whether the cable is used
letter, size and corresponds as an e s h , p h e c a b l e ,
to the--G. size. or a t ~ r , m ~ g $ e . I
* L -,

I This cable i S segment A o f wire number 2 15 i n the No. 2 d. c. power sys tern.
The cable size is A.W. G . 2 0 . The cable is an earth cable. I
 SERIES CODING (AN EXAMPLE)
- 1

This is segment A of Cables from terminals 1 and 3 of LP VALVE

cable No, 1 of the No. 2 RIGHT have neither a common junction with
unit of circuit function cable No. 1 nor with each other and s o
Q. become cables 2 and 3 respectively each
I starting with segment A .

- ( C 9 ) - 0 2Q3C20

2Q3E20 ---

1
Segment A of cable No, 3 goes t o connector Segment B of cable No, 3 goes to connector block
k- terrninai L6. L 6 is common for three terminal C9, a common terminal for two cables,
cables. Therefore the other two retain the therefore the other cable from C9 still bears cable
cable No. 3 but now have segment letters B No. 3 but now has segment letter c,
and D respectively, +l L

'I h
The Maintenance Manuals and Wiring Diagrams of most modern types of public transport
aircraft are laid out and drawn t o the specification of the AIR TRANSPORT ASSOCIATION
of AMERICA.

MANUAL STRU CTURE

Each manual is sub-divided s o that pages describing a unit, or instructing for a parti-
-
cular fob, can be removed and used separately the description part primarily for
training, and the maintenance part for the personnel working on t h e aircraft.

The structure of the manual is a s follows:

I
.
24 'Electrical Power1'
-
The manual is broken into 100 STANDARD CHAPTERS e , g . Chapter

2 Each Chapter is sub-divided into Sections, e.g. 24-3 1 "Main

Generation System".
\
3 Each Section may be sub-divided into*
"Transformer Rectifier Unit".

4 Each Subject is divided into Topics, e . g . 8tDescriptionand

Operation". "Maintenance PracticesM, etc.

NOTE: In the 'three dash number' identity system used, the first
number is the chapter, the second the section and the third
subject. The full dash number is given o n e a c h page.

,. 5 Each topic is identified by a separate range of page numbers.

Thus the description of each unit always starts on page 1,
trouble shooting on page 10 1, and maintenance practices on
page 201.
 INSPECTION OF CABLING IN AIRCRAFT

Check the insulation for Check cables passing Check that insulation and
damage especially where through ribs for -chafing. protective coverings have
cables are running close to not been affected by cli-
any moving parts. matic conditions or -
oil,
fuel,etc.
-
F
=
,

DUCT DIVISION No.1 FLYING CONTRaS MAIN CABLE

PLATE GENERAL No.1 ENGINE DUCT
\ I No. I GENERATOR I

Protective sleeves on Cable runs from fixed to After installation of a cable

connections
- -- should be moveable parts of the structure the circuit should be given
--L_. /-

checked for damage or should not be subjected to strain

-m -
a continuity, insulation and
deterioration. or exces sive flexing. functional check.
SATISFACTORY CONDITION The following specific faults are typical of those which should be
identified and actioned. The probability of discovery is related
to the type of INSPECTION prescribed.

The following are examples only of checks for damage, leaks, deter-
ioration and other discrepancies, and are not intended to represent
a total list of all possible faults:

Metal parts e.g. all structural members, bodies or casings of units in systems
and instruments, electrical and radio installations, metal pipes,
ducting, tubes, rods, levers etc.
Cleanliness. External evidence of damage, leaks, overheating or
discharge. Bulging. Obstruction of drainage or vent holes - and
serviceability of fasteners,
Security of attachments, fasteners, connections locking and bonding.
Freedom from cracks (visual), distortion, dents, scores, chafing,
evident wear, pulled or missing fasteners, e.g., rivets, bolts, screws,
Seperation of bond, failure of welds and spot welds. Deterioration of
protective treatment and corrosion. Correct fitment and sealing of
fairings. Fluid ingress.
Security of electrical terminals and signs of overheating or 'arcingt,
removing covers where necessary.
SATISFACTORY CONDITION
Rubber, Fabric, Fibre qlass and plastic parts e.g.

ducting, f l e x i b l e pipes, flexible mountings, seals, insulating of electrical c a b l e s , windows, etc.

Cleanliness, cracks, cuts, chafing, kinking, twisting, crushing, contraction - sufficient free
length.
Identification markings,
Deterioration, Crazing. Loss of flexibility, overheating.
Fluid soakage and distortion.

Security of attachment (supports, packings and electrical bonding correctly positioned, serviceable
and secure), connections and leaks.

Control System Components Correct alignment - no fouling. Free movement. Distortion. Evidence
of bowing. Scores, Chafing. Fraying. Kinking. Evidence of wear. Flattening. Cracks. Corrosion.
Loose Rivets. Deterioration of Protective Treatment, Electrical bonding correctly positioned,
undamaged and secure. Attachments, and connections and locking secure. Identification markings.

Electric Motors, Alternators, Generators and Actuators

Cleanliness, scoring, pitting. Evidence of overheating or fluid ingress, Corrosion. Security.
Distortion. If covers required to be removed, brushes free in holders, wear and correct bedding
adequate and spring tension.

Relays, Solenoids, Constactors, Switches, Indicator and Warning Lamps. Cleanliness. Pitting
or burning of contacts where accessible. Correct gaps. Evidence of overheating. Cracks.
Corrosion. Security. Covers secure. Legibility of markings. Cracked glasses, freedom from
condensation.
Batteries Corrosion, spilt electrolite, security and cleanliness, attachment of terminals,
condition of case and battery vent system.
 PREPARATION OF CABLFS FOR CRIMPING

When stripping cables the The end of the conductor must be

left square. The bared conductor
L-

correct length of insulation must be removed must be free from any insulating
material.
strands should not be s e v e r e d or damaged

l a y of t h e strands should be r e - i m p o s e d with

a light twist.

PRE-I NSU L ATED

COPPER SLEEVE

I . ' 8 +1/32in

B = BARREL LENGTH
-.c--.y--
STRIPPING LENGTH = BARREL LENGTH +.-
C = ~N~ULATION'GRIP
. @, 8 [
RECEIVING
BARREL AND
TONGUE

When S tripping braided cables the insulation and should

be removed separately to avoid damage t o the conductor.
 CRIMPING TOOLS

B 9
The tool specified , i n STANDARD PRACTICES, for a
particular crimped joint m u s t be used. (X*. #/#l

The insulation adjustment pins must be adjusted to

conform to the *d of insulation for the particular
cable to be useh.

W h e n a l u m i n i u m or aluminium alloy terminations are

to be d&mped to a l u m i n i u m conductors, a corrosion-
inhibiting agent must be used.

-
The correct fluid m u s t be used i n hydraulicaiiy- . DETAIL. ' A
operated tools. The relief valve settings must be
accurately maintained. H AN DLE

lYELLO* I
-- - . . .
BLUE
. .....-

I16-14
e-*>

/
COLOUR C O D E D HANDLES DETAIL '8'
GRIM PING TOOLS

W l RE SlZ E RANGE
STAMPED HERE . INSULATION CRIMPING
ADJUSTMENT PIN

WINDOW INDENT FACES LOCATOR

DETAIL 'B'
LOCATOR

C L A I I - C R I M P RATCHET y /

TERM INAL BARREL RESTS

AGAl NS 1 LOCATOR
'
DETAIL ' A
 CORRECTLY FORMED CRIMPS

The conductor is protruding

a t least *8

CORRECT
POSITION OF CRIMP DISTANCE
MARKS ON INSULATION- m1
ASSEMBLY
THE CRIMPING AT COMPLETE
THIS POINT
S O M P R E S S THE
S L E € V ~ UNDERNEATH f INSULATION GRIP

The cable is supported by The 'dott coding is impressed on t h e insulation,

t h e sleeve. of P.1, D,G, connectors, during t h e crimping
process. The number of 'dots1 is a n indication
that t h e correct tool h a s been used to effect the
connection. (S m 2
'ZLiE@#I$&"),
 . IN-LINE CONNECTORS
~ ~ ~ ~

It is generally permissible to repair single-core

cables with IN-LINE CRIMPS pjovided that they
are.

@ NOT- 10 A.W.G.
&-a

NOT at H . T. voltage..
@ tL

i t r u r e lngrrss
NOT in a high temperature zone. Seoling Slrtvt

/n-line Crimp Bclorr

Crimping Oprr ation

ln-line Crimp Aft e r

Crimping Operation

/n -/in l C r i m p Wit h S ea/ing

- - - - which prohibits
NOT enclosed within ducting S/eeve /n Position

@ inspection.

NOT for specialist u s e e.g. screened,

- - co-axial,
@ thermo-couple , -etc.
U -* -..

-r
 IN-LINE CONNECTORS

@ A multiplicity of in-line connectors in any

f
one @ To facilitate i n s pection;in-line connectors
cable should be avoided. In any case:no more should be located on t h e outer surface of
than LKQ-spudes shall be made in a n y ten feet
-. . t h e loom.
 LOADING AND CONNECTING OF TERMINAL BLOCKS

---

A B C
METHOD OF CONNECTING METHOD OF CONNECTING METROD OF FITTING
3, RING TONGUE TERMINALS. 4 RING TONGUE TERMINALS. CONNECTING LINKS. LINK
I S ALWAYS FITTED AT BASE
OF STUD.

METHOD OF FITTING
TRANSVERSE LINKS,
 VOLTAGE
".
U__.--P" a -
DROP TEST ON CRIMPED TERMINATIONS
-- - n .
-_._I-

TYPICAL ARRANGEMENT
TERMINAL TAG TEST
The maxi mum allowable
millivoit drop is u s u a l l y
5mV/1OA. I
 +-..-
A TYPICAL EARTH POINT
'--l-

Earth points at which electrical equipment may be connected t o the

airframe are usually limited i n number and are chosen and designed
with care.

EARTH POST
ASSEMBLY

G ~ r r ~ s i oplates
n or tags are usually incorporated at each earth point
to prevent electrolytic action between the base of the assembly and
the aircraft structure.

7
6z7
-3:
@ The resistance of the earth point assembly should be checked between
the attachment lugs and the airframe. The resiptance must not exceed
the value S pecified in t h e * ~ a i n t e n a n c eManual (e.g. 0 . 0 2 5 a ) 62WM&ffp4
@ A rnillivolt --d r o m t must also be carried out. , bp 5&fih/'
___---\ .
/

\
1
If the earth point fails either test the assembly should be removed and
the contact surfaces cleaned with a fine abrasive. It should be CORROSION PLATE 4 , m&
reassembled with, i f applicable, new corrosion plates. The area .
should be sealed and treated with anti-oxidant compound in accordance
with the particular maintenance manual.
 Sel fvAppraisa1 Questions

1 In ATA 100 which chapter contains details on 6 A heavy duty connection is checked by
A/C electrical power
't
a milli-volt drop test
a Chap. 20 / rnilli-voltdroptestatratedcurrent
Chap,24 C millf -volt drop t e s t a t rated voltage .
c Chap.30

2 The conductor in tersil cable i s 7 A. C. feeder cables are twisted together t o

b
a tinned copper a improve power factor
L-b nickel platedcopper &-p r t ~ k h n t ) red11ce radio interference
c stainless steel. impmvemechanicalstrength.
/..!.
J
H? .
Copper is an inferior conductor t o aluminium The recommended distance between inline crinlps
3
when comparing
8
is
A
weight for weight
4c csa with csa
load for load,

4 A cable is 9 Can the pressure of the insulation crimp jaws be

a t h e conductor / . changed on the Red/Blue P. I. D.G. crimping

a currentrating
l cross sectional area
c currentlweight ratio. + Yes with pins
c Yes by adjusting t h e torque applied to t h e
5 The cross sectional area of a conductor is handles.
increased therefore resistance will
10 The number of dots impressed on the insulation of
a increase proportionally pre-insulated connectors during crimping indicates
& decrease proportionally that the
c decrea sa inverse1 y proportionally.
.a crimp is properly formed
correct tool was used to effect the connection
-2
C comct connector has been a pplisd .
 Self-Appraisal Questions

Before effecting a crimp the bare ends of a

cable should be

H twisted lightly in the direction of l a y

b straightened out
c
-
tightly twisted.