STANDARD PRACTICES MANUAL ALL

Standard Practices - Electrical Power

407. Tools and Processes for Stripping Cables

A. General
This work card describes the procedure and tools to be used for stripping single-conductor,
multi-conductor, coaxial and shielded, twisted-conductor cables.

B. Description of equipment
(1) STRIPMASTER mechanical wire stripper (Figure 2, DETAIL A)

The conductor is stripped using blades fitted on a stripper which allows the operator to
cut and extract the insulation in a single operation.

The stripper to be used depends on:

- the type of wire (part number - type of insulation),

- the gage.
The table below lists the tools to be used according to the type of cable:

Complete stripper
IF STA- Grip
Dielectric Cable Gage Vice Blade DAVUM
TUS IDEAL color
TMC
KAPTON 10 (US) L5215 L5262 Black
10 to 14
KAPTON L5215 45.1611.1 Black
(US)
45.1610.1
16 to 26
A KAPTON L5217 L5260 Black
(US)
L5263
KAPTON
E CF/DK (1) 14 to 10 L5215 45-1939-1 Blue
(metric)
KAPTON
C CF/DK (1) 16 to 26 L5217 45-2020-1 Blue
(metric)
G ETFE BN TMC-MPS
L5217 L521 1 TMC-PC
KAPTON 16 to 26 Black
CF/DM (2) TMC-MPI TMC W1 W1
(metric)
3
D TMC-MPS
KAPTON L5217 TMC-PC
CF/DM (2) 14 to 10 TMC W2 Grey
(metric) TMC-MPI VV2
4
ETFE TMC-MPS
F (metric) BN
L5217 45-2824-1 TMC-PC
16 to 26 45-2834-9 Green
KAPTON AD/DR TMC-MPI TMCVV3 VV3
(metric) DM/CF (3) 3

D TMC-MPS
KAPTON AD/DR L5217 45-2825-1 TMC-PC
14 to 10 45-2835-9 Green
(metric) DM/CF (3) TMC-MPI TMC W4 W4
4

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Complete stripper
IF STA- Grip
Dielectric Cable Gage Vice Blade DAVUM
TUS IDEAL color
TMC
16 to 10
VINYL (US) L5215 L4420 Red

16 to 26
VINYL (US) L5215 L4994 Red

Fire
NA (DW/DL/ 16 to 22 LB-4621 55-3002-1 55-3002 Grey
9857-28)
Fire
NA (DW/DL/ 18 to 24 LB-4621 55-3004-1 55-3004 Grey
9857-28)

Table 1 Blade and vice P/N according to type of cable

NOTE

1. Blades which must be used to strip CF and DK

cables manufactured before 2000 (date code:
00 on cable).
2. Blades which can be used for CF, DM (and DK)
cables manufactured from 2000 (date code: ≥
00 on cable).
3. Blades which must be used for DR cables. Can
be used on CF and DM cables manufactured
from 2000 (date code: 00 on cable).

Cable type
Nominal section Strippers and
according to Cable gage Blades
code blades
standard
45-1775-1
030-020 12-14 45-1774
L5210
EN and ASN-E
012-002 16-24 45-1773 15-1773-1
012-001 16-26 45-171 L5211
050-020 10-14 45-1611 45-1608-1
LN and NSA
012-001 16-26 45-610 45-1654-1
SPEC 55 012-001 16-26 45-1987 45-1987-1
050-020 10-14 45-2835-9 45-2825-1
EN2267-009/010
012-001 16-26 45-2834-9 45-2824-1

Table 2 Type of stripper and blade according to section of cable to be stripped

(2) Fitting blades

1. The first time the blades are fitted after wear has been found on them:

- After positioning the blades on the stripper, slightly tighten the fixed blade without
locking the screws.
- Close the stripper.
- Check that the blades are on the same plane as the stripping contact areas.
- Lock the screws.

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NOTE

The lateral play of the movable blade must be less

than 0,1 mm.

(3) Thermal stripper PB 150M

(a) Description of power supply unit (Figure 1, DETAIL A)

- "On/Off" switch (1)

- "Buzzer" switch (2)
- "Time" switch (3)
- Stripper holder (4)
- Time setting potentiometer (5)
- "Time" light (6)
- Electrode holder (7)
- Electrode (8)
- "Teflon" setting potentiometer (9)
- Unit fuse (10)
- Heating power-setting potentiometer (11)

(b) Electrode holder (Figure 1, DETAIL B)

- Stripper mechanical-setting knob (12)

- Electrode attachment screw (13)
- Electrodes (8)

THE ELECTRODES (8) ARE AUTOMATICALLY

POWERED WHEN THE STRIPPER (7) IS CLOSED.

THE SPEED AT WHICH THEY ARE POWERED IS

DETERMINED BY THE MECHANICAL POSITION
OF THE STRIPPER SETTING KNOB (12).

The electrodes are made of a special alloy with high oxidation resistance. They
are bevelled to cleanly and accurately cut the insulation. The insulation is burned
locally without damaging the conductors.

(c) Protection against smoke

A DEDICATED WIRE-STRIPPING WORKSTATION

SHALL BE EQUIPPED WITH A SMOKE EXHAUST
SYSTEM (FAN OR SUCTION BOX) EXCEPT IF
THE ROOM VOLUME MEANS THAT THE SMOKE
IS RAPIDLY EXTRACTED.

DO NOT INHALE THE SMOKE PRODUCED WHEN

USING THE STRIPPER.

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(4) IDEAL 45-402 cable stripper (Figure 1, DETAIL C)

(5) Scalpel (Figure 1, DETAIL D)

USE THE SKINNING KNIFE, UTILITY KNIFE OR

SCALPEL WITH CARE SO AS NOT TO DAMAGE
THE CABLE.

USE THIS EQUIPMENT WHEN THE OTHER

PROCESSES CANNOT BE USED.

(6) Automatic stripper (Figure 2, DETAIL B)

The automatic stripper is equipped with round cutting disks. The machine’s parameters
are set according to the gage type and stripping length.

(7) Large-gage stripper KNIPEX 16 10 135 SB (Figure 2, DETAIL C)

C. Procedure
(1) Using mechanical wire stripper

(a) Preliminary check

Prior to use, check:

- There are no burrs and oxidation marks on the blades.

- The blades are positioned on the same plane.

ANY ROUGHNESS ON THE JAWS OF THE VICE

CAN DAMAGE THE INSULATION.

- The surface condition of the vice jaws.

- With the tool empty, that the blades and vice open and close normally
without any friction points.

(b) Stripping

- Offer up the conductor in the lower half-slot corresponding to the wire gage.
- Center the conductor by adjusting the length to be stripped (use the stop on
the stripper, if there is one).
- Fully squeeze the grips.
- Slowly release the grips to open the movable vice.
- Remove the stripped conductor.
- Completely release the grips.

(c) Stripper maintenance

1 Cleaning

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- If necessary, after several stripping operations, clean the stripper

blades using a brush moistened with a degreasing product.

2 Periodic check

- Direct check of tool: the operator directly checks the tool prior to use
according to paragraph "Preliminary check".
- Stripping check.
After each stripping operation, an inspection is carried out in accordance with
the acceptance criteria given in paragraph "Check".

If there is a persistent fault, send the tool for repair or replace the blades.

- Checking stripping tools after first use or after changing the blades.
When the stripping blades have been replaced or on any other work carried
out on the strippers, the operator will check the tool (refer to "Direct check of
tool").

A wire specimen corresponding to the blades and vice fitted on the tool
has been stripped and checked using the acceptance criteria defined in
paragraph D. "Check" (with a x30 or more magnifying glass).

If the fault persists, the tool will be overhauled or discarded.

- Tool identification.
The mechanical wire strippers will be identified by:

. The name of the manufacturer (or trademark).

. The part numbers on the blade and vice parts.

. The numbers of the various gages which can be fitted on the tool shall be
shown on the stripper.

. The colors of the grips as per Table 1.

(2) Using thermal stripper PB 150M (or equivalent)

(a) Preliminary check

Prior to use, check:

- There are no burrs, nicks, roughness, oxidation marks and particles of burnt
insulation on the electrodes.
- The bevelling of the electrodes.
- The junction point between the electrodes (no gap between the two
electrodes in the closed position).
- The temperature setting of the heating elements according to the type of
insulation to be removed.
- The setting of the travel stop mechanism.
- The stripper is suitable for the type and section of cable to be stripped (if
necessary, carry out a test on a cable off cuts).

(b) Setting the stripper

The settings depend on the stripper, the pliers and type of cable to be stripped.

- Carry out a prior test with the following settings:

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. Power: 7
. Teflon: 7
. Time: 5

NOTE

If the burn-through does not occur normally, increase

the power and/or time.

(c) Stripping at standard cable end

- Position the cable to be stripped between the jaws as shown in Figure 2,

DETAIL D.
- The cable is stripped after cutting the insulation in two actions, by rotating
the electrode holder through 90˚ after the first incision.
- The 4 notches made in the insulation in this way usually cover the entire
perimeter of the cable and enable the insulation to be removed just by
pulling it.
- If the insulation is not completely cut, 2 more incisions must be made, 45˚
from the first two.
If the cable cannot be stripped using the above method, proceed as follows:

LIGHTLY BRING THE JAWS TOGETHER SO AS

NOT TO DAMAGE THE METAL BRAID.

- Grip the cable and wait for the jaws to heat.

- Apply a rotational movement around the jaws.
- Withdraw the jaws from the notch when the insulation is severed.
- Pull off the end of the insulation using a non-slip pad.
- Check the condition of the braid (Figure 2, DETAIL E). If the braid is
marked, the stripping is refused.

(d) Shield connection

1 Window stripping

- Method 1:
. Strip the end of the cable with the IDEAL 45-402 cable stripper
suitable for the backshell used and cut the shielding flush with the
insulation.
. Using the IDEAL 45-402 cable stripper, cut a notch where the window
is required.
. Slide the insulation in order to obtain the window (Figure 2, DETAIL
F).
- Method 2: mandatory on busbar and coaxial cable shield connectors
. Cut two notches according to the self-sealing sheath used (Figure 3,
DETAIL A).
. Cut two symmetrical and diagonal notches, as shown in Figure 3,
DETAIL B.
. Remove the two parts of the insulation by hand in order to produce
the window.

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2 Stripping at shielded cable end

- Strip the end of the cable with the IDEAL 45-402 cable stripper suitable
for the backshell used and cut the shielding flush with the insulation.
- Cut a notch according to the self-sealing sheath used and remove the
insulation (Figure 3, DETAIL C).

(e) Electrode holder for large section cable

Eurocopter recommends that the electrode holder 150MG00 be used to strip large
section cables.

- Mark the cable with the cable stripper.

- Bend the insulation to break it and remove it using a suitable tool (e.g.
socket wrench with the correct diameter for the cable).

(3) Using IDEAL 45-402 cable stripper

(a) Preliminary check

Prior to use, check:

- The condition of disk cutter (2) (no oxidation marks, etc. Replace the cutter
with the spare cutter (1) if necessary) (Figure 3, DETAIL D).
- The effectiveness of the return spring.
- The stripper is suitable for the type and section of cable to be stripped (if
necessary, carry out a test on a cable offcut).

(b) Stripping cable end (Figure 3, DETAIL D)

- Position disk cutter (2) of stripper at stripping point.

- Make three turns around the cable (the number of turns depends on the
wear of the cutter).
- Slightly bend the cable several times at the point where it has been cut to
separate the insulation.
- Pull off the end of the sheath using a non-slip pad.

(c) Window stripping

- Same principle as for thermal stripper PB 150M shielding connection

paragraph.

(4) Using skinning knife, utility knife or scalpel

USE THIS TOOL WITH PARTICULAR CARE. IT

CAN INFLICT SERIOUS INJURIES.

(a) Preliminary check

Prior to use, check:

- The condition of the blade (no oxidation marks, etc.).

- Blade is locked.
- The tool is suitable for the type and section of cable to be stripped (if

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necessary, carry out a test on a cable off cuts).

(b) Stripping at cable end (Figure 3, DETAIL E)

DO NOT TOUCH THE SHIELDING WHEN

CUTTING THE SHEATH.

- Make a cut in the sheath "A" but do not cut through it entirely.
- Slightly bend the cable several times "B" at the point where it has been cut
to separate the insulation.
- Pull off the end of the sheath "C" using a non-slip pad.

(c) Window stripping (Figure 3, DETAIL F)

- Same principle as for thermal stripper PB 150M (or equivalent) Shielding

Connection paragraph.
- Notches "D", cutting in center "E" and removal of center part "F" (Figure 3,
DETAIL F).

(5) Use of large-gage stripper KNIPEX 16 10 135

(a) Preliminary checks

- Check that the blade is in good condition (no signs of oxidation, etc.).
- Check that the tool is suited to the type and section of the cable being
stripped, and if needed, perform a test on a short piece of cable.
- Make sure that the blade never comes in contact with the conductor
anywhere around the cable, in order not to damage the conductor.

(b) Stripping cable end

- Position blade of stripper at stripping point.

- Make three turns around the cable (the number of turns depends on the
wear of the cutter).
- Slightly bend the cable several times at the point where is has been cut to
separate the insulation.
- Pull off the end of the sheath.
If it is difficult to remove the insulation, use a suitable tool (e.g. socket
wrench adapted to the cable diameter) to remove the insulation.

(c) Tool check

1 Periodic check

Direct check of tool: the operator directly checks the tool prior to use.

Visual checks:

- Good condition of blade (no signs of oxidation, etc.).

- Effectiveness of the return spring.

D. Check
Figure 4

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(1) Check of insulation stripping on coaxial cables

- Comply with the stripping values "A", "B" and "C" as per the manufacturer’s
specifications (DETAIL A).

(2) Check of stripping on cables (DETAIL B)

Check:

- Conductor for correct condition.

- Strands are neatly cut.
- Insulation is neatly cut.

(3) Stripping acceptance criteria

(a) The stripping is accepted in the following cases:

- The strands are not twisted (DETAIL C).

- The strands are marked but the copper is not visible (DETAIL D).
- The insulation has not been cleanly cut within length limit "L" ≤ 1 mm
(DETAIL E).
- The strands have not been cleanly cut within length limit "L" ≤ 1 mm
(DETAIL F).
- The insulation is on the strands within length limit "L" ≤ 1 mm (DETAIL G).

(b) The stripping is refused in the following cases:

- The insulation has not been cleanly cut within length limit "L" > 1 mm
(DETAIL E).
- The strands have not been cleanly cut within length limit "L" > 1 mm
(DETAIL F).
- The insulation is on the strands within length limit "L" > 1 mm (DETAIL G).
- Marking on insulation: nicks, burn marks, conductor visible (DETAIL H).
- Strands sheared (DETAIL I).
- Incorrect cleaning: burnt insulation particles present on braid or stands
(DETAIL J).

(4) Specific case of large-gage cables (Figure 5)

(a) The stripping is accepted in the following cases:

For large-gage cables ( > gage 10), the cutting and accidental damage to a certain
number of strands is acceptable within the limits defined below.

AWG gage Section mm2 Max. number of strands cut or

marked
8 to 4 9 - 22 4
2 to 0000 37 - 107 12

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NOTE

For ECS0844A* cables, markings around the entire

circumference are acceptable.

Strands not cleanly cut: L less than or equal to 3 mm

(DETAIL A).

Core does not have an oval shape, and there are no

signs of oxidation (DETAIL B).

(b) The stripping is rejected in the following cases:

Strands sheared (DETAIL C).

Oval shape of core, preventing connection with the end-piece (DETAIL D).

Signs of insulation of the strands: L greater than 1 mm (DETAILS E and F).

Incorrect cleaning:

- Insulation residue (Kapton, PTFE, etc.).

- Burnt insulation on braids.

(5) Specimen check during manufacturing

(a) Mechanical wire stripper

- Strip a wire specimen corresponding to the blade and vice fitted on the tool.
- Check stripping using "Stripping acceptance criteria".

(b) Thermal stripper PB 150M (or equivalent)

- Strip a specimen batch of WL coaxial cable (outer sheath and core).

- Check stripping using "Stripping acceptance criteria".

(c) IDEAL 45-402 cable stripper

- Strip a specimen batch of TK20 two-wire cable (outer sheath and wire).
- Check stripping using "Stripping acceptance criteria".

(d) Large-gage stripper KNIPEX 16 30 135

A cable test specimen shall be stripped (outer sheath), and the check shall be
done as per the stripping acceptance criteria.

E. Safety
The tools must be handled with great care. They may cause serious injuries. It is
recommended to use a safety knife with self-retracting blade.

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Figure 1

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Figure 2

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Figure 3

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Figure 4

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Figure 5

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