STANDARD PRACTICES MANUAL ALL

Standard Practices - Electrical Power

103. Repair Procedure for Single-Conductor, Two-Conductor, Three-Conductor

and Four-Conductor Shielded Cables
A. General
Before performing any work, refer to the acceptability criteria for standard electrical
components (20-80-20-442).

This card gives four procedures for repairing shielded cables according to the number of
conductors.

- single-conductor cables,
- two-conductor cables,
- three-conductor cables,
- four-conductor cables.

NOTE

The rules for routing harnesses must be complied

with when splices have been added to the cables as
per 20-02-01-415.

THE USE OF SPLICES ON SHIELDED CABLES IS

SUBJECT TO THE FOLLOWING RESTRICTIONS:
- THE ADDITION OF A NON-REFERENCED
SPLICE MUST BE SUBMITTED FOR PRIOR
APPROVAL BY THE AIRBUS HELICOPTERS
CUSTOMER SUPPORT SERVICES.
- NO MORE THAN 2 SPLICES ARE
AUTHORIZED ON THE SAME CABLE
SEGMENT.
- IT IS FORBIDDEN TO USE SPLICES IN HOT
AREAS ( > 110˚C).
- THE SPLICES WILL BE POSITIONED AT
THE EDGE OF THE BUNDLE/HARNESS SO
AS TO BE VISIBLE WHEN INSPECTIONS
ARE CARRIED OUT.
- THE SPLICES MUST BE STAGGERED
TO GUARANTEE THAT THERE IS NO
OVERHEATING AND TO LIMIT THE
THICKNESS OF THE HARNESS (FIGURE 1
DETAIL A). IF THIS IS NOT POSSIBLE, A
MAXIMUM OF TWO JUXTAPOSED SPLICES
IS ACCEPTABLE.

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IT IS STRONGLY RECOMMENDED TO REPLACE

THE DAMAGED CABLE AS QUICKLY AS
POSSIBLE IN ORDER TO RECOVER THE REPAIR
CAPABILITY.

DO NOT TOUCH THE STRIPPED WIRES WITH

YOUR FINGERS WHEN CARRYING OUT THE
CRIMPING OPERATION. CONTAMINATION OF
THE CONTACT ELEMENTS COULD DEGRADE
ELECTRIC CONDUCTION.

Shielded cables are repaired using "Solder shield" type interconnection kits and a heat-
shrinkable sheath.

B. Equipment required
(1) Tools

Cutting pliers Stripping pliers Cutter

(Figure 1 , DETAIL D) (Figure 1 , DETAIL E) (Figure 1 , DETAIL F)

Table 1 Splice Tools - Description

Crimping tool for cable core splices:

AD-1377S (Tyco Part Number) or GMT232 (M22520/37-01)
(Figure 1 , DETAIL G) (Figure 1 , DETAIL H)
(AD-1377S (Raychem) GMT232 (M22520/37-01)

Table 2 Splice Tools - Description

FACOM E2005 Hot air gun with PR25D Reflector

electronic temperature control (Tyco Part Number)
(Figure 1 , DETAIL I) with (Figure 1 , DETAIL J)

Table 3 Splice Tools - Description

(2) Materials

- "Soldershield" kit D-150-02XX

The following table gives the value of XX according to the number of conductors and
the gauge.

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Tyco Kit Number of Conductors

Gauge Color Code
P/N D-150-02XX Allowed
28 1 20 to 26 red
29 1 16 to 20 blue
30 1 12 to 16 yellow
31 2 20 to 26 red
32 2 16 to 18 blue
33 2 14 yellow
34 2 12 yellow
35 3 or 4 24 to 26 red
36 3 or 4 20 to 22 red
37 3 or 4 16 to 18 blue
38 3 or 4 12 to 14 yellow

Table 4 Choice of Kit D-150-02XX

(3) Description of the Repair Kit

This kit of components D-150-02XX includes one or more splices to reconnect the
damaged shielded cable conductors. It also includes one or more sealing sleeves ASN-
E0541 and a heat-sealable soldershield sleeve ABS1471.

Splice Sealing Sleeve Crimp Soldershield

(Figure 1 , DETAIL A) (Figure 1 , DETAIL B) (Figure 1 , DETAIL C)

Table 5 Splice - Description

C. Procedure
(1) Process

The repair process consists in cutting and reconnecting the conductors using splices.
The heat-sealable braiding is used to reconnect the cable shielding. The heat-shrinkable
sleeve insulates the cable. This repair can be applied to single-conductor and multi-
conductor cables.

NOTE

If the length is not long enough, it is recommended

that a jumper is used.

(2) Cable Preparation

(a) Single-Conductor Shielded Cable (Figure 2, DETAIL A)

- Make a clean cut through the damaged area.

- Strip the outer sheath over 25 mm ± 1 mm on each end of the shielded
cable to be connected.
- Prepare the two ends in accordance with the dimensions given in DETAIL A
(20-80-20-407).

(b) Two-Conductor Shielded Cable (Figure 2, DETAILS B, C and D)

- Strip the outer sheath of the shielded cable over L2 = 75 mm ± 1 mm

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(DETAIL B).
- Place the damage at L1 = 23 mm ± 0.5 mm so that you can stagger the
splices (DETAIL B).
- Cut the shielding in the middle and leave it for the moment (DETAIL B).
- Make a clean cut through the damaged conductor.
- Prepare the first end to be connected in accordance with the dimensions
given in DETAIL C for stripping the two-conductor shielded cables and those
given in DETAIL D for stripping the second end (20-80-20-407).

(c) Three-Conductor Shielded Cable (Figure 3)

- Strip the outer sheath of the shielded cable over L2 = 75 mm ± 1 mm

(DETAIL A).
- Place the damage at L1 = 37,5 mm ± 0.5 mm so that you can stagger the
splices (DETAIL A).
- Cut the shielding in the middle and leave it for the moment (DETAIL A).
- Make a clean cut through the damaged conductor.
- Prepare the first end to be connected in accordance with the dimensions
given in DETAIL B for stripping the three-conductor cables and those in
DETAIL C for the second end (20-80-20-407).

(d) Four-Conductor Shielded Cable (Figure 4)

- Strip the outer sheath of the shielded cable over L2 = 75 mm ± 1 mm

(DETAIL A).
- Place the damage at L1 = 23 mm ± 0.5 mm so that you can stagger the
splices (DETAIL A).
- Cut the shielding in the middle and leave it for the moment (DETAIL A).
- Make a clean cut through the damaged conductor.
- Prepare the two ends to be connected in accordance with the dimensions
given in DETAIL B (20-80-20-407).

(3) Assembly Method (Figure 5 to Figure 9)

NOTE

The assembly method is the same for the repair of

a single-conductor shielded cable and of a multi-
conductor shielded cable.

- Cut and slide onto the cable a 150 mm length of protective sheath
VG95343T05E***A (Figure 5, DETAIL A).
- Thread the soldershield sleeve onto one end of the cable, starting with the
smallest diameter as shown in Figure 5, DETAIL B.
- Put the splice in the crimping tool AD-1377S or GMT232 (M22520/37-01) after
having selected the correct imprint (Figure 5, DETAIL C).
- Tighten the crimping tool slightly to hold the splice without distorting it.
- Push the stripped cable into the splice up to the center mark on the "window."
- Check the position of the splice and the cable before crimping.
- Tighten the crimping tool until it operates in order to crimp the splices as shown in
Figure 6, DETAILS A, B and C for the two-conductor, three-conductor and four-
conductor cables (20-80-20-401).
- Thread the sealing sleeves over the longest conductors and leave them for the
moment (Figure 7, DETAIL A).
- Crimp the second end of the splice (Figure 7, DETAIL B) (20-80-20-401).
- Center the insulating sleeves over the splices and shrink them using the hot air

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gun (Figure 7, DETAIL C).

- Put the cable shielding in place, winding it over L2 = 10 mm minimum and place
the marks at L1 = 15 mm ± 1 mm from the edge of the sheath, as shown in
Figure 7, DETAIL D (two-conductor cable), Figure 7, DETAIL E (three-conductor
cable) and Figure 7, DETAIL F (four-conductor cable.
- Bring over the soldershield sleeve and center it between the marks, turning it in
the same direction as the shielding twist (Figure 8, DETAIL A).
- Shrink the heat-sealable braiding until the shielding is fully sealed in the sleeve,
starting in the center and then moving the hot air slowly towards one end and then
the other (Figure 8, DETAIL B).

THE BRAIDING MUST NOT CHANGE COLOR NOR

BE DAMAGED (FIGURE 8, DETAIL C).

- Let the cable cool before handling it.

- Using an indelible marker, make a mark L1 = 20 mm ± 1 mm from the
soldershield (Figure 9, DETAIL A).
- Bring the heat-shrinkable sheath VG95343T05E**A up to the marks.
- Shrink the heat-shrinkable sheath VG95343T05E**A using the hot air gun (
Figure 9, DETAIL B).

D. Repairing with a jumper

(Figure 10)

(1) Principle

- The repair is carried out using the same type and gage of cable as the one to be
repaired.
- A zone of at least 100 mm is required for the repair.
- The splices must be staggered to ensure there is no overthickness on the
harness.
Keep a distance of 15 mm between each splice. It is possible to spread the
splices around the periphery of the harness so that they are not in contact with
each other.

(2) Preparing the jumper

- Cut and strip a 50 mm - 150 mm section of the cable (DETAIL A).

NOTE

The length of the jumper must be long enough to

allow the splices to be staggered.

(3) Assembly method

- Apply the same method as described in paragraph C. Jumper insertion procedure.

E. Electrical check of the repair

- Check the continuity of the repaired cable using a multimeter (core and shielding, R ≤ 8

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ohms).
- Check the insulation resistance between the core and the shielding (500 V = R > 20
M’Ω).
- Carry out the functional tests.

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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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Figure 6

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Figure 7

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Figure 8

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20 mm ± 1 mm

Figure 9

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6,5 mm ± 0,5 mm
6,5 mm ± 0,5 mm
6,5 mm ± 0,5 mm

6,5 mm ± 0,5 mm

50 mm à 150 mm

Figure 10

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