Safety Regulation Group

AIRWORTHINESS INFORMATION LEAFLET

Ref: Date: Department: This Leaflet will not necessarily be kept up to date by reissues. AIL/0140, Issue 2 12 August 2002 A/C Systems & Equipment

SUBJECT TITLE: PURPOSE:

Aircraft Electrical Cables

This Leaflet provides guidance material on the approval or acceptance of aircraft electrical cables. Documents are listed in paragraph 2. 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 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. RF cables are not considered in this Leaflet.

REFERENCES: FOREWORD:

CONTENTS
1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4 4.1 4.2 4.3 4.4 4.5 4.6 Introduction Applicable Requirements Design Responsibility Approval of Cables Modification And Repair Classification Of Cables Airframe Cables Interconnect Cables Equipment Wire Fire Resistant Cables Fireproof Cables Multicore Screened And Jacketed Cables Data Bus Specifications and Cable Type Identification British Standard Specifications UK Military Specifications US Military Specifications Manufacturers Specifications International Standards Cable Manufacturers Specifications

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5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6 6.1 6.2 6.3 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 8

Cable Performance Application Temperature Cable Size Voltage Rating Flammability And Toxicity Wet Arc Tracking Mechanical Properties Fluid Contamination Cable Construction Conductors Conductor Plating Dielectrical Materials/Cable Types Cable Failures Wet Arc Tracking Minyvin BMS 13-28 Abrasion Conductor Knuckling Through Red Plague Glycol Fires Poor Solderability Approved Cables List of Accessory Approvals Manufacturers code letters

Appendix A Appendix B

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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.

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 or JAR 25. The following list is provided for guidance purposes only: BCAR Section D6-13 paragraph 7.1 BCAR Section K6-13 paragraph 7.1 BCAR Section G6-14 paragraph 7.1 JAR 25 25.1309 25.1353 25.1355 25.1359 Equipment, Systems and Installation Electrical Equipment and Installation Distribution System Electrical System Fire and Smoke Protection Cables and Associated Fittings and Equipment Cables and Associated Fittings and Equipment Cables and Associated Fittings and Equipment

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. See also CAAIP Leaflet 11-22 Apendix 24-3. Electrical Cable Failure and CAAIP Leaflet 11-22 Appendix 20-4, 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 Cable 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 product 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

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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. 2.3 Modification and Repair Cables used as replacements, or used for modifications of an aircraft, should be of a type approved by the manufacturer for that particular aircraft type unless an alternative is selected by an approved design authority. 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 manufactured overseas, the manufacturing sources approved by the aircraft manufacturer 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 standards achieved by aircraft manufacturers 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, MIL-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 Dept., 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 Stockists 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.

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Classification Of Cable 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 A82. The term 'Module Wire' is sometimes used for this class of cable in the USA.

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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).

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.

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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 specifications 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-XXXX. 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

Manufacturers Specifications Aircraft manufacturers 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 manufacturer, i.e. a cable which is 'approved' for use by one manufacturer 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 Materiel 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.

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

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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 40C rise by electrical heating and that operating temperature and installed life are directly related. The temperature rating of an airframe cable is determined by its construction as noted in paragraph 6, and will be classified at one of the following temperatures: 105C (obsolescent cable types), 135C, 150C, 210C and 260C. Clearly this temperature rating has to be known when evaluating any design application. 5.3 Cable Size Cable is usually identified by a size number which approximates to the A.W.G. (American Wire Gauge) size of the conductor. However, some cables employ a number which refers to the square millimeters 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 (CAAIP Leaflet 11-22 Appendix 24-3 should be observed). Current rating data usually relates to a temperature rise of 40C 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 20C 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 significantly 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 is provided.

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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 for 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 CAAIP Leaflet 11-22 Appendix 24-3 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 designs 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 CAAIP. Leaflet 11-22 Appendix 24-3.

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6 6.1

Cable Construction 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 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 135C Silver plated copper maximum continuous temperature 200C Nickel plated copper maximum continuous temperature 260C Nickel Clad plated copper maximum continuous temperature 260C 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 150C 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 designs available except in general terms. Extensive studies have been made, especially in the USA, in an attempt to determine an optimum cable type. The conclusions 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

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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 design perform well on the British Standard test for wet arc tracking - see paragraph 5.6. The most commonly used wrapped insulation material is Kapton1, 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 designs, 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 designs provide good overall performance including excellent mechanical strength, especially the newer higher hybrid types. 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 (BS G221) 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 CAAIP Leaflet 11-22 Appendix 24-3 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.

1. Kapton is a Du-Pont trademark

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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 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 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 CAAIP Leaflet 11-22 Appendix 20-4).

7.5

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

7.6

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

7.7

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

7.8

Poor Solderability It should be recognised that the quantity of free tin on 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 soon as the cable is manufactured and thus prolonged storage should be avoided. This is not the total list of cable problems but it does, perhaps, indicate the importance of specifying electrical cable of an appropriate type and quality. It is the design intent that the present generation of CAA Approved cables should last an airframe life but this will only be achieved if installations are designed and maintained with care and cable selection is made such that operating conditions, especially maximum temperature, seldom if ever, approach the specified limiting parameters.

Approved Cables A list of CAA Accessory Approved cables as at March 1989 is given in Appendix A.

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APPENDIX A - PART 1 CAA ACCESSORY APPROVED CABLES

The following is a list of Accessory Approved cables at the date of issue of this Information Leaflet. Information is supplied on the cable types where available. In all cases, the cables are approved for use in aircraft subject to limitations as specified in the appropriate DDP. For further information contact should be sought with the manufacturers. 1 1.1 B.I.C.C. Cable to Specification BS2G233 Approval Reference E14012 Description The cables are single and multicore airframe and interconnect, multicore sheathed airframe and interconnect and single and multicore screened and sheathed types. Conductors and braids are tin plated, the insulation and sheath being ETFE extruded and irradiated. Temperature range: -65C to +135C Size: Single core airframe 26 to 10 AWG Single core interconnect 26 to 18 AWG Sheathed and screened and sheathed airframe 1-4 cores, 26 to 16 AWG Sheathed and screened and sheathed interconnect 1-4 cores, 26 to 16 AWG 1.2 Cable to Specification ECM 63 Approval Reference E13458 Description The cables are single core or multicore metsheath, having conductors of tinned annealed copper or silver plated copper alloy insulated with extruded ETFE. Temperature range: -65C to +120C (tinned conductors) -65C to +150C (silver plated conductors) Size: Silver plated high strength copper alloy conductor size 26 and 24 AWG only. Tinned copper conductor size 22-12 AWG (Medium wall) NOTE: Thin wall cable also available, intended for internal wiring of equipment.

Silver plated high strength copper alloy conductors - size 24AWG only and tinned copper conductor - sizes 22-12 AWG (Thick wall). 1.3 Cable to Specification ECM 65 (ACT 260) Approval Reference E13528 Description The cables are single and multicore airframe and interconnect, multicore sheathed airframe and interconnect and single and multicore screened and sheathed types. Conductors and braids are nickel plated, the insulation and sheath being a composite of polyimide and PTFE. Temperature range: -65C to +260C

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Size: Single core airframe 24 to 12 AWG Single core interconnect 24 to 18 AWG Sheathed and screened and sheathed airframe, 1-4 cores, 24 to 16 AWG Sheathed and screened and sheathed airframe, 1-4 cores, 24 to 18 AWG 1.4 Cable to Specification ECM66 (ACT 150) Approval Reference E13663 Description The cables are single and multicore airframe and interconnect, multicore sheathed airframe and interconnect and single and multicore screened and sheathed types. Conductors and braids are silver plated, the insulation and sheath being a composite of polyimide and PTFE. Temperature range: -65C to +150C Size: Single core airframe 24 to 12 AWG Single core interconnect 24 to 18 AWG Sheathed and screened and sheathed airframe 1-4 cores, 24 to 16 AWG Sheathed and screened and sheathed interconnect 1-4 cores, 24 to 18 AWG 1.5 Cable to Specification ECM 45 Approval Reference E12560 Description Two core compensating cable comprising nickel chromium nickel aluminium conductors, insulated with layers of FEP coated Kapton tape and PTFE tape, sheathed with layers of Kapton tape and PTFE tape. Temperature range 55C top +260C 1.6 Cable to Specification ECM 47 Approval Reference E12020 Description Thermocouple extension cable - twin sheathed flat design having conductors of nickel chromium and nickel aluminium insulated with Kapton/glass fibre braid/coloured PTFE tape all sintered. The sheath over the flat twin is of Kapton tape and coloured PTFE tape (sintered). Temperature range 55C to +150C 1.7 Cable to Specification ECM 60 Approval Reference E12859 Description The cables are single core, having conductors of nickel coated copper. The insulation is a composite of silicone rubber, quartz and PTFE. Temperature range 40C to +260C

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1.8

Cable to Specification ECM 52 Approval Reference E12357 Description The cables are single core, having conductors of nickel coated copper. The insulation is a composite of silicone rubber, quartz and PTFE. Temperature range 40C to +260C

1.9

Cable to Specification ECM 44 (KP260) Approval Reference E12079 Description The cables are single core, screened and sheathed and multicore screened and sheathed having nickel plated copper alloy (size 24 only) or nickel plated copper alloy (size 24 only) or nickel plated copper conductors and braids insulated and sheathed where appropriate with a combination of PTFE and Kapton/FEP tapes are sintered. Temperature range 65C to +260C Sizes: Single core 24 to 12 AWG

Rists Wire and Cable Ltd.

2.1

Polyimide 3000SS (Code 1143 and 1144) Approval Reference E12518 Description Single core screened and sheathed Kapton insulated cables with silver plated copper alloy and silver plated copper conductors. Temperature range 65C to +150C

2.2

Polyimide 1500 (Code 1147) Approval Reference E12576 Description Single core Kapton insulated cable with a top coat of FEP lacquer having electro tinned copper conductors. Temperature range 65C to +135C Sizes: 22-12 AWG

2.3

Polyimide 2000 (Code 1148) Approval Reference E12577 Description Silver plated copper alloy and silver plated copper conductors with Kapton insulation.

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2.4

Type 6000 and 6000T Approval Reference E13787 Description Single core cables sizes 22-10 inclusive with silver plated copper conductors. Single core cable sizes 24 and 26 with silver plated copper alloy conductors. All cables insulated with FEP/Kapton/FEP tape and PTFE tape overall. Twisted single cables (two, three and four) also available sizes 26-16. Temperature range 65C to +150C

2.5

Type 7000 and 7000T Approval Reference E13844 Description Single core cables, sizes 22-10 inclusive with nickel plated copper conductors. Single core cables, sizes 26 and 24 with nickel plated copper alloy conductors. All cables are insulated with FEP/Kapton/FEP tape and PTFE tape overall. Twisted single cables (two, three and four) also available, sizes 26-16. Temperature range 65C to +260C

3 3.1

Raychem Limited Raychem Type 44 Approval Reference E11623 Description Silver plated high strength copper alloy conductors or tin plated copper conductors. The insulation is made up of radiation crosslinked polyolefin polymer with a protective sheath of polyvinylidene fluoride. The following part numbers are identified with respective limitations: 44A0811-XX-Colour 44A0812-XX-Colour 44A0814-XX-Colour 44A0211-XX-Colour 44A0212-XX-Colour 44A0214-XX-Colour 44A0111-XX-Colour 44A0112-XX-Colour 44A0114-XX-Colour 44A1211-XX-Colour 44A1212-XX-Colour 44A1214-XX-Colour 44A1111-XX-Colour 44A1112-XX-Colour 44A1114-XX-Colour XX denote AWG size Temperature range 75C to 140C

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Airframe constructions

Light Airframe/Interconnect construction

Thin wall equipment wire constructions

Screened and sheathed Airframe cable

Screened and sheathed equipment wire

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3.2

Raychem Type 55 Approval Reference E11749 Silver plated high strength copper alloy or tin plated copper or silver plated copper conductors. The insulation is made up of an extruded radiation crosslinked fluoropolymer. The constructions are types 1 and 2 in single, two, three and four conductors and 'metsheath' versions. A cross reference sheet between this specification and Raychem's type 55 wire part numbering system is given below: Type Type 1 single -XX (size)-colour Type 1 twisted pair -XX-colours Type 1 twisted triple -XX-colours Type 1 twisted quad -XX-colours Type 2 single -XX (size)-colour Type 2 twisted pair -XX-colours Type 2 twisted triple-XX-colours Type 2 twisted quad -XX-colours Type 2 single+screen+sheath-XX-colours Type 2 twisted pair+screen+sheathXX-colours Type 2 twisted triple+screen+sheathXX-colours Part Number 55A8022-24*to 10-X(colour) 55A8622-24*to 10-X/X (colours) 55A8623-24*to 10-X/X/X 55A8813-24*to 10-X/X/X/X 55A8776-24*to 16-X(colour) 55A8777-24*to 20-X/X 55A8778-24*to 20-X/X/X 55A8814-24*to 16-X/X/X/X 55A8744-24*to 16-X-X (sheath colour) 55A8745-24*to 16-X/X-X 55A8746-24*to 16-X/X/X-X

* Size 24 has silver plated high strength copper alloy conductors. All other conductors under the part numbers shown have tin coated copper conductors. Temperature range 75C to 150C 4 4.1 Societe Filotex Coaxial cables : RG58CU, RG214U, RG316U and RG142U Approval Reference AR454 4.2 Lightweight cable type KTTP Approval Reference AR452 Description Sealed lapped tape, tin plated design. 4.3 PTFE insulated 200C cable type Approval Reference AR413 KZ0405, EF2219 and KZ0607 (Equipment wire) 4.4 KPF 260 type, 260C, 600V to spec FX0502 Approval Reference AR321 4.5 Aluminium alloy conductor cable to spec SP545 for Airframe use Approval Reference AR283

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4.6

Efglas type (600V, 260C) - BSG222 Nickel plated copper + PTFE tapes, glass fibre tape and glass fibre braid coated with PTFE insulation. Size: 0000 - 10 AWG- AR648 12 - 22 AWG- AR649

5 5.1

Kabelwerke Reinshagen GmbH Types R200, R201 and R202 Approval Reference E13203 PTFE insulated wires

5.2

Types R197, R198 and R199 Approval Reference E13202 PTFE insulated wires

5.3

Types R195 and R196 Approval Reference E13201 PTFE insulated wires

5.4

Type No. R151YU Approval Reference E12806 Aluminium conductor, insulated FEP-coated polyimide film and braid

6 6.1

Huber and Suhner AG Huber and Suhner AG (80144 Series) Approval Reference E14011 Description The cables are available in types 01 (interconnect) and 02 (airframe) and consist of silver plated high strength copper alloy stranded conductors. The conductors are insulated with extruded radiation crosslinked polyolefine and sheathed with extruded radiation crossliked modified polyvinylidenefluoride of thickness individually defined for each type. Temperature range: -75C to 120C

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APPENDIX A - PART 2 : CAA ACCESSORY APPROVED CABLES NOW DECLARED OBSOLESCENT

The following is a list of obsolescent cables i.e. cables only acceptable for maintenance purposes on aircraft originally wired with such cable types and unsuitable for new designs. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 2 2.1 3 3.1 3.2 4 4.1 5 5.1 5.2 B.I.C.C. Minyvin (DDP H/TECH/P197) Nyvin (DPP H/TECH/P108) Minyvin, Duminyvin, Triminyvin and Minyvinmetsheath (DDP H/TECH/P114) Minyvin and Minyvinmetsheath (DDP H/TECH/P110) Duminyvinmetsheath and Triminyvinmetsheath (DDP H/TECH/P109) Metric Minyvin cables (DDP H/TECH/P119 and P120) Nyvin (DDP H/TECH/P103) Tersilsheath (DDP WGC/L/W/666) Uninyvinlarge (DDP H/TECH/P104) Minyvin (DDP H/TECH/P100) Flexyvin (DDP H/TECH/P101) Cable to spec ECM55 (AKB) Cable to spec ECM17 Cable to spec ECM49 KPSN (KP135) Fothergill and Harvey Limited Cable to spec 'FHK 254' Rists Wire and Cables Limited Flexvin (DDP No. 13) Minyvin (DDP No. 15) Societe Filotex PAN 6423 and 6425 (KTCL) Fileca Types AMO2, AMO4 and AMO6 Types FAMH02, FAMH04 and FAMH06 AR230 AR412 AR194 E6441 E8308 E12374 E7998 E7996 E9178 E8691 E8238 E11566 E6379 E6411 E6418 E4273 E4289 E12304 E13284 E12279

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APPENDIX B
Identification marks These marks are purely for identification purposes. New applications for marks should be made to the British Standards Institution, 2 Park Street, London, W1A 2BS. Use of the committee reference ACE 6 will assist BSI in dealing with the correspondence connected with this list. B1 Manufacturers' identification marks AEI Cables Ltd. WL Gore and Associates (UK) Ltd. British Insulated Callenders Cables Ltd. Pirelli General Cable Works Ltd. Reliance Cords and Cables Ltd. Rist's Ltd. Delta Enfield Cables Ltd. Huber and Suhner AG The Concordia Electric Wire and Cable Co. Ltd. Davu Wires and Cables Ltd. Duratube and Wire Ltd. Ripaults Ltd. London Electric Wire Co. and Smith's Ltd. Permanoid Ltd. Standard Telephones and Cables Ltd. Raychem Ltd. Sterling Cable Co. Ltd. Fothergill and Harvey Ltd., Tygadure Division Vactite Wire Co. Ltd. Connollys (Blackley) Ltd. Brand Rex Ltd. Crompton Parkinson Telephone Cables Ltd. B2 Country of origin identification marks United Kingdom Switzerland France GBX CHX FF AA AB BB CC DD EE FF GG HH KK LL NN PP QQ RR SS TT UU VV WW XX YY ZZ

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