10 - Cable Connector (EWIS) (140 Slides - 2 WK)

UNIVERSITI KUALA LUMPUR
Malaysian Institute of Aviation Technology
STUDENT’S NOTES
SUBJECT :
ELECTRICAL FUNDAMENTAL 1
Subject Code ELE 1042

Revision : Page No :1
Original Date : 15/01/07
TABLE OF CONTENT
Page
ELECTRON THEORY 04
STATIC ELECTIRCITY & CONDUCTION 20

ELECTRICAL TERMINOLOGY 37
RESISTANCE / RESISTOR 72
CAPACITANCE 87
GENERATION OF ELECTRICITY 129
INDUCTANCE / INDUCTOR 140

MAGNETISM 164
DC SOURCES OF ELECTRICITY 195

DC CIRCUITS 252

TABLE OF CONTENT
Page
POWER 276
ELECTRICAL TEST EQUIPMENT 288
CABLES AND CONNECTORS 334
REFERENCES 403

 Bonding
Jumper / Strap

 Bonding
Jumper / Strap

• Wire Bundle riding on Structure

Cause of wiring degradation
• Wiring is affected by :
Vibration
Moisture
Maintenance
Contamination
Heat
installation

• Bend Radii problem – Less than 10 times the

Diameter

• Heat Discoloration
• Clamp Damaged Insulation

• Overheated wire
at the Splice

✈ JAA TGL 47 & INT/POL/25/12-1

 Bonding Straps in Tanks
• Straps Missing, Broken, Loose. . .

• Straps Frayed/Worn as a result of
wing movement
✗ Lightning Strikes have resulted in the loss of
aircraft due to poor bonding!
✗ Poor/Missing bonds are often caused by
Maintenance Error! You are only 1 fault
away from an unsafe condition!
Subject Code
11ELE 1042
Revision : Fuel Tank Safety Training
Original Issue 1 Rev 0 Oct 2016
Phase 2


13. Cables and Connectors

 Aircraft
accident due
to bad
maintenance
practices.


• Wires improperly tied, riding on Hydraulic lines
• Wires contaminated with caustic fluid

13. Cables and Connectors (cont’d)


 Aircraft wire/cable
 Is defined as sheath (covered) wire
 Purpose as a medium for current flow &
complete the circuit (source → load →
ground).
 Designed to withstand extreme vibration,
abrasion & adverse weather condition
especially for high altitude flying ( T- 56.5
degree at 35000ft)

 Factor when choosing wire:
• Can carry the required current without producing

excessive heat or voltage drop.
• The insulation must prevent electrical leakage and strong
to stand abrasion.
 2 types of cable used:

• Copper strand
• Aluminum strand
 Stranded for protection against breakage from vibration


 Copper
 Used on almost all aircraft’s wiring
 Better conductor than aluminum
 Coated with tin, silver or nickel to prevent oxidation
 Size 22 – 4/0 (0000) AWG
 Before 1990’s, use MIL-W-5089
• Annealed copper coated with tin. (softened by
mean of heat treatment)
• PVC, nylon, glass braided insulator, rated to
600V

 Copper
 But PVC emits toxic fumes when burn.
 Copper has relatively high tensile strength (the greatest
stress a substance can bear along its length without
tearing apart).
 Copper can also be easily soldered.
 However, copper is more expensive and heavier than
aluminum.

 Aluminum
 MIL-W-7072
 Used for carrying large amount of current in long
distance
 Can replace copper due to copper’s high cost & limited in
market.
 More susceptible than copper – save weight
 Disadvantages:-
• Greater resistance
• Can carry 2/3 current of the same size copper wire
• Easily broken by vibration ( crystallize)

 Limitation of Aluminum Wire
• Wire smaller than 8 gauge is not allowed (easily broken)

• Never attached to engine mount / severe vibration area
• Do not install at frequent disconnect area
• Never use in length less than 3 feet
• Never use at corrosion fume area
• Not recommended for communication & navigation
(safety precaution during emergency)
 Aluminum wire that is 2 gauge number smaller ( 2 size

larger) than copper, carries the same amount of current.
 E.g. – replace 12 gauge of copper wire with at 10 gauge

wire of aluminum. Subject Code ELE 1042
Current carrying capacity of

a conductor of same wire
size

Aluminum wire that is 2

gauge number smaller
(2 size larger) than
Copper  carries the same
amount of current.
Ex. Copper size 6 – 100 A

Aluminum size 4 – 100 A

 Factors to be considered in selecting

wires/cables
 Conductor material and insulation
• Copper or aluminum material

• Flexibility – no. of strands
• Insulation material with ratings in heat, abrasion and
flexibility
• Length and type of installation also important in
selecting the correct size.

 Factors to be considered in selecting

wires/cables
 Current carrying capability
• Refer to table 11-9 and table 11-10, AC43-13-1B, pg

11-25
• Aluminum is best for large current for long distance.
o Save weight, allow lighter aircraft
• Wire size must be derated if routed in bundle

o Due to Heat generated in bundle

 Copper
wire


 Aluminum
wire

 Measured in:
 Wire sizes
- American Wire Gage (AWG)
- Standard Wire Gage (SWG)
 To determine wire size, use Wire

Gage Tool - insert stripped
portion.
 Gauge size related to cross

sectional area of wire
 Cross sectional is expressed in

circular mils

 Size of the wire is a function of its diameter & indicated by

a unit called circular mil
 1 circular mil is equal to cross sectional area of 0.001-in

diameter wire
 To determine the size in circular mils of a wire, simply

square the wire’s diameter measured in thousandths of an
inch.
 For example, the size of a wire that is 0.025 inch in

diameter is:
0.025 inch = 25 thousandths of an inch
252 = 625 circular mils
The smaller the AWG number, the larger the wire size

 Allowable Voltage Drop
 specify the allowable voltage drop for different

system voltage
Nominal Allowable Voltage Drop
System Continuous Intermittent
Voltage Operation operation
14 0.5 1.0
28 1.0 2.0
115 4.0 8.0
200 7.0 14.0

 To choose the wire size for given length, current,

voltage system, use wire chart (copper only)
 To determine wire size for given length:

• 1st , determine the operation voltage
• 2nd , the allowable voltage drop
• 3rd, either operate as continuous or intermittent
 Refer chart
 To find wire size for aluminum, follow steps as for

copper then convert to aluminum
 The curves represent the ability of a wire to carry

current without overheating


Example 1 :
A cow flap motor draws intermittent current of 6 Amp for 28 V system
with 40 feet length for installation. Find suitable wire size for this system
without causing overheating.
To find wire size for given length
a. 1st , know the operating voltage – 28V
b. 2nd , length of wire – 40 feet
c. 3rd , operating current – 6 Amp
d. 4th , continuous or intermittent - intermittent
e. 5th , refer chart for wire size
The correct cable size for this system is size ______ AWG
Example 2:
i) Voltage system = 14 V
ii) Wire length = 12 ft
iii) Cables in conduit
iv) Current = 70 A
Find wire size for given length.
a) The correct cable size for this system is size ______ AWG
b) The wire size for aluminum cable is ______ AWG


 Types of Wires
Coaxial Cable
Two core twisted shielded wire
Single core shielded wire

Single core unshielded wire

 Single wire / cable (shielded / unshielded)

Twisted Pair
 Multiple core wire /cable twisted

(shielded / unshielded) Twisted
unshielded pair
 Coaxial Cable
Conductor Conductor
Twisted
shielded pair
Insulation -
Radiation Crosslinked,
Modified ETFE Insulations -
Radiation Crosslinked, Modified ETFE Inner layer colored blue
Pair Shielded & Jacketed Primary Wire Twisted Pair

Single Pair

 Single wire / cable (unshielded)
• Most aircraft wires are of stranded wire.

• Available as Single Wire or Twisted Wire (2 or 3 or 4 core/wire).
• Common size used from AWG 0 to 24
• AWG 24 and 22 normally for signal wires e.g. communication

and navigation system.
• AWG 20 and 18 normally for Avionics system power and ground
wire.
• AWG 0 to 6 normally for electrical power wire e.g. generator and
battery.


• The insulations may stand up as high as 1000V voltage rating.
• PVC  221 F or 105 C.
• Fluorocarbon materials  392 F or 200 C.
• Commonly used type of wires
- Mil-W-22759 – PTFE, ETFE Insulated, Copper or Copper
Alloy Conductor airframe wire.
Stranding Finished Wire
Wire Size
Part Number (Number of Strands x Diameter
(AWG)
AWG Size of Each Strand) (Inches)
M22759/34-24-XX 24 19 x 36 0.045 ± 0.002
M22759/34-22-XX 22 19 x 34 0.050 ± 0.002
M22759/34-20-XX 20 19 x 32 0.058 ± 0.002
Note:"XX" in the part number shall be replaced with the desired color code designators in accordance with MIL-STD-681


- Mil-W- 81044 – Irradiated wire for aircraft and hook-up.
Conductor:
Soft annealed tinned copper, stranded as listed.
Insulation:
Irradiation cross-linked extruded Polyalkene meeting the requirements of Mil-W-81044/9
Jacket:
Clear Irradiation cross-linked extruded Polyvinylidene Flouride (PVF) with a wall thickness of 0.005
+/- .001 inches on Mil-W-81044/9.
Ratings:
150°C conductor temperature, 600 Volts.
Cable – any group of two or more conductors separately

insulated & grouped together by an outer sleeve
 Shielded wire / cable

• A stranded wire with insulated wire that encased in a braided
metal jacket. Then protected from abrasion with nylon jacket.
• To avoid interference from external or internal signal source.
• Available as a single wire or twisted pair (2 cores) or twisted 3
or 4 cores.
• Twisted cable/wire is to cancel the electromagnetic field
produced by the wires when the current flow into it.
• Electromagnetic field produced by AC causing interference to
electronic equipment.

 Shielded wire / cable
• To prevent radio frequency interference (RFI) – shielding the

wire
• Usage e.g. : magnetic compass; the wires in the shielded wire
is twisted to reduce magnetic fields effect.- cancel each other
- Mil-W-27500 – PTFE, ETFE Insulated, Copper or Copper
Alloy Conductor airframe wire.
e.g. P/N: M27500C26SD4S23, where
M27500 C 26 SD 4 S 23
Military Individual Basic Wire Number of
Braid Shield Outer
Specification Wire Size Insulation Wires in
Coverage Coating Jacket
Number (AWG) Type Cable

Shielded & Jacketed

Twisted Pair
Single Pair
Twisted
unshielded pair
Twisted
shielded pair
Shielded wire or cable

 Coaxial cable
• Also called “Coax Cable”.

• Mainly for Communication & Navigation equipment.
• Antennas to its receivers.
• Braided metal:- hold in RFI & protect from outside RFI
- Mil-W-17 – Coaxial Cable
Detail Type Generic Type Impedance Cable

Specification Designation Designation (Ohms) Type
MIL-C-17/60 M17/60-RG142 RG142/U 50 ± 2 Flexible
MIL-C-17/93 M17/93-RG178 RG178/U 50 ± 2 Flexible


 Wire Marking
 To provide:
- safety of operation.
- safety of maintenance personnel.
- ease of maintenance.
 No standard system
 Consist of combination of letter & number
 Should identify:
- type of circuit
- location in circuit
- section of wire from power source
- wire size
e.g. : L21A20N
L – lighting
21 – 21st wire in circuit
A – 1st segment of wire
20 - Wire gage
N – connect to ground
 Some use 2 letter identification  give detail location
 Place wire marking at:

- 12” to 15” interval along a wire, for hot stamping or laser marking
- 24” to 36” interval along a wire, for sleeve marking.

Ex : L21 A20N
L – lighting
21 – 21st wire in circuit
A – 1st segment of wire
20 – wire gauge
N – connect to ground


 Wire Marking
 At each end of wire
 Wire less than 3” long  No marking

required
 Wire 3” - 7” long  mark at the center
 Print to read horizontally from left to right

 Print vertically from top to bottom
 Color should be contrast with wire

insulation
 Should not impair the characteristic of the
wire
 Method of Marking
 Direct marking
- print on the outer covering

 Methods of Wire Marking

 Indirect Marking
- used on coax cable, bundle.
- use printed heat-shrinkable sleeve/ tubing/ pressure-sensitive
tape (in the form of small flag).
- individual wire inside cable  marked within 3” from end.
- metallic sleeve/band MUST NOT be used.
 Types of wire marking

- hot stamp
- dot matrix
- ink jet
- laser
- heat shrinkable sleeves
- tape
Hot-stamping
marking
machine
Laser marking machine
Heat shrinkable sleeve marking

Heat shrinkable sleeve marking Pressure Sensitive Tape

 Wire Bundle
 A compact group of electrical wires held together with
special wrapping devices or waxed string.
 for neatest, organized and efficient routing.

Wire Bundle

 Limit the number of wires in a bundle :-

- the number of wires in a bundle should be less than 75 wires or
- the size of diameter is 1½ to 2 inches.
 to prevent possibility of single wire faulting & damage entire

bundle
 main and back-up system wire CANNOT be bundled together.
 ignition wire, shielded wire and wires unprotected from circuit

breaker SHOULD be SEPARATED
 bend radii for bundle - more than 10 times the outside diameter of
bundle.
 Tying & Lacing

 Tie the bundle every 3-4 inches
 Tie with nylon strap (TYRAP), or spot
ties made of waxed linen or nylon
cord.
 2 types of lacing:
1) Single-cord lacing.
+ used for diameter of 1 inch or less.
+ can be continuous series of loop or single ties (clove
hitch secure with square knot).

Spot Tie Using Wax Linen or Nylon Cord
Tyrap Gun
Continues series of loop

Single ties – clove hitch secure

with square knot
 Tying & Lacing
2) Double-cord lacing
 for larger bundle.
 Lacing should not be used for bundle

installed around an engine since a break in
the lacing cord, loosens an entire section
of the bundle.
 After tied, some are covered with heat-

shrinkable tubing, spiral wrap & others.

Double Cord Lacing

Wire Bundle Wrapped With Coil Spaghetti

 Wiring Installation
 Open Wiring
- Wires/bundles route through aircraft without protective covering
- quickest & easiest way to install and troubleshoot
- at area exposed to outside environment, use good abrasive
resistance insulated wire & low moisture absorption
 Conduit
- to provides mechanical protection & metal conduit as shielding
- enclosed wires in rigid (thin metal tubing) or flexible (braided
metal) conduit

Open Wiring

Open Wiring

Flexible Braided Metal Tubing
Wire Bundle In Conduit

 Examples of protection of aircraft cable:
• aircraft cable is protected against chaffing or abrasion of the

insulator using rubber grommet or cut nylon, against the a/c
structure
• a/c cable that is route in the wheel well area is protected

against soaking in hydraulic fluid using rubber sleeve.
• a/c cable that run along the engine is protected against heat by
TEFLON tape or Fiberglass material in the cable.

 Shielding
 Shielding = intercepting the electrical energy and shunting it to
ground (the field is trapped by the braided metal and carry to the
ground).
 protect from electromagnetic interference by wire carrying

Alternating current.
 consist a braid of tin-plated or cadmium-plated copper wire.
- connected to ground thru a crimped-on ring terminal.
 in electrical system – both end grounded.

 in electronic system – only one end grounded.
 DO NOT solder the connection since it may overheat and cause
to break.
Shielded & Jacketed

Single Pair
Shielded Wire

 Routing Wire
 Route without interfere with controls or moving components
unless mechanical guard is installed
 DO NOT route it:
- in location likely be used as a handhold
- in place that it can be damaged by person entering or
leaving the area, or by any baggage or cargo
- closer than 6 inches from the bottom of fuselage (bilge)
- below a battery
- closer than 3 inches from control cable

 Overhead routing is preferable

 Routing Wire
 If need to be routed parallel to
oxygen or fluid lines, wiring
MUST be above or same
level, and no closer than 6
inches from lines.
 Use clamp to support wires &

center it through a bulkhead
hole.
- install grommet if clearance

less than ¼ inch or 3/8 inch.

 Clamping
 Secure bundle close enough together with cushioned clamps

to avoid wire sagging and vibrate excessively.
 Allow slack of ½ inch deflection between 2 supports.

- Enough slack at last support/each end
- For easier removal or installation.
- To prevent mechanical strain.
 To permit shifting component for maintenance.

 Spaced with interval not exceed 24 inches.
 Assure not to pinch the wire by using correct size of clamp.



 Wire Terminations
 Wire/Cable Terminals
• Also known as connector, tag, lug or cable end.
• Purpose: to allow the cable be connected on electrical

components.
• Wire terminals are of :
- The preinsulated/ insulated type

- Non insulated type
Preinsulated Terminal Lug

Non Insulated Terminal Lug

WIRE TERMINATIONS
• Permanently installed wires are terminated with crimped-on terminals (solderless terminals)
• For frequent connection and disconnection, AN/MS quick disconnect connectors are used.
1. Wire/Cable Terminals
 - also known as connector, tag, lug or cable end
 - purpose is to allow the cable be connected on electrical components
 - there are three types of wire terminals:
 a. Ring type – most common or preferred type
 - not easy to disconnect or slide
 - used to connect on stud or electrical ground
 - the tongue or tag provides support the wire strands and also
 indicates wire size

Revision :
Original
WIRE TERMINATIONS - cont
 b. Hook type – also known as spade type

 - use to connect on instruments
 c. Slotted type – not commonly used
 - easy to dislocate
Ring Type Hook Slotted Type

Type
Revision :
Original
WIRE TERMINATIONS - cont
 Wire terminals are of :

a. The preinsulated/insulated type
Are used by cable of size AWG 10 and below; and color-coded
as:
 i. Small Yellow – AN 26 to AN 22
 ii. Red - AN 20 to AN 18
 iii. Blue - AN 16 to AN 14
 iv. Large Yellow – AN 12 to AN 10

Revision :
Original
 Stripping
• Cutting the insulation & pulling it from the end of wire.
• Expose as little conductor as necessary.
• Not to damage the conductor beyond limit.
• Use correct size stripper.
• FAA specifies limit for allowable nicked or broken strands.

- E.g.: copper 20AWG with 19 strands – 2 nicked, no broken
• Larger the number of strands, the greater the acceptable

number of nicked/broken
• Also reduce current carrying capability of the wire

To remove the insulator from the conductor use wire stripper

 Crimping
• Crimping is the squeezing of terminal around a wire to secure
the wire & provide a good electrical connection.
• 2 types of crimping tool used are:
- Ratchet crimping tool

+ is most preferable & meet specification.
+ it will not open until proper size is reached
+ are classified as:
Pre Insulated Diamond Grip (P.I.D.G)
Diamond grip (D.G)
- Pneumatic crimping tool

+ is used on bigger cable, size AWG 0 - 0000
CrimpingTools
Crimping tool for bigger cable sizes from AWG 0 – 0000

When crimping, one will crimp the

barrel for good conductivity and
other will crimp insulation support
to prevent wire strain




 Wire Splices
• Crimped-on pre-insulated splice - Color-coded

like wire terminals
• For non-insulated splice, protective sleeve must

be installed to prevent shorting.


There should NOT be more than one splice

between two connection or each wire segment
Staggered Splices In Wire Bundle

Terminal Strips
Wires are usually joined at terminal strips.
A terminal strip fitted with barriers may be used to prevent

the terminals on adjacent studs from contacting each other.
Studs should be anchored against rotation.
When more than four terminals are to be connected

together, a small metal bus should be mounted across two
or more adjacent studs.

 Terminal Strips
• Made of plastic or paper-base phenolic compound.

• High mechanical strength.
• Good insulator.
• Groups of threaded stud mounted into the strip.

• Studs from size 6 up to 1 inch of diameter are available.
• Small size for low current.

• For power circuit, studs size 10 (smallest) and above are normally
used.
• Wires terminated with crimped-on terminals are secured to the

threaded stud with washer and nut.

• Make sure the terminal’s contact surface carry the current, not terminal
strip’s stud.
• Most aircraft use is of barrier type.
• Barrier between the adjacent to keep wires separated.
• Ideal installation, two terminals for one stud.
• Should NOT be more than four terminals stacked on one stud.

• For more than four terminals, use Bus Strap to join the studs together.
• Bus Bar can be made from terminal strip with the use of Bus Strap.
• When stacking four terminals, the wire butts are offset to another and
make the lie flat.
• These mainly used for interconnection of wiring or mostly using as

grounding junction.



 Terminal Junction Module Type
• These mainly used for interconnection of wiring or mostly using as

grounding junction.
• Using pin which is crimped to the wire and insert in the module.
• The module pins come with several wire sizes.

Junction Boxes
Junction boxes are

used for collecting,
organizing, and
distributing circuits to
the appropriate
harnesses that are
attached to the
equipment

 Terminal Junction Box

• It housed the terminal strips.
• To protect wire from physical damage &
electrical short circuit.
• Wire bundle installation in the junction box

must be proper to avoid chafing.
• for fire resistance  aluminum or an

acceptable plastic material.
• for fire proof Stainless steel / heat

resistance alloy  placed at high heat/ fire
area

 Bonding/ Grounding
• Bonding is a process that grounds all components in a\c together
electrically
• Bonding to metal airframe with conductor to eliminate the build up of

unwanted static charges.
• Figure shows the proper ground terminal arrangement.
• To reduce interference and possibility of fire.
• Bonding strap :
- must be large enough to handle all return current.
+ Resistance between component & a/c structure = 0.005 ohm
or less.
+ Resistance of bonding strap is 0.003 ohm or less.

• Bonding strap
- long enough for free movement.
- made of material that does not produce galvanic corrosion.
+ Use aluminum washer to minimize corrosion to a/c.
+ Recommended to use jumper made of aluminum
+ Copper jumper use with part made of stainless steel,
cadmium plated steel, copper, brass or bronze.
- should have enough mechanical strength to withstand constant

flexing.
- should easily installed to allow removal of bonded component.
• Grounding to provide return path for electrical components

• Grounding performed on most ground equipment
• Particularly during fueling, cause fire hazard from static charges spark
at fuel opening


Grounding

Grounding
 AN/ MS Connectors
• Installed on wire that frequently disconnect for easier
removal and reinstallation. Ex: avionic components.
• 2 types of common connector are:

- AN (Army Navy)
- MS (Military Spec.)
• Connector consists of 2 parts:
- Socket (receptacle) – female

- Pin (plug) – male

• Wire installed to pin/socket connector by:
- Crimping
+ Pin/sockets are first crimped to wire then :
- slipped into connector  by insertion tools
- to remove wire  use extraction tools
+ 1/32 to 3/32 wire exposed
- Soldering.
+ Less used
+ Apply small amount of solder to stripped wire (tinning process)
+ Fill solder pot with solder
+ Insert the wire while keeping the solder pot molten.
+ Hold the wire until solder solidifies
+ Should leave about 1/32 of an inch stranded wire between the top of
solder pot and the insulation for flexibility.
Wire installed to the connector either by

crimping or soldering

• Since more than one of the same type connector may be installed,
insert orientation identification becomes very important.
• Insertion slot prevent wrong mating part connected together.
• To reduce accidental short, power connection uses socket while

ground side (load connection) uses pins.



 Soldering
• Is a process of joining 2 metals together permanently
using an alloy to form a reliable electrical connection
thru wetting action.

When exposed to heat, solder react into 3 stages :

Ex : solid > plastic form > liquid form
Solder when melted flow from hot area to cold area

Soldering Station Solder Pump

Clean the iron "bit"  (soldering iron tip) using a damp

sponge.
The soldering iron featured is an Ungar Concept 2100 Soldering Station. Other
popular brands of soldering equipment include Weller and Antex
Revision :
Original
Cleaning of soldering iron tip

Apply a clean soldering iron tip to the copper solder

pad and the component lead, in order to heat both
items at the same time.

Revision :
Original
 Continue heating and apply a few millimetres of solder.

Remove the iron and allow the solder joint to cool
naturally.

Revision :
Original
 It only takes a second or two, to make the perfect joint,

which should be nice and shiny. Check the Guide for
troubleshooting help.
Revision :
Original
It should flow smoothly onto the lead and track to form a volcano shape as shown in the
diagram. Apply the solder to the joint, not the iron.
It should look shiny and have a 'volcano' shape. If not, you will need to reheat it and feed
in a little more solder. This time ensure that both the lead and track are heated fully before
applying solder.
Joint should be free of ‘icicling’, ie. sharp points of solder which may cause arcing or corona
effects.
The mechanical strength of a soldered joint shouldn’t be checked by twisting, pulling

or pushing a component or lead  poor/broken connection
Bad Soldering
1. A tenfold excess of solder on this hand-soldered printed

circuit board, and (extreme left) an incomplete solder joint with
poor coverage. There is no need to add more solder "for luck".
Revision :
Original
END OF TOPIC 13
CABLES AND CONNECTORS

Mini Quiz to check your understanding

1. ?
(A) .
(B) .
(C) .
2. ?
(A) .
(B) .
(C) .
3. ?
(A) .
(B) .
(C) .
Thank You
KP(JPS)5195/US/38

REFERENCES
 Jeppesen Sanderson Training
Product A& P Technician Airframe
Textbook.


10 - Cable Connector (EWIS) (140 Slides - 2 WK)

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UNIVERSITI KUALA LUMPUR

Malaysian Institute of Aviation Technology

Subject Code ELE 1042

STATIC ELECTIRCITY & CONDUCTION 20

INDUCTANCE / INDUCTOR 140

DC SOURCES OF ELECTRICITY 195

Subject Code ELE 1042

Subject Code ELE 1042

Subject Code ELE 1042

Subject Code ELE 1042

• Wire Bundle riding on Structure

Subject Code ELE 1042

Cause of wiring degradation

Subject Code ELE 1042

• Bend Radii problem – Less than 10 times the

Subject Code ELE 1042

• Clamp Damaged Insulation

Subject Code ELE 1042

Subject Code ELE 1042

✈ JAA TGL 47 & INT/POL/25/12-1

• Straps Missing, Broken, Loose. . .

Subject Code ELE 1042

Subject Code ELE 1042

13. Cables and Connectors

Subject Code ELE 1042

Subject Code ELE 1042

• Wires improperly tied, riding on Hydraulic lines

• Wires contaminated with caustic fluid

Subject Code ELE 1042

13. Cables and Connectors (cont’d)

Subject Code ELE 1042

13. Cables and Connectors (cont’d)

Subject Code ELE 1042

 Factor when choosing wire:

• Can carry the required current without producing

 2 types of cable used:

 Stranded for protection against breakage from vibration

Subject Code ELE 1042

Subject Code ELE 1042

13. Cables and Connectors (cont’d)

Subject Code ELE 1042

Subject Code ELE 1042

 Limitation of Aluminum Wire

• Wire smaller than 8 gauge is not allowed (easily broken)

 Aluminum wire that is 2 gauge number smaller ( 2 size

 E.g. – replace 12 gauge of copper wire with at 10 gauge

Current carrying capacity of

Subject Code ELE 1042

Aluminum wire that is 2

Ex. Copper size 6 – 100 A

Subject Code ELE 1042

 Factors to be considered in selecting

• Copper or aluminum material

Subject Code ELE 1042

 Factors to be considered in selecting

• Refer to table 11-9 and table 11-10, AC43-13-1B, pg

• Wire size must be derated if routed in bundle

Subject Code ELE 1042

Subject Code ELE 1042

Subject Code ELE 1042

Subject Code ELE 1042

 To determine wire size, use Wire

 Gauge size related to cross