Академический Документы
Профессиональный Документы
Культура Документы
Sect 2 Chap 4
SECTION 2
CHAPTER 4
MS25036
MS25274
REFERENCE SPECIFICATIONS
2.
The following specifications are applicable to
electrical wiring installation:
AN742
AN936
AN960
MIL-DTL-23053
MIL-DTL-25038
MIL-DTL-5593
MIL-DTL-8777
MIL-DTL-8794
MIL-I-631
MIL-K-81786
MIL-PRF-46846
MIL-PRF-8516
MIL-T-81714
MIL-W-22759
MIL-W-81044
MS18029
MS21919
MS25435
MS3373
MS35489
MS51957
NAS1070
NASM21042
NASM21266
NASM22529
NASM25440
NASM35338
NASM35649
NASM35650
NASM961
NEMA
WC27500
SAE AS25281
SAE AS27212
SAE AS50881
SAE AS 6136
MIL-I-7444
SAE AS735
DEFINITIONS
3.
The following definitions are applicable to electrical
wiring installation:
6.
Wiring specifications generally limit the size of wire
bundles to 5 cm diameter.
a.
e.
7.
When several wires are grouped at junction boxes,
terminal boards, panels, etc., retain the identity of the
group within a bundle by spot ties, as shown in Figure 4
1.
f.
Combing Wires
8.
Comb out all wires, except those listed in
paragraph 9, so that wires will be parallel to each other in
a group or bundle.
Twisting Wires
WIRE TYPES
4.
The wires most commonly used in aircraft
electrical systems are in accordance with the
specifications listed in Table 41. See Section 2, Chapter
1, for details of conductor, insulation, voltage and
temperature.
9.
When specified on applicable engineering
drawings, twist together the following wires:
a.
Aluminium
High Temperature
Fire Resistant
MIL-W-22759
N/A
MIL-DTL-8777
*MIL-W-22759
MIL-DTL-25038
#22
#20
#18
#16
#14
#12
#10
#8
#6
#4
2 Wires
10
3 Wires
10
10
7.5
6.5
10
8.5
6.5
5.5
e.
f.
Bend Radii
Slack
12. Do not install single wires or wire bundles with
excessive slack. Slack between support points such as
cable clamps should normally not exceed 12.7mm. (See
Figure 43.) This is the maximum that it should be
possible to deflect the wire with moderate hand force.
This may be exceeded if the wire bundle is thin and the
clamps are far apart but the slack must never be so great
that the wire bundle can touch any surface against which
it may abrade. Allow a sufficient amount of slack near
each end for any or all of the following:
a.
CAUTION
Never bend coaxial cable to a smaller radius than six
times the outside diameter.
14. When it is not possible to hold the bending radius
of single wires to the above limits, enclose bend in tight
plastic tubing for at least 5cm each side of the bend.
f.
k.
l.
Support
18. Bind and support wire and wire bundles to meet
the following requirements:
a.
f.
j.
Protection
19. Install and route wires and wire bundles to protect
them from the following:
a.
Chafing or abrasion.
b. High temperature.
c.
e.
i.
f.
j.
CAUTION
Do not depend on insulating sleeving as protection
against abrasion or chafing, or as a substitute for
good routing practice.
CAUTION
Never use a low temperature insulated wire to
replace a high temperature insulated wire.
22. Many coaxial cables have soft plastic insulation
such as polyethylene. These are especially subject to
deformation and deterioration at elevated temperatures.
Avoid all high temperature areas with these cables.
CAUTION
Do not route any wire so that it can possibly come
closer than 12.7mm to a plumbing line. Factory
installed wiring within 12.7mm of a fluid line should be
moved when possible. If moving the wiring is not
possible, the wiring should be wrapped, tied, and
clamped to maintain separation from the fluid line.
CAUTION
Never support any wire or wire bundle from a
plumbing line carrying flammable fluids or oxygen.
Clamps may be used only to Ensure separation.
CAUTION
If it is necessary to move or repair wires which have a
protective jacket with a drainage hole at the low point,
make sure drainage hole is still at the low point
afterward. If the location of the low point has
changed, punch a new hole in the protective jacket at
the new low point.
CONDUIT
Introduction
33. Conduit is used to protect electric wire and cable
from abrasion, corrosive fluids, high temperatures, RF
interference, and damage from cargo handling or
activities of aircraft personnel. Extensive use of conduit is
undesirable because of weight therefore it is used only in
areas where harmful conditions exist, in parts of aircraft
hard to get at for permanent installation, and in short runs
compatible with its protective function.
34. Conduit is available in metallic or non-metallic
(plastic) form. Metallic conduit is either rigid or flexible;
non-metallic conduit is flexible.
METALLIC CONDUIT
Damage Limitations
35.
a.
Minimum Bend
Radii (mm)
3.175
9.525
4.75
14.275
6.35
19.05
9.525
28.575
12.7
38.1
15.875
47.625
19.05
57.15
12.4
76.2
31.75
95.25
38.1
114.3
44.45
133.35
50.8
152.4
NON-METALLIC CONDUIT
40. Non-metallic conduit is made of flexible plastic
tubing, conforming to Military Specifications MIL-I-631 or
MIL-I-7444. There is no specification for rigid non-metallic
conduit; phenolic tubing is sometimes used.
HEAT-SHRINKABLE TUBING
41. In certain applications heat shrinkable tubing may
be an appropriate alternate to flexible conduit. Details of
various types of heat-shrinkable tubing are listed below.
SAE AMS-DTL-23053/4, Class 2
42. Table 44 provides details of SAE AMS-DTL23053/4 Insulation Sleeving, Electrical, Heat Shrinkable,
Polyolefin, Dual-Wall, Outer Wall Crosslinked, Class 2
(Flame Retardant). This sleeving consists of an outer wall
which shrinks and an inner wall that flows when heated. It
is rated from -55C to 110C and has a dielectric strength
of 500 volts/mil. Heat shrinkable dual wall sleeving is
suitable for one step potting, encapsulating, or moisture
sealing of electrical components.
SAE AMS DTL-23053/5, Class 1
43. Table 45 provides details of SAE AMS-DTL23053/5 Insulation Sleeving, Electrical, Heat Shrinkable,
Polyolefin, Flexible, Crosslinked, Class 1 (Flame
Resistant). This sleeving is rated from -55C to 135C
and has a dielectric strength of 500 volts/mil. Heat
shrinkable flexible polyolefin sleeving is suitable for light
duty harness jackets, wire colour coding, marking or
identification.
SAE AMS-DTL-23053/8
SAE AMS-DTL-23053/12
44.
Table 46 provides details of SAE AMS-DTL23053/8 Insulation Sleeving, Electrical, Heat Shrinkable,
Polyvinylidene Fluoride, Semi-Rigid, Crosslinked. This
sleeving is clear and is rated from -55C to 175C. It has
a dielectric strength of 800 volts/mil up to 12.7mm
diameter and 600 volts/mil over 12.7mm diameter. Heat
shrinkable semi-rigid polyvinylidene fluoride sleeving is
suitable for wire or termination strain relief.
45. Table 47 provides details of SAE AMS-DTL23053/12 Insulation Sleeving, Electrical, Heat Shrinkable,
Polytetrafluoroethylene. This sleeving is produced in 5
classes (which relate to wall thickness) and is rated from
-67C to 250C. It has a dielectric strength of 800
volts/mil. This sleeving is suitable for use in areas where
resistance to flame and high temperature is required.
Minimum Inside
Diameter Expanded
(mm)
M23053/4-201-*
6.05
3.18
0.74 0.13
M23053/4-202-*
9.02
4.75
0.74 0.13
M23053/4-203-*
12.07
6.35
0.76 0.13
M23053/4-204-*
18.09
9.53
0.89 0.13
M23053/4-205-*
24.13
12.70
1.07 0.13
M23053/4-206-*
36.20
19.05
1.19 0.13
Notes:
1.
* is replaced with appropriate number to indicate colour. (0-Black, 2-Red, 4-Yellow, 9-White, etc.)
Minimum Inside
Diameter Expanded
(mm)
M23053/5-101-*
1.17
0.58
0.41 0.08
M23053/5-102-*
1.60
0.79
0.43 0.08
M23053/5-103-*
2.36
1.17
0.51 0.08
M23053/5-104-*
3.18
1.58
0.51 0.08
M23053/5-105-*
4.75
2.36
0.51 0.08
M23053/5-106-*
6.35
3.18
M23053/5-107-*
9.53
4.75
0.64 0.08
M23053/5-108-*
12.70
6.35
M23053/5-109-*
19.05
9.53
M23053/5-110-*
25.40
12.70
M23053/5-111-*
38.10
19.05
M23053/5-112-*
50.80
25.40
M23053/5-113-*
76.20
38.10
M23053/5-114-*
19.60
50.80
0.64 0.08
0.64 0.08
0.76 0.08
0.89 0.13
1.02 0.15
1.14 0.18
1.27 0.20
1.40 0.23
Notes:
1.
10
* is replaced with appropriate number to indicate colour. (0-Black, 2-Red, 4-Yellow, 9-White, etc.)
Minimum Inside
Diameter Expanded
(mm)
M23053/8-001-C
1.17
0.58
0.25 0.05
M23053/8-002-C
1.60
0.79
0.25 0.05
M23053/8-003-C
2.36
1.17
0.25 0.05
M23053/8-004-C
3.18
1.58
0.25 0.05
M23053/8-005-C
4.75
2.36
0.25 0.05
M23053/8-006-C
6.35
3.18
M23053/8-007-C
9.53
4.75
0.31 0.08
M23053/8-008-C
12.70
6.35
M23053/8-009-C
19.05
9.53
M23053/8-010-C
25.40
12.70
M23053/8-011-C
38.10
19.05
0.31 0.08
0.31 0.08
0.43 0.08
0.48 0.08
0.51 0.08
Notes:
1.
* is replaced with appropriate number to indicate colour. (0-Black, 2-Red, 4-Yellow, 9-White, etc.)
Minimum Inside
Diameter Expanded
(mm)
Class 1 - Thick
Wall
M23053/12-101-*
4.22
3.30
M23053/12-102-*
0.76 0.13
6.35
4.90
M23053/12-103-*
0.76 0.13
8.38
6.53
M23053/12-104-*
0.76 0.13
10.54
8.13
M23053/12-105-*
0.76 0.13
12.65
9.73
M23053/12-106-*
0.76 0.13
14.73
11.38
M23053/12-107-*
16.92
12.95
0.76 0.15
M23053/12-108-*
19.00
14.53
M23053/12-109-*
21.08
16.18
M23053/12-110-*
23.24
17.78
M23053/12-111-*
25.4
19.41
M23053/12-112-*
29.72
22.63
M23053/12-113-*
33.78
25.91
0.76 0.15
0.76 0.15
0.76 0.15
0.81 0.15
1.01 0.18
1.14 0.18
1.27 0.20
11
Minimum Inside
Diameter Expanded
(mm)
1.27
0.69
M23053/12-203-*
0.30 0.05
1.52
0.99
M23053/12-206*
0.40 0.07
2.16
1.37
M23053/12-208-*
0.40 0.07
3.05
1.83
M23053/12-212-*
0.40 0.07
4.32
2.57
M23053/12-216-*
0.40 0.07
6.10
3.58
M23053/12-220-*
9.40
5.69
0.51 0.10
M23053/12-224-*
11.43
7.90
M23053/12-227-*
11.94
8.54
M23053/12-230-*
19.05
13.31
M23053/12-232-*
28.78
19.96
M23053/12-233-*
33.28
23.14
M23053/12-234-*
38.10
26.31
0.51 0.10
0.51 0.10
0.64 0.15
0.64 0.15
0.90 0.20
0.90 0.20
0.90 0.20
Class 3 - Thin
Wall
0.86
0.38
M23053/12-301-*
0.23 0.05
1.17
0.56
M23053/12-303-*
0.25 0.07
1.52
0.99
M23053/12-306-*
0.30 0.07
1.93
1.24
M23053/12-308-*
0.30 0.07
3.05
1.83
M23053/12-312-*
0.30 0.07
4.82
2.57
M23053/12-316-*
6.10
3.58
0.30 0.07
M23053/12-320-*
9.40
5.69
M23053/12-324-*
10.92
7.06
M23053/12-327-*
11.94
8.81
M23053/12-330-*
0.38 0.10
0.38 0.10
0.38 0.10
0.38 0.10
Class 4 - Very
Thin Wall
12
M23053/12-401-*
1.27
0.64
M23053/12-403-*
0.15 0.05
1.52
0.97
M23053/12-406-*
0.15 0.05
2.16
1.37
M23053/12-408-*
0.15 0.05
2.79
1.60
M23053/12-412-*
0.15 0.05
4.32
2.51
M23053/12-416-*
0.20 0.05
6.10
3.53
M23053/12-420-*
9.40
5.44
0.20 0.05
M23053/12-424-*
11.45
7.65
M23053/12-426-*
11.94
8.81
0.25 0.07
0.25 0.07
0.25 0.07
Minimum Inside
Diameter Expanded
(mm)
Class 5 - High
Shrink Thin Wall
M23053/12-501-*
1.98
0.64
M23053/12-503-*
0.23 0.05
4.75
1.27
M23053/12-506-*
0.30 0.05
9.53
2.44
M23053/12-508-*
0.30 0.05
12.70
3.66
M23053/12-512-*
0.38 0.10
19.05
5.69
M23053/12-514-*
0.38 0.10
25.40
7.06
M23053/12-516-*
38.10
10.16
0.38 0.10
M23053/12-518-*
50.80
13.20
M23053/12-520-*
63.50
16.51
M23053/12-522-*
76.20
19.69
M23053/12-524-*
88.90
22.86
M23053/12-526-*
101.60
26.04
0.38 0.10
0.51 0.13
0.51 0.13
0.51 0.13
0.51 0.13
0.51 0.13
Notes:
1.
* is replaced with appropriate number to indicate colour. (0-Black, 2-Red, 4-Yellow, 9-White, etc.)
CABLE CLAMPS
Chloroprene Cushion Clamps
47. The Chloroprene cushion clamps listed in Table 4
8 are intended for general purpose clamping applications
including electrical wire bundle clamping. A part number
example is listed below:
WARNING
Heat guns with electric Motors are not explosion proof
and are not approved for use in hazardous locations
or where explosion proof equipment is required.
Compressed air/nitrogen heat gun M83521/5-01 or
equivalent are the only heat guns that may be used in
hazardous locations.
WARNING
Heating the heat shrink tubing and Polyurethane
insulated wire or cables above 315C will cause
Polyurethane coatings to release irritating gases.
c.
13
14
Part
Number
Inside
Diameter
(mm)
Part
Number
Inside
Diameter
(mm)
MS21919WDG2
3.18
MS21919WDG16
25.40
MS21919WDG3
4.75
MS21919WDG17
26.97
MS21919WDG4
6.35
MS21919WDG18
28.58
MS21919WDG5
7.92
MS21919WDG19
30.15
MS21919WDG6
9.53
MS21919WDG20
31.75
MS21919WDG7
11.10
MS21919WDG21
33.32
MS21919WDG8
12.70
MS21919WDG24
38.10
MS21919WDG9
14.27
MS21919WDG26
41.28
MS21919WDG10
15.88
MS21919WDG28
44.45
MS21919WDG11
17.45
MS21919WDG30
47.63
MS21919WDG12
19.05
MS21919WDG32
50.80
MS21919WDG13
20.62
MS21919WDG36
57.15
MS21919WDG14
22.22
MS21919WDG40
63.5
MS21919WDG15
23.08
MS21919WDG48
76.2
Inside
Diameter
(mm)
Part
Number
Inside
Diameter
(mm)
MS21919WCJ2
3.18
MS21919WCJ16
25.40
MS21919WCJ3
4.75
MS21919WCJ17
26.97
MS21919WCJ4
6.35
MS21919WCJ18
28.58
MS21919WCJ5
7.92
MS21919WCJ19
30.15
MS21919WCJ6
9.53
MS21919WCJ20
31.75
MS21919WCJ7
11.10
MS21919WCJ21
33.32
MS21919WCJ8
12.70
MS21919WCJ24
38.10
MS21919WCJ9
14.27
MS21919WCJ26
41.28
MS21919WCJ10
15.88
MS21919WCJ28
44.45
MS21919WCJ11
17.45
MS21919WCJ30
47.63
MS21919WCJ12
19.05
MS21919WCJ32
50.80
MS21919WCJ13
20.62
MS21919WCJ36
57.15
MS21919WCJ14
22.22
MS21919WCJ40
63.5
MS21919WCJ15
23.08
MS21919WCJ48
76.2
AC 21-99 A
Aircraft Wiring and Bondin
ng
Sect 2 Chap
p4
Installation
I
of Cable Clam
mps
side
Ins
Diam
meter
(m
mm)
Part
P
Nu
umber
nside
In
Dia
ameter
(
(mm)
MS21919
9WDF2
3.18
MS2191
19WDF16
25.40
MS21919
9WDF3
4.75
MS2191
19WDF17
26.97
MS21919
9WDF4
6.35
MS2191
19WDF18
28.58
MS21919
9WDF5
7.92
MS2191
19WDF19
30.15
MS21919
9WDF6
9.53
MS2191
19WDF20
31.75
MS21919
9WDF7
1
11.10
MS2191
19WDF21
33.32
MS21919
9WDF8
1
12.70
MS2191
19WDF24
38.10
MS21919
9WDF9
1
14.27
MS2191
19WDF26
41.28
MS21919
9WDF10
1
15.88
MS2191
19WDF28
44.45
MS21919
9WDF11
1
17.45
MS2191
19WDF30
47.63
MS21919
9WDF12
1
19.05
MS2191
19WDF32
50.80
MS21919
9WDF13
2
20.62
MS2191
19WDF36
57.15
MS21919
9WDF14
2
22.22
MS2191
19WDF40
63.5
MS21919
9WDF15
2
23.08
MS2191
19WDF48
76.2
53.
5
Install MS21919
M
cable
e clamps as sh
hown in Figure
e
410.
4
The mo
ounting screw
w should be above
a
the wire
e
bundle,
b
if posssible. It is also d
desirable that the back of the
e
cable
c
clamp rest against a structural member. Use
e
hardware,
h
as shown in Fig
gure 411, to
o mount cable
e
clamps
c
to struccture. Be careful not to pinch
h wires in cable
e
clamp.
c
If the wire bundle iis smaller tha
an the nearesst
clamp
c
size, or
o if a clamp of the prope
er size is no
ot
available,
a
wra
ap the wire b
bundle with the
t
necessaryy
number
n
of turn
ns of insulating
g tape so that the bundle will
be
b held securrely in the clam
mp. If the clam
mp can not be
e
installed witho
out pinching and/or crushing the wiring
g
harness,
h
repla
ace the clamp
p with the nex
xt larger clamp
p
size
s
that will securely hold the harness in place.
1
15
NOTE
MS21919 cable clamps are cushioned with insulating
material to prevent abrasion of wires. Never use metal
clamps without cushions to hold wires
54. MS25281 nylon cable clamps may be used to
support wire bundles up to 50mm in diameter in open
wiring, or inside junction boxes and on the back of
instrument panels. When installing nylon cable clamps,
use a large diameter metal washer under the screw head
or nut securing the clamp.
WARNING
The plastic strap must be cut flush with the boss
surface in order to eliminate painful cuts and
scratches from protruding strap ends.
CAUTION
Do not use nylon cable clamps where the ambient
temperature may exceed 85C.
NOTE
MS25281 plastic cable clamps, spaced at intervals not
to exceed 60cm, may be used for wire support provided
every fourth clamp is a rubber cushion type
(MS21919W). The use of plastic cable clamps on other
than horizontal runs should be avoided unless the
installation is such that slack cannot accumulate
between clamping points.
55. Mount cable clamps directly to Z members of
structure. Use angle bracket with two mounting screws if
structural member is angled as shown in Figure 412.
56. Where additional clearance is required between
cable and aircraft structure or equipment, a cable clamp
standoff may be used. Suitable standoffs are identified in
Table 411
16
Thread Size
L35064A2B075
19.6
0.1640-32UNJC (8/32)
L35064A2B100
25.4
0.1640-32UNJC (8/32)
L35064A2B125
31.75
0.1640-32UNJC (8/32)
L35064A2B150
38.10
0.1640-32UNJC (8/32)
L35064A2B175
44.45
0.1640-32UNJC (8/32)
L35064A2B200
50.8
0.1640-32UNJC (8/32)
L35064A2C075
19.6
0.1900-32UNJF (10/32)
L35064A2C100
25.4
0.1900-32UNJF (10/32)
L35064A2C125
31.75
0.1900-32UNJF (10/32)
L35064A2C150
38.10
0.1900-32UNJF (10/32)
L35064A2C175
44.45
0.1900-32UNJF (10/32)
L35064A2C200
50.8
0.1900-32UNJF (10/32)
17
Standard
Material
MS35489
120C
TFE
260C
MIL-C-22529 &
MS21266
MIL-C-22529 &
MS21266
85C
TEETH
Figure 4- 17 Connecting Terminal Lugs to Terminal
Board
CUT LINE
Figure 4- 16 Cutting Caterpillar Grommet
18
Stud Thread
Application
Torque Steel
Number of Studs
MS27212-1-20
6-32UNC-2A
8-10
20
MS27212-2-16
10-32UNC-2A
20-29
16
MS27212-3-8
1/4-28UNF-2A
60-70
MS27212-4-8
5/16-24UNF-2A
90-140
MS27212-5-8
3/8-24UNF-2A
115-175
Note: Terminal boards and covers are procured in full lengths with number of studs indicated.
Cut to suit needs at installation.
Studs
Maximum (N)
Nut Assembly
Dash No.
Threaded Metal
Insert
Retaining
Ring Part
Number
20
21
.138-32UNC-2B
MS166241040
16
22
.190-32UNC-2B
MS166241040
23
.250-28UNF-2B
MS166241062
24
.312-24UNF-2B
MS166241062
25
.375-24UNF-2B
MS166241062
16
26
.164-32UNC-2B
MS166241040
NOTES:
19
20
Figure 420 Hardware for Wiring Terminal Boards With Combination of Terminals
CAUTION
Do not use AN960D aluminium washers.
62. MS27212 terminal boards have studs moulded in
and therefore do not require hardware for attaching studs
to the terminal board. Use same hardware for installing
terminal lugs for MS25123 terminal boards (refer to
paragraph 56 and Figure 418). Mounting screws are
insulated with MS3373 insulators when using MS27212
terminal boards.
63. Place aluminium terminal lugs over a MS25440 or
NAS1070 plated flat washer of the correct size for
terminal and stud (see Table 414). Follow the terminal
lugs with another MS25440 or NAS1070 flat washer, a
CAUTION
Do not place any washer in the current path between
two aluminium terminal lugs or between two copper
terminal lugs.
CAUTION
Never place a lockwasher directly against the tongue
or pad of an aluminium terminal or busbar.
64. To join a copper terminal lug to an aluminium
terminal lug, place a MS25440 or NAS1070 flat washer
over the nut that holds the stud in place. Follow with the
aluminium terminal lug, another MS25440 washer, the
copper terminal lug, AN960 or AN960C plain washer,
MS35338 split steel lockwasher, and MS35649 or
MS35650 plain nut or MS21042 self-locking nut. See
Figure 420 for details.
21
MS No.
MS25440-3
8, 6, 4,
Stud Size
No. 10
NAS 1070-416
MS25440-4
8, 6, 4, 2, 1, 1/0
6.35mm
NAS 1070-516
MS25440-5
8, 6, 4, 2, 1, 1/0, 2/0
7.92mm
NAS 1070-616
MS25440-6
8, 6, 4, 2, 1, 1/0, 2/0
9.53mm
NAS 1070-716
MS25440-6A
NAS 1070-816
MS25440-8
Plain Nuts
Self-locking Nuts
0.375 24
0.500 20
110 120
135 150
115 125
150 170
3/0, 4/0
9.53mm
2, 1, 1/0, 2/0
12.70mm
CAUTION
22
Terminal Size
Nut Torque
40
100
135 165
220 250
440 470
23
NOTE
Terminal lug offset is positioned so that barrel cannot
contact busbars. This allows proper seating of tongue
on busbar.
24
CAUTION
Do not bend terminal lugs to an angle greater than 90
degrees. Do not subject terminal lugs to more than
one bending operation.
Connecting Terminal Lugs to Equipment
76. When connecting wired terminal lugs to terminals
on switches, relays, and other equipment, the terminal
lugs may be bent at the barrel tongue junction if
necessary to permit installation. When bending is
required, keep the bend radius as large as possible,
while keeping the bend as small as possible. If protection
from adjacent equipment or personnel is necessary,
exposed terminal lugs may be covered with an easily
removable non-corrosive sealant, such as RTV3145 or
equivalent.
CAUTION
No ties or splices are permitted inside a conduit.
Feeding Wires into Conduit
78. Feed wires through a short length of conduit by
taping the end of the bundle together and pushing it
gent1y through. Longer runs of conduit or conduit with
complex bends will require a leader. Make a leader out of
a flannel or other soft cloth patch attached to a string long
enough to pass completely through the conduit. The
patch should fit loosely in conduit. (See Figure 428.)
Use compressed air at no more than 240kPa (35psi) to
blow patch and attached string through the conduit. Tie
wire bundle securely to string and tape over junction to
cover all wire ends. Pull string through conduit while
careful1y feeding wires into other end. After wire is
installed, remove tape and detach string.
Supporting Wires at End of Rigid Conduit
79. Use an MS21919 cable clamp to support wires at
each end of conduit. Place the cable clamp in a direct
line with the conduit end to prevent chafing of wires at
end of conduit. Place cable clamp as close to end of
conduit as practicable, but never more than 25cm away.
(See Figure 429.)
NOTE
Do not leave wire slack inside conduit. Wires should be
free, but not taut, inside conduit.
25
INSTALLATION OF CONNECTORS
Assembly of Connectors to Receptacles
80.
WARNING
Unless otherwise required by specific equipment
technical data, power should be removed from the
affected circuit to avoid shock hazard and possible
arcing of connectors.
CAUTION
Do not use excessive force to mate connectors to
receptacles.
a.
CAUTION
Figure 428 Leader for Conduit
CAUTION
Never use a torque wrench or pliers to lock coupling
rings.
26
WARNING
Unless otherwise required by specific equipment
technical data, power should be removed from the
affected circuit to avoid shock hazard and possible
arcing of connectors.
a.
CAUTION
Do not pull on attached wires.
c.
CAUTION
Do not misconnect plugs and receptacles by forcing
pins into the resilient insert, either by misalignment of
properly mating connectors or by joining connectors
with identical shells but differently keyed insert
arrangements.
e.
Coding of Connectors
82. As a design objective, receptacles whose plugs
are interchangeable are not located in close proximity to
each other. However, when installation requirements are
such that these receptacles are in adjacent locations, use
clamps on the plug wires or assemble plugs and
receptacles so as to use one of the alternate insert
positions, to make it physically impossible to connect a
plug into the wrong receptacle. Also, colour-code the
connector plug body and the flange or mounting area of
the receptacle.
a.
CAUTION
Be careful not to lock the plug while cocked, i.e., two
locking rivets engaged and one not engaged.
Mounting Connectors
84. Before mounting receptacles to the back of a panel
or bulkhead, make sure there is sufficient clearance to
couple the plug to the receptacle. Make sure that
mounting hardware does not interfere with the installation
of the locking ring.
Installing Conduit on Connectors
85. When installing a stepped-down conduit on the
back shell of a connector having large wires (size No. 8
or larger), add an additional back shell to the connector
before installing the conduit. This will allow the wire
bundle to decrease in diameter gradually and prevent
sharp bends in the wires. (See Figure 430)
27
CAUTION
Use nylon cable straps on wire bundles containing
coaxial cable in accordance with Section 2,
CHAPTER 7.
Support Inside Junction Boxes
87. Use MS21919 cable clamps to support wires
across hinged doors so that wires will be twisted and not
bent when the door is opened. See Figure 432 for
correct and incorrect methods of support.
88. Attach wire bundles to walls of junction box to
prevent chafing or abrasion against terminal studs or
other items in box. Tie up slack (required for terminal
rework) to prevent snagging.
28
29
30
31
TYPICAL
CONTACT
SINGLE SPLICE
DOUBLE SPLICE
200C
max
32
Wire Barrel
20
22D
28, 26
24, 22
0.76/
1.37
16
22
26, 24
22
0.86/
1.52
16
20
24, 22
20
1.02/
2.11
14
16
20, 18
16
1.65/
2.77
12
12
14, 12
2.46/
3.61
Feedthrough
Conductor
Size
Insulation
O.D.
Series II
Mating
Size
Wire Barrel
Conductor
Size
Insulation
O.D.
22
22
26, 24
22
0.76/
1.37
Size
Spec. Sheet
22D
22
20
16
12
M81714/17
M81714/1
M81714/2
M81714/3
M81714/4
20
20
24, 22
20
0.86/
1.52
16
16
20, 18
16
1.02/
2.11
22
20
16
12
M81714/6
M81714/7
M81714/8
M81714/9
12
12
14, 12
1.65/
2.77
Splice
Size
Spec. Sheet
Single
Type
All
M81714/11
Double
All
M81714/12
Size
Spec. Sheet
Track
Type
Feedback
All
M81714/5
Feedthrough
All
M81714/10
Series II
Module Feedback
Type
Size
Spec. Sheet
Non-electrical
All
M81714/60
Distribution
All
M81714/61
Electronic
All
M81714/62
Grounding
All
M81714/63
Size
Spec. Sheet
Single
All
M81714/65
Double
All
M81714/66
Splice
Type
Track
Type
Size
Spec. Sheet
Feedback
All
M81714/67
33
34
Contact
Crimping Tools
Wire
Barrel
Size
Wire
Size
Range
Contact
Ins/Rem
Tools
Part No.
Bin
Code
Mating
End
Size
Basic
Positioner
or
Turret
22D
M39029/1-507
507
20
22D
22-28
M22520/2-32
M22520/2-32
M81968/14-01
or
MS27534-22D
or
M81969/8-01
and
M81969/8-02
22
M39029/1-100
100
16
22
22-26
M22520/2-01
M22520/2-11
M81969/14-10
or
MS27534-20
20
M39029/1-101
101
16
20
20-24
M22520/2-01
M22520/1-01
M22520/2-11
M22520/1-02
(blue)
M81969/14-10
or
MS27534-20
16
M39029/1-102
102
14
16
16-20
M22520/2-01
M22520/1-02
(blue)
M81969/14-03
or
MS27534-16
12
M39029/1-103
103
12
12
12-14
M22520/2-01
22520/1-02
(yellow)
M81969/14-04
or
MS27534-12
Series I
Module
Block
Size
Contact
Crimping Tools
Wire
Barrel
Size
Wire
Size
Range
Contact
Ins/Rem
Tools
Part No.
Bin
Code
Mating
End
Size
Basic
Positioner
or
Turret
22
M39029/22-191
191
22
22
22-26
M22520/7-01
M22520/7-11
M81968/16-04
20
M39029/22-192
192
20
20
20-24
M22520/1-01
Daniels No.
Th343 (red)
M81969/14-10
16
M39029/22-193
193
16
16
16-20
M22520/1-01
Daniels No.
Th343 (blue)
M81969/14-03
12
M39029/22-605
605
12
12
12-14
M22520/1-01
M22520/1-16
M81969/16-03
Crimping of Terminals
98. The terminals are crimped on the wires, using the
appropriate crimping tool as indicated in Table 419.
Crimping is accomplished as follows:
a.
Series
Contact Size
20 and 22
16 and 12
22,20,16
12
II
Wire Stripping
Dimensions (mm)
3.18 to 3.96
5.54 to 6.35
5.26 + 0.76
5.72 + 0.51
NOTE
Wires may be stripped by any of the methods listed in
Section 2, Chapter 3.
35
NOTE
No insertion-extraction tool, whether plastic or metal,
should be subjected to mishandling or left loose among
tools in a toolbox. They should be stored and carried in
a separate container to prevent being damaged. Their
tapered ends in particular shall be protected when the
tool is not in use. The tips of all tools shall be inspected
prior to use. Tools with broken, cracked, or bent tips
shall not be used.
NOTE
All cavities shall be filled with contacts. Sealing plugs
will be inserted in the cavities in the rear of all unwired
contacts.
b. Pull the wire back through the tool, until the tip of
the tool seats against the shoulder of the contact.
c.
b. Slowly slide the tool along the wire into the insert
cavity until it engages the contact rear and a
positive resistance is felt. At this time, the contact
retaining fingers are in the unlocked position.
c.
36
Adhesive Type
Specification
Black
Self-bonding
MIL-I-46852
Red
Self-bonding
MIL-I-46852
Black
Non-adhesive
MIL-S-1103GE
NOTE
Silicone rubber tapes shall not be used where they will be exposed to fluids such as jet fuels, hydraulic fluids, engine oils, silicone damping
fluid (DC-200), etc. These fluids may cause silicone rubber tapes to swell and/or lose adhesive properties.
37
Blank Page
38