Page 196 AC 49.13-1А 1972 Section 5. CONNECTORS 478, GENERAL PURPOSE CONNECTORS. Connec tors (plugs and receptacles) are used to facilitate maintenance when frequent disconnection is required. Since the wires are soldered to the connector inserts, the joints should be individually installed and the wire bundle firmly supported to avoid damage by vibration. Connectors have been particularly vulnerable to corrosion in the past, due to condensation within the shell. Special connectors with waterproof features have been developed and may be used may be pro to replace nonwaterproof type plugs in areas where moisture causes a connector problem.
Use a replacement connector of the same basic type and design as the connector it replaces.
Connectors that are susceptible to corrosion difficulties may be treated with a chemically inert waterproof jelly. When replacing connector assemblies, use the socket-type insert on that half which is live or "hot" after the connector is disconnected to prevent unintentional grounding.
479. TYPES OF CONNECTORS. Connectors are identified by AN numbers and are divided into types and classes with manufacturer's variations in each type and class. The manufacturer's variations are differences in appearance and in the method of meeting the specification;
however, they do not preclude mating plugs and receptacles of different manufacturers.
There are six basic types of AN connectors used in aircraft which are further broken down into five classes as indicated in figures it is important that the soldered connectors are readily accessible. The back shell is held together by a threaded ring or by screws.
Class C-A pressurized connector with inserts that are not removable. Looks like a Class A connector but the inside sealing arrangement is sometimes different and is used on walls of bulkheads of pressurized equipment.
Class D-Moisture and vibration resisting connector which has a sealing grommet in the back shell. Wires are threaded through tight fitting holes in the grommet, thereby sealing against moisture.
Class K-A fireproof connector used in areas where it is vital that the electric current is not interrupted, even though connector may be exposed to continuous open flame. Wires are crimped to the pin or socket contacts and the shells are made of steel, This class of connectors is normally longer than the other classes of connectors.
480. AN CONNECTOR IDENTIFICATION. Code letters and numbers are marked on the coupling ring or shell to identify the connector. This code provides all the information necessary to obtain the correct replacement for a defective or damaged part. To facilitate ready identification the code found on a typical connector (aa shown in figure 11.22) is explained as follows:
a. The letters AN indicate the connector was made to a onvarnment standard
AC 43.13-1А Page 197 1972 AN 3102 AN 3100 BOX RECEPTACLE WALL RECEPTACLE AN 3101
CABLE RECEPTACLE AN 3106 AN 3106 STRAIGHT PLUG AN 3107 STRAIGHT PLUG
QUICK DISCONNECT PLUG AN 3108 AN 3106
ANGLE PLUG ANGLE PLUG FIGURE 11.20.-AN connectors.
Page 198 AC 43.13-1A 1972
STANDARD AN 3106 CLASS TYPE NUMBER SIZE
INSERT ARRANGEMENT NUMBER
CONTACT STYLE
INSERT ROTATION FIGURE 11.22.-AN connector marking.
•. Number 4 indicates a certain arrangement of contacts; however, this number does not indicate the number of contacts. Manufacturers of connectors provide charts giving diagrams of the various contact arrangements.
f. Letter (s) indicates contact style. This letter may be either a (P) or (S) which indicates whether the contacts are pins or sockets.
g. A letter may or may not follow the contact ture connector, rectangular shell connector, connectors with short body shells or of split shell construction used in applications where potting is required.
482. POTTING COMPOUNDS, Potting compounds meeting Specification MIL-S-8516 are prepared in ready-to-use tube-type dispensers, or in the unmixed state consisting of the base compound and accelerator packed in paired
AC 43.13-1A 1972 to the base compound and includes the time expended during the mixing and application processes. Mixed compounds that are not to be used immediately must be cooled and thawed quickly to avoid wasting the short working life. Chilled compounds should be thawed by blowing compressed air over the outside of the container, Normally the compound will be ready for use in 5 to 10 minutes.
CAUTION Do not use heat or blow compressed air into the container when restoring to working tempersture.
483. POTTING CONNECTORS. Connectors that have been potted primarily offer protection against concentration of moisture in the SPARE SPARE
FILL ALL SPARE
CONTACTS WITH
MAXIMUM SIZE WIRES Page 199 connectors. A secondary benefit of potting is the reduced possibility of breakage between the contact and wire due to vibration.
Solder wires to all contacts of the connector prior to the application of the potting compound, Wires that are not to be used should be long enough to permit splicing at a later date.
Identify the wires not used as shown in figure
11.28 and cap the cut ends with potting compound prior to securing to the wire bundle.
After the soldering operation, scrape off the resin and wash the connector with clean stoddard solvent, brushing vigorously. Rinse the areas to be potted with methylene chloride and complete the potting operation within 2 hours after this cleaning. Allow the potting com-
- IDENTIFY SPARE WIRES
WITH CODE LETTER TO
CORRESPOND WITH CONTACT
pound to cure for 24 hours at a room temperature of 70° to 75° F. or carefully place in a drying oven at 100° F. for 3 to 4 hours.
484. THROUGH BOLTS. Through bolts are sometimes used to make feeder connections through bulkheads, fuselage skin, or firewalls. Mount through bolts in such a manner that they are mechanically secure and independent of the terminal nuts. Provide sufficient cross section to insure adequate conductivity against overheating and enough contact area to minimize voltage drop. Mechanically secure such bolts independent of the terminal mounting nuts, taking particular care to avoid dissimilar metals among the terminal hardware. During inspection, pay particular attention to the condition of the insulator plate or spacer and the insulating boot that covers the completed terminal assembly.
485. TERMINAL STRIPS. Wires are usually joined AC 43.13-1A 1972 at terminal strips. Use a terminal strip fitted with barriers to prevent the terminals on adjacent studs from contacting each other. Studs must be anchored against rotation. When more than four terminals are to be connected together, use two or more adjacent studs and mount a small metal bus across the studs. In all cases, the current is to be carried by the terminal contact surfaces and not by the stud itself. Replace defective studs with studs of the same size and material as terminal strip studs of the smaller sizes may shear due to overtightening the nut. Assure that the replacement stud is securely mounted in the terminal strip and that the terminal securing nut is tight.
Mount terminal strips in such a manner that loose metallic objects cannot fall across the terminals or studs. It is good practice to provide at least one spare stud for future circuit expansion, or in case a stud is broken.
486.-496. RESERVED.
AC 43.13-1A Page 201 1972 Section 6. CONDUITS
497. GENERAL, Conduit is available in metallic and nonmetallic materials and in both rigid and flexible form. Primarily, its purpose is for mechanical protection of the wire within, although some radio interference shielding may be provided.
498. SIZE OF CONDUIT, When selecting conduit size for a specific wire bundle application, it ia common practice to allow for ease in maintenance and possible future circuit expansion by specifying the conduit inner diameter about 25 percent larger than the maximum diameter of the wire bundle. The nominal diameter of rigid metallic conduit is the O.D. Therefore, to obtain the I.D., subtract twice the tube wall thickness.
499. CONDUIT FITTINGS, From the abrasion standpoint, conduit is vulnerable at its ends.
Affix suitable fittings to conduit ends in such manner that a smooth surface comes in contact with wire within. When fittings are not used, flare the end of the conduit to prevent wire insulation damage. Support the conduit using clamps along the conduit run.
as much a8 80 percent of the tube area. Minimum acceptable tube bend radii for rigid conduit is shown in figure 11.24. Kinked or wrinkled bends in rigid conduits are not considered acceptable. Tubing bends that have been flattened into an ellipse and the minor diameter is less than 75 percent of the nominal tubing diameter is not considered satisfactory because the tube area will have been reduced at least 10 percent. Carefully deburr tubing that has been formed and cut to final length to prevent wire insulation damage. When installing replacement tube sections with fittings at both ends, exercise care to eliminate mechanical strain.
502. FLEXIBLE CONDUIT. Flexible aluminum conduit conforming to Specification MIL-C-6186 is available in two types; Type I, Bare Flexible Conduit, and Type II, Rubber Covered Flexible Conduit. Flexible brass conduit conforming to Specification MIL-C-7981 is available and normally used instead of flexible aluminum where necessary to minimize radio interference. Flexible conduit may be used where it is impractical to use rigid conduit such as areas that have
500. CONDUIT INSTALLATION. Many of the past troubles with conduit can be avoided by proper Nominal Minimum bond attention to the following details: 1408 O.D. rodil (inches)
a. Do not locate conduit where passengers or maintenance personnel might use it as a handhold or footstep.
b. Provide drainholes at the lowest point in a conduit run. Drilling burrs should be carefully removed.
c. Support conduit to prevent chafing against structure and to avoid stressing its end fittings.
301. RIGID CONDUIT. Repair conduit sections that have been damaged to preclude injury to the wires or wire bundle which may consume FIoURE 11.24.-Bend radii for rigid condult.
Chap 11 Par 497
Pergo 202 motion between conduit ends or where complex bends are necessary. The use of transparent adhesive tape is recommended when cutting flexible tubing with a hacksaw to minimize fraying of the braid. Center the tape over the eut reference mark and saw through the tape.
AC 43.73-TA 1972 After cutting the flexible conduit, remove the transparent tape, trim the frayed ends of the braid, remove burrs from inside the conduit, and install coupling nut and ferrule. Minimum acceptable bending radii for flexible conduit is shown in fgure 11.25.
FIGURE 11.25.-Minimum bending radii for flexible aluminum or brass conduit.
Nominal I.D. Minimum bending of conduit radise ineido (Imohes) (Imoice)
393.-513. RESERVED.
Per 502 Chap 11
AC 43.13-1А Page 203 1972 Section 7. ROUTING, TYING, LACING, AND CLAMPING
514. GENERAL. Route and support aircrait wiring and conduits to prevent relative movement within the aircraft and provide protection against chafing between wires or other objects.
Provide extra protection where wires or wire bundles may be subjected to rough handling.
Soft insulation tubing is not regarded as satisfactory mechanical protection against abrasion or considered a substitute for proper clamping or tying. Secure all wiring so it is electrically and mechanically sound and neat in appearance.
515. WIRE BEND RADII. A wire bundle consists of a quantity of wires fastened or secured together-all traveling in the same direction.
Wire bundles may consist of two or more groups of wires. It is often advantageous to have a number of wire groups individually tied within the wire bundle for ease of identity at a later date, as shown in figure 11.26. To improve the appearance and to minimize the possibility of insulation abrasion, comb wire groups and bundles so the wires lie parallel to each other. A combing tool similar to that shown in figure 11.27 may be made from any suitable insulating material, taking care to assure all edges are rounded to protect the wire insulation. Bends in wire groups or bundles should not be less than 10 times the outside diameter of the wire group or bundle. However, a bend 8 times the diameter is acceptable to facilitate connections to terminal strips,
BUNDLE TIE GROUP TIE BUNDLE TIE
- 118- "APPROX. 3" FIGURE 11.27.-Comb for straightening wires in bundles.
provided the wire group or bundle is supported at each end of the bend.
516. SLACK. Normally, wire groups or bundles should not exceed 1/2 inch deflection between support points, as shown in figure 11.28. This measurement may be exceeded provided there is no possibility of the wire group or bundle touching a surface which may cause abrasion.
o. Provide sufficient slack at each end to:
(1) Permit replacement of terminals;
(2) Prevent mechanical strain on wires;
(3) Permit shifting of equipment for maintenance purposes.
517. ROUTING WIRES. In the process of accom- FIGURE 11.26.-Group and bundle ties. plishing an aircraft repair, it is often neces- Chap 11 Par 514
Page 204 AC 43.12-14 1972 1/2 INCH MAXIMUM
WITH NORMAL HAND PRESSURE FIGURE 11.28.-Slack between supports.
sary or desirable to reroute a group or bundle of wire. When it is necessary to deviate from the routing used by the manufacturer, consider the following:
o. Chafing. Protect wires or wire groups against chafing or abrasion where contact with other wires or sharp surfaces would damage the insulation. When a wire bundle passes through a hole in a bulkhead, support as shown in figure 11.9. Insert a grommet if a wire passes within 1/4 inch of the hole edge, as shown in figure 11.10.
b. Protection Against Battery Acids, Solvents, and Fluids. It is not advisable to route wires below & battery or closer than 6 inches from the bilge of the fuselage. Protect wires that will be exposed to damage from fluids by an outer sleeving of plastic tubing, as shown in figure 11.29. Extend the plastic tubing well beyond the area of exposure and provide a 1/8- inch drainhole at the lowest point. Assure the wire insulation is not damaged when cutting the hole in the plastic. Frequently inspect wires exposed to battery acid or fluids and replace when the insulation jacket shows signs of discoloration or saturation by fluids.
c. Protection in Wheel Wells and Landing Gear Areas. Wires located on landing gear and in the wheel well area can be exposed to many hazardous conditions if not suitably protected. Encase all wiring attached to a landing gear or located in the wheel well areas in conduit or protect by sleeves of flexible tubing and secure to prevent relative movement. Where wire bun- Par 517 DRAINAGE HOLE 1/8 INCH DIAMETER AT LOWEST POINT IN TUBING. MAKE THE
HOLE AFTER INSTALLATION IS COMPLETE
AND LOWEST POINT IS FIRMLY ESTABLISHED FIGURE 11.28.-Drainage hole in low point of tubing.
des pass fiex points, there should be no strain on attachments or excessive slack when parts are fully extended or retracted. Inspect the wiring and protective tubing frequently and replace at the first sign of wear.
d. Protection Against Personnel and Cargo. Install wiring so the structure affords protection against its use as a handhold and damage from cargo. Where the structure does not afford adequate protection, use conduit or provide a suitable mechanical guard.
e. Protection Against High Temperature. Wire insulation deteriorates rapidly when subjected Chap 11
AC 43.13-1A 1972 to high temperatures. Insulate wires that must be run through hot areas with a material such as asbestos, fiberglass or equivalent high temperature-resistant product. Wherever possible, keep wires separated from high-temperature equipment; and when replacing wires, do not use low-temperature insulated wires to replace high-temperature insulated wires.
f. Wiring Precoutions. Maintain a minimum clearance of 8 inches from any control cable.
When this clearance cannot be maintained, install a mechanical guard. When wiring is run parallel to combustible fluid or oxygen lines, maintain as much separation as possible. Locate wires above or on a level with the fluid lines and, wherever possible, maintain a minimum separation of 6 inches. Where the separation is 1/2 inch to 2 inches, install clamps as shown in figure 11.30 to maintain separation.
These clamps are not to be used as a means of supporting the wire bundle. Install additional clamps to support the wire bundle and fasten the clamps to the same structure used to support the fluid line to prevent relative motion.
Maintain a minimum separation of at least 1/2 inch between plumbing lines and any wire.
518. CLAMPING. Support wires and wire bundies using clamps meeting Specification MS-21919. Exercise care to assure the wire is FIGURE 11.80.-Separation of wires from plumbing lines, Chap 11 Page 205 not pinched when installing clamps to support electrical wiring as shown in figures 11.31 through 11.84. Whenever practical, rest the back of the clamp against a structural member. Install clamps in such manner that the electrical wires do not come in contact with other parts of the aircraft when subjected to vibration. Leave sufficient slack between the last clamp and the electrical equipment to prevent strain at the terminal and to minimize adverse effects on shockmounted equipment.
Where wires or wire bundles pass through bulkheads or other structural members, provide a grommet or suitable clamp to prevent abrasion.
519. TIES AND LACING. Ties, lacing, and straps are used to secure wire groups or bundles, to provide ease of maintenance, inspection, and installation. Cord meeting Specification MIL-C-5649 and twine meeting Specification JAM-T-718 are suitable for lacing or tying wires. In lieu of applying ties, straps meeting Specification MS-17821 or MS-17822 may be used in areas where the temperature does not exceed 120° C. or where the wiring can be damaged by operating units if the strap fails.
a. Lacing. Lace wire groups or bundles inside junction boxes or other enclosures. Single cord-lacing method shown in figure 11.35 may be used for wire groups or bundles 1 inch in diameter or less. The recommended knot for starting the single cord-lacing method is a clove hitch secured by a double-looped overhand knot as shown in step "a" of figure 11.85. Use the double cord-lacing method on wire bundles 1 inch in diameter or larger as shown in figure
11.86. When using the double cord-lacing method, employ a bowline on a bight as the starting knot. Reference step "a" of figure
11.36.
b. Tying. Use wire group or bundle ties where the supports for the wire are more than 12 inches apart. A tie consists of a clove hitch around the wire group or bundle secured by a square knot as shown in figure 11.87.
520.-530. RESERVED.
Par 517
Робро 206 AC 42.13-14 1972
DANGEROUS ANGLES MAX. ·50
SAFE ANGLES FIGURE 11.81.-Safe angle for cable clamps.
MS 21919
CABLE CLAMP OR
EQUIVALENT AN 5I5 SCREW AN 960 AN 960
PLAIN WASHER, PLAIN WASHER, AN 9368
LOCKWASHER, AN 935 EXTERNAL TEETH AN 365 NUT, LOCKWASHER, AN 340 NUT SELF-LOCKING SPLIT FIGURE 11.82.-Typical mounting hardware for MS-2019 cable clamps.
Par 519 Chap 11
AC 43.13-1A Page 207 :1972 MS 21919 CABLE CLAMPS
STRUCTUA "ANGLE" MEMBER "Z" MEMBER AN 730
CORRECT CLAMP
ANGLE BRACKET MS 21919
CABLE CLAMP Ot
EQUIVALENT FIGURE 11.84.-Installing cable clamps to tubular structure.
WIRE IS PINCHED IN CLAMP
INCORRECT FIGURE 11.88.-Installing cable clamp to structure.
Par 519 Chap 11